Suzuki GRAND VITARA XL-7 Owner's Manual
Suzuki GRAND VITARA XL-7 Owner's Manual

Suzuki GRAND VITARA XL-7 Owner's Manual

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WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by
these signal words.
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 maintenance easier or instructions clearer.
WARNING:
This service manual is intended for authorized Suzuki dealers and qualified service mechanics only.
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the driver
and passengers.
WARNING:
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to "Air Bag System Components and Wiring Location View" under
"General Description" in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and "Ser-
vice Precautions" under "On-Vehicle Service" in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
• If the air bag system and another vehicle system both need repair, Suzuki recommends that the air
bag system be repaired first, to help avoid unintended air bag system activation.
• Do not modify the steering wheel, instrument panel or any other air bag system component (on or
around air bag system components or wiring). Modifications can adversely affect air bag system
performance and lead to injury.
• If the vehicle will be exposed to temperatures over 93°C (200°F) (for example, during a paint baking
process), remove the air bag system components (air bag (inflator) modules, forward sensor(s),
SDM and/or seat belt pretensioners) beforehand to avoid component damage or unintended activa-
tion.
Important

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Summary of Contents for Suzuki GRAND VITARA XL-7

  • Page 1 Either of these two conditions may result in severe injury. • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
  • Page 2 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 4 Table of Contents GENERAL INFORMATION TRANSMISSION, CLUTCH AND General Information DIFFERENTIAL Maintenance and Lubrication Manual Transmission HEATING AND AIR CONDITIONING Automatic Transmission Heater and Ventilation Clutch Air Conditioning Transfer STEERING, SUSPENSION, WHEELS Differential (Front) AND TIRES Differential (Rear) Steering, Suspension, Wheels and Tires ELECTRICAL SYSTEM Front End Alignment Electrical System...
  • Page 6: Table Of Contents

    GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual. CONTENTS Precautions............0A-2 Identification Information.......0A-6 Precaution for Vehicles Equipped with A Vehicle Identification Number .......
  • Page 7: Precautions

    • If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air bag sys- tem be repaired first, to help avoid unintended air bag system activation.
  • Page 8: Servicing And Handling

    GENERAL INFORMATION 0A-3 Servicing and handling WARNING: Many of service procedures require disconnection of “AIR BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver and Passenger Air Bag (Inflator) Modules • For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65°C (150°F), without high humidity and away from electric noise.
  • Page 9 0A-4 GENERAL INFORMATION WARNING: • During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system.
  • Page 10 GENERAL INFORMATION 0A-5 CAUTION: • Even when the accident was light enough not to cause air bags to activate, be sure to inspect sys- tem parts and other related parts according to instructions under “REPAIR AND INSPECTION REQUIRED AFTER AN ACCIDENT” in SECTION 10B. •...
  • Page 11: Identification Information

    0A-6 GENERAL INFORMATION Identification Information Vehicle Identification Number The vehicle body number is on the left side of instrument panel and punched on the chassis inside the tire housing on the right front side.
  • Page 12: Engine Identification Number

    GENERAL INFORMATION 0A-7 Engine Identification Number The number is punched on the cylinder block. Engine Identification Number Specification A 100001 Sequential Number Engine Displacement (27 2.7 Liter) Engine Type Transmission Identification Number The A/T manufacture’s identification number is located on the transmission case as shown.
  • Page 13: Warning, Caution And Information Labels

    0A-8 GENERAL INFORMATION Warning, Caution and Information Labels The figure below shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels. If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary. 1.
  • Page 14: Maintenance And Lubrication

    • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
  • Page 15: Maintenance Schedule

    0B-2 MAINTENANCE AND LUBRICATION Maintenance Schedule Maintenance Schedule under Normal Driving Conditions NOTE: • This interval should be judged by odometer reading or months, whichever comes first. • This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at the same intervals respectively.
  • Page 16: Brakes

    MAINTENANCE AND LUBRICATION 0B-3 (× 1,000) Interval Miles (× 1,000) Months CHASSIS AND BODY 6-1. Clutch (pedal and fluid level) – – – 6-2. Brake discs and pads (thickness, wear, damage) Brake drums and shoes (wear, damage) – – – 6-3.
  • Page 17: Maintenance Recommended Under Severe Driving Conditions

    0B-4 MAINTENANCE AND LUBRICATION Maintenance Recommended under Severe Driving Conditions If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is recommended that applicable maintenance operation be performed at the particular interval as given in the chart below.
  • Page 18: Maintenance Service

    MAINTENANCE AND LUBRICATION 0B-5 Maintenance Service Engine and Emission Control ITEM 1-1 Drive belt inspection and replacement WARNING: All inspection and replacement are to be performed with ENGINE NOT RUNNING. WATER PUMP AND GENERATOR DRIVE BELT INSPEC- TION 1) Disconnect negative (–) cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanli- ness.
  • Page 19: Engine Oil And Filter Replacement

    0B-6 MAINTENANCE AND LUBRICATION POWER STEERING PUMP AND/OR A/C COMPRESSOR DRIVE BELTS (IF EQUIPPED) INSPECTION 1) Disconnect negative (–) cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanli- ness. If any defect exists, replace. Check belt for tension. If belt tension is out of above specification, adjust it referring to Section 1B or 3B1.
  • Page 20 MAINTENANCE AND LUBRICATION 0B-7 1) Drain engine oil by removing drain plug. 2) After draining oil, wipe drain plug clean. Reinstall drain plug, and tighten it securely as specified below. Tightening torque Engine oil drain plug (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft) 3) Loosen oil filter by using oil filter wrench (special tool).
  • Page 21 0B-8 MAINTENANCE AND LUBRICATION 6) Replenish oil until oil level is brought to FULL level mark on dipstick. (oil pan and oil filter capacity). The filler inlet is at the top of the cylinder head cover. It is recommended to use engine oil of SE, SF, SG, SH or SJ grade.
  • Page 22 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 23 1A-2 HEATER AND VENTILATION General Description The heater, an in and out air selectable-type hot water heater, is so constructed that it is possible to assure an agreeable ventilation at all times by providing the ventilator air outlets at the center and both sides (right and left) of the instrument panel, the hot air outlet at a place close to the feet, and the defroster air outlets at places, right and left, along the windshield glass.
  • Page 24: Heater And Ventilation 1A

    HEATER AND VENTILATION 1A-3 Rear Duct 1. Heater unit 2. Rear duct REMOVAL 1) Disconnect negative (–) cable at battery. 2) Remove front and second seats. 3) Remove console box. 4) Take off carpet till rear duct is totally exposed. 5) Remove rear duct.
  • Page 25 1A-4 HEATER AND VENTILATION...
  • Page 26 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
  • Page 27 1B-2 AIR CONDITIONING (OPTIONAL) Charging ............ 1B-22 Rear Blower Motor Relay and Solenoid Valve Relay..........1B-34 On-Vehicle Service ........1B-25 Rear A/C Main Switch........ 1B-34 Precaution..........1B-25 Rear Blower Motor Resistor....... 1B-35 Piping ............. 1B-25 Rear Blower Motor Switch ......1B-36 Handling refrigerant HFC-134a (R-134a) 1B-26 Rear A/C No.1 and No.2 Duct ....
  • Page 28: General Description

    AIR CONDITIONING (OPTIONAL) 1B-3 General Description Refrigerant Type Whether the A/C in the vehicle being serviced uses HFC-134a (R-134a) or CFC-12 (R-12) is indicated on LABEL on the com- pressor. Also, it can be checked by the shape of the service (charge) valve.
  • Page 29: Major Components And Location

    1B-4 AIR CONDITIONING (OPTIONAL) Major Components And Location [A] : Dual A/C model 6. Receiver/dryer 13. Suction pipe 20. Ventilation air [B] : Single A/C model 7. Front expansion valve 14. Discharge pipe 21. Rear A/C air 1. Front cooling unit 8.
  • Page 30 AIR CONDITIONING (OPTIONAL) 1B-5 [A] : Dual A/C LH steering model 4. Condenser 11. Low pressure charge valve [B] : Dual A/C RH steering model 5. Sight glass 12. Floor liquid pipe [C] : Single A/C LH steering model 6. Refrigerant (dual) pressure sensor 13.
  • Page 31: Diagnosis

    1B-6 AIR CONDITIONING (OPTIONAL) Diagnosis General Main A/C system (front A/C system) Condition Possible Cause Correction Cool air does not No refrigerant Perform recover, evacuation and come out (A/C system charging. does not operative) Fuse blown Check “IG METER”, “REAR DEFG” and “A/C”...
  • Page 32 AIR CONDITIONING (OPTIONAL) 1B-7 Condition Possible Cause Correction Cool air does not Insufficient or excessive charge of refrigerant Check charge of refrigerant. come out or insuffi- Refrigerant leak in system Check system for leaks. cient cooling (A/C sys- Condenser clogged Check condenser.
  • Page 33: Rear A/C System

    1B-8 AIR CONDITIONING (OPTIONAL) Rear A/C system Condition Possible Cause Correction Cool air dose not come Solenoid valve relay faulty Check solenoid valve relay, and then out (Rear blower motor replace if necessary normal operative) Solenoid valve faulty Check solenoid valve, and then replace if necessary Diode in rear A/C harness faulty Check diode, and then replace rear A/C...
  • Page 34: Quickly Checking Of Refrigerant Charge (If Equipped With Sight Glass)

    AIR CONDITIONING (OPTIONAL) 1B-9 Quickly Checking of Refrigerant Charge (If Equipped with Sight Glass) The following procedure can be used for quickly checking whether the A/C system has a proper charge of refrigerant or not. 1) Run engine at fast idle. 2) Operate A/C at the following conditions for a few minutes.
  • Page 35: Performance Diagnosis

    1B-10 AIR CONDITIONING (OPTIONAL) Performance Diagnosis 1) Confirm that vehicle and environmental conditions are as fol- lows. • Vehicle is not exposed to direct sun. • Ambient temperature is within 15 - 35 °C (59 - 95 °F). 2) Make sure that high pressure valve (1) and low pressure valve (2) of manifold gauge (3) are firmly closed.
  • Page 36 AIR CONDITIONING (OPTIONAL) 1B-11 9) Check for each pressure of low side and high side if it is within shaded range of graph. If each gauge reading is out of specified pressure, correct defective part referring to “PERFORMANCE DIAGNOSIS TABLE”. Example : Gauges should read as follows when ambient temperature is 30 °C (86 °F)
  • Page 37: Performance Diagnosis Table

    1B-12 AIR CONDITIONING (OPTIONAL) Performance diagnosis table HIGH PRESSURE GAUGE Condition Possible Cause Correction Pressure high Refrigerant overcharged Recharge. (“A” area of high side Expansion valve frozen or clogged Check expansion valve. graph) Clogged refrigerant passage of high side Clean or replace. Condenser cooling fan malfunction (Insufficient cooling Check condenser cooling fan.
  • Page 38: Detail Diagnosis Table

    AIR CONDITIONING (OPTIONAL) 1B-13 Detail diagnosis table (at ambient temperature within 30 - 35 °C (85 - 95 °F)) Condition Possible Cause Correction MANIFOLD Detail GAUGE (kg/cm (psi) 0.23 - 0.35 1.4 - 1.75 Normal condition – – (2.3 - 3.5) (14 - 17.5) (33 - 50) (200 - 249)
  • Page 39: Wiring Circuit

    1B-14 AIR CONDITIONING (OPTIONAL) Wiring Circuit BLK/WHT RED/BLK RED/BLU YEL/GRN LT GRN PNK/BLK BLU/WHT PNK/BLU PNK/GRN PNK/WHT RED/BLK BLU/WHT BLU/WHT BLU/ORN YEL/GRN RED/BLK WHT/RED YEL/GRN RED/BLK RED/BLU YEL/BLU 1. Front blower motor main relay 10. Compressor relay 19. Battery 28. Solenoid valve relay 2.
  • Page 40: Inspection Of A/C Controller And Its Circuits

    AIR CONDITIONING (OPTIONAL) 1B-15 Inspection of A/C Controller and Its Circuits CAUTION: A/C controller and ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to A/C controller and ECM with couplers disconnected from it. A/C Controller (1) and its circuits can be checked at A/C controller wiring couplers by measuring voltage.
  • Page 41 1B-16 AIR CONDITIONING (OPTIONAL) SYSTEM CIRCUIT AC-A-1 AC-A-7 AC-A-9 E61-8 AC-A-4 AC-B-2 AC-A-13 E61-17 AC-B-1 AC-A-16 AC-A-2 E61-22 A: To “FRONT BLOW” fuse 1. Front blower motor relay 6. Dual (refrigerant) pressure switch 11. Condenser cooling fan motor B: To “REAR DEFG” fuse 2.
  • Page 42 AIR CONDITIONING (OPTIONAL) 1B-17 A/C CONTROLLER VOLTAGE VALUES TABLE Measurement Terminal Wire Circuit Normal value Condition ground BLK/ Controller main Ground to Ignition switch ON with engine AC-A-1 10 – 14 V power supply engine (Fig B) stopped BLK/ Controller main Ground to body AC-A-2 –0.4 –...
  • Page 43 1B-18 AIR CONDITIONING (OPTIONAL) Measurement Terminal Wire Circuit Normal value Condition ground A/C evaporator temperature sen- 1.8 V sor temperature at approx. 15 °C (3520 Ω) (59 °F) with engine running A/C evaporator temperature sen- A/C evaporator sor temperature at approx. 4.5 °C temperature WHT/ Ground to...
  • Page 44: Refrigerant Recovery, Evacuation And Charging

    AIR CONDITIONING (OPTIONAL) 1B-19 Refrigerant Recovery, Evacuation and Charging WARNING: • Your eyes should not be exposed to refrigerant (liquid). Any liquid Refrigerant-134a escaping by accident shows a temperature as low as approx. –6 °C (21.2 °F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause a serious injury.
  • Page 45: Recovery

    1B-20 AIR CONDITIONING (OPTIONAL) Recovery NOTE: • When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment (1). Discharging it into atmo- sphere would cause adverse effect to environments. • When handling recovery and recycling equipment, be sure to follow the instruction manual for the equip- ment.
  • Page 46: Evacuating

    AIR CONDITIONING (OPTIONAL) 1B-21 Evacuating Evacuating procedure CAUTION: Do not evacuate before recovering refrigerant in system. NOTE: Whenever opened (exposed to atmospheric air), air con- ditioning system must be evacuated by using a vacuum pump. The A/C system should be attached with a mani- fold gauge set, and should be evacuated for approx.
  • Page 47: Checking System For Pressure Leaks

    1B-22 AIR CONDITIONING (OPTIONAL) Checking system for pressure leaks After completing the evacuation, close manifold gauge high pres- sure valve (HI) and low-pressure valve (LO) and wait 10 minutes. Verify that low-pressure gauge reading has not changed. CAUTION: If the gauge reading moves closer to “0”, there is a leak somewhere.
  • Page 48 AIR CONDITIONING (OPTIONAL) 1B-23 The initial charging of the A/C system is performed from the high- pressure side with the engine stopped. And next, this method must be followed by charging from the low- pressure side with the engine running. 1) Check to make sure that hoses are routed properly after evacuating the system.
  • Page 49 1B-24 AIR CONDITIONING (OPTIONAL) c) Purge any air existing in center charging hose When using refrigerant container tap valve, use following procedure to purge air. i) Once fully tighten refrigerant container tap valve and then loosen (open) plate nut slightly. ii) Open low pressure valve of manifold gauge set a little.
  • Page 50: On-Vehicle Service

    AIR CONDITIONING (OPTIONAL) 1B-25 On-Vehicle Service WARNING: Should refrigerant HFC-134a (R-134a) strike your eye(s), consult a doctor immediately. • DO NOT USE YOUR HAND TO RUB AFFECTED EYE(S). Instead, use quantities of fresh cold water to splash it over affected area to thus gradually raise its temperature above the freezing point.
  • Page 51: Handling Refrigerant Hfc-134A

    1B-26 AIR CONDITIONING (OPTIONAL) • Never use heat for bending pipes. When bending a pipe, try to make its bending radius as slight as possible. • Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system, install a blind plug or cap to the fitting immediately.
  • Page 52: Replenishing Compressor Oil

    AIR CONDITIONING (OPTIONAL) 1B-27 Replenishing compressor oil CAUTION: Be sure to use HFC-134a (R-134a) compressor oil. When replacing air conditioning parts with new ones, it is neces- sary to replenish oil by the amount supposedly remaining in each part. WHEN CHANGING GAS ONLY When it is unavoidable to change gas without replacing any com- ponent part for engine removal and installation or for some other reason, replenish 20 cm...
  • Page 53: Rear A/C Unit (Rear A/C Evaporator)

    1B-28 AIR CONDITIONING (OPTIONAL) Rear A/C Unit (Rear A/C Evaporator) 1. Rear blower fan cover 6. Rear A/C unit mounting clip 11. Solenoid valve mounting bracket Do not reuse 2. Rear A/C unit mounting bush 7. Rear blower motor assembly 12.
  • Page 54: Rear Expansion Valve

    AIR CONDITIONING (OPTIONAL) 1B-29 4) Loosen floor suction pipe and floor liquid pipe mounting bolt (1). 2. Muffler 5) Remove rear A/C No.1 duct (1). 6) Disconnect rear A/C unit wire couplers (2). 7) Remove rear A/C unit mounting bolts (3), and then remove rear A/C unit (4).
  • Page 55: Rear A/C Evaporator Temperature Controller

    1B-30 AIR CONDITIONING (OPTIONAL) REMOVAL 1) Remove rear A/C unit referring to “REAR A/C UNIT” in this section. 2) Disconnect solenoid valve connector (1). 3) Loosen solenoid valve bracket mounting screws (2). 4) Remove rear liquid pipe and rear suction pipe bolt (1), and then disconnect rear liquid pipe (2) and rear suction pipe (3) with solenoid valve and its bracket from rear expansion valve (4).
  • Page 56: Refrigerant Pipes And Hoses

    AIR CONDITIONING (OPTIONAL) 1B-31 INSPECTION 1) Connect battery positive (+) cable to terminal “b” and battery negative (–) cable to terminal “c” as shown. 2) Using ohmmeter, check continuity between terminal “a” and terminal “b” at specified temperature as shown. Rear A/C evaporator temperature controller specification : “A”...
  • Page 57: Solenoid Valve

    1B-32 AIR CONDITIONING (OPTIONAL) Solenoid Valve REMOVAL 1) Remove rear A/C unit referring to “REAR A/C UNIT” in this section. 2) Disconnect solenoid valve connector (1). 3) Loosen solenoid valve flared nuts (2). 4) Remove solenoid valve bracket mounting screws (3), and then remove rear liquid pipe (4) and rear suction pipe (5) from rear expansion valve.
  • Page 58: Rear Blower Motor Assembly

    AIR CONDITIONING (OPTIONAL) 1B-33 Rear Blower Motor Assembly REMOVAL 1) Remove solenoid valve referring to “SOLENOID VALVE” in this section. 2) Disconnect rear blower motor coupler (1). 3) Remove rear blower motor assembly (2) from rear A/C unit (3). INSPECTION 1) Check continuity between two terminal as shown.
  • Page 59: Rear Blower Motor Relay And Solenoid Valve Relay

    1B-34 AIR CONDITIONING (OPTIONAL) Rear Blower Motor Relay and Solenoid Valve Relay INSPECTION 1) Disconnect negative (–) cable at battery. 2) Remove rear blower motor relay (1) and/or solenoid valve relay (2) from vehicle. 3) Check that there is no continuity between terminal “c” and “d”.
  • Page 60: Rear Blower Motor Resistor

    AIR CONDITIONING (OPTIONAL) 1B-35 INSPECTION • Check rear A/C main switch for each terminal-to-terminal continuity. If check results are not specified, replace rear A/C main switch. TERMINAL POSITION INSTALLATION Reverse removal procedure for installation. Rear Blower Motor Resistor REMOVAL 1) Remove rear A/C unit referring to “REAR A/C UNIT” in this section.
  • Page 61: Rear Blower Motor Switch

    1B-36 AIR CONDITIONING (OPTIONAL) Rear Blower Motor Switch 1. Rear blower motor switch 5. Rear A/C air louver holder Install proper direction as shown in figure 2. Bulb 6. Rear A/C air louver 3. Bracket 7. Knob 4. Rear A/C air louver case INSPECTION •...
  • Page 62: Rear A/C No.1 And No.2 Duct

    AIR CONDITIONING (OPTIONAL) 1B-37 Rear A/C No.1 and No.2 Duct Rear A/C No.1 duct REMOVAL 1) Remove rear A/C unit referring to “REAR A/C UNIT” in this section. 2) Remove rear A/C No.1 duct (1). INSTALLATION Reverse removal procedure to install rear A/C No.1 duct (1). Rear A/C No.2 duct CAUTION: Never remove rear A/C No.2 duct (2) from head lining.
  • Page 63: Compressor Assembly

    1B-38 AIR CONDITIONING (OPTIONAL) Compressor Assembly CAUTION: None of refrigerant, compressor oil and component parts is interchangeable between two types of A/C: one using CFC-12 (R-12) and the other using HFC-134a (R-134a). For identification between these two types, refer to page 66. When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
  • Page 64 AIR CONDITIONING (OPTIONAL) 1B-39 REMOVAL 1) Run engine at idle with A/C ON for 10 minutes. 2) Disconnect negative (–) cable at battery. 3) Recover refrigerant from refrigeration system using recovery and recycling equipment. NOTE: The amount of compressor oil at removed must be mea- sured and the same amount must be poured when install- ing the compressor.
  • Page 65 1B-40 AIR CONDITIONING (OPTIONAL) INSTALLATION CAUTION: Be sure to use HFC-134a (R-134a) compressor oil. Reverse removal procedure to install compressor assembly not- ing the following instructions. • If compressor was replaced, pour new compressor oil with the same amount as that drained from compressor. Refer to “REPLENISHING COMPRESSOR OIL”...
  • Page 66: Magnet Clutch

    AIR CONDITIONING (OPTIONAL) 1B-41 Magnet Clutch 1. Armature plate bolt 3. Circlip 5. Shim (s) 7. Compressor body assembly 2. Armature plate 4. Magnet clutch 6. Magnet clutch coil 8. Magnet clutch assembly INSPECTION Check the following items. • Check no sigh of compressor oil leakage •...
  • Page 67 1B-42 AIR CONDITIONING (OPTIONAL) 5) Using special tool, remove circlip. Special tool (A) : 09900-06107 6) Remove magnet clutch lead wire clamp screw, and remove magnet clutch read wire ground terminal. 7) Remove magnet clutch with puller. NOTE: Be careful not to damage pulley when tapping magnet clutch.
  • Page 68 AIR CONDITIONING (OPTIONAL) 1B-43 4) Install magnet clutch (1). a) Set magnet clutch squarely over clutch installation boss. b) Place special tool onto clutch bearing. Ensure that edge rests only on inner race of bearing. Special tool (A) : 09991-06010 c) Install new circlip.
  • Page 69: Required Service Materials

    1B-44 AIR CONDITIONING (OPTIONAL) Required Service Materials Recommended SUZUKI product Material (Part Number) Compressor oil (refrigerant oil) COMPRESSOR OIL (ND-OIL8, 250 cc) • O-ring (99000-27080) • Each component Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft Refrigerant pipe (8 mm (0.31 in.)) Refrigerant pipe (12.7 mm (0.5 in.))
  • Page 70 FRONT END ALIGNMENT 3A-1 SECTION 3A FRONT END ALIGNMENT NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual. CONTENTS General Information ........3A-1 On-Vehicle Service ......... 3A-1 Alignment Service Data (without Load) ..3A-1 Reference Information ........
  • Page 71 3A-2 FRONT END ALIGNMENT...
  • Page 72 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
  • Page 73 3B1-2 POWER STEERING (P/S) SYSTEM General Description Power Steering (P/S) Pump Power steering (P/S) pump specification : The specification of this power steering pump is the same as the specification of the same section in the service manual mentioned in this manual except for data of relieved pressure shown below. Relieved pressure : 7850 kPa (78.5 kg/cm , 1116 psi)
  • Page 74 POWER STEERING (P/S) SYSTEM 3B1-3 Hydraulic Pressure in P/S Circuit Hydraulic pressure check 1) After cleaning joint of high pressure hose and P/S pump thoroughly, disconnect hose from pump and install special tool (oil pressure gauge, attachment and hose). CAUTION: Take care not to cause damage to A/C condenser during service operation, if equipped.
  • Page 75 3B1-4 POWER STEERING (P/S) SYSTEM 5) Check relief pressure. a) Increase engine speed to about 1500 r/min (rpm). Close gauge valve gradually while watching pressure increase indicated by gauge and take reading of relief pressure (maximum hydraulic pressure). When it is higher than specified values, possible cause is malfunction of relief valve.
  • Page 76 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On- Vehicle Service” in air bag system section before performing service on or around the air bag sys- tem components or wiring.
  • Page 77 3C1-2 AIR BAG STEERING WHEEL AND COLUMN General Description This double tube type steering column has the following three important features in addition to the steering func- tion: • The column is energy absorbing, designed to compress in a front-end collision. •...
  • Page 78 AIR BAG STEERING WHEEL AND COLUMN 3C1-3 Diagnosis For diagnosis of the steering wheel and steering column, refer to Section 3. For diagnosis of the air bag system, refer to Section 10B. Inspection and Repair Required after Accident After an accident, whether the air bag has been deployed or not, be sure to perform checks, inspections and repairs described under “CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE”...
  • Page 79: Steering Column

    3C1-4 AIR BAG STEERING WHEEL AND COLUMN Steering Column CAUTION: Once the steering column is removed from the vehicle, the column is extremely susceptible to dam- age. Dropping the column assembly on its end could collapse the steering shaft or loosen the plastic shear pins which maintain column length leaning on the column assembly could cause it to bend or deform.
  • Page 80 AIR BAG STEERING WHEEL AND COLUMN 3C1-5 6) Remove steering upper shaft upper joint bolt (1) and nut (2) and disconnect steering upper shaft upper joint removing in arrow direction in the figure. 7) Remove steering column (1) mounting bolts (2 pieces) (2) and nuts (2 pieces) (3).
  • Page 81 3C1-6 AIR BAG STEERING WHEEL AND COLUMN 3) Install steering column assembly (1) with contacting upper side of lower bracket slits to mounting bolts. Tighten steering column lower mounting nuts (3) first and then upper mount- ing bolts (2) to specified torque. Tightening torque Steering column mounting bolts and nuts (b) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
  • Page 82 AIR BAG STEERING WHEEL AND COLUMN 3C1-7 Steering Upper Shaft Assembly CAUTION: Never turn steering wheel while steering upper shaft assembly is removed. Should it have been turned and contact coil (on combina- tion switch) have got out of its centered position, it needs to be centered again.
  • Page 83 3C1-8 AIR BAG STEERING WHEEL AND COLUMN INSPECTION Check steering shaft damage and operation referring to CHECK STEERING COLUMN AND STEERING UPPER SHAFT FOR ACCIDENT DAMAGE later in this section. INSTALLATION 1) Be sure that front tires and steering wheel are in straight ahead position.
  • Page 84 AIR BAG STEERING WHEEL AND COLUMN 3C1-9 6) Install steering upper shaft upper joint bolt (2) and nut (1). Tighten steering upper shaft upper joint nut (1) to specified torque. Tightening torque Steering upper shaft upper joint nut (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft) 1, (a) Steering Lower Shaft Assembly...
  • Page 85 3C1-10 AIR BAG STEERING WHEEL AND COLUMN INSTALLATION 1) Be sure that front wheels and steering wheel are in straight ahead position. 2) Align flat part “A” of lower shaft assembly (1) with bolt hole “B” of shaft joint as shown in the figure. Then insert shaft joint (1) into lower shaft assembly (2).
  • Page 86 AIR BAG STEERING WHEEL AND COLUMN 3C1-11 Checking Steering Column and Steering Upper Shaft for Accident Damage NOTE: Vehicles involved in accidents resulting in body damage, where steering column has been impacted or air bag deployed, may have a damaged or misaligned steering column.
  • Page 87 3C1-12 AIR BAG STEERING WHEEL AND COLUMN • Take measurement “b” as shown in the figure. If it is shorter than specified length, replace steering upper shaft assembly with new one. “b” Steering upper shaft assembly length “b” : 419.0 ± 1.0 mm (16.50 ± 0.04 in.) Tightening Torque Specification Tightening torque Fastening part...
  • Page 88: Front Suspension

    FRONT SUSPENSION 3D-1 SECTION 3D FRONT SUSPENSION CAUTION: • All front suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
  • Page 89 3D-2 FRONT SUSPENSION Tightening Torque Specification...
  • Page 90: Rear Suspension

    REAR SUSPENSION 3E-1 SECTION 3E REAR SUSPENSION NOTE: • For the descriptions (items) not found in this section, refer to the same section of the Service Man- ual mentioned in the FOREWORD of this manual. • All suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense.
  • Page 91 3E-2 REAR SUSPENSION 2) Remove circlip from axle shaft. 3) In order to remove retainer ring (1) from axle shaft (3), grind with a grinder two portion (2) of bearing retainer ring as illus- trated till it becomes thin. CAUTION: Be careful not to grind axle shaft.
  • Page 92 REAR SUSPENSION 3E-3 6) Remove stud bolt(s) (1) by using hydraulic press (2). INSTALLATION Install removed parts in reverse order of removal procedure, not- ing the following. 1) Aligning serrations between new stud bolt(s) (1) and flange (4), install new stud bolt(s) (1) by tightening nut (2) as shown in the figure.
  • Page 93 3E-4 REAR SUSPENSION 5) Apply grease “A” to axle shaft inner oil seal lip as shown in the figure. “A” : Grease 99000-25010 1. Axle housing 6) Apply water tight sealant “B” to mating surfaces of brake back plate and rear axle hub (2). “B”...
  • Page 94: Rear Axle Shaft Inner Oil Seal

    REAR SUSPENSION 3E-5 Rear Axle Shaft Inner Oil Seal INSTALLATION 1) Using special tool drive in oil seal until it contacts oil seal pro- tector in axle housing. NOTE: • Make sure that oil seal is free from inclination as it is installed.
  • Page 95: Tightening Torque Specification

    72.5 Wheel speed sensor bolt 15.5 Required Service Material Recommended SUZUKI product Material (Part Number) Lithium grease SUZUKI SUPER GREASE A • Oil seal lip (99000-25010) Brake fluid DOT 3 • Brake reservoir tank Sealant SUZUKI BOND NO. 1215 • Joint seam of axle and brake back plate (99000-31110) •...
  • Page 96: Special Tool

    REAR SUSPENSION 3E-7 Special Tool 09921-57810 09924-74510 09926-88310 09927-18411 Counter shaft holder Bush remover handle Oil seal installer Universal puller 09942-15510 09943-35512 09944-88210 Sliding hammer Brake drum remover Bearing installer...
  • Page 97 3E-8 REAR SUSPENSION...
  • Page 98: Wheels And Tires

    WHEELS AND TIRES 3F-1 SECTION 3F WHEELS AND TIRES NOTE: • For the descriptions (items) not found in this section, refer to the same section of the Service Man- ual mentioned in the FOREWORD of this manual. • All wheel fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense.
  • Page 99 3F-2 WHEELS AND TIRES...
  • Page 100: Oil Seal

    FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL 4A2-1 SECTION 4A2 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual. CONTENTS On-Vehicle Service........
  • Page 101: On-Vehicle Service

    4A2-2 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL On-Vehicle Service Drive Shaft ASSEMBLY CAUTION: • To prevent any problem caused by washing solution, do not wash joint boots. Degreasing of those parts with cloth is allowed. • Bend each boot band against forward rotation. •...
  • Page 102 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL 4A2-3 6) Install circlip (1) by using snap ring plier. 7) Apply grease to entire surface of cage. Use joint grease in tube included in spare part. 8) Insert cage into outer race and fit circlip (1) into groove of outer race.
  • Page 103 4A2-4 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL Required Service Material Recommended SUZUKI product Material (Part Number) Lithium grease SUZUKI SUPER GREASE A • Drive shaft oil seal (99000-25010) • Wheel spindle part of differential side drive shaft (RH) Sealant SEALING COMPOUND 366E •...
  • Page 104: Propeller Shafts

    PROPELLER SHAFTS 4B-1 SECTION 4B PROPELLER SHAFTS NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual. CONTENTS General Description ........4B-1 Tightening Torque Specification ....4B-2 On-Vehicle Service.........
  • Page 105: Propeller Shaft

    Front propeller shaft flange nuts 36.5 Rear propeller shaft flange nuts 46.5 Center support bolts 36.5 Required Service Material Recommended SUZUKI product Material (Part Number) Thread lock cement THREAD LOCK CEMENT SUPER 1322 • Rear propeller shaft flange bolts (99000-32110)
  • Page 106 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
  • Page 107 5-2 BRAKES Diagnosis Diagnosis Table For the item not found in this column, refer to the same item of the same section in the service manual men- tioned in the FOREWORD of this manual. Condition Possible Cause Correction Brake warning light Parking brake applied Release parking brake and check turns on after engine...
  • Page 108 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
  • Page 109: General Description

    5A-2 BRAKES PIPE/HOSE/MASTER CYLINDER General Description Master Cylinder Assembly The master cylinder has two pistons and three piston cups. Its hydraulic pressure is produced in the primary (“a” in the figure below) and secondary (“b”) chambers. The hydraulic pressure produced in the primary chamber (“a”) acts on the rear wheel brakes.
  • Page 110: On-Vehicle Service

    BRAKES PIPE/HOSE/MASTER CYLINDER 5A-3 On-Vehicle Service Front Brake Hose/Pipe REMOVAL 1) Raise and suitably support vehicle. Remove tire and wheel. This operation is not necessary when removing pipes connecting master cylinder and flexible hose. 2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe. INSTALLATION 1) Reverse removal procedure for brake hose and pipe installation procedure.
  • Page 111 5A-4 BRAKES PIPE/HOSE/MASTER CYLINDER For RH steering vehicle [D]: View D 1. E-ring [a]: Clamp a 2. Flexible hose [b]: Clamp b 3. Hose washer [c]: Clamp d 4. Hose bolt T: Top side 5. Brake caliper F: Front side 6.
  • Page 112 BRAKES PIPE/HOSE/MASTER CYLINDER 5A-5 For LH steering vehicle [D]: View D 1. E-ring [a]: Clamp a 2. Flexible hose [b]: Clamp b 3. Hose washer [d]: Clamp d 4. Hose bolt T: Top side 5. Brake caliper F: Front side 6.
  • Page 113: Master Cylinder Reservoir

    5A-6 BRAKES PIPE/HOSE/MASTER CYLINDER Master Cylinder Reservoir REMOVAL 1) Disconnect reservoir lead wire at coupler. 2) Clean outside of reservoir (1). 3) Take out fluid with syringe or such. 4) Remove reservoir stopper (3). 2. Master cylinder 5) Remove reservoir (1). NOTE: Do not allow brake fluid to get on painted surfaces.
  • Page 114: Master Cylinder Assembly

    BRAKES PIPE/HOSE/MASTER CYLINDER 5A-7 Master Cylinder Assembly REMOVAL NOTE: Do not allow brake fluid to get on painted surfaces. 1) Disconnect reservoir lead wire (1) at coupler. 2) Clean around reservoir cap (2) and take out fluid with syringe or such. 3) Disconnect brake pipes from master cylinder (3) and ABS actuator (4).
  • Page 115: Brake Booster

    5A-8 BRAKES PIPE/HOSE/MASTER CYLINDER Brake Booster 1. Brake master cylinder assembly 4. Push rod clevis 7. Clip 2. Brake booster assembly 5. Nut 8. Plate 3. Gasket 6. Clevis pin 9. Seal CLEARANCE BETWEEN BOOSTER PISTON ROD AND MASTER CYLINDER PISTON CHECK AND ADJUSTMENT The length of booster piston rod (1) is adjusted to provide speci- fied clearance “0”...
  • Page 116 BRAKES PIPE/HOSE/MASTER CYLINDER 5A-9 4) If measured depth is out of above specifications, adjust to specifications below by turning adjusting screw of piston rod. Special tool (F) : 09952-16021 Depth “d” of piston rod for adjustment : 16.3 – 16.6 mm (0.642 – 0.653 in.)
  • Page 117: Tightening Torque Specification

    5A-10 BRAKES PIPE/HOSE/MASTER CYLINDER Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft Brake flexible hose bolt (Brake caliper/2 way joint) 17.0 Brake hose / pipe bracket bolt ABS actuator bracket bolt Master cylinder attaching nut Booster nut Clevis nut 18.0 2-way joint mounting bolt Brake pipe flare nut...
  • Page 118 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
  • Page 119: General Description

    5C-2 PARKING AND REAR BRAKE General Description Drum Brake Assembly The drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is main- tained appropriate at all times. Rear brake is a drum type. It uses leading trailing operation when brake pedal is depressed and when parking brake is applied on level road.
  • Page 120: On-Vehicle Service

    PARKING AND REAR BRAKE 5C-3 On-Vehicle Service Parking Brake Cable 1. Parking brake switch 6. Equalizer 11. Color ring 16. Crossmember 21. Parking brake cable nut 2. Parking brake lever 7. Pin 12. Cable 17. Chassis frame Tightening torque 3. Parking brake lever bolt 8.
  • Page 121 5C-4 PARKING AND REAR BRAKE Cracked, scored, or grooved drum A cracked, drum is unsafe for further service and must be replaced. Do not attempt to weld a cracked drum. Smooth up any slight scores. Heavy or extensive scoring will cause excessive brake lining wear and it will probably be neces- sary to resurface drum braking surface.
  • Page 122: Wheel Cylinder

    PARKING AND REAR BRAKE 5C-5 Wheel Cylinder INSTALLATION For the details, refer to the same item of the same section in the service manual mentioned in the FOREWORD of this manual not- ing the following points. • Take off bleeder plug cap from brake pipe and connect pipe (or pipes) to wheel cylinder (1) just enough to prevent fluid from leaking.
  • Page 123 5C-6 PARKING AND REAR BRAKE 4) Tighten brake back plate nuts to specified torque. Tightening torque Brake back plate nut (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft) 5) Install wheel cylinder, and tighten wheel cylinder bolts and brake pipe flare nut (or nuts) to specified torque. Tightening torque Wheel cylinder bolt : 13.5 N·m (1.35 kg-m, 10.0 lb-ft)
  • Page 124: Tightening Torque Specification

    PARKING AND REAR BRAKE 5C-7 Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft Wheel cylinder bleeder plug 0.75 Parking brake lever bolt 17.0 Wheel cylinder bolt 13.5 1.35 10.0 Brake pipe flare nut 12.0 Brake back plate nut 36.5 Wheel nut 10.0...
  • Page 125 5C-8 PARKING AND REAR BRAKE...
  • Page 126 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
  • Page 127 (Using SUZUKI Scan Tool)...... 5E2-29 DTC C1055 (DTC 55) – Rear Inlet ABS Hydraulic Unit Operation Check Solenoid Circuit........5E2-24 (Not Using Suzuki Scan Tool)....5E2-29 DTC C1042 (DTC 42) – Right-Front ABS Hydraulic Unit/Control Module Outlet Solenoid Circuit ......5E2-24 Assembly ..........
  • Page 128: General Description

    ANTILOCK BRAKE SYSTEM (ABS) 5E2-3 General Description Components/Parts Location The ABS (Antilock Brake System) controls the fluid pressure applied to the wheel cylinder of each brake from the master cylinder so that each wheel is not locked even when hard braking is applied. This ABS has also the following function.
  • Page 129: Abs Hydraulic Unit/Control Module Assembly

    5E2-4 ANTILOCK BRAKE SYSTEM (ABS) ABS Hydraulic Unit/control Module Assembly ABS control module is a component of ABS hydraulic unit/control module assembly and has the following functions. Self-diagnosis function ABS control module diagnoses conditions of the system compo- nent parts (whether or not there is any abnormality) all the time and indicates the results (warning of abnormality occurrence and DTC) through the ABS warning lamp as described below.
  • Page 130: Diagnosis

    ANTILOCK BRAKE SYSTEM (ABS) 5E2-5 Diagnosis To ensure that the trouble diagnosis is done accurately and smoothly, observe “PRECAUTIONS IN DIAGNOSING TROU- BLES” and follow “ABS DIAGNOSTIC FLOW TABLE”. Precautions in Diagnosing Troubles • If the vehicles was operated in any of the following ways, ABS warning lamp may light momentarily but this does not indicate anything abnormal in ABS.
  • Page 131: Abs Diagnostic Flow Table

    5E2-6 ANTILOCK BRAKE SYSTEM (ABS) ABS Diagnostic Flow Table Refer to the following pages for the details of each step. Step Action 1) Perform “Customer Complaint Analysis”. Go to Step 2. Go to Step 5. 2) Perform “Problem Symptom Confirmation”. 3) Perform “Diagnostic Trouble Code Check, Record and Clearance”.
  • Page 132 ANTILOCK BRAKE SYSTEM (ABS) 5E2-7 1) MALFUNCTION ANALYSIS a) 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 a questionnaire form as shown below will facilitate collecting information to the point required for proper analysis and diagnosis.
  • Page 133 5E2-8 ANTILOCK BRAKE SYSTEM (ABS) b) Problem Symptom Confirmation Check if what the customer claimed in “CUSTOMER QUESTIONNAIRE” is actually found in the vehicle and if that symptom is found, whether it is identified as a failure. (This step should be shared with the cus- tomer if possible.) Check warning lamps related to brake system referring to “EBD WARNING LAMP (BRAKE WARNING LAMP) CHECK”...
  • Page 134: Abs Warning Lamp Check

    ANTILOCK BRAKE SYSTEM (ABS) 5E2-9 ABS Warning Lamp Check 1) Turn ignition switch ON. 2) Check that ABS warning lamp (1) comes ON for about 2 sec- onds and then goes off. If any faulty condition is found, advance to Diagnostic Flow Table-A, B, C or D.
  • Page 135: Diagnostic Trouble Code (Dtc) Check (Using Abs Warning Lamp)

    5E2-10 ANTILOCK BRAKE SYSTEM (ABS) Diagnostic Trouble Code (DTC) Check (Using ABS Warning Lamp) 1) Perform ABS WARNING LAMP CHECK described above. 2) Using service wire (4), connect diagnosis switch terminal (2) of monitor coupler (1) to ground (3). 3) Turn ignition switch ON. 4) Read flashing of ABS warning lamp which represents DTC as shown in example below and write it down.
  • Page 136: Diagnostic Trouble Code (Dtc) Check (Using Suzuki Scan Tool)

    2) Turn ignition switch ON. 3) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool operator’s manual for further details. 4) After completing the check, turn ignition switch off and dis- connect SUZUKI scan tool from DLC.
  • Page 137: Diagnostic Trouble Code (Dtc) Table

    FLOW TABLE” in this section) and “DTC CHECK” and con- firm that normal DTC (DTC 12) is displayed ; not malfunction DTC. NOTE: It is also possible to clear DTC by using SUZUKI scan tool. Refer to Cartridge Manual for procedure to clear DTC. Diagnostic Trouble Code (DTC) Table CAUTION: Be sure to perform “ABS DIAGNOSTIC FLOW TABLE”...
  • Page 138 ANTILOCK BRAKE SYSTEM (ABS) 5E2-13 (displayed (indicated by ABS warning lamp flashing DIAGNOSTIC ITEMS on SUZUKI ABS warning pattern scan tool) lamp) C1022 C1026 Wheel speed sensor circuit or sensor ring C1032 C1036 C1041 Inlet solenoid valve circuit C1042 Outlet solenoid valve circuit...
  • Page 139: System Circuit

    5E2-14 ANTILOCK BRAKE SYSTEM (ABS) System Circuit 1. Battery 11. ABS fail-safe transistor (Solenoid valve transistor) 21. To ECM and SDM (if equipped) 2. Main fuses 12. ABS pump motor transistor 22. Stop lamp 3. Ignition switch 13. Pump motor 23.
  • Page 140: Switch On

    ANTILOCK BRAKE SYSTEM (ABS) 5E2-15 Table-A ABS Warning Lamp Circuit Check – Lamp Does Not Come “ON” at Ignition Switch ON 1. Main fuse 5. ABS warning lamp 9. Brake fluid level switch 2. Ignition switch 6. Brake warning lamp 10.
  • Page 141 Perform diagnostic trouble code check. Is there Go to Step 2. Go to Step 3. any DTC (including code No.12, NO CODES on SUZUKI scan tool) exists? Does malfunction DTC (other than code No.12) Go to Step 7 of “ABS Go to Step 3.
  • Page 142 ANTILOCK BRAKE SYSTEM (ABS) 5E2-17 Table-C ABS Warning Lamp Circuit Check – The Lamp Flashes Continuously While Ignition Switch Is ON 1. ABS warning lamp in combination meter 3. Diagnosis monitor coupler 3-2. Diagnosis ground terminal 2. ABS hydraulic unit/control module assembly 3-1.
  • Page 143: Connected To Ground

    5E2-18 ANTILOCK BRAKE SYSTEM (ABS) Table-D Code (DTC) Is Not Outputted Even with Diagnosis Switch Terminal Connected to Ground 1. ABS warning lamp in combination meter 3. Diagnosis monitor coupler 3-2. Diagnosis ground terminal 2. ABS hydraulic unit/control module assembly 3-1.
  • Page 144: On" Steady

    ANTILOCK BRAKE SYSTEM (ABS) 5E2-19 Table-E EBD Warning Lamp (Brake Warning Lamp) Check – Lamp Comes “ON” Steady CIRCUIT DESCRIPTION EBD warning lamp (brake warning lamp) is controlled by parking brake switch, brake fluid level switch and ABS control module/hydraulic unit assembly through lamp driver module in combination meter. Refer to “TABLE – A” for circuit diagram.
  • Page 145: Dtc C1015 (Dtc 15) - G Sensor Circuit And 4Wd Lamp Circuit

    5E2-20 ANTILOCK BRAKE SYSTEM (ABS) DTC C1015 (DTC 15) – G Sensor Circuit and 4WD Lamp Circuit 1. Ignition switch 3. ABS hydraulic unit/control module assembly 5. 4WD lamp 7. 4WD switch 2. G sensor 4. ABS hydraulic unit/control module connector 6.
  • Page 146 ANTILOCK BRAKE SYSTEM (ABS) 5E2-21 INSPECTION Step Action 1) Turn ignition switch ON. Go to Step 2. Replace bulb or repair its Does 4WD lamp turn ON when 4WD switch circuit. turns ON? 1) Ignition switch OFF. Go to Step 3. Repair 4WD control sys- 2) Check for proper connection to ECM (PCM) tem.
  • Page 147: Dtc C1021 (Dtc 21), Dtc C1022

    5E2-22 ANTILOCK BRAKE SYSTEM (ABS) DTC C1021 (DTC 21), DTC C1022 (DTC 22) – Right-Front Wheel Speed Sensor Circuit or Sensor Ring DTC C1025 (DTC 25), DTC C1026 (DTC 26) – Left-Front Wheel Speed Sensor Circuit or Sensor Ring DTC C1031 (DTC 31), DTC C1032 (DTC 32) – Right-Rear Wheel Speed Sensor Circuit or Sensor Ring DTC C1035 (DTC 35), DTC C1036 (DTC 36) –...
  • Page 148 ANTILOCK BRAKE SYSTEM (ABS) 5E2-23 INSPECTION Step Action 1) Disconnect applicable ABS wheel speed sensor coupler Go to Step 2. Replace ABS wheel with ignition switch OFF. speed sensor 2) Measure resistance between terminals of ABS wheel assembly. speed sensor. Refer to “FRONT WHEEL SPEED SEN- SOR”...
  • Page 149: Dtc C1041 (Dtc 41) - Right-Front Inlet Solenoid Circuit

    5E2-24 ANTILOCK BRAKE SYSTEM (ABS) DTC C1041 (DTC 41) – Right-Front Inlet Solenoid Circuit DTC C1045 (DTC 45) – Left-Front Inlet Solenoid Circuit DTC C1055 (DTC 55) – Rear Inlet Solenoid Circuit DTC C1042 (DTC 42) – Right-Front Outlet Solenoid Circuit DTC C1046 (DTC 46) –...
  • Page 150: Circuit

    ANTILOCK BRAKE SYSTEM (ABS) 5E2-25 DTC C1057 (DTC 57) – Power Source Circuit 1. Ignition switch 3. ABS hydraulic unit/control module assembly 2. Main fuse 4. ABS hydraulic unit/control module connector DESCRIPTION The ABS control module monitors the power source voltage at terminal “E136-18”. When the power source volt- age becomes extremely high or low, this DTC will be set.
  • Page 151: Dtc C1061 (Dtc 61) - Abs Pump Motor Circuit

    5E2-26 ANTILOCK BRAKE SYSTEM (ABS) DTC C1061 (DTC 61) – ABS Pump Motor Circuit 1. ABS hydraulic unit/control module assembly 3. ABS pump motor 5. ABS hydraulic unit/control module connector 2. ABS pump motor relay 4. ABS fail safe relay DESCRIPTION The ABS control module monitors the voltage at monitor terminal of pump motor circuit constantly with the igni- tion switch turned ON.
  • Page 152: Dtc C1063 (Dtc 63) - Abs Fail-Safe Relay Circuit

    ANTILOCK BRAKE SYSTEM (ABS) 5E2-27 DTC C1063 (DTC 63) – ABS Fail-Safe Relay Circuit 1. Ignition switch 3. ABS hydraulic unit/control module connector 5. Fail-safe relay 2. ABS hydraulic unit/control module assembly 4. To solenoid valves DESCRIPTION ABS control module monitors the voltage at the terminal of solenoid circuit constantly with ignition switch turned ON.
  • Page 153: Dtc C1071 (Dtc 71) - Abs Control Module

    5E2-28 ANTILOCK BRAKE SYSTEM (ABS) DTC C1071 (DTC 71) – ABS Control Module 1. ABS hydraulic unit/control module assembly 3. ABS pump motor 5. ABS hydraulic unit/control module connector 2. ABS pump motor relay 4. ABS fail safe relay DESCRIPTION This DTC will be set when an internal malfunction is detected in the ABS control module.
  • Page 154: On-Vehicle Service

    ON. Then DTC will be set in ABS control mod- ule. ABS Hydraulic Unit Operation Check (Using SUZUKI Scan Tool) 1) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. Special tool (A) : SUZUKI scan tool 2) Turn ignition switch to ON position and check actuator opera- tion using “HYDRAULIC CONTROL TEST”...
  • Page 155 5E2-30 ANTILOCK BRAKE SYSTEM (ABS) 9) Perform following checks with help of another person. 10) Brake pedal (1) should be depressed. a) Ignition switch turned to ON position by one person. b) Wheel should be turned by another person’s hand. At this time, check that: •...
  • Page 156: Abs Hydraulic Unit/Control Module Assembly

    ANTILOCK BRAKE SYSTEM (ABS) 5E2-31 ABS Hydraulic Unit/Control Module Assembly CAUTION: Never disassemble ABS hydraulic unit/control module assembly, loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of ABS hydraulic unit/ control module assembly. 16 N·m (1.6 kg-m) N·m (1.0 kg-m) N·m (0.9 kg-m)
  • Page 157 5E2-32 ANTILOCK BRAKE SYSTEM (ABS) 3) Using special tool, loosen flare nuts (1) and disconnect brake pipes (2) from ABS hydraulic unit/control module assembly (3). Special tool 09950-78220 NOTE: Put bleeder plug cap onto pipe to prevent fluid from spill- ing.
  • Page 158: Rear Sensor Rotor (Retainer Ring)

    ANTILOCK BRAKE SYSTEM (ABS) 5E2-33 Rear Sensor Rotor (Retainer Ring) REMOVAL 1) Remove rear axle shaft assembly. Refer to “REAR AXLE SHAFT” in Section 3E. 2) In order to remove sensor rotor (retainer ring) (2) from shaft (1), grind with a grinder one part “A” of the sensor rotor (retainer ring) as shown till it becomes thin.
  • Page 159: Tightening Torque Specification

    Parking lever assembly mounting bolt : (f) 17.0 Special Tool 09950-78220 09931-76011 09931-76030 Flare nut wrench (10 mm) Tech 1A kit (SUZUKI scan Mass storage cartridge for 16/14 pin DLC cable for tool) Tech 1A Tech 1A (See NOTE A.)
  • Page 160 ANTILOCK BRAKE SYSTEM (ABS) 5E2-35 Tech 2 kit (SUZUKI scan tool) (See NOTE B.) NOTE: A. This kit includes the following items and substitutes for the Tech 2 kit. 1. Storage case, 2. Operator’s manual, 3. Tech 1A, 4. DLC cable, 5. Test lead/probe, 6. Power source cable, 7.
  • Page 161 5E2-36 ANTILOCK BRAKE SYSTEM (ABS)
  • Page 162 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
  • Page 163 6-1-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Table A-4 Malfunction Indicator Lamp Circuit Malfunction ........6-1-82 Check – MIL Does Not Flash or Just DTC P0335 Crankshaft Position Sensor Remains ON Even with Grounding Circuit Malfunction ........6-1-84 Diagnosis Switch Terminal (Vehicle with DTC P0340 (DTC No.42) Camshaft Monitor Connector) ........
  • Page 164: General Information

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-3 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 165: Precaution On Fuel System Service

    6-1-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) • When disconnecting couplers, don’t pull wire harness but make sure to hold coupler itself. With lock type coupler, be sure to unlock before disconnection. Attempt to disconnect coupler without unlocking may result in damage to coupler. When connecting lock type coupler, insert it till clicking sound is heard and connect it securely.
  • Page 166: Fuel Pressure Relief Procedure

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-5 Fuel Pressure Relief Procedure CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. After making sure that engine is cold, relief fuel pressure as fol- lows.
  • Page 167: Engine Diagnosis

    (For the details, refer to description on Freeze frame data.) • It is possible to communicate by using not only SUZUKI scan tool (2) but also generic scan tool. (Diagnostic information can be accessed by using a scan tool.)
  • Page 168 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-7 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).
  • Page 169 DLC (1) is in compliance with SAEJ1962 in its installation posi- tion, the shape of connector and pin assignment. K line of ISO 9141 is used for SUZUKI scan tool or generic scan tool to communicate with ECM (PCM), ABS control module and Air bag SDM.
  • Page 170: On-Board Diagnostic System (Vehicle With Monitor Connector)

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-9 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 running, and indicates the result by turning on of flashing mal- function indicator lamp (1).
  • Page 171: Precaution In Diagnosing Trouble

    ECM (PCM) memory. Such disconnection will erase memorized information in ECM (PCM) memory. • Diagnostic information stored in ECM (PCM) memory can be cleared as well as checked by using SUZUKI scan tool or generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
  • Page 172: Engine Diagnostic Flow Table

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-11 Engine Diagnostic Flow Table Refer to following pages for the detail of each step. Step Action Customer Complaint Analysis Go to Step 2. Perform customer com- 1) Perform customer complaint analysis. plaint analysis. Was customer complaint analysis performed? DTC(s)/Freeze Frame Data Check Record DTC(s)/Freeze...
  • Page 173 6-1-12 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) STEP 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 174 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-13 STEP 2. DIAGNOSTIC TROUBLE CODE (DTC)/FREEZE FRAME DATA CHECK First, check DTC, referring to “DIAGNOSTIC TROUBLE CODE CHECK” in this section. If DTC is indicated, record DTC and freeze frame data. After that clear DTC referring to “DIAGNOSTIC TROUBLE CODE CLEARANCE” in this section. DTC indicates 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 175 6-1-14 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) STEP 6. AND 7. RECHECKING AND RECORD OF DTC Refer to “DTC Check” in this section for checking procedure. STEP 8. ENGINE BASIC INSPECTION AND ENGINE DIAGNOSIS TABLE Perform basic engine check according to the “ENGINE BASIC INSPECTION FLOW TABLE” first. When the end of the flow table has been reached, check the parts of the system suspected as a possible cause referring to “ENGINE DIAGNOSIS TABLE”...
  • Page 176 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-15 STEP 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 177: Malfunction Indicator Lamp (Mil) Check

    “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 (2). 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 178: Diagnostic Trouble Code (Dtc) Clearance

    1) Check malfunction indicator lamp referring to “Malfunction Indicator Lamp Check” in this section. 2) With the ignition switch OFF position, disconnect SUZUKI scan tool if connected and using service wire (4), connect diagnosis switch terminal (1) to ground terminal (2) in moni- tor connector (3).
  • Page 179: Diagnostic Trouble Code (Dtc) Table

    6-1-18 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) [Without using scan tool] 1) Turn the ignition switch OFF position. 2) Disconnect battery negative cable for specified time below to erase diagnostic trouble code stored in ECM memory and reconnect it. Time required to erase DTC: Ambient Time to cut power to ECM...
  • Page 180 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-19 (vehicle (vehicle DETECTING CONDITION DTC NO. DETECTED ITEM without with (DTC will set when detecting : ) monitor monitor connector) connector) Response time of HO2S-1 output volt- HO2S circuit slow response 2 driving P0133 age between rich and lean is longer (Bank 1 - Sensor 1)
  • Page 181 6-1-20 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) (vehicle (vehicle DETECTING CONDITION DTC NO. DETECTED ITEM without with (DTC will set when detecting : ) monitor monitor connector) connector) Short term fuel trim or total fuel trim (short and long terms added) is larger 2 driving P0174 Fuel system too lean (Bank 2)
  • Page 182: For A/T System (Refer To Section 7B1 For Diagnosis)

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-21 (vehicle (vehicle DETECTING CONDITION DTC NO. DETECTED ITEM without with (DTC will set when detecting : ) monitor monitor connector) connector) Difference between desired idle speed Idle air control system mal- and actual idle speed continues to 2 driving P0505 function...
  • Page 183: For Immobilizer Control System (Refer To Section 8G For Diagnosis)

    6-1-22 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) (vehicle (vehicle DETECTING CONDITION DTC NO. DETECTED ITEM without with (DTC will set when detecting : ) monitor monitor connector) connector) P0753 Monitor signal OFF is detected when 1 driving (No.61) Shift solenoid A (#1) electrical shift solenoid A (#1) is ON or monitor cycle applicable...
  • Page 184: Fail-Safe Table

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-23 Fail-Safe Table When any of the following DTCs is detected, ECM (PCM) enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ECM (PCM) detects normal condition after that. DTC NO.
  • Page 185: Scan Tool Data

    Be sure to use the timing light to check the ignition timing referring to Section 6F2. NOTE: • For asterisk (✱) marked item in “OTHER” column, item can be read only SUZUKI scan tool. • When checking the data with the engine running at idle or racing, be sure to shift M/T gear to the neutral gear position and A/T gear to the “Park”...
  • Page 186 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-25 NORMAL CONDITION/ SCAN TOOL DATA CONDITION OTHER REFERENCE VALUE INJ PULSE WIDTH B2 At specified idle speed with no load after 2.0 – 3.3 msec ✱ warming up. At 2500 r/min with no load after warming up. 2.2 –...
  • Page 187 6-1-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) NORMAL CONDITION/ SCAN TOOL DATA CONDITION OTHER REFERENCE VALUE PNP SIGNAL (Transmis- With ignition switch ON, selector lever in “P” P/N Range sion Range Switch) (for 4- or “N” position ✱ A/T) With ignition switch ON, selector lever in “R”, D Range “D”, “2”...
  • Page 188: Scan Tool Data Definitions

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-27 Scan tool data definitions COOLANT TEMP (Engine Coolant Temp., °C/°F) It is detected by engine coolant temp. sensor. INTAKE AIR TEMP (°C/°F) It is detected by intake air temp. sensor. DESIRE IDLE (Desired Idle Speed RPM) The desired idle speed is an ECM (PCM) internal parameter which indicates the ECM (PCM) requested idle.
  • Page 189 6-1-28 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) TP SENSOR VOLT (TP Sensor Output Voltage, V) Throttle Position Sensor reading provides throttle valve opening information in the from of voltage. O2S B1 S1 (HO2S Bank 1 Sensor 1 Output Voltage, V) / O2S B2 S1 (HO2S Bank 2 Sensor 1 Output Voltage, V) It indicates output voltage of HO2S SENSOR 1 installed on exhaust manifold (pre-catalyst).
  • Page 190 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-29 EGR VALVE (%) This parameter indicates opening rate of EGR valve which controls the amount of EGR flow. A/C SWITCH (ON/OFF) ON : Command for operation being output from A/C amplifier to compressor. OFF : Command for operation not being output.
  • Page 191 6-1-30 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) SHIFT SOL #2 CON/MON (Shift Solenoid #2, B Command/monitor, ON/OFF) CON-ON : ON command being output to shift solenoid #2, B. CON-OFF : ON command not being output. MON-ON : Electricity being passed to shift solenoid #2, B. MON-OFF : Electricity not being passed.
  • Page 192: Engine Diagnosis Table

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-31 Engine Diagnosis Table Perform troubleshooting referring to following table when ECM (PCM) has detected no DTC and no abnormality has been found in visual inspection and engine basic inspection previously. Condition Possible Cause Correction Hard starting Faulty idle air control system...
  • Page 193 6-1-32 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Condition Possible Cause Correction Improper engine idling Faulty spark plug Spark plugs in Section 6F2. or engine fails to idle Faulty ignition coil with ignitor Ignition coil in Section 6F2. Fuel pressure out of specification “DIAG.
  • Page 194 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-33 Condition Possible Cause Correction Surges Defective spark plug Spark plugs in Section 6F2. (Engine power varia- (excess carbon deposits, improper gap, and tion under steady burned electrodes, etc.) throttle or cruise. Variable fuel pressure “DIAG.
  • Page 195 6-1-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Condition Possible Cause Correction Poor gasoline mileage Faulty spark plug (improper gap, heavy depos- Spark plugs in Section 6F2. its, and burned electrodes, etc.) Fuel pressure out of specification “DIAG. FLOW TABLE B-3” in this section.
  • Page 196 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-35 Condition Possible Cause Correction Engine noise Faulty hydraulic valve lash adjuster Hydraulic valve lash adjuster in (Note : Before check- Section 6A2. ing the mechanical Worn valve stem and guide Valves inspection in Section 6A2. noise, make sure the Weak or broken valve spring Valve springs inspection in Section...
  • Page 197: Inspection Of Pcm (Ecm) And Its Circuits

    6-1-36 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 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 pro- hibited to connect voltmeter or ohmmeter to PCM (ECM) with couplers disconnected from it.
  • Page 198 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-37 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Power source for CO adjusting E61-1 10 – 14 V Ignition switch ON resistor (if equipped) E61-2 Power source for back up 10 – 14 V Ignition switch ON and OFF E61-3 –...
  • Page 199 6-1-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Ignition switch ON, A/C not oper- A/C condenser fan motor relay E61-22 10 – 14 V ated and Engine coolant temp. : (if equipped) less than 113°C, 235°F For 3 sec.
  • Page 200 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-39 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Ignition switch ON, Throttle valve at 0.5 – 1.2 V idle position C51-3-9 Throttle position sensor Ignition switch ON, Throttle valve at 3.4 – 4.7 V full open position 1.0 –...
  • Page 201 6-1-40 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION A/T input speed sensor (–) C51-1-10 About 2.5 V Ignition switch ON (A/T vehicle) A/T input speed sensor (+) C51-1-11 About 2.5 V Ignition switch ON (A/T vehicle) Deflects between Ignition switch ON, crankshaft C51-1-12...
  • Page 202 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-41 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION C51-2-1 Fuel injector No.2 10 – 14 V Ignition switch ON C51-2-2 Fuel injector No.1 C51-2-3 – – – 10 – 14 V Ignition switch ON Heater of HO2S-1 (bank 1) C51-2-4 At specified idle speed after engine (if equipped)
  • Page 203 6-1-42 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) RESISTANCE CHECK 1) Disconnect couplers (1) from ECM/PCM with ignition switch OFF. CAUTION: Never touch terminals of ECM/PCM itself or connect volt- meter or ohmmeter (2). 2) Check resistance between each pair of terminals of discon- nected couplers (1) as listed in following table.
  • Page 204: On" Or Dims At Ignition Switch On

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-43 Table A-1 Malfunction Indicator Lamp Circuit Check – Lamp Does Not Come “ON” or Dims at Ignition Switch ON (But Engine at Stop) WIRING DIAGRAM 1. MIL 2. To ignition switch 3. Main fuse 4.
  • Page 205 6-1-44 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Step Action ECM power and ground circuit check : Go to Step 3. Go to “TABLE A-3 ECM Does engine start? (PCM) POWER AND GROUND CIRCUIT CHECK” in this section. If engine is not cranked, go to “DIAGNOSIS”...
  • Page 206: On (Vehicle With Monitor Connector)

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-45 Table A-3 Malfunction Indicator Lamp Check – MIL Flashes at Ignition Switch ON (Vehicle with Monitor Connector) WIRING DIAGRAM/CIRCUIT DESCRIPTION Refer to TABLE A-1. TROUBLESHOOTING Step Action MIL Flashing Pattern check: Go to Step 2. Go to “Diagnosis”...
  • Page 207 6-1-46 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 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. MIL 2. To ignition switch 3.
  • Page 208 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-47 INSPECTION Step Action Main relay operating sound check : Go to Step 5. Go to Step 2. Is operating sound of main relay heard at igni- tion switch ON? Fuse check : Go to Step 3.
  • Page 209: Dtc P0100 (Dtc No.33, 34) Mass Air Flow Circuit Malfunction

    6-1-48 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0100 (DTC No.33, 34) Mass Air Flow Circuit Malfunction WIRING DIAGRAM 1. Main fuse 2. Main relay 3. ECM/PCM 4. Mass air flow sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Any one of the following conditions are detected for 5 •...
  • Page 210 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-49 DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
  • Page 211: Dtc P0110 (Dtc No.23, 25) Intake Air Temp. (Iat) Circuit Malfunction

    6-1-50 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0110 (DTC No.23, 25) Intake Air Temp. (IAT) Circuit Malfunction WIRING DIAGRAM 1. IAT sensor 2. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Any one of the conditions are detected for 5 sec. con- •...
  • Page 212 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-51 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. Check IAT sensor and its circuit : Go to Step 3. Intermittent trouble.
  • Page 213: Dtc P0115 (Dtc No.14, 15) Engine Coolant Temp. Circuit Malfunction

    6-1-52 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0115 (DTC No.14, 15) Engine Coolant Temp. Circuit Malfunction WIRING DIAGRAM 1. ECT sensor 2. To combination (ECT) meter 3. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Any one of the conditions are detected for 5 sec.
  • Page 214 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-53 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. Check ECT sensor and its circuit : Go to Step 3. Intermittent trouble.
  • Page 215: Dtc P0120 (Dtc No.21, 22) Throttle Position Circuit Malfunction

    6-1-54 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0120 (DTC No.21, 22) Throttle Position Circuit Malfunction WIRING DIAGRAM 1. Throttle position sensor 2. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following conditions are detected for 5 sec. continuously. •...
  • Page 216 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-55 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE”. Check TP sensor and its circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition Check for intermittent switch OFF and then turn ignition switch...
  • Page 217: Dtc P0121 Throttle Position Circuit Range/Performance Problem

    6-1-56 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0121 Throttle Position Circuit Range/Performance Problem WIRING DIAGRAM/CIRCUIT DESCRIPTION Refer to DTC P0120. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Throttle opening change is smaller than specification •...
  • Page 218 Does voltage vary within specified value linearly as shown in the figure? Check TP sensor and its circuit (not using SUZUKI If voltmeter was used, Go to Step 6. scan tool) : check terminal C51-3-9 for 1) Turn ignition switch ON.
  • Page 219: Dtc P0130 (Dtc No.13) Ho2S-1 (Bank 1) Circuit Malfunction Or No Activity Detected

    6-1-58 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0130 (DTC No.13) HO2S-1 (Bank 1) Circuit Malfunction or No Activity Detected WIRING DIAGRAM 1. HO2S heater relay 2. ECM (PCM) 3. HO2S-1 (Bank-1) DTC DETECTING CONDITION AND TROUBLE AREA NOTE: For vehicle with monitor connector, DTC will set when following only (*) mark condition is detected.
  • Page 220 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-59 DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
  • Page 221: Dtc P0133 Ho2S-1 (Bank 1) Circuit Slow Response

    6-1-60 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Step Action Short term fuel trim check : Intermittent trouble Go to DTC P0171/ 1) Run engine at 2000 r/min. for 60 sec. or faulty ECM P0172 Diag. Flow 2) With engine idling, check short term fuel trim displayed (PCM).
  • Page 222: Dtc P0135 Ho2S-1 (Bank 1) Heater Circuit Malfunction

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-61 DTC P0135 HO2S-1 (Bank 1) Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0130. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following condition is detected when HO2S heater is HO2S-1 heater circuit electrically live (2 driving cycle detection logic).
  • Page 223 6-1-62 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Step Action HO2S heater control circuit check : Substitute a known-good Faulty HO2S heater relay 1) With ignition switch OFF, install HO2S ECM (PCM) and recheck. or “BLK” wire open, “BLU” heater relay. wire open or shorted to 2) With ignition switch ON leaving engine OFF, ground circuit...
  • Page 224: Dtc P0136 Ho2S-2 (Bank 1) Circuit Malfunction

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-63 DTC P0136 HO2S-2 (Bank 1) Circuit Malfunction WIRING DIAGRAM 1. HO2S heater relay 2. ECM (PCM) 3. HO2S-2 (Bank-1) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC will set when any one of following conditions is detected (2 driving •...
  • Page 225 6-1-64 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) NOTE: Check to make sure that following conditions are satisfied when using this “DTC CONFIRMATION PROCEDURE”. • Intake air temp. : – 8°C (18°F) or higher • Engine coolant temp. : – 8 – 110°C (18 – 230°F) •...
  • Page 226: Dtc P0141 Ho2S-2 (Bank 1) Heater Circuit Malfunction

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-65 DTC P0141 HO2S-2 (Bank 1) Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0136. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following condition is detected when HO2S-2 heater operates (2 HO2S-2 heater or its circuit driving cycle detection logic).
  • Page 227 6-1-66 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. HO2S-2 heater check : Go to Step 3. Replace HO2S-2. 1) Disconnect HO2S-2 coupler with ignition switch OFF.
  • Page 228: Dtc P0150 (Dtc No.26) Ho2S-1 (Bank 2) Circuit Malfunction Or No Activity Detected

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-67 DTC P0150 (DTC No.26) HO2S-1 (Bank 2) Circuit Malfunction or No Activity Detected WIRING DIAGRAM 1. HO2S heater relay 2. ECM (PCM) 3. HO2S-1 (Bank-2) DTC DETECTING CONDITION AND TROUBLE AREA NOTE: For vehicle with monitor connector, DTC will set when following only (*) mark condition is detected.
  • Page 229 6-1-68 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
  • Page 230: Dtc P0153 Ho2S-1 (Bank 2) Circuit Slow Response

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-69 Step Action Short term fuel trim check : Intermittent trouble Go to DTC P0174/ 1) Run engine at 2000 r/min. for 60 sec. or faulty ECM P0175 Diag. Flow 2) With engine idling, check short term fuel trim displayed (PCM).
  • Page 231: Dtc P0155 Ho2S-1 (Bank 2) Heater Circuit Malfunction

    6-1-70 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0155 HO2S-1 (Bank 2) Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0150. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following condition is detected when HO2S heater is HO2S-1 heater circuit electrically live (2 driving cycle detection logic).
  • Page 232 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-71 Step Action HO2S heater control circuit check : Substitute a known-good Faulty HO2S heater relay 1) With ignition switch OFF, install HO2S ECM (PCM) and recheck. or “BLK” wire open, “BLU” heater relay. wire open or shorted to 2) With ignition switch ON leaving engine OFF, ground circuit, “BLK/RED”...
  • Page 233: Dtc P0156 Ho2S-2 (Bank 2) Circuit Malfunction

    6-1-72 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0156 HO2S-2 (Bank 2) Circuit Malfunction WIRING DIAGRAM 1. HO2S heater relay 2. ECM (PCM) 3. HO2S-2 (Bank-2) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC will set when any one of following conditions is detected (2 driving •...
  • Page 234 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-73 NOTE: Check to make sure that following conditions are satisfied when using this “DTC CONFIRMATION PROCEDURE”. • Intake air temp. : – 8°C (18°F) or higher • Engine coolant temp. : – 8 – 110°C (18 – 230°F) •...
  • Page 235: Dtc P0161 Ho2S-2 (Bank 2) Heater Circuit Malfunction

    6-1-74 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0161 HO2S-2 (Bank 2) Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0156. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following condition is detected when HO2S-2 heater operates (2 HO2S-2 heater or its circuit driving cycle detection logic).
  • Page 236 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-75 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. HO2S-2 heater check : Go to Step 3. Replace HO2S-2. 1) Disconnect HO2S-2 coupler with ignition switch OFF.
  • Page 237: Dtc P0171/P0172 Fuel System Too Lean/Rich (Bank 1)

    6-1-76 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0171/P0172 Fuel System Too Lean/Rich (Bank 1) DTC DETECTING CONDITION AND POSSIBLE CAUSE DTC DETECTING CONDITION TROUBLE AREA When running after engine warmed (2 driving cycle • Vacuum leaks (air inhaling) detection logic).
  • Page 238 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-77 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. Is there DTC (s) other than “DTC P0171/ Go to applicable DTC Go to Step 3.
  • Page 239: Dtc P0174/P0175 Fuel System Too Lean/Rich (Bank 2)

    6-1-78 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0174/P0175 Fuel System Too Lean/Rich (Bank 2) DTC DETECTING CONDITION AND POSSIBLE CAUSE DTC DETECTING CONDITION TROUBLE AREA When running after engine warmed (2 driving cycle • Vacuum leaks (air inhaling) detection logic).
  • Page 240 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-79 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. Is there DTC (s) other than “DTC P0174/ Go to applicable DTC Go to Step 3.
  • Page 241: Dtc P0300/P0301/P0302/P0303/P0304/P0305/P0306 Random Misfire/Cylinder

    6-1-80 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306 Random Misfire/Cylinder 1 Misfire/Cylinder 2 Misfire/Cylinder 3 Misfire/Cylinder 4 Misfire Detected/Cyl- inder 5 Misfire Detected/Cylinder 6 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 242 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-81 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. Ignition system inspection : Go to Step 3. Faulty ignition coil, wire 1) Check spark plug and ignition spark of cylin- harness, or other system der where misfire occurs, referring to “IGNI-...
  • Page 243 6-1-82 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0325 (DTC No.43) Knock Sensor Circuit Malfunction CIRCUIT DESCRIPTION 1. Knock sensor 2. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC will set when one of the following condition is •...
  • Page 244 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-83 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. Knock sensor and its circuit check : Knock sensor and its cir- Go to Step 3.
  • Page 245: Dtc P0335 Crankshaft Position Sensor Circuit Malfunction

    6-1-84 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0335 Crankshaft Position Sensor Circuit Malfunction WIRING DIAGRAM 1. CKP sensor 2. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA CKP sensor signal is not input while 100 pulses of CKP sensor circuit CMP sensor signal are input after engine start.
  • Page 246 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-85 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE” in this section. CKP sensor and its circuit resistance check : Go to Step 4. Go to Step 3.
  • Page 247: Dtc P0340 (Dtc No.42) Camshaft Position Sensor Circuit Malfunction

    6-1-86 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0340 (DTC No.42) Camshaft Position Sensor Circuit Malfunction WIRING DIAGRAM 1. CMP sensor 2. To main relay 3. ECM (PCM) SYSTEM DESCRIPTION CMP sensor detects REF signal and POS signal. • REF signal : 4 pulses/1 revolution of camshaft. There are 2 different kinds of wavelength. Based on REF sig- nal, ECM (PCM) judges which cylinder is at TDC.
  • Page 248 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-87 DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA CMP sensor signal is not inputted for 3 sec. even though CMP sensor circuit engine start signal is being inputted. CMP sensor Engine starter signal circuit REF signal pattern is incorrect while POS signal varies.
  • Page 249 6-1-88 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Step Action CMP sensor (REF) signal check : Go to Step 6. Faulty “YEL/GRN” wire 1) With ignition switch OFF, connect CMP sensor or CMP sensor. coupler. If OK, substitute a 2) Disconnect couplers from ignition coil assembly known-good ECM and fuel injectors.
  • Page 250: Dtc P0400 Exhaust Gas Recirculation Flow Malfunction

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-89 DTC P0400 Exhaust Gas Recirculation Flow Malfunction SYSTEM/WIRING DIAGRAM 1. EGR valve 5. ECM (PC) 2. Intake manifold 6. MAP sensor 3. Exhaust gas 7. Main fuse 4. Sensed information 8. Main relay...
  • Page 251 6-1-90 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA During deceleration (engine speed high with closed • EGR valve throttle position) in which fuel cut is involved, difference • EGR passage in intake manifold pressure between when EGR valve is •...
  • Page 252 Go to Step 4. 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 6E2. Is it in good condition?
  • Page 253: Dtc P0403 (Dtc No.51) Exhaust Gas Recirculation Circuit Malfunction

    6-1-92 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0403 (DTC No.51) Exhaust Gas Recirculation Circuit Malfunction WIRING DIAGRAM 1. Main fuse 4. ECM (PCM) 2. Main relay 3. EGR valve DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA High voltage is detected at EGR valve stepping motor EGR valve (stepping motor) or its circuit ECM...
  • Page 254 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-93 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. EGR valve check : Go to Step 3. EGR valve malfunction. 1) With ignition switch OFF, disconnect connec- tor from EGR valve.
  • Page 255: Dtc P0420 Catalyst System Efficiency Below Threshold (Bank 1)

    6-1-94 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0420 Catalyst System Efficiency Below Threshold (Bank 1) SYSTEM DIAGRAM 1. HO2S-1 (Bank-1) 4. TWC 2. HO2S-2 (Bank-1) 5. ECM (PCM) 3. WU-TWC CIRCUIT DESCRIPTION Exhaust oxygen concentration at the pre-catalyst and the post-catalyst of WU-TWC is detected from HO2S-1 and HO2S-2 respectively and accordingly ECM (PCM) controls the closed loop which then controls the fuel injection volume.
  • Page 256 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-95 DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
  • Page 257: Dtc P0430 Catalyst System Efficiency Below Threshold (Bank 2)

    6-1-96 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0430 Catalyst System Efficiency Below Threshold (Bank 2) SYSTEM DIAGRAM 1. HO2S-1 (Bank-2) 4. TWC 2. HO2S-2 (Bank-2) 5. ECM (PCM) 3. WU-TWC CIRCUIT DESCRIPTION Exhaust oxygen concentration at the pre-catalyst and the post-catalyst of WU-TWC is detected from HO2S-1 and HO2S-2 respectively and accordingly ECM (PCM) controls the closed loop which then controls the fuel injection volume.
  • Page 258 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-97 DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
  • Page 259: Dtc P0443 Evap Control System Purge Control Valve Circuit Malfunction

    6-1-98 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0443 Evap Control System Purge Control Valve Circuit Malfunction SYSTEM/WIRING DIAGRAM 1. Main fuse 3. EVAP canister purge valve 2. Main relay 4. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Monitor signal of EVAP canister purge valve is different...
  • Page 260 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-99 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. 3) Start engine and warm up it completely. 4) Increase vehicle speed to 55 km/h (35 mph) or more.
  • Page 261: Evap Canister Purge System Inspection

    6-1-100 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Evap canister purge system inspection 1) Warm up engine to normal operating temperature. 2) Hoist vehicle so that all wheels rotate freely. 3) Set M/T in “Neutral” or A/T in “P” position and parking brake. 4) Disconnect purge hose (1) from EVAP canister.
  • Page 262: Vacuum Hose Inspection

    Replace as necessary. Evap canister purge valve and its circuit inspection 1) Connect SUZUKI scan tool to DLC (1) with ignition switch OFF and disconnect vacuum hoses from each pipe. 2) Turn ignition switch ON, clear DTC and select “MISC TEST”...
  • Page 263 6-1-102 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 5) Connect 12 V-battery to EVAP canister purge valve (3) termi- nals. In this state, blow hose “A” (1). Air should come out of hose “B” (2). If check result is not as described, replace EVAP canister purge valve.
  • Page 264: Dtc P0460 Fuel Level Sensor Circuit High Input

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-103 DTC P0460 Fuel Level Sensor Circuit High Input WIRING DIAGRAM/CIRCUIT DESCRIPTION 1. Fuel level sensor 2. Fuel meter in combination meter 3. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Fuel level sensor output voltage higher than specified •...
  • Page 265 6-1-104 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. Does fuel level meter in combination meter indi- Replenish fuel tank with Go to Step 3.
  • Page 266: Dtc P0500 (Dtc No.24) Vehicle Speed Sensor Malfunction

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-105 DTC P0500 (DTC No.24) Vehicle Speed Sensor Malfunction WIRING DIAGRAM 1. Speedometer 2. Vehicle speed sensor 3. Cruise control module (if equipped) 4. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Vehicle speed signal not inputted although fuel is kept •...
  • Page 267 6-1-106 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
  • Page 268 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-107 Step Action VSS visual inspection: Poor VSS connection or VSS Replace VSS. 1) Remove VSS referring to “TRANSFER” malfunction. section. If connection is OK, substi- 2) Check VSS drive and driven gears for tute a known-good VSS and damage and excessive wear.
  • Page 269: Dtc P0505 Idle Air Control System Malfunction

    6-1-108 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0505 Idle Air Control System Malfunction SYSTEM/WIRING DIAGRAM 1. Throttle body 3. ECM (PCM) 5. FIA valve 7. Main relay 2. Idle air control valve 4. Sensed information 6. Main fuse DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA...
  • Page 270 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-109 DTC CONFIRMATION PROCEDURE NOTE: Check to make sure that following condition is satisfied when using this “DTC CONFIRMATION PRO- CEDURE”. • Intake air temp. : – 8°C (18°F) or higher • Engine coolant temp. : – 8 – 110°C (18 – 230°F) •...
  • Page 271: Dtc P0601 (Dtc No.71) Internal Control Module Memory Check Sum Error

    6-1-110 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Step Action Was idle speed higher than specification in Check FIA valve for mal- Check parts or system Step 2? function. which can cause engine Check abnormal air inhal- low idle. ing from intake manifold, Check FIA valve for stuck.
  • Page 272: Dtc P1408 Manifold Absolute Pressure Sensor Circuit Malfunction

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-111 DTC P1408 Manifold Absolute Pressure Sensor Circuit Malfunction WIRING DIAGRAM 1. MAP sensor 2. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA • While engine is running after being warmed up and •...
  • Page 273 6-1-112 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 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 274: Dtc P1450/P1451 Barometric Pressure Sensor Circuit Malfunction/Performance Problem

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-113 DTC P1450/P1451 Barometric Pressure Sensor Circuit Malfunction/Perfor- mance Problem SYSTEM DESCRIPTION Barometric pressure sensor is installed in ECM (PCM). DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC P1450 : •...
  • Page 275: Dtc P1500 Engine Starter Signal Circuit Malfunction

    6-1-114 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P1500 Engine Starter Signal Circuit Malfunction WIRING DIAGRAM 1. Engine start switch in ignition (main) switch 2. Starting motor 3. Transmission range sensor (switch) 4. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA •...
  • Page 276: Dtc P1510 Ecm Back-Up Power Supply Malfunction

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-115 DTC P1510 Ecm Back-Up Power Supply Malfunction WIRING DIAGRAM 1. Main fuse box 3. ECM (PCM) 2. 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 277: Inspection

    6-1-116 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Table B-1 Fuel Pump Circuit Inspection WIRING DIAGRAM 1. To ignition switch 4. Fuel pump relay 2. Main fuse 5. Fuel pump 3. Main relay 6. ECM (PCM) INSPECTION CAUTION: Check to make sure that connection is made between correct terminals. Wrong connection can cause damage to ECM, wire harness etc.
  • Page 278 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-117 Step Action Fuel pump relay check : “BLK/WHT” or “WHT/ Replace fuel pump relay. 1) Check fuel pump relay referring to “FUEL GRN” circuit open or poor PUMP RELAY INSPECTION” in Section E61-23 connection.
  • Page 279: Inspection

    6-1-118 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) INSPECTION Step Action Check injector for operating sound : Go to Step 2. Go to Step 3. Using sound scope, check each injector for operating sound at engine cranking. Do all 6 injectors make operating sound? Wire harness check : Fuel injector circuit is in “PNK”, “PNK/BLK”, “PNK/...
  • Page 280 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-119 Table B-3 Fuel Pressure Inspection SYSTEM DIAGRAM 1. Injector 4. Fuel filter 2. Delivery pipe 5. Fuel pump 3. Fuel pressure regulator Special tool (A) : 09912-58441 (B) : 09912-58431 (C) : 09919-58421 INSPECTION NOTE: Before using the following flow table, check to make sure that battery voltage is higher than 11 V.
  • Page 281 6-1-120 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Step Action 1) Start engine and warm it up to normal oper- Normal fuel pressure. Clogged vacuum passage ating temperature. for fuel pressure regula- 2) Keep it running at specified idle speed. tor or faulty fuel pressure Is fuel pressure then within 210 –...
  • Page 282 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-121 Table B-4 Idle Air Control System Inspection WIRING DIAGRAM 1. Throttle body 3. ECM (PCM) 5. Main fuse 2. Idle air control valve 4. Sensed information 6. Main relay INSPECTION Step Action Check engine idle speed and IAC duty Go to Step 2.
  • Page 283 Go to Step 7. A/C signal circuit open or to Step 1 of “Table B-5”. (A/C signal can short, or A/C system mal- be also checked by using SUZUKI scan function. tool.) Is it in good condition? Check FIA valve.
  • Page 284 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-123 Table B-5 A/C Signal Circuits Inspection (If Equipped) WIRING DIAGRAM 1. A/C control module (amplifier) 2. ECM (PCM) INSPECTION Step Action Check A/C Signal Circuit. Go to Step 2. “YEL/BLK” circuit open or 1) Check voltage at terminal E61-17 with ignition short, Evaporative tem- switch ON.
  • Page 285 6-1-124 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Table B-6 A/C Condenser Fan Motor Relay Control System Inspection (If Equipped) WIRING DIAGRAM 1. To ignition switch 3. A/C fuse 5. A/C condenser fan motor 2. Main fuse 4. A/C condenser fan motor relay 6.
  • Page 286: Special Tool

    Checking tool set (See NOTE “A”.) 09917-47011 09930-88521 09931-76011 Vacuum pump gauge Injector test lead Tech 1A kit (SUZUKI scan Mass storage cartridge for tool) (See NOTE “B”.) Tech 1A 09931-76030 14/16 pin DLC cable for Tech 2 kit (SUZUKI scan Tech 1A tool) (See NOTE “C”.)
  • Page 287 6-1-126 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
  • Page 288 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
  • Page 289: On-Vehicle Service

    6A2-2 ENGINE MECHANICAL (H27 ENGINE) On-Vehicle Service Throttle Body and Intake Manifold 1. Air cleaner box 6. Intake manifold 11. Gasket 16. Throttle body bolt 2. Intake air hose 7. Intake manifold gasket 12. IAT sensor Tightening Torque 3. Intake air pipe 8.
  • Page 290 ENGINE MECHANICAL (H27 ENGINE) 6A2-3 REMOVAL 1) Release fuel pressure in fuel feed line by referring to Section CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. 2) Disconnect negative (–) cable at battery. 3) Drain coolant.
  • Page 291 6A2-4 ENGINE MECHANICAL (H27 ENGINE) 8) Disconnect accelerator cable (1) and A/T throttle cable (2) (for A/T vehicle) from throttle body. 9) Disconnect water hoses (3) from throttle body. 10) Disconnect injector wire (1) coupler. 11) Disconnect brake booster hose (2) from intake manifold. 12) Disconnect couplers of TP sensor (1) and IAC valve (2).
  • Page 292 ENGINE MECHANICAL (H27 ENGINE) 6A2-5 19) Disconnect hoses of heater, EVAP canister, fuel feed and fuel return. 1. Heater hose 2. Fuel feed hose 3. Fuel return hose 4. EVAP canister hose 20) Remove throttle body (1) and intake collector (2) from intake manifold (3).
  • Page 293 6A2-6 ENGINE MECHANICAL (H27 ENGINE) INSTALLATION 1) Install new intake manifold gaskets (1) to cylinder heads. 2) Install intake manifold (1). Tighten bolts and nuts to specified torque. Tightening torque Intake manifold bolt and nut (a) : 23 N·m (2.3 kg-m, 16.5 lb-ft) 3) Install throttle body (2) to intake collector (1) with new throttle body gasket.
  • Page 294 ENGINE MECHANICAL (H27 ENGINE) 6A2-7 6) Connect hoses of heater, EVAP canister, fuel feed and fuel return. 1. Heater hose 2. Fuel feed hose 3. Fuel return hose 4. EVAP canister hose 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.
  • Page 295 6A2-8 ENGINE MECHANICAL (H27 ENGINE) 16) Connect water hoses (3) to throttle body. 17) Connect accelerator cable (1) and A/T throttle cable (2) (for A/T vehicle) to throttle body. 18) Install surge tank pipe (2) to intake manifold with new gas- kets and intake air pipe (1) to throttle body.
  • Page 296: Exhaust Manifold

    ENGINE MECHANICAL (H27 ENGINE) 6A2-9 26) Upon completion of installation, verify that there is no fuel leakage at each connection according to procedure described in Section 6. Exhaust Manifold WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot.
  • Page 297 6A2-10 ENGINE MECHANICAL (H27 ENGINE) 4) Disconnect EGR pipe from right (No.2) bank exhaust mani- fold if right side exhaust manifold is removed. 5) Remove oil level gauge guide (3) if left side exhaust manifold is removed. 6) Detach P/S pump assembly as following, if left side exhaust manifold is removed.
  • Page 298 ENGINE MECHANICAL (H27 ENGINE) 6A2-11 INSTALLATION 1) Install new manifold gaskets to cylinder heads and No.1 pipe gasket to exhaust No.1 pipe. 2) Install exhaust manifolds. • Always install new bolts with pre-coated adhesive to the locations with ✱ mark. •...
  • Page 299 6A2-12 ENGINE MECHANICAL (H27 ENGINE) 7) Reverse removal procedure to install front propeller shaft if removed. When installing propeller shaft, align match mark (1). Use following specification to torque universal joint flange. Tightening torque Universal joint flange bolt (c) : 55 N·m (5.5 kg-m, 40.0 lb-ft) 8) Connect EGR pipe to left (No.1) bank exhaust manifold (1).
  • Page 300: Lh (No.1) Bank 2Nd Timing Chain And Chain Tensioner

    ENGINE MECHANICAL (H27 ENGINE) 6A2-13 LH (No.1) Bank 2nd Timing Chain and Chain Tensioner 1. LH bank 2nd timing chain 5. Camshaft sprocket bolt 9. Timing chain tensioner adjuster No. 3 bolt 2. Timing chain tensioner adjuster No.3 6. Timing chain guide No.4 10.
  • Page 301: Camshaft And Valve Lash Adjuster

    6A2-14 ENGINE MECHANICAL (H27 ENGINE) Camshaft and Valve Lash Adjuster 1. RH bank 2nd timing chain 6. LH bank intake camshaft 11. Timing chain guide No.5 2. RH bank exhaust camshaft 7. LH bank exhaust camshaft 12. Valve lash adjuster 3.
  • Page 302 ENGINE MECHANICAL (H27 ENGINE) 6A2-15 INSPECTION Cam wear Using a micrometer, measure cam height. If measured height is below its limit, replace camshaft. Intake cam height : Standard : 40.402 – 40.562 mm (1.5906 – 1.5969 in.) Limit : 40.300 mm (1.3581 in.) Exhaust cam height : Standard : 39.428 –...
  • Page 303 6A2-16 ENGINE MECHANICAL (H27 ENGINE) 6) Remove housing, and using scale (2) on gaging plastic (1) envelop, measure gaging plastic (1) width at its widest point. Camshaft journal clearance : Standard : 0.045 – 0.099 mm (0.0018 – 0.0039 in.) Limit : 0.12 mm (0.0047 in.) If measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft journal.
  • Page 304: Valves And Cylinder Heads

    ENGINE MECHANICAL (H27 ENGINE) 6A2-17 Valves and Cylinder Heads 1. Cylinder block 6. Exhaust valve 11. Valve stem oil seal 16. Cylinder head bolt (hex hole bolt) 2. RH bank cylinder head 7. Intake valve 12. Valve spring retainer Tightening Torque 3.
  • Page 305 6A2-18 ENGINE MECHANICAL (H27 ENGINE) 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 306 ENGINE MECHANICAL (H27 ENGINE) 6A2-19 5) Install cylinder head to block. After applying oil to cylinder head bolts, tighten them gradu- ally as follows. a) Tighten all bolts to 53 N·m (5.3 kg-m, 38.5 lb-ft) according to numerical order in the figure. b) In the same manner as in a), tighten them to 84 N·m (8.4 kg-m, 61.0 lb-ft).
  • Page 307 6A2-20 ENGINE MECHANICAL (H27 ENGINE) 12) Install oil pan and oil pump strainer. Refer to “OIL PAN AND OIL PUMP STRAINER” in this sec- tion. 13) Install cylinder head cover. Refer to “CYLINDER HEAD COVER” in this section. 14) Install exhaust manifold. Refer to “EXHAUST MANIFOLD”...
  • Page 308 ENGINE MECHANICAL (H27 ENGINE) 6A2-21 Piston, Piston Rings, Connecting Rods and Cylinders 1. Top ring 5. Connecting rod : 9. Piston pin circlip Tightening Torque Clean bearing installing surface when install. 2. 2nd ring 6. Connecting rod bearing cap : 10.
  • Page 309 6A2-22 ENGINE MECHANICAL (H27 ENGINE) INSPECTION Cylinders • Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use over size piston. • Using a cylinder gauge, measure cylinder bore in thrust and axial directions at 2 positions (1, 2) as shown in the figure.
  • Page 310 ENGINE MECHANICAL (H27 ENGINE) 6A2-23 • Piston clearance : Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, rebore cylinder and use oversize piston. Piston clearance : 0.02 –...
  • Page 311 6A2-24 ENGINE MECHANICAL (H27 ENGINE) ASSEMBLY 1) 2 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 312 ENGINE MECHANICAL (H27 ENGINE) 6A2-25 NOTE: • Install circlip with its cut part facing as shown in the figure. • Install so that circlip end gap comes within such range as indicated by arrow “A”. 1. Piston 2. Arrow mark 3.
  • Page 313: Unit Repair Overhaul

    6A2-26 ENGINE MECHANICAL (H27 ENGINE) Unit Repair Overhaul Engine Assembly REMOVAL 1) Release fuel pressure in fuel feed line. Refer to “FUEL PRESSURE RELIEF PROCEDURE” in Section 6. 2) Disconnect negative (–) cable at battery. 3) Remove engine hood. 4) Drain engine oil. 5) Drain coolant.
  • Page 314 ENGINE MECHANICAL (H27 ENGINE) 6A2-27 12) Disconnect the following electric lead wires : • Injector wire coupler • CMP sensor coupler • Ignition coil couplers • CKP sensor coupler • MAP sensor coupler • TP sensor (1) coupler • IAC valve (2) coupler •...
  • Page 315 6A2-28 ENGINE MECHANICAL (H27 ENGINE) 24) Remove A/T fluid hose clamps (1) from engine mounting bracket (2). (for A/T vehicle) 25) Remove clutch housing lower plate. 26) Remove torque converter bolts (for A/T vehicle). 27) Remove starter motor. 28) Lower vehicle. 29) Support transmission.
  • Page 316 ENGINE MECHANICAL (H27 ENGINE) 6A2-29 3) Tighten bolts and nuts fastening cylinder block and transmis- sion to specified torque. Tightening torque Transmission to cylinder block bolt and nut (b) : 85 N·m (8.5 kg-m, 61.5 lb-ft) 1. Bolt (short) 2. Bolt (Long) 4) Remove lifting device 5) Tighten torque converter bolts to specified torque (for A/T vehicle).
  • Page 317: Main Bearings, Crankshaft And Cylinder Block

    6A2-30 ENGINE MECHANICAL (H27 ENGINE) Main Bearings, Crankshaft and Cylinder Block 1. Cylinder block 6. Rear oil seal 11. O-ring [A]: Sealant application amount 2. Lower crankcase : 7. Flywheel (M/T) Drive plate 12. Clutch housing plate Tightening Torque Apply sealant 99000-31150 to lower (A/T) crankcase mating surface.
  • Page 318 ENGINE MECHANICAL (H27 ENGINE) 6A2-31 Main bearing clearance Check clearance by using gaging plastic (1) according to the fol- lowing procedure. 1) Remove crankcase. 2) Clean bearings and main journals. 3) Place a piece of gaging plastic to full width of bearing (paral- lel to crankshaft) on journal, avoiding oil hole.
  • Page 319 6A2-32 ENGINE MECHANICAL (H27 ENGINE) Selection of main bearings • STANDARD BEARING : If bearing is in malcondition, or bearing clearance is out of specification, select a new standard bearing according to the following procedure and install it. 1) First check journal diameter. As shown in the figure, crank web has stamped numbers and alphabet at the center.
  • Page 320 ENGINE MECHANICAL (H27 ENGINE) 6A2-33 3) There are 5 kinds of standard bearings differing in thickness. To distinguish them, they are painted in following colors at the position as shown in the figure. Each color indicates the following thickness at the center of bearing.
  • Page 321 6A2-34 ENGINE MECHANICAL (H27 ENGINE) • UNDERSIZE BEARING (0.25 mm) : 0.25 mm undersize bearing is available, in 5 kinds varying in thickness. To distinguish them, each bearing is painted in the following colors at such position as shown in the figure. Each color represents the following thickness at the center of bearing.
  • Page 322 ENGINE MECHANICAL (H27 ENGINE) 6A2-35 INSPECTION Honing or reboring cylinders 1) When any cylinder needs reboring, all other cylinders must also be rebored at the same time. 2) Select oversized piston according to amount of cylinder wear. Oversize piston specification : Size Piston diameter Standard...
  • Page 323: Special Tool

    6A2-36 ENGINE MECHANICAL (H27 ENGINE) Special Tool 09911-97810 09913-75510 09915-47310 09915-64510 Oil seal installer Bearing installer Oil filter wrench Compression gauge 09915-64530 09915-67010 09915-67310 09915-77310 Compression gauge hose Compression gauge Vacuum gauge Oil pressure gauge attachment (c) 09916-14510 09916-14910 09916-34541 09916-37810 Valve lifter Valve lifter attachment...
  • Page 324 ENGINE MECHANICAL (H27 ENGINE) 6A2-37 09916-84511 09917-68221 09917-87810 09917-98221 Forceps Camshaft lock holder Valve guide installer Valve stem seal installer 09918-08210 09919-28610 09924-17810 09926-58010 Vacuum gauge hose joint Protective sleeve Flywheel holder Bearing puller attachment 09944-36011 09911-97710 09915-76510 Steering wheel remover Oil seal guide Oil pressure gauge attachment...
  • Page 325 6A2-38 ENGINE MECHANICAL (H27 ENGINE)
  • Page 326: Engine Cooling

    ENGINE COOLING 6B-1 SECTION 6B ENGINE COOLING NOTE: • For the descriptions (items) not found in this section, refer to the descriptions of H25 engine in the same section of service manual mentioned in the FOREWORD of this manual. CONTENTS Maintenance ............6B-2 Coolant............
  • Page 327 6B-2 ENGINE COOLING Maintenance Coolant Anti-freeze proportioning chart : °C –16 –36 Freezing temperature °F –33 Antifreeze/Anticorrosion coolant concentration ltr. 2.7/6.4 4.6/4.6 Ratio of compound to cooling water US pt 5.8/13.7 9.8/9.8 Imp. pt. 4.8/11.3 8.1/8.1 Coolant capacity : Engine, radiator Reservoir Total and heater...
  • Page 328: Engine Fuel

    ENGINE FUEL 6C-1 SECTION 6C ENGINE FUEL NOTE: For the descriptions (items) not found in this section, refer to the same section of Service Manual mentioned in the FOREWORD of this manual. CONTENTS General Description ........6C-1 On-Vehicle Service ........6C-2 Fuel System ..........
  • Page 329: Fuel Tank

    6C-2 ENGINE FUEL On-Vehicle Service Fuel Tank REMOVAL 1) Relieve fuel pressure in fuel feed line referring to Section 6 or Section 6-1. CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. 2) Disconnect negative (–) cable at battery.
  • Page 330 ENGINE FUEL 6C-3 10) Disconnect fuel vapor hose and return hose from pipes. 11) Remove fuel tank protector (if equipped) from vehicle. 12) Lower fuel tank gradually while holding it horizontally and pull out coupler at fuel pump. 1. Fuel pump 2.
  • Page 331 6C-4 ENGINE FUEL INSTALLATION 1) Install fuel pump assembly, fuel cut valve and vapor control valve to fuel tank. Refer to “FUEL PUMP” in this section. 2) Connect fuel hoses to fuel tank, fuel cut valve, and vapor control valve, check valve and fuel pump assembly. After connecting, clamp hoses securely.
  • Page 332: Fuel Lines

    ENGINE FUEL 6C-5 Fuel Lines Due to the fact that fuel feed line is under high pressure, this sys- tem requires special consideration for service. The feed pipe uses screw couplings and hose clamps. INSPECTION Visually inspect fuel lines for evidence of fuel leakage, hose cracking and deterioration, or damage.
  • Page 333 6C-6 ENGINE FUEL...
  • Page 334 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
  • Page 335 6E2-2 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Fuel injector.......... 6E2-26 Main relay ..........6E2-41 Electronic Control System......6E2-31 Fuel pump relay ........6E2-42 Engine control module (ECM)/ Fuel cut operation ........ 6E2-43 powertrain control module (PCM) ..6E2-31 Emission Control System......
  • Page 336: System Flow

    ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-3 System Flow...
  • Page 337: System Diagram

    6E2-4 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) System Diagram...
  • Page 338 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-5 1. Air cleaner 22. Fuel level sensor 39. A/C controller (if equipped) 2. Intake air temp. sensor 23. Monitor connector (if equipped) 40. Data link connector/Immobilizer control mod- ule (if equipped) 3.
  • Page 339: Air Intake System

    6E2-6 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Air Intake System The main components of the air intake system are air cleaner, mass air flow sensor, air cleaner, intake air pipe, throttle body, intake collector, idle air control valve and intake manifold. The air (by the amount corresponding to the throttle valve opening and engine speed) is filtered by the air cleaner, passes through the throttle body, is distributed by the intake manifold and finally drawn into each com- bustion chamber.
  • Page 340: Fuel Delivery System

    ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-7 Fuel Delivery System The fuel delivery system consists of the fuel tank, fuel pump, fuel filter, fuel pressure regulator, delivery pipe and fuel injectors. The fuel in the fuel tank is pumped up by the fuel pump, filtered by the fuel filter and fed under pressure to each injector through the delivery pipe.
  • Page 341: Electronic Control System

    6E2-8 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Electronic Control System The electronic control system consists of 1) various sensors which detect the state of engine and driving condi- tions, 2) ECM (PCM) which controls various devices according to the signals from the sensors and 3) various controlled devices.
  • Page 342 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-9 WHT/BLU C51-2-19 C51-2-2 ORN/BLU C51-2-20 C51-2-1 PNK/BLK C51-2-30 C51-2-9 PNK/GRN C51-2-8 PNK/BLU GRY/GRN YEL/GRN C51-1-12 C51-2-22 YEL/BLU GRY/BLK C51-1-13 C51-2-21 GRY/YEL C51-3-26 BLU/BLK PPL/WHT C51-3-10 C51-2-15 LT GRN GRY/YEL C51-3-5 C51-2-14...
  • Page 343 6E2-10 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) TERMINAL ARRANGEMENT OF ECM (PCM) CONNECTOR (VIEWED FROM HARNESS SIDE) 1. Fuel injector No.1 17. “O/D OFF” lamp (A/T) 34. Power steering pressure switch 2. Fuel injector No.2 18.
  • Page 344 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-11 TERMINAL CIRCUIT TERMINAL CIRCUIT TERMINAL CIRCUIT C51-3-1 Intake air temp. (IAT) sensor C51-3-13 Power source for TP sensor C51-3-25 Ground for IAT sensor, MAP sensor and oxygen sensor (if equipped) C51-3-2 Engine coolant temp.
  • Page 345: Engine And Emission Control Input/Output Table

    6E2-12 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Engine and Emission Control Input/Output Table Input Function Output Main relay control Main relay Fuel pump control Fuel pump relay Injectors Injection control Idle air control IAC valve Ignition coil with igniter Ignition control MIL control...
  • Page 346: On-Vehicle Service

    ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-13 On-Vehicle Service 1. Brake booster hose pipe 8. EGR pipe (if equipped) 15. EVAP canister 2. Vacuum hose for fuel pressure regulator 9. Exhaust manifold 16. Tank pressure control valve 3.
  • Page 347: Accelerator Cable Adjustment

    6E2-14 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Accelerator Cable Adjustment 1) With throttle valve closed, check accelerator pedal play which should be within following specification. If measured value is out of specification, adjust accelerator cable (1) to specification with cable adjusting nut (2).
  • Page 348: Idle Speed/Idle Air Control (Iac) 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] 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. Special tool (A) : SUZUKI scan tool 2) Warm up engine to normal operating temperature.
  • Page 349: [Not Using Suzuki Scan Tool] (Vehicle With Monitor Connector)

    6E2-16 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) [Not using SUZUKI scan tool] (vehicle with monitor connector) 1) Disconnect scan tool from DLC if connected. 2) Warm up engine to normal operating temperature. 3) Stop engine and connect duty meter (3) between duty output terminal and ground terminal of monitor connector (1).
  • Page 350: Idle Mixture Inspection/Adjustment

    ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 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 (CO %) 0.8 –...
  • Page 351: Air Intake System

    6E2-18 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Air Intake System Throttle body 1. Throttle body 4. Water hose 2. Intake collector 5. MAF sensor 3. Breather hose 6. TP sensor REMOVAL 1) Disconnect negative (–) cable at battery. 2) Drain cooling system.
  • Page 352 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-19 6) Remove surge tank cover. Remove intake air pipe (1) and surge tank pipe (2). 7) Disconnect connectors of TP sensor and IAC valve. 8) Disconnect ground wire at connector. 9) Remove clamp bracket (1) and harness clamps from intake collector.
  • Page 353 6E2-20 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) CLEANING CAUTION: • Do not blow compressed air through bypass air pas- sage with IAC valve installed to throttle body. This will cause IAC valve to malfunction. •...
  • Page 354: Idle Air Control Valve (Iac Valve)

    ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-21 14) Install strut tower bar (1) and tighten bolts. 15) Refill cooling system. 16) Connect negative (–) cable at battery. 17) Adjust accelerator cable and A/T throttle cable, refer to “ACCELERATOR CABLE ADJUSTMENT”...
  • Page 355: Fast Idle Air Valve

    6E2-22 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 3) Remove air cleaner outlet hose and remove IAC valve from throttle body. 4) Connect connector to IAC valve. 5) Check that plunger (1) of IAC valve moves once and then stops as soon as ignition switch (2) is turned OFF after cranking engine for 2 sec.
  • Page 356: Fuel Delivery System

    ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-23 Fuel Delivery System Fuel pressure inspection 1) Relieve fuel pressure in fuel feed line referring to “FUEL PRESSURE RELIEF PROCEDURE” in Section 6-1. 2) Disconnect fuel feed hose from (3) delivery fuel feed pipe (1). CAUTION: A small amount of fuel may be released when fuel feed hose is removed.
  • Page 357: Fuel Pump

    6E2-24 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 8) After checking fuel pressure, remove fuel pressure gauge (1). CAUTION: As fuel feed line is still under high fuel pressure, make sure to release fuel pressure according to following pro- cedures.
  • Page 358: Fuel Pressure Regulator

    ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-25 REMOVAL Remove fuel tank from body according to procedure described in Section 6C and remove fuel pump 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.
  • Page 359: Fuel Injector

    6E2-26 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) INSTALLATION For installation, reverse removal procedure and note the follow- ings. • Use new O-ring. • Apply thin coat of gasoline to O-ring to facilitate installation. • Tighten fuel pressure regulator (1) bolts to specified torque. Tightening torque Fuel pressure regulator bolt (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
  • Page 360 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-27 REMOVAL 1) Relieve fuel pressure in fuel feed line referring to “FUEL PRESSURE RELIEF PROCEDURE” in Section 6-1. 2) Remove throttle body intake collector, refer to “THROTTLE BODY”...
  • Page 361 6E2-28 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 1) Install injector (1) and fuel pressure regulator (2) to special tool (injector checking tool). NOTE: Remove grommet from injector, then install injector to special tool and tighten bolts by hand. Special tool (A) : 09912-58421 2) Connect special tools (hoses and attachment) to pipes of...
  • Page 362 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-29 INSTALLATION 1) Replace injector O-ring (1) with new one using care not to damage it. Install grommet (2) to injector. 2) Check if insulator (1) is scored or damaged. If it is, replace with new one.
  • Page 363 6E2-30 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 5) Install fuel connect pipe (1) and tighten union bolts to speci- fied torque with new gaskets (3). Tightening torque Fuel connect pipe union bolt (b) : 30 N·m (3.0 kg-m, 22.0 lb-ft) 6) Install fuel feed pipe (2) and tighten union bolt to specified torque with new gaskets.
  • Page 364: Electronic Control System

    ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 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 negative (–) cable from battery.
  • Page 365: Mass Air Flow Sensor (Maf Sensor)

    6E2-32 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Mass air flow sensor (MAF sensor) INSPECTION NOTE: Use voltmeter with high-impedance (10 kΩ Ω Ω Ω /V minimum) or digital type voltmeter. 1) Connect voltmeter (1) to “B+” terminal of MAF sensor (2) coupler disconnected and ground (3).
  • Page 366 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-33 REMOVAL 1) Disconnect negative (–) cable at battery and coupler (1) from MAF sensor (3). 2) Remove air cleaner outlet hose (2) from throttle body and MAF sensor (3). 3) Remove MAF sensor from air cleaner case.
  • Page 367: Intake Air Temperature (Iat) Sensor

    6E2-34 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Intake air temperature (IAT) sensor REMOVAL 1) Disconnect negative (–) cable at 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 368: Throttle Position Sensor (Tp Sensor)

    ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-35 Throttle position sensor (TP sensor) INSPECTION 1) Disconnect negative (–) cable at battery and coupler from TP sensor (4). 2) Using ohmmeter, check resistance between terminals under each condition given in table below.
  • Page 369: Engine Coolant Temperature Sensor (Ect Sensor)

    6E2-36 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 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...
  • Page 370: Heated Oxygen Sensor (Sensor 1)

    ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-37 Heated oxygen sensor (sensor 1) REMOVAL WARNING: To avoid danger of being burned, do not touch exhaust system when system is hot. Oxygen sensor removal should be performed when system is cool. 1) Disconnect negative (–) cable from battery.
  • Page 371: Heated Oxygen Sensor (Sensor 2)

    6E2-38 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) HEATER INSPECTION 1) Disconnect HO2S-1 or -2 coupler. 2) Using ohmmeter, measure resistance between terminals “VB” and “GND” of HO2S coupler (1). If found faulty, replace HO2S. NOTE: Temperature of HO2S affects resistance value largely.
  • Page 372: Vehicle Speed Sensor (Vss)

    ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-39 HEATER INSPECTION Refer to “HEATED OXYGEN SENSOR (SENSOR 1) HEATER INSPECTION” Vehicle speed sensor (VSS) ON-VEHICLE INSPECTION 1) Hoist vehicle. 2) Release parking brake lever, set transmission in neutral and transfer in “2H”.
  • Page 373 6E2-40 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) INSPECTION 1) Check sensor O-ring (1) for damage and deterioration. Replace as necessary. 2) Arrange 3 new 1.5 V batteries (2) in series and connect its positive terminal to “Vin” terminal of MAP sensor (1) and negative terminal to “Ground”...
  • Page 374: Fuel Level Sensor (Sender Gauge)

    ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-41 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 (1) to intake manifold (2). 4) Connect connector to sensor (1) securely.
  • Page 375: Fuel Pump Relay

    6E2-42 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 3) Check resistance between each two terminals as in table below. If check results are as specified, proceed to next operation check. If not, replace. Main relay resistance: TERMINALS RESISTANCE ∞...
  • Page 376: Fuel Cut Operation

    ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-43 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.
  • Page 377: Emission Control System

    6E2-44 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Emission Control System EGR system (if equipped) EGR SYSTEM INSPECTION (USING SUZUKI SCAN TOOL) 1) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. Special tool (A) : SUZUKI scan tool...
  • Page 378: Evap Canister

    ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-45 INSPECTION 1) Check resistance between following terminals of EGR valve (1) in each pair. If found faulty, replace EGR valve assembly. EGR valve resistance: Terminals Standard resistance A –...
  • Page 379: Vacuum Passage

    6E2-46 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 1) Disconnect vacuum hoses from EVAP canister and remove EVAP canister. 2) When air is blown into tank pipe, there should be no restric- tion of flow through purge pipe and air pipe. If operation differs from above description, EVAP canister must be replaced.
  • Page 380: Pcv System

    ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-47 PCV System NOTE: Be sure to check that there is no obstruction in PCV valve or its hoses before checking engine idle speed/IAC duty for obstructed PCV valve or hose hampers its accu- rate checking.
  • Page 381: Pcv Hose

    6E2-48 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) PCV system NOTE: Be sure to check that there is no obstruction in PCV valve or its hoses (6) before checking engine idle speed/ IAC duty for obstructed PCV valve or hose hampers its accurate checking.
  • Page 382 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-49 09917-47010 09930-88521 09931-76011 Vacuum pump gauge Injector test lead Tech 1A kit (SUZUKI scan Mass storage cartridge for tool) (See NOTE “B”.) Tech 1A 09931-76030 14/16 pin DLC cable for...
  • Page 383 6E2-50 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
  • Page 384 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
  • Page 385: General Description

    6F2-2 IGNITION SYSTEM (FOR H27 ENGINE) 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 386: System Wiring

    IGNITION SYSTEM (FOR H27 ENGINE) 6F2-3 System Wiring NOTE: For ECM (PCM) terminal assignment, refer to Section 6E2. 1. To ignition switch 8. Ignition coil assembly (For No.3 cylinder) 2. “IG COIL METER” fuse 9. Ignition coil assembly (For No.4 cylinder) 3.
  • Page 387: Diagnosis

    6F2-4 IGNITION SYSTEM (FOR H27 ENGINE) Diagnosis Condition Possible Cause Correction Engine cranks, but will Blown fuse for ignition coil assembly Replace. not start or hard to Loose connection or disconnection of lead wire Connect securely. start (No spark) Faulty spark plug (s) Replace.
  • Page 388 IGNITION SYSTEM (FOR H27 ENGINE) 6F2-5 Step Action CMP Sensor Check Substitute a known-good Tighten CMP sensor bolt 1) Check CMP sensor. ECM (or PCM) and then or replace CMP sensor. Refer to Step 6 or 7 of “DTC P0340 DIAG. repeat Step 2.
  • Page 389: Ignition Spark Check

    3) Check to be sure that idle speed is within specification. Refer to Section 6E2. 4) Connect SUZUKI scan tool to DLC (1) with ignition switch OFF, restart engine and fix ignition timing by using fixed spark mode of SUZUKI scan tool.
  • Page 390 5) Set timing light to ignition harness for No.1 cylinder. 6) Using timing light, check that timing observed from viewpoint is within specification. Initial ignition timing of viewpoint (when it is fixed by SUZUKI scan tool) : 5 ± 1° BTDC Ignition order : 1-6-5-4-3-2...
  • Page 391: On-Vehicle Service

    6F2-8 IGNITION SYSTEM (FOR H27 ENGINE) On-Vehicle Service Ignition Coil Assembly (Igniter and Ignition Coil) REMOVAL 1) Remove ignition coil cover. 2) Disconnect ignition coil coupler. 3) Remove ignition coil bolt (1), and then pull out ignition coil assembly (2). INSPECTION Check ignition coil assembly for the following : •...
  • Page 392 IGNITION SYSTEM (FOR H27 ENGINE) 6F2-9 INSPECTION CAUTION: When servicing the iridium/platinum spark plugs (slender center electrode type plugs), do not touch the center electrode to avoid damage to it. The electrode is not strong enough against mechanical force as it is slender and its material is not mechanically tough.
  • Page 393: Cmp Sensor

    6F2-10 IGNITION SYSTEM (FOR H27 ENGINE) CMP Sensor CAUTION: Disassembly is prohibited. If anything faulty is found, replace as an assembly unit. REMOVAL 1) Disconnect CMP sensor coupler (2). 2) Remove A/T fluid level gauge and filler tube. 3) Remove CMP sensor (1) by removing bolt (3). INSTALLATION NOTE: After installing CMP sensor, adjust ignition timing.
  • Page 394 IGNITION SYSTEM (FOR H27 ENGINE) 6F2-11 2) Install CMP sensor to camshaft. Fit the dog of CMP sensor coupling into the slots of cam- shaft, when installing. The dogs of CMP sensor coupling are offset. Therefore, if the dogs can not be fitted into the slots, turn the CMP sensor shaft by 180 degree and try again.
  • Page 395: Noise Suppressor

    6F2-12 IGNITION SYSTEM (FOR H27 ENGINE) Noise Suppressor REMOVAL 1) Disconnect coupler of noise suppressor (1). 2) Remove noise suppressor (1) from harness (2). INSPECTION Using ohmmeter, check to be sure that capacitor (condenser) in noise suppressor is not conductive. If check result is not satisfactory, replace noise suppressor.
  • Page 396: Special Tool

    IGNITION SYSTEM (FOR H27 ENGINE) 6F2-13 Special Tool 09930-76420 09931-76011 09931-76030 Timing light (Dry cell type) Tech 1A kit (SUZUKI scan 16/14 pin DLC cable for Mass storage cartridge for tool) (See NOTE “A”.) Tech 1A Tech 1A Tech 2 kit (SUZUKI scan tool) (See NOTE “B”.)
  • Page 397 6F2-14 IGNITION SYSTEM (FOR H27 ENGINE)
  • Page 398: Charging System

    • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 399: General Description

    6H-2 CHARGING SYSTEM General Description Generator B : Generator output (Battery terminal) L : Lamp terminal 5. Stator core 10. Rear end frame D : Dummy terminal 1. Pulley 6. Field coil 11. Drive end frame E : Ground 2. Pulley nut 7.
  • Page 400: Unit Repair Overhaul

    CHARGING SYSTEM 6H-3 Unit Repair Overhaul Generator Assembly 1. Pulley nut 6. Driver end bearing 11. Wave washer 16. Regulator 21. Terminal plate 2. Pulley 7. Bearing retainer 12. Rear end frame 17. Brush 3. Drive end bearing 8. Rotor 13.
  • Page 401 6H-4 CHARGING SYSTEM • Using ohmmeter, check that there is no continuity between slip ring and rotor. If there is continuity, replace rotor. • Check slip rings for roughness or scoring. If rough or scored, replace rotor. Using a vernier caliper, measure the slip ring diameter. If the diameter is less than minimum, replace