Suzuki Swift User Manual
Suzuki Swift User Manual

Suzuki Swift User Manual

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IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions
carefully. To emphasize special information, the
words WARNING, CAUTION and NOTE have spe-
cial meanings. Pay special attention to the messages
highlighted by these signal words.
WARNING:
Indicates a potential hazard that could result
in death or injury.
CAUTION:
Indicates a potential hazard that could result
in vehicle damage.
NOTE:
Indicates special information to make mainte-
nance easier or instructions clearer.
WARNING:
This service manual is intended for authorized
SUZUKI dealers and qualified service me-
chanics only. Inexperienced mechanics or
mechanics without the proper tools and
equipment may not be able to properly per-
form the services described in this manual.
Improper repair may result in injury to the me-
chanic and may render the vehicle unsafe for
the driver and passengers.

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Summary of Contents for Suzuki Swift

  • Page 1 Indicates special information to make mainte- nance easier or instructions clearer. WARNING: This service manual is intended for authorized SUZUKI dealers and qualified service me- chanics only. Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly per- form the services described in this manual.
  • Page 2 Therefore, note that illustra- tions may differ from the vehicle being actually serviced. The right is reserved to make changes at any time without notice. OVERSEAS SERVICE DEPARTMENT  COPYRIGHT SUZUKI MOTOR CORPORATION 2000...
  • Page 3: Related Manuals

    RELATED MANUALS Related manuals listed below are in the chronological order with the latest one at the top. For the efficient use of manuals, start with one at the top of the list (i.e., the latest one). If desired section, item or description is not found in it, try next one in the list and do the same one by one till what is being searched is found.
  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION GENERAL INFORMATION General Information Maintenance and Lubrication HEATING AND AIR CONDITIONING Heater and Ventilation Air Conditioning (Oprional) ENGINE General Information and Diagnosis (TBI for G10) General Information and Diagnosis (TBI for G13) General lnformation and Diagnosis (SFI for G13) Engine Mechanical (G10 Engine) Engine Mechanical...
  • Page 5: Table Of Contents

    GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION CONTENTS HOW TO USE THIS MANUAL ............. . . 0A- 2 PRECAUTIONS .
  • Page 6: How To Use This Manual

    0A-2 GENERAL INFORMATION HOW TO USE THIS MANUAL 1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a CONTENTS on the first page of EACH SECTION, where the main items in that section are listed.
  • Page 7 D If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag deploy- ment.
  • Page 8 0A-4 GENERAL INFORMATION HANDLING AND SERVICING ALWAYS CARRY AIR BAG (INFLATOR) MODULE WITH TRIM COVER (AIR BAG OPENING) AWAY WARNING: FROM BODY. D Many of service procedures require disconnection of “AIR BAG” fuse and air bag (inflator) modules (driver and passenger) from deployment loop to avoid an accidental deployment.
  • Page 9 GENERAL INFORMATION 0A-5 CAUTION: D Even when the accident was light enough not to cause air bags to deploy, be sure to inspect system parts and other related parts according to instructions under “Repair and Inspection Required after an Accident” in Section 9J. D When servicing parts other than air bag system, if shocks may be applied to air bag system component parts, re- move those parts beforehand.
  • Page 10: General Precautions

    0A-6 GENERAL INFORMATION GENERAL PRECAUTIONS The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply. WARNING: D Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING POINTS”...
  • Page 11 GENERAL INFORMATION 0A-7 D When removing the battery, be sure to disconnect the nega- tive cable first and then the positive cable. When reconnect- ing the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. D When removing parts that are to be reused, be sure to keep them arranged in an orderly manner so that they may be rein- stalled in the proper order and position.
  • Page 12 0A-8 GENERAL INFORMATION D When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be re- installed correctly. D After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks. D For vehicles equipped with fuel injection systems, never dis- connect the fuel line between the fuel pump and injector without first releasing the fuel pressure, or fuel can be...
  • Page 13: Precautions For Catalytic Converter

    GENERAL INFORMATION 0A-9 D Always be careful not to handle electrical parts (computer, relay, etc.) in a rough manner or drop them. PRECAUTIONS FOR CATALYTIC CONVERTER For vehicles equipped with a catalytic converter, use only un- leaded gasoline and be careful not to let a large amount of un- burned gasoline enter the converter or it can be damaged.
  • Page 14 0A-10 GENERAL INFORMATION D When disconnecting connectors, never pull the wiring har- ness. Unlock the connector lock first and then pull them apart by holding connectors themselves. D When connecting connectors, also hold connectors and put them together until they lock securely (a click is heard). D When installing the wiring harness, fix it with clamps so that no slack is left.
  • Page 15 GENERAL INFORMATION 0A-11 D Be careful not to touch the electrical terminals of parts which use microcomputers (e.g. electronic control unit like as ECM, PCM, P/S controller, etc.). The static electricity from your body can damage these parts. D Never connect any tester (voltmeter, ohmmeter, or whatever) to electronic control unit when its coupler is disconnected.
  • Page 16: Electrical Circuit Inspection Procedure

    0A-12 GENERAL INFORMATION D When checking connection of terminals, check its male half for bend and female half for excessive opening and both for locking (looseness), corrosion, dust, etc. D Before measuring voltage to check for electrical system, check to make sure that battery voltage is 11 V or higher. Such terminal voltage check at low battery voltage will lead to erroneous diagnosis.
  • Page 17 GENERAL INFORMATION 0A-13 3) Using a test male terminal, check both terminals of the circuit be- ing checked for contact tension of its female terminal. Check each terminal visually for poor contact (possibly caused Check contact tension by inserting and removing just by dirt, corrosion, rust, entry of foreign object, etc.).
  • Page 18 0A-14 GENERAL INFORMATION If measurements were taken as shown in the figure at the left and results were as listed below, it means that the circuit is open be- tween terminals B-1 and A-1. Voltage Between: C-1 and body ground: Approx. 5 V B-1 and body ground: Approx.
  • Page 19: Intermittent And Poor Connection

    GENERAL INFORMATION 0A-15 INTERMITTENT AND POOR CONNECTION Most intermittent are caused by faulty electrical connections or wir- ing, although a sticking relay or solenoid can occasionally be at fault. When checking it for proper connection, perform careful check of suspect circuits for: D Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
  • Page 20: Precaution For Installing Mobile Communication Equipment

    0A-16 GENERAL INFORMATION PRECAUTION FOR INSTALLING MOBILE COMMUNICATION EQUIPMENT When installing mobile communication equipment such as CB (Citi- zens-Band)-radio or cellular-telephone, be sure to observe the fol- lowing precautions. Failure to follow cautions may adversely affect electronic control system. D Keep the antenna as far away as possible from the vehicle’s elec- tronic control unit.
  • Page 21: Precaution In Servicing Full-Time 4Wd Vehicle

    GENERAL INFORMATION 0A-17 PRECAUTION IN SERVICING FULL-TIME 4WD VEHICLE When performing any of the following types of work, be sure to make the vehicle as front wheel drive by cutting transmission of driving force to the rear wheels. Otherwise, rear wheels are driven and vehicle accidents, damage and personal injury may result.
  • Page 22: Identification Information

    0A-18 GENERAL INFORMATION IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER The number is punched on the front dash panel in the engine room. IDENTIFICATION WHETHER VEHICLE EQUIPPED WITH WU-TWC OR NOT It can be identified by the shape of exhaust manifold (1) and ex- haust pipe (2).
  • Page 23: Warning, Caution And Information Labels

    GENERAL INFORMATION 0A-19 WARNING, CAUTION AND INFORMATION LABELS The figure below shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels. If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary. NOTE: Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only.
  • Page 24: Vehicle Lifting Points

    0A-20 GENERAL INFORMATION VEHICLE LIFTING POINTS WARNING: D Before applying hoist to underbody, always take vehicle balance throughout service into consider- ation. Vehicle balance on hoist may change depending of what part to be removed. D Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.
  • Page 25 GENERAL INFORMATION 0A-21 In raising front or rear vehicle end off the floor by jacking, be sure When using floor jack: to put the jack against the center portion of front cross member (1) or rear cross member (2). WARNING: D Never apply jack against suspension parts (i.e., stabilizer, etc.) or vehicle floor, or it may get deformed.
  • Page 26: Abbreviations And Symbols May Be Used In This Manual

    0A-22 GENERAL INFORMATION ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL ABBREVIATIONS : Anti-Lock Brake System EBCM : Electronic Brake Control ATDC : After Top Dead Center Module, ABS Control Module : American Petroleum Institute : Engine Control Module : Automatic Transmission Fluid ECT Sensor : Engine Coolant Temperature...
  • Page 27 GENERAL INFORMATION 0A-23 : Left Hand : Throttle Body Fuel Injection LSPV : Load Sensing Proportioning (Single-Point Fuel Injection, Valve SPI) : Torque Converter Clutch : Transmission Control Module MAF Sensor : Mass Air Flow Sensor (Air Flow (A/T Controller, A/T Control Sensor, AFS, Air Flow Meter, Module) AFM)
  • Page 28 0A-24 GENERAL INFORMATION SYMBOLS SYMBOL DEFINITION SYMBOL DEFINITION Tightening torque Apply SUZUKI BOND NO. 1216 99000-31160 Apply oil (Engine, transmission, Apply SILICONE SEALANT transfer, differential) 99000-31120 Apply fluid (Brake, power steering or Apply SEALING COMPOUND 366E automatic transmission fluid) 99000-31090...
  • Page 29: Metric Fasteners

    GENERAL INFORMATION 0A-25 FASTENERS INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are metric fasteners. When replacing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch and strength. FASTENER STRENGTH IDENTIFICATION Most commonly used metric fastener strength property classes are 4T, 6.8, 7T, 8.8 and radial line with the class identification embossed on the head of each bolt.
  • Page 30: Standard Tightening Torque

    0A-26 GENERAL INFORMATION STANDARD TIGHTENING TORQUE Each fastener should be tightened to the torque specified in each section of this manual. If no description or specifi- cation is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fasten- NOTE: D For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening torque...
  • Page 31: Maintenance And Lubrication

    D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 32: Maintenance Schedule

    0B-2 MAINTENANCE AND LUBRICATION MAINTENANCE SCHEDULE NORMAL CONDITION SCHEDULE This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at Interval: the same intervals respectively. This interval should be judged by 1,000) odometer reading or months, whichever comes first.
  • Page 33 MAINTENANCE AND LUBRICATION 0B-3 This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at Interval: the same intervals respectively. This interval should be judged by This interval should be judged by 1,000) odometer reading or months, whichever comes first.
  • Page 34 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 35: Maintenance Service

    MAINTENANCE AND LUBRICATION 0B-5 MAINTENANCE SERVICE ENGINE ITEM 1-1 Drive Belt Inspection and Replacement WARNING: Disconnect negative cable at battery before checking and replacing belt. A/C Compressor and/or Power Steering Pump Drive Belt Vehicle with A/C Inspection (If equipped) 1) Detach air cleaner assembly from vehicle body and shift its posi- tion.
  • Page 36 0B-6 MAINTENANCE AND LUBRICATION Water Pump Belt Replacement Replace belt with a new one. Refer to SECTION 6B for replacement procedure of pump belt. NOTE: When replacing belt with a new one, adjust belt tension to 5 – 7 mm (0.20 – 0.27 in.). ITEM 1-2 Camshaft Timing Belt Replacement Replace belt with new one.
  • Page 37 MAINTENANCE AND LUBRICATION 0B-7 ITEM 1-4 Proper Engine Oil Viscosity Chart Engine Oil and Filter Change WARNING: New and used engine oil can be hazardous. Be sure to read “WARNING” in General Precaution in SEC- TION 0A and observe what in written there. Use engine oil of SE, SF, SG, SH or SJ grade.
  • Page 38 0B-8 MAINTENANCE AND LUBRICATION 7) Replenish oil until oil level is brought to FULL level mark on dip- stick (oil pan and oil filter capacity). Filler inlet is at the top of cyl- inder head cover. 8) Start engine and run it for three minutes. Stop it and wait another 5 minutes before checking oil level.
  • Page 39 MAINTENANCE AND LUBRICATION 0B-9 1) Remove radiator cap when engine is cool. 2) Loosen radiator drain plug (1) to drain coolant. 3) Remove reservoir and drain. 4) Tighten drain plug securely. Also install reservoir. 5) Slowly pour specified amount of coolant to the base of radiator filler neck, and run engine, with radiator cap removed, until ra- diator upper hose is hot.
  • Page 40: Ignition System

    0B-10 MAINTENANCE AND LUBRICATION IGNITION SYSTEM ITEM 2-1 Spark Plugs Replacement Replace spark plugs with new ones referring to SECTION 6F or 6F1. ITEM 2-2 Distributor Cap and Rotor Inspection (if equipped) D Check distributor cap and rubber caps for cracks. D Clean dusty and stained parts using a dry, soft cloth.
  • Page 41 MAINTENANCE AND LUBRICATION 0B-11 2) Visually check that air cleaner filter is not excessively dirty, dam- 1.0 liter engine aged or oily. 3) Clean filter with compressed air from air outlet side of filter. 4) Install air cleaner filter into case. 5) Clamp case cap securely and install hose to case and bracket if removed.
  • Page 42: Emission Control System

    0B-12 MAINTENANCE AND LUBRICATION EMISSION CONTROL SYSTEM ITEM 4-1 PCV (Positive Crankcase Ventilation) Valve Inspection Check crankcase ventilation hoses and PCV hoses for leaks, cracks or clog, and PCV valve (1) for stick or clog. Refer to ON-VE- HICLE SERVICE of SECTION 6E1 or 6E2 for PCV valve checking procedure.
  • Page 43 MAINTENANCE AND LUBRICATION 0B-13 ITEM 5-2 Brake Hoses and Pipes Inspection Perform this inspection where there is enough light and use a mirror as necessary. D Check brake hoses and pipes for proper hook-up, leaks, cracks, chafing, wear, corrosion, bends, twists and other damage. Replace any of these parts as necessary.
  • Page 44 0B-14 MAINTENANCE AND LUBRICATION ITEM 5-4 “a”: Parking brake lever stroke: Brake Lever and Cable Inspection 4 – 9 notches (With 20 kg or 44 lbs of pull pressure) Parking brake lever D Check tooth tip of each notch for damage or wear. If any damage or wear is found, replace parking lever.
  • Page 45 MAINTENANCE AND LUBRICATION 0B-15 [Wheel disc inspection] Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. [Tire rotation] Rotate tires referring to SECTION 3F. Wheel Bearing Inspection 1) Check front wheel bearing for wear, damage, abnormal noise or rattles.
  • Page 46 0B-16 MAINTENANCE AND LUBRICATION D Check front and rear suspension systems for damaged, loose or missing parts; also for parts showing signs of wear or lack of lu- brication. Repair or replace defective parts, if any. D Check front suspension arm ball joint stud dust seals for leakage, detachment, tear or any other damage.
  • Page 47 MAINTENANCE AND LUBRICATION 0B-17 ITEM 6-7 Manual Transmission Oil Inspection and Change [Inspection] 1) Inspect transmission case for evidence of oil leakage. Repair leaky point if any. 2) Make sure that vehicle is placed level for oil level check. 3) Remove oil level plug of transmission. 4) Check oil level.
  • Page 48 0B-18 MAINTENANCE AND LUBRICATION ITEM 6-9 Automatic Transmission [Fluid level inspection] 1) Inspect transmission case for evidence of fluid leakage. Repair leaky point, if any. 2) Make sure that vehicle is placed level for fluid level check. 3) Check fluid level. For fluid level checking procedure, refer to ON-VEHICLE SER- VICE in SECTION 7B and be sure to perform it under specified conditions.
  • Page 49 MAINTENANCE AND LUBRICATION 0B-19 ITEM 6-10 All Latches, Hinges and Locks Inspection Doors Check that each door of front, rear and back doors opens and closes smoothly and locks securely when closed. If any malfunction is found, lubricate hinge and latch or repair door lock system.
  • Page 50 0B-20 MAINTENANCE AND LUBRICATION FINAL INSPECTION Exhaust System Check Check for leakage, cracks or loose supports. WARNING: Clutch (For manual transmission) When carrying out road tests, select a safe Check for the following. place where no man or no running vehicle is D Clutch is completely released when depressing seen so as to prevent any accident.
  • Page 51: Recommended Fluids And Lubricants

    MAINTENANCE AND LUBRICATION 0B-21 [Parking brake] Body, Wheels and Power Transmitting System Check that lever has proper travel. Check that body, wheels and power transmitting sys- tem are free from abnormal noise and abnormal WARNING: vibration or any other abnormal condition. With vehicle parked on a fairly steep slope, Meters and Gauge make sure nothing is in the way downhill to...
  • Page 52 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 53 6-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) Diagnostic Trouble Code Clearance ..6-14 DTC P0302 Cylinder 2 Misfire Detected 6- 68 Diagnostic Trouble Code Table ..6-15 DTC P0303 Cylinder 3 Misfire Detected 6- 68...
  • Page 54: General Information

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-3 GENERAL INFORMATION STATEMENT ON CLEANLINESS AND CARE An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of an inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important.
  • Page 55 6-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) PRECAUTION ON FUEL SYSTEM SERVICE HOSE CONNECTION D Work must be done with no smoking, in a well-ventilated area and With short pipe, fit hose as far as it reaches pipe joint as away from any open flames.
  • Page 56 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-5 FUEL PRESSURE RELIEF PROCEDURE CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. After making sure that engine is cold, release fuel pressure as fol- lows.
  • Page 57: General Description

    ECM (PCM) memory as freeze frame data. (For the details, refer to description on Freeze frame data.) D It is possible to communicate by using not only SUZUKI scan tool (Tech-1) (2) but also generic scan tool. (Diagnostic information...
  • Page 58 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-7 Warm-up Cycle A warm-up cycle means sufficient vehicle operation such that the coolant temperature has risen by at least 22_C (40_F) from engine starting and reaches a minimum temperature of 70_C (160_F). Driving Cycle A “Driving Cycle”...
  • Page 59 DLC (1) is in compliance with SAEJ1962 in its installation position, line the shape of connector and pin assignment. Serial data line (K line of ISO 9141) is used for SUZUKI scan tool (Tech-1) or generic scan tool to communicate with ECM (PCM). Body ground...
  • Page 60 ECM (PCM) memory. D Diagnostic information stored in ECM (PCM) memory can be cleared as well as checked by using SUZUKI scan tool (Tech-1) or generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
  • Page 61 6-10 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) ENGINE DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION Customer Complaint Analysis Go to Step 2. Perform customer 1) Perform customer complaint analysis referring to the complaint analysis.
  • Page 62 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-11 1. CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
  • Page 63 6-12 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE) User name: Model: VIN: Date of issue: Date Reg. Date of problem: Mileage: PROBLEM SYMPTOMS j Difficult Starting j Poor Driveability j No cranking j Hesitation on acceleration j No initial combustion j Back fire/jAfter fire j No combustion...
  • Page 64 “Diagnostic Flow Table A-2” for troubleshooting. DIAGNOSTIC TROUBLE CODE (DTC) CHECK 1) Prepare SUZUKI scan tool (Tech-1) or generic scan tool. 2) With ignition switch OFF, connect it to data link connector (DLC) (1) located on underside of instrument panel at driver’s seat side.
  • Page 65 6-14 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE 1) Connect SUZUKI scan tool (Tech-1) or generic scan tool to data link connector in the same manner as when making this connec- tion for DTC check.
  • Page 66 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-15 DIAGNOSTIC TROUBLE CODE (DTC) TABLE DETECTING CONDITION DETECTING ITEM (DTC will set when detecting:) Low pressure-high vacuum-low voltage Manifold absolute pressure (or MAP sensor circuit shorted to ground) P0105 1 driving cycle circuit malfunction High pressure-low vacuum-high voltage (or MAP sensor circuit open)
  • Page 67 6-16 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DETECTING CONDITION DETECTING ITEM (DTC will set when detecting:) Crankshaft position sensor P0335 No signal during engine running 1 driving cycle circuit malfunction Camshaft position sensor P0340 No signal for 2 sec. during engine cranking 1 driving cycle circuit malfunction Output waveforms of HO2S-1 and HO2S-2...
  • Page 68 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-17 DETECTING CONDITION DETECTING ITEM (DTC will set when detecting:) Transmission range sensor (switch) No signal or multiple signals inputted with 1 driving P0705 circuit malfunction (A/T) shifted in “D” range cycle Output speed sensor circuit No signal while running vehicle with “D”...
  • Page 69 6-18 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) FAIL-SAFE TABLE When any of the following DTCs is detected, ECM (PCM) enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ECM (PCM) detects normal condition after that. DTC NO.
  • Page 70 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-19 VISUAL INSPECTION Visually check following parts and systems. INSPECTION ITEM REFERRING SECTION D Engine oil – – – – – level, leakage Section 0B D Engine coolant – – – – – level, leakage Section 0B D Fuel –...
  • Page 71 Is it 800 – 900 r/min.? Check ignition timing as follows. Go to “ENGINE Check ignition control 1) Select “MISC” mode on SUZUKI scan tool and DIAGNOSIS TABLE”. related parts referring fix ignition timing to initial one. See Fig. 2.
  • Page 72 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-21 Fig. 1 for Step 5 Fig. 2 for Step 6 Fig. 3 for Step 6 SELECT MENU Select “DATA F4: MISC TEST LIST” mode Fig. 4 for Step 8 Fig. 5 for Step 11...
  • Page 73 6-22 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) ENGINE DIAGNOSIS TABLE Perform troubleshooting referring to following table when ECM (PCM) has detected no DTC and no abnormality has been found in visual inspection and engine basic inspection previously. Condition Possible Cause Referring Item Hard Starting...
  • Page 74 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-23 Condition Possible Cause Referring Item D Improper oil viscosity Low oil pressure Engine oil and oil filter change in Section 0B D Malfunctioning oil pressure switch Oil pressure switch inspection in Section 8 D Clogged oil strainer Oil pan and oil pump strainer...
  • Page 75 6-24 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) Condition Possible Cause Referring Item D Inoperative thermostat Overheating Thermostat in Section 6B D Poor water pump performance Water pump in Section 6B D Clogged or leaky radiator Radiator in Section 6B D Improper engine oil grade Engine oil and oil filter change in Section 0B...
  • Page 76 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-25 Condition Possible Cause Referring Item Engine hesitates Ignition system out of order D Spark plug faulty or plug gap out of adjustment (Momentary lack of Spark plugs in Section 6F D Leaky high-tension cord response as High-tension cords in Section 6F accelerator is...
  • Page 77 6-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) Condition Possible Cause Referring Item Engine has no Ignition system out of order D Faulty spark plug power Spark plugs in Section 6F D Faulty ignition coil with ignitor Ignition coil in Section 6F D Leaks, loose connection or disconnection of High-tension cords in Section 6F high-tension cord...
  • Page 78 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-27 Condition Possible Cause Referring Item Improper engine Ignition system out of order D Faulty spark plug idling or engine Spark plugs in Section 6F D Leaky or disconnected high-tension cord fails to idle High-tension cords in Section 6F D Faulty ignition coil with ignitor Ignition coil in Section 6F...
  • Page 79 6-28 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) Condition Possible Cause Referring Item Excessive Ignition system out of order D Faulty spark plug hydrocarbon (HC) Spark plugs in Section 6F D Leaky or disconnected high-tension cord emission or carbon High-tension cords in Section 6F D Faulty ignition coil with ignitor monoxide (CO)
  • Page 80 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-29 SCAN TOOL DATA As the data values given below are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases where the checked value does not fall within each specified data range.
  • Page 81 6-30 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) NORMAL CONDITION / SCAN TOOL DATA CONDITION REFERENCE VALUES DESIRED IDLE At idling with no load after warming up, M / T 850 r / min 850 r / min (DESIRED IDLE SPEED) at neutral, A / T at “P”...
  • Page 82 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-31 NORMAL CONDITION / SCAN TOOL DATA CONDITION REFERENCE VALUES VSS (for 4-A / T) At stop. 0 km / h 0 MPH (Vehicle Speed Sensor) SHIFT SOL1 Ignition switch ON, selector lever is shifted at P, CON (Command Signal) R or N range MON (Monitor Signal)
  • Page 83 6-32 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) SCAN TOOL DATA DEFINITIONS FUEL SYSTEM (FUEL SYSTEM STATUS) MAF (MASS AIR FLOW RATE, gm/s, lb/min) Air/fuel ratio feedback loop status displayed as either It represents total mass of air entering intake manifold open or closed loop.
  • Page 84 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-33 CANIST PURGE DUTY (EVAP CANISTER VSS (A/T) (km/h, MPH) PURGE FLOW DUTY, %) If is computed by using pulse signals from vehicle This parameter indicates valve ON (valve open) time (output) speed sensor on automatic transmission. rate within a certain set cycle of EVAP purge solenoid TRANS RANGE (TRANSMISSION RANGE valve which controls the amount of EVAP purge.
  • Page 85 6-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) INSPECTION OF ECM (PCM) AND ITS CIRCUITS ECM (PCM) and its circuits can be checked at ECM (PCM) wiring couplers by measuring voltage and resistance. CAUTION: ECM (PCM) cannot be checked by itself. It is strictly prohib- ited to connect voltmeter or ohmmeter to ECM (PCM) with coupler disconnected from it.
  • Page 86 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-35 TER- WIRE STANDARD CIRCUIT CONDITION MINAL COLOR VOLTAGE ECM (PCM) ground – – W/Bl Power source 10 – 14 V Ignition switch ON — Blank — — — Blank — — —...
  • Page 87 6-36 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) TER- WIRE STANDARD CIRCUIT CONDITION MINAL COLOR VOLTAGE Power source for sensor 4.75 – 5.25 V Ignition switch ON Camshaft position sensor (+) — — Crankshaft position sensor — — Ignition switch ON, ISC actuator 0 –...
  • Page 88 MINAL COLOR VOLTAGE Data link connector V / W 4 – 6 V Ignition switch ON (SUZUKI serial data line) Vehicle speed sensor (+) (A / T) 0.4 – 0.8 V Ignition switch ON Indicator deflection Ignition switch ON Y / G...
  • Page 89 6-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) RESISTANCE CHECK 1) Disconnect ECM (PCM) couplers from ECM (PCM) with ignition switch OFF. CAUTION: Never touch terminals of ECM (PCM) itself or connect voltmeter or ohmmeter. 2) Check resistance between each terminal of couplers discon- nected.
  • Page 90: Component Location

    ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-39 COMPONENT LOCATION INFORMATION SENSORS CONTROL DEVICES OTHERS -1. MAP sensor a: Fuel injector A: ECM (PCM) -2. TP sensor b: EVAP canister purge valve B: Main relay -3. IAT sensor c: Fuel pump relay C: EVAP canister -4.
  • Page 91 6-40 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) TABLE A-1 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK – LAMP DOES NOT COME “ON” AT IGNITION SWITCH ON (BUT ENGINE AT STOP) CIRCUIT DESCRIPTION Malfunction indicator lamp in combination meter Main relay Ignition switch “IG COIL METER”...
  • Page 92 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-41 TABLE A-2 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK – LAMP REMAINS “ON” AFTER ENGINE STARTS WIRING DIAGRAM/CIRCUIT DESCRIPTION – Refer to table A-1. INSPECTION STEP ACTION Diagnostic Trouble Code (DTC) check Go to Step 2 of ENGINE Go to Step 2.
  • Page 93 6-42 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) TABLE A-3 ECM (PCM) POWER AND GROUND CIRCUIT CHECK – MIL DOESN’T LIGHT AT IGNITION SWITCH ON AND ENGINE DOESN’T START THOUGH IT IS CRANKED UP CIRCUIT DESCRIPTION Malfunction indicator lamp in combination meter Ignition switch Main fuse “IG COIL METER”...
  • Page 94 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-43 STEP ACTION ECM (PCM) Power Circuit Check Check ground circuits Go to Step 6. 1) Using service wire, ground terminal C02-22 and “Bl/B” and “W/Bl” for measure voltage between terminal C02-2 and open.
  • Page 95 6-44 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P0105 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION To TP sensor MAP sensor To other sensors DTC DETECTING CONDITION POSSIBLE CAUSE D MAP: 5 kPa, 37.5 mmHg or less D “G”...
  • Page 96 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-45 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” Go to Step 2. Go to “ENGINE DIAG. performed? FLOW TABLE”. Check MAP Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition Check for intermittent switch OFF.
  • Page 97 6-46 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P0110 INTAKE AIR TEMP. (IAT) CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION IAT sensor To other sensors DTC DETECTING CONDITION POSSIBLE CAUSE D Low intake air temperature (High voltage-High resistance) D “Gr” circuit open or shorted to power D “G”...
  • Page 98 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-47 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check IAT Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition switch Check for intermittent OFF.
  • Page 99 6-48 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P0115 ENGINE COOLANT TEMPERATURE (ECT) CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION ECT sensor To combination To other sensors (ECT) meter DTC DETECTING CONDITION POSSIBLE CAUSE D Low engine coolant temperature (High voltage-High resistance) D “Gr /W”...
  • Page 100 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-49 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check ECT Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool with ignition switch OFF.
  • Page 101 6-50 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P0120 THROTTLE POSITION CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION To other sensors Throttle position sensor To other sensors DTC DETECTING CONDITION POSSIBLE CAUSE D Signal voltage high D “G” circuit open D “Lg/W” circuit open or shorted to ground D Signal voltage low D “Lg”...
  • Page 102 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-51 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” Go to Step 2. Go to “ENGINE DIAG. performed? 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 103 6-52 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P0121 THROTTLE POSITION CIRCUIT RANGE/PERFORMANCE PROBLEM CIRCUIT DESCRIPTION To other sensors Throttle position sensor To other sensors DTC DETECTING CONDITION POSSIBLE CAUSE D After engine warmed up. D TP sensor malfunction D While vehicle running at specified engine speed.
  • Page 104 TABLE”. Check TP Sensor and Its Circuit. If voltmeter was Go to Step 3. 1) Turn ignition switch OFF and connect SUZUKI scan tool to used, check DLC. terminal C01-6 for 2) Turn ignition switch ON and check TP sensor output poor connection.
  • Page 105 6-54 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P0130 HEATED OXYGEN SENSOR (HO2S) CIRCUIT MALFUNCTION (SENSOR-1) CIRCUIT DESCRIPTION To other sensor Main fuse Ignition switch Heater To generator DTC DETECTING CONDITION POSSIBLE CAUSE D When running at idle speed after engine warmed up D Heated oxygen sensor-1 malfunction D “G”...
  • Page 106 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-55 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Is there DTC(s) other than HO2S-1 Go to applicable DTC Go to Step 3. (DTC P0130)? Diag.
  • Page 107 6-56 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC CONFIRMATION PROCEDURE – Refer to DTC P0130 section. INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Is there DTC(s) other than HO2S-1 (DTC P0133)? Go to applicable DTC Replace HO2S-1.
  • Page 108 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-57 DTC P0135 HEATED OXYGEN SENSOR (HO2S) HEATER CIRCUIT MALFUNCTION (SENSOR-1) CIRCUIT DESCRIPTION To other sensor Main fuse Ignition switch “IG COIL METER” To generator Heater DTC DETECTING CONDITION POSSIBLE CAUSE D HO2S-1 heater circuit open or shorted to ground DTC will set when A or B condition is met.
  • Page 109 6-58 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check Heater for Operation. Intermittent trouble Go to Step 3. 1) Check voltage at terminal C01-8. See Fig. 1. Check for intermittent 2) Warm up engine to normal operating temperature.
  • Page 110 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-59 DTC P0136 HEATED OXYGEN SENSOR (HO2S) CIRCUIT MALFUNCTION (SENSOR-2) CIRCUIT DESCRIPTION To other sensor To other sensor Main fuse Ignition switch “IG COIL METER” Heater To ignition coil DTC DETECTING CONDITION POSSIBLE CAUSE D Exhaust gas leakage DTC will set when A or B condition is detected.
  • Page 111 6-60 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester, on a level road.
  • Page 112 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-61 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check exhaust system for leakage, loose Go to Step 3. Repair or replace. connection and damage.
  • Page 113 6-62 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P0141 HEATED OXYGEN SENSOR (HO2S) HEATER CIRCUIT MALFUNCTION (SENSOR-2) CIRCUIT DESCRIPTION To other sensor To other sensor Main fuse Ignition switch Heater “IG COIL METER” To ignition coil DTC DETECTING CONDITION POSSIBLE CAUSE D HO2S-2 heater circuit open or shorted DTC will set when A or B condition it met.
  • Page 114 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-63 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check HO2S-2 Heater and Its Circuit. Intermittent trouble. Go to Step 3. 1) Warm up engine to normal operating temperature.
  • Page 115 6-64 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P0171 FUEL SYSTEM TOO LEAN DTC P0172 FUEL SYSTEM TOO RICH CIRCUIT DESCRIPTION Sensed information Signal to decrease amount of fuel injection Signal to increase amount of fuel injection Fuel (PCM) injector High voltage...
  • Page 116 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-65 DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester on a level road.
  • Page 117 6-66 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Is there DTC(s) other than fuel system Go to applicable Go to Step 3. (DTC P0171/P0172)? DTC Diag.
  • Page 118 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-67 STEP ACTION Check engine coolant temp. sensor for performance Go to Step 9. Replace engine (See Section 6E1). coolant temp. sensor. Is it in good condition? Check intake air temp. sensor for performance Go to Step 10.
  • Page 119 6-68 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P0300 RANDOM MISFIRE DETECTED (Misfire detected at 2 or more cylinders) DTC P0301 CYLINDER 1 MISFIRE DETECTED DTC P0302 CYLINDER 2 MISFIRE DETECTED DTC P0303 CYLINDER 3 MISFIRE DETECTED Ignition coil Igniter Ignition switch “I / G COIL METER”...
  • Page 120 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-69 DTC DETECTING CONDITION POSSIBLE CAUSE D Engine under other than high revolution condition D Engine overheating D Not on rough road D Vacuum leaks (air inhaling) from air intake system D Engine speed changing rate D Ignition system malfunction (spark plug(s), high- Below D Manifold absolute...
  • Page 121 6-70 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE“. Is there DTC other than Fuel system (DTC P0171/P0172) Go to applicable Go to Step 3.
  • Page 122 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-71 STEP ACTION Check PCV valve for clogging (See Section 6E1). Go to Step 7. Replace PCV valve. Is it in good condition? Check EVAP Canister Purge Valve for Closing. Check EVAP Go to Step 8.
  • Page 123 6-72 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P0335 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION Crankshaft sensor timing belt pulley DTC DETECTING CONDITION POSSIBLE CAUSE D No CKP sensor signal during 1 revolution of D CKP sensor circuit open or short. D Crankshaft timing belt pulley teeth damaged.
  • Page 124 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-73 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check CKP Sensor for Resistance. Go to Step 3. Replace CKP sensor. 1) Disconnect CKP sensor connector with ignition switch OFF.
  • Page 125 6-74 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P0340 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION Camshaft Sensor rotor position sensor in distributor DTC DETECTING CONDITION POSSIBLE CAUSE D No CMP sensor signal for 2 seconds at engine D CMP sensor circuit open or short.
  • Page 126 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-75 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Is DTC P1500 (Engine starter signal circuit Go to DTC P1500 Go to Step 3. malfunction) detected? Diag.
  • Page 127 6-76 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD CIRCUIT DESCRIPTION To other sensor To other sensors Heated oxygen sensor-1 Heated oxygen sensor-2 Warm up three way catalytic converter (if equipped) Three way catalytic converter ECM (PCM) monitors oxygen concentration in the exhaust gas which has passed the three way catalytic converter by HO2S-2.
  • Page 128 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-77 DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and tester, on a level road.
  • Page 129 6-78 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check Short Term Fuel Trim. Go to Step 3. Check fuel system. Did short term fuel trim vary within –20% –+20% Go to DTC P0171/P0172 range in step 3) of DTC confirmation test?
  • Page 130 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-79 DTC P0443 PURGE CONTROL VALVE CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION Main relay Main fuse To other valves EVAP canister purge valve EVAP canister Surge purge valve tank Fuel vapor separator Tank pressure control valve Fuel filter cap Fuel...
  • Page 131 6-80 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) Fig. 1 for Step 1 DTC P0480 RADIATOR FAN CONTROL SYSTEM MALFUNCTION CIRCUIT DESCRIPTION “IG COIL METER” Radiator fan Ignition switch relay Main fuse Radiator fan motor DTC DETECTING CONDITION POSSIBLE CAUSE D Low voltage at terminal C02-20 when engine coolant D “B/W”...
  • Page 132 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-81 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check Radiator Cooling Fan Relay and Its Circuit. Intermittent trouble or Go to Step 3. 1) Turn ignition switch ON.
  • Page 133 6-82 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P0500 VEHICLE SPEED SENSOR (VSS) MALFUNCTION (M/T) CIRCUIT DESCRIPTION C03-2 Vehicle speed sensor in combination meter C03-2 DTC DETECTING CONDITION POSSIBLE CAUSE D VSS signal not inputted while vehicle running in “D” D “B/Bl”...
  • Page 134 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-83 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Does speedometer indicate vehicle speed? Go to Step 3. Speedometer cable disconnected or broken.
  • Page 135 6-84 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P0500 VEHICLE SPEED SENSOR (VSS) MALFUNCTION FOR A/T VEHICLE (A/T) Vehicle speed sensor (on A / T) C03-2 Counter shaft gear C03-13 C03-2 C03-13 CIRCUIT DESCRIPTION – Refer to Section 6E1 for VSS operation. DTC DETECTING CONDITION POSSIBLE CAUSE D While fuel is kept cut at lower than 4000 r/min for...
  • Page 136 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-85 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check VSS for Resistance. Go to Step 3. Replace VSS. 1) Disconnect VSS connection with ignition switch OFF. 2) Check for proper connection to VSS at “Bl”...
  • Page 137 6-86 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P0505 IDLE CONTROL SYSTEM MALFUNCTION CIRCUIT DESCRIPTION Main relay Main fuse Idle speed control relay To TP sensor Idle speed control actuator DTC DETECTING CONDITION POSSIBLE CAUSE D Malajusted accelerater cable DTC will set when A, B or C condition is met.
  • Page 138 FLOW TABLE”. Check Idle Control System. Check TP sensor (Go to Go to Step 3. 1) Connect SUZUKI scan tool to DLC with ignition DTC P0121 Flow Table) switch OFF, set parking brake and block drive If TP sensor is OK, wheels.
  • Page 139 Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check CTP Switch Operation. Intermittent trouble. Go to Step 3. 1) Connect SUZUKI scan tool to DLC with ignition Check for intermittent switch OFF. referring to 2) Turn ignition switch ON. “Intermittent and...
  • Page 140 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-89 DTC P0601 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR DTC DETECTING CONDITION POSSIBLE CAUSE DTC P0601: Data write error (or check sum error) ECM (PCM) when written into ECM (PCM) : 2 driving cycle detection logic, continuous monitoring. DTC CONFIRMATION PROCEDURE 1) Turn ignition switch OFF.
  • Page 141 6-90 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P1250 EARLY FUEL EVAPORATION (EFE) HEATER CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION Main relay Main fuse EFE heater relay EFE heater DTC DETECTING CONDITION POSSIBLE CAUSE D Voltage low at terminal C01-12 during engine D “Y/R”, “W”...
  • Page 142 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-91 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check EFE Heater and Its Circuit. Intermittent trouble. Go to Step 3. Check for voltage at terminal C01-12 of ECM (PCM) Check for intermittent connector connected, under following each...
  • Page 143 6-92 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P1450 BAROMETRIC PRESSURE SENSOR LOW/HIGH INPUT DTC P1451 BAROMETRIC PRESSURE SENSOR PERFORMANCE PROBLEM WIRING DIAGRAM/CIRCUIT DESCRIPTION Barometric pressure sensor is installed in ECM (PCM). DTC DETECTING CONDITION POSSIBLE CAUSE D ECM (PCM) (barometric pressure sensor) DTC P1450: D Barometric pressure: 136 kPa 1025 mmHg or higher, or malfunction...
  • Page 144 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-93 DTC P1500 ENGINE STARTER SIGNAL CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION M / T vehicle Main fuse Ignition switch (starter Starter switch) A / T vehicle Transmission range sensor (switch) Main fuse Ignition switch (starter Starter...
  • Page 145 6-94 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) DTC P1510 ECM (PCM) BACK-UP POWER SUPPLY MALFUNCTION CIRCUIT DESCRIPTION Main fuse To DLC “DOME” Battery voltage is supplied so that diagnostic trouble code memory, values for engine control learned by ECM (PCM), etc.
  • Page 146 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-95 BLANK...
  • Page 147 6-96 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) TABLE B-1 FUEL INJECTOR CIRCUIT CHECK To other circuits “IG Ignition COIL switch METER” Main Main fuse relay Injector resistor Fuel injector INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2.
  • Page 148 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-97 STEP ACTION Check Injector Resistor for Resistance. “W/Bl”, “Y/G” or “Y/B” Replace resistor. 1) Disconnect resistor connector with ignition switch wire open or poor OFF. C02-12 connection. 2) Check for proper connection to resistor at each If wires and terminals.
  • Page 149 6-98 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) TABLE B-2 FUEL PUMP AND ITS CIRCUIT CHECK To other circuits Ignition switch Main Main fuse relay Fuel pump relay Fuel pump INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2.
  • Page 150 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-99 Fig. 1 for Step 2 Fig. 2 for Step 3 Fig. 3 for Step 4 1. Service wire 2. Relay box Fig. 4 for Step 4...
  • Page 151 6-100 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) TABLE B-3 FUEL PRESSURE CHECK 1. Fuel pump 6. Special tool 2. Fuel filter (Fuel pressure gauge & 3. Throttle body 3-way joint) 4. Fuel injector 7. Fuel feed line 5. Fuel pressure regulator 8.
  • Page 152 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-101 STEP ACTION With fuel pump operated and fuel return hose Faulty fuel pressure Shortage of fuel or fuel blocked by pinching it, is fuel pressure applied? regulator. pump or its circuit defective (refer to B-2 FUEL PUMP ANDITS CIRCUIT CHECK).
  • Page 153 6-102 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) TABLE B-4 A/C SIGNAL CIRCUITS CHECK (VEHICLE WITH A/C) (A / C ON output signal) A / C amplifier (A / C input signal) INSPECTION STEP ACTION D “Bl/R” wire open or Check A/C (Input) Signal Circuit.
  • Page 154 INSPECTION STEP ACTION Check PSP Switch Signal Circuit. PSP switch signal “Bl/W” circuit open or 1) Connect SUZUKI scan tool to DLC with ignition circuit is in good short, PSP switch switch OFF. condition. malfunction or power 2) Start engine and select “DATA LIST” mode on steering system scan tool.
  • Page 155: Special Tool

    4. DLC cable (14 / 26 pin, 09931-76040) 5. Test lead / probe 6. Power source cable 7. DLC cable adaptor 8. Self-test adaptor 09931-76011 09931-76030 SUZUKI scan tool (Tech 1 A) kit Mass storage cartridge 16 / 14 pin DLC cable...
  • Page 156 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G13) 6-1 SECTION 6 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G13) NOTE: For the details of this section, refer to same section of the Service Manual mentioned in the FOREWORD of this manual.
  • Page 157: Table Of Contents

    D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 158 6-1-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) DTC P0300 Random Misfire DTC P0601 Internal Control Module Detected ......6-1- 69 Memory Check Sum Error .
  • Page 159 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-3 GENERAL INFORMATION STATEMENT ON CLEANLINESS AND CARE An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of an inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important.
  • Page 160 6-1-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) PRECAUTION ON FUEL SYSTEM SERVICE HOSE CONNECTION D Work must be done with no smoking, in a well-ventilated area and With short pipe, fit hose as far as it reaches pipe joint as away from any open flames.
  • Page 161 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 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, release fuel pressure as fol- lows.
  • Page 162 ECM (PCM) memory as freeze frame data. (For the details, refer to description on Freeze frame data.) D It is possible to communicate by using not only SUZUKI scan tool (Tech-1) (2) but also generic scan tool. (Diagnostic information...
  • Page 163 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 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). Driving Cycle A “Driving Cycle”...
  • Page 164 DLC (1) is in compliance with ISO 15031-3 (SAEJ1962) in its instal- lation position, the shape of connector and pin assignment. Serial data line (K line of ISO 9141) is used for SUZUKI scan tool (Tech-1) to communicate with ECM (PCM).
  • Page 165 ECM (PCM) memory. D Diagnostic information stored in ECM (PCM) memory can be cleared as well as checked by using SUZUKI scan tool (Tech-1) or generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
  • Page 166 6-1-10 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) ENGINE DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION Customer Complaint Analysis Go to Step 2. Perform customer 1) Perform customer complaint analysis referring to the complaint analysis.
  • Page 167 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-11 1. CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
  • Page 168 6-1-12 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE) User name: Model: VIN: Date of issue: Date of Reg. Date of problem: Mileage: PROBLEM SYMPTOMS j Difficult Starting j Poor Driveability j No cranking j Hesitation on acceleration j No initial combustion j Back fire/jAfter fire j No combustion...
  • Page 169 “Diagnostic Flow Table A-2” for troubleshooting. DIAGNOSTIC TROUBLE CODE (DTC) CHECK 1) Prepare SUZUKI scan tool (Tech-1). 2) With ignition switch OFF, connect it to data link connector (DLC) (1) located on underside of instrument panel at driver’s seat side.
  • Page 170 DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE [Using SUZUKI scan tool] 1) Connect SUZUKI scan tool (Tech-1) to data link connector in the same manner as when making this connection for DTC check. 2) Turn ignition switch ON. 3) Erase DTC and pending DTC according to instructions dis- played on scan tool.
  • Page 171 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-15 DIAGNOSTIC TROUBLE CODE (DTC) TABLE NOTE: 1 driving cycle: MIL lights up when DTC is detected in the first driving cycle. 2 driving cycles: MIL lights up when the same DTC is detected also in the next driving cycle after DTC is detected and stored temporarily in the first driving cycle.
  • Page 172 6-1-16 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) DETECTING CONDITION DETECTING ITEM (DTC will set when detecting:) Crankshaft position sensor 1 driving P0335 No signal for 2 sec. During engine cranking circuit malfunction cycle Camshaft position sensor circuit 1 driving P0340 No signal during engine running cycle...
  • Page 173 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-17 DETECTING CONDITION DETECTING ITEM (DTC will set when detecting:) Transmission Range Sensor Circuit P0705 Malfunction P0720 Output Speed Sensor Circuit Malfunction Shift Solenoid A P0751 Performance or Stuck Off Refer to Section 7B P0753 Shift Solenoid A Circuit Shift Solenoid B...
  • Page 174 6-1-18 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 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 175 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-19 VISUAL INSPECTION Visually check following parts and systems. INSPECTION ITEM REFERRING SECTION D Engine oil – – – – – level, leakage Section 0B D Engine coolant – – – – – level, leakage Section 0B D Fuel –...
  • Page 176 Is it 700 – 800 r/min? Check ignition timing as follows: “ENGINE DIAGNO- Check ignition control 1) Using SUZUKI scan tool, select “MISC” mode on SIS TABLE” in this related parts referring SUZUKI scan tool and fix ignition timing to initial section.
  • Page 177 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-21 Fig. 1 for Step 5 Fig. 2 for Step 6 Fig. 3 for Step 6 When using SUZUKI scan tool Select “DATA LIST” mode SELECT MENU F4: MISC TEST Fig. 4 for Step 7...
  • Page 178 6-1-22 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) ENGINE DIAGNOSIS TABLE Perform troubleshooting referring to following table when ECM (PCM) has detected no DTC and no abnormality has been found in visual inspection and engine basic inspection previously. Condition Possible Cause Referring Item Hard Starting...
  • Page 179 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-23 Condition Possible Cause] Referring Item D Improper oil viscosity Low oil pressure Engine oil and oil filter change in Section 0B D Malfunctioning oil pressure switch Oil pressure switch inspection in Section 8 D Clogged oil strainer Oil pan and oil pump strainer...
  • Page 180 6-1-24 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) Condition Possible Cause Referring Item D Inoperative thermostat Overheating Thermostat in Section 6B D Poor water pump performance Water pump in Section 6B D Clogged or leaky radiator Radiator in Section 6B D Improper engine oil grade Engine oil and oil filter change in Section 0B...
  • Page 181 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-25 Condition Possible Cause Referring Item Engine hesitates Ignition system out of order D Spark plug faulty or plug gap out of adjustment (Momentary lack of Spark plugs in Section 6F1 D Leaky high-tension cord response as High-tension cords in Section 6F1 accelerator is...
  • Page 182 6-1-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) Condition Possible Cause Referring Item Engine has no Ignition system out of order D Faulty spark plug power Spark plugs in Section 6F1 D Faulty ignition coil with ignitor Ignition coil in Section 6F1 D Leaks, loose connection or disconnection of High-tension cords in Section 6F1 high-tension cord...
  • Page 183 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-27 Condition Possible Cause Referring Item Improper engine Ignition system out of order D Faulty spark plug idling or engine Spark plugs in Section 6F D Leaky or disconnected high-tension cord fails to idle High-tension cords in Section 6F D Faulty ignition coil with ignitor Ignition coil in Section 6F...
  • Page 184 6-1-28 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) Condition Possible Cause Referring Item Excessive Ignition system out of order D Faulty spark plug hydrocarbon (HC) Spark plugs in Section 6F1 D Leaky or disconnected high-tension cord emission or carbon High-tension cords in Section 6F1 D Faulty ignition coil with ignitor monoxide (CO)
  • Page 185 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-29 SCAN TOOL DATA As the data values given below are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases where the checked value does not fall within each specified data range.
  • Page 186 6-1-30 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) NORMAL CONDITION / SCAN TOOL DATA CONDITION REFERENCE VALUES DESIRED IDLE At idling with no load after warming up, M / T 750 r / min (DESIRED IDLE SPEED) at neutral, A / T at “P” range TP SENSOR VOLT Throttle valve fully closed More than 0.2 V...
  • Page 187 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-31 SCAN TOOL DATA DEFINITIONS FUEL SYSTEM (FUEL SYSTEM STATUS) MAF (MASS AIR FLOW RATE, gm/s, lb/min) Air/fuel ratio feedback loop status displayed as either It represents total mass of air entering intake manifold open or closed loop.
  • Page 188 6-1-32 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) CANIST PURGE DUTY (EVAP CANISTER PURGE FLOW DUTY, %) This parameter indicates valve ON (valve open) time rate within a certain set cycle of EVAP purge solenoid valve which controls the amount of EVAP purge. 0% means that the purge valve is completely closed while 100% is a fully open valve.
  • Page 189 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-33 INSPECTION OF ECM (PCM) AND ITS CIRCUITS ECM (PCM) and its circuits can be checked at ECM (PCM) wiring couplers by measuring voltage and resistance. CAUTION: ECM (PCM) cannot be checked by itself. It is strictly prohib- ited to connect voltmeter or ohmmeter to ECM (PCM) with coupler disconnected from it.
  • Page 190 6-1-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) TERMINAL NORMAL CIRCUIT CONDITION VOLTAGE Ground — — Ground — — Ground — — EVAP canister purge valve 10 – 14 V Ignition switch ON Indication deflection deflection Power steering switch repeated Ignition switch ON 0 V and...
  • Page 191 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-35 TERMINAL NORMAL CIRCUIT CONDITION VOLTAGE A/C ON output signal Ignition switch ON 10 – 14 V Ignition switch ON EGR valve (stepper motor coil 1) 0 – 1 V Engine running at idle speed Data link connector 10 –...
  • Page 192 6-1-36 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) TERMINAL NORMAL CIRCUIT CONDITION VOLTAGE 0 – 1 V Ignition switch ON Malfunction indicator lamp Malfunction indicator lamp 10 – 14 V When engine running Indicator deflection Ignition switch ON Vehicle speed sensor (M/T) repeated Front left tire turned slowly with front right 0 V and...
  • Page 193 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-37 Resistance Check 1) Disconnect ECM (PCM) couplers from ECM (PCM) with ignition switch OFF. CAUTION: Never touch terminals of ECM (PCM) itself or connect voltmeter or ohmmeter. 2) Check resistance between each terminal of couplers discon- nected.
  • Page 194 6-1-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) COMPONENT LOCATION INFORMATION SENSORS CONTROL DEVICES OTHERS -1. MAP sensor a: Fuel injector A: ECM (PCM) -2. TP sensor b: EVAP canister purge valve B: Main relay -3. IAT sensor c: Fuel pump relay C: EVAP canister -4.
  • Page 195 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-39 TABLE A-1 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK – LAMP DOES NOT COME “ON” AT IGNITION SWITCH ON (BUT ENGINE AT STOP) CIRCUIT DESCRIPTION Malfunction indicator lamp in combination meter Fuse box Ignition switch Main...
  • Page 196 6-1-40 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) TABLE A-2 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK – LAMP REMAINS “ON” AFTER ENGINE STARTS WIRING DIAGRAM/CIRCUIT DESCRIPTION – Refer to table A-1. INSPECTION STEP ACTION Diagnostic Trouble Code (DTC) check Go to Step 2 of ENGINE Go to Step 2.
  • Page 197 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-41 TABLE A-3 ECM (PCM) POWER AND GROUND CIRCUIT CHECK – MIL DOESN’T LIGHT AT IGNITION SWITCH ON AND ENGINE DOESN’T START THOUGH IT IS CRANKED UP CIRCUIT DESCRIPTION Malfunction indicator lamp in combination meter Fuse box Ignition switch...
  • Page 198 6-1-42 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) STEP ACTION ECM (PCM) Power Circuit Check Check ground circuits Go to Step 6. 1) Using service wire, ground terminal C02-10 and “B/Y” and “B” for measure voltage between terminal C02-5/6 and open.
  • Page 199 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-43 DTC P0105 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION To TP sensor sensor To other sensors DTC DETECTING CONDITION POSSIBLE CAUSE D MAP: 4.9 kpa, 37 mmHg or less D “G” circuit open D “P”...
  • Page 200 6-1-44 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) MAP Sensor Individual Check 1) Disconnect coupler from MAP sensor (1). 2) Remove MAP sensor (1). 3) Arrange 3 new 1.5 V batteries (2) in series (check that total volt- age is 4.5 – 5.0 V) and connect its positive terminal to “Vin” termi- nal of sensor and negative terminal to “Ground”...
  • Page 201 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-45 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” Go to Step 2. Go to “ENGINE DIAG. performed? FLOW TABLE”. Check MAP Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition Check for intermittent switch OFF.
  • Page 202 6-1-46 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) DTC P0110 INTAKE AIR TEMP. (IAT) CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION IAT sensor To other sensors DTC DETECTING CONDITION POSSIBLE CAUSE D Low intake air temperature (High voltage-High resistance) D “Gr /R” circuit open or shorted to power D High intake air temperature (Low voltage-Low resistance) D “G”...
  • Page 203 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-47 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check IAT Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition switch Check for intermittent OFF.
  • Page 204 6-1-48 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) DTC P0115 ENGINE COOLANT TEMPERATURE (ECT) CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION To combination To other sensors (ECT) meter DTC DETECTING CONDITION POSSIBLE CAUSE D Low engine coolant temperature (High voltage-High resistance) D “Lg/R” circuit open or shorted to power D High engine coolant temperature (Low voltage-Low resistance) D “G”...
  • Page 205 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-49 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check ECT Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool with ignition switch OFF.
  • Page 206 6-1-50 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) DTC P0120 THROTTLE POSITION CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION To MAP sensor Throttle position sensor To other sensors DTC DETECTING CONDITION POSSIBLE CAUSE D Signal voltage high D “G” circuit open D Signal voltage low D “Gr”...
  • Page 207 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-51 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” Go to Step 2. Go to “ENGINE DIAG. performed? 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 208 6-1-52 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) DTC P0121 THROTTLE POSITION CIRCUIT RANGE/PERFORMANCE PROBLEM CIRCUIT DESCRIPTION To other sensors Throttle position sensor To other sensors DTC DETECTING CONDITION POSSIBLE CAUSE D After engine warmed up. D TP sensor malfunction D While vehicle running at specified engine speed.
  • Page 209 If voltmeter was Go to Step 3. When using SUZUKI scan tool: used, check 1) Turn ignition switch OFF and connect SUZUKI scan tool to terminal C03-5 for DLC. poor connection. 2) Turn ignition switch ON and check TP sensor output...
  • Page 210 6-1-54 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) DTC P0130 HEATED OXYGEN SENSOR (HO2S) CIRCUIT MALFUNCTION (SENSOR-1) CIRCUIT DESCRIPTION To other sensor Fuse box Ignition switch Heater Main fuse To HO2S-2 heater DTC DETECTING CONDITION POSSIBLE CAUSE D When running at idle speed after engine warmed up D Heated oxygen sensor-1 malfunction D “G”...
  • Page 211 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-55 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Is there DTC(s) other than HO2S-1 Go to applicable DTC Go to Step 3. (DTC P0130)? Diag.
  • Page 212 6-1-56 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) DTC P0133 HEATED OXYGEN SENSOR (HO2S) CIRCUIT SLOW RESPONSE (SENSOR-1) WIRING DIAGRAM/CIRCUIT DESCRIPTION – Refer to DTC P0130 section. DTC DETECTING CONDITION POSSIBLE CAUSE D When running at specified idle speed after engine D Heated oxygen sensor-1 malfunction warmed up and running at specified vehicle speed, response time (time to change from lean to rich or...
  • Page 213 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-57 DTC P0134 HEATED OXYGEN SENSOR (HO2S) CIRCUIT NO ACTIVITY DETECTED (SENSOR-1) CIRCUIT DESCRIPTION – Refer to DTC P0130 section. DTC DETECTING CONDITION POSSIBLE CAUSE D Engine warmed up. D “G” or “R” circuit open or short D While running under other than high load and high D Heated oxygen sensor malfunction D Fuel system malfunction...
  • Page 214 6-1-58 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) DTC P0135 HEATED OXYGEN SENSOR (HO2S) HEATER CIRCUIT MALFUNCTION (SENSOR-1) CIRCUIT DESCRIPTION To other sensor Fuse box Ignition switch Heater Main fuse To HO2S-2 heater DTC DETECTING CONDITION POSSIBLE CAUSE D HO2S-1 heater circuit open or shorted to ground DTC will set when A or B condition is met.
  • Page 215 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-59 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go t o“ENGINE DIAG. FLOW TABLE”. Check Heater for Operation. Intermittent trouble Go to Step 3. 1) Check voltage at terminal C01-7. See Fig. 1. Check for intermittent 2) Warm up engine to normal operating temperature.
  • Page 216 6-1-60 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) DTC P0136 HEATED OXYGEN SENSOR (HO2S) CIRCUIT MALFUNCTION (SENSOR-2) CIRCUIT DESCRIPTION To other sensor Ignition Main switch fuse Heater To HO2S-1 heater DTC DETECTING CONDITION POSSIBLE CAUSE D Exhaust gas leakage DTC will set when A or B condition is detected.
  • Page 217 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-61 DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester, on a level road.
  • Page 218 6-1-62 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check exhaust system for leakage, loose Go to Step 3. Repair or replace. connection and damage.
  • Page 219 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-63 DTC P0141 HEATED OXYGEN SENSOR (HO2S) HEATER CIRCUIT MALFUNCTION (SENSOR-2) CIRCUIT DESCRIPTION To other sensor Ignition Main switch fuse Heater To HO2S-1 heater DTC DETECTING CONDITION POSSIBLE CAUSE D HO2S-2 heater circuit open or shorted DTC will set when A or B condition it met.
  • Page 220 6-1-64 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check HO2S-2 Heater and Its Circuit. Intermittent trouble. Go to Step 3. 1) Warm up engine to normal operating temperature.
  • Page 221 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-65 DTC P0171 FUEL SYSTEM TOO LEAN DTC P0172 FUEL SYSTEM TOO RICH CIRCUIT DESCRIPTION Signal to decrease amount of fuel injection Signal to increase amount of fuel injection Sensed information High voltage Low voltage Fuel injector A / F mixture...
  • Page 222 6-1-66 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester on a level road.
  • Page 223 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-67 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Is there DTC(s) other than fuel system Go to applicable Go to Step 3. (DTC P0171/P0172)? DTC Diag.
  • Page 224 6-1-68 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) STEP ACTION Check engine coolant temp. sensor for performance Go to Step 9. Replace engine (See Section 6E2). coolant temp. sensor. Is it in good condition? Check intake air temp. sensor for performance Go to Step 10.
  • Page 225 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-69 DTC P0300 RANDOM MISFIRE DETECTED (Misfire detected at 2 or more cylinders) DTC P0301 CYLINDER 1 MISFIRE DETECTED DTC P0302 CYLINDER 2 MISFIRE DETECTED DTC P0303 CYLINDER 3 MISFIRE DETECTED DTC P0304 CYLINDER 4 MISFIRE DETECTED Ignition coil assembly for No.1 &...
  • Page 226 6-1-70 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) DTC DETECTING CONDITION POSSIBLE CAUSE D Engine under other than high revolution condition D Engine overheating D Not on rough road D Vacuum leaks (air inhaling) from air intake system D Engine speed changing rate D Ignition system malfunction (spark plug(s), high- Below D Manifold absolute...
  • Page 227 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-71 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE“. Is there DTC other than Fuel system (DTC P0171/P0172) Go to applicable Go to Step 3.
  • Page 228 6-1-72 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) STEP ACTION Check PCV valve for clogging (See Section 6E2). Go to Step 7. Replace PCV valve. Is it in good condition? Check EVAP Canister Purge Valve for Closing. Check EVAP Go to Step 8.
  • Page 229 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-73 DTC P0335 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION Crankshaft timing belt pulley sensor DTC DETECTING CONDITION POSSIBLE CAUSE D NO CKP sensor signal for 2 seconds at engine D CKP sensor circuit open or short. D Crankshaft timing belt pulley teeth damaged.
  • Page 230 6-1-74 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) INSPECTION NOTE: If starter circuit is open (i.e., start signal circuit is OK but starter fails to run), this DTC is stored in memory at starter switch ON, even though CKP sensor is in good condition. When starter motor fails to run and this DTC appears, check starter circuit first.
  • Page 231 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-75 DTC P0340 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION To ignition Camshaft switch position sensor Signal rotor on Camshaft DTC DETECTING CONDITION POSSIBLE CAUSE D No CMP sensor signal during engine running D CMP sensor circuit open or short.
  • Page 232 6-1-76 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check CMP Sensor and connector for proper Go to Step 3. Correct. installation.
  • Page 233 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-77 STEP ACTION Check signal rotor for the following, using mirror. Intermittent trouble or Clean rotor teeth or See Fig. 4. faulty ECM (PCM). replace CMP sensor. D Damage Check for intermittent D No foreign material attached referring to Is it in good condition?
  • Page 234 6-1-78 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) DTC P0400 EXHAUST GAS RECIRCULATION FLOW MALFUNCTION CIRCUIT DESCRIPTION Main relay Ignition switch Relay EGR valve Main fuse DTC DETECTING CONDITION POSSIBLE CAUSE D While running at specified vehicle speed after D EGR valve or its circuit D EGR passage engine warm-up...
  • Page 235 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-79 DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester, on a level road.
  • Page 236 Go to Step 5. EGR Valve Operation Check Go to Step 4. Go to Step 5. 1) With ignition switch OFF, install SUZUKI scan tool. 2) Check EGR system referring to section 6E2. Is it in good condition? MAP Sensor Check Intermittent trouble Repair or replace.
  • Page 237 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-81 DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD CIRCUIT DESCRIPTION To other sensor Heated Heated oxygen oxygen sensor-2 sensor-1 Warm up three way Three way catalytic converter catalytic converter ECM (PCM) monitors oxygen concentration in the exhaust gas which has passed the three way catalytic converter by HO2S-2.
  • Page 238 6-1-82 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and tester, on a level road.
  • Page 239 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-83 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check Short Term Fuel Trim. Go to Step 3. Check fuel system. Did short term fuel trim vary within –20% –+20% Go to DTC P0171/P0172 range in step 3) of DTC confirmation test?
  • Page 240 6-1-84 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) DTC P0443 EVAP PURGE CONTROL VALVE CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION 1. EVAP canister purge valve 2. To main relay 3. ECM (PCM) 4. Sensed information 5. Intake manifold 6. EVAP canister 7.
  • Page 241 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-85 DTC P0480 RADIATOR COOLING FAN CONTROL SYSTEM MALFUNCTION CIRCUIT DESCRIPTION Radiator cooling fan relay Main Radiator cooling relay Fan motor Relay “RDTR” (Radiator fan) DTC DETECTING CONDITION POSSIBLE CAUSE D Low voltage at terminal C02-18 when engine coolant D “B/W”...
  • Page 242 6-1-86 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check Radiator Cooling Fan Relay and Its Circuit. Intermittent trouble or Go to Step 3. 1) Turn ignition switch ON.
  • Page 243 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-87 DTC P0500 VEHICLE SPEED SENSOR (VSS) MALFUNCTION FOR M/T VEHICLE CIRCUIT DESCRIPTION Vehicle speed sensor in combination meter DTC DETECTING CONDITION POSSIBLE CAUSE D While fuel is kept cut at lower than 4000 r/min for D Speedometer cable broken D “P”, “Y/G”...
  • Page 244 6-1-88 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Does speedometer indicate vehicle speed? Go to Step 3. Speedometer cable disconnected or broken.
  • Page 245 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-89 DTC P0500 VEHICLE SPEED SENSOR (VSS) MALFUNCTION FOR A/T VEHICLE CIRCUIT DESCRIPTION Output shaft speed sensor (on A / T) Counter shaft gear DTC DETECTING CONDITION POSSIBLE CAUSE D While fuel is kept cut at lower than 4000 r/min for D “P”...
  • Page 246 6-1-90 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check VSS for Resistance. Go to Step 3. Replace VSS. 1) Disconnect VSS connection with ignition switch OFF. 2) Check for proper connection to VSS at “P”...
  • Page 247 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-91 DTC P0505 IDLE CONTROL SYSTEM MALFUNCTION CIRCUIT DESCRIPTION Main relay Relay box Main fuse To other valve IAC valve DTC DETECTING CONDITION POSSIBLE CAUSE D No closed signal to IAC valve is detected after D “R /B”, “V/W”...
  • Page 248 Check Idle Air Control System. Intermittent trouble or Go to Step 3. When using SUZUKI scan too: faulty ECM (PCM). 1) Connect SUZUKI scan tool to DLC with ignition Check for intermittent switch OFF, set parking brake and block drive referring to “Intermittent wheels.
  • Page 249 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-93 DTC P0601 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR DTC DETECTING CONDITION POSSIBLE CAUSE DTC P0601: Data write error (or check sum error) ECM (PCM) when written into ECM (PCM) : 1 driving cycle detection logic, continuous monitoring. DTC CONFIRMATION PROCEDURE 1) Turn ignition switch OFF.
  • Page 250 ECM (PCM) and LIST” mode on scan tool. recheck. 3) Check manifold absolute pressure. See Fig. 1. Is it barometric pressure (approx. 100 kPa, 760 mmHg) at sea level? Fig. 1 for Step 1 When using SUZUKI scan tool:...
  • Page 251 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-95 STEP ACTION Check MAP Sensor Check air intake Replace MAP 1) Remove MAP sensor from intake manifold and connect system for air sensor. vacuum pump gauge to MAP sensor. See Fig. 2. being drawn in 2) Connect scan tool to DLC and turn ignition switch ON.
  • Page 252 6-1-96 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) DTC P1500 ENGINE STARTER SIGNAL CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION M/T vehicle Main fuse Ignition switch (starter switch) Starter A/T vehicle Transmission Main range sensor (switch) fuse Ignition switch (starter switch) Starter DTC DETECTING CONDITION POSSIBLE CAUSE D Low voltage at terminal C03-17 when cranking...
  • Page 253 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-97 DTC P1510 ECM (PCM) BACK-UP POWER SUPPLY MALFUNCTION CIRCUIT DESCRIPTION Main Fuse box fuse DOME RADIO “LAMP” Battery voltage is supplied so that diagnostic trouble code memory, values for engine control learned by ECM (PCM), etc.
  • Page 254 6-1-98 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) TABLE B-1 FUEL INJECTOR CIRCUIT CHECK Fuse box Main relay Ignition switch No.1 injector No.2 injector Relay box No.3 injector No.4 injector Main fuse INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2.
  • Page 255 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-99 TABLE B-2 FUEL PUMP AND ITS CIRCUIT CHECK Ignition Main relay switch Main relay Fuel pump relay Main fuse Fuel pump INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG.
  • Page 256 6-1-100 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) Fig. 1 for Step 2 Fig. 2 for Step 3 Fig. 3 for Step 4...
  • Page 257 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-101 TABLE B-3 FUEL PRESSURE CHECK 1. Fuel injector 2. Delivery pipe 3. Fuel regulator 4. Fuel filter 5. Fuel pump Special Tool (A) Gauge (09912-58441) (B) Hose (09912-58431) (C) 3-way joint (09912-58490) INSPECTION STEP ACTION...
  • Page 258 6-1-102 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) STEP ACTION Was no fuel pressure applied in step 1? Go to Step 8. Go to Step 9. With fuel pump operated and fuel return hose blocked Faulty fuel pressure Shortage of fuel or fuel by pinching it, is fuel pressure applied? regulator.
  • Page 259 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-103 TABLE B-4 A/C SIGNAL CIRCUITS CHECK (VEHICLE WITH A/C) (A / C ON output signal) A / C amplifier (A / C input signal) INSPECTION STEP ACTION Check A/C (input) Signal Circuit. Go to Step 2.
  • Page 260 Go to Step 2. When using SUZUKI scan tool: good condition. 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. 2) Start engine and select “DATA LIST” mode on scan tool. 3) Check power steering pressure switch. See Fig. 1.
  • Page 261 Electric load signal “Br/Y” circuit open When using SUZUKI scan tool: circuit is in good or short, Electric 1) Connect SUZUKI scan tool to DLC with ignition condition. load diodes switch OFF. malfunction or 2) Start engine and select “DATA LIST” mode on Each electric load scan tool.
  • Page 262 6-1-106 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) TABLE B-7 RADIATOR COOLING FAN CONTROL SYSTEM CHECK Radiator cooling fan relay Main Radiator cooling relay Fan motor Relay “RDTR” (Radiator fan) INSPECTION STEP ACTION Check Fan Control System. Radiator cooling Go to Step 2.
  • Page 263 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-107 Fig. 1 for Step 1 Fig. 2 for Step 3 When using SUZUKI scan tool: 1. Radiator cooling fan relay Fig. 3 for Step 4 1. Battery 2. Radiator fan motor coupler...
  • Page 264: Special Tools

    5. Test lead / probe 6. Power source cable 7. DLC cable adaptor 8. Self-test adaptor 09917-47910 09930-88530 09931-76011 Vacuum pump gauge Injector test lead SUZUKI scan tool (Tech 1 A) kit 09931-76030 Mass storage cartridge 16 / 14 pin DLC cable...
  • Page 265: Engine Mechanical

    D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 266: Oil Pressure Check

    6A-2 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) ON-VEHICLE SERVICE ENGINE VACUUM CHECK The engine vacuum that develops in the intake line is a good indica- tor of the condition of the engine. The vacuum checking procedure is as follows: 1) Warm up engine to normal operating temperature. 2) With engine stopped, remove blind plug hose from intake man- ifold and connect special tool (vacuum gauge and joint) to va- cated threaded hole.
  • Page 267 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-3 3) Install special tool (Oil pressure gauge) to vacated threaded hole. Special Tool (A): 09915-77311 (B): 09915-78211 NOTE: At this time, be very careful not to exert force to where heated oxygen sensor and its lead wire are connected. 4) Reinstall oil filter.
  • Page 268: Cylinder Head Cover

    6A-4 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) CYLINDER HEAD COVER REMOVAL 1) Disconnect negative cable at battery. 2) Remove air cleaner assembly. 3) Remove high-tension cord clamps (2) from cylinder head cover. 4) Disconnect breather hose from cylinder head cover. 5) Remove cylinder head cover nuts and then seal washers (1).
  • Page 269 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-5 THROTTLE BODY AND INTAKE MANIFOLD 1. Stay 2. Throttle body 3. Gasket 4. EFE heater : Tightening Torque 5. Intake manifold 6. Gasket : Do not reuse REMOVAL 1) Relieve fuel pressure according to procedure described in “FUEL PRESSURE RELIEF PROCEDURE”...
  • Page 270 6A-6 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 4) Remove air cleaner assembly. 5) Disconnect the following electric lead wires: D EGR valve D ISC actuator (2) D Ground wires from intake manifold D Fuel injector (4) D TP sensor (3) D EFE heater (5) D Engine coolant temp.
  • Page 271 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-7 INSTALLATION 1) Install throttle body to intake manifold. (Refer to Section 6E.) 2) Install intake manifold gasket to cylinder head. Use a new gas- ket. 3) Install intake manifold (1) with throttle body to cylinder head. D Install clamps (3) as shown in figure, and tighten bolts and nuts to specification.
  • Page 272: Exhaust Manifold

    6A-8 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) EXHAUST MANIFOLD 1. Exhaust manifold 2. Gasket 3. Cover 4. Heated oxygen sensor 5. Pipe seal 6. Exhaust pipe : Tightening Torque 7. WU-TWC (if equipped) 8. Exhaust pipe bolt : Do not reuse WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot.
  • Page 273 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-9 INSTALLATION 1) Install manifold gasket to cylinder head. Before installing gasket, check it for deterioration or damage, and replace as necessary. 2) Install exhaust manifold (1). Tighten manifold bolts and nuts to specified torque. Tightening Torque (a): 23 N m (2.3 kg-m, 17.0 lb-ft)
  • Page 274 6A-10 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) TIMING BELT AND BELT TENSIONER 1. Timing belt 2. Tensioner 3. Tensioner plate 4. Tensioner spring 5. Spring damper 6. Camshaft timing pulley 7. Pin 8. Pulley bolt 9. Seal 10. Inside cover seal 11.
  • Page 275 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-11 8) Loosen crankshaft pulley bolts (1) and remove crankshaft pulley (2). 9) Remove timing belt outside cover (1). 10) Align 4 timing marks as shown in figure to facilitate its installa- tion. 1. “V” mark on cylinder head cover 2.
  • Page 276 6A-12 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) CAUTION: After timing belt is removed, never turn camshaft and crank- shaft independently more than such an extent as shown be- low. If turned, interference may occur among piston and valves, and parts related to piston and valves may be dam- aged.
  • Page 277 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-13 3) Check that timing mark (3) on camshaft timing belt pulley (1) is aligned with “V” mark (2) on cylinder head cover (4). If not, align two marks by turning camshaft but be careful not to turn it more than its allowable turning range which is described on previous page.
  • Page 278 6A-14 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 7) Install timing belt outside cover. Before installing, make sure that rubber seal (1) is between wa- ter pump and oil pump case and another between water pump and cylinder head. Tightening Torque (c): 11 N m (1.1 kg-m, 8.0 lb-ft) 8) Install crankshaft pulley (2).
  • Page 279 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-15 CAMSHAFT AND HYDRAULIC VALVE LASH ADJUSTER 1. Cylinder head cover 2. Gasket 3. Cylinder head 4. Camshaft housing No.1: Apply sealant 99000-31110 to mating surface. 5. Camshaft housing No.2 6. Camshaft housing No.3: Apply sealant 99000-31110 to mating surface.
  • Page 280 6A-16 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6) Remove camshaft housings from cylinder head. 7) Remove camshaft from cylinder head. 8) Remove valve lash adjuster from cylinder head. NOTE: D Never disassemble hydraulic valve lash adjuster. D Don’t apply force to body of adjuster, for oil in high pres- Don’t apply force sure chamber in adjuster will leak.
  • Page 281 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-17 INSPECTION Camshaft journal wear: D Check camshaft journals and camshaft housings for pitting, scratches, wear or damage. If any malcondition is found, replace camshaft or cylinder head with housing. Never replace cylinder head without replacing housings.
  • Page 282 6A-18 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) INSTALLATION 1) Before installing valve lash adjuster to cylinder head, fill oil pas- sage of cylinder head (1) with engine oil according to the follow- ing procedure. Pour engine oil through camshaft journal oil holes (2) and check that oil comes out from oil holes in sliding part of valve lash ad- juster.
  • Page 283 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-19 D As camshaft housing No.1 (1) retains camshaft in proper position as to thrust direction, make sure to first fit No.1 hous- ing to No.1 journal of camshaft securely. 2. No.2 housing 3. No.3 housing D After applying engine oil to housing bolts, tighten them tem- porarily first.
  • Page 284 6A-20 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) CAUTION: D Don’t turn camshaft or start engine (i.e., valves should not be operated) for about half an hour after reinstalling hydraulic valve lash adjusters and camshaft. As it takes time for valves to settle in place, operating engine within half an hour after their installation may cause interference to occur between valves and piston.
  • Page 285 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-21 VALVES AND CYLINDER HEAD 1. Cylinder head 2. Cylinder head bolt 3. Valve guide 4. Cylinder head gasket: “TOP” mark provided on gasket comes to crankshaft pulley side, facing up (toward cylinder head side). 5.
  • Page 286 6A-22 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) Valve Springs D Referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of breakage or weak- ening. Remember, weakened valve springs can cause chatter, not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure.
  • Page 287 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-23 PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS 1. Top ring 2. 2nd ring 3. Oil ring 4. Piston 5. Connecting rod 6. Connecting rod bearing cap : Apply engine oil to sliding 7. Connecting rod bearing surfaces of each part.
  • Page 288: Engine Assembly

    6A-24 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) UNIT REPAIR OVERHAUL ENGINE ASSEMBLY REMOVAL 1) Relieve fuel pressure according to procedure described in “FUEL PRESSURE RELIEF PROCEDURE” of Section 6. 2) Remove engine hood after disconnecting front window washer hose. 3) Disconnect battery cables at battery and remove battery and its tray.
  • Page 289 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-25 11) Disconnect the following cables. For M / T model D Accelerator cable from throttle body. D Clutch cable from transmission. (For M/T model) D Gear select cable and oil pressure control cable from trans- mission.
  • Page 290 6A-26 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) INSTALLATION For M / T model 1) Lift engine with transmission into engine compartment, but do not remove lifting device. 2) Install right side engine mounting to its bracket. 3) Install left side engine mounting and its bracket. 4) Install rear mounting to body.
  • Page 291 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-27 MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK 78 N m (7.8 kg-m) 1. Cylinder block 2. Front oil seal 3. Main bearing 12 N m (1.2 kg-m) 4. Bearing cap 5. Cap washer 6. Cap bolt 7.
  • Page 292 6A-28 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) INSTALLATION NOTE: D All parts to be installed must be perfectly clean. D Be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins, connecting rod bearings, pistons, pis- ton rings and cylinder bores. D Journal bearings, bearing caps, connecting rods, rod bear- ings, rod bearing caps, pistons and piston rings are in com- bination sets.
  • Page 293 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-29 5) Install oil seal housing and its gasket. Install new gasket. Do not reuse gasket removed in disassem- bly. Oil lip portion of oil seal before installing. Tighten housing bolts to specification. After installing oil seal housing, gasket edges might bulge out; if so, cut them off to make them flush with cylinder block and oil seal housing.
  • Page 294 6A-30 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) SPECIAL TOOLS 09915-47310 09915-64512 Oil filter wrench Compression gauge 09910-38211 Piston pin remover and installer 1. Base 2. Base cap 3. Driver handle 1. 09915-77311 4. Piston pin guide for installation Oil pressure gauge 5.
  • Page 295 Flywheel holder Oil seal guide (Vinyl resin) REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI BOND NO. 1207C D Mating surfaces of cylinder block and oil pan. (99000-31150) Sealant Sealant D Mating surfaces of camshaft housings SUZUKI BOND NO. 1215 (99000-31110) (No.1 &...
  • Page 296: Table Of Contents

    D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 297 6A1-2 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) GENERAL DESCRIPTION ENGINE The engine is a water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit equipped with its S.O.H.C. (Single Overhead Camshaft) valve mechanism arranged for “V”-type valve configuration and 16 valves (IN 2 and EX 2/one cylinder).
  • Page 298: Engine Lubrication

    ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-3 ENGINE LUBRICATION The oil pump is of a trochoid type, and mounted on crankshaft at crankshaft pulley side. Oil is drawn up through oil pump strainer and passed through pump to oil filter. The filtered oil flows into two paths in cylinder block.
  • Page 299: Cylinder Block

    6A1-4 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) CYLINDER BLOCK The cylinder block is made of cast aluminum alloy and This allows a gradual change in thrust pressure has 4 cylinders arranged “In-Line”. A cylindrical cast against the cylinder wall as the piston travels its path. iron sleeve is installed in each cylinder.
  • Page 300: Compression Check

    ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-5 ON-VEHICLE SERVICE COMPRESSION CHECK Check compression pressure on all four cylinders as follows: 1) Warm up engine. 2) Stop engine after warming up. NOTE: After warming up engine, place transmission gear shift le- ver in “Neutral”...
  • Page 301 (vacuum gauge and joint) between intake manifold and vacuum hose disconnected. Special Tool (A): 09915-67311 (B): 09918-08210 SUZUKI GENUINE PARTS (C): Hose 09343-03087 (D): 3-way joint 09367-04002 3) Run engine at specified idle speed, and read vacuum gauge. Vacuum should be within the following specification.
  • Page 302 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-7 OIL PRESSURE CHECK NOTE: Prior to checking oil pressure, check the following items. D Oil level in oil pan. If oil level is low, add oil up to Full level mark on oil level gauge.
  • Page 303 6A1-8 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6) Before reinstalling oil pressure switch (1), be sure to wrap its screw threads with sealing tape (2) and tighten switch to speci- fied torque. NOTE: If sealing tape edge is bulged out from screw threads of switch, cut it off.
  • Page 304: Valve Lash (Clearance)

    ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-9 VALVE LASH (CLEARANCE) 1) Remove negative cable at battery. 2) Remove cylinder head cover referring to item “Cylinder Head cover”. 3) Remove engine under cover of right side from body. 4) Using special tool and wrench (1), turn crankshaft pulley clock- wise until “V”...
  • Page 305 6A1-10 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6) If valve lash is out of specification, adjust it to specification by turning adjusting screw after loosening lock nut. After adjustment, tighten lock nut to specified torque while hold- ing adjusting screw stationary, and then make sure again that valve lash is within specification.
  • Page 306: Air Cleaner Element

    ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-11 AIR CLEANER ELEMENT REMOVAL 1) Disconnect air cleaner outlet hose from case after loosening its clamp (2) and removing bolt (1) shown in figure. 2) Remove air cleaner cap (3) from case by unhooking its clamps, then take out air cleaner element.
  • Page 307: Air Cleaner Outlet Hose

    6A1-12 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) AIR CLEANER OUTLET HOSE REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect resonator after loosening its clamp. 3) Disconnect breather hose from air cleaner outlet hose. 4) Disconnect IAT sensor wire at coupler. 5) Remove bolt and then air cleaner outlet hose after loosening its clamps.
  • Page 308 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-13 CYLINDER HEAD COVER REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect breather hose (2) and PCV valve (3) from head cov- 3) Disconnect ignition coil couplers (6). 4) Remove ignition coil assemblies (5) with high-tension cord (4). 5) Remove cylinder head cover (1) with cylinder head cover gasket and O-rings.
  • Page 309 6A1-14 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) THROTTLE BODY AND INTAKE MANIFOLD 1. Intake manifold 7. Fuel pressure regulator 2. Throttle body 8. EVAP canister purge valve 3. Gasket 9. MAP sensor 4. EGR valve 10. O-ring : Tightening Torque 5.
  • Page 310 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-15 7) Disconnect the following electric lead wires and release clamp: D Ground wires (5) from intake manifold D TP sensor (3) D IAC valve (4) D Fuel injectors D EVAP canister purge valve (2) D MAP sensor (6) D EGR valve (1) 8) Disconnect the following hoses:...
  • Page 311 6A1-16 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 10) Remove intake manifold rear stiffener (1) and generator adjust arm reinforcement (2) from intake manifold (3). 11) Remove intake manifold with throttle body from cylinder head, and then its gasket. INSTALLATION Reverse removal procedure for installation noting the followings. D Use new intake manifold gasket.
  • Page 312 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-17 EXHAUST MANIFOLD 1. Exhaust manifold 2. Gasket 3. Cover 4. Heated oxygen sensor : Tightening Torque 7. Gasket : Do not reuse 8. Exhaust No.1 pipe. WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot.
  • Page 313 6A1-18 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) INSTALLATION 1) Install new gaskets to cylinder head. 2) Install exhaust manifold. Tighten bolts and nuts to specified torque. Tightening Torque (a): 32 N m (3.2 kg-m, 23.5 lb-ft) 3) Install exhaust manifold cover(s) (1). 4) Connect oxygen sensor coupler (3) and clamp (2) its wire se- curely.
  • Page 314 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-19 TIMING BELT AND BELT TENSIONER 1. Timing belt 2. Tensioner 3. Tensioner plate 4. Tensioner spring 5. Camshaft timing pulley 6. Tensioner bolt 7. Pulley bolt 8. Seal 9. Inside cover seal 10. Inside cover 11.
  • Page 315 6A1-20 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 8) Lock crankshaft inserting flat end rod or the like (2) between fly- wheel ring gear and transmission case, after removing clutch housing (torque converter housing for A/T) lower plate. With crankshaft locked, remove crankshaft timing belt pulley bolt (3).
  • Page 316 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-21 CAUTION: D After timing belt is removed, never turn camshaft and crankshaft independently more than such an extent as shown in figure. If turned, interference may occur among piston and valves, and parts related to piston and valves may be damaged.
  • Page 317 6A1-22 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 2) Install tensioner (2) and tensioner plate (3): Do not tighten tensioner bolt (1) with wrench yet. Hand tighten only at this time. Check to ensure that plate movement in arrow direction as shown in figure causes tensioner to move in the same direction.
  • Page 318 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-23 6) To take up slack of timing belt, turn crankshaft two rotations clockwise after installing it. After making sure that belt is free from slack, tighten tensioner stud first and then tensioner bolt to each specified torque.
  • Page 319 6A1-24 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 12) Install water pump pulley (1) and drive belt. Tightening Torque (a): 11 N m (1.1 kg-m, 8.0 lb-ft) 13) Adjust drive belt tension referring to Section 6B. 14) Adjust power steering pump belt tension or A/C compressor belt tension, if equipped.
  • Page 320: Oil Pan And Oil Pump Strainer

    ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-25 OIL PAN AND OIL PUMP STRAINER 1. Oil pan: Apply sealant 99000-31150 to oil pan mating surface. 2. Oil pump strainer 3. Seal : Tightening Torque 4. Drain plug gasket 5. Drain plug : Do not reuse 6.
  • Page 321 6A1-26 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6) Remove oil pan (3) and then oil pump strainer (1). 2. O-ring CLEANING D Clean mating surfaces of oil pan and cylinder block. Remove oil, old sealant, and dusts from mating surfaces and oil pan inside.
  • Page 322 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-27 3) Install new gasket and drain plug to oil pan. Tighten drain plug to specified torque. Tightening Torque (a): 50 N m (5.0 kg-m, 36 lb-ft) 4) Install clutch (torque converter) housing lower plate. 5) Install CKP sensor (1) and connect its coupler, then clamp its harness.
  • Page 323: Oil Pump

    6A1-28 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) OIL PUMP 1. Rotor plate 2. Inner rotor: Apply thin coat of engine oil. 3. Outer rotor: Apply thin coat of engine oil. 4. Gasket 5. Pin 6. Pin 7. Relief valve: Apply thin coat of engine oil. 8.
  • Page 324 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-29 7) Remove oil pump assembly (1) after removing bolts (2). DISASSEMBLY 4. Guide seal 1) Remove oil level gauge guide bolt (3) and pull out guide (2) from oil pump (1). 2) Remove rotor plate (1). 3) Remove outer rotor (1) and inner rotor (2).
  • Page 325 6A1-30 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) NOTE: When installing oil seal (1), press-fit it till its end face is flush with oil pump case (2) end face. D Check outer and inner rotors, rotor plate, and oil pump case for excessive wear or damage.
  • Page 326 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-31 4) Install rotor plate. Tighten 5 screw securely. After installing plate, check to be sure that gears turn smoothly by hand. Tightening Torque (a): 11 N m (1.1 kg-m, 8.0 lb-ft) 5) Apply engine oil to guide seal (3) and install guide seal and guide 1.
  • Page 327 6A1-32 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 5) Install timing pulley key (2) and crank timing belt pulley (3) and crankshaft pulley pin (1). Refer to figure for proper installation of these parts. With crankshaft locked using flat end rod or the like (5), tighten crank timing belt pulley bolt (4) to specified torque.
  • Page 328: Rocker Arms, Rocker Arm Shaft And Camshaft

    ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-33 ROCKER ARMS, ROCKER ARM SHAFT AND CAMSHAFT 1. Camshaft 2. Camshaft oil seal 3. Rocker arm shaft 4. O-ring 5. Rocker shaft bolt 6. Rocker arm (IN) 7. Rocker arm No.1 (EX) 8. Rocker arm No.2 (EX) : Do not reuse 9.
  • Page 329 6A1-34 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 4) Disconnect CMP sensor coupler from CMP sensor. 5) Remove CMP sensor case (1) from cylinder head. Place a container or rag under CMP sensor case, for a small amount of oil flows out during removal of case. 6) After loosening all valve adjusting screw lock nuts (2), turn ad- justing screws (1) back all the way to allow all rocker arms (3) to move freely.
  • Page 330 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-35 10) Remove rocker arm shaft bolts (1). 2. Rocker arm shaft 11) Remove exhaust rocker arms (1) and rocker arm spring (2) by pulling out rocker arm shaft to battery side after removing bat- tery.
  • Page 331 6A1-36 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) Rocker Arm-to-Rocker Arm Shaft Clearance Using a micrometer and a bore gauge, measure rocker shaft dia. and rocker arm l.D. Difference between two readings is arm-to-shaft clearance on which a limit is specified. If limit is exceeded, replace shaft or arm, or both.
  • Page 332 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-37 Check clearance by using gaging plastic. The procedure is as follows. 1) Clean housing and camshaft journals. 2) Install camshaft to cylinder head. 3) Place a piece of gaging plastic the full width of journal of cam- shaft (parallel to camshaft).
  • Page 333 6A1-38 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) INSTALLATION 1) Apply engine oil to rocker arm shaft and rocker arms. 2) Check O-ring for damage or deterioration. Install O-ring to rock- er arm shaft. 3) Install rocker arm shaft (3) with shaft bolt holes (4) facing up, rocker arm (exhaust side) (2) and rocker arm spring (1).
  • Page 334 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-39 D Embossed marks are provided on each camshaft housing, in- dicating position and direction for installation. Install housing as indicated by these marks. D Indicates position from timing D As camshaft housing No. 1 retains camshaft in proper position belt side.
  • Page 335 6A1-40 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 10) Using special tool, tighten pulley bolt to specified torque. Tightening Torque (a): 60 N m (6.0 kg-m, 43.5 lb-ft) Special Tool (A): 09917-68221 11) Install belt tensioner, timing belt, outside cover, crankshaft pulley and water pump belt as previously outlined.
  • Page 336 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-41 VALVES AND CYLINDER HEAD 3.5 N m (0.35 kg-m) 1. Valve cotters 10. Camshaft housing: 2. Valve spring retainer Apply sealant to mating surface of 3. Valve spring: No.1 and No.6 housings. be sure to position 11.
  • Page 337 6A1-42 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 5) Remove intake manifold rear stiffener (1) and generator adjust arm reinforcement (2) from intake manifold. 6) Disconnect the following electric wires: D Ignition coil assembly D Injectors, TP sensor and D Ground wires from IAC valve wires at the intake manifold coupler...
  • Page 338 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-43 9) Remove cylinder head cover (1) as previously outlined. Loosen all valve lash adjusting screws fully. 4. High-tension cords 2. Breather hose 5. Ignition coil assembly 3. PCV valve 6. Ignition coil coupler 10) Remove timing belt and camshaft as previously outlined.
  • Page 339 6A1-44 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) DISASSEMBLY 1) For ease in servicing cylinder head, remove CMP sensor case, intake manifold with throttle body and exhaust manifold from cyl- inder head. 2) Remove rocker arms and washers by pulling its shaft out to transmission side.
  • Page 340 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-45 INSPECTION Valve Guides Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide.
  • Page 341 6A1-46 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) D Inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be resurfaced, but not so much as to grind off its chamfer. When it is worn so much that its chamfer is gone, replace valve.
  • Page 342 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-47 D Valve seat repair: A valve seat (2) not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.
  • Page 343 6A1-48 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) D Flatness of gasketed surface: Using a straightedge and thickness gauge, check surface at a to- tal of 6 locations. If distortion limit, given below, is exceeded, cor- rect gasketed surface with a surface plate and abrasive paper of about #400 (Waterproof silicon carbide abrasive paper): place paper on and over surface plate, and rub gasketed surface against paper to grind off high spots.
  • Page 344 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-49 Valve Springs D Referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of breakage or weak- ening. Remember, weakened valve springs can cause chatter, not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure.
  • Page 345 6A1-50 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) ASSEMBLY 1) Before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) to remove burrs and make it truly round. Special Tool (A): 09916-34542 (B): 09916-38210 2) Install valve guide to cylinder head. Heat cylinder head uniformly at a temperature of 80 to 100_C (176 to 212_F) so that head will not be distorted, and drive new valve guide into hole with special tools.
  • Page 346 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-51 5) Install new valve stem seal (1) to valve guide. After applying engine oil to seal and spindle of special tool (Valve guide installer handle), fit oil seal to spindle, and then install seal to valve guide by pushing special tool by hand.
  • Page 347 6A1-52 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 9) Install rocker arms, washers, rocker arm shaft and camshaft as previously outlined. 10) Install CMP sensor case, intake manifold and exhaust man- ifold. INSTALLATION 1) Remove oil gasket and oil on mating surfaces and install new head gasket (1) as shown in figure, that is, “TOP”...
  • Page 348 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-53 4) Reverse removal procedure for installation. 5) Adjust water pump drive belt tension by referring to “ENGINE COOLING” section. 6) Adjust power steering pump belt tension or A/C compressor belt tension, if equipped. Refer to Section 0B.
  • Page 349: Piston, Piston Rings, Connecting Rods And Cylinders

    6A1-54 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) PISTON, PISTON RINGS, CONNECTING RODS AND CYLINDERS 1. Top ring 2. 2nd ring 3. Oil ring 4. Piston 5. Connecting rod 6. Connecting rod bearing cap 7. Connecting rod bearing 8. Piston pin 9.
  • Page 350 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-55 DISASSEMBLY 1) Using piston ring expander, remove two compression rings (Top and 2nd) and oil ring from piston. 2) Remove piston pin from connecting rod. D Ease out piston pin circlips (1), as shown. D Force piston pin out.
  • Page 351 6A1-56 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) INSPECTION Cylinders D Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use oversize piston. D Using a cylinder gauge, measure cylinder bore in thrust and axial directions at two positions as shown in figure.
  • Page 352 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-57 D Piston clearance: Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, re- bore cylinder and use oversize piston.
  • Page 353 6A1-58 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) Piston Rings To measure end gap, insert piston ring (3) into cylinder bore and then measure the gap by using thickness gauge (2). If measured gap is out of specification, replace ring. NOTE: Decarbon and clean top of cylinder bore before inserting pis- ton ring.
  • Page 354 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-59 Crank Pin and Connecting Rod Bearings D Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is dam- aged, or out-of-round or taper is out of limit, replace crankshaft or regrind crank pin to undersize and use undersize bearing.
  • Page 355 6A1-60 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 5) Remove cap and using a scale (2) on gaging plastic (1) enve- lope, measure gaging plastic width at the widest point (clear- ance). If clearance exceeds its limit, use a new standard size bearing and remeasure clearance.
  • Page 356 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-61 c) Stamped number on piston and that on cylinder block should correspond. That is, install number 2 stamped piston to cylinder which is identified with number 2 and a number 1 piston to cylin- der with number 1.
  • Page 357 6A1-62 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) INSTALLATION OR CONNECTION 1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crankpins. NOTE: Do not apply oil between connecting rod and bearing or be- tween bearing cap and bearing. 2) Install guide hoses over connecting rod bolts.
  • Page 358 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-63 6) Reverse removal procedure for installation, as previously out- lined. 7) Adjust water pump drive belt tension referring to Section 6B. 8) Adjust power steering pump belt tension or A/C compressor belt tension, if equipped. Refer to Section 0B.
  • Page 359 6A1-64 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) UNIT REPAIR OVERHAUL ENGINE ASSEMBLY REMOVAL 1) Release fuel pressure in fuel feed line by referring to Section 2) Remove battery. 3) Remove engine hood after disconnecting windshield washer hose. 4) Drain cooling system. WARNING: To help avoid danger of being burned, do not remove drain plug (2) and radiator cap while engine and radiator...
  • Page 360 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-65 12) Disconnect the following electric wires: D Ignition coil assembly D Ground wires from intake manifold D Engine oil pressure switch D EVAP canister purge valve (if equipped) D Engine coolant temp. sensor D Fuel injectors D Power steering pressure switch (if equipped) D Oxygen sensor-1...
  • Page 361 6A1-66 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 15) Remove exhaust No.1 pipe. 16) Remove right and left engine under covers. 17) Remove gear shift control shaft from transmission and remove extension rod (M/T). 18) Drain engine and transmission oil. 19) Disconnect drive shaft joints from differential gears of trans- mission or center bearing support referring to Section 4.
  • Page 362 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-67 INSTALLATION 1) Lift engine with transmission into engine compartment, but do not remove support device. 2) Install engine right mounting to right mounting bracket and stiff- ener. 3) Install engine left mounting to body. 4) Install rear mounting to body (For M/T model) Install torque rod (For A/T model) 5) Tighten bolts and nuts of all parts installed in above steps 2),...
  • Page 363 6A1-68 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK 78 N m (7.8 kg-m) for flywheel 95 N m (9.5 kg-m) for drive plate 1. Cylinder block 7. Crankshaft: 10. Pin 2. Front oil seal: Apply engine oil to crankshaft 11.
  • Page 364 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-69 REMOVAL 1) Remove engine assembly from body as previously outlined. 2) Remove clutch cover, clutch disc and flywheel (drive plate for A/T). Special Tool (A): 09924-17810 1. Flywheel bolt 3) Remove crankshaft pulley, timing belt and crankshaft timing pulley.
  • Page 365 6A1-70 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) INSPECTION Crankshaft Crankshaft runout Using a dial gauge, measure runout at center journal. Rotate crank- shaft slowly. If runout exceeds its limit, replace crankshaft. Limit on runout: 0.06 mm (0.0023 in.) Crankshaft thrust play Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing (1) and journal bearing caps installed.
  • Page 366 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-71 Main Bearings General information D Service main bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, and each of them has 5 kinds of bear- ings differing in tolerance. D Upper half of bearing (2) has oil groove (3) as shown in figure. Install this half with oil groove to cylinder block (1).
  • Page 367 6A1-72 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 5) Remove cap and using scale (2) on gaging plastic (1) envelope, measure gaging plastic width at its widest point. If clearance ex- ceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit.
  • Page 368 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-73 2) Next, check bearing cap bore diameter without bearing. On mat- ing surface of cylinder block, four alphabets are stamped as shown in figure. Three kinds of alphabets (“A”, “B” and “C”) represent the follow- ing cap bore diameters.
  • Page 369 6A1-74 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 4) From numerals stamped on crank webs (1) of No.2 and No.3 cyl- inders and the alphabets stamped on mating surface of cylinder block, determine new standard bearing to be installed to journal, by referring to table given below.
  • Page 370 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-75 D If necessary, regrind crankshaft journal and select under-size bearing to use with it as follows. 1) Regrind journal to the following finished diameter. Finished diameter: 44.732 – 44.750 mm (1.7611 – 1.7618 in.) 2) Using micrometer, measure reground journal diameter.
  • Page 371 6A1-76 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) Flywheel D If ring gear is damaged, cracked or worn, replace flywheel. D If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel. D Check flywheel for face runout with dial gauge. If runout exceeds its limit, replace flywheel.
  • Page 372 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-77 5) Rebore and hone cylinder to calculated dimension. NOTE: Before reboring, install all main bearing caps in place and tighten to specification to avoid distortion of bearing bores. 6) Measure piston clearance after honing. INSTALLATION NOTE: D All parts to be installed must be perfectly clean.
  • Page 373 6A1-78 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 3) Install crankshaft to cylinder block. 4) Install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side. Fit them sequen- tially in ascending order, 1, 2, 3, 4 and 5, starting from pulley side. After installing bearing cap stiffeners, tighten bearing cap bolts in such order as shown in figure a little at a time and repeat it till they are tightened to specified torque.
  • Page 374 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-79 8) Install pistons and connecting rods as previously outlined. 9) Install oil pump strainer and oil pan as previously outlined. 10) Install cylinder head assembly to cylinder block as previously outlined. 11) Install camshaft, crankshaft timing belt pulley, timing belt, crankshaft pulley, water pump pulley, etc., as previously out- lined.
  • Page 375 6A1-80 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) SPECIAL TOOLS 1. 09915-64510-001 Compression gauge 2. 09915-64510-002 Connector 3. 09915-64530 Hose 09915-67311 09918-08210 09915-77311 4. 09915-67010 Vacuum gauge Vacuum gauge hose joint Oil pressure gauge Attachment 09917-18211 09919-16020 09926-18210 09917-68221 Tappet adjuster wrench 17 mm socket Oil seal guide (Vinyl resin) Camshaft pulley holder...
  • Page 376 Flywheel holder Oil filter wrench REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI BOND NO.1207C D Mating surfaces of cylinder block and oil pan. Sealant (99000-31150) D Mating surfaces of camshaft housings (No.6). SUZUKI BOND NO.1215 D Mating surfaces of CMP sensor case and cylinder...
  • Page 377 6A1-82 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) TIGHTENING TORQUE SPECIFICATIONS TIGHTENING TORQUE FASTENING PARTS FASTENING PARTS kg-m lb-ft Oil pressure switch Valve adjusting screw lock nuts Cylinder head cover bolts Intake manifold bolts and nuts 17.0 Timing belt tensioner stud Timing belt tensioner bolt 18.0 Timing belt cover bolts and nut...
  • Page 378: Engine Cooling

    ENGINE COOLING 6B-1 SECTION 6B ENGINE COOLING NOTE: For the descriptions (items) not found in this section, refer to the same section of Service Manual men- tioned in FOREWORD of this manual. CONTENTS GENERAL DESCRIPTION ..............6B-2 DIAGNOSIS .
  • Page 379 6B-2 ENGINE COOLING GENERAL DESCRIPTION COOLING SYSTEM CIRCULATION During engine warm-up (thermostat closed), the water pump discharges coolant into the water jacket chamber adjacent to No.1 cylinder. Coolant then flows through the cylinder block and the cylinder heat. Coolant then returns to the water pump through intake manifold, heater inlet hose, heater unit, heater outlet hose, and water intake pipe.
  • Page 380: Cooling Fan

    ENGINE COOLING 6B-3 THERMOSTAT A wax pellet type thermostat is used in the coolant outlet passage to control the flow of engine coolant, to provide fast engine warm up and to regulate coolant temperatures. A wax pellet element is hermetically contained in a metal case, and expands when heated and contracts when cooled.
  • Page 381 6B-4 ENGINE COOLING COOLANT (WATER) TEMP. GAUGE The coolant temp. gauge is included in engine coolant temp. (ECT) sensor (1). This gauge activates a temp. meter in the instrument cluster. DIAGNOSIS Condition Possible Cause Correction D Loose or broken water pump belt Engine overheats Adjust or replace.
  • Page 382 ENGINE COOLING 6B-5 MAINTENANCE COOLANT The coolant recovery system is standard. The coolant in the radiator expands with heat, and the overflow is col- lected in the reservoir tank. When the system cools down, the coolant is drawn back into the radiator. The cooling system has been filled at the factory with a quality coolant that is either 50/50 mixture of water and GOLDEN CRUISER 1200 (ethylene glycol antifreeze.) or 30/70 mixture of water and GOLDEN CRUISER 1200.
  • Page 383 6B-6 ENGINE COOLING COOLING SYSTEM FLUSH AND REFILL WARNING: To help avoid danger of being burned, do not remove radia- tor cap while engine and radiator cap while engine and ra- diator are still hot. Scalding fluid and steam can be blown out under pressure if cap is taken off too soon.
  • Page 384 ENGINE COOLING 6B-7 ON-VEHICLE SERVICE WARNING: D Check to make sure that engine coolant temperature is cold before removing any part of cooling system. D Also be sure to disconnect negative cord from battery ter- minal before removing any part. COOLING WATER PIPES OR HOSES REMOVAL 1) Drain cooling system.
  • Page 385 6B-8 ENGINE COOLING 4) Remove thermostat (1). 2. Thermostat case INSPECTION 1) Make sure that air bleed valve (1) of thermostat is clean. Should this valve be clogged, engine would tend to overheat. 2) Check to make sure that valve seat is free from foreign matters which would prevent valve from seating tight.
  • Page 386: Water Pump

    ENGINE COOLING 6B-9 WATER PUMP 1) Disconnect negative cable at battery. 2) Drain cooling system. 3) Remove timing belt and tensioner according to procedure de- scribed in “TIMING BELT AND TENSIONER” of Section 6A or 6A1. 4) Remove water pump belt adjusting arm. 5) Remove water pump assembly (1).
  • Page 387 6B-10 ENGINE COOLING 5) Install crankshaft pulley, water pump pulley, and pump drive belt referring to Section 6A or 6A1. 6) Adjust water pump belt tension. 7) Install fender apron extension on right side. 8) Install air cleaner assembly. 9) Connect negative cable at battery. 10) Fill cooling system.
  • Page 388: 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 men- tioned in FOREWORD of this manual. CONTENTS GENERAL DESCRIPTION ....6C-1 ON-VEHICLE SERVICE .
  • Page 389: Fuel Lines

    6C-2 ENGINE FUEL ON-VEHICLE SERVICE 1. Fuel tank 2. Fuel pump and level gauge 3. Fuel filler cap 4. 2-way check valve 5. Breather hose 6. Fuel feed line 7. Fuel return line 8. Fuel vapor line 9. Fuel cut valve 10.
  • Page 390 ENGINE FUEL 6C-3 7) As fuel tank has no drain plug, drain fuel tank by pumping fuel out through fuel tank filler or fuel tank inlet. Use hand operated pump to drain fuel tank. WARNING: Never drain or store fuel in an open container to avoid possibility of fire or explosion.
  • Page 391: Fuel Pump Assembly

    6C-4 ENGINE FUEL FUEL PUMP ASSEMBLY REMOVAL 1) Remove fuel tank (1) from vehicle referring to “FUEL TANK” in this section. 2) Disconnect fuel feed hose (2), fuel return hose (3) and breather hose (4) from fuel pump assembly (5). 3) Remove fuel pump assembly from fuel tank by removing screws.
  • Page 392: Table Of Contents

    D Service on or around Air Bag System Components or Wiring must be performed only by an authorized Suzuki dealer. Please observe all WARNINGS and SERVICE PRECAUTIONS in Section 9J under “On- Vehicle Service” and the Air Bag System Component and Wiring Location view in Section 9J before performing service on or around Air Bag System Components or Wiring.
  • Page 393 6E1-2 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) GENERAL DESCRIPTION The engine and emission control system is divided into 3 major sub-systems: air/fuel delivery system, electronic control system and emission control system. Air/fuel delivery system includes fuel pump, throttle body, etc. Electronic control system includes ECM, various sensors and controlled devices.
  • Page 394 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-3 1. Tank pressure control valve 17. Warm up three way catalytic 32. VSS (on A/T) 2. Fuel liquid separator convertor (WU-TWC) 33. Transmission range sensor 3. Fuel tank (if equipped) (switch) (A/T) 4.
  • Page 395 6E1-4 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) AIR AND FUEL DELIVERY SYSTEM The main components of this system are fuel tank, opens according to the injection signal from ECM. fuel pump, fuel filter, throttle body (including fuel injec- The fuel relieved by the fuel pressure regulator re- tor, fuel pressure regulator and idle speed control ac- turns through the fuel return line to the fuel tank.
  • Page 396 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-5 ELECTRONIC CONTROL SYSTEM D Fuel pump control system The electronic control system consists of 1) various D A/C control system (if equipped) sensors which detect the state of engine and driving D Radiator fan control system conditions, 2) ECM which controls various devices D Evaporative emission control system...
  • Page 397 6E1-6 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) IG COIL METER...
  • Page 398 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-7 CON- TERMI- CON- TERMI- CIRCUIT CIRCUIT NECTOR NECTOR ECM ground Data link connector Power source (from main relay) Vehicle speed sensor (+) (A / T) Vehicle speed sensor (M / T) Blank Transmission range sensor (switch) “2”...
  • Page 399: Accelerator Cable Adjustment

    6E1-8 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) ON-VEHICLE SERVICE GENERAL When the hoses have been disconnected and system’s component removed for service, be sure to reinstall component properly, and route and connect hoses correctly after service. Refer to Emission Control Information Label for proper connection of hoses (if equipped).
  • Page 400: Fuel Pressure

    ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-9 NOTE: Before starting engine, place transmission gear shift lever in “Neutral” (shift selector lever to “P” range for A/T model), and set parking brake and block drive wheels. 1) Warm up engine to normal operating temperature. 2) Set tachometer.
  • Page 401 6E1-10 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6) Start engine and warm it up to normal operating temperature. If engine doesn’t start, turn ignition switch ON to operate fuel pump and after 2 seconds turn it OFF. Repeat this 3 or 4 times and then check fuel pressure.
  • Page 402: Fuel Pump

    ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-11 FUEL PUMP ON-VEHICLE INSPECTION WARNING: When fuel filler cap is removed in any procedure, work must be done with no smoking, in a well-ventilated area and away from any open flames. 1) Remove filler cap and turn ON ignition switch.
  • Page 403: Throttle Body

    6E1-12 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) THROTTLE BODY Negative Positive terminal terminal Throttle Viewed from “A” stop screw 1. Fuel injector wire 2. Fuel injector 3. Upper O-ring 4. Lower O-ring 5. Throttle upper body 6. Gasket 7.
  • Page 404 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-13 DISASSEMBLY NOTE: D Be sure not to remove either fuel pressure regulator or idle speed control actuator from throttle body. They are factory adjusted precisely. D Be sure to replace gaskets and O-rings as well as worn or damaged parts.
  • Page 405 6E1-14 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) ASSEMBLY 1) Install injector wire and coupler to throttle body. Use new O-ring. Tighten injector wire coupler screw to specified torque. Tightening Torque (a): 2.0 N m (0.20 kg-m, 1.5 lb-ft) 2) Install new gasket to lower body.
  • Page 406 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-15 2) Install throttle body to EFE heater and tighten bolts to specified torque. Tightening Torque (a): 23 N m (2.3 kg-m, 17.0 lb-ft) 3) Install accelerator cable to throttle valve lever and cable brack- 4) Connect fuel, cooling water and vacuum hoses to throttle body, and clamp securely.
  • Page 407 6E1-16 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) REMOVAL NOTE: Use care when handling fuel injector especially not to damage filter and its needle. Also, because injector is an electrical component, it should not be immersed in any type of liquid solvent or cleaner, or it may get damaged.
  • Page 408 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-17 3) Make sure that injector wire O-ring is free from any damage and deterioration, and apply thin coat of spindle oil or gasoline to O- ring. Install injector wire and tighten new wire screw to specified torque.
  • Page 409 6E1-18 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP SENSOR) MAP SENSOR INDIVIDUAL CHECK 1) Disconnect MAP sensor vacuum hose from filter. 2) Disconnect coupler from MAP sensor. 3) Remove MAP sensor. 4) Arrange 3 new 1.5 V batteries in series (check that total voltage is 4.5 –...
  • Page 410 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-19 THROTTLE POSITION SENSOR (TP SENSOR) INSPECTION Check TP sensor referring to step 2 of DTC P0121 Flow Table. If malfunction is found, replace. REMOVAL 1) Disconnect battery negative cable at battery. 2) Remove air cleaner assembly referring to Section 6A.
  • Page 411 1. Plunger 2. Throttle lever screw 3) Loosen TP sensor screws. a) Connect SUZUKI scan tool to DLC with ignition switch OFF. b) Select “Data List” mode on SUZUKI scan tool. c) Observe TP sensor voltage. 4) Turn TP sensor clockwise or counterclockwise and tighten TP sensor screw at a position where voltage as specified below is obtained.
  • Page 412: Engine Coolant Temperature Sensor

    ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-21 INSPECTION Immerse temperature sensing part of IAT sensor in water (or ice) and measure resistance between sensor terminals while heating water gradually. If measured resistance doesn’t show such characteristic as shown in left figure, replace IAT sensor.
  • Page 413 6E1-22 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) INSPECTION Immerse temperature sensing part of ECT sensor in water (or ice) and measure resistance between sensor terminals while heating water gradually. If measured resistance doesn’t show such characteristic as shown in left figure, replace ECT sensor.
  • Page 414 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-23 HEATED OXYGEN SENSOR (SENSOR-1 AND SENSOR-2) OXYGEN SENSOR HEATER INSPECTION 1) Disconnect sensor coupler. 2) Using ohmmeter, measure resistance between terminals “V ” and “GND” of sensor coupler. NOTE: Temperature of sensor affects resistance value largely. Make sure that sensor heater is at correct temperature.
  • Page 415 6E1-24 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) VEHICLE SPEED SENSOR (VSS) For M/T INSPECTION 1) Disconnect negative cable at battery. 2) Remove combination meter from instrument panel. 3) Connect ohmmeter between “VSS” terminal (2) and “GND” ter- minal (3) of combination meter and turn cable joint (1) of speedometer with a screwdriver.
  • Page 416 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-25 CRANKSHAFT POSITION SENSOR INSPECTION Check crankshaft position sensor referring to step 1 and 2 of DTC P0335 Flow Chart. If malfunction is found, replace. REMOVAL 1) Hoist vehicle. 2) Remove fender apron extension on right side. 3) Disconnect connector from crankshaft position sensor.
  • Page 417 6E1-26 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) FUEL PUMP RELAY INSPECTION 1) Disconnect negative cable at battery. 2) Remove fuel pump relay (1) from relay box (2). 3) Structure of fuel pump relay is the same as that of main relay. Check its resistance and operation using the same procedure as that for main relay.
  • Page 418 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-27 1) Connect scan tool to DLC with ignition switch OFF, if it is avail- able. 2) Warm up engine to normal operating temperature. 3) Select “Data List” mode on scan tool to check “IAC duty”. 4) Apply load to engine as described below and check that idle speed is kept at specified level and “IAC duty”...
  • Page 419 6E1-28 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 3) Arrange 4 new 1.5 V batteries in series (6.0 V in total). With throttle lever in contact with plunger of ISC actuator, con- nect these batteries to ISC actuator terminals and check ISC ac- tuator for operation.
  • Page 420: Isc Actuator Relay

    ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-29 ISC ACTUATOR RELAY INSPECTION 1) Disconnect negative cable at battery. 2) Remove ISC actuator relay from relay box. 3) Structure of ISC actuator relay is the same as that of main relay. Check its resistance and operation using the same procedure as that for main relay.
  • Page 421: Efe Heater Relay

    “ON” position. 1. Radiator fan motor Connect SUZUKI scan tool (2) to DLC (3). Start engine and keep it running to warm it up. Now check to ensure that radiator fan is started when the coolant temperature displayed on SUZUKI scan tool reaches 96_C (205_F).
  • Page 422: Radiator Fan

    ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-31 RADIATOR FAN CONTROL RELAY (RFC RELAY) INSPECTION 1) Disconnect negative cable at battery. 2) Remove RFC relay from relay box. 3) Structure of RFC relay is the same as that of main relay. Check its resistance and operation using the same procedure as that for main relay.
  • Page 423 6E1-32 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) EMISSION CONTROL SYSTEM EVAPORATIVE EMISSION CONTROL SYSTEM EVAP CANISTER PURGE 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 424 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-33 EVAP CANISTER PURGE VALVE INSPECTION WARNING: Do not suck the air through valve. Fuel vapor inside valve is harmful. 1) With the ignition switch OFF position, disconnect coupler from EVAP canister purge valve. 2) Check resistance between two terminals of EVAP canister purge valve.
  • Page 425 6E1-34 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) EVAP CANISTER INSPECTION WARNING: DO NOT SUCK nozzles on EVAP canister. Fuel vapor inside EVAP canister is harmful. 1) Disconnect vacuum hoses from EVAP canister and remove EVAP canister. 2) When air is blown into tank pipe, there should be no restriction of flow through purge pipe and air pipe.
  • Page 426 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-35 PCV VALVE INSPECTION 1) Disconnect PCV hose from PCV valve. 2) Run engine at idle. 3) Place your finger over end of PCV valve to check for vacuum. If there is no vacuum, check for clogged valve. Replace as nec- essary.
  • Page 427 5. Test lead / probe 6. Power source cable 7. DLC cable adaptor 8. Self-test adaptor 09913-76011 09931-76030 SUZUKI scan tool (Tech 1A) kit Mass storage cartridge 16 / 14 pin DLC cable 1. Fuel pressure gauge 09912-58441 2. Pressure hose 09912-58431 3.
  • Page 428 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G13) 6E1-1 SECTION 6E1 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G13) NOTE: For the details of this section, refer to the same section of the Service Manual mentioned in the FORE- WORD of this manual.
  • Page 429: Table Of Contents

    D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 430 6E2-2 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) GENERAL DESCRIPTION The engine and emission control system is divided Fuel delivery system includes fuel pump, delivery into 4 major sub-systems: air intake system, fuel de- pipe, fuel pressure regulator, etc. Electronic control livery system, electronic control system and emission system includes ECM (PCM), various sensors and control system.
  • Page 431 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-3...
  • Page 432 6E2-4 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
  • Page 433 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-5...
  • Page 434: Air Intake System

    6E2-6 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) AIR INTAKE SYSTEM The main components of the air intake system are air is distributed by the intake manifold (5) and finally cleaner (1), air cleaner outlet hose (2), throttle body drawn into each combustion chamber.
  • Page 435 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-7 FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank (11), take manifold (4) by the fuel pressure regulator (3), fuel pump (12), fuel filter (10), fuel pressure regulator the fuel is injected into the intake port of the cylinder (3), delivery pipe (2) and fuel injectors (1).
  • Page 436 6E2-8 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) ELECTRONIC CONTROL SYSTEM D Fuel pump control system The electronic control system consists of 1) various D A/C control system (if equipped) sensors which detect the state of engine and driving D Radiator fan control system conditions, 2) ECM (PCM) which controls various de- D EGR system...
  • Page 437 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-9 ENGINE & EMISSION CONTROL INPUT/OUTPUT TABLE ELECTRIC CONTROL DEVICE OUTPUT INPUT FUEL LEVEL SENSOR For detecting fuel level BAROMETRIC PRESSURE SENSOR START SWITCH f f f f f f f f f IGNITION SWITCH LIGHTING SWITCH REAR DEFOGGER SWITCH (IF EQUIPPED)
  • Page 438 6E2-10 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
  • Page 439 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-11...
  • Page 440 6E2-12 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) WIRE WIRE CON- CON- CIRCUIT CIRCUIT TERMINAL TERMINAL NECTOR COLOR NECTOR COLOR Ground for ECM / PCM W / R “N”-range signal (A / T) B / Or Ground for drive circuit Heated oxygen sensor-2 B / Or Ground for drive circuit...
  • Page 441 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-13 ON-VEHICLE SERVICE ACCELERATOR CABLE ADJUSTMENT 1) With throttle valve closed, check accelerator pedal play which should be within following specification. Pedal play “a”: 2 – 7 mm (0.08 – 0.27 in.) If measured value is out of specification, adjust it to specification with cable adjusting nut (2).
  • Page 442 “Neutral” (shift selector lever to “P” range for A/T vehicle), and set parking brake and block drive wheels. 1) Connect SUZUKI scan tool (1) to DLC with ignition switch OFF, if it is available. 2) Warm up engine to normal operating temperature.
  • Page 443 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-15 AIR INTAKE SYSTEM THROTTLE BODY CAUTION: Do not remove or adjust throttle stop screw as it is factory adjusted precisely CAUTION: Do not disassemble IAC valve. Disassembly spoils its original performance 1.
  • Page 444 6E2-16 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 5) Disconnect electric coupler from TP sensor (2) and IAC valve (3). 6) Remove throttle body from intake manifold. 7) Disconnect engine coolant hoses (1) from throttle body. Disassembly NOTE: While disassembling and assembling throttle body, use spe- cial care not to deform levers on throttle valve shaft or cause damage to any other parts.
  • Page 445 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-17 2) Connect engine coolant hoses (1). 3) Install throttle body (4) to intake manifold. 4) Connect coupler to TP sensor (2) and IAC valve (3) securely. 5) Install air cleaner outlet hose (1) and pipe. 6) Connect accelerator cable and adjust cable play to specifica- tion.
  • Page 446: Fuel Pressure Inspection

    6E2-18 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) Installation 1) Install new O-ring (2) to IAC valve (1). 2) Install IAC valve (1) to throttle body (3). Tighten IAC valve screws to specified torque. Tightening Torque (a): 3.3 N m (0.33 kg-m, 2.5 lb-ft) 3) Install throttle body to intake manifold referring to “Throttle Body Installation”...
  • Page 447 5) Check fuel pressure as follows. CONDITION FUEL PRESSURE With fuel pump 270 – 310 kPa [Not using SUZUKI scan tool] operating and 2.7 – 3.1 kg / cm a) Turn ignition switch ON to operate fuel pump and after 2 seconds engine stopped 38.4 –...
  • Page 448 6E2-20 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) [Using SUZUKI scan tool] a) Connect SUZUKI scan tool to DLC with ignition switch OFF. b) Turn ignition switch ON and then select “DATA LIST” mode on scan tool. c) Make sure that vehicle condition is as following.
  • Page 449 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-21 FUEL PUMP On-Vehicle Inspection CAUTION: When fuel filler cap is removed in any procedure, work must be done in a well-ventilated area, keep away from any open flames and without smoking. NOTE: The fuel pressure regulator is the one body with the fuel pump assembly so individual inspection of it is impossible.
  • Page 450: Fuel Pressure Regulator

    6E2-22 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) FUEL PRESSURE REGULATOR Removal 1) Relieve fuel pressure according to procedure described in sec- tion 6. 2) Disconnect battery negative cable at battery. 3) Disconnect vacuum hose (3) from fuel pressure regulator (1). 4) Disconnect fuel return hose (2) from fuel pressure regulator (1).
  • Page 451 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-23 FUEL INJECTOR On-Vehicle Inspection 1) Using sound scope (1) or such, check operating sound of injec- tor (2) when engine is running or cranking. Cycle of operating sound should vary according to engine speed.
  • Page 452 6E2-24 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) Inspection WARNING: As fuel is injected in this inspection, perform in a well venti- lated area and away from open flames. Use special care to prevent sparking when connecting and disconnecting test lead to and from battery. 1) Install injector (1) and fuel pressure regulator (2) to special tool (injector checking tool).
  • Page 453 6) Operate fuel pump and apply fuel pressure to injector as follows: When using SUZUKI scan tool : a) Connect SUZUKI scan tool to DLC with ignition switch OFF. b) Turn ignition switch ON, clear DTC and select “MISC TEST”...
  • Page 454 6E2-26 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) Installation For installation, reverse removal procedure and note following pre- cautions. D Replace injector O-ring (1) with new one using care not to dam- age it. D Check if cushion (2) is scored or damaged. If it is, replace with new one.
  • Page 455 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-27 ELECTRONIC CONTROL SYSTEM ENGINE CONTROL MODULE (POWERTRAIN CONTROL MODULE) [ECM (PCM)] CAUTION: As ECM (PCM) consists of precision parts, be careful not to expose it to excessive shock. Removal 1) Disconnect battery negative cable at battery. 2) Disable air bag system, refer to “DISABLING THE AIR BAG SYSTEM”...
  • Page 456 6E2-28 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) THROTTLE POSITION SENSOR (TP SENSOR) Inspection 1) Disconnect negative cable at battery and coupler from TP sen- sor. 2) Using ohmmeter, check resistance between terminals under each condition given in table below. TERMINALS RESISTANCE Between 1 and...
  • Page 457 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-29 INTAKE AIR TEMPERATURE SENSOR (IAT SENSOR) Removal 1) Disconnect battery negative cable at battery. 2) Disconnect coupler from IAT sensor (1). 3) Remove IAT sensor (1) from air cleaner outlet hose (2). Inspection Immerse temperature sensing part of IAT sensor in water (or ice) and measure resistance between sensor terminals while heating...
  • Page 458 6E2-30 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) ENGINE COOLANT TEMPERATURE SENSOR (ECT SENSOR) Removal 1) Disconnect battery negative cable at battery. 2) Drain coolant referring to Section 6B. WARNING: To help avoid danger of being burned, do not remove ra- diator cap while engine and radiator are still hot.
  • Page 459 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-31 HEATED OXYGEN SENSOR (Sensor-1 and Sensor-2) Oxygen Sensor Heater Inspection 1) Disconnect sensor coupler. 2) Using ohmmeter, measure resistance between terminals “V ” and “GND” of sensor coupler. NOTE : Temperature of sensor affects resistance value largely. Make sure that sensor heater is at correct temperature.
  • Page 460 6E2-32 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) CAMSHAFT POSITION SENSOR Inspection Check camshaft position sensor referring to DTC P0340 Diag. Flow Table in Section 6. If malfunction is found, replace. Removal 1) Disconnect negative cable at battery. 2) Disconnect connector from camshaft position sensor. 3) Remove camshaft position sensor from sensor case (distributorless ignition case).
  • Page 461 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-33 VEHICLE SPEED SENSOR (VSS) Inspection Check vehicle speed sensor referring to step 3 of DTC P0500 Flow Table. If malfunction is found, replace. Removal/Installation Refer to Section 7A. FUEL LEVEL SENSOR (GAUGE) Inspection Refer to Section 8.
  • Page 462 6E2-34 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 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), A/C is OFF and that parking brake lever is pulled all the way up.
  • Page 463: Egr System

    EMISSION CONTROL SYSTEM EGR SYSTEM System Inspection (using SUZUKI scan tool) 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. 2) Turn ignition switch ON and then select “DATA LIST” mode on scan tool. 3) Make sure that vehicle condition is as following.
  • Page 464 6E2-36 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) Inspection 1) Check resistance between following terminals of EGR valve in each pair. Terminal Standard resistance A – B C – B 20 – 24 Ω F – E D – E 1.
  • Page 465 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-37 1) Disconnect purge hose (1) from EVAP canister. 2) Place finger against the end of disconnected hose and check that vacuum is not felt there when engine is cool and running at idle speed.
  • Page 466 6E2-38 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) EVAP Canister Inspection WARNING: DO NOT SUCK nozzles on EVAP canister. Fuel vapor inside EVAP canister is harmful. 1) Check outside of EVAP canister visually. 2) Disconnect vacuum hoses from EVAP canister. 3) Check that there should be no restriction of flow through purge pipe (2) and air pipe (3) when air is blown (4) into tank pipe (1).
  • Page 467 5. Test lead / probe 6. Power source cable 7. DLC cable adaptor 8. Self-test adaptor 09930-88530 09931-76011 Injector test lead SUZUKI scan tool (Tech 1A) kit Mass storage cartridge 09931-76030 16 / 14 pin DLC cable TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening parts...
  • Page 468 D Service on or around Air Bag System Components or Wiring must be performed only by an authorized Suzuki dealer. Please observe all WARNINGS and SERVICE PRECAUTIONS in Section 9J under “On- Vehicle Service” and the Air Bag System Component and Wiring Location view in Section 9J before performing service on or around Air Bag System Components or Wiring.
  • Page 469 6F-2 IGNITION SYSTEM 1. Battery 2. Main fuse 3. Ignition switch 4. Main relay 5. Ignition coil 6. Igniter 7. Noise suppressor 8. Distributor 9. Rotor 10. Signal rotor 11. Pick up coil 12. Spark plug To combination meter...
  • Page 470 IGNITION SYSTEM 6F-3 DIAGNOSIS Condition Possible Cause Correction D Blown fuse for ignition coil Engine cranks, but will Replace D Loose connection or disconnection of lead wire or not start or hard to start Connect securely high-tension cord(s) D Faulty high-tension cord(s) Replace D Faulty spark plug(s) Adjust, clean or replace...
  • Page 471 6F-4 IGNITION SYSTEM STEP ACTION Ignition Coil Power Supply and Ground Circuit Go to Step 7. Repair or replace. Check 1) Check ignition coil power supply (“B/W” wire) circuit for open and short. Are circuits in good condition? Ignition Coil Check Go to Step 8.
  • Page 472 IGNITION SYSTEM 6F-5 ON-VEHICLE SERVICE IGNITION SPARK TEST 1) Disconnect injector coupler at throttle body side. WARNING: Without disconnection of injector coupler, combustible gas may come out from spark plug holes during this test and may get ignited in engine room. 2) Remove spark plugs and connect them to high-tension cords, and then ground spark plugs.
  • Page 473: Spark Plugs

    6F-6 IGNITION SYSTEM 6) If resistance exceeds specification, inspect distributor terminal and replace high-tension cord(s) and/or distributor cap as re- quired. CAUTION: D Never attempt to use metal conductor high-tension cords as replacing parts. D Insert each cap portion fully when installing high-tension cords.
  • Page 474 IGNITION SYSTEM 6F-7 IGNITION COIL PRIMARY 1) Pull out high-tension cord by gripping its cap. 2) Disconnect ignition coil coupler. 3) Measure primary and secondary coil resistances. Ignition coil resistance (at 20_C, 68_F) : 0.87 – 1.05 Ω Primary Secondary : 11.2 – 15.2 kΩ 4) If resistance is out of specification, replace coil with new one.
  • Page 475 6F-8 IGNITION SYSTEM DISTRIBUTOR DISTRIBUTOR CAP AND ROTOR INSPECTION Check cap and rotor for crack and their terminals for corrosion and wear. Replace as necessary. SIGNAL ROTOR AIR GAP INSPECTION 1) Remove distributor cap and rotor. 2) Using thickness gauge, measure air gap, between signal rotor tooth and CMP sensor (generator).
  • Page 476: Ignition Timing

    “Neutral” (shift selector lever to “P” range for A/T model), and set parking brake. INSPECTION AND ADJUSTMENT 1) Connect SUZUKI scan tool (1) to DLC (2) with ignition switch OFF. 2) Start engine and warm it up to normal operating temperature.
  • Page 477 6F-10 IGNITION SYSTEM DISTRIBUTOR UNIT 1. Cap 2. Cap seal 3. Cap screw 4. Rotor 5. CMP sensor (Signal generator) 6. Screw 7. Cover 8. Housing 9. O-ring DISMOUNTING 1) Disconnect distributor lead coupler. 2) Remove distributor cap screws and cap. 3) Remove distributor flange bolts.
  • Page 478 5. Test lead/probe 6. Power source cable 7. DLC cable adaptor 8. Self-test adaptor 09913-76011 09931-76030 SUZUKI scan tool (Tech 1A) kit Mass storage cartridge 16 / 14 pin DLC cable 09900-27301 09930-76420 Timing light (DC 12 V) Timing light (Dry cell type)
  • Page 479 IGNITION SYSTEM (TBI FOR G13) 6F-1 SECTION 6F IGNITION SYSTEM (TBI FOR G13) NOTE: For the details of this section, refer to the same section of the Service manual mentioned in the FORE- WORD of this manual.
  • Page 480 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 481 6F1-2 IGNITION SYSTEM (SFI FOR G13) GENERAL DESCRIPTION The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below and has an electronic ignition control system. D ECM (PCM) It detects the engine and vehicle conditions 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 ignitor (power unit) in the ignition coil assembly.
  • Page 482 IGNITION SYSTEM (SFI FOR G13) 6F1-3 SYSTEM WIRING DIAGRAM 1. Ignition switch 5. CMP sensor 11. Sensed information D MAP sensor D Park / Neutral position signal 2. Main relay 6. CKP sensor D ECT sensor 3. Ignition coil assembly 7.
  • Page 483 6F1-4 IGNITION SYSTEM (SFI FOR G13) IGNITION SYSTEM DIAGNOSTIC FLOW TABLE STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE” in section 6. Ignition Spark Test Go to Step 11. Go to Step 3. 1) Check all spark plugs for condition and type referring to “Spark Plugs”...
  • Page 484 IGNITION SYSTEM (SFI FOR G13) 6F1-5 ON-VEHICLE SERVICE IGNITION SPARK TEST 1) Disconnect all injector couplers (1) from injectors (2). WARNING: Without disconnection of injector couplers, combustible gas may come out from spark plug holes during this test and may get ignited in engine room. 2) Remove spark plug and check it for condition and type referring to “Spark Plugs”...
  • Page 485 6F1-6 IGNITION SYSTEM (SFI FOR G13) 5) Install high-tension cords (1) to spark plugs and ignition coil as- semblies (2) while gripping each cap. CAUTION: D Never attempt to use metal conductor high-tension cords as replacing parts. D Insert each cap portion fully when installing high-ten- sion cords.
  • Page 486: Crankshaft Position Sensor

    D Before starting engine, place transmission gear shift lever in “Neutral” (shift selector lever to “P” range for A/T model), and set parking brake. INSPECTION 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. Special Tool (A): 09931-76011 (SUZUKI scan tool) (B): Mass storage cartridge (C): 09931-76030 (16/14 pin DLC cable) 2) Start engine and warm it up to normal operating temperature.
  • Page 487 6F1-8 IGNITION SYSTEM (SFI FOR G13) 5) Fix ignition timing to initial one as follow. Select “MISC” mode on SUZUKI scan tool and fix ignition tim- ing to initial one. 6) Detach air cleaner case and shift air cleaner case and hose position to observe ignition timing.
  • Page 488 4. DLC cable (14 / 26 pin, 09931-76040) 5. Test lead / probe 6. Power source cable 7. DLC cable adaptor 8. Self-test adaptor 09931-76011 09931-76030 SUZUKI scan tool (Tech 1A) kit Mass storage cartridge 16 / 14 pin DLC cable...
  • Page 489: Exhaust System

    EXHAUST SYSTEM 6K-1 SECTION 6K EXHAUST SYSTEM NOTE: For the descriptions (items) not found in this section, refer to the same section of Service Manual men- tioned in FOREWORD of this manual. CONTENTS ON-VEHICLE SERVICE ..............6K-1 ON-VEHICLE SERVICE [For 1.0...
  • Page 490 6K-2 EXHAUST SYSTEM [For 1.0 2WD N / B model] [For 1.3 2WD H / B model] 1. Exhaust manifold 6. Exhaust No.2 pipe 7. Gasket 2. Seal 3. WU-TWC 8. Muffler 4. Exhaust pipe 9. Muffler mounting : Do not reuse 5.
  • Page 491 EXHAUST SYSTEM 6K-3 [For 1.3 2WD N / B model] 45 N m (4.5 kg-m) [For 1.3 4WD model] 1. Exhaust manifold 7. Muffler 2. Seal 8. Muffler mounting 3. Exhaust No.1 pipe 9. Heated oxygen sensor 4. Exhaust No.2 pipe : Do not reuse 5.
  • Page 492 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 493 7B-2 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) Table B-1 Gear Shift Failure in “D” or Output shaft speed sensor check ..7B-39 “2” Range ......7B-38 Shift solenoid valve circuit check .
  • Page 494 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-3 GENERAL DESCRIPTION The automatic transmission consists of the hydraulic torque converter, electronically controlled 3-speed automatic transmission, countershaft and differential. The transmission consists of 2 planetary gears, 2 disk clutches, 1 band brake, 1 disk brake and 1 one-way clutch. Its operation is controlled by selecting a position from 6 positions (P, R, N, D, 2 and L ranges) manually by means of the selector lever installed on the compartment floor.
  • Page 495 7B-4 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) COMPONENTS OPERATION CHART Forward Direct Second 1st & Reverse One-way Parking Lock Range Gear Clutch Clutch Brake Brake Clutch Pawl Parking – – – **f** – Reverse – – – –...
  • Page 496 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-5 ELECTRONIC SHIFT CONTROL SYSTEM [G10 Engine Model] 1. PCM 7. Malfunction indicator lamp (MIL) 11. Ignition switch 2. Camshaft position (CMP) sensor 8. Data link connector (DLC) 12. Main relay 3.
  • Page 497 7B-6 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) [G13 Engine Model] 1. PCM 7. Malfunction indicator lamp (MIL) 11. Ignition switch 2. Camshaft position (CMP) sensor 8. Data link connector (DLC) 12. Main relay 3. Throttle position (TP) sensor 9.
  • Page 498 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-7 POWERTRAIN CONTROL MODULE (PCM) The powertrain control module controls the shift solenoid B (2nd brake solenoid valve) and the shift solenoid A (direct clutch sole- noid valve) by sending electric signals to them so as to attain auto- matic gear shift between the 1st and 2nd gears, and the 2nd and 3rd gears.
  • Page 499 7B-8 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) TRANSMISSION RANGE SENSOR (SHIFT SWITCH) Being linked with the selector lever, this sensor changes selector lever positions into electric signals and send them to the engine control module. The contact points of this sensor for P and N ranges are also connected with the starting motor circuit.
  • Page 500 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-9 OUTPUT SHAFT SPEED SENSOR (A/T VSS) The output shaft speed sensor consists of a magnetic core with magnet and coil. It is mounted on transmission case with 0.6 mm (0.024 in.) air gap between the core end and countershaft gear tooth.
  • Page 501 7B-10 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) [G13 Engine Model] Upshift Downshift VEHICLE SPEED Selector D or 2 D or 2 Gear 1→2 2→3 3→2 2→1 2→1 Throttle Speed km/h Full close mile/h km/h Full open mile/h...
  • Page 502 MIL turn OFF although DTC stored in its memory will remain. D It is possible to communicate with PCM through data link connect- er (DLC) by using SUZUKI scan tool (Tech-1). (Diagnostic information can be checked and erased by using a scan tool) 2 Driving Cycle Detection Logic Refer to Section 6 or 6-1 for details.
  • Page 503 Such disconnection will clear memorized information in PCM. D Using SUZUKI scan tool (Tech-1) the diagnostic information stored in PCM memory can be checked and cleared as well. Before its use, be sure to read Operator’s (instruction) Manual supplied with it carefully to have good understanding of its functions and usage.
  • Page 504 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-13 AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION Customer Complaint Analysis Go to Step 2. Perform 1) Perform customer complaint analysis referring to the next customer page.
  • Page 505 7B-14 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 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 (shown in next page) will facilitate collecting information to the point required for proper analysis and diagnosis.
  • Page 506 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-15 CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE) User name: Model: VIN: Date of issue: Date Reg. Date of problem: Mileage: PROBLEM SYMPTOMS j Vehicle does not move (R, D, 2, L range) j No upshift automatically (j 1st to 2nd j 2nd to 3rd j 2 range j D range) j No downshift automatically (j 3rd to 2nd j 2nd to 1st j 2 range j D range) j No gear change manually (j 1st $ 2nd j 2nd $ 3rd)
  • Page 507: Diagnostic Trouble Code Check

    3) Turn ignition switch ON. 4) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool opera- tor’s manual for further details. 5) After completing the check, turn ignition switch OFF and discon- nect SUZUKI scan tool from data link connector (DLC).
  • Page 508 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-17 DIAGNOSTIC TROUBLE CODE (DTC) TABLE DETECTING CONDITION DTC NO. DETECTING ITEM (DTC will set when detecting:) Transmission range sensor No signal or multiple signals inputted with shifted in 1 driving P0705 P0705 circuit malfunction...
  • Page 509 7B-18 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) VISUAL INSPECTION Visually check following parts and systems. INSPECTION ITEM REFERRING SECTION D A/T fluid– – – – – level, leakage, color Section 0B D A/T fluid hoses – – – – – disconnection, looseness, deterioration Section 7B D Throttle cable –...
  • Page 510 When using SUZUKI scan tool: Flow Table. 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. 2) Turn ignition switch ON and check transmission range signal (P, R, N, D, 2 or L) on display when shifting manual selector to each range.
  • Page 511 7B-20 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) SYMPTOM-TO-INSPECTION TABLE APPLICABLE DIAGNOSTIC FLOW TABLE. OR SYMPTOM CHECK (DESCRIBED IN THIS SECTION) No starting or slipping in any drive range A/T DIAGNOSTIC FLOW TABLE A-1 Gear change failure A/T DIAGNOSTIC FLOW TABLE A-2 Excessive shock at range selection or gear change A/T DIAGNOSTIC FLOW TABLE A-3 Engine brake fails to operate...
  • Page 512 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-21 DTC P0705 TRANSMISSION RANGE SENSOR (SWITCH) CIRCUIT MALFUNCTION *1: For G10 engine model *2: For G13 engine model 1. PCM 2. Transmission range sensor Gr / Bl (*1), R / B (*2) 3.
  • Page 513 Intermittent Go to Step 3. When using SUZUKI scan tool: trouble. Check 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. for intermittent 2) Turn ignition switch ON and check transmission range referring to signal (P, R, N, D, 2 or L) on display when shifting manual “INTERMITTENT...
  • Page 514 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-23 Fig. 4 for Step 4. Fig. 5 for Step 4. Terminal Range...
  • Page 515 7B-24 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) DTC P0720 OUTPUT SPEED SENSOR (A/T VSS) CIRCUIT MALFUNCTION Counter shaft gear *1: For G10 engine model *2: For G13 engine model 1. PCM 2. Output shaft speed sensor 3. Terminal arrangement of PCM coupler (Viewed from harness side) CIRCUIT DESCRIPTION –...
  • Page 516 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-25 TROUBLESHOOTING STEP ACTION Was “AUTOMATIC TRANSMISSION DIAGNOSTIC Go to Step 2. Go to FLOW TABLE” performed? ”AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE”. Check Output Shaft Speed Sensor for Resistance. Go to Step 3. Replace output 1) Disconnect output shaft speed sensor connector with shaft speed...
  • Page 517 7B-26 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) DTC P0753 SHIFT SOLENOID-A (NO.1) ELECTRICAL DTC P0758 SHIFT SOLENOID-B (NO.2) ELECTRICAL *1: For G10 engine model *2: For G13 engine model 1. PCM 2. Shift solenoid-A (No.1, Direct clutch solenoid) 3.
  • Page 518 Intermittent Go to Step 3. When using SUZUKI scan tool: trouble. 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. Check for 2) Turn ignition switch ON. intermittent 3) Select “Data list” mode on scan tool. See Fig. 1.
  • Page 519 7B-28 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) DTC P0751 SHIFT SOLENOID-A (No.1) PERFORMANCE OR STUCK OFF DTC P0756 SHIFT SOLENOID-B (No.2) PERFORMANCE OR STUCK OFF CIRCUIT DESCRIPTION PCM monitors throttle opening, engine speed, vehicle speed and gear position and compares the actual engine speed and its specified value (i.e., engine speed obtained by PCM through calculation using the throttle open- ing/gear position and vehicle speed).
  • Page 520 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-29 TROUBLESHOOTING STEP ACTION Was “AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW Go to Step 2. Go to TABLE” performed? “AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE”. Is DTC other than shift malfunction (DTC P0751/P0756) Go to applicable Go to Step 3.
  • Page 521 7B-30 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) TABLE A-1 NO STARTING OR SLIPPING IN ANY DRIVE RANGE STEP ACTION Was “AUTOMATIC TRANSMISSION DIAGNOSTIC Go to Step 2. Go to FLOW TABLE” performed? “AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE”. Is engine rpm at stall test normal? Transmission Go to Step 3.
  • Page 522 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-31 TABLE A-2 GEAR CHANGE FAILURE STEP ACTION Was “AUTOMATIC TRANSMISSION DIAGNOSTIC Go to Step 2. Go to “AUTOMATIC FLOW TABLE” performed? TRANSMISSION DIAGNOSTIC FLOW TABLE”. Disconnect solenoid valve wire coupler and perform Go to Step 3.
  • Page 523 7B-32 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) STALL TEST This test is to check overall performance of automatic transmission and engine by measuring stall speed at D and R ranges. Be sure to perform this test only when transmission fluid is at normal operating temperature (70–80_C/158–176_F) and its level is be- tween FULL HOT and LOW HOT.
  • Page 524: Line Pressure Test

    AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-33 LINE PRESSURE TEST This test is to check oil pressure system for operation by measuring oil pressure in oil pressure line. Make sure to perform this test only when transmission fluid is at normal operating temperature. NOTE: D Make sure that transmission fluid level is between FULL HOT and LOW HOT marks on oil level gauge at normal operating...
  • Page 525 7B-34 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 9) Possible causes for out-of-specification line pressure are as follows. Check each part which is suspected to be the cause. Line pressure Possible causes D Regulator valve defective Higher than specification D Throttle valve in valve body in D and R ranges defective...
  • Page 526 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-35 ROAD TEST This test is to check if upshift and downshift take place at specified speeds while actually driving vehicle on a level road. WARNING: D Carry out the test in very little traffic area to prevent an ac- cident.
  • Page 527 7B-36 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) MANUAL ROAD TEST This test checks the gears being used in L, 2 or D range when driven with unoperated gear shift control system. Test drive vehicle on a level road. 1) With selector lever in P range, start engine and warm it up.
  • Page 528 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) 7B-37 “P” RANGE TEST 1) Stop vehicle on a slope, shift selector lever to P range and at the same time apply parking brake. 2) After stopping engine, release parking brake lever gradually and check that vehicle remains stationary.
  • Page 529 7B-38 AUTOMATIC TRANSMISSION (3 A / T) (VEHICLE WITH WU-TWC) TABLE B-1 GEAR SHIFT FAILURE IN “D” OR “2” RANGE STEP ACTION Was “TABLE A-2 GEAR CHANGE FAILURE” performed? Go to Step 2. Go to “TABLE A-2”. Is gear no shift at all? Go to Step