Suzuki Engine 2002 GRAND VITARA SQ625 Service Manual

Page 2: Foreword

Foreword this manual (volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (service) and for disassembly and assembly of major components (unit repair-overhaul). Volume 1 contains chassis, electrical and body sections (all ...

Page 4: Table Of Contents

Table of contents general information engine 0a 6 general information 0a engine general information and diagnosis (g16/j20) 6 0b 6-1 maintenance and lubrication 0b 6a1 heating and air conditioning engine general information and diagnosis (h25) 6-1 1a 6a2 heater and ventilation 1a 1b 6a4 air conditio...

Page 7

6-2 engine general information and diagnosis (g16/j20 engines) engine diagnosis.............................................. 6-8 general description ........................................ 6-8 on-board diagnostic system (vehicle without diagnosis connector) ......................... 6-8 on-board d...

Page 9: General Information

6-4 engine general information and diagnosis (g16/j20 engines) general information statement of cleanliness and care an automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of inch)...

Page 11

6-6 engine general information and diagnosis (g16/j20 engines) precaution on fuel system service • work must be done with no smoking, in a well-ventilated area and away from any open flames. • as fuel feed line (between fuel pump and fuel pressure regu- lator) is still under high fuel pressure even ...

Page 13: Engine Diagnosis

6-8 engine general information and diagnosis (g16/j20 engines) engine diagnosis general description this vehicle is equipped with an engine and emission control system which are under control of ecm (pcm). The engine and emission control system in this vehicle are controlled by ecm (pcm). Ecm (pcm) ...

Page 15

6-10 engine general information and diagnosis (g16/j20 engines) freeze frame date ecm (pcm) stores the engine and driving conditions (in the form of data as shown at the figure) at the moment of the detection of a malfunction in its memory. This data is called “freeze frame data”. Therefore, it is p...

Page 17

6-12 engine general information and diagnosis (g16/j20 engines) on-board diagnostic system (vehicle with diagnosis connector) ecm diagnosis troubles which may occur in the area including the following parts when the ignition switch is on and the engine is running, and indicates the result by turning...

Page 19

6-14 engine general information and diagnosis (g16/j20 engines) engine diagnostic flow table refer to the following pages for the details of each step. Step action yes no 1 customer complaint analysis 1) perform customer complaint analysis refer- ring to “customer complaint analysis” in the followin...

Page 21

6-16 engine general information and diagnosis (g16/j20 engines) 8. Engine basic check and engine diagnosis table perform basic engine check according to the “engine basic check” first. When the end of the flow table has been reached, check the parts of the system suspected as a possible cause referr...

Page 23

6-18 engine general information and diagnosis (g16/j20 engines) malfunction indicator lamp (mil) check 1) turn on ignition switch (but the engine at stop) and check that mil lights. If mil does not light up or dims, go to “diagnostic flow table a-1” for troubleshooting. If mil flushes, go to “diagno...

Page 25

6-20 engine general information and diagnosis (g16/j20 engines) diagnostic trouble code (dtc) clearance [using scan tool] 1) connect generic scan tool or suzuki scan tool to data link connector in the same manner as when making this connec- tion for dtc check. 2) turn ignition switch off and then on...

Page 27

6-22 engine general information and diagnosis (g16/j20 engines) diagnostic trouble code (dtc) table dtc no. Detecting item detecting condition (dtc will set when detecting :) mil (vehicle without monitor connector) mil (vehicle with moni- tor connec- tor) p0100 (no.34) mass air flow circuit mal- fun...

Page 29

6-24 engine general information and diagnosis (g16/j20 engines) p1451 barometric pressure sen- sor performance problem difference between manifold absolute pressure (map sensor value) and baro- metric pressure (barometric pressure sen- sor value) is larger than specification during cranking. 2 drivi...

Page 31

6-26 engine general information and diagnosis (g16/j20 engines) 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 condi-...

Page 33

6-28 engine general information and diagnosis (g16/j20 engines) brake sw ignition switch on brake pedal is depress- ing on brake pedal is releas- ing off blower fan ignition switch on blower fan switch on on blower fan switch off off a/c condenser fan ignition switch on a/c not operating off a/c ope...

Page 35

6-30 engine general information and diagnosis (g16/j20 engines) maf (mass air flow rate, g/s, lb/min.) it represents total mass of air entering intake manifold which is measured by mass air flow sensor. Calc load (calculated load value, %) engine load displayed as a percentage of maximum possible lo...

Page 37

6-32 engine general information and diagnosis (g16/j20 engines) gear position (1st, 2nd, 3rd or 4th) the gear position is determined on the basis of the command state signals generated from pcm (ecm) to shift solenoids a and b ( # 1 and # 2) and displayed as shown in the table below. Throt pos level...

Page 39

6-34 engine general information and diagnosis (g16/j20 engines) engine basic check this check is very important for troubleshooting when ecm (pcm) has detected no dtc and no abnormality has been found in visual inspection. Follow the flow table carefully. Step action yes no 1 was “engine diag. Flow ...

Page 41

6-36 engine general information and diagnosis (g16/j20 engines) engine has no power engine overheating. Refer to “overheating” in this table. Ignition system out of order. • defective spark plug. “spark plugs” in section 6f1 or 6f2. • faulty ignition coil with ignitor “ignition coil assembly” in sec...

Page 43

6-38 engine general information and diagnosis (g16/j20 engines) surges (engine power varia- tion under steady throttle or cruise. Feels like the vehicle speeds up and down with no change in the accelerator pedal.) ignition system out of order. • defective spark plug (excess carbon deposits, improper...

Page 45

6-40 engine general information and diagnosis (g16/j20 engines) excessive engine oil consumption oil entering combustion chamber • sticky piston ring “pistons, piston rings, connecting rods and cylinders” in section 6a1 or 6a4. • worn piston and cylinder “pistons, piston rings, connecting rods and c...

Page 47

6-42 engine general information and diagnosis (g16/j20 engines) inspection of pcm (ecm) and its circuits pcm (ecm) and its circuits can be checked at pcm (ecm) wiring couplers by measuring voltage, pulse signal and resistance. Voltage check 1) remove pcm (ecm) cover from bracket referring to “engine...

Page 49

6-44 engine general information and diagnosis (g16/j20 engines) e61 13 ppl/grn (canvas top model) serial communication line of data link connector 12 v (if equipped) 10 – 14 v ignition switch turned on ppl/red (other than canvas top model) 14 wht/red test switch terminal (if equipped) 10 – 14 v igni...

Page 51

6-46 engine general information and diagnosis (g16/j20 engines) e61 31 orn/blu selector switch signal of power mode/normal mode for a/t 0 – 1 v ignition switch turned on, a/t power mode/normal mode selector selected at power mode 10 – 14 v ignition switch turned on, a/t power mode/normal mode select...

Page 53

6-48 engine general information and diagnosis (g16/j20 engines) c51-3 24 yel/blu a/c condenser fan motor relay output (other than canvas top model, if equipped) 10 – 14 v ignition switch turned on, engine coolant temperature under 113°c, 235°f or a/c request signal high input 0 – 1v ignition switch ...

Page 55

6-50 engine general information and diagnosis (g16/j20 engines) c51-1 26 orn/wht 4wd low (4l) switch signal 0 – 1 v ignition switch turned on, transfer selector lever selected at “4l” posi- tion 10 – 14 v ignition switch turned on, transfer selector lever selected at “4h” or “2h” position 27 grn/blu...

Page 57

6-52 engine general information and diagnosis (g16/j20 engines) c51-2 15 lt grn/ wht egr valve (stepper motor coil 2) output (if equipped) 10 – 14 v ignition switch turned on *0 – 1 v ↑ ↓ 8 – 14 v (repeated indicator) while engine running (output signal is active low duty pulse. Pulse generated time...

Page 59

6-54 engine general information and diagnosis (g16/j20 engines) resistance check 1) disconnect couplers from ecm/pcm with ignition switch off. 2) check resistance between each pair of terminals of discon- nected couplers as listed in the following table. Caution: never touch terminals of ecm/pcm its...

Page 61

6-56 engine general information and diagnosis (g16/j20 engines) table a-1 malfunction indicator lamp circuit check – mil does not come “on” or dims at ignition switch on (but engine at stop) wiring diagram circuit description when the ignition switch is turned on, ecm causes the main relay to turn o...

Page 63

6-58 engine general information and diagnosis (g16/j20 engines) table a-3 mil check – mil flashes at ignition switch on (vehicle with monitor connector) wiring diagram/circuit description refer to table a-1. Inspection table a-4 mil check – mil does not flash or just remains on even with grounding d...

Page 65

6-60 engine general information and diagnosis (g16/j20 engines) inspection step action yes no 1 main relay operating sound check : is operating sound of main relay heard at igni- tion switch on? Go to step 5. Go to step 2. 2 fuse check : is main “fi” fuse in good condition? Go to step 3. Check for s...

Page 67

6-62 engine general information and diagnosis (g16/j20 engines) troubleshooting step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 maf sensor check : 1) connect scan tool to dlc with ignition switch off. 2) start engine and check maf value ...

Page 69

6-64 engine general information and diagnosis (g16/j20 engines) troubleshooting step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check iat sensor and its circuit. 1) connect scan tool with ignition switch off. 2) turn ignition switch on. ...

Page 71

6-66 engine general information and diagnosis (g16/j20 engines) troubleshooting step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check ect sensor and its circuit. 1) connect scan tool with ignition switch off. 2) turn ignition switch on. ...

Page 73

6-68 engine general information and diagnosis (g16/j20 engines) troubleshooting step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check tp sensor and its circuit. 1) connect scan tool to dlc with ignition switch off and then turn ignition ...

Page 75

6-70 engine general information and diagnosis (g16/j20 engines) troubleshooting (dtc p0121) fig. For step 4 and 5 step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 is there a dtc related to tp sensor (dtc p0120)? Go to applicable dtc diag....

Page 77

6-72 engine general information and diagnosis (g16/j20 engines) dtc confirmation proceudre 1) connect scan tool to dlc with ignition switch off. 2) turn on ignition switch and clear dtc, pending dtc and freeze frame data by using scan tool and start engine. 3) increase vehicle speed to 55 km/h (35 m...

Page 79

6-74 engine general information and diagnosis (g16/j20 engines) dtc p0133 ho2s-1 circuit slow response wiring diagram refer to dtc p0130. Dtc detecting condition and trouble area dtc cconfirmation procedure refer to dtc p0130. Troubleshooting dtc detecting condition trouble area following conditions...

Page 81

6-76 engine general information and diagnosis (g16/j20 engines) dtc p0135 ho2s-1 heater circuit malfunction wiring diagram refer to dtc p0130. Dtc detecting conditin and trouble area dtc confirmation procedure 1) connect scan tool with ignition switch off. 2) turn on ignition switch and clear dtc, p...

Page 83

6-78 engine general information and diagnosis (g16/j20 engines) dtc p0136 ho2s-2 circuit malfunction wiring diagram dtc detecting condition and trouble area dtc confirmation procedure [a] : canvas top model 1. To ignition switch 3. Fuse box [b] : other than canvas top model 2. Ho2s-2 4. Ecm (pcm) dt...

Page 85

6-80 engine general information and diagnosis (g16/j20 engines) dtc p0141 ho2s-2 heater circuit malfunction wiring diagram refer to dtc p0136. Dtc detecting condition and trouble are dtc confirmation procedure 1) connect scan tool with ignition switch off. 2) turn on ignition switch and clear dtc, p...

Page 87

6-82 engine general information and diagnosis (g16/j20 engines) dtc p0171 fuel system too lean dtc p0172 fuel system too rich system diagram refer to “electronic control system description” in section 6e1. Dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dl...

Page 89

6-84 engine general information and diagnosis (g16/j20 engines) dtc p0300 random misfire detected dtc p0301 cylinder 1 misfire detected dtc p0302 cylinder 2 misfire detected dtc p0303 cylinder 3 misfire detected dtc p0304 cylinder 4 misfire detected system description ecm (pcm) measures the angle sp...

Page 91

6-86 engine general information and diagnosis (g16/j20 engines) dtc p0325 (dtc no.43) knock sensor circuit malfunction wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition off. 2) turn on ignition switch and clear dtc by using s...

Page 93

6-88 engine general information and diagnosis (g16/j20 engines) dtc p0335 crankshaft position sensor circuit malfunction wiring diagram reference connect oscilloscope between terminals c51-2-19 (+) and c51-2-20 (–) of ecm (pcm) connector connected to ecm (pcm) and check ckp sensor signal. Oscillosco...

Page 95

6-90 engine general information and diagnosis (g16/j20 engines) [a] fig. For step 3 / [b] fig. For step 4 / [c] fig. For step 4. 4 ckp sensor visual inspection : 1) check visually ckp sensor and signal rotor (crankshaft timing belt pulley for g16 or ckp sensor plate (4) on crankshaft for j20) for th...

Page 97

6-92 engine general information and diagnosis (g16/j20 engines) dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) turn on ignition switch and clear dtc, pending dtc and freeze frame data by using scan tool. 3) crank engine for 3 seconds or more and keep it at idle f...

Page 99

6-94 engine general information and diagnosis (g16/j20 engines) [a] fig. For step 5 / [b] fig. For step 8 g16 / [c] fig. For step 10 j20 / [d] fig. For step 9 g16 / [e] fig. For step 11 j20

Page 101

6-96 engine general information and diagnosis (g16/j20 engines) dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) turn on ignition switch and clear dtc, pending dtc and freeze frame data by using scan tool and warm up engine ...

Page 103

6-98 engine general information and diagnosis (g16/j20 engines) dtc p0403 (dtc no.51) exhaust gas recirculation circuit malfunction wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) turn on ignition switch and ...

Page 105

6-100 engine general information and diagnosis (g16/j20 engines) dtc p0420 catalyst system efficiency below threshold system diagram circuit description exhaust oxygen concentration at the pre-twc and the post-twc is detected from ho2s-1 and ho2s-2 respectively and accordingly ecm (pcm) controls the...

Page 107

6-102 engine general information and diagnosis (g16/j20 engines) dtc p0443 evap control system purge control valve circuit malfunction wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) turn on ignition switch a...

Page 109

6-104 engine general information and diagnosis (g16/j20 engines) evap canister purge valve inspection 1) with ignition switch off, disconnect coupler from canister purge valve. 2) check resistance between two terminals of evap canister purge valve. If resistance is as specified, proceed to next oper...

Page 111

6-106 engine general information and diagnosis (g16/j20 engines) troubleshooting step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table” in this section. 2 does fuel level meter in combination meter indi- cate “e” (empty)? Replenish fuel tank with ...

Page 113

6-108 engine general information and diagnosis (g16/j20 engines) troubleshooting (dtc p0500/dtc no.24) step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 does speedometer indicate vehicle speed? Faulty “blu/yel” wire or poor c51-2-25 connec...

Page 115

6-110 engine general information and diagnosis (g16/j20 engines) dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) turn on ignition switch and clear dtc, pending dtc and freeze frame data by using scan tool and warm up engine completely. 3) run engine at idle speed ...

Page 117

6-112 engine general information and diagnosis (g16/j20 engines) dtc p0601 (dtc no.71) internal control module memory check sum error system description internal control module is installed in ecm (pcm). Dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc ...

Page 119

6-114 engine general information and diagnosis (g16/j20 engines) troubleshooting (dtc p1408) step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 map sensor signal check : 1) remove ecm (pcm) cover. 2) check voltage between c51-3-8 and c51-3-...

Page 121

6-116 engine general information and diagnosis (g16/j20 engines) dtc p1500 engine starter signal circuit malfunction wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) turn on ignition switch and clear dtc by us...

Page 123

6-118 engine general information and diagnosis (g16/j20 engines) table b-1 fuel pump circuit inspection wiring diagram inspection [a] : canvas top model and other than canvas top model with immobilizer control system 2. Fuel pump relay 5. Fuel pump [b] : other than canvas top model with immobilizer ...

Page 125

6-120 engine general information and diagnosis (g16/j20 engines) table b-2 fuel injectors and circuit inspection wiring diagram inspection 1. Main relay 3. Injector no.2 5. Injector no.4 7. Ecm (pcm) 2. Injector no.1 4. Injector no.3 6. To ignition switch step action yes no 1 check injector for oper...

Page 127

6-122 engine general information and diagnosis (g16/j20 engines) table b-3 fuel pressure inspection system diagram inspection (a) : gauge (c) : attachment 2. Delivery pipe 4. Fuel filter (b) : hose 1. Injector 3. Fuel pressure regulator 5. Fuel pump note: before using following flow table, check to ...

Page 129

6-124 engine general information and diagnosis (g16/j20 engines) table b-4 idle air control system inspection wiring diagram inspection 1. Throttle body 3. Ecm (pcm) 5. Main relay 2. Idle air control valve 4. Sensed information 6. Ecm (pcm) step action yes no 1 check engine idle speed and iac duty r...

Page 131

6-126 engine general information and diagnosis (g16/j20 engines) 10 was iac duty more than about 30% in step 1 of this table? Check parts or system which can cause engine low idle. • air inhaling from between throttle body and maf sensor. • egr valve malfunction (leakage from valve seat) • accessory...

Page 133

6-128 engine general information and diagnosis (g16/j20 engines) table b-6 a/c signal circuits inspection (other than canvas top model, if equipped) wiring diagram circuit description hvac control module outputs a/c on signal to ecm (pcm) when a/c switch and heater blower motor are turned on. Then c...

Page 135

6-130 engine general information and diagnosis (g16/j20 engines) table b-7 a/c condenser fan motor relay control system inspection (canvas top model, if equipped) wiring diagram inspection 1. To ignition switch 5. A/c condenser fan motor relay 2. “rear defg” fuse for canvas top model, “heater” fuse ...

Page 137

6-132 engine general information and diagnosis (g16/j20 engines) table b-8 a/c condenser fan motor relay control system inspection (other than canvas top model, if equipped) wiring diagram circuit description a/c condenser fan is turned on by ecm (pcm) when engine coolant temperature is higher than ...

Page 139

6-134 engine general information and diagnosis (g16/j20 engines) table b-9 a/c compressor relay control system inspection (other than can- vas top model, if equipped) wiring diagram circuit description a/c compressor relay is turned on by ecm (pcm) when a/c signal inputted to ecm (pcm) and engine co...

Page 141: Special Tool

6-136 engine general information and diagnosis (g16/j20 engines) special tool 09917-47010 09930-88530 see note “a”. Vacuum pump gauge injector test lead tech 2 kit (suzuki scan tool) (see note “b”.) note: • “a” : this kit includes the following items. 1. Pressure gauge 09912-58441, 2. Pressure hose ...

Page 143

6-1-2 engine general information and diagnosis (h25 engine) on-board diagnostic system (vehicle with diagnosis connector) ........... 6-1-12 precaution in diagnosing trouble.............. 6-1-13 engine diagnostic flow table ................... 6-1-14 malfunction indicator lamp (mil) check..............

Page 145: General Information

6-1-4 engine general information and diagnosis (h25 engine) general information statement of cleanliness and care an automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of inch). A...

Page 147

6-1-6 engine general information and diagnosis (h25 engine) precaution on fuel system service • work must be done with no smoking, in a well-ventilated area and away from any open flames. • as fuel feed line (between fuel pump and fuel pressure regu- lator) is still under high fuel pressure even aft...

Page 149: Engine Diagnosis

6-1-8 engine general information and diagnosis (h25 engine) engine diagnosis general description this vehicle is equipped with an engine and emission control system which are under control of ecm (pcm). The engine and emission control system in this vehicle are controlled by ecm (pcm). Ecm (pcm) has...

Page 151

6-1-10 engine general information and diagnosis (h25 engine) freeze frame data ecm (pcm) stores the engine and driving conditions (in the form of data as shown at the figure) at the moment of the detection of a malfunction in its memory. This data is called “freeze frame data”. Therefore, it is poss...

Page 153

6-1-12 engine general information and diagnosis (h25 engine) on-board diagnostic system (vehicle with diagnosis connector) ecm diagnosis troubles which may occur in the area including the following parts when the ignition switch is on and the engine is running, and indicates the result by turning on...

Page 155

6-1-14 engine general information and diagnosis (h25 engine) engine diagnostic flow table refer to following pages for the detail of each step. Step action yes no 1 customer complaint analysis 1) perform customer complaint analysis refer- ring to “customer complaint analysis” in the following. Was c...

Page 157

6-1-16 engine general information and diagnosis (h25 engine) 1. Customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point requir...

Page 159

6-1-18 engine general information and diagnosis (h25 engine) 5. Trouble symptom confirmation based on information obtained in step 1 “customer complaint analysis” and step 2 “dtc/freeze frame data check”, confirm trouble symptoms. Also, reconfirm dtc according to “dtc conformation procedure” describ...

Page 161

6-1-20 engine general information and diagnosis (h25 engine) malfunction indicator lamp (mil) check 1) turn on ignition switch (but the engine at stop) and check that mil (1) lights. If mil does not light up, go to “diagnostic flow table a-1” for troubleshooting. 2) start engine and check that mil t...

Page 163

6-1-22 engine general information and diagnosis (h25 engine) diagnostic trouble code (dtc) clearance [using scan tool] 1) with ignition switch off, connect generic scan tool or suzuki scan tool to data link connector (dlc). 2) turn ignition switch on. 3) erase dtc according to instructions displayed...

Page 165

6-1-24 engine general information and diagnosis (h25 engine) p0154 (vehicle without diagno- sis connector)/ p0150 (vehicle with diagnosis connector) (no.26) ho2s (bank 2 – sensor 1) no activity detected output voltage of ho2s-1 fails to go above specification (or ho2s-1 circuit open). 2 driving cycl...

Page 167

6-1-26 engine general information and diagnosis (h25 engine) dtc no. Detecting item detecting condition (dtc will set when detecting : ) mil p0705 (no.72) transmission range circuit malfunction refer to section 7b1 p0715 (no.76) input/turbine speed sensor circuit malfunction p0720 (no.75) a/t vss si...

Page 169

6-1-28 engine general information and diagnosis (h25 engine) 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 condi- ti...

Page 171

6-1-30 engine general information and diagnosis (h25 engine) trans range ignition switch on, selector lever is at “r”, “n”, “d”, “2” or “l” range. R, n, d, 2 or l ✱ brake sw (brake, stop lamp, switch) ignition switch on, brake pedal is released. Off ✱ ignition switch on, brake pedal is depressed. On...

Page 173

6-1-32 engine general information and diagnosis (h25 engine) throttle pos (absolute throttle position, %) when throttle position sensor is fully closed position, throttle opening is indicated as 0% and 100% for full open position. Tp sensor volt (tp sensor output voltage, v) throttle position sensor...

Page 175

6-1-34 engine general information and diagnosis (h25 engine) shift sol # 1 con/mon (shift solenoid # 1, a command/monitor, on/off) con-on : on command being output to shift solenoid # 1, a. Con-off : on command not being output. Mon-on : electricity being passed to shift solenoid # 1, a. Mon-off : e...

Page 177

6-1-36 engine general information and diagnosis (h25 engine) engine has no power engine overheating. Refer to “overheating” in this table. Ignition system out of order. • defective spark plug “spark plugs” in section 6f2. • faulty ignition coil with ignitor “ignition coil assembly” in section 6f2. F...

Page 179

6-1-38 engine general information and diagnosis (h25 engine) excessive detona- tion (the engine makes sharp metallic knocks that change with throttle opening. Sounds like pop corn popping.) engine overheating refer to “overheating” in this table. Ignition system out of order. • faulty spark plug “sp...

Page 181

6-1-40 engine general information and diagnosis (h25 engine) engine noise see note below. Valve noise • faulty hydraulic valve lash adjuster “camshaft and valve lash adjuster” in sec- tion 6a2. • worn valve stem and guide “valves and cylinder heads” in section 6a2. • weak or broken valve spring “val...

Page 183

6-1-42 engine general information and diagnosis (h25 engine) 1. Ecm (pcm) 2. Connector (viewed from harness side) terminal number wire color circuit normal voltage condition e61-1 wht/grn fuel pump relay output (with- out immobilizer control sys- tem) 0 – 2.5 v while 3 sec. After ignition switch tur...

Page 185

6-1-44 engine general information and diagnosis (h25 engine) e61-23 ppl duty output terminal (if equipped) 0 – 1 v ignition switch turned on immobilizer indicator lamp output (if equipped) 10 – 14 v while engine running 0 – 1 v ignition switch turned on with engine stop e61-24 ppl/wht serial communi...

Page 187

6-1-46 engine general information and diagnosis (h25 engine) c51-3-10 yel/blu reference signal for cmp sensor ✱ 0 – 0.6 v ↑↓ 4 – 6 v (repeated indicator) engine running at idling after warming up. (sensor signal is pulse. Pulse fre- quency varies depending on engine speed. (4 pulses are generated pa...

Page 189

6-1-48 engine general information and diagnosis (h25 engine) c51-1-7 orn/blk “4wd” lamp output 0 – 1 v ignition switch turned on, transfer selector selected at “4h” or “4l” range 10 – 14 v ignition switch turned on, transfer selector selected at “2h” range c51-1-8 blu/grn a/t input shaft speed senso...

Page 191

6-1-50 engine general information and diagnosis (h25 engine) c51-2-4 lt grn/ wht egr valve (stepper motor coil 2) output (if equipped) 10 – 14 v ignition switch turned on ✱ 0 – 1 v ↑↓ 8 – 14 v (repeated indicator) while engine running. (output signal is active low duty pulse. Pulse generated time de...

Page 193

6-1-52 engine general information and diagnosis (h25 engine) c51-2-22 blk/brn ignition coil no.6 output 0 – 0.6 v ignition switch turned on ✱ 0 – 0.6 v ↑↓ 2 – 4 v (repeated indicator) engine running (output signal is active high pulse. Pulse frequency varies depending on engine speed.) c51-2-23 brn/...

Page 195

6-1-54 engine general information and diagnosis (h25 engine) c51-2-7 – c51-2-20 fuel injector no.1 10 – 14 Ω – c51-2-6 – c51-2-20 fuel injector no.2 c51-2-19 – c51-2-20 fuel injector no.3 c51-2-18 – c51-2-20 fuel injector no.4 c51-2-28 – c51-2-20 fuel injector no.5 c51-2-27 – c51-2-20 fuel injector ...

Page 197

6-1-56 engine general information and diagnosis (h25 engine) troubleshooting step action yes no 1 test switch terminal check (vehicle with moni- tor connector) : 1) check test switch terminal of monitor con- nector for being grounded. 2) with ignition switch on leaving engine off, measure voltage be...

Page 199

6-1-58 engine general information and diagnosis (h25 engine) table a-4 malfunction indicator lamp check mil does not flash or just remains on even with grounding diagnosis switch terminal (vehi- cle with monitor connector) wiring diagram/circuit description refer to table a-1. Troubleshooting step a...

Page 201

6-1-60 engine general information and diagnosis (h25 engine) troubleshooting step action yes no 1 main relay operating sound check : is operating sound of main relay heard at igni- tion switch on? Go to step 5. Go to step 2. 2 fuse check : is main fuse in good condition? Go to step 3. Check for shor...

Page 203

6-1-62 engine general information and diagnosis (h25 engine) dtc confirmation procedure • intake air temperature : between –14°c and 70°c (6.8°f and 158°f) • atmospheric pressure : higher than 560 mmhg (altitude : lower than 2790 m (9150 ft)) 1) with ignition switch off, connect scan tool. 2) turn o...

Page 205

6-1-64 engine general information and diagnosis (h25 engine) • intake air temperature : between –14°c and 70°c (68°f and 158°f) • atmospheric pressure : higher than 560 mmhg (altitude : lower than 2790 m (9150 ft)) 1) with ignition switch off, connect scan tool. 2) turn on ignition switch, clear dtc...

Page 207

6-1-66 engine general information and diagnosis (h25 engine) • atmospheric pressure : higher than 560 mmhg (altitude : lower than 2790 m (9150 ft)) • intake air temperature : between –14°c and 70°c (6.8°f and 158°f) 1) with ignition switch off, connect scan tool. 2) turn on ignition switch, clear dt...

Page 209

6-1-68 engine general information and diagnosis (h25 engine) dtc troubleshooting fig. For step 2 step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 tp sensor reference voltage check : 1) wit ignition switch off, disconnect tp sen- sor coupl...

Page 211

6-1-70 engine general information and diagnosis (h25 engine) dtc troubleshooting fig. For step 5 step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 tp sensor signal check : 1) remove ecm (pcm) cover. 2) start engine and warm up for normal o...

Page 213

6-1-72 engine general information and diagnosis (h25 engine) dtc confirmation procedure 1) with ignition switch off, connect scan tool. 2) turn on ignition switch and clear dtc by using scan tool if any. 3) start engine and warm up to normal operating temperature. 4) increase vehicle speed till engi...

Page 215

6-1-74 engine general information and diagnosis (h25 engine) dtc p0133 ho2s (bank-1 sensor-1) circuit slow response wiring diagram refer to dtc p0130. Dtc detecting condition and trouble area dtc confirmation procedure 1) with ignition switch off, connect scan tool. 2) turn on ignition switch and cl...

Page 217

6-1-76 engine general information and diagnosis (h25 engine) 3 ho2s voltage check : 1) remove ecm (pcm) cover. 2) start engine and check voltage between c51- 3-4 and c51-3-20 while repeating racing engine. Does the voltage indicate 0.5 v or more even at once? Poor c51-3-4 and/or c51- 3-20 terminal c...

Page 219

6-1-78 engine general information and diagnosis (h25 engine) fig. For step 2, 3 4 ho2s heater control circuit check : 1) with ignition switch off, install ho2s heater relay. 2) with ignition switch on leaving engine off, check voltage between c51-3-6 and ground. Is the voltage 10 – 14 v? Substitute ...

Page 221

6-1-80 engine general information and diagnosis (h25 engine) • intake air temperature : between –14°c and 70°c (6.8°f and 158°f) • atmospheric pressure : higher than 560 mmhg (altitude : lower than 2790 m (9150 ft)) • following dtcs are not detected : p0110 (no.23, 25), p0335, p0460, p1450 and p1451...

Page 223

6-1-82 engine general information and diagnosis (h25 engine) fig. For step 2, 3 4 ho2s heater control circuit check : 1) with ignition switch off, install ho2s heater relay. 2) with ignition switch on leaving engine off, check voltage between c51-3-17 and ground. Is the voltage 10 – 14 v? Substitute...

Page 225

6-1-84 engine general information and diagnosis (h25 engine) dtc confirmation procedure • intake air temperature : between –14°c and 70°c (6.8°f and 158°f) • atmospheric pressure : higher than 560 mmhg (altitude : lower than 2790 m (9150 ft)) • following dtc is not detected : p0135 1) with ignition ...

Page 227

6-1-86 engine general information and diagnosis (h25 engine) dtc p0153 ho2s (bank-2 sensor-1) circuit slow response wiring diagram refer to dtc p0150. Dtc detecting condition and trouble area dtc confirmation procedure • intake air temperature : between –14°c and 70°c (6.8°f and 158°f) • atmospheric...

Page 229

6-1-88 engine general information and diagnosis (h25 engine) 3 ho2s voltage check : 1) remove ecm (pcm) cover. 2) start engine and check voltage between c51- 3-15 and c51-3-20 while repeating racing engine. Does the voltage indicate 0.5 v or more even at once? Poor c51-3-15 and/or c51-3- 20 terminal...

Page 231

6-1-90 engine general information and diagnosis (h25 engine) fig. For step 2, 3 4 ho2s heater control circuit check : 1) with ignition switch off, install ho2s heater relay. 2) with ignition switch on leaving engine off, check voltage between c51-3-5 and ground. Is the voltage 10 – 14 v? Substitute ...

Page 233

6-1-92 engine general information and diagnosis (h25 engine) • intake air temperature : between –14°c and 70°c (6.8°f and 158°f) • atmospheric pressure : higher than 560 mmhg (altitude : lower than 2790 m (9150 ft)) • following dtcs are not detected : p0110 (no.23, 25), p0335, p0460, p01450 and p014...

Page 235

6-1-94 engine general information and diagnosis (h25 engine) fig. For step 2, 3 and 4 4 ho2s heater control circuit check : 1) with ignition switch off, install ho2s heater relay (1). 2) with ignition switch on leaving engine off, check voltage between c51-3-16 and ground. Is the voltage 10 – 14 v? ...

Page 237

6-1-96 engine general information and diagnosis (h25 engine) 6 check fuel injector circuit referring to “table b- 3” in this section. Is it in good condition? Go to step 7. Repair or replace. 7 check fuel level sensor referring to step 3 of “dtc p0460 diag. Flow table” in this section. Is check resu...

Page 239

6-1-98 engine general information and diagnosis (h25 engine) 6 check fuel injector circuit referring to “table b- 3” in this section. Is it in good condition? Go to step 7. Repair or replace. 7 check fuel level sensor referring to step 3 of “dtc p0460 diag. Flow table” in this section. Is check resu...

Page 241

6-1-100 engine general information and diagnosis (h25 engine) dtc troubleshooting step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 ignition system inspection : 1) check spark plug and ignition spark of cylin- der where misfire occurs, ref...

Page 243

6-1-102 engine general information and diagnosis (h25 engine) [a] fig. 1 for step 3 / [b] fig. 2 for step 3 1. Knock sensor 2. Knock sensor connector.

Page 245

6-1-104 engine general information and diagnosis (h25 engine) dtc troubleshooting fig. For step 3 step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 ckp sensor and its circuit resistance check : 1) with ignition switch off, disconnect ecm (...

Page 247

6-1-106 engine general information and diagnosis (h25 engine) dtc confirmation procedure 1) with ignition switch off, connect scan tool. 2) turn on ignition switch and clear dtc by using scan tool if any. 3) crank engine for 8 sec. 4) check dtc by using scan tool. Dtc troubleshooting note: check to ...

Page 249

6-1-108 engine general information and diagnosis (h25 engine) dtc p0400 exhaust gas recirculation flow malfunction (dtc no.51) system / wiring diagram system description [a] : terminal arrangement of ecm (pcm) coupler viewed from harness side 2. Intake manifold 4. Egr valve (stepper motor) 1. Egr va...

Page 251

6-1-110 engine general information and diagnosis (h25 engine) [a] fig. For step 4 / [b] fig. For step 5 4 egr valve power supply circuit check : 1) with ignition switch off, disconnect egr valve coupler (1). 2) with ignition switch on, check voltage between c04-2 (“blu/blk” wire terminal of egr valv...

Page 253

6-1-112 engine general information and diagnosis (h25 engine) troubleshooting (dtc p0403/dtc no.51) step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 egr valve check : 1) with ignition switch off, disconnect connector from egr valve. 2) ch...

Page 255

6-1-114 engine general information and diagnosis (h25 engine) dtc detecting condition and trouble area dtc confirmation procedure • intake air temperature : between –14°c and 70°c (6.8°f and 158°f) • atmospheric pressure : higher than 560 mmhg (altitude : lower than 2790 m (9150 ft)) • following dtc...

Page 257

6-1-116 engine general information and diagnosis (h25 engine) dtc p0443 evap control system purge control valve circuit malfunction wiring diagram dtc detecting condition and trouble area dtc confirmation procedure 1) connect scan tool to dlc with ignition switch off. 2) turn on ignition switch and ...

Page 259

6-1-118 engine general information and diagnosis (h25 engine) evap canister purge valve and its circuit check 1) disconnect vacuum hoses from vacuum pipes. 2) with ignition switch on, blow into hose “a”. Air should not come out of hose “b”. 3) if you have suzuki scan tool, perform step a). If not, p...

Page 261

6-1-120 engine general information and diagnosis (h25 engine) evap canister purge system check 1) warm up engine to normal operating temperature. 2) hoist vehicle so that all wheels rotate freely. 3) set m/t in “neutral” or a/t in “p” position and parking brake. 4) disconnect purge hose (1) from eva...

Page 263

6-1-122 engine general information and diagnosis (h25 engine) dtc troubleshooting step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 fuel level sensor signal circuit check : 1) with ignition switch off, disconnect combi- nation meter couple...

Page 265

6-1-124 engine general information and diagnosis (h25 engine) • intake air temperature : between –14°c and 70°c (6.8°f and 158°f) • atmospheric pressure : higher than 560 mmhg (altitude : lower than 2790 m (9150 ft)) 1) with ignition switch off, connect scan tool. 2) turn on ignition switch and clea...

Page 267

6-1-126 engine general information and diagnosis (h25 engine) dtc p0505 idle air control system malfunction system / wiring diagram [a] : terminal arrangement of ecm (pcm) coupler viewed from harness side 2. Fast idle control system 4. Engine coolant 6. Cold 1. Iac valve 3. Bypass air 5. Main relay ...

Page 269

6-1-128 engine general information and diagnosis (h25 engine) fig. For step 5 5 iac valve power supply voltage check : 1) connect ecm (pcm) couplers. 2) with ignition switch off, disconnect coupler (1) of iac valve. 3) with ignition switch on, check voltage between (“blu/blk” wire terminal of iac va...

Page 271

6-1-130 engine general information and diagnosis (h25 engine) dtc p1408 manifold absolute pressure sensor circuit malfunction wiring diagram dtc detecting condition and trouble area dtc confirmation procedure [a] : terminal arrangement of ecm (pcm) coupler viewed from harness side 1. Map sensor dtc ...

Page 273

6-1-132 engine general information and diagnosis (h25 engine) dtc p1450 barometric pressure sensor circuit malfunction dtc p1451 barometric pressure sensor performance problem system description barometric pressure sensor is installed in ecm (pcm). Dtc detecting condition and trouble area dtc confir...

Page 275

6-1-134 engine general information and diagnosis (h25 engine) dtc p1500 engine start signal circuit malfunction wiring diagram circuit description engine start signal is sent from engine starter circuit while engine cranking. Dtc detecting condition and trouble area [a] : terminal arrangement of ecm...

Page 277

6-1-136 engine general information and diagnosis (h25 engine) dtc p1510 ecm back-up power supply malfunction wiring diagram circuit description battery voltage is translated to 5 v in ecm (pcm) back-up circuit. The voltage is supplied to keep dtc memory, values that ecm (pcm) has learned to control ...

Page 279

6-1-138 engine general information and diagnosis (h25 engine) table b-1 fuel pump circuit check wiring diagram circuit description fuel pump relay is turned on • for 3 sec. After ignition switch is turned on • while start engine signal is inputted. • while engine is running. [a] : terminal arrangeme...

Page 281

6-1-140 engine general information and diagnosis (h25 engine) table b-2 fuel injector circuit check wiring diagram [a] : terminal arrangement of ecm (pcm) coupler viewed from harness side 1. Fuel injector 2. Main relay.

Page 283

6-1-142 engine general information and diagnosis (h25 engine) table b-3 fuel pressure check system diagram system description fuel pressure regulator keeps the fuel pressure applied to injector 290 kpa higher than that in intake manifold at all times. Inspection (a) : gauge (c) : attachment 2. Deliv...

Page 285

6-1-144 engine general information and diagnosis (h25 engine) table b-4 a/c signal circuit check (if equipped) circuit diagram circuit description hvac control module outputs a/c on signal to ecm (pcm) when a/c switch and heater blower motor are turned on. Then compressor and condenser fan are turne...

Page 287

6-1-146 engine general information and diagnosis (h25 engine) step action yes no 1 a/c condenser fan motor control circuit check 1) remove ecm (pcm) cover. 2) measure voltage between e61-5 and vehi- cle body ground with ignition turned on. Is voltage 10 – 14 v? Go to step 3. Go to step 2. 2 a/c cond...

Page 289

6-1-148 engine general information and diagnosis (h25 engine) 3 a/c compressor control signal check 1) start engine. 2) turn on a/c switch and heater blower motor switch. 3) measure voltage between e61-21 and vehi- cle body ground with engine running. Is voltage 0 – 1 v? Go to step 4. Go to step 5. ...

Page 291

6-1-150 engine general information and diagnosis (h25 engine).

Page 293: General Description

6a1-2 engine mechanical (g16 engine) general description engine the engine is a water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit equipped with its s.O.H.C. (single overhead camshaft) valve mechanism arranged for “v”-type valve configuration and 16 valves (in 2 and ex 2/ one cylinder)....

Page 295: On-Vehicle Service

6a1-4 engine mechanical (g16 engine) on-vehicle service compression check check compression pressure on all four cylinders as follows : 1) warm up engine. 2) stop engine after warming up. 3) disconnect fuel injector wire harness connector. 4) remove ignition coil assemblies and all spark plugs refer...

Page 297

6a1-6 engine mechanical (g16 engine) 2) with engine stopped, disconnect fuel pressure regulator vac- uum hose from intake manifold and connect 3-way joint, hoses and special tool (vacuum gauge and joint) between intake manifold and vacuum hose disconnected. Special tool (a) : 09915-67311 (b) : 09918...

Page 299

6a1-8 engine mechanical (g16 engine) valve lash (clearance) 1) remove negative cable at battery. 2) remove cylinder head cover referring to “cylinder head cover” in this section. 3) using 17 mm socket, turn crankshaft pulley (1) clockwise until “v” mark (in white paint) (2) on pulley aligns with “0”...

Page 301

6a1-10 engine mechanical (g16 engine) clean blow off dust by compressed air from air outlet side of element. Installation reverse removal procedure for installation. Cylinder head cover removal 1) disconnect negative cable at battery. 2) remove ignition coil assemblies with high-tension cord. 3) dis...

Page 303

6a1-12 engine mechanical (g16 engine) removal 1) relieve fuel pressure according to fuel pressure relief proce- dure described in “fuel pressure relief procedure” section 6. 2) disconnect negative cable at battery. 3) drain cooling system. 4) remove air intake hose. 5) disconnect the following elect...

Page 305

6a1-14 engine mechanical (g16 engine) • check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been rein- stalled. • refill cooling system referring to “cooling system flush and refill” in section 6b. • adjust water pump drive belt tension referring to...

Page 307

6a1-16 engine mechanical (g16 engine) 5) connect heated oxygen sensor-1 connector (1) and fit con- nector to bracket (2). 6) connect negative cable at battery. Check exhaust system for exhaust gas leakage. Timing belt and belt tensioner components 3. Engine hook 1. Timing belt 4. Tensioner spring 7....

Page 309

6a1-18 engine mechanical (g16 engine) 8) remove timing belt tensioner, tensioner plate (2), tensioner spring (5) and timing belt (1). Inspection • inspect timing belt for wear or crack. Replace it as necessary. • inspect tensioner for smooth rotation. 3. Tensioner bolt 4. Tensioner stud caution: • a...

Page 311

6a1-20 engine mechanical (g16 engine) 5) install timing belt and tensioner spring (2). With two sets of marks aligned and tensioner plate pushed up, install timing belt on two pulleys in such a way that drive side of belt (1) is free from any slack. And then install tensioner spring as shown in figu...

Page 313

6a1-22 engine mechanical (g16 engine) removal 1) raise vehicle. 2) remove front differential housing (1) with differential (2) referring to “dismounting” in section 7e. 3) disconnect ckp sensor coupler and remove ckp sensor by removing its bolt. (if equipped) 4) drain engine oil by removing drain pl...

Page 315

6a1-24 engine mechanical (g16 engine) 2) install new seal (2) in the position as shown in figure. 3) install oil pump strainer (1) and oil pan (3). Tighten strainer bolt first and then bracket bolt to specified torque. Tightening torque oil pump strainer bolt (a) : 11 n·m (1.1 kg-m, 8.0 lb-ft) oil p...

Page 317

6a1-26 engine mechanical (g16 engine) removal 1) disconnect negative cable at battery. 2) remove timing belt referring to “timing belt and belt ten- sioner” in this section. 3) remove generator and its bracket. 4) remove crankshaft timing belt pulley (3). To lock crankshaft, engage special tool (gea...

Page 319

6a1-28 engine mechanical (g16 engine) • check outer and inner rotors, rotor plate, and oil pump case for excessive wear or damage. Measurement • radial clearance check radial clearance between outer rotor (1) and case, using thickness gauge. If clearance exceeds its limit, replace outer rotor or cas...

Page 321

6a1-30 engine mechanical (g16 engine) 3) install oil pump to cylinder block. As there are 2 types of oil pump bolts, refer to figure for their correct use and tighten them to specified torque. Tightening torque oil pump bolt (a) : 11 n·m (1.1 kg-m, 8.0 lb-ft) 4) install rubber seal between oil pump ...

Page 323

6a1-32 engine mechanical (g16 engine) removal 1) disconnect negative cable at battery. 2) remove engine hood lock (1) from front upper member. 3) remove radiator referring to “radiator” in section 6b. 4) remove timing belt referring to “timing belt and belt ten- sioner” in this section. 5) remove ca...

Page 325

6a1-34 engine mechanical (g16 engine) 14) remove exhaust rocker arms (1) and rocker arm spring (2) by pulling rocker arm shaft to front side. Inspection adjusting screw and rocker arm if tip of adjusting screw (1) is badly worn, replace it. Rocker arm (2) must be replaced if its cam-riding face (3) ...

Page 327

6a1-36 engine mechanical (g16 engine) check clearance by using gaging plastic. The procedure is as follows. 1) clean housing and camshaft journals. 2) install camshaft to cylinder head. 3) place a piece of gaging plastic the full width of journal of camshaft (parallel to camshaft). 4) install camsha...

Page 329

6a1-38 engine mechanical (g16 engine) 6) fill small amount of engine oil into arm pivot holding part (3) of rocker arm shaft. Install rocker arm (intake side) (1) with clips (2) to rocker arm shaft. 7) apply engine oil to cams and journals on camshaft and put camshaft on cylinder head. Install camsh...

Page 331

6a1-40 engine mechanical (g16 engine) 13) after applying sealant to part “a” as shown in figure, install cmp sensor case to cylinder head and tighten its fixing bolts to specified torque. Connect cmp sensor connector. “a” sealant : 99000-31110 tightening torque cmp sensor case bolt (a) : 11 n·m (1.1...

Page 333

6a1-42 engine mechanical (g16 engine) 4) remove intake manifold stiffener (1). 5) remove air intake hose. 6) disconnect the following electric wires, and then release above wire harnesses from clamps. • throttle position sensor • idle air control valve • engine coolant temp. Sensor • camshaft positi...

Page 335

6a1-44 engine mechanical (g16 engine) disassembly 1) for ease in servicing cylinder head, remove intake manifold with throttle body and exhaust manifold from cylinder head. 2) remove rocker arms and rocker arm shaft referring to “rocker arms, rocker arm shaft and camshaft” in this sec- tion. 3) usin...

Page 337

6a1-46 engine mechanical (g16 engine) valves • remove all carbon from valves. • inspect each valve for wear, burn or distortion at its face and stem and, as necessary, replace it. • measure thickness of valve head. If measured thickness exceeds limit, replace valve. Valve head thickness • inspect va...

Page 339

6a1-48 engine mechanical (g16 engine) • flatness of gasketed surface : using a straightedge and thickness gauge, check surface at a total of 6 locations. If distortion limit, given below, is exceeded, correct gasketed surface with a surface plate and abrasive paper of about #400 (waterproof silicon ...

Page 341

6a1-50 engine mechanical (g16 engine) assembly 1) before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) so remove burrs and make it truly round. Special tool (a) : 09916-34542 (b) : 09916-38210 2) install valve guide to cylinder head. Heat cylinder head u...

Page 343

6a1-52 engine mechanical (g16 engine) 9) install rocker arms, springs and rocker arm shaft referring to “rocker arms, rocker arm shaft and camshaft” in this sec- tion. 10) install intake manifold and exhaust manifold. Installation 1) remove old gasket and oil on mating surfaces and install knock pin...

Page 345

6a1-54 engine mechanical (g16 engine) removal 1) remove cylinder head from cylinder block referring to “valves and cylinder head” in this section. 2) drain engine oil. 3) remove oil pan and oil pump strainer referring to “oil pan and oil pump strainer” in this section. 4) mark cylinder number on all...

Page 347

6a1-56 engine mechanical (g16 engine) 3) piston clearance : measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, rebore cylinder and use oversize piston. P...

Page 349

6a1-58 engine mechanical (g16 engine) crank pin and connecting rod bearings 1) inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is damaged, or out-of-round or taper is out of limit, replace crankshaft or regrind crank pin referr...

Page 351

6a1-60 engine mechanical (g16 engine) c) stamped number on piston and that on cylinder block should correspond. That is, install number 2 stamped pis- ton to cylinder which is identified with number 2 and a num- ber 1 piston to cylinder with number 1. Piston and cylinder specification also, a letter...

Page 353

6a1-62 engine mechanical (g16 engine) 5) install bearing cap (1) : point arrow mark (2) on cap to crankshaft pulley side (3). Tighten cap nuts to specification. Tightening torque connecting rod bearing cap nut (a) : 35 n·m (3.5 kg-m, 25.5 lb-ft) 6) reverse removal procedure for installation, as prev...

Page 355

6a1-64 engine mechanical (g16 engine) 9) disconnect the following hoses : • canister purge hose from evap canister purge valve • radiator outlet hose from inlet pipe • brake booster hose from intake manifold • vacuum hose from intake manifold • heater inlet and outlet hose from pipe • fuel feed hose...

Page 357

6a1-66 engine mechanical (g16 engine) 22) install lifting device. 23) remove engine mounting bracket nuts (r & l). 24) before lifting engine, check to ensure all hoses, electric wires and cables are disconnected from engine. 25) remove engine assembly from chassis and transmission by lifting a littl...

Page 359

6a1-68 engine mechanical (g16 engine) 9) check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been rein- stalled. 10) refill engine with engine oil referring to item “engine oil and filter change” in section 0b. 11) refill cooling system referring to...

Page 361

6a1-70 engine mechanical (g16 engine) removal 1) remove engine assembly from body referring to “engine assembly” in this section. 2) remove clutch cover, clutch disc and flywheel (drive plate for a/t). Special tool (a) : 09924-17811 3) remove crankshaft pulley, timing belt and crankshaft timing pull...

Page 363

6a1-72 engine mechanical (g16 engine) out-of-round and taper (uneven wear) of journals an unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length (or both). This dif- ference, if any, is determined by taking micrometer readings. If any one of jour...

Page 365

6a1-74 engine mechanical (g16 engine) selection of main bearings standard bearing : 1) first check journal diameter by using following procedure. As shown in figure, crank webs of no.2 and no.3 cylinders have five stamped numerals. Three kinds of numerals (“1”, “2” and “3”) represent following journ...

Page 367

6a1-76 engine mechanical (g16 engine) 4) from numerals stamped on crank webs of no.2 and no.3 cylinders and the alphabets stamped on mating surface of cylinder block, determine new standard bearing to be installed to journal, by referring to table given below. For example, if numeral stamped on cran...

Page 369

6a1-78 engine mechanical (g16 engine) for oil seal installation, press-fit rear oil seal (1) so that oil seal housing (2) end face is flush with oil seal end face. Flywheel • if ring gear is damaged, cracked or worn, replace flywheel. • if the surface contacting clutch disc is damaged, or exces- siv...

Page 371

6a1-80 engine mechanical (g16 engine) 2) install thrust bearings (1) to cylinder block between no.2 and no.3 cylinders. Face oil groove (2) sides to crank webs. 3) install crankshaft to cylinder block. 4) install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to cranksh...

Page 373: Special Tool

6a1-82 engine mechanical (g16 engine) special tool 09915-67311 09918-08210 09915-77311 see note “a”. Vacuum gauge vacuum gauge hose joint oil pressure gauge 09917-18211 09927-56010 09926-18210 09917-68221 tappet adjuster wrench gear stopper oil seal guide (vinyl resin) camshaft pulley holder 09916-8...

Page 375

6a1-84 engine mechanical (g16 engine) tightening torque specifications fastening part tightening torque n•m kg-m lb-ft oil pressure switch 14 1.4 10.5 rocker arm adjusting screw lock nut 12 1.2 9.0 cylinder head cover bolt 11 1.1 8.0 exhaust no.1 pipe bolt or nut 50 5.0 36.5 heated oxygen sensor-1 4...

Page 377: General Description

6a2-2 engine mechanical (h25 engine) general description engine the engine is a water-cooled, 60° v6 cylinders, 4 stroke cycle gasoline unit with its dohc (double overhead camshaft) valve mechanism arranged for “v” type valve configuration. The double overhead camshaft is mounted over the cylinder h...

Page 379: On-Vehicle Service

6a2-4 engine mechanical (h25 engine) on-vehicle service compression check check compression pressure on all 6 cylinders as follows : 1) warm up engine. 2) stop engine after warming up. 3) remove ignition coil covers and disconnect ignition coil har- ness couplers. 4) remove all ignition coils (1) an...

Page 381

6a2-6 engine mechanical (h25 engine) oil pressure check 1) remove oil pressure switch from cylinder block. 2) install special tool (oil pressure gauge) to vacated threaded hole. For lh steering vehicle, use oil pressure gauge (special tool (a)) with special tool (b) instead of the steel adaptor supp...

Page 383

6a2-8 engine mechanical (h25 engine) clean blow off dust by blowing compressed air from air outlet side of element (i.E., the side facing up when installed in air cleaner case). Installation 1) install element to air cleaner box. 2) install air cleaner upper case..

Page 385

6a2-10 engine mechanical (h25 engine) 3) drain coolant. 4) detach fuse/relay box. 5) remove strut tower bar. 6) disconnect coupler from intake air temp. Sensor. 7) remove surge tank cover (1). 8) remove air cleaner upper case, intake air hose, intake air pipe (1) and surge tank pipe (2) as one compo...

Page 387

6a2-12 engine mechanical (h25 engine) 21) remove throttle body (1) and intake collector (2) from intake manifold (3). 22) disconnect iac valve hose (1) and evap canister purge hose valve from intake collector. 23) remove throttle body (2) from intake collector. 24) remove iac valve, egr valve and ev...

Page 389

6a2-14 engine mechanical (h25 engine) 7) install egr pipe (3) with new gaskets. 8) connect evap canister purge valve hose (4) and heater hose (5). 9) connect pcv hose (6), breather hose (8) and water hose (7). 10) connect couplers of manifold absolute pressure (map) sen- sor, evap canister purge val...

Page 391

6a2-16 engine mechanical (h25 engine) exhaust manifold components removal 1) disconnect negative cable at battery. 2) remove air cleaner upper case and intake air hose. 3) detach couplers from their bracket and disconnect oxygen sensor lead wires at couplers. 4) remove oil level gauge guide (3). 5) ...

Page 393

6a2-18 engine mechanical (h25 engine) installation 1) install new manifold gaskets to cylinder heads and no.1 pipe gasket to exhaust no.1 pipe. 2) install exhaust manifolds. • always install new bolts with pre-coated adhesive to the locations with ★ mark. • tighten both manifold nuts and bolts to sp...

Page 395

6a2-20 engine mechanical (h25 engine) 10) connect negative cable to battery. 11) upon completion of installation, start engine and check that no exhaust gas leakage exists. Cylinder head covers components removal 1) remove throttle body and intake manifold. Refer to “throttle body and intake manifol...

Page 397

6a2-22 engine mechanical (h25 engine) oil pan and oil pump strainer components removal 1) remove oil level gauge guide. 2) raise vehicle and remove both front wheels. 3) remove rack and pinion assembly. Refer to “power steering gear box assembly” in section 3b1 for removal. 4) remove front different...

Page 399

6a2-24 engine mechanical (h25 engine) 3) apply sealant “a” to upper oil pan (1) sealing surface area as shown in figure. “a” : sealant 99000-31250 sealant amount width “a” : 3 mm (0.12 in.) height “b” : 2 mm (0.08 in.) 4) place the upper oil pan (1) on the cross member and sus- pension member (just ...

Page 401

6a2-26 engine mechanical (h25 engine) timing chain cover components removal 1) disconnect negative cable at battery. 2) drain engine oil. 3) drain coolant. 4) remove throttle body and intake manifold. Refer to item “throttle body and intake manifold” in this sec- tion for removal. 5) remove cylinder...

Page 403

6a2-28 engine mechanical (h25 engine) installation reverse removal sequence to install timing chain cover noting the following points. • using special tool (bearing installer), install new oil seal, its surface is flash with edge of timing chain cover. Special tool (d) : 09913-75510 • apply sealant ...

Page 405

6a2-30 engine mechanical (h25 engine) oil pump components removal 1) disconnect negative cable at battery. 2) drain engine oil. 3) drain coolant. 4) remove oil pan, oil pump strainer and timing chain cover. Refer to “timing chain cover” in this section. 1. Oil pump chain 5. Oil pump no.1 case 9. Cas...

Page 407

6a2-32 engine mechanical (h25 engine) inspection • check outer rotor, inner rotor and oil pump cases for exces- sive wear or damage. • check relief valve for excessive wear or damage. • measure free length and tension of oil relief spring (1). Oil pump relief spring length standard : 63.5 mm (2.5 in...

Page 409

6a2-34 engine mechanical (h25 engine) lh (no.1) bank 2nd timing chain and chain tensioner components removal 1) disconnect negative cable at battery. 2) drain engine oil. 3) drain coolant. 4) remove timing chain cover. Refer to “timing chain cover” in this section for removal. 1. Lh bank 2nd timing ...

Page 411

6a2-36 engine mechanical (h25 engine) 9) remove lh bank intake camshaft sprocket. 10) remove lh bank 2nd timing chain. Inspection timing chain guide no.4 and no.5 check shoe (3) for wear or damage. Camshaft sprocket check teeth of sprocket (1) for wear or damage. Timing chain check timing chain (1) ...

Page 413

6a2-38 engine mechanical (h25 engine) 4) check that knock-pins of intake and exhaust camshafts are aligned with match marks on cylinder head as shown in fig- ure. 5) install lh bank 2nd timing chain by aligning yellow plate (1) of chain with arrow mark (2) on idler sprocket no.2. 6) install sprocket...

Page 415

6a2-40 engine mechanical (h25 engine) 12) apply oil to timing chains, tensioner adjusters, sprockets and guides. 13) install timing chain cover, oil pan, front differential housing, p/s system, cooling system, intake manifold with throttle body and other parts. 14) refill cooling system, p/s system,...

Page 417

6a2-42 engine mechanical (h25 engine) inspection timing chain guides no.1 and no.2 check shoe for wear or damage. Timing chain tensioner check shoe (1) for wear or damage. 1st timing chain crankshaft sprocket check teeth of sprocket (1) for wear or damage. Rh bank 1st timing chain intake camshaft sp...

Page 419

6a2-44 engine mechanical (h25 engine) installation 1) check timing mark on crankshaft as shown in figure. 2) install 1st timing chain crankshaft sprocket (2) to crankshaft (1) as shown in figure. Confirm that tooth for ckp sensor are free from metal parti- cles and damage. 3) check timing mark on rh...

Page 421

6a2-46 engine mechanical (h25 engine) 12) install idler sprocket no.1 (1). Tightening torque idler sprocket no.1 bolt (c) : 45 n·m (4.5 kg-m, 32.5 lb-ft) 13) with latch (2) of tensioner adjuster no.1 (4) returned and plunger (1) pushed back into body, insert stopper (3) into latch and body. After in...

Page 423

6a2-48 engine mechanical (h25 engine) rh (no.2) bank 2nd timing chain and chain tensioner components 1. Rh bank 2nd timing chain 6. Rh bank intake camshaft 11. Timing chain guide no.3 bolt 2. Timing chain tensioner adjuster no.2 7. Rh bank exhaust camshaft housing 12. Timing chain tensioner adjuster...

Page 425

6a2-50 engine mechanical (h25 engine) inspection timing chain guide no.3 check shoe (1) for wear or damage. Rh bank 2nd timing chain sprockets check teeth of sprocket for wear or damage. Rh bank 2nd timing chain check timing chain (1) for wear or damage. Timing chain tensioner adjuster no.2 • check ...

Page 427

6a2-52 engine mechanical (h25 engine) 7) check position of camshaft housings. Embossed marks are provided on each camshaft housing, indicating position and direction for installation. Install hous- ings as indicated by these marks. 8) after applying oil to housing bolts, tighten them temporarily fir...

Page 429

6a2-54 engine mechanical (h25 engine) 7) put match marks (3) to oil pump chain (1) and oil pump sprocket (2). 8) remove oil pump chain guide. 9) remove oil pump chain. 10) remove oil pump drive sprocket. Inspection oil pump chain guide check shoe (1) for wear or damage. Oil pump drive sprocket check...

Page 431

6a2-56 engine mechanical (h25 engine) 5) install 1st timing chain. Refer to “1st timing chain and chain tensioner” in this sec- tion for installation. 6) install lh bank 2nd timing chain. Refer to “lh (no.1) bank 2nd timing chain and chain ten- sioner” in this section for installation. 7) install ti...

Page 433

6a2-58 engine mechanical (h25 engine) removal 1) disconnect negative cable at battery. 2) drain engine oil. 3) drain coolant. 4) remove timing chain cover. Refer to “timing chain cover” in this section for removal. 5) remove lh bank 2nd timing chain. Refer to “lh (no.1) bank 2nd timing chain and cha...

Page 435

6a2-60 engine mechanical (h25 engine) check clearance by using gaging plastic. The procedure is as fol- lows. 1) clean housings and camshaft journals. 2) make sure that all valve lash adjusters are removed and install camshaft to cylinder head. 3) place a piece of gaging plastic the full width of jo...

Page 437

6a2-62 engine mechanical (h25 engine) installation 1) before installing valve lash adjuster to cylinder head (1), fill oil passage of cylinder head with engine oil according to fol- lowing procedure. Pour engine oil through oil holes (2) and check that oil comes out from oil holes in sliding part of...

Page 439

6a2-64 engine mechanical (h25 engine) 9) after applying oil to housing bolts, tighten them temporarily first. Then tighten them by following sequence as indicated in figure. Tighten a little at a time and evenly among bolts and repeat tightening sequence two or three times before they are tightened ...

Page 441

6a2-66 engine mechanical (h25 engine) valves and cylinder heads components 1. Cylinder block 6. Exhaust valve 11. Valve stem oil seal 16. Cylinder head bolt (hex hole bolt) 2. Rh bank cylinder head 7. Intake valve 12. Valve spring retainer tightening torque 3. Lh bank cylinder head 8. Valve spring s...

Page 443

6a2-68 engine mechanical (h25 engine) disassembly 1) using special tools (a), (b) & (c), compress valve springs and then remove valve cotters (1) by using special tool (d). Special tool (a) : 09916-14510 (b) : 09916-14910 (c) : 09919-28610 (d) : 09916-84511 2) release special tool, and remove spring...

Page 445

6a2-70 engine mechanical (h25 engine) • inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be resurfaced, but not too much to grind off its chamber. When it is worn out too much that its chamber is gone, replace valve. • check each valve for radia...

Page 447

6a2-72 engine mechanical (h25 engine) • check cylinder head for cracks on intake and exhaust ports, combustion chambers, and head surface. Using straightedge and thickness gauge, check flatness of gasketed surface at a total of 6 locations. If distortion limit, given below, is exceeded, correct gask...

Page 449

6a2-74 engine mechanical (h25 engine) assembly 1) before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) so as to remove burrs and make it truly round. Special tool (e) : 09916-34542 (f) : 09916-38210 2) install valve guide to cylinder head. Heat cylinder ...

Page 451

6a2-76 engine mechanical (h25 engine) installation 1) clean mating surface on cylinder head and cylinder block. Remove oil, old gasket and dust from mating surface. 2) install knock pin (4) to cylinder block. 3) apply sealant “a” to cylinder head gasket (1) as shown in fig- ure. “a” : sealant 99000-...

Page 453

6a2-78 engine mechanical (h25 engine) 21) refill engine with engine oil, referring to “engine oil and fil- ter change” in section 0b. 22) refill cooling system referring to “cooling system flush and refill” in section 6b. 23) refill front differential housing with gear oil if drained, refer- ring to...

Page 455

6a2-80 engine mechanical (h25 engine) 5) remove oil pump. Refer to “oil pump” in this section for removal. 6) mark cylinder number on all pistons, connecting rods and connecting rod caps. 7) remove rod bearing caps. 8) install guide hose (1) over threads of rod bolts. This prevents damage to bearing...

Page 457

6a2-82 engine mechanical (h25 engine) • piston clearance : measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, rebore cylinder and use oversize piston. Pi...

Page 459

6a2-84 engine mechanical (h25 engine) crank pin and connecting rod bearings • crank pin diameter : inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is damaged, or out-of-round or taper is out of limit, replace crankshaft or regr...

Page 461

6a2-86 engine mechanical (h25 engine) 1) check stamped numbers on connecting rod and its cap as shown. Three kinds of numbers (“1”, “2” and “3”) represent the fol- lowing connecting rod big end inside diameters. For example, stamped number “1” indicates that correspond- ing connecting rod big end in...

Page 463

6a2-88 engine mechanical (h25 engine) assembly a) each piston has stamped number (1 or 2) on its piston head. It represents outer diameter of piston. B) there are also stamped numbers of 1 and 2 on the cylinder block as shown. C) stamped number on piston and cylinder block must corre- spond. That is...

Page 465

6a2-90 engine mechanical (h25 engine) 2) install guide hoses over connecting rod bolts. These guide hoses protect crank pin and threads of rod bolt from damage during installation of connecting rod and piston assembly. 3) when installing piston and connecting rod assembly into cyl- inder bore, point...

Page 467: Unit Repair Overhaul

6a2-92 engine mechanical (h25 engine) unit repair overhaul engine assembly removal 1) release fuel pressure in fuel feed line. Refer to “fuel pressure relief procedure” in section 6-1. 2) disconnect negative cable at battery. 3) remove engine hood. 4) drain engine oil. 5) drain coolant. 6) remove ra...

Page 469

6a2-94 engine mechanical (h25 engine) 23) remove exhaust no.1 pipe. Refer to “exhaust manifold” in this section for removal. 24) remove exhaust manifold stiffener from transmission. 25) remove a/t fluid hose clamps (1) from engine mounting bracket (2). (for a/t vehicle) 26) remove clutch housing low...

Page 471

6a2-96 engine mechanical (h25 engine) 6) tighten bolts and nuts of exhaust no.1 pipe (1) to specified torque. Tightening torque exhaust no.1 pipe bolt and nut (d) : 50 n·m (5.0 kg-m, 36.5 lb-ft) 7) install front differential housing with differential to chassis if removed. Refer to “remounting” in s...

Page 473

6a2-98 engine mechanical (h25 engine) removal 1) remove engine assembly from vehicle referring to “engine assembly” in this section. 2) remove clutch and flywheel (for m/t vehicle) or drive plate (for a/t vehicle). For clutch removal, refer to “clutch cover, clutch disc and flywheel” in section 7c1....

Page 475

6a2-100 engine mechanical (h25 engine) out-of-round and taper (uneven wear) of journals an unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length (or both). This dif- ference, if any, is determined by taking micrometer readings. If any one of jou...

Page 477

6a2-102 engine mechanical (h25 engine) 5) remove crankcase and using scale (2) on gaging plastic (1) envelop, measure gaging plastic width at its widest point. If clearance exceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit. A new standard bearing may produce p...

Page 479

6a2-104 engine mechanical (h25 engine) 4) from number stamped on crank webs at its center and alphabets stamped on crankcase lower side, determine new standard bearing to be installed to journal, by referring to table shown below. For example, if number stamped on crank webs is “1” and alphabet stam...

Page 481

6a2-106 engine mechanical (h25 engine) cylinder block distortion of gasketed surface • using straightedge and thickness gauge, check gasketed surface for distortion and, if flatness exceeds its limit, correct it. Flatness limit of cylinder block 0.06 mm (0.0024 in.) honing or reboring cylinders 1) w...

Page 483

6a2-108 engine mechanical (h25 engine) 6) install crankcase (1) to cylinder block. Apply oil to crankcase bolts before installing them. Tighten crankcase bolts gradu- ally as follows. A) tighten all bolts to 42 n·m (4.2 kg-m, 30.5 lb-ft) according to numerical order in figure. B) loosen all bolts un...

Page 485: Special Tool

6a2-110 engine mechanical (h25 engine) special tool 09911-97811 09913-75510 09915-47311 09915-64512 oil seal installer bearing installer oil filter wrench compression gauge 09915-64530 09915-67010 09915-67311 09915-77311 compression gauge hose compression gauge attachment (c) vacuum gauge oil pressu...

Page 487: Required Service Material

6a2-112 engine mechanical (h25 engine) required service material material recommended suzuki product (part number) use sealant suzuki bond no. 1207f 99000-31250 • to apply to mating surfaces of cylin- der block and oil pan. • to apply to mating surfaces of cylin- der block and timing chain cover. • ...

Page 489

6a2-114 engine mechanical (h25 engine).

Page 491: General Description

6a4-2 engine mechanical (j20 engine) general description engine the engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its dohc (double overhead camshaft) valve mechanism arranged for “v” type valve configuration and 16 valves (4 valves/one cylinder). The double overhead ...

Page 493: On-Vehicle Service

6a4-4 engine mechanical (j20 engine) on-vehicle service compression check check compression pressure on all 4 cylinders as follows : 1) warm up engine. 2) stop engine after warming up. 3) disconnect accelerator cable (3) from clamp (4) (for lh steering vehicle only). 4) disconnect ignition coil coup...

Page 495

6a4-6 engine mechanical (j20 engine) engine vacuum check the engine vacuum that develops in the intake line is a good indi- cator of the condition of the engine. The vacuum checking proce- dure is as follows : 1) warm up engine to normal operating temperature and make sure that engine idle speed is ...

Page 497

6a4-8 engine mechanical (j20 engine) 3) start engine and warm it up to normal operating tempera- ture. 4) after warming up, raise engine speed to 4,000 r/min and measure oil pressure. Oil pressure specification 390 – 470 kpa (3.9 – 4.7 kg/cm 2 , 55.5 – 66.8 psi) at 4,000 r/min (rpm) 5) after checkin...

Page 499

6a4-10 engine mechanical (j20 engine) 3) drain coolant. 4) remove air cleaner outlet hose. 5) disconnect the following electric lead wires : • egr valve coupler • iac valve coupler • tp sensor coupler • evap canister purge valve coupler • ground terminal from intake manifold • map sensor 6) disconne...

Page 501