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Suzuki Swift User Manual

Other manuals for Swift: Owner's Manual, Owner's Manual
Manual is about: Swift Suzuki

Summary of Swift

  • Page 1

    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. Note: indicates special information t...

  • Page 2: Foreword

    () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x foreword this supplementary service manual is a supplement to sf series service manu- als mentioned in next page and has been prepared exclusively for the following applicable mod- el. Applicable model: sf310/s...

  • 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 ...

  • Page 4

    6 6 6-1 6a 6a1 6b 6c 6e1 6e1 6e2 6f 6f 6f1 6g 6h 6k general information general information maintenance and lubrication 1a 1b table of contents section 0a 0b 7b 8 8a 8g heating and air conditioning heater and ventilation air conditioning (oprional) engine general information and diagnosis (tbi for g...

  • Page 5: Section 0A

    General information 0a-1 0a section 0a general information contents how to use this manual 0a- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions 0a- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 6: How To Use This Manual

    1. Flywheel bolts or drive plate bolts for a / t vehicle 6) install oil pump. Refer to “oil pump”. 7) install flywheel (for m / t vehicle) or drive plate (for a / t vehicle). Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts to specified torque. Special tool...

  • Page 7: Precautions

    1. Air bag wire harness 2. Driver air bag (inflator) module 3. Passenger air bag (inflator) module 4. Sdm general information 0a-3 precautions precaution for vehicles equipped with a supplemental restraint (air bag) system warning: d the configuration of air bag system parts are as shown in the figu...

  • Page 8

    1. Slit on workbench 2. Workbench vise 3. Lower mounting bracket always carry air bag (inflator) module with trim cover (air bag opening) away from body. Always place air bag (inflator) module on workbench with trim cover (air bag opening) up, away from loose objects. 0a-4 general information handli...

  • 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...

  • Page 10

    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 ea...

  • 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 reus...

  • 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 vehi...

  • Page 13

    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- burne...

  • 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)....

  • 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 wh...

  • Page 16

    1. Check for loose connection sensor ecm 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 m...

  • Page 17

    1. Looseness of crimping 2. Open 3. Thin wire (single strand of wire) check contact tension by inserting and removing just for once 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 term...

  • Page 18

    1. Other parts 1. To other parts 2 v voltage drop 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 bod...

  • Page 19

    1. Check contact tension by inserting and removing just once 2. Check each terminal for bend and proper alignment 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 occasional...

  • Page 20

    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 contr...

  • Page 21

    1. Transfer lock bolt 2. Shift fork shaft testing following items d speedometer d chassis dynamo d brake d wheel balance (on car type) towing vehicle with front or rear wheels lifted up driving front wheels which are jacked up 4wd 2wd general information 0a-17 precaution in servicing full-time 4wd v...

  • Page 22: Identification Information

    M / t a / t g10 g13 [a] [a] [b] [b] 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...

  • Page 23

    Note: air bag caution / warning labels are attached on the vehicle equipped with air bag system only. Air bag caution label tire information placard child lock caution label fuel limitation emission control information label (if equipped) a / c warning label (if equipped with a / c) engine cooling f...

  • Page 24: Vehicle Lifting Points

    1. Front left tire 2. Rear left tire 3. Front 4. Front fender left panel 5. Rear left panel 6. Embossed-mark when using frame contact hoist: front support location rear support location 110 mm (4.3 in.) support location forward of embossed-mark 120 mm (4.7 in.) support location rearward of embossed-...

  • Page 25

    When using floor jack: general information 0a-21 in raising front or rear vehicle end off the floor by jacking, be sure 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 vehi...

  • Page 26

    0a-22 general information a abs : anti-lock brake system atdc : after top dead center api : american petroleum institute atf : automatic transmission fluid alr : automatic locking retractor ac : alternating current a / t : automatic transmission a / c : air conditioning abdc : after bottom dead cent...

  • Page 27

    General information 0a-23 l lh : left hand lspv : load sensing proportioning valve m maf sensor : mass air flow sensor (air flow sensor, afs, air flow meter, afm) map sensor : manifold absolute pressure sensor (pressure sensor, ps) max : maximum mfi : multiport fuel injection (multipoint fuel inject...

  • Page 28

    G (base color) g (base color) y (stripe color) 0a-24 general information symbols symbol definition symbol definition tightening torque apply suzuki bond no. 1216 99000-31160 apply oil (engine, transmission, transfer, differential) apply silicone sealant 99000-31120 apply fluid (brake, power steering...

  • Page 29: Fasteners Information

    General information 0a-25 metric bolts-identification class numbers or marks correspond to bolt strength-increasing numbers represent increasing strength. Nut strength identification fasteners information metric fasteners most of the fasteners used for this vehicle are metric fasteners. When replaci...

  • Page 30

    0a-26 general information self-lock nut 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. W...

  • Page 31: Section 0B

    0b maintenance and lubrication 0b-1 section 0b maintenance and lubrication warning: for vehicles equipped with supplemental restraint (air bag) system: 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 co...

  • Page 32: Maintenance Schedule

    0b-2 maintenance and lubrication maintenance schedule normal condition schedule interval: this interval should be judged by 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 the same intervals respectivel...

  • Page 33

    Maintenance and lubrication 0b-3 interval: this interval should be judged by 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 the same intervals respectively. This interval should be judged by odometer r...

  • 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 give...

  • Page 35: Maintenance Service

    Vehicle with a/c vehicle with a/c and power steering vehicle with power steering 1. A/c compressor pulley 2. Power steering pump pulley 3. Tension pulley 4. Crankshaft pulley maintenance and lubrication 0b-5 maintenance service engine item 1-1 drive belt inspection and replacement warning: disconnec...

  • Page 36

    1. Thickness gauge in ex 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 re...

  • Page 37

    Maintenance and lubrication 0b-7 proper engine oil viscosity chart 1. Oil pan 2. Oil drain plug 1. Oil filter item 1-4 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. Us...

  • Page 38

    1. Full level mark (hole) 2. Low level mark (hole) oil pan capacity oil filter capacity others total 1.0 l and 1.3 l engine about 3.1 liters (6.5 / 5.5 us / lmp pt.) about 0.2 liter (0.4 / 0.3 us / lmp pt.) about 0.3 liter (0.6 / 0.5 us / lmp pt.) about 3.6 liters (7.5 / 6.3 us / lmp pt.) 0b-8 maint...

  • Page 39

    For a / t for m / t 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 radiat...

  • Page 40

    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...

  • Page 41

    1.0 liter engine 1.3 liter engine maintenance and lubrication 0b-11 2) visually check that air cleaner filter is not excessively dirty, dam- 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 insta...

  • Page 42

    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 c...

  • 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 the...

  • Page 44

    “a”: parking brake lever stroke: 4 – 9 notches (with 20 kg or 44 lbs of pull pressure) 1. Wear indicator 1. Clutch pedal “a”: free travel 0b-14 maintenance and lubrication item 5-4 brake lever and cable inspection parking brake lever d check tooth tip of each notch for damage or wear. If any damage ...

  • Page 45

    1. Drive shaft 2. Boot 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 f...

  • Page 46

    1. Ball joint stud dust seal (boot) 2. Suspension arm 1. Tie-rod end boot 2. Steering gear case boot 3. Universal joint 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. Repa...

  • Page 47

    2wd 4wd 1. Oil filler / level plug 2. Oil drain plug 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 chec...

  • Page 48

    1. Oil level gauge 2. Full hot mark 3. Low hot mark 4. Full cold mark 5. Low cold mark 1. Drain plug 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 ve...

  • Page 49

    “a”: oil point 1. Upper hinge 2. Lower hinge 3. Door 4. Body 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 ...

  • Page 50

    0b-20 maintenance and lubrication final inspection seats check that seat slides smoothly and locks securely at any position. Also check that reclining mechanism of front seat back allows it to be locked at any angle. Seat belt inspect belt system including webbing, buckles, latch plates, retractors ...

  • Page 51

    Maintenance and lubrication 0b-21 [parking brake] check that lever has proper travel. Check to ensure that parking brake is fully effective when the vehicle is stopped on the safe slope and brake lever is pulled all the way. Steering d check to ensure that steering wheel is free from in- stability, ...

  • Page 52: Section 6

    6 engine general information and diagnosis (tbi for g10) 6-1 general information 6- 3 . . . . . . . . . . . . . . Statement on cleanliness and care 6- 3 . . . . . General information on engine service 6- 3 . . Precaution on fuel system service 6- 4 . . . . . Fuel pressure relief procedure 6- 5 . . ....

  • Page 53

    Diagnostic trouble code clearance 6-14 . . . . . Diagnostic trouble code table 6-15 . . . . . . . . . Fail-safe table 6-18 . . . . . . . . . . . . . . . . . . . . . . . Visual inspection 6-19 . . . . . . . . . . . . . . . . . . . . . Engine basic inspection 6-20 . . . . . . . . . . . . . . . Engine ...

  • Page 54: General Information

    1. No.1 cylinder 2. No.2 cylinder 3. No.3 cylinder 1 2 3 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 t...

  • Page 55

    Hose connection clamp securely at a position 3 to 7mm (0.12–0.27 in.) from hose end. With short pipe, fit hose as far as it reaches pipe joint as shown. Hose pipe clamp clamps securely at a position 3 to 7 mm (0.12–0.27 in.) from hose end. With following type pipe, fit hose as far as its peripheral ...

  • 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. 1) place transmission gear...

  • Page 57: Engine Diagnosis

    6-6 engine general information and diagnosis (tbi for g10) 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 58

    An example of freeze frame data 1. Trouble code p0102 (1st) 2. Engine speed 782 rpm 3. Eng cool tmp. 80 _c 4. Vehicle spd. 0 km/h 5. Map sensor 39 kpa 6. St. Term ft1 – 0.8% lean 7. Lg. Term ft1 – 1.6% lean 8. Fuel 1 stat. Closed loop 9. Fuel 2 stat. Not used 10. Load value 25.5% 1st, 2nd or 3rd in ...

  • Page 59

    Body ground ecm (pcm) ground serial data line (k line of iso 9141) suzuki serial data line 6-8 engine general information and diagnosis (tbi for g10) in the 2nd through the 4th frames, the freeze frame data of each malfunction is stored in the order as the malfunction is detected. These data are not...

  • Page 60

    Engine general information and diagnosis (tbi for g10) 6-9 precaution in diagnosing trouble d don’t disconnect couplers from ecm (pcm), battery cable from battery, ecm (pcm) ground wire harness from engine or main fuse before confirming diagnostic information (dtc, freeze frame data, etc.) stored in...

  • 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 yes no 1 customer complaint analysis 1) perform customer complaint analysis referring to the next page. Was customer complaint analysis perf...

  • 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 require...

  • 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 no cranking j no initial combustion j no combustion j poor starting at ( jcold jwar...

  • Page 64

    Engine general information and diagnosis (tbi for g10) 6-13 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 mil dims), go to “diagnostic flow table a-1” for troubleshooting. 2) start engine and check t...

  • 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. 2) turn ignition switch on. 3) erase dtc and pending...

  • Page 66

    Engine general information and diagnosis (tbi for g10) 6-15 diagnostic trouble code (dtc) table dtc no. Detecting item detecting condition (dtc will set when detecting:) mil p0105 manifold absolute pressure circuit malfunction low pressure-high vacuum-low voltage (or map sensor circuit shorted to gr...

  • Page 67

    6-16 engine general information and diagnosis (tbi for g10) dtc no. Detecting item detecting condition (dtc will set when detecting:) mil p0335 crankshaft position sensor circuit malfunction no signal during engine running 1 driving cycle p0340 camshaft position sensor circuit malfunction no signal ...

  • Page 68

    Engine general information and diagnosis (tbi for g10) 6-17 dtc no. Detecting item detecting condition (dtc will set when detecting:) mil p0705 transmission range sensor (switch) circuit malfunction (a / t) no signal or multiple signals inputted with shifted in “d” range 1 driving cycle p0720 output...

  • 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. Detected item fail-s...

  • Page 70

    Engine general information and diagnosis (tbi for g10) 6-19 operation visual inspection visually check following parts and systems. Inspection item referring section d engine oil – – – – – level, leakage d engine coolant – – – – – level, leakage d fuel – – – – – level, leakage d a/t fluid – – – – – ...

  • Page 71

    6-20 engine general information and diagnosis (tbi for g10) engine basic inspection 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 72

    Select “data list” mode select menu f4: misc test 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 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...

  • Page 74

    Engine general information and diagnosis (tbi for g10) 6-23 condition possible cause referring item low oil pressure d improper oil viscosity d malfunctioning oil pressure switch d clogged oil strainer d functional deterioration of oil pump d worn oil pump relief valve d excessive clearance in vario...

  • Page 75

    6-24 engine general information and diagnosis (tbi for g10) condition possible cause referring item overheating d inoperative thermostat d poor water pump performance d clogged or leaky radiator d improper engine oil grade d clogged oil filter or oil strainer d poor oil pump performance d faulty rad...

  • Page 76

    Engine general information and diagnosis (tbi for g10) 6-25 condition possible cause referring item engine hesitates (momentary lack of response as accelerator is depressed. Can occur at all vehicle speeds. Usually most severe when first trying to make vehicle move, as from a stop sign.) ignition sy...

  • Page 77

    6-26 engine general information and diagnosis (tbi for g10) condition possible cause referring item engine has no power ignition system out of order d faulty spark plug d faulty ignition coil with ignitor d leaks, loose connection or disconnection of high-tension cord engine overheating fuel system ...

  • Page 78

    Engine general information and diagnosis (tbi for g10) 6-27 condition possible cause referring item improper engine idling or engine fails to idle ignition system out of order d faulty spark plug d leaky or disconnected high-tension cord d faulty ignition coil with ignitor fuel system out of order d...

  • Page 79

    6-28 engine general information and diagnosis (tbi for g10) condition possible cause referring item excessive hydrocarbon (hc) emission or carbon monoxide (co) ignition system out of order d faulty spark plug d leaky or disconnected high-tension cord d faulty ignition coil with ignitor low compressi...

  • Page 80

    Engine general information and diagnosis (tbi for g10) 6-29 ambient temp. 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 g...

  • Page 81

    6-30 engine general information and diagnosis (tbi for g10) scan tool data condition normal condition / reference values desired idle at idling with no load after warming up, m / t 850 r / min (desired idle speed) g g , at neutral, a / t at “p” range 850 r / min tp sensor volt (throttle position ign...

  • Page 82

    Engine general information and diagnosis (tbi for g10) 6-31 scan tool data condition normal condition / reference values vss (for 4-a / t) (vehicle speed sensor) at stop. 0 km / h 0 mph shift sol1 con (command signal) mon (monitor signal) ignition switch on, selector lever is shifted at p, r or n ra...

  • Page 83

    6-32 engine general information and diagnosis (tbi for g10) scan tool data definitions fuel system (fuel system status) air / fuel ratio feedback loop status displayed as either open or closed loop. Open indicates that ecm (pcm) ignores feedback from the exhaust oxygen sensor. Closed indicates final...

  • Page 84

    Engine general information and diagnosis (tbi for g10) 6-33 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 ...

  • Page 85

    6-34 engine general information and diagnosis (tbi for g10) 1. Ecm (pcm) 2. Ecm (pcm) couplers (viewed from harness side) 1. Ecm (pcm) 2. Couplers 3. Body ground 4. Service wire 16 c03 c02 c01 1 2 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 12 13 14 15 16 17 18 19 20 21 22 ...

  • Page 86

    Engine general information and diagnosis (tbi for g10) 6-35 connect or “c02 ” ter- minal wire color circuit standard voltage condition 1 b ecm (pcm) ground – – 2 w / bl power source 10 – 14 v ignition switch on 3 — blank — — 4 — blank — — 5 — blank — — 6 — blank — — 7 r / g evap canister purge valve...

  • Page 87

    6-36 engine general information and diagnosis (tbi for g10) connect or “c01 ” ter- minal wire color circuit standard voltage condition 1 lg power source for sensor 4.75 – 5.25 v ignition switch on 2 or camshaft position sensor (+) — — 3 w / b crankshaft position sensor (+) — — 4 gr / g closed thrott...

  • Page 88

    Engine general information and diagnosis (tbi for g10) 6-37 connect or “c03 ” ter- minal wire color circuit standard voltage condition 1 v / w data link connector (suzuki serial data line) 4 – 6 v ignition switch on bl vehicle speed sensor (+) (a / t) 0.4 – 0.8 v ignition switch on 2 y / g vehicle s...

  • Page 89

    6-38 engine general information and diagnosis (tbi for g10) 1 2 1. Ecm (pcm) coupler disconnected 2. Ohmmeter 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 resis...

  • Page 90

    Engine general information and diagnosis (tbi for g10) 6-39 information sensors - 1. Map sensor - 2. Tp sensor - 3. Iat sensor - 4. Ect sensor - 5. Heated oxygen sensor-1 - 6. Vss - 7. Ignition coil - 8. Battery - 9. Cmp sensor (in distributor) - 10. A/c contoller (if equipped) - 11. Ckp sensor - 12...

  • Page 91

    6-40 engine general information and diagnosis (tbi for g10) “ig coil meter” main relay ignition switch in fuse malfunction indicator lamp in combination meter table a-1 malfunction indicator lamp circuit check – lamp does not come “on” at ignition switch on (but engine at stop) circuit description w...

  • 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 yes no 1 diagnostic trouble code (dtc) check 1) check dtc referring...

  • Page 93

    Main fuse ignition switch main fuse malfunction indicator lamp in combination meter relay box “ig coil meter” 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...

  • Page 94

    Engine general information and diagnosis (tbi for g10) 6-43 fig. 1 for step 2 fig. 2 for step 2 fig. 3 for step 2 1. Main relay 2. Relay box step action yes no 5 ecm (pcm) power circuit check 1) using service wire, ground terminal c02-22 and measure voltage between terminal c02-2 and ground at ignit...

  • Page 95

    Map sensor to tp sensor to other sensors 6-44 engine general information and diagnosis (tbi for g10) dtc p0105 manifold absolute pressure (map) circuit malfunction circuit description dtc detecting condition possible cause d map: 5 kpa, 37.5 mmhg or less (low pressure – high vacuums – low voltage) o...

  • Page 96

    Engine general information and diagnosis (tbi for g10) 6-45 fig. 1 for step 2 fig. 2 for step 3 scan tool dlc inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check map sensor and its circuit. 1) connect scan tool to dlc with i...

  • Page 97

    To other sensors iat sensor 6-46 engine general information and diagnosis (tbi for g10) dtc p0110 intake air temp. (iat) circuit malfunction circuit description dtc detecting condition possible cause d low intake air temperature (high voltage-high resistance) or d high intake air temperature (low vo...

  • Page 98

    Engine general information and diagnosis (tbi for g10) 6-47 fig. 1 for step 2 fig. 2 for step 3 fig. 3 for step 4 scan tool dlc inspection 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 ...

  • Page 99

    Ect sensor to combination (ect) meter to other sensors 6-48 engine general information and diagnosis (tbi for g10) dtc p0115 engine coolant temperature (ect) circuit malfunction circuit description dtc detecting condition possible cause d low engine coolant temperature (high voltage-high resistance)...

  • Page 100

    Engine general information and diagnosis (tbi for g10) 6-49 fig. 1 for step 2 fig. 2 for step 3 fig. 3 for step 4 scan tool dlc inspection 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 ...

  • Page 101

    To other sensors throttle position sensor to other sensors 6-50 engine general information and diagnosis (tbi for g10) dtc p0120 throttle position circuit malfunction circuit description dtc detecting condition possible cause d signal voltage high or d signal voltage low d “g” circuit open d “lg/w” ...

  • Page 102

    Engine general information and diagnosis (tbi for g10) 6-51 fig. 1 for step 2 fig. 2 for step 3 fig. 3 for step 4 scan tool “lg” “lg/w” “3” “4” “1” inspection 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 circui...

  • Page 103

    To other sensors throttle position sensor to other sensors 6-52 engine general information and diagnosis (tbi for g10) dtc p0121 throttle position circuit range/performance problem circuit description dtc detecting condition possible cause d after engine warmed up. D while vehicle running at specifi...

  • Page 104

    Engine general information and diagnosis (tbi for g10) 6-53 fig. 1 for step 2 fig. 2 for step 2 fig. 3 for step 3 closed (condition “a”) fully open throttle opening condition “a” clearance between throttle lever and throttle stop screw is less than 0.35 mm (0.014 in.). Clearance “1” “3” “4” inspecti...

  • Page 105

    To generator to other sensor main fuse ignition switch heater 6-54 engine general information and diagnosis (tbi for g10) dtc p0130 heated oxygen sensor (ho2s) circuit malfunction (sensor-1) circuit description dtc detecting condition possible cause d when running at idle speed after engine warmed u...

  • Page 106

    Engine general information and diagnosis (tbi for g10) 6-55 fig. 1 for step 3 fig. 2 for step 3 normal fig. 1 ho2s-1 output voltage 1 cycle time response time inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 is there dtc(s) oth...

  • Page 107

    6-56 engine general information and diagnosis (tbi for g10) dtc confirmation procedure – refer to dtc p0130 section. Inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 is there dtc(s) other than ho2s-1 (dtc p0133)? Go to applicab...

  • Page 108

    To generator to other sensor heater ignition switch main fuse “ig coil meter” engine general information and diagnosis (tbi for g10) 6-57 dtc p0135 heated oxygen sensor (ho2s) heater circuit malfunction (sensor-1) circuit description dtc detecting condition possible cause dtc will set when a or b co...

  • Page 109

    6-58 engine general information and diagnosis (tbi for g10) fig. 1 for step 2 fig. 2 for step 3 c01-8 inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check heater for operation. 1) check voltage at terminal c01-8. See fig. 1. ...

  • Page 110

    To other sensor heater ignition switch main fuse “ig coil meter” to ignition coil to other sensor engine general information and diagnosis (tbi for g10) 6-59 dtc p0136 heated oxygen sensor (ho2s) circuit malfunction (sensor-2) circuit description dtc detecting condition possible cause dtc will set w...

  • Page 111

    6-60 engine general information and diagnosis (tbi for g10) lusual driving: driving at 30 – 40 mph, 50 – 60 km/h including short stop according to traffic signal. (under driving condition other than high-load, high-engine speed, rapid accelerating and decelerating) 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11)...

  • Page 112

    Engine general information and diagnosis (tbi for g10) 6-61 inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check exhaust system for leakage, loose connection and damage. Is it good condition? Go to step 3. Repair or replace. ...

  • Page 113

    6-62 engine general information and diagnosis (tbi for g10) to other sensor heater ignition switch main fuse “ig coil meter” to ignition coil to other sensor dtc p0141 heated oxygen sensor (ho2s) heater circuit malfunction (sensor-2) circuit description dtc detecting condition possible cause dtc wil...

  • Page 114

    Engine general information and diagnosis (tbi for g10) 6-63 fig. 1 for step 2 inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check ho2s-2 heater and its circuit. 1) warm up engine to normal operating temperature. 2) stop engi...

  • Page 115

    6-64 engine general information and diagnosis (tbi for g10) sensed information exhaust gas fuel injector a / f mixture signal to decrease amount of fuel injection signal to increase amount of fuel injection high voltage low voltage injector heated oxygen sensor-1 a / f mixture becomes richer oxygen ...

  • 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 ca...

  • Page 117

    6-66 engine general information and diagnosis (tbi for g10) inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 is there dtc(s) other than fuel system (dtc p0171 / p0172)? Go to applicable dtc diag. Flow table. Go to step 3. 3 che...

  • Page 118

    Engine general information and diagnosis (tbi for g10) 6-67 fig. 1 for step 3 fig. 2 for step 4 fig. 3 for step 5 fig. 4 for step 6 1. Throttle body 2. Fuel feed hose good no good step action yes no 8 check engine coolant temp. Sensor for performance (see section 6e1). Is it in good condition? Go to...

  • Page 119

    Ignition coil igniter ignition switch main fuse injector resistor fuel injector crankshaft position sensor camshaft position sensor ground at engine “i / g coil meter” main relay 6-68 engine general information and diagnosis (tbi for g10) dtc p0300 random misfire detected (misfire detected at 2 or m...

  • Page 120

    Engine general information and diagnosis (tbi for g10) 6-69 below specified value dtc detecting condition possible cause d engine under other than high revolution condition d not on rough road d engine speed changing rate d manifold absolute pressure changing rate d throttle opening changing rate d ...

  • Page 121

    6-70 engine general information and diagnosis (tbi for g10) inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table“. 2 is there dtc other than fuel system (dtc p0171 / p0172) and misfire (dtc p0300-p0303)? Go to applicable dtc diag. Flow...

  • Page 122

    Engine general information and diagnosis (tbi for g10) 6-71 1. Throttle body 2. Fuel feed hose good no good 1. Injector connector step action yes no 6 check pcv valve for clogging (see section 6e1). Is it in good condition? Go to step 7. Replace pcv valve. 7 check evap canister purge valve for closi...

  • Page 123

    Oscilloscope waveforms crankshaft timing belt pulley ckp sensor 2v/div. 5ms/div. Waveforms at specified idle speed 6-72 engine general information and diagnosis (tbi for g10) dtc p0335 crankshaft position (ckp) sensor circuit malfunction circuit description dtc detecting condition possible cause d n...

  • Page 124

    Engine general information and diagnosis (tbi for g10) 6-73 inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check ckp sensor for resistance. 1) disconnect ckp sensor connector with ignition switch off. 2) then check for proper...

  • Page 125

    Display of fuel injection signal using oscilloscope 1. Cmp sensor signal 2. Fuel injector signal 3. Fuel injection time 2v/div. 20v/div. 1 2 10ms/div waveforms at specified idle speed 3 sensor rotor in distributor camshaft position sensor 6-74 engine general information and diagnosis (tbi for g10) d...

  • Page 126

    Engine general information and diagnosis (tbi for g10) 6-75 fig. 1 for step 3 fig. 2 for step 5 “a”: air gap inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 is dtc p1500 (engine starter signal circuit malfunction) detected? Go...

  • Page 127

    6-76 engine general information and diagnosis (tbi for g10) oscilloscope waveforms engine running at closed loop condition fuel cut idle after fuel cut 0.5 v / div 2 sec. / div heated oxygen sensor-1 warm up three way catalytic converter (if equipped) three way catalytic converter to other sensor to...

  • Page 128

    Engine general information and diagnosis (tbi for g10) 6-77 1) 2) 3) 4) 35 – 45 mph (55 – 65 km / h) 30 – 40 mph (50 – 60 km / h) 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 durin...

  • Page 129

    6-78 engine general information and diagnosis (tbi for g10) inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check short term fuel trim. Did short term fuel trim vary within – 20% – +20% range in step 3) of dtc confirmation tes...

  • Page 130

    Engine general information and diagnosis (tbi for g10) 6-79 main fuse main relay to other valves evap canister purge valve evap canister purge valve surge tank tank pressure control valve fuel vapor separator fuel filter cap fuel level sensor fuel tank evap canister dtc p0443 purge control valve cir...

  • Page 131

    6-80 engine general information and diagnosis (tbi for g10) fig. 1 for step 1 main fuse ignition switch “ig coil meter” radiator fan relay radiator fan motor dtc p0480 radiator fan control system malfunction circuit description dtc detecting condition possible cause d low voltage at terminal c02-20 ...

  • Page 132

    Engine general information and diagnosis (tbi for g10) 6-81 fig. 1 for step 2 fig. 2 for step 3 1. Radiator fan relay 2. Relay box inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check radiator cooling fan relay and its circui...

  • Page 133

    6-82 engine general information and diagnosis (tbi for g10) vehicle speed sensor in combination meter c03-2 c03-2 dtc p0500 vehicle speed sensor (vss) malfunction (m/t) circuit description dtc detecting condition possible cause d vss signal not inputted while vehicle running in “d” range or during f...

  • Page 134

    Engine general information and diagnosis (tbi for g10) 6-83 fig. 1 for step 3 fig. 2 for step 4 c03-2 inspection 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? Go to step 3. Speedometer cable dis...

  • Page 135

    6-84 engine general information and diagnosis (tbi for g10) vehicle speed sensor (on a / t) counter shaft gear pcm c03-2 c03-13 bl p c03-2 c03-13 dtc p0500 vehicle speed sensor (vss) malfunction for a/t vehicle (a/t) circuit description – refer to section 6e1 for vss operation. Dtc detecting conditi...

  • Page 136

    Engine general information and diagnosis (tbi for g10) 6-85 fig. 1 for step 2 fig. 2 for step 3 inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check vss for resistance. 1) disconnect vss connection with ignition switch off. 2...

  • Page 137

    Main fuse main relay idle speed control relay to tp sensor idle speed control actuator 6-86 engine general information and diagnosis (tbi for g10) dtc p0505 idle control system malfunction circuit description dtc detecting condition possible cause dtc will set when a, b or c condition is met. A: thr...

  • Page 138

    Engine general information and diagnosis (tbi for g10) 6-87 fig. 1 for step 3 fig. 2 for step 3 fig. 3 for step 3 1. Isca relay 2. Relay box dtc p0505 inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check idle control system. ...

  • Page 139

    6-88 engine general information and diagnosis (tbi for g10) fig. 1 for step 2 fig. 2 for step 3 lever is apart from plunger lever contacts with plunger condition “a”: throttle lever is in contact with isc actuator plunger condition “b”: throttle lever is apart from plunger dtc p0510 closed throttle ...

  • 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) when written into ecm (pcm) : 2 driving cycle detection logic, continuous monitoring. Ecm (pcm)...

  • Page 141

    Main fuse main relay efe heater efe heater relay 6-90 engine general information and diagnosis (tbi for g10) dtc p1250 early fuel evaporation (efe) heater circuit malfunction circuit description dtc detecting condition possible cause d voltage low at terminal c01-12 during engine warming up or d vol...

  • Page 142

    Engine general information and diagnosis (tbi for g10) 6-91 1. Relay box 2. “ptc” inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check efe heater and its circuit. Check for voltage at terminal c01-12 of ecm (pcm) connector co...

  • Page 143

    6-92 engine general information and diagnosis (tbi for g10) fig. 1 for step 1 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 conditio...

  • Page 144

    Main fuse m / t vehicle ignition switch (starter switch) starter a / t vehicle main fuse ignition switch (starter switch) transmission range sensor (switch) starter pcm engine general information and diagnosis (tbi for g10) 6-93 dtc p1500 engine starter signal circuit malfunction circuit description...

  • Page 145

    To dlc “dome” main fuse 6-94 engine general information and diagnosis (tbi for g10) dtc p1510 ecm (pcm) back-up power supply malfunction circuit description battery voltage is supplied so that diagnostic trouble code memory, values for engine control learned by ecm (pcm), etc. Are kept in ecm (pcm) ...

  • Page 146: Blank

    Engine general information and diagnosis (tbi for g10) 6-95 blank.

  • Page 147

    “ig coil meter” main fuse ignition switch main relay to other circuits injector resistor fuel injector 6-96 engine general information and diagnosis (tbi for g10) table b-1 fuel injector circuit check inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engin...

  • Page 148

    Engine general information and diagnosis (tbi for g10) 6-97 step action yes no 6 check injector resistor for resistance. 1) disconnect resistor connector with ignition switch off. 2) check for proper connection to resistor at each terminals. 3) if connection is ok, check resistance. Is resistance 1....

  • Page 149

    6-98 engine general information and diagnosis (tbi for g10) main fuse ignition switch to other circuits main relay fuel pump relay fuel pump caution: check to make sure that connection is made between correct terminals. Wrong connection can cause damage to ecm (pcm), wire harness, etc. Table b-2 fue...

  • Page 150

    Engine general information and diagnosis (tbi for g10) 6-99 fig. 1 for step 2 fig. 2 for step 3 1. Service wire 2. Relay box fig. 3 for step 4 fig. 4 for step 4.

  • Page 151

    1. Fuel pump 2. Fuel filter 3. Throttle body 4. Fuel injector 5. Fuel pressure regulator 6. Special tool (fuel pressure gauge & 3-way joint) 7. Fuel feed line 8. Fuel return line 6-100 engine general information and diagnosis (tbi for g10) table b-3 fuel pressure check inspection step action yes no ...

  • Page 152

    Engine general information and diagnosis (tbi for g10) 6-101 fig. 1 for step 1 1. Fuel pressure gauge & 3way joint step action yes no 8 with fuel pump operated and fuel return hose blocked by pinching it, is fuel pressure applied? Faulty fuel pressure regulator. Shortage of fuel or fuel pump or its ...

  • Page 153

    A / c amplifier (a / c on output signal) (a / c input signal) 6-102 engine general information and diagnosis (tbi for g10) table b-4 a/c signal circuits check (vehicle with a/c) inspection step action yes no 1 check a / c (input) signal circuit. 1) check voltage at terminal c03-19. While engine runn...

  • Page 154

    Power steering pressure switch engine general information and diagnosis (tbi for g10) 6-103 table b-5 power steering pressure (psp) switch signal circuit check (if equipped) inspection step action yes no 1 check psp switch signal circuit. 1) connect suzuki scan tool to dlc with ignition switch off. ...

  • Page 155: Special Tool

    6-104 engine general information and diagnosis (tbi for g10) 09931-76011 suzuki scan tool (tech 1 a) kit 1. Storage case 2. Operator’s manual 3. Tech 1 a 4. Dlc cable (14 / 26 pin, 09931-76040) 5. Test lead / probe 6. Power source cable 7. Dlc cable adaptor 8. Self-test adaptor - 1. Pressure gauge 0...

  • Page 156: Section 6

    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: Section 6-1

    6-1 engine general information and diagnosis (sfi for g13) 6-1-1 general information 6-1- 3 . . . . . . . . . . . . . . Engine diagnosis 6-1- 6 . . . . . . . . . . . . . . . . . . . General description 6-1- 6 . . . . . . . . . . . . . . . . . . . On-board diagnostic system 6-1- 6 . . . . . . . . . ....

  • Page 158

    6-1-2 engine general information and diagnosis (sfi for g13) dtc p0300 random misfire detected 6-1- 69 . . . . . . . . . . . . . . . . . . . . . . . . . . Dtc p0301 cylinder 1 misfire detected 6-1- 69 . . . . . . . . . . . . . . . . . . . . . . . . . . Dtc p0302 cylinder 2 misfire detected 6-1- 69 ....

  • Page 159: General Information

    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...

  • Page 160

    Hose connection clamp securely at a position 3 to 7mm (0.12–0.27 in.) from hose end. With short pipe, fit hose as far as it reaches pipe joint as shown. Hose pipe clamp clamps securely at a position 3 to 7 mm (0.12–0.27 in.) from hose end. With following type pipe, fit hose as far as its peripheral ...

  • 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. 1) place transmission ge...

  • Page 162: Engine Diagnosis

    6-1-6 engine general information and diagnosis (sfi for g13) 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) ha...

  • Page 163

    An example of freeze frame data 1. Trouble code p0102 (1st) 2. Engine speed 782 rpm 3. Eng cool tmp. 80 _c 4. Vehicle spd. 0 km/h 5. Map sensor 39 kpa 6. St. Term ft1 – 0.8% lean 7. Lg. Term ft1 – 1.6% lean 8. Fuel 1 stat. Closed loop 9. Fuel 2 stat. Not used 10. Load value 25.5% 1st, 2nd or 3rd in ...

  • Page 164

    B+ body ground ecm (pcm) ground serial data line (k line of iso 9141) 6-1-8 engine general information and diagnosis (sfi for g13) in the 2nd through the 4th frames, the freeze frame data of each malfunction is stored in the order as the malfunction is detected. These data are not updated. Shown in ...

  • Page 165

    Engine general information and diagnosis (sfi for g13) 6-1-9 precaution in diagnosing trouble d don’t disconnect couplers from ecm (pcm), battery cable from battery, ecm (pcm) ground wire harness from engine or main fuse before confirming diagnostic information (dtc, freeze frame data, etc.) stored ...

  • 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 yes no 1 customer complaint analysis 1) perform customer complaint analysis referring to the next page. Was customer complaint analysis pe...

  • 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 requi...

  • 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 no cranking j no initial combustion j no combustion j poor starting at ( jcold...

  • Page 169

    Engine general information and diagnosis (sfi for g13) 6-1-13 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 mil dims), go to “diagnostic flow table a-1” for troubleshooting. 2) start engine and check...

  • Page 170

    6-1-14 engine general information and diagnosis (sfi for g13) 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 pen...

  • 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 a...

  • Page 172

    6-1-16 engine general information and diagnosis (sfi for g13) dtc no. Detecting item detecting condition (dtc will set when detecting:) mil p0335 crankshaft position sensor circuit malfunction no signal for 2 sec. During engine cranking 1 driving cycle p0340 camshaft position sensor circuit malfunct...

  • Page 173

    Engine general information and diagnosis (sfi for g13) 6-1-17 dtc no. Detecting item detecting condition (dtc will set when detecting:) mil p0705 transmission range sensor circuit malfunction p0720 output speed sensor circuit malfunction p0751 shift solenoid a performance or stuck off refer to secti...

  • 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. Detected item fail...

  • Page 175

    Engine general information and diagnosis (sfi for g13) 6-1-19 operation visual inspection visually check following parts and systems. Inspection item referring section d engine oil – – – – – level, leakage d engine coolant – – – – – level, leakage d fuel – – – – – level, leakage d a/t fluid – – – – ...

  • Page 176

    6-1-20 engine general information and diagnosis (sfi for g13) engine basic inspection 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. Fl...

  • Page 177

    Select “data list” mode select menu f4: misc test when using suzuki scan tool 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 fig. 4 for step 7 fig. 5 for step 10

  • 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 referri...

  • Page 179

    Engine general information and diagnosis (sfi for g13) 6-1-23 condition possible cause] referring item low oil pressure d improper oil viscosity d malfunctioning oil pressure switch d clogged oil strainer d functional deterioration of oil pump d worn oil pump relief valve d excessive clearance in va...

  • Page 180

    6-1-24 engine general information and diagnosis (sfi for g13) condition possible cause referring item overheating d inoperative thermostat d poor water pump performance d clogged or leaky radiator d improper engine oil grade d clogged oil filter or oil strainer d poor oil pump performance d faulty r...

  • Page 181

    Engine general information and diagnosis (sfi for g13) 6-1-25 condition possible cause referring item engine hesitates (momentary lack of response as accelerator is depressed. Can occur at all vehicle speeds. Usually most severe when first trying to make vehicle move, as from a stop sign.) ignition ...

  • Page 182

    6-1-26 engine general information and diagnosis (sfi for g13) condition possible cause referring item engine has no power ignition system out of order d faulty spark plug d faulty ignition coil with ignitor d leaks, loose connection or disconnection of high-tension cord engine overheating fuel syste...

  • Page 183

    Engine general information and diagnosis (sfi for g13) 6-1-27 condition possible cause referring item improper engine idling or engine fails to idle ignition system out of order d faulty spark plug d leaky or disconnected high-tension cord d faulty ignition coil with ignitor fuel system out of order...

  • Page 184

    6-1-28 engine general information and diagnosis (sfi for g13) condition possible cause referring item excessive hydrocarbon (hc) emission or carbon monoxide (co) ignition system out of order d faulty spark plug d leaky or disconnected high-tension cord d faulty ignition coil with ignitor low compres...

  • 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 conditio...

  • Page 186

    6-1-30 engine general information and diagnosis (sfi for g13) scan tool data condition normal condition / reference values desired idle (desired idle speed) at idling with no load after warming up, m / t at neutral, a / t at “p” range 750 r / min tp sensor volt (throttle position ignition switch on ...

  • Page 187

    Engine general information and diagnosis (sfi for g13) 6-1-31 scan tool data definitions fuel system (fuel system status) air / fuel ratio feedback loop status displayed as either open or closed loop. Open indicates that ecm (pcm) ignores feedback from the exhaust oxygen sensor. Closed indicates fin...

  • 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 i...

  • Page 189

    Engine general information and diagnosis (sfi for g13) 6-1-33 1. Ecm (pcm) 2. Ecm (pcm) couplers (viewed from harness side) 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 b...

  • Page 190

    6-1-34 engine general information and diagnosis (sfi for g13) connect or “c01 ” terminal no. Circuit normal voltage condition 1 ground — — 2 ground — — 3 ground — — 4 evap canister purge valve 10 – 14 v ignition switch on indication deflection 5 power steering switch deflection repeated 0 v and igni...

  • Page 191

    Engine general information and diagnosis (sfi for g13) 6-1-35 connect or “c02 ” terminal no. Circuit normal voltage condition 1 a / c on output signal 0 v ignition switch on 2 egr valve (stepper motor 10 – 14 v ignition switch on 2 coil 1) 0 – 1 v engine running at idle speed 3 data link connector 1...

  • Page 192

    6-1-36 engine general information and diagnosis (sfi for g13) connect or “c03 ” terminal no. Circuit normal voltage condition 1 malfunction indicator lamp 0 – 1 v ignition switch on 1 malfunction indicator lamp 10 – 14 v when engine running 2 vehicle speed sensor (m / t) indicator deflection repeate...

  • Page 193

    1 2 1. Ecm (pcm) coupler disconnected 2. Ohmmeter 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 res...

  • Page 194

    Information sensors - 1. Map sensor - 2. Tp sensor - 3. Iat sensor - 4. Ect sensor - 5. Heated oxygen sensor-1 5-1. Heated oxygen sensor-2 - 6. Vss (a / t) - 7. Transmission range switch (a / t) - 8. Battery - 9. Cmp sensor - 10. Ckp sensor - 11. Fuel level sensor (gauge) (in fuel tank) - 12. Psp sw...

  • Page 195

    Main fuse ignition switch main relay malfunction indicator lamp in combination meter relay box fuse box c01-1 c01-2 c01-3 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 st...

  • 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 yes no 1 diagnostic trouble code (dtc) check 1) check dtc referri...

  • Page 197

    Main fuse ignition switch main relay malfunction indicator lamp in combination meter relay box fuse box 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 cra...

  • Page 198

    6-1-42 engine general information and diagnosis (sfi for g13) fig. 1 for step 2 fig. 2 for step 2 fig. 3 for step 2 step action yes no 5 ecm (pcm) power circuit check 1) using service wire, ground terminal c02-10 and measure voltage between terminal c02-5 / 6 and ground at ignition switch on. Is it ...

  • Page 199

    Map sensor to other sensors to tp sensor engine general information and diagnosis (sfi for g13) 6-1-43 dtc p0105 manifold absolute pressure (map) circuit malfunction circuit description dtc detecting condition possible cause d map: 4.9 kpa, 37 mmhg or less (low pressure – high vacuums – low voltage)...

  • 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- ...

  • Page 201

    Engine general information and diagnosis (sfi for g13) 6-1-45 fig. 1 for step 2 fig. 2 for step 3 inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check map sensor and its circuit. 1) connect scan tool to dlc with ignition swit...

  • Page 202

    6-1-46 engine general information and diagnosis (sfi for g13) iat sensor to other sensors dtc p0110 intake air temp. (iat) circuit malfunction circuit description dtc detecting condition possible cause d low intake air temperature (high voltage-high resistance) d high intake air temperature (low vol...

  • Page 203

    Engine general information and diagnosis (sfi for g13) 6-1-47 fig. 1 for step 2 fig. 2 for step 3 fig. 3 for step 4 inspection 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 to dlc ...

  • Page 204

    6-1-48 engine general information and diagnosis (sfi for g13) to combination (ect) meter to other sensors note: before inspecting, be sure to check that cool- ant temp. Meter in combination meter indi- cates normal operating temperature (engine is not overheating). Dtc p0115 engine coolant temperatu...

  • Page 205

    Engine general information and diagnosis (sfi for g13) 6-1-49 fig. 1 for step 2 fig. 2 for step 5 fig. 3 for step 6 inspection 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 ig...

  • Page 206

    Throttle position sensor to map sensor to other sensors 6-1-50 engine general information and diagnosis (sfi for g13) dtc p0120 throttle position circuit malfunction circuit description dtc detecting condition possible cause d signal voltage high d signal voltage low d “g” circuit open d “gr” circui...

  • Page 207

    Engine general information and diagnosis (sfi for g13) 6-1-51 fig. 1 for step 2 fig. 2 for step 3 fig. 3 for step 4 inspection 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 w...

  • Page 208

    6-1-52 engine general information and diagnosis (sfi for g13) throttle position sensor to other sensors to other sensors dtc p0121 throttle position circuit range/performance problem circuit description dtc detecting condition possible cause d after engine warmed up. D while vehicle running at speci...

  • Page 209

    Engine general information and diagnosis (sfi for g13) 6-1-53 fig. 1 for step 2 fig. 2 for step 2 fig. 3 for step 2 fig. 4 for step 3 closed (condition “a”) fully open throttle opening when using suzuki scan tool: when not using suzuki scan tool: inspection step action yes no 1 was “engine diag. Flo...

  • Page 210

    6-1-54 engine general information and diagnosis (sfi for g13) ignition switch main fuse to ho2s-2 heater to other sensor heater fuse box dtc p0130 heated oxygen sensor (ho2s) circuit malfunction (sensor-1) circuit description dtc detecting condition possible cause d when running at idle speed after ...

  • Page 211

    Engine general information and diagnosis (sfi for g13) 6-1-55 fig. 1 for step 3 fig. 2 for step 3 normal inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 is there dtc(s) other than ho2s-1 (dtc p0130)? Go to applicable dtc diag....

  • Page 212

    6-1-56 engine general information and diagnosis (sfi for g13) fig. 1 ho2s-1 output voltage 1 cycle time response time 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 whe...

  • Page 213

    Engine general information and diagnosis (sfi for g13) 6-1-57 fig. 1 for step 3 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 while running under other than ...

  • Page 214

    Ignition switch main fuse to ho2s-2 heater to other sensor heater fuse box 6-1-58 engine general information and diagnosis (sfi for g13) dtc p0135 heated oxygen sensor (ho2s) heater circuit malfunction (sensor-1) circuit description dtc detecting condition possible cause dtc will set when a or b con...

  • Page 215

    Engine general information and diagnosis (sfi for g13) 6-1-59 fig. 1 for step 2 fig. 2 for step 3 inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go t o“engine diag. Flow table”. 2 check heater for operation. 1) check voltage at terminal c01-7. See fig. 1. 2) w...

  • Page 216

    6-1-60 engine general information and diagnosis (sfi for g13) to other sensor main fuse ignition switch heater to ho2s-1 heater dtc p0136 heated oxygen sensor (ho2s) circuit malfunction (sensor-2) circuit description dtc detecting condition possible cause dtc will set when a or b condition is detect...

  • Page 217

    Engine general information and diagnosis (sfi for g13) 6-1-61 lusual driving: driving at 30 – 40 mph, 50 – 60 km/h including short stop according to traffic signal. (under driving condition other than high-load, high-engine speed, rapid accelerating and decelerating) 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 1...

  • Page 218

    6-1-62 engine general information and diagnosis (sfi for g13) inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check exhaust system for leakage, loose connection and damage. Is it good condition? Go to step 3. Repair or replace...

  • Page 219

    Engine general information and diagnosis (sfi for g13) 6-1-63 to other sensor main fuse ignition switch heater to ho2s-1 heater dtc p0141 heated oxygen sensor (ho2s) heater circuit malfunction (sensor-2) circuit description dtc detecting condition possible cause dtc will set when a or b condition it...

  • Page 220

    6-1-64 engine general information and diagnosis (sfi for g13) fig. 1 for step 2 inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check ho2s-2 heater and its circuit. 1) warm up engine to normal operating temperature. 2) stop en...

  • Page 221

    Engine general information and diagnosis (sfi for g13) 6-1-65 ignition switch main fuse main relay to ignition switch to other sensor relay box no.1 injector no.2 injector no.3 injector no.4 injector fuse box signal to decrease amount of fuel injection signal to increase amount of fuel injection hig...

  • 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 ...

  • Page 223

    Engine general information and diagnosis (sfi for g13) 6-1-67 inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 is there dtc(s) other than fuel system (dtc p0171 / p0172)? Go to applicable dtc diag. Flow table. Go to step 3. 3 c...

  • Page 224

    6-1-68 engine general information and diagnosis (sfi for g13) fig. 1 for step 3 fig. 2 for step 4 fig. 3 for step 5 fig. 4 for step 5 fig. 5 for step 5 fig. 6 for step 6 1. Fuel delivery pipe 2. Fuel feed hose 3. Fuel pressure gauge & 3 way joint step action yes no 8 check engine coolant temp. Senso...

  • Page 225

    Engine general information and diagnosis (sfi for g13) 6-1-69 ignition coil assembly for no.1 & no.4 spark plugs ignition coil assembly for no.2 & no.3 spark plugs ignition switch main relay main fuse relay box to ignition switch ckp sensor cmp sensor no.1 injector no.2 injector no.3 injector no.4 i...

  • Page 226

    Below specified value 6-1-70 engine general information and diagnosis (sfi for g13) 1. Ckp sensor signal 2. No.1 fuel injector signal 3. No.3 fuel injector signal 4. Fuel injection time display of fuel injection signal using oscilloscope waveforms at specified idle speed 5ms/div dtc detecting condit...

  • Page 227

    Engine general information and diagnosis (sfi for g13) 6-1-71 inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table“. 2 is there dtc other than fuel system (dtc p0171 / p0172) and misfire (dtc p0300-p0304)? Go to applicable dtc diag. Fl...

  • Page 228

    6-1-72 engine general information and diagnosis (sfi for g13) disconnect connectors when checking plugs for spark 1. Fuel delivery pipe 2. Fuel feed hose 3. Fuel pressure gauge & 3 way joint step action yes no 6 check pcv valve for clogging (see section 6e2). Is it in good condition? Go to step 7. R...

  • Page 229

    Engine general information and diagnosis (sfi for g13) 6-1-73 crankshaft timing belt pulley ckp sensor oscilloscope waveforms waveforms at engine cranking (260 r/min) waveforms at specified idle speed 16 waives for 10 _ signals 13 waives for 10 _ signals 30 _ signal 30 _ signal 0.5 v / div. 10 ms / ...

  • 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 t...

  • Page 231

    Engine general information and diagnosis (sfi for g13) 6-1-75 to ignition switch signal rotor on camshaft camshaft position sensor waveforms at specified idle speed oscilloscope waveforms 2 v / div. Crank angle 20 ms / div. 180 _ 720 _ dtc p0340 camshaft position (cmp) sensor circuit malfunction cir...

  • Page 232

    6-1-76 engine general information and diagnosis (sfi for g13) inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check cmp sensor and connector for proper installation. Is cmp sensor installed properly and connector connected sec...

  • Page 233

    Engine general information and diagnosis (sfi for g13) 6-1-77 gnd vout b+ magnetic substance (iron) mirror step action yes no 7 check signal rotor for the following, using mirror. See fig. 4. D damage d no foreign material attached is it in good condition? Intermittent trouble or faulty ecm (pcm). C...

  • Page 234

    6-1-78 engine general information and diagnosis (sfi for g13) ignition switch main fuse relay box main relay egr valve 2 c13 dtc p0400 exhaust gas recirculation flow malfunction circuit description dtc detecting condition possible cause d while running at specified vehicle speed after engine warm-up...

  • Page 235

    Engine general information and diagnosis (sfi for g13) 6-1-79 1) 2) 3) 4) 5) 6) 7) engine speed 4000 r/min 0 vehicle speed 0 50 – 55 mph 80 – 88 km/h (keep throttle valve opening constantly) dtc confirmation procedure warning: d when performing a road test, select a place where there is no traffic o...

  • Page 236

    6-1-80 engine general information and diagnosis (sfi for g13) 1. Egr valve coupler inspection step action yes no 1 was engine diag. Flow table performed? Go to step 2. Go to engine diag. Flow table. 2 do you have suzuki scan tool? Go to step 3. Go to step 5. 3 egr valve operation check 1) with ignit...

  • Page 237

    Engine general information and diagnosis (sfi for g13) 6-1-81 oscilloscope waveforms heated oxygen sensor-1 to other sensor heated oxygen sensor-2 warm up three way catalytic converter three way catalytic converter engine running at closed loop condition fuel cut idle after fuel cut 0.5 v / div 2 se...

  • Page 238

    6-1-82 engine general information and diagnosis (sfi for g13) 1) 2) 3) 4) 41 – 46 mph (65 – 75 km / h) 28 – 34 mph (45 – 55 km / h) 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 dur...

  • Page 239

    Engine general information and diagnosis (sfi for g13) 6-1-83 inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check short term fuel trim. Did short term fuel trim vary within – 20% – +20% range in step 3) of dtc confirmation t...

  • Page 240

    6-1-84 engine general information and diagnosis (sfi for g13) 1. Evap canister purge valve 2. To main relay 3. Ecm (pcm) 4. Sensed information 5. Intake manifold 6. Evap canister 7. Tank pressure control valve 8. Fuel vapor line 9. Fuel tank fig. 1 for step 1 dtc p0443 evap purge control valve circu...

  • Page 241

    Radiator cooling fan relay to ecm main relay relay box “rdtr” (radiator fan) radiator cooling fan motor engine general information and diagnosis (sfi for g13) 6-1-85 dtc p0480 radiator cooling fan control system malfunction circuit description dtc detecting condition possible cause d low voltage at ...

  • Page 242

    6-1-86 engine general information and diagnosis (sfi for g13) fig. 1 for step 2 fig. 2 for step 3 fig. 3 for step 3 inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check radiator cooling fan relay and its circuit. 1) turn igni...

  • Page 243

    Engine general information and diagnosis (sfi for g13) 6-1-87 vehicle speed sensor in combination meter dtc p0500 vehicle speed sensor (vss) malfunction for m/t vehicle circuit description dtc detecting condition possible cause d while fuel is kept cut at lower than 4000 r/min for longer than 4 sec....

  • Page 244

    6-1-88 engine general information and diagnosis (sfi for g13) fig. 1 for step 3 fig. 2 for step 4 inspection 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? Go to step 3. Speedometer cable disconn...

  • Page 245

    Output shaft speed sensor (on a / t) counter shaft gear engine general information and diagnosis (sfi for g13) 6-1-89 dtc p0500 vehicle speed sensor (vss) malfunction for a/t vehicle circuit description dtc detecting condition possible cause d while fuel is kept cut at lower than 4000 r/min for long...

  • Page 246

    6-1-90 engine general information and diagnosis (sfi for g13) fig. 1 for step 2 fig. 2 for step 3 inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check vss for resistance. 1) disconnect vss connection with ignition switch off....

  • Page 247

    Engine general information and diagnosis (sfi for g13) 6-1-91 relay box main fuse main relay iac valve to other valve dtc p0505 idle control system malfunction circuit description dtc detecting condition possible cause d no closed signal to iac valve is detected after engine start. : 2 driving cycle...

  • Page 248

    6-1-92 engine general information and diagnosis (sfi for g13) fig. 1 for step 1 fig. 2 for step 2 when using suzuki scan tool: when not using suzuki scan tool: inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check idle air con...

  • 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) when written into ecm (pcm) : 1 driving cycle detection logic, continuous monitoring. Ecm (pc...

  • Page 250

    6-1-94 engine general information and diagnosis (sfi for g13) fig. 1 for step 1 when using suzuki scan tool: 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 ec...

  • Page 251

    Applying vacuum displayed value on scan tool 0 barometric pressure (approx. 100 kpa, 760 mmhg) 27 kpa 200 mmhg barometric pressure – 27 kpa (approx. 73 kpa, 560 mmhg 67 kpa 500 mmhg barometric pressure – 67 kpa (approx. 33 kpa, 260 mmhg) engine general information and diagnosis (sfi for g13) 6-1-95 ...

  • Page 252

    6-1-96 engine general information and diagnosis (sfi for g13) main fuse m/t vehicle a/t vehicle ignition switch (starter switch) starter starter transmission range sensor (switch) main fuse ignition switch (starter switch) dtc p1500 engine starter signal circuit malfunction circuit description dtc d...

  • Page 253

    Engine general information and diagnosis (sfi for g13) 6-1-97 fuse box main fuse dome radio “lamp” dtc p1510 ecm (pcm) back-up power supply malfunction circuit description battery voltage is supplied so that diagnostic trouble code memory, values for engine control learned by ecm (pcm), etc. Are kep...

  • Page 254

    6-1-98 engine general information and diagnosis (sfi for g13) ignition switch main fuse main relay relay box no.1 injector no.2 injector no.3 injector no.4 injector fuse box table b-1 fuel injector circuit check inspection step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. G...

  • Page 255

    Engine general information and diagnosis (sfi for g13) 6-1-99 main fuse ignition switch main relay fuel pump relay main relay fuel pump caution: check to make sure that connection is made between correct terminals. Wrong connection can cause damage to ecm (pcm), wire harness, etc. Table b-2 fuel pum...

  • 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 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) table b-3 fuel pressure check inspection step action yes on 1 1) re...

  • Page 258

    6-1-102 engine general information and diagnosis (sfi for g13) 1. Fuel delivery pipe 2. Fuel feed hose 3. Fuel return hose special tool (a) gauge (b) hose (c) 3-way joint step action yes on 7 was no fuel pressure applied in step 1? Go to step 8. Go to step 9. 8 with fuel pump operated and fuel retur...

  • Page 259

    Engine general information and diagnosis (sfi for g13) 6-1-103 a / c amplifier (a / c on output signal) (a / c input signal) table b-4 a/c signal circuits check (vehicle with a/c) inspection step action yes no 1 check a / c (input) signal circuit. 1) check voltage at terminal c02-16. See fig. 1. Whi...

  • Page 260

    6-1-104 engine general information and diagnosis (sfi for g13) power steering pressure switch power steering pump fig. 1 for step 1 fig. 2 for step 2 table b-5 power steering pressure (psp) switch signal circuit check (if equipped) inspection step action yes no 1 check psp switch signal circuit. Whe...

  • Page 261

    Engine general information and diagnosis (sfi for g13) 6-1-105 heater blower switch rear defogger switch tail light relay (lighting switch) diodes in junction/ fuse block fig. 1 for step 1 fig. 2 for step 1 table b-6 electric load signal circuit check inspection step action yes no 1 check electric l...

  • Page 262

    6-1-106 engine general information and diagnosis (sfi for g13) radiator cooling fan relay to ecm main relay relay box “rdtr” (radiator fan) radiator cooling fan motor table b-7 radiator cooling fan control system check inspection step action yes no 1 check fan control system. 1) connect scan tool to...

  • Page 263

    Engine general information and diagnosis (sfi for g13) 6-1-107 fig. 1 for step 1 fig. 2 for step 3 fig. 3 for step 4 when using suzuki scan tool: 1. Radiator cooling fan relay 1. Battery 2. Radiator fan motor coupler.

  • Page 264: Special Tools

    6-1-108 engine general information and diagnosis (sfi for g13) 09917-47910 vacuum pump gauge 09930-88530 injector test lead 09931-76011 suzuki scan tool (tech 1 a) kit mass storage cartridge 09931-76030 16 / 14 pin dlc cable 1. Storage case 2. Operator’s manual 3. Tech 1 a 4. Dlc cable (14 / 26 pin,...

  • Page 265: Section 6A

    6a engine mechanical (g10, 1-cam 6-valves engine) 6a-1 section 6a engine mechanical (g10, 1-cam 6-valves engine) warning: for vehicles equipped with supplemental restraint (air bag) system: d service on and around the air bag system components or wiring must be performed only by an autho- rized suzu...

  • Page 266: On-Vehicle Service

    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 ...

  • Page 267

    3 / 4 turn 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...

  • Page 268

    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 cove...

  • Page 269

    1. Stay 2. Throttle body 3. Gasket 4. Efe heater 5. Intake manifold 6. Gasket : tightening torque : do not reuse engine mechanical (g10, 1-cam 6-valves engine) 6a-5 throttle body and intake manifold removal 1) relieve fuel pressure according to procedure described in “fuel pressure relief procedure”...

  • Page 270

    1. Throttle body 1. Throttle body 2. Isc actuator 5. Clamp 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...

  • Page 271

    2. Ground 1. Throttle body 2. Isc actuator coupler 3. Tp sensor coupler 4. Fuel injector coupler 5. Efe heater coupler 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 he...

  • Page 272

    1. Exhaust manifold 2. Gasket 3. Cover 4. Heated oxygen sensor 5. Pipe seal 6. Exhaust pipe 7. Wu-twc (if equipped) 8. Exhaust pipe bolt : tightening torque : do not reuse 6a-8 engine mechanical (g10, 1-cam 6-valves engine) exhaust manifold warning: to avoid danger of being burned, do not service ex...

  • Page 273

    2. Wu-twc 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. Tigh...

  • Page 274

    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. Inside cover 12. Outside cover seal 13. Outside cover 14. Tensioner stud 15. Tensioner bolt 16. Tensioner spring screw : tightening to...

  • Page 275

    1. “v” mark on cylinder head cover 2. Timing mark on camshaft timing belt pulley 3. Arrow mark on oil pump case 4. Punch mark on crankshaft timing belt pulley engine mechanical (g10, 1-cam 6-valves engine) 6a-11 8) loosen crankshaft pulley bolts (1) and remove crankshaft pulley (2). 9) remove timing...

  • Page 276

    6a-12 engine mechanical (g10, 1-cam 6-valves engine) 1. Camshaft allowable turning range – – – by timing mark, within 90 _ from “v” mark on head cover on both right and left. 2. Crankshaft allowable turning range – – – by punch mark, within 90 _ from arrow mark on oil pump case on both right and lef...

  • Page 277

    1. Crank timing belt pulley bolt direction of crankshaft 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 tu...

  • 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 cr...

  • Page 279

    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. 7. Camshaft 8. Oil seal 9. Valve lash adjuster 10. Camshaft housing bolt 1. Cranksh...

  • Page 280

    Don’t apply force 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 adju...

  • 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 h...

  • Page 282

    D indicates position from timing belt side. Install in numerical order starting from timing belt side. D indicates direction of housing. Install so that arrow is directed toward timing belt side. 6a-18 engine mechanical (g10, 1-cam 6-valves engine) installation 1) before installing valve lash adjust...

  • Page 283

    2. No.2 housing 3. No.3 housing 3. Rod 4. Shop cloth 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. D after applying engine oil...

  • 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 hal...

  • Page 285

    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. Pin 6. Camshaft 7. Valve lash adjuster 8. Valve cotters 9. Valve spring retainer 10. Valve spring: be sure to positi...

  • 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 pow...

  • Page 287

    1. Cylinder block 2. Feeler gauge 3. Piston ring 4. 120 mm (4.72 in.) 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. Connecting rod nut : tightening torque : apply engine oil to sliding : surfaces of each part....

  • Page 288: Unit Repair Overhaul

    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 cabl...

  • Page 289

    1. Rear mounting 2. Left mounting 3. Left mounting bracket 4. Right mounting 5. Right mounting bracket for m / t model for a / t model 1. Rear mounting 2. Rear mounting no.2 bracket 3. Rear mounting no.1 bracket 4. Left mounting no.1 bracket 5. Stopper 6. Left mounting 7. Left mounting no.2 bracket ...

  • Page 290

    1. Rear mounting 2. Rear mounting no.2 bracket 3. Rear mounting no.1 bracket 4. Rear mounting bracket 5. Left mounting body bracket 6. Left mounting 7. Left mounting bracket 8. Right mounting bracket 9. Right mounting for m / t model for a / t model 1. Rear mounting 2. Rear mounting no.2 bracket 3. ...

  • Page 291

    1. Cylinder block 2. Front oil seal 3. Main bearing 4. Bearing cap 5. Cap washer 6. Cap bolt 7. Timing pulley key 8. Crankshaft 9. Thrust bearing: set oil grooves of bearing to weds. 10. Rear oil seal 11. Pin 12. Oil seal housing gasket 13. Oil seal housing 14. Housing bolt 15. Input shaft bearing 1...

  • Page 292

    2.Upper half of bearing (a) 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 b...

  • 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 mi...

  • Page 294: Special Tools

    09915-47310 oil filter wrench 09915-64512 compression gauge 09910-38211 piston pin remover and installer 1. Base 2. Base cap 3. Driver handle 4. Piston pin guide for installation 5. Piston pin guide for removal 6. Spring 7. Spring guide 09915-67311 vacuum gauge 1. 09915-77311 oil pressure gauge 2. 0...

  • Page 295: Required Service Materials

    09916-56011 valve guide installer 09917-98221 valve stem seal installer 09918-08210 vacuum gauge hose joint 09919-16010 deep socket 09924-17810 flywheel holder 09926-18210 oil seal guide (vinyl resin) engine mechanical (g10, 1-cam 6-valves engine) 6a-31 required service materials materials recommend...

  • Page 296: Section 6A1

    6a1 engine mechanical (g13b, 1-cam 16-valves engine) 6a1-1 section 6a1 engine mechanical (g13b, 1-cam 16-valves engine) warning: for vehicles equipped with supplement restraint (air bag) system: d service on and around the air bag system components or wiring must be performed only by an autho- rized...

  • Page 297: General Description

    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...

  • Page 298

    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

    1. Rocker arm shaft 2. Rocker arm (ex) 3. Intake valve 4. Exhaust valve 5. Rocker arm (in) 6. Camshaft 7. Clip 8. Pivot ex in cylinder block the cylinder block is made of cast aluminum alloy and has 4 cylinders arranged “in-line”. A cylindrical cast iron sleeve is installed in each cylinder. Cranksh...

  • Page 300: On-Vehicle Service

    1 2 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” (shift se...

  • Page 301

    6a1-6 engine mechanical (g13b, 1-cam 16-valves engine) 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. Note: after warming up e...

  • 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. D oil quality. If oil is discolored, or deteriorated, change it. F...

  • 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. Tightening torqu...

  • Page 304

    2 in ex (a) 1 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 cra...

  • Page 305

    1. Thickness gauge in ex 360 _ in ex 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 scre...

  • Page 306

    3 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 elemen...

  • Page 307

    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 t...

  • Page 308

    3 3 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- er. 3) disconnect ignition coil couplers (6). 4) remove ignition coil assemblies (5) with high-tension cor...

  • Page 309

    1. Intake manifold 2. Throttle body 3. Gasket 4. Egr valve 5. Fuel delivery pipe 6. Fuel injector 7. Fuel pressure regulator 8. Evap canister purge valve 9. Map sensor 10. O-ring 11. Gasket 12. Cushion : tightening torque : do not reuse 1 2 6a1-14 engine mechanical (g13b, 1-cam 16-valves engine) thr...

  • 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 follo...

  • Page 311

    1. Long bolt 2. Short bolt 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 re...

  • Page 312

    : tightening torque : do not reuse 1. Exhaust manifold 2. Gasket 3. Cover 4. Heated oxygen sensor 7. Gasket 8. Exhaust no.1 pipe. 2 1 engine mechanical (g13b, 1-cam 16-valves engine) 6a1-17 exhaust manifold warning: to avoid danger of being burned, do not service exhaust system while it is still hot...

  • Page 313

    (b) (a) 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 o...

  • Page 314

    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. Outside cover seal 12. Outside cover 13. Tensioner stud 14. Damper 1. Water pump pulley : tightening torque engine mechanica...

  • Page 315

    1. “v” mark on cylinder head cover 2. Timing mark by “e” on camshaft timing belt pulley 3. Arrow mark on oil pump case 4. Punch mark on crankshaft timing belt pulley 4. Tensioner stud 6. Damper 6 6a1-20 engine mechanical (g13b, 1-cam 16-valves engine) 8) lock crankshaft inserting flat end rod or the...

  • Page 316

    1. Camshaft allowable turning range - - - by timing mark, within 90 _ from “v” mark on head cover on both right and left. 2. Crankshaft allowable turning range - - - by punch mark, within 90 _ from arrow mark on oil pump case on both right and left. Engine mechanical (g13b, 1-cam 16-valves engine) 6...

  • Page 317

    4. Damper 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...

  • Page 318

    1. Clamp 1. Long bolt 2. Short bolt 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 sp...

  • 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 equipp...

  • Page 320

    1. Oil pan: apply sealant 99000-31150 to oil pan mating surface. 2. Oil pump strainer 3. Seal 4. Drain plug gasket 5. Drain plug 6. Ckp sensor : tightening torque : do not reuse engine mechanical (g13b, 1-cam 16-valves engine) 6a1-25 oil pan and oil pump strainer removal 1) raise vehicle. 2) drain e...

  • Page 321

    2. O-ring 6a1-26 engine mechanical (g13b, 1-cam 16-valves engine) 6) remove oil pan (3) and then oil pump strainer (1). Cleaning d clean mating surfaces of oil pan and cylinder block. Remove oil, old sealant, and dusts from mating surfaces and oil pan inside. D clean oil pump strainer screen. Instal...

  • 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 co...

  • Page 323

    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. Spring 9. Retainer 10. Retainer ring 11. Front oil seal: apply engine oil to contact part of crankshaft with oil sea...

  • Page 324

    4. Guide seal engine mechanical (g13b, 1-cam 16-valves engine) 6a1-29 7) remove oil pump assembly (1) after removing bolts (2). Disassembly 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). Ins...

  • 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. Measurement d radial clearance check radia...

  • Page 326

    (a) 1. Oil pump 1. No. 1 bolts (short) 2. No. 2 bolts (long) 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) a...

  • 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...

  • Page 328

    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) 9. Valve adjusting screw 10. Valve adjusting screw 11. Clip 12. Lock nut 13. Rocker arm spring : tightening torque : do not reuse : apply engine oil ...

  • Page 329

    1. Oil plug 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 v...

  • Page 330

    Ex in 2. Rocker arm shaft engine mechanical (g13b, 1-cam 16-valves engine) 6a1-35 10) remove rocker arm shaft bolts (1). 11) remove exhaust rocker arms (1) and rocker arm spring (2) by pulling out rocker arm shaft to battery side after removing bat- tery. Inspection adjusting screw and rocker arm if...

  • 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 s...

  • 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

    A: timing belt side b: flywheel side 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 ...

  • Page 334

    Engine mechanical (g13b, 1-cam 16-valves engine) 6a1-39 d indicates position from timing belt side. Install in numerical order starting from timing belt side. D indicates direction of housing. Install so that arrow is directed toward timing belt side. D embossed marks are provided on each camshaft h...

  • Page 335

    6a1-40 engine mechanical (g13b, 1-cam 16-valves engine) 1. O-ring 2 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 wate...

  • Page 336

    : do not reuse 1. Valve cotters 2. Valve spring retainer 3. Valve spring: be sure to position spring in place with its bottom end (small-pitch end) facing the bottom (valve spring seat side). 4. Valve stem seal 5. Valve spring seat 6. Exhaust valve 7. Intake valve 8. Cylinder head bolt 9. Camshaft h...

  • Page 337

    6a1-42 engine mechanical (g13b, 1-cam 16-valves engine) d ignition coil assembly d ground wires from intake manifold d evap canister purge valve d ect sensor d injectors, tp sensor and iac valve wires at the coupler d heated oxygen sensor 1 d map sensor 5) remove intake manifold rear stiffener (1) a...

  • Page 338

    3 2. Breather hose 3. Pcv valve 4. High-tension cords 5. Ignition coil assembly 6. Ignition coil coupler a: camshaft pulley side b: cmp sensor case side engine mechanical (g13b, 1-cam 16-valves engine) 6a1-43 9) remove cylinder head cover (1) as previously outlined. Loosen all valve lash adjusting s...

  • 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. 3) using ...

  • 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. If clearance e...

  • 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. D seating con...

  • 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. 1) exha...

  • 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...

  • 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 ...

  • Page 345

    “a”: valve guide protrusion (11.5 mm) 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) inst...

  • Page 346

    A: valve spring retainer side b: valve spring seat side 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 s...

  • Page 347

    A: crankshaft pulley side b: flywheel side a: camshaft pulley side b: cmp sensor case side 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- ifol...

  • 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. 7) a...

  • Page 349

    1. Top ring 2. 2nd ring 3. Oil ring 4. Piston 5. Connecting rod 6. Connecting rod bearing cap 7. Connecting rod bearing 8. Piston pin 9. Piston pin circlip 10. Connecting rod bearing cap nut : do not reuse : tightening torque : apply engine oil to sliding : surface of each part. 6 10 6a1-54 engine m...

  • 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. Cleaning clean carbo...

  • Page 351

    “a”: 50 mm (1.96 in.) “b”: 95 mm (3.74 in.) “a”: 23 mm (0.91 in.) 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, re...

  • Page 352

    “a”: 23 mm (0.91 in.) 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- ...

  • Page 353

    1. Cylinder block “a”: 120 mm (4.72 in.) 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...

  • 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 regri...

  • Page 355

    1 or 2 piston no.1 cylinder no.2 cylinder no.3 cylinder no.4 cylinder crank pulley side flywheel side 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 clear...

  • Page 356

    2. Arrow mark 4. Oil hole the oil hole should come on intake side 1. Arrow mark 2. 1st ring end gap 3. 2nd ring end gap and oil ring spacer gap 4. Oil ring upper rail gap 5. Oil ring lower rail gap 6. Intake side 7. Exhaust side crankshaft pulley side circlip or engine mechanical (g13b, 1-cam 16-val...

  • Page 357

    A: crankshaft pulley side b: flywheel side 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 c...

  • 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...

  • Page 359: Unit Repair Overhaul

    1 2 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 6. 2) remove battery. 3) remove engine hood after disconnecting windshield washer hose. 4) drain cooling system. Warning: to hel...

  • 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 pre...

  • 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 d...

  • Page 362

    (a) 1 2 3 (a) (a) 6 7 4 5 (a) m / t m/t 9 (a) 4 7 (a) 8 1. Right mounting 2. Right mounting bracket 3. Left mounting 4. Left mounting bracket 5. Left mounting bracket stiffener 6. Rear mounting 7. Rear mounting bracket 8. Rear torque rod 9. Rear torque rod bracket engine mechanical (g13b, 1-cam 16-v...

  • Page 363

    1. Cylinder block 2. Front oil seal: apply engine oil to contact part of crankshaft with oil seal lip. 3. Main bearing: apply engine oil to bearing inside surfaces. 4. Bearing cap 5. Cap bolt: apply engine oil to bolt and bearing surfaces. 6. Timing pulley key 7. Crankshaft: apply engine oil to cran...

  • Page 364

    1. Flywheel bolt 2. Bolt 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 3) remove crankshaft pulley, timing belt and cr...

  • 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...

  • Page 366

    1. Gaging plastic 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 oi...

  • 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. A new standard bearing...

  • Page 368

    1. Paint 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. A...

  • Page 369

    2. Scale 1. Paint 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 belo...

  • 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 ...

  • Page 371

    “a”: 23 mm (0.91 in.) 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 ...

  • 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...

  • Page 373

    1. Short bolts 2. Long bolts 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 ...

  • 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...

  • Page 375: Special Tools

    1. 09915-64510-001 compression gauge 2. 09915-64510-002 connector 3. 09915-64530 hose 4. 09915-67010 attachment 09915-67311 vacuum gauge 09918-08210 vacuum gauge hose joint 09915-77311 oil pressure gauge 09917-18211 tappet adjuster wrench 09919-16020 17 mm socket 09926-18210 oil seal guide (vinyl re...

  • Page 376: Required Service Materials

    09917-98221 valve stem seal installer 09916-77310 piston ring compressor 09924-17810 flywheel holder 09915-47330 oil filter wrench engine mechanical (g13b, 1-cam 16-valves engine) 6a1-81 required service materials materials recommended suzuki product use sealant suzuki bond no.1207c (99000-31150) d ...

  • Page 377

    6a1-82 engine mechanical (g13b, 1-cam 16-valves engine) tightening torque specifications fastening parts tightening torque fastening parts n . M kg-m lb-ft oil pressure switch 13 1.3 9.5 valve adjusting screw lock nuts 12 1.2 9.0 cylinder head cover bolts 11 1.1 8.0 intake manifold bolts and nuts 23...

  • Page 378: Section 6B

    6b 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 379: General Description

    8. Heater inlet hose 9. Heater outlet hose 10. Radiator 11. Oil cooler (a / t only) 12. Engine 13. Ect sensor 1. Radiator inlet hose 2. Radiator outlet hose 3. Water intake pipe 4. Thermostat 5. Water pump 6. Iac valve (throttle body) 7. Breather pipe (air cleaner outlet hose) 6b-2 engine cooling ge...

  • Page 380

    1. Cooling fan motor 2. Radiator 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 cas...

  • Page 381: Diagnosis

    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 engine overheats d loose or broken water pump belt d not enough co...

  • Page 382: Maintenance

    Engine cooling 6b-5 anti-freeze propor- tioning char t coolant cap acity g13 engine g10 engine 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...

  • Page 383

    2. Outlet hose 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 soo...

  • Page 384: On-Vehicle Service

    1. Radiator hose 2. Clamp 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...

  • Page 385

    2. Thermostat case 2. Thermometer 3. Heater upside 6b-8 engine cooling 4) remove thermostat (1). 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 wh...

  • Page 386

    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). Ins...

  • 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: Section 6C

    6c engine fuel 6c-1 general description 6c-1 . . . . . . . . . . . . . . Fuel system 6c-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump assembly 6c-1 . . . . . . . . . . . . . . . . . . . On-vehicle service 6c-2 . . . . . . . . . . . . . . . . Fuel lines 6c-2 . . . . . . . . . . . ...

  • Page 389: 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. Fuel tank pad 11. Fuel tank fixer bolt : tightening torque 6c-2 engine fuel on-vehicle service fuel lines inspection visua...

  • Page 390

    1. Return hose 2. Vapor hose 3. Feed hose 4. Fuel tank 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 poss...

  • Page 391

    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. Inspect...

  • Page 392: Section 6E1

    Engine and emission control system (tbi for g10) 6e1-1 general description 6e1- 2 . . . . . . . . . . . . . . Air and fuel delivery system 6e1- 4 . . . . . Electronic control system 6e1- 5 . . . . . . On-vehicle service 6e1- 8 . . . . . . . . . . . . . . . . General 6e1- 8 . . . . . . . . . . . . . ...

  • Page 393: General Description

    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. Ele...

  • Page 394

    Engine and emission control system (tbi for g10) 6e1-3 1. Tank pressure control valve 2. Fuel liquid separator 3. Fuel tank 4. Fuel pump 5. Fuel level sensor (gauge) 6. Fuel filter 7. Fuel pressure regulator 8. Throttle body 9. Fuel injector 10. Map sensor 11. Tp sensor 12. Isc actuator (including c...

  • Page 395

    1. Air cleaner 2. Throttle body 3. Fuel injector 4. Fuel pressure regulator 5. Intake manifold 6. Fuel filter 7. Fuel tank 8. Fuel pump 9. Fuel feed line 10. Fuel return line 11. Air 12. Fuel 13. Air/fuel mixture 6e1-4 engine and emission control system (tbi for g10) the main components of this syst...

  • Page 396

    Information sensors 1. Map sensor 2. Tp sensor 3. Iat sensor 4. Ect sensor 5. Heated oxygen sensor-1 6. Vss 7. Ignition coil 8. Battery 9. Distributor (cmp sensor) 10. A / c controller (if equipped) 11. Ckp sensor 12. Ctp switch (in isc actuator) 13. Heated oxygen sensor-2 controlled devices a : fue...

  • Page 397

    6e1-6 engine and emission control system (tbi for g10) ig coil meter fi.

  • Page 398

    Engine and emission control system (tbi for g10) 6e1-7 con- nector c02 termi- nal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 ecm ground power source (from main relay) blank blank blank blank evap canister purge valve shift solenoid-b (a / t) shift solenoid-a (a / t) igniter...

  • Page 399: On-Vehicle Service

    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 labe...

  • Page 400

    Engine and emission control system (tbi for g10) 6e1-9 1. Throttle body 2. Fuel feed hose 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 operat...

  • 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. Note: check that batte...

  • Page 402

    Engine and emission control system (tbi for g10) 6e1-11 1. Fuel filler 2. Ignition switch 3. Fuel return hose 4. Fuel feed hose 1. Fuel pump 2. Filter 3. Fuel tank 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-...

  • Page 403

    6e1-12 engine and emission control system (tbi for g10) 1. Fuel injector wire 2. Fuel injector 3. Upper o-ring 4. Lower o-ring 5. Throttle upper body 6. Gasket 7. Throttle lower body 8. Isc actuator 9. Tp sensor 10. Injector sub wire coupler 11. O-ring 12. Injector wire cover caution: as throttle st...

  • Page 404

    Engine and emission control system (tbi for g10) 6e1-13 1. Fuel injector wire 2. Fuel pressure regulator 3. Tp sensor 4. Screws 5. Isc actuator 1. Injector chamber 2. Fuel return passage 3. Fuel feed passage 4. Vacuum passage for fuel pressure regulator 5. Vacuum passage for map sensor 6. Air induct...

  • Page 405

    6e1-14 engine and emission control system (tbi for g10) (a) 1. Lower body 2. Gasket 1. Wire cover 2. Fuel injector wire 3. Screws 2. Efe heater 3. Gasket 1. Intake manifold assembly 1) install injector wire and coupler to throttle body. Use new o-ring. Tighten injector wire coupler screw to specifie...

  • Page 406

    Engine and emission control system (tbi for g10) 6e1-15 1. Injector coupler 2. Tp sensor 3. Water hose 4. Vacuum hose 5. Isc actuator 6. Fuel return hose 7. Fuel feed hose 1. Injector coupler good no good 2) install throttle body to efe heater and tighten bolts to specified torque. Tightening torque...

  • Page 407

    6e1-16 engine and emission control system (tbi for g10) 1. Injector 1 3 2 1. Injector cavity 2. Lower o-ring 3. Upper o-ring 1. Positive terminal removal note: use care when handling fuel injector especially not to damage filter and its needle. Also, because injector is an electrical component, it s...

  • Page 408

    Engine and emission control system (tbi for g10) 6e1-17 1. Ecm 2. Instrument panel 3. Steering wheel 1. Injector wire 2. Screws 1. Stay 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 a...

  • Page 409

    6e1-18 engine and emission control system (tbi for g10) 1 2 4 3 1. Map sensor 2. 1.5 v battery (4.5 v in total) 3. Vacuum pump 4. Digital type voltmeter manifold absolute pressure sensor (map sensor) map sensor individual check 1) disconnect map sensor vacuum hose from filter. 2) disconnect coupler ...

  • Page 410

    Engine and emission control system (tbi for g10) 6e1-19 1. Tp sensor 2. Tp sensor adjusting holes 3. Tp sensor screw holes 4. Turn tp sensor after fitting and align holes. 1. Throttle stop screw 2. Throttle lever 3. Thickness gauge throttle position sensor (tp sensor) inspection check tp sensor refe...

  • Page 411

    6e1-20 engine and emission control system (tbi for g10) 1. Plunger 2. Throttle lever screw 2) check to make sure that plunger of isc actuator and throttle le- ver screw are not in contact with each other. If they are, warm up engine. 3) loosen tp sensor screws. A) connect suzuki scan tool to dlc wit...

  • Page 412

    Engine and emission control system (tbi for g10) 6e1-21 ( ) for reference k Ω temperature 0 32 20 68 40 104 60 140 80 _c 176 _f (5.88) 2.21–2.69 (1.14) (0.58) 0.29–0.35 2 1 1. Ect sensor 2. Distributor inspection immerse temperature sensing part of iat sensor in water (or ice) and measure resistance...

  • Page 413

    6e1-22 engine and emission control system (tbi for g10) ( ) for reference k Ω temperature 0 32 20 68 40 104 60 140 80 _c 176 _f (5.74) 2.28–2.61 (1.15) (0.584) 0.303–0.326 1. Ect sensor 2. Distributor inspection immerse temperature sensing part of ect sensor in water (or ice) and measure resistance ...

  • Page 414

    Engine and emission control system (tbi for g10) 6e1-23 1. Viewed from terminal side 1. Exhaust manifold 2. Heated oxygen sensor sensor-1 sensor-2 heated oxygen sensor (sensor-1 and sensor-2) oxygen sensor heater inspection 1) disconnect sensor coupler. 2) using ohmmeter, measure resistance between ...

  • 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 cabl...

  • Page 416

    Engine and emission control system (tbi for g10) 6e1-25 1. Main relay 2. Relay box 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...

  • Page 417

    6e1-26 engine and emission control system (tbi for g10) 1. Throttle body 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 t...

  • 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 tha...

  • Page 419

    6e1-28 engine and emission control system (tbi for g10) 1. 1.5 v battery (6.0 v in total) “a” “b” “c” 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...

  • Page 420

    Engine and emission control system (tbi for g10) 6e1-29 1. Isc actuator relay 2. Relay box 1. Efe heater 2. Rubber cover 3. “red” wire 4. “black” wire isc actuator relay inspection 1) disconnect negative cable at battery. 2) remove isc actuator relay from relay box. 3) structure of isc actuator rela...

  • Page 421

    6e1-30 engine and emission control system (tbi for g10) 1. Insulator 2. Lower gasket 3. Heater 1. Intake manifold 2. Efe heater 1. Efe heater relay 2. Relay box 1. Radiator fan motor inspection d check lower gasket for damage and deterioration. Replace as necessary. D check heater and insulator for ...

  • Page 422

    Engine and emission control system (tbi for g10) 6e1-31 1. Rfc relay 2. Relay box 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 opera...

  • Page 423

    6e1-32 engine and emission control system (tbi for g10) rh lh 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 p...

  • 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 te...

  • Page 425

    6e1-34 engine and emission control system (tbi for g10) 1. Tank pipe 2. Purge pipe 3. Air pipe 4. Blow air 1. Tank pressure control valve 2. Orange side 3. Black side 4. To canister 5. From fuel tank evap canister inspection warning: do not suck nozzles on evap canister. Fuel vapor inside evap canis...

  • Page 426

    Engine and emission control system (tbi for g10) 6e1-35 1. Pcv valve 1. Proper size hose 2. Blow air 3. Pcv valve 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 clogge...

  • Page 427: Special Tools

    09913-76011 suzuki scan tool (tech 1a) kit mass storage cartridge 09931-76030 16 / 14 pin dlc cable 1. Fuel pressure gauge 09912-58441 2. Pressure hose 09912-58431 3. 3-way joint & hose 09912-58490 09917-47010 vacuum pump gauge 1. Storage case 2. Operator’s manual 3. Tech 1a 4. Dlc cable (14 / 26 pi...

  • Page 428: Section 6E1

    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: Section 6E2

    6e2 engine and emission control system (sfi for g13) 6e2-1 general description 6e2- 2 . . . . . . . . . . . . . . Air intake system 6e2- 6 . . . . . . . . . . . . . . . . . . Fuel delivery system 6e2- 7 . . . . . . . . . . . . . . Electronic control system 6e2- 8 . . . . . . Engine and emission cont...

  • Page 430: General Description

    6e2-2 engine and emission control system (sfi for g13) the engine and emission control system is divided into 4 major sub-systems: air intake system, fuel de- livery system, electronic control system and emission control system. Air intake system includes air cleaner, throttle body, iac valve and in...

  • 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

    6e2-6 engine and emission control system (sfi for g13) the main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), throttle body (3), idle air control valve (4) and intake manifold (5). The air (by the amount corresponding to the throttle valve (6) opening and engi...

  • Page 435

    6. Evap canister purge valve engine and emission control system (sfi for g13) 6e2-7 the fuel delivery system consists of the fuel tank (11), fuel pump (12), fuel filter (10), fuel pressure regulator (3), delivery pipe (2) and fuel injectors (1). The fuel in the fuel tank (11) is pumped up by the fue...

  • Page 436

    6e2-8 engine and emission control system (sfi for g13) information sensors - 1. Map sensor - 2. Tp sensor - 3. Iat sensor - 4. Ect sensor - 5. Heated oxygen sensor-1 5-1. Heated oxygen sensor-2 - 6. Vss (a / t) - 7. Transmission range switch (a / t) - 8. Battery - 9. Cmp sensor - 10. Ckp sensor - 11...

  • Page 437

    Engine and emission control system (sfi for g13) 6e2-9 fuel pump rela y fuel inject o r ho2s hea ter iac v a l v e ignition coil with igniter egr v a l v e ev ap canister purge v a l v e a/c control module radia t or f an rela y mil main rela y signal from sensor, switch and control module output in...

  • Page 438

    6e2-10 engine and emission control system (sfi for g13) p r n d 2 l.

  • Page 439

    Engine and emission control system (sfi for g13) 6e2-11.

  • Page 440

    12 w / r “n”-range signal (a / t) 13 r heated oxygen sensor-2 14 y / r “d”-range signal (a / t) 15 r / w “r”-range signal (a / t) 16 lg / b a / c sw signal 17 r / w egr valve (stepper motor coil 4) 18 p / g radiator fan relay 19 y / bl fuel pump relay 20 —— ——— 21 w / b “p”-range signal (a / t) 22 p...

  • Page 441: On-Vehicle Service

    1. Accelerator cable 3. Lock nut 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 ...

  • Page 442

    6e2-14 engine and emission control system (sfi for g13) idle speed/idle air control (iac) duty inspection before idle speed / iac duty check, make sure of the following. D lead wires and hoses of electronic fuel injection and engine emission control systems are connected securely. D accelerator cabl...

  • Page 443

    Engine and emission control system (sfi for g13) 6e2-15 caution: do not disassemble iac valve. Disassembly spoils its original performance caution: do not remove or adjust throttle stop screw as it is factory adjusted precisely 1. Throttle body 2. Throttle stop screw 3. Tp sensor 4. O-ring 5. Idle a...

  • Page 444

    6e2-16 engine and emission control system (sfi for g13) 1 2 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...

  • Page 445

    2 1 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 c...

  • Page 446

    3. Fuel return pipe 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 throttl...

  • Page 447

    270 – 310 kpa 2.7 – 3.1 kg / cm 2 38.4 – 44.0 psi at specified idle speed with 1 min. After engine (fuel pump) stop (pressure re- duces as time passes) over 200 kpa 2.0 kg / cm 2 28.4 psi condition fuel pressure with fuel pump operating and engine stopped 200 – 240 kpa 2.0 – 2.4 kpa 28.4 – 34.1 psi ...

  • 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. D vehicle speed = 0 kph d engin...

  • Page 449

    1. Fuel filler 2. Ignition switch 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 pressur...

  • Page 450

    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...

  • 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. If no sound or an unusual sound is...

  • 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...

  • Page 453

    When not using suzuki scan tool : when using suzuki scan tool : 4. Keep as far apart as possible engine and emission control system (sfi for g13) 6e2-25 4) install suitable vinyl tube onto injector nozzle to prevent fuel from splashing out when injecting. 5) put graduated cylinder under injector as ...

  • 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. D ...

  • 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. ...

  • Page 456

    1 2 3 1. Ground terminal 2. Reference voltage terminal 3. Output voltage terminal (a) 1 2 3 4 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 resista...

  • 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 par...

  • Page 458

    2.297 – 2.595 0.298 – 0.320 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- diato...

  • Page 459

    Engine and emission control system (sfi for g13) 6e2-31 1. Viewed from terminal side sensor-1 sensor-2 “v b ” “gnd” heated oxygen sensor (sensor-1 and sensor-2) oxygen sensor heater inspection 1) disconnect sensor coupler. 2) using ohmmeter, measure resistance between terminals “v b ” and “gnd” of s...

  • Page 460

    (a) 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 camshaf...

  • 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. 1) warm ...

  • Page 463

    1 2 1. Suzuki scan tool display 2. Egr valve opening (0: close, 100: full open) engine and emission control system (sfi for g13) 6e2-35 2) connect battery (1) to radiator fan motor coupler (2) as shown in figure, then check that the radiator fan motor operates smoothly. If radiator fan motor does no...

  • Page 464

    6e2-36 engine and emission control system (sfi for g13) 1. Egr valve 2. Connector 1 2 1. Egr valve 2. Valve 3. Valve seat 3 inspection 1) check resistance between following terminals of egr valve in each pair. Terminal standard resistance a – b c – b f – e d – e 20 – 24 Ω if found faulty, replace eg...

  • 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. 3) connect purge hose to evap canister and warm up engi...

  • 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 rest...

  • Page 467: Special Tools

    Engine and emission control system (sfi for g13) 6e2-39 09930-88530 injector test lead 09931-76011 suzuki scan tool (tech 1a) kit mass storage cartridge 09931-76030 16 / 14 pin dlc cable 1. Pressure gauge 09912-58441 2. Pressure hose 09912-58431 3. 3-way joint & hose 09912-58490 4. Checking tool set...

  • Page 468: Section 6F

    6f ignition system 6f-1 general description 6f- 1 . . . . . . . . . . . . . . Diagnosis 6f- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . On-vehicle service 6f- 5 . . . . . . . . . . . . . . . . Ignition spark test 6f- 5 . . . . . . . . . . . . . . . . . . . . High-tension cords 6f- 5 . . ...

  • Page 469

    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 6f-2 ignition system.

  • Page 470: Diagnosis

    Ignition system 6f-3 diagnosis condition possible cause correction engine cranks, but will not start or hard to start d blown fuse for ignition coil d loose connection or disconnection of lead wire or high-tension cord(s) d faulty high-tension cord(s) d faulty spark plug(s) d cracked rotor or cap d ...

  • Page 471

    6f-4 ignition system step action yes no 6 ignition coil power supply and ground circuit check 1) check ignition coil power supply (“b / w” wire) circuit for open and short. Are circuits in good condition? Go to step 7. Repair or replace. 7 ignition coil check 1) check ignition coil for resistance, r...

  • Page 472: On-Vehicle Service

    1. Injector coupler 2. Throttle body 3. Air cleaner case 4. Cylinder head cover 1. High-tension code 2. Cap 1. High-tension cord 2. Ohmmeter ignition system 6f-5 on-vehicle service ignition spark test 1) disconnect injector coupler at throttle body side. Warning: without disconnection of injector co...

  • Page 473

    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...

  • Page 474

    Primary secondary 1. Ohmmeter ignition system 6f-7 ignition coil 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) primary : 0.87 – 1.05 Ω secondary : 11.2 – 15.2 k Ω 4)...

  • Page 475

    1. Pickup coil 2. Signal rotor 3. Screws 1. Distributor 2. Coupler 3. Ohmmeter 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 c...

  • Page 476

    1. Crankshaft pulley 2. Water pump pulley a: to be advanced b: to be retarded 1. Distributor flange bolt 2. Distributor ignition system 6f-9 ignition timing note: before starting engine, place transmission gear shift lever in “neutral” (shift selector lever to “p” range for a/t model), and set parki...

  • Page 477

    1. Cap 2. Cap seal 3. Cap screw 4. Rotor 5. Cmp sensor (signal generator) 6. Screw 7. Cover 8. Housing 9. O-ring a: slot offset 1. Distributor case 2. O-ring 3. Distributor coupling 4. Camshaft 6f-10 ignition system distributor unit dismounting 1) disconnect distributor lead coupler. 2) remove distr...

  • Page 478: Special Tools

    Ignition system 6f-11 09913-76011 suzuki scan tool (tech 1a) kit mass storage cartridge 09931-76030 16 / 14 pin dlc cable 09930-76420 timing light (dry cell type) 1. Storage case 2. Operator’s manual 3. Tech 1a 4. Dlc cable (14/26 pin, 09931-76040) 5. Test lead/probe 6. Power source cable 7. Dlc cab...

  • Page 479: Section 6F

    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: Section 6F1

    6f1 ignition system (sfi for g13) 6f1-1 general description 6f1-2 . . . . . . . . . . . . . . Diagnosis 6f1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . On-vehicle service 6f1-5 . . . . . . . . . . . . . . . . Ignition spark test 6f1-5 . . . . . . . . . . . . . . . . . . . . High-tension ...

  • Page 481: General Description

    1. Ecm (pcm) 2. Ignition coil assembly for no.1 and no.4 spark plugs 3. Ignition coil assembly for no.2 and no.3 spark plugs 4. Cmp sensor 5. Ckp sensor 6. Map sensor 7. Ect sensor 8. Iat sensor 9. Tp sensor 10. Vss (a / t) 11. Transmission range switch (a / t) 12. High-tension cords 13. Vss (speedo...

  • Page 482: Diagnosis

    1. Ignition switch 2. Main relay 3. Ignition coil assembly for no.1 and no.4 spark plugs 4. Ignition coil assembly for no.2 and no.3 spark plugs 5. Cmp sensor 6. Ckp sensor 7. No.1 spark plug 8. No.2 spark plug 9. No.3 spark plug 10. No.4 spark plug 11. Sensed information d map sensor d ect sensor d...

  • Page 483

    6f1-4 ignition system (sfi for g13) ignition system diagnostic flow table step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table” in section 6. 2 ignition spark test 1) check all spark plugs for condition and type referring to “spark plugs” section...

  • Page 484: On-Vehicle Service

    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) remov...

  • Page 485

    “a” 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 c...

  • Page 486

    Ignition system (sfi for g13) 6f1-7 5) measure secondary coil for resistance. Secondary coil resistance : 7.6 – 10.2 k Ω at 20_c, 68_f if resistance is out of specification, replace ignition coil assem- bly. 6) install ignition coil assembly. 7) tighten ignition coil bolts, and then connect ignition...

  • 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. 7) using timing light (1), check t...

  • Page 488: Special Tools

    09931-76011 suzuki scan tool (tech 1a) kit 1. Storage case 2. Operator’s manual 3. Tech 1a 4. Dlc cable (14 / 26 pin, 09931-76040) 5. Test lead / probe 6. Power source cable 7. Dlc cable adaptor 8. Self-test adaptor mass storage cartridge 09931-76030 16 / 14 pin dlc cable ignition system (sfi for g1...

  • Page 489: Section 6K

    6k 1. Exhaust manifold 2. Seal 3. Wu-twc 4. Exhaust pipe 5. Muffler 6. Muffler mounting 7. Gasket 8. Heated oxygen sensor : tightening torque : do not reuse [for 1.0 ȏ 2wd h/b model] exhaust system 6k-1 section 6k exhaust system note: for the descriptions (items) not found in this section, refer to ...

  • Page 490

    [for 1.0 ȏ 2wd n/b model] [for 1.3 ȏ 2wd h/b model] : do not reuse : tightening torque 6. Exhaust no.2 pipe 7. Gasket 8. Muffler 9. Muffler mounting 10. Heated oxygen sensor 11. Exhaust center pipe 1. Exhaust manifold 2. Seal 3. Wu-twc 4. Exhaust pipe 5. Exhaust no.1 pipe 6k-2 exhaust system.

  • Page 491

    : do not reuse : tightening torque 1. Exhaust manifold 2. Seal 3. Exhaust no.1 pipe 4. Exhaust no.2 pipe 5. Gasket 6. Exhaust center pipe 7. Muffler 8. Muffler mounting 9. Heated oxygen sensor [for 1.3 ȏ 4wd model] [for 1.3 ȏ 2wd n/b model] 45 n . M (4.5 kg-m) exhaust system 6k-3.

  • Page 492: Section 7B

    7b automatic transmission (3 a / t) (vehicle with wu-twc) 7b-1 general description 7b- 3 . . . . . . . . . . . . . . Electronic shift control system 7b- 5 . . . . . . . . . Diagnosis 7b-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . On-board diagnostic system 7b-11 . . . . . . . . . . . Pr...

  • Page 493

    7b-2 automatic transmission (3 a / t) (vehicle with wu-twc) table b-1 gear shift failure in “d” or “2” range 7b-38 . . . . . . . . . . . . . . . . . . . . . . . . . . Table b-2 gear is shifted to 2nd gear in “l” range vehicle does not move backward in “r” range 7b-38 . . . . . . . . . . . . . . Tran...

  • Page 494: General Description

    1. Final gear 2. Differential gear assembly 3. Counter shaft 4. 1st and reverse brake 5. Counter driven gear 11. Forward clutch 12. Direct clutch 13. Input shaft 14. Torque converter 15. Oil pump 6. Output shaft 7. Rear planetary gear 8. Front planetary gear 9. Valve body assembly 10. Oil strainer a...

  • Page 495

    7b-4 automatic transmission (3 a / t) (vehicle with wu-twc) components operation chart range gear forward clutch direct clutch second brake 1st & reverse brake one-way clutch parking lock pawl p parking – – – ** f ** – f r reverse – f – f – – n neutral – – – – – – 1st f – – – f – d 2nd f – f – – – 3...

  • Page 496

    [g10 engine model] 1. Pcm 2. Camshaft position (cmp) sensor 3. Throttle position (tp) sensor 4. Engine coolant temperature (ect) sensor 5. Transmission range sensor (shift switch) 6. Output shaft speed sensor (a / t vss) 7. Malfunction indicator lamp (mil) 8. Data link connector (dlc) 9. Shift solen...

  • Page 497

    7b-6 automatic transmission (3 a / t) (vehicle with wu-twc) [g13 engine model] 1. Pcm 2. Camshaft position (cmp) sensor 3. Throttle position (tp) sensor 4. Engine coolant temperature (ect) sensor 5. Transmission range sensor (shift switch) 6. Output shaft speed sensor (a / t vss) 7. Malfunction indi...

  • Page 498

    1. Pcm 2. Instrument panel tp sensor transmission range sensor output shaft speed sensor (a / t vss) shift solenoid-b (2nd brake solenoid valve) shift solenoid-a (direct clutch solenoid valve) pcm 1. Throttle position sensor 2. Throttle body a: ground 3. Ground terminal 4. Reference voltage terminal...

  • Page 499

    1. Transmission range sensor 2. Select cable 1. Transmission 2. Shift solenoid-b (no.2, 2nd brake solenoid valve) 3. Shift solenoid-a (no.1, direct clutch solenoid valve) 4. Oil strainer 7b-8 automatic transmission (3 a / t) (vehicle with wu-twc) transmission range sensor (shift switch) being linked...

  • Page 500

    1. Countershaft gear 2. Output shaft speed sensor a: magnetic core end d or 2 1 →2 18 11 52 33 d 2 →3 33 21 97 61 3 →2 14 9 82 51 d or 2 2 →1 14 9 37 23 l 2 →1 37 23 37 23 full close full open km / h mile / h km / h mile / h throttle speed gear selector vehicle speed upshift downshift throttle v a l...

  • Page 501

    7b-10 automatic transmission (3 a / t) (vehicle with wu-twc) d or 2 1 →2 18 11 58 36 d 2 →3 30 19 110 69 3 →2 14 9 97 61 d or 2 2 →1 14 9 40 25 l 2 →1 40 25 40 25 full close full open km / h mile / h km / h mile / h throttle speed gear selector vehicle speed upshift downshift throttle v a l ve openi...

  • Page 502: Diagnosis

    1. Malfunction indicator lamp (mil) 2. Data link connector (dlc) 3. Suzuki scan tool (tech-1) automatic transmission (3 a / t) (vehicle with wu-twc) 7b-11 diagnosis this vehicle is equipped with an electronic transmission control system, which control the automatic shift up and shift down timing, et...

  • Page 503

    7b-12 automatic transmission (3 a / t) (vehicle with wu-twc) precaution in diagnosing trouble d don’t disconnect couplers from pcm, battery cable from battery, pmc ground wire harness from engine or main fuse before checking the diagnosis information (dtc, freeze frame data, etc.) stored in pcm memo...

  • 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 yes no 1 customer complaint analysis 1) perform customer complaint analysis referring to the next page. Was customer compla...

  • 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 informatio...

  • 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 rang...

  • Page 507

    1. Malfunction indicator lamp (mil) 1. Data link connector (dlc) 1. Data link connector (dlc) 7b-16 automatic transmission (3 a / t) (vehicle with wu-twc) malfunction indicator lamp (mil) check refer to the same item in section 6 or 6-1 for checking procedure. Diagnostic trouble code(s) check 1) tur...

  • Page 508

    Automatic transmission (3 a / t) (vehicle with wu-twc) 7b-17 diagnostic trouble code (dtc) table dtc no. Detecting item detecting condition (dtc will set when detecting:) mil p0705 transmission range sensor no signal or multiple signals inputted with shifted in 1 driving p0705 g 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 d a/t fluid hoses – – – – – disconnection, looseness, deterioration d throttle cable – – – – – play,...

  • Page 510

    Automatic transmission (3 a / t) (vehicle with wu-twc) 7b-19 fig. 1 for step 5. Fig. 2 for step 5. Fig. 3 for step 5. When not using suzuki scan tool: lever position terminal selector automatic transmission basic check this check is very important for troubleshooting when pcm (ecm) has detected no d...

  • Page 511

    7b-20 automatic transmission (3 a / t) (vehicle with wu-twc) symptom-to-inspection table symptom applicable diagnostic flow table. Or 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 exces...

  • Page 512

    *1: for g10 engine model *2: for g13 engine model 1. Pcm 2. Transmission range sensor 3. From ignition switch 4. Shift indicator 5. Backup lamp 6. Terminal arrangement of pcm coupler (viewed from harness side) gr / bl (*1), r / b (*2) automatic transmission (3 a / t) (vehicle with wu-twc) 7b-21 dtc ...

  • Page 513

    7b-22 automatic transmission (3 a / t) (vehicle with wu-twc) fig. 1 for step 2. Fig. 2 for step 2. Fig. 3 for step 2. When not using suzuki scan tool: l ever position terminal selector troubleshooting step action yes no 1 was “automatic transmission diagnostic flow table” performed? Go to step 2. Go...

  • Page 514

    Automatic transmission (3 a / t) (vehicle with wu-twc) 7b-23 fig. 4 for step 4. Fig. 5 for step 4. Range terminal 6 5 1 8 2 3 4 9 10 p p r n n d 2 l.

  • Page 515

    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) 7b-24 automatic transmission (3 a / t) (vehicle with wu-twc) dtc p0720 output speed sensor (a/t vss) circuit malfunction circuit ...

  • Page 516

    Automatic transmission (3 a / t) (vehicle with wu-twc) 7b-25 fig. 1 for step 2. Fig. 2 for step 3. Fig. 3 for step 3. Troubleshooting step action yes no 1 was “automatic transmission diagnostic flow table” performed? Go to step 2. Go to ”automatic transmission diagnostic flow table”. 2 check output ...

  • Page 517

    1. Pcm 2. Shift solenoid-a (no.1, direct clutch solenoid) 3. Shift solenoid-b (no.2, 2nd brake solenoid) 4. Terminal arrangement of pcm coupler (viewed from harness side) *1: for g10 engine model *2: for g13 engine model 7b-26 automatic transmission (3 a / t) (vehicle with wu-twc) dtc p0753 shift so...

  • Page 518

    Automatic transmission (3 a / t) (vehicle with wu-twc) 7b-27 fig. 1 for step 2. Fig. 2 for step 2. Fig. 3 for step 3. When using suzuki scan tool: when not using suzuki scan tool: terminal for solenoid-b (c29-2) terminal for solenoid-a (c29-1) troubleshooting step action yes no 1 was “automatic tran...

  • Page 519

    Acceptable range 1st gear (solenoids on and on) 2nd gear (solenoids on and off) 3rd gear (solenoids off and off) vehicle speed engine speed 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) perfor...

  • Page 520

    Automatic transmission (3 a / t) (vehicle with wu-twc) 7b-29 troubleshooting step action yes no 1 was “automatic transmission diagnostic flow table” performed? Go to step 2. Go to “automatic transmission diagnostic flow table”. 2 is dtc other than shift malfunction (dtc p0751 / p0756) displayed? Go ...

  • 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 yes no 1 was “automatic transmission diagnostic flow table” performed? Go to step 2. Go to “automatic transmission diagnostic flow table”. 2 is engine rpm at stall test norma...

  • Page 522

    Automatic transmission (3 a / t) (vehicle with wu-twc) 7b-31 table a-2 gear change failure step action yes no 1 was “automatic transmission diagnostic flow table” performed? Go to step 2. Go to “automatic transmission diagnostic flow table”. 2 disconnect solenoid valve wire coupler and perform manua...

  • 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/...

  • Page 524

    1. Front drive shaft (lh) 2. Oil pan 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 operat...

  • Page 525

    1. Drive shaft (lh) 2. Oil pan 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 higher than specification in d and r ranges d regula...

  • 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. D the test requires...

  • Page 527

    1. Solenoid valve wire coupler (disconnected) 2. Transmission 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 sele...

  • Page 528

    Without battery voltage with battery voltage 1. Oiler (with transmission fluid) 2. Solenoid valve 3. 12v battery “a”: side hole (should be dry) “b”: exhausting fluid 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 rang...

  • 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 yes no 1 was “table a-2 gear change failure” performed? Go to step 2. Go to “table a-2”. 2 is gear no shift at all? Go to step 3. Go to step 4. 3 perform vehicle speed sensor che...

  • Page 530

    1. Pcm coupler disconnected automatic transmission (3 a / t) (vehicle with wu-twc) 7b-39 transmission range sensor check check transmission range sensor referring to step 2 of dtc p0705 flow table. Output shaft speed sensor check 1) turn off ignition switch. 2) disconnect coupler(s) from powertrain ...

  • Page 531

    1. Output shaft speed sensor 1. Pcm coupler disconnected 7b-40 automatic transmission (3 a / t) (vehicle with wu-twc) separately from the above inspection, output shaft speed sensor itself can be checked on its resistance by disconnecting coupler. Note: d function of output shaft speed sensor can be...

  • Page 532

    1. Solenoid valve wire coupler 2. Terminal for shift solenoid-a. (direct clutch solenoid) 3. Terminal for shift solenoid-b. (2nd brake solenoid) 4. 12 v battery 5. Shift solenoid-b. (2nd brake solenoid valve) 6. Shift solenoid-a. (direct clutch solenoid valve) automatic transmission (3 a / t) (vehic...

  • Page 533: Special Tools

    7b-42 automatic transmission (3 a / t) (vehicle with wu-twc) tightening torque specifications refer to the same section of the service manual mentioned in the “foreword” of this manual. Special tools refer to the same section of the service manual mentioned in the “foreword” of this manual..

  • Page 534: Section 8

    8 body electrical system 8-1 section 8 body electrical system warning: for vehicles equipped with supplemental restraint (air bag) system: 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 ...

  • Page 535: General Description

    Note: terminal arrangement of coupler viewed from harness side. Coupler a 1. To generator w / r 2. To ignition switch b / w 3. To ecm v / g 4. To ecm v 5. Blank – 6. To ect sensor y / w 7. Blank — 8. To engine oil pressure switch y / b 9. To ecm br 10. Blank — 11. To sdm (if equipped) bl 12. Blank —...

  • Page 536: Diagnosis

    Type 1 type 2 body electrical system 8-3 keyless entry system (if equipped) the keyless entry system uses radio wave. When the button on the transmitter is pressed, a signal is transmitted in the form of radio wave to the receiver. Then the signal causes the door lock controller to lock and unlock t...

  • Page 537

    1. Slot 1. To power door lock controller (unlock) 2. To power door lock controller (lock) 3. To ig switch 5. To door switch 6. To gnd 8. To battery 8-4 body electrical system keyless entry system (if equipped) transmitter replacement of the battery if the transmitter becomes unreliable, replace the ...

  • Page 538

    Body electrical system 8-5 code registration procedure 1) start of code registration (initial conditions: ig switch off, all doors closed) 2) open the door and then turn on the ig switch within 10 seconds. 3) turn off the ig switch within 10 seconds after it is turned on. 4) turn the door switch on ...

  • Page 539: Section 8G

    8g immobilizer control system 8g-1 general description 8g- 2 . . . . . . . . . . . . . . On-board diagnostic system (self-diagnosis function) 8g- 4 . . . . . . . . . . . . . Diagnosis 8g- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions in diagnosing troubles 8g- 6 . . . . . . . ....

  • Page 540: General Description

    Ignition key transponder code immobilizer control module ecm (1) (2) (3) (4) 1. Coil antenna 2. Immobilizer control module 3. Engine control module (ecm) 4. Ignition key 8g-2 immobilizer control system general description the immobilizer control system designed to prevent vehicle burglar consists of...

  • Page 541

    Immobilizer control system 8g-3 vehicle without monitor coupler 1. Coil antenna 2. Immobilizer control module 3-1. Ecm (g10 engine) 3-2. Ecm (g13 engine without monitor coupler) 3-3. Ecm (g13 engine with monitor coupler) 4. Immobilizer diagnostic coupler 4-1. Diagnostic output terminal 4-2. Ground t...

  • Page 542

    0.5 time (sec.) ignition switch on high immobilizer control system is normal immobilizer control system is abnormal low 0.5 0.5 0.5 0.5 high low 8g-4 immobilizer control system on-board diagnostic system (self-diagnosis function) immobilizer control module & ecm diagnose troubles which may occur in ...

  • Page 543

    Immobilizer control system 8g-5 0.5 time (sec.) ignition switch on high immobilizer control system is normal immobilizer control system is abnormal low 0.5 0.5 0.5 0.5 high low with the ignition switch turned on (but the engine at stop) regard- less of the condition of the engine and emission contro...

  • Page 544: Diagnosis

    8g-6 immobilizer control system diagnosis ecm and immobilizer control module have on-board diagnostic system (a system self-diagnosis function) as described previously. Investigate where the trouble is by referring to “diagnostic flow table” and “diagnostic trouble code table” on later pages. Precau...

  • Page 545

    Immobilizer control system 8g-7 [intermittent troubles] d there are cases where output of diagnostic output terminal and / or malfunction indicator lamp indicate a diagnostic trouble code representing a trouble which occurred only temporarily and has gone. In such case, it may occur that good parts ...

  • Page 546

    8g-8 immobilizer control system fig. 1 for step 1 fig. 2 for step 1 fig. 3 for step 2 1. Monitor coupler 2. Service wire a: diagnosis switch terminal b: ground terminal fig. 4 for step 3 “check engine” light 0.5 on off time (sec.) diagnostic flow table step action yes no 1 1) make sure that diagnosi...

  • Page 547

    Immobilizer control system 8g-9 step action yes no 1 1) check immobilizer indicator lamp while ignition switch is on (but without starting engine). See fig. 1. Dose immobilizer indicator lamp flash? Go to step 3. D if immobilizer indicator lamp remains on, go to step 2. D if immobilizer indicator la...

  • Page 548

    8g-10 immobilizer control system 1. Immobilizer diagnostic coupler example : d coil antenna failure (code no.13) voltmeter indicator d normal (no code) voltmeter indicator time (sec.) time (sec.) code no. 13 code no. 13 code no. 13 high low high low 1. Monitor coupler 2. Service wire a: diagnosis sw...

  • Page 549

    Immobilizer control system 8g-11 example: when serial data link wire is defective (code no.83) on off malfunction indicator lamp code no.83 code no.83 code no.83 time (sec.) 1. Data link connector (dlc) 3) after completing the check, turn ignition switch off and discon- nect service wire from monito...

  • Page 550

    8g-12 immobilizer control system example: d coil antenna failure (code no.13) example: d normal voltmeter indicator voltmeter indicator high low high low code no. 13 code no. 13 code no. 13 diagnostic trouble code table immobilizer control module diagnostic trouble code diagnostic area diagnosis no....

  • Page 551

    3 to ecm a5 a7 a3 1. Main fuse 2. Main relay 3. Immobilizer control module 4. Immobilizer diagnostic coupler 4-1. Diagnostic output terminal 4-2. Ground terminal in cabin check voltage between a3 terminal and body ground with ignition switch turned on. Is it 10 – 14 v? “ f ” wire open. 1. Connect vo...

  • Page 552

    8g-14 immobilizer control system 1. Main fuse 2. Main relay 3. Ecm 4. Immobilizer indicator lamp (vehicle not equipped with monitor coupler) for g10 engine for g13b engine for g10 engine for g13b engine a-2 immobilizer indicator lamp check (immobilizer indicator lamp dose not light at ignition switc...

  • Page 553

    1. Main fuse 2. Main relay 3. Ecm 4. Immobilizer indicator lamp (vehicle not equipped with monitor coupler) for g10 engine for g13b engine for g10 engine for g13b engine immobilizer control system 8g-15 a-3 immobilizer indicator lamp check (immobilizer indicator lamp remains on after engine starts) ...

  • Page 554

    1 1. Ignition key with built-in transponder 1. Data link connector (dlc) 8g-16 immobilizer control system how to register ignition key register the ignition key with a built-in transponder in immobilizer control module by using the following procedure. 1) prepare suzuki scan tool (tech 1a kit and ca...

  • Page 555: Procedure After Immobilizer

    Immobilizer control system 8g-17 7) if any other transponder code for ignition key with a built-in transponder needs to be registered, repeat above steps 3), 5) and 6). Note: d up to 4 transponder codes for ignition key with a built-in transponder can be registered. D it is not possible to register ...

  • Page 556: Procedure After Ecm

    8g-18 immobilizer control system 09931-76030 16 / 14 pin dlc cable 09931-76011 suzuki scan tool (tech 1a kit) 1. Storage case 2. Operator’s manual 3. Tech 1a 4. Dlc cable (14 / 26 pin, 09931-76040) 5. Test lead / probe 6. Power source cable 7. Dlc cable adapter 8. Self-test adapter immobilizer cartr...

  • Page 557

    Prepared by overseas service department 1st ed. July, 2000 printed in japan printing: 556.