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Suzuki Engine 2002 GRAND VITARA SQ625, Service Manual

The 2002 SUZUKI GRAND VITARA SQ625 Service Manual is available for free download on manualshive.com. This comprehensive manual provides detailed instructions for maintaining and servicing your vehicle's engine, ensuring optimal performance. Download the manual now to access essential information for keeping your Suzuki engine running smoothly.

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ENGINE MECHANICAL (G16 ENGINE) 6A1-41

Valves and Cylinder Head

COMPONENTS

REMOVAL

1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro-

cedure” in Section 6.

2) Disconnect negative cable at battery.

3) Drain cooling system.

1. Valve cotters

6. Exhaust valve

11. Oil jet

2. Valve spring retainer

7. Intake valve

12. Valve guide

3. Valve spring

8. Cylinder head bolt

: Refer to Step 3) of “Installation”.

Tightening torque

4. Valve stem seal

9. Cylinder head

: “TOP” mark provided on gasket comes to 
crankshaft pulley side, facing up.

Do not reuse.

5. Valve spring seat

10. Knock pin

: Apply engine oil to sliding surface of each part.

WARNING:

• Check to make sure that engine coolant temperature is

cold before removing any part of cooling system.

• Also be sure to disconnect negative cable from battery

terminal before removing any part.

4

1

1

4

5

5

7

12

9

6

3

2

3

2

11

10

68 N·m (6.8 kg-m)

8

Summary of Contents for Engine 2002 GRAND VITARA SQ625

Page 1: ...by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing service o...

Page 2: ...one to obtain the full performance of the vehicle When replacing parts or servicing by disassembling it is recommended to use SUZUKI genuine parts tools and service materials lubricant sealants etc as...

Page 3: ...Q420 SQ625 JA627 Wiring Diagram Manual 99512 52D10 015 Applicable model mentioned in Fore word of this manual Other than vehicle identification number of 2S2GTA03C00 and 2S2GTA52C00 SQ416 SQ420 SQ625...

Page 4: ...1 Wheels and Tires 3F Ignition System J20 H25 6F2 4A2 7A DRIVE SHAFT PROP SHAFT Cranking System Reduction Type 6G 4B 7A1 Front Drive Shaft Shaft Bearing Oil Seal 4A2 Charging System 6H 7B1 Propeller S...

Page 5: ......

Page 6: ...der General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Pr...

Page 7: ...75 DTC P0135 HO2S 1 Heater Circuit Malfunction 6 76 DTC P0136 HO2S 2 Circuit Malfunction 6 78 DTC P0141 HO2S 2 Heater Circuit Malfunction 6 80 DTC P0171 Fuel System Too Lean DTC P0172 Fuel System Too...

Page 8: ...0 ENGINES 6 3 Table B 8 A C Condenser Fan Motor Relay Control System Inspection Other than Canvas Top Model If Equipped 6 132 Table B 9 A C Compressor Relay Control System Inspection Other than Canvas...

Page 9: ...d A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surface on initial operation Whenever valve train components pistons piston rings con...

Page 10: ...ause it to be bent against strainer resulting in damaged oil pick up unit It should be kept in mind while working on engine that 12 volt electrical system is capable of violent and damaging short circ...

Page 11: ...cted when engine and exhaust system are hot Fuel or fuel vapor hose connection varies with each type of pipe When reconnecting fuel or fuel vapor hose be sure to con nect and clamp each hose correctly...

Page 12: ...n of servicing connect fuel pump relay to its connector Fuel leakage check procedure After performing any service on fuel system check to make sure that there are no fuel leakages as follows 1 Turn ON...

Page 13: ...nctions When the ignition switch is turned ON with the engine at a stop MIL 1 turns ON to check the bulb and or circuit of the malfunction indicator lamp MIL When ECM PCM detects a malfunction which g...

Page 14: ...rts engine startup and engine shutoff 2 DRIVEING CYCLE DETECTION LOGIC The malfunction detected in the first driving cycle is stored in ECM PCM memory in the form of pending DTC but the mal function i...

Page 15: ...a can be stored The first frame stores the freeze frame data of the mal function which was detected first However the freeze frame data stored in this frame is updated according to the priority descri...

Page 16: ...nicate with an electronic control unit Air bag SDM etc FRAME FRAME 1 FRAME 2 FRAME 3 FRAME 4 MALFUNCTION DETECTED ORDER FREEZE FRAME DATA to be updated 1st FREEZE FRAME DATA 2nd FREEZE FRAME DATA 3rd...

Page 17: ...ol system is free from any trouble after the engine start while engine is running malfunction indicator lamp 1 turns OFF When ECM detects a trouble which has occurred in the above areas it makes malfu...

Page 18: ...s to what functions are available and how to use it Priorities for diagnosing troubles Vehicle without monitor connector If two or more diagnostic trouble codes DTCs are stored proceed to the flow tab...

Page 19: ...tep 11 Go to Step 5 4 Visual Inspection 1 Perform visual inspection referring to the Visual Inspection in the following Is there any faulty condition Go to Step 8 5 Trouble Symptom Confirmation 1 Conf...

Page 20: ...o incorrect diagnosis trouble diagnosis of a normal circuit or difficulty in troubleshooting 3 AND 4 VISUAL INSPECTION As a preliminary step be sure to perform visual check of the items that support p...

Page 21: ...C DIAG FLOW TABLE Based on the DTC indicated in Step 6 or 7 and referring to the applicable DTC diag flow table in this section locate the cause of the trouble namely in a sensor switch wire harness c...

Page 22: ...NERAL INFORMATION AND DIAGNOSIS G16 J20 ENGINES 6 17 Customer Problem Inspection Form Example NOTE The above form is standard sample It should be modified according to conditions characteristic of eac...

Page 23: ...1 located on under side of instrument panel at driver s seat side Special tool A SUZUKI scan tool 3 Turn ignition switch ON and confirm that MIL lights 4 Read DTC pending DTC and freeze frame data ac...

Page 24: ...FF read DTC from flashing pattern of malfunction indicator lamp Refer to Diagnostic Trouble Code Table If lamp remains ON or does not flash go to Diagnostic Flow Table A 4 4 After completing the check...

Page 25: ...FF position 2 Disconnect battery negative cable for specified time below to erase diagnostic trouble code stored in ECM memory and reconnect it Time required to erase DTC NOTE DTC and freeze frame dat...

Page 26: ...n from engine start P0120 No 21 22 TP SENSOR Each control except 4 A T is performed on the basis of 124 5 throttle valve opening 4 A T control is performed on the basis of 0 throttle valve open ing P0...

Page 27: ...le P0130 HO2S circuit malfunction Sensor 1 Min output voltage of HO2S higher than specification 2 driving cycles Not applica ble Max output voltage of HO2S lower than specification P0133 HO2S circuit...

Page 28: ...rcuit open or short 1 driving cycle 1 driving cycle P0420 Catalyst system efficiency below threshold Output waveforms of HO2S 1 and HO2S 2 are similar Time from output voltage change of HO2S 1 to that...

Page 29: ...ranking 2 driving cycles Not applica ble P1500 Starter signal circuit mal function Starter signal is not inputted from engine cranking till its start and after or it is always inputted 2 driving cycle...

Page 30: ...43 No 65 No 66 TCC Solenoid Valve Electrical P0751 Shift Solenoid A 1 Performance or Stuck off P0753 No 61 No 62 Shift Solenoid Valve A 1 P0756 Shift Solenoid B 2 Performance or Stuck off P0758 No 63...

Page 31: ...is indicated turn OFF A C all electric loads P S and all the other necessary switches SCAN TOOL DATA CONDITION NORMAL CONDITION REFERENCE VALUE OTHER COOLANT TEMP Engine Coolant Temp At specified idle...

Page 32: ...no load after warming up 10 25 TOTAL FUEL TRIM At specified idle speed after warming up 35 35 MAP Intake Manifold Abso lute Pressure At specified idle speed after warming up 25 35 kPa 7 4 10 in Hg CA...

Page 33: ...ccording to throttle valve opening SHIFT SOL 1 A CON Shift Solenoid 1 Com mand Signal MON Shift Solenoid 1 Mon itor Ignition switch ON Selector lever is shifted at P R N D 2 or L range Vehicle stops O...

Page 34: ...computation A value of 0 indi cates no correction a value greater than 0 means an enrichment correction and a value less than 0 implies an enleanment correction LONG FT B1 LONG TERM FUEL TRIM Long te...

Page 35: ...S 1 OUTPUT VOLTAGE V It indicates output voltage of HO2S 1 installed on exhaust manifold pre catalyst OXYGEN SENSOR B1 S2 HO2S 2 OUTPUT VOLTAGE V It indicates output voltage of HO2S 2 installed on exh...

Page 36: ...t detects P S operation A C SWITCH ON OFF ON Command for A C operation being output from A C amplifier HVAC control module OFF Command for operation not being output PNP SIGNAL TRANSMISSION RANGE SWIT...

Page 37: ...OFF ON command not being output MON ON Electricity being passed to shift solenoid 1 A MON OFF Electricity not being passed SHIFT SOL 2 CON MON SHIFT SOLENOID 2 B COMMAND MONITOR ON OFF CON ON ON comma...

Page 38: ...orrosion of terminal Drive belt tension damage Section 0B Throttle cable play after warm up engine installation Section 6E1 6E2 Vacuum hoses of air intake system disconnection loose ness deterioration...

Page 39: ...d to ignition system 7 Is immobilizer control system equipped Go to Step 8 Go to Step 9 8 Check immobilizer system malfunction as fol lows 1 Check immobilizer indicator lamp or MIL malfunction indicat...

Page 40: ...n of ECM PCM and Its Circuit in this section Low compression Compression Check in Section 6A1 or 6A4 Faulty hydraulic valve lash adjuster Camshafts and Valve Lash Adjuster in Section 6A4 Compression l...

Page 41: ...pressure regu lator Malfunctioning fuel pump Diag Flow Table B 3 in this section Engine and emission control system out of order Maladjusted TP sensor installation angle TP sensor in Section 6E1 Fault...

Page 42: ...n Section 6E1 Faulty ECM PCM Inspection of ECM PCM and Its Circuit in this section Low compression Previously outlined Others Malfunctioning PCV valve PCV System in Section 6E1 Engine hesitates Moment...

Page 43: ...M PCM and Its Circuit in this section Excessive detonation The engine makes sharp metallic knocks that change with throttle opening Sounds like pop corn popping Engine overheating Refer to Overheating...

Page 44: ...gnition system out of order Faulty spark plug improper gap heavy deposits and burned elec trodes etc Spark Plugs in Section 6F1 or 6F2 Engine and emission control system out of order Fuel pressure out...

Page 45: ...gap Pistons Piston Rings Connecting Rods and Cylinders in Section 6A1 or 6A4 Worn or damaged valve stem seal Valves and Cylinder Head in Section 6A1 or 6A4 Worn valve stem Valves and Cylinder Head in...

Page 46: ...Pistons Piston Rings Connecting Rods and Cylinders in Section 6A1 or 6A4 Worn crankpin Pistons Piston Rings Connecting Rods and Cylinders in Section 6A1 or 6A4 Loose connecting rod nuts Pistons Piston...

Page 47: ...1 2 Check voltage at each terminal of couplers connected using voltmeter 1 and oscilloscope 2 CAUTION PCM ECM cannot be checked by itself It is strictly pro hibited to connect voltmeter or ohmmeter to...

Page 48: ...put for tachometer 0 0 8 V Ignition switch turned ON with engine stop 0 1 V 8 14 V Repeated indicator While engine running Output signal is pulse Pulse fre quency varies depending on engine speed 3000...

Page 49: ...signal if equipped 10 14 V High input Ignition switch turned ON Blower fan selector selected OFF position or A C switch turned OFF or A C evaporator temp less than 2 5 C 36 5 F 0 1 V Low input Ignitio...

Page 50: ...engine running 10 14 V On and after the ignition switch is turned ON for 3 sec with engine stop 24 GRY YEL Ground for CO adjusting resistor Canvas Top model if equipped Below 0 3 V Ignition switch tu...

Page 51: ...1 V Ignition switch turned ON Stop lamp not lighted up 10 14 V Ignition switch turned ON Stop lamp lighted up 35 C51 3 1 LT BLU Intake air temp IAT sensor signal 3 7 3 9 V Ignition switch turned ON I...

Page 52: ...12 shield ground Ground of shield wire for heated oxygen sensor 1 if equipped Below 0 3 V Ignition switch turned ON 13 GRY RED Output of 5 V power source for throttle position TP sensor 4 5 5 5 V Ign...

Page 53: ...clutch TCC solenoid output for A T 0 1 V Ignition switch turned ON A T Lock up not operated 10 14 V Ignition switch turned ON while A T Lock up operated 9 10 BLU GRN A T input shaft speed sen sor sig...

Page 54: ...lected at P position 0 1 V Ignition switch turned ON Selector switch selected at other than P position 19 20 shield ground Ground of shield wire for A T output shaft speed sensor Below 0 3 V Ignition...

Page 55: ...active low pulse Pulse frequency varies depending on engine speed 2 PNK Fuel injector No 1 output 10 14 V Ignition switch turned ON 0 0 6 V 10 14 V Repeated indicator Engine running Output signal is...

Page 56: ...lse Pulse generated times depending vehicle condition 11 GRY BLU IAC valve output stepper motor coil 3 0 1 V Ignition switch turned ON 0 1 V 8 14 V Repeated indicator While engine running Output signa...

Page 57: ...cle condition 18 BLK ORN Canvas Top model 4WD switch signal 0 1 V Ignition switch turned ON Transfer selector lever selected at 4H or 4L position PNK BLU other than Canvas Top model 10 14 V Ignition s...

Page 58: ...2 4 V Repeated indicator Engine running Output signal is active high pulse Pulse frequency varies depending on engine speed 25 BLU YEL Vehicle speed sensor signal 0 1 V 10 14 V Repeated indicator Veh...

Page 59: ...ls of discon nected couplers as listed in the following table CAUTION Never touch terminals of ECM PCM itself or connect volt meter or ohmmeter CAUTION Be sure to connect ohmmeter probe from wire harn...

Page 60: ...Body ground Shift solenoid B A T 11 15 C51 1 2 and Body ground Shift solenoid A A T C51 1 8 and Body ground TCC solenoid A T C51 2 1 and C51 3 4 Fuel injector No 2 13 16 C51 2 2 and C51 3 4 Fuel injec...

Page 61: ...es the main relay to turn ON close the contact point Then ECM being supplied with the main power turns ON the malfunction indicator lamp MIL When the engine starts to run and no malfunction is detecte...

Page 62: ...in Sec tion 6G or 6G1 3 MIL Circuit Check 1 Turn ignition switch OFF and disconnect connectors from ECM 2 Check for proper connection to ECM at ter minal E61 7 3 If OK then using service wire ground...

Page 63: ...Is diag switch terminal connected to ground via service wire System is in good condi tion YEL circuit shorted to ground If circuit is OK substitute a known good ECM PCM and recheck Step Action Yes No...

Page 64: ...Switch On and Engine Doesn t Start Though It Is Cranked Up WIRING DIAGRAM CIRCUIT DESCRIPTION When the ignition switch is turned ON the main relay turns ON the contact point closes and the main power...

Page 65: ...ignition switch disconnect con nectors from ECM PCM and install main relay 2 Check for proper connection to ECM PCM at terminals C51 3 20 E61 9 C51 3 15 and C51 3 4 3 If OK then measure voltage betwe...

Page 66: ...se 2 Main relay 3 Mass air flow sensor 4 ECM PCM DTC DETECTING CONDITION TROUBLE AREA Following conditions are detected for 5 sec continuously Engine running Less than 0 64 mA MAF sensor output curren...

Page 67: ...3 MAF sensor power supply Check 1 With ignition switch OFF disconnect MAF sensor coupler 2 With ignition switch ON check voltage between BLU BLK wire terminal of MAF sensor coupler and ground Is volta...

Page 68: ...on switch and clear DTC pending DTC and freeze frame data by using scan tool and run engine at idle speed and engine coolant temp 110 C 230 F or lower for 10 sec or more 3 Check DTC and pending DTC by...

Page 69: ...n with ignition switch ON is volt age applied to LT BLU wire terminal about 4 6 V Go to Step 4 LT BLU wire open or shorted to power or poor C51 3 1 connection If wire and connection are OK substitute...

Page 70: ...and clear DTC pending DTC and freeze frame data by using scan tool and run engine at idle speed for 10 sec or more 3 Check DTC and pending DTC by using scan tool 1 ECT sensor 2 To combination ECT met...

Page 71: ...n with ignition switch ON is volt age applied to ORN BLK wire terminal about 4 6 V Go to Step 4 ORN BLK wire open or shorted to power or poor C51 3 2 connection If wire and connection are OK substitut...

Page 72: ...ith ignition switch OFF 2 Turn ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool and run engine at idle speed for 10 sec or more 3 Check DTC and pending DTC by usin...

Page 73: ...TP sensor with ignition switch OFF 2 Check for proper connection to TP sensor at each terminals GRY RED wire RED GRN wire and GRY YEL wire 3 If OK then with ignition switch ON check voltage between G...

Page 74: ...or more Engine speed is kept constant in this step 8 Stop vehicle 9 Repeat Step 6 to 8 10 Check DTC and pending DTC by using scan tool DTC DETECTING CONDITION TROUBLE AREA Throttle opening change is...

Page 75: ...eck terminal C51 3 9 for poor connection If OK substitute a known good ECM PCM and recheck Go to Step 6 5 Check TP Sensor and Its Circuit 1 Turn ignition switch ON 2 Check voltage at terminal C51 3 9...

Page 76: ...bed for DTC Confirmation Procedure P0130 LOW VOLTAGE 4 5 V or more HO2S circuit voltage is detected when 5 V power is connected to HO2S circuit in ECM PCM or Max output voltage of HO2S is 0 6 V or low...

Page 77: ...r monitoring test has completed by using scan tool If not in both of above checks i e no pending DTC and oxygen sensor moni toring test not completed check vehicle condition environmental and repeat S...

Page 78: ...3 V indicated Go to Step 4 Go to Step 3 3 HO2S 1 Check 1 With ignition switch OFF disconnect HO2S 1 connector 2 Check for proper connection to HO2S 1 at each terminal 3 If OK connect voltmeter GRY YEL...

Page 79: ...onditions described for DTC Confirmation Procedure Hi Lo cycle TRANS TIME displayed on scan tool of HO2S 1 output voltage is longer than specification or response rates of Hi Lo and Lo Hi TRANS TIME d...

Page 80: ...t racing engine Repeat depressing accelerator pedal 5 to 6 times continuously to enrich A F mixture and take foot off from pedal to enlean and check HO2S output voltage dis played on scan tool Is over...

Page 81: ...pending DTC by using scan tool DTC DETECTING CONDITION TROUBLE AREA Following condition is detected when HO2S heater is electri cally live Current of HO2S heater is 5 3 A or more or less than 0 15 A o...

Page 82: ...pply Check 1 Connect HO2S coupler 2 Check voltage between C51 2 4 terminal of ECM PCM coupler and body ground with ignition switch ON Is it 10 14 V Go to Step 4 BLK WHT or GRY wire open poor HO2S coup...

Page 83: ...to HO2S circuit in ECM PCM While running with A F feed back average output voltage during specified time is too high or too low or while running with A F feed back max output voltage during specified...

Page 84: ...75 kPa or more Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 HO2S 2 Output Voltage Check 1 Connect scan tool to DLC with ignition switch OFF 2...

Page 85: ...sensor heater monitoring test not completed check vehicle conditions environmental and repeat Steps 3 through 5 DTC DETECTING CONDITION TROUBLE AREA Following condition is detected when HO2S 2 heater...

Page 86: ...connector 2 Check voltage between E61 3 terminal of ECM PCM connector and body ground with ignition switch ON Is it 10 14 V Go to Step 4 BLK WHT or PNK GRN circuit open shorted to ground If wire and...

Page 87: ...too lean Short term fuel trim less than 11 or long term fuel trim less than 11 and total trim less than 30 is detected Fuel trim too rich 2 driving cycles detection logic Vacuum leaks air inhaling Ex...

Page 88: ...injectors referring to Fuel Injector in Section 6E1 Is check result satisfactory Go to Step 6 Faulty injector s 6 Check fuel level sensor referring to DTC P0460 Diag Flow Table in this section Is che...

Page 89: ...Misfire which causes catalyst to overheat during 200 engine revolutions is detected at 2 or more cylinders MIL flashes as long as this misfire occurs continu ously Misfire which affects exhaust emissi...

Page 90: ...l injector s referring to Fuel Injector in Section 6E1 Is check result satisfactory Go to Step 6 Replace 6 Ignition Timing Inspection 1 Check ignition timing referring to Ignition Tim ing Check in Sec...

Page 91: ...sensor 2 ECM PCM DTC DETECTING CONDITION TROUBLE AREA Knock sensor output voltage 3 98 V or more Knock sensor output voltage 0 90 V or less RED BLU circuit open or shorted to ground Knock sensor malfu...

Page 92: ...connector 3 With ignition switch at ON position check voltage from RED BLU to body ground ter minal of knock sensor connector See Fig 1 Is it 4 5 V Substitute a known good knock sensor and recheck RE...

Page 93: ...n WIRING DIAGRAM REFERENCE Connect oscilloscope between terminals C51 2 19 and C51 2 20 of ECM PCM connector connected to ECM PCM and check CKP sensor signal Oscilloscope Waveforms A G16 Engine 1 CKP...

Page 94: ...less 560 mmHg 75 kPa or more Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 CKP Sensor and Its Circuit Resistance Check 1 With ignition switch O...

Page 95: ...shaft timing belt pulley for G16 or CKP sensor plate 4 on crankshaft for J20 for the followings See Fig Damage No foreign material attached Correct installation Are they in good condition Intermittent...

Page 96: ...ECM PCM and check CMP sensor signal Oscilloscope Waveforms DTC DETECTING CONDITION AND TROUBLE AREA A G16 Engine 1 Signal rotor on camshaft 3 To main relay B J20 Engine 2 CMP sensor 4 ECM PCM A G16 E...

Page 97: ...Flow Table 2 Is engine cranked Go to Step 3 Go to Section 6G or 6G1 3 Is there DTC P1500 Engine starter signal circuit Go to DTC P1500 Diag Flow Table Go to Step 4 4 Check CMP Sensor and connector for...

Page 98: ...CM PCM Check for intermittent referring to Intermit tent and Poor Connec tion in Section 0A Clean rotor teeth or replace camshaft 10 Check CMP Sensor 2 for Operation as follows 1 Remove CMP sensor 2 2...

Page 99: ...6 94 ENGINE GENERAL INFORMATION AND DIAGNOSIS G16 J20 ENGINES A Fig for Step 5 B Fig for Step 8 G16 C Fig for Step 10 J20 D Fig for Step 9 G16 E Fig for Step 11 J20...

Page 100: ...S 6 95 DTC P0400 Exhaust Gas Recirculation Flow Malfunction SYSTEM WIRING DIAGRAM A Canvas top model 2 Intake manifold 5 Main fuse 8 Fuse box B Other than Canvas top model 3 Exhaust gas 6 Main relay 9...

Page 101: ...st not completed check vehicle conditions environmental and repeat Steps 3 through 6 DTC DETECTING CONDITION TROUBLE AREA During deceleration engine speed high with closed throttle position in which f...

Page 102: ...replace 6 EGR Valve Power Supply Circuit Check 1 With ignition switch OFF disconnect EGR valve coupler 2 With ignition switch ON check voltage between C04 2 BLU BLK wire terminal of EGR valve coupler...

Page 103: ...it for 10 sec 4 Check DTC and pending DTC by using scan tool 1 Main fuse 3 EGR valve 2 Main relay 4 Fuse box DTC DETECTING CONDITION TROUBLE AREA Low voltage is detected at EGR valve stepping motor el...

Page 104: ...Check 1 Connect connector to EGR valve 2 Remove ECM PCM cover and disconnect connector from ECM PCM 3 Check for proper connection to ECM PCM at system related terminals 4 If OK check for resistance b...

Page 105: ...d TWC then passes HO2S 2 at the exhaust oxygen con centration similar to that of the pre catalyst without being oxygenated or converted Thus waveforms of HO2S 1 and HO2S 2 output voltages become alike...

Page 106: ...reful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road NOTE Check to make sure that the following conditions are s...

Page 107: ...pending DTC by using scan tool 1 Main relay 3 EVAP canister purge valve 5 ECM PCM 2 Main fuse 4 Fuse box DTC DETECTING CONDITION TROUBLE AREA Monitor signal of EVAP canister purge valve is different f...

Page 108: ...P canister purge valve wire harness and vacuum pas sage Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Check EVAP canister purge system for opera...

Page 109: ...8 35 at 20 C 68 F 3 Disconnect vacuum hoses from intake manifold and its EVAP canister 4 With coupler disconnected blow into hose A 1 Air should not come out of hose B 2 5 Connect 12 V battery to EVAP...

Page 110: ...g DTC by using scan tool 1 Fuel level sensor 2 Fuel meter in combination meter 3 ECM PCM DTC DETECTING CONDITION TROUBLE AREA Fuel level sensor output voltage higher than specified value is detected f...

Page 111: ...onnection in Section 0A 4 Is voltage in Step 3 9 14 V BLU WHT wire shorted to power circuit or fuel level meter malfunction Go to Step 5 5 Check Fuel Level Sensor 1 Turn ignition switch OFF and discon...

Page 112: ...ay 3 Vehicle speed sensor DTC DETECTING CONDITION TROUBLE AREA Vehicle speed signal not inputted although fuel is kept cut for longer than 5 seconds 2 driving cycles detection logic Vehicle speed sens...

Page 113: ...open short 4 VSS Signal Harness Check 1 With ignition switch ON leaving engine OFF check voltage between BLU YEL and BLK YEL wire terminal of VSS coupler Is voltage 4 V or more Go to Step 5 Go to Ste...

Page 114: ...ox 2 Idle air control valve 4 Sensed information 6 Main relay 8 ECM PCM DTC DETECTING CONDITION TROUBLE AREA Engine idle speed is 100 r min or more lower than target idle speed for longer than 20 sec...

Page 115: ...le speed within specification Intermittent trouble or faulty ECM PCM Check for intermittent referring to Intermittent and Poor Connection in Section 0A Go to Step 3 3 IAC Valve Check 1 Check IAC valve...

Page 116: ...from intake manifold throttle body PCV valve and EVAP canister purge control system Check parts or system which can cause engine low idle Air inhaling from between throttle body and MAF sensor EGR va...

Page 117: ...ND TROUBLE AREA DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool 3 Start engi...

Page 118: ...unning after being warmed up and with throttle opening smaller than specification higher than 4 6 V manifold absolute pressure sensor output voltage is detected for specified time or with throttle ope...

Page 119: ...idling 4 6 V or lower Is check result as specified Intermittent trouble or faulty ECM PCM Check for intermittent referring to Intermittent and Poor Connection in Section 0A Go to Step 3 3 MAP Sensor...

Page 120: ...ore 5 Stop vehicle and run engine at idle 6 Repeat steps 3 5 2 times 7 Check DTC and pending DTC by using scan tool TROUBLESHOOTING DTC P1450 P1451 DTC DETECTING CONDITION TROUBLE AREA DTC P1450 Barom...

Page 121: ...TION TROUBLE AREA Engine starts even though vehicle is at stop and engine start signal is not inputted Engine start signal is inputted for specified time while engine is running 2 driving cycles detec...

Page 122: ...in 3 Check DTC and pending DTC by using scan tool TROUBLESHOOTING 1 Fuse box 2 Main fuse box 3 To DLC 4 ECM PCM DTC DETECTING CONDITION TROUBLE AREA Back up circuit voltage lower than specification is...

Page 123: ...Fuel pump circuit is in good condition Go to Step 2 2 Fuel Pump Circuit Check 1 With ignition switch OFF remove fuel pump relay from connector 2 Check for proper connection to relay at each terminal 3...

Page 124: ...6 119 Fig for Step 2 A Left hand steering vehicle canvas top model B Right hand steering vehicle canvas top model C Left hand steering vehicle other than canvas top model D Right hand steering vehicle...

Page 125: ...Go to Step 3 2 Wire Harness Check 1 Remove ECM PCM cover and discon nect connectors from ECM PCM 2 Check for resistance between following terminals of ECM PCM connector dis connected Fuel injector cir...

Page 126: ...20 ENGINES 6 121 4 Check power circuit of injectors for open and short Is it normal Check all 4 injectors for resistance respectively If resistance is OK substi tute a known good ECM PCM and recheck P...

Page 127: ...1 8 kg cm2 25 6 psi or higher fuel pressure retained for 1 minute after fuel pump is stopped at Step 1 Go to Step 3 Go to Step 4 3 1 Start engine and warm it up to normal oper ating temperature 2 Keep...

Page 128: ...ng it check fuel pressure Is it 450 kPa 4 5 kg cm2 64 0 psi or more Faulty fuel pressure regu lator Clogged fuel filter restricted fuel feed hose or pipe faulty fuel pump or fuel leakage from hose con...

Page 129: ...relay 2 Idle air control valve 4 Sensed information 6 ECM PCM Step Action Yes No 1 Check engine idle speed and IAC duty referring to Idle Speed IAC Duty Inspec tion in Section 6E1 Is idle speed IAC du...

Page 130: ...to Step 1 of Table B 5 or Table B 6 A C if equipped A C signal can be also checked by using SUZUKI scan tool Is it in good condition Go to Step 7 A C signal circuit open or short or A C system mal fu...

Page 131: ...30 in Step 1 of this table Check parts or system which can cause engine low idle Air inhaling from between throttle body and MAF sensor EGR valve malfunction leakage from valve seat Accessory engine l...

Page 132: ...o to Step 2 YEL BLK circuit open or short Evaporative tem perature is below 1 C 34 F or faulty A C sys tem 2 Check A C Cut Signal Circuit 1 Check voltage at terminal E61 8 A C cut signal specification...

Page 133: ...eter ECT meter 7 A C compressor relay 12 DLC 17 Ignition switch 3 HVAC control module 8 Refrigerant pressure switch 13 HTR 60 A fuse 18 Battery 4 A C condenser fan motor relay 9 Heater blower motor re...

Page 134: ...17 and ground under following conditions A C switch signal specification Ignition switch ON and A C switch and or heater blower switch OFF 10 14 V Ignition switch ON and both A C switch and heater bl...

Page 135: ...prevent personal injury This fan is electric and can come on whether or not the engine is running The fan can start automatically in response to the ECT sensor with the ignition switch in the ON posi...

Page 136: ...und Other than conditions A and B in Step 2 10 14 V Under condition A or B in Step 2 0 1 V Is check result as specified Fuse blown RED RED BLK or RED BLU circuit open malfunction of condenser fan moto...

Page 137: ...nser fan motor relay 9 Heater blower motor relay 14 HTR 40 A fuse 12V C51 3 24 C51 3 6 C51 3 17 C51 2 28 1 18 E61 8 7 E61 17 E61 16 E61 13 E61 2 17 GRN BLK PNK WHT 3 A C 10 8 11 9 PPL RED 12 BB YEL WH...

Page 138: ...ge between C51 3 24 and vehicle body ground with engine running Is voltage 0 1 V Go to Step 4 Go to Step 5 4 A C condenser control circuit check 1 Turn OFF ignition switch 2 Check for fuse blowout at...

Page 139: ...Battery 4 A C condenser fan motor relay 9 Heater blower motor relay 14 HTR 40 A fuse 12V C51 3 24 C51 3 6 C51 3 17 C51 2 28 1 18 E61 8 7 E61 17 E61 16 E61 13 E61 2 17 GRN BLK PNK WHT 3 A C 10 8 11 9 P...

Page 140: ...OFF ignition switch 2 Check for fuse blowout at A C 25 A fuse 3 If OK check A C compressor relay referring to A C Compressor Relay and Condenser Fan Motor Relay in Section 6E1 Is check result as speci...

Page 141: ...tachment 09919 46010 4 Checking tool set 09912 58421 4 1 Tool body washer 4 2 Body plug 4 3 Body attachment 4 4 Holder 4 5 Return hose clamp 4 6 Body attachment 2 washer 4 7 Hose attachment 1 4 8 Hose...

Page 142: ...ponents and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please o...

Page 143: ...Bank 1 Sensor 1 No Activity Detected DTC No 13 6 1 75 DTC P0135 HO2S Bank 1 Sensor 1 Heater Circuit Malfunction 6 1 77 DTC P0136 HO2S Bank 1 Sensor 2 Circuit Malfunction 6 1 79 DTC P0141 HO2S Bank 1 S...

Page 144: ...mance Problem 6 1 132 DTC P1500 Engine Start Signal Circuit Malfunction 6 1 134 DTC P1510 ECM Back Up Power Supply Malfunction 6 1 136 Table B 1 Fuel Pump Circuit Check 6 1 138 Table B 2 Fuel Injector...

Page 145: ...protect and lubricate the surface on initial operation Whenever valve train components pistons piston rings con necting rods rod bearings and crankshaft journal bearings are removed for service they s...

Page 146: ...ing short circuits When performing any work where electrical terminals could possibly be grounded ground cable of the battery should be disconnected at battery Any time the air cleaner air cleaner out...

Page 147: ...ompleted Never run engine with fuel pump relay disconnected when engine and exhaust system are hot Fuel or fuel vapor hose connection varies with each type of pipe When reconnecting fuel or fuel vapor...

Page 148: ...ressure in lines Fuel connections are now safe for servicing 5 Upon completion of servicing install fuel pump relay to fuse and relay box Fuel leakage check procedure After performing any service on f...

Page 149: ...Diagnosis Connector ECM PCM in this vehicle has following functions When the ignition switch is turned ON with the engine at a stop MIL 1 turns ON to check the circuit of the malfunction indicator lam...

Page 150: ...ngine startup and engine shutoff 2 Driving Cycles Detection Logic The malfunction detected in the first driving cycle is stored in ECM PCM memory in the form of pending DTC and freeze frame data but t...

Page 151: ...first frame stores the freeze frame data of the mal function which was detected first However the freeze frame data stored in this frame is updated according to the priority described below If malfun...

Page 152: ...AME FRAME 1 FRAME 2 FRAME 3 FRAME 4 MALFUNCTION DETECTED ORDER FREEZE FRAME DATA to be updated 1st FREEZE FRAME DATA 2nd FREEZE FRAME DATA 3rd FREEZE FRAME DATA No malfunction No freeze frame data No...

Page 153: ...lectronic Fuel Injection system is free from any trouble after the engine start while engine is run ning malfunction indicator lamp 1 turns OFF When ECM detects a trouble which has occurred in the abo...

Page 154: ...nd how to use it Priorities for diagnosing troubles vehicle without monitor connector If two or more diagnostic trouble codes DTCs are stored proceed to the flow table of the DTC which was detected ea...

Page 155: ...tion 1 Confirm trouble symptom based on cus tomer complaint analysis DTC s Freeze frame data in Step 1 in the following Is trouble symptom identified Go to Step 6 Go to Step 7 6 DTC Freeze Frame Data...

Page 156: ...INE 6 1 15 11 Final Confirmation Test 1 Clear DTC if any 2 Perform final confirmation test referring to Final Confirmation Test in the following Is there any problem symptom malfunction DTC or abnorma...

Page 157: ...it occurred as described by the customer For this purpose use of such an inspection form will facilitate collecting information to the point required for proper anal ysis and diagnosis CUSTOMER PROBL...

Page 158: ...20 No 75 P0741 P0743 No 65 66 P0751 P0753 P0756 P0758 No 63 64 or P1875 is indicated in this step proceed to DIAGNOSIS in Section 7B1 INSPECTION ITEM REFERRING SECTION Engine oil level leakage Section...

Page 159: ...Table 2 Check battery voltage Is it 11 V or more Go to Step 3 Charge or replace battery 3 Is engine cranked Go to Step 4 Go to Diagnosis Table in Section 6G 4 Does engine start Go to Step 5 Go to Step...

Page 160: ...to occur e g wire harness connector etc referring to Intermittent and Poor Connectio in Section 0A and related circuit of DTC recorded in Step 2 11 FINAL CONFIRMATION TEST Confirm that the problem sym...

Page 161: ...ted on underside of instrument panel at driver s seat side Special tool A SUZUKI scan tool 3 Turn ignition switch ON and confirm that MIL lights 4 Read DTC and freeze frame data according to instructi...

Page 162: ...ON position and leaving engine OFF read DTC from flashing pattern of malfunction indicator lamp Refer to Diagnostic Trouble Code Table If lamp remains ON go to Diagnostic Flow Table A 1 4 After comple...

Page 163: ...on 2 Disconnect battery negative cable for specified time below to erase diagnostic trouble code stored in ECM memory and reconnect it Time required to erase DTC NOTE DTC and freeze frame data stored...

Page 164: ...plicable Max output voltage of HO2S 1 is lower than specification P0133 HO2S circuit slow response Bank 1 Sensor 1 Response time of HO2S 1 output voltage between rich and lean is longer than specifica...

Page 165: ...nd long term added is smaller than specification for speci fied time or longer Fuel trim toward lean side is large 2 driving cycles Not applicable P0174 Fuel system too lean Bank 2 Short term fuel tri...

Page 166: ...le speed sensor mal function No signal while running in D range or during fuel cut at deceler ating 1 driving cycle 1 driving cycle P0505 Idle control system malfunc tion No closed signal to IAC valve...

Page 167: ...1 Shift solenoid A 1 performance or stuck off P0753 No 61 No 62 Shift solenoid A 1 electrical P0756 Shift solenoid B 2 performance or stuck off P0758 No 63 No 64 Shift solenoid B 2 electrical P1875 4W...

Page 168: ...med on the basis of 8 deg throttle opening A T control is performed on the basis of 0 throttle position Detected value of TP sensor output voltage is 0 10 V min and 4 80 V max P0500 No 24 VEHICLE SPEE...

Page 169: ...tor connector 750 rpm CLOSED THROT POS Closed Throttle Position Ignition switch ON Accelerator pedal released ON Accelerator pedal depressed OFF IAC FLOW DUTY At specified idle speed after warming up...

Page 170: ...ne running at idle speed and steering wheel at straighta head position OFF Engine running at idle speed and steering wheel turned to the right or left as far as it stops ON A C SWITCH if equipped When...

Page 171: ...SELECT SW Power Normal Change Switch Ignition switch ON P N change switch is at normal position NORMAL Ignition switch ON P N change switch is at power position POWER 4WD L SW 4WD Low Switch Ignition...

Page 172: ...e air fuel mixture computation A value of 0 indi cates no correction a value greater than 0 means an enrichment correction and a value less than 0 implies an enleanment correction LONG FT B1 LONG TERM...

Page 173: ...en sensor s as feedback for fuel control OPEN DRIVE COND Open loop due to driving conditions Power enrichment etc OPEN SYS FAULT Open loop due to detected system fault CLOSED ONE O2S Closed loop but f...

Page 174: ...dicated fuel level may be only 70 even when the fuel tank is full ELECTRIC LOAD ON OFF ON Small light switch ON or rear window defogger switch ON OFF Small light switch OFF and rear window defogger sw...

Page 175: ...command not being output MON ON Electricity being passed to TCC solenoid MON OFF Electricity not being passed TRANS RANGE TRANSMISSION RANGE R N D 2 or L It indicates transmission range according to...

Page 176: ...CM PCM Inspection of ECM PCM and Its Circuit in this section Low compression Compression Check in Section 6A2 Faulty hydraulic valve lash adjuster Camshaft and Valve Lash Adjuster in Sec tion 6A2 Comp...

Page 177: ...s Dragging brakes Diagnosis Table in Section 5 Slipping clutch Diagnosis Table in Section 7C Improper engine idling or engine fails to idle Ignition system out of order Faulty spark plug Spark Plugs i...

Page 178: ...y TP sensor ECT sensor or MAF sensor TP Sensor ECT Sensor or MAF Sen sor in Section 6E2 Faulty ECM PCM Inspection of ECM PCM and Its Circuit in this section Low compression Previously outlined Surges...

Page 179: ...r Fuel Injector in Section 6E2 Faulty ECM PCM Inspection of ECM PCM and Its Circuit in this section Others Excessive combustion chamber depos its Valves and Cylinder Heads and Pistons Piston Rings Con...

Page 180: ...Faulty A C condenser fan control system Diag Flow Table B 5 in this section Excessive engine oil consumption Oil entering combustion chamber Sticky piston ring Piston Piston Rings Connecting Rods and...

Page 181: ...Connecting Rods and Cylinders in Section 6A2 Worn crankpin Piston Piston Rings Connecting Rods and Cylinders in Section 6A2 Loose connecting rod nuts Piston Piston Rings Connecting Rods and Cylinders...

Page 182: ...ked at ECM PCM wiring couplers by measuring voltage pulse signal and resistance Voltage Check 1 Remove ECM PCM cover from bracket referring to Engine Control Module ECM Power train Control Module PCM...

Page 183: ...Output signal is pulse Pulse frequency varies depending on engine speed 3000 r min 100 Hz E61 5 YEL BLU A C condenser fan motor relay if equipped 10 14 V Ignition switch turned ON Engine cool ant tem...

Page 184: ...Off switch pushed 10 14 V Ignition switch turned ON while OD On Off switch not pushed E61 15 BLK RED Electric load signal for rear defogger switch if equipped 0 1 V Ignition switch turned ON rear def...

Page 185: ...d ON with A C evaporator temp more than 4 C 39 2 F E61 29 RED YEL Electric load signal for clear ance lamp 0 1 V Ignition switch turned ON Clearance lamp not lighted up 10 14 V Ignition switch turned...

Page 186: ...er after warmed up C51 3 5 BLK RED Heater output of heated oxy gen sensor 1 Bank 2 if equipped 10 14 V Ignition switch turned ON 0 1 V 10 14 V Repeated indicator Engine running at idling after warming...

Page 187: ...4 RED BLK Oxygen signal of heated oxy gen sensor 2 Bank 1 if equipped 0 5 1 5 V Ignition switch turned ON Deflects between over 1 2 V and under 0 6 V While engine running at 2 000 r min for 1min or lo...

Page 188: ...warmed up C51 3 25 BLK GRN Ground for ECM Below 0 3 V Ignition switch turned ON C51 3 26 BLK BLU Ground for ECM Below 0 3 V Ignition switch turned ON C51 1 1 GRN RED Shift solenoid B output for A T 0...

Page 189: ...ignal 0 1 V Ignition switch turned ON 4 6 V 4 6 V Repeated indicator Engine running at idling after warming up between A T output shaft speed sensor signal and Input signal is sinusoidal waveform Wave...

Page 190: ...gnition switch turned ON Transfer selector lever selected at 4H or 4L position 0 1 V Ignition switch turned ON Transfer selector lever selected at 2H position C51 1 19 GRN BLU L position signal for tr...

Page 191: ...0 14 V Ignition switch turned ON with engine stop 0 0 6 V 10 14 V Repeated indicator Engine running Output signal is active low pulse Pulse frequency varies depending on engine speed C51 2 8 BLK GRN G...

Page 192: ...8 14 V Repeated indicator While engine running Output signal is active low duty pulse Pulse generated time depending vehi cle condition C51 2 17 LT GRN YEL EGR valve stepper motor coil 3 output if eq...

Page 193: ...e depending vehi cle condition C51 2 25 GRY BLU IAC valve output stepper motor coil 3 10 14 V Ignition switch turned ON 0 1 V 8 14 V Repeated indicator While engine running Output signal is active low...

Page 194: ...51 2 3 A C condenser fan motor relay if equipped 75 110 Battery disconnected and ignition switch ON E61 8 E61 35 Main relay 160 240 E61 12 Body ground Fuel level sensor 117 5 122 5 Fuel level is Empty...

Page 195: ...r No 3 C51 2 18 C51 2 20 Fuel injector No 4 C51 2 28 C51 2 20 Fuel injector No 5 C51 2 27 C51 2 20 Fuel injector No 6 C51 2 15 C51 2 20 IAC valve stepper motor coil 1 21 23 C51 2 14 C51 2 20 IAC valve...

Page 196: ...ECM causes the main relay to turn ON Then ECM PCM being supplied with the main power turns ON the malfunction indicator lamp When the engine starts to run and no malfunction is detected in the system...

Page 197: ...d condition Go to Step 2 Test switch terminal circuit is shorted to ground Repair or correct 2 Ignition Switch Signal check 1 Remove ECM PCM cover 2 With ignition switch ON leaving engine OFF check vo...

Page 198: ...check DTC Is there any DTC s Go to Step 2 of Engine Diag Flow Table in this section Go to Step 2 2 MIL Circuit check 1 With ignition switch OFF disconnect cou plers from ECM PCM Does MIL turn ON at i...

Page 199: ...tch OFF and disconnect connectors from ECM PCM Does MIL turn ON at ignition switch ON PPL YEL circuit shorted to ground Go to Step 2 2 ECM PCM Connection check 1 Turn ignition switch OFF Is connector...

Page 200: ...ignition switch ON and engine does not start though it is cranked up WIRING DIAGRAM CIRCUIT DESCRIPTION When the ignition switch is turned ON the main relay turns ON and the main power is supplied to...

Page 201: ...eck 1 Turn OFF ignition switch disconnect con nectors from ECM PCM and install main relay 2 Check for proper connection to ECM PCM at terminals C51 2 3 20 21 and E61 8 3 If OK then measure voltage bet...

Page 202: ...AREA A Terminal arrangement of ECM PCM coupler viewed from harness side 1 Main relay 2 Mass air flow sensor DTC DETECTING CONDITION TROUBLE AREA Engine running and more than 5 0 V MAF sensor output vo...

Page 203: ...test should be carried out with 2 person a driver and tester on a level road Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 MAF Sensor Power Sup...

Page 204: ...than 0 16 V IAT sensor output voltage continues for 5 sec More than 5 0 V IAT sensor output voltage continues for 5 sec IAT sensor circuit IAT sensor ECM PCM NOTE Check to make sure that following co...

Page 205: ...n 0A 3 Check Wire Harness 1 Disconnect IAT sensor connector 1 with igni tion switch OFF 2 Check for proper connection to IAT sensor at LT BLU and GRY YEL wire terminals 3 If OK then with ignition swit...

Page 206: ...CEDURE A Terminal arrangement of ECM PCM coupler viewed from harness side 1 ECT sensor DTC DETECTING CONDITION TROUBLE AREA ECT sensor signal terminal voltage is less than 0 16 V for 5 sec ECT sensor...

Page 207: ...re Harness 1 Disconnect ECT sensor connector 2 Check engine coolant temp displayed on scan tool Is 40 C 40 F indicated Replace ECT sensor ORN BLK wire shorted to ground If wire is OK substitute a know...

Page 208: ...sing scan tool A Terminal arrangement of ECM PCM coupler viewed from harness side 1 Throttle position sensor DTC DETECTING CONDITION TROUBLE AREA TP sensor signal terminal voltage continues less than...

Page 209: ...wire terminal of TP sensor coupler and ground Is voltage 4 5 5 5 V Go to Step 3 GRY RED wire open or shorted to ground circuit or power circuit or poor C51 3 11 connection GRY YEL wire open or poor C...

Page 210: ...CONDITION TROUBLE AREA Throttle opening is detected as small rationality low while engine is running under high road and high speed conditions or as large rationality high while engine is running unde...

Page 211: ...Repair or replace 4 TP Sensor Performance check 1 Check TP Sensor referring to Section 6E2 Is check result as specified Go to Step 5 Faulty TP sensor 5 TP Sensor Reference Voltage check 1 With ignitio...

Page 212: ...DETECTING CONDITION AND TROUBLE AREA A Terminal arrangement of ECM PCM coupler viewed form harness side 2 HO2S 4 IG COIL fuse 1 HO2S heater relay 3 Main fuse DTC DETECTING CONDITION TROUBLE AREA Minim...

Page 213: ...and 158 F Atmospheric pressure higher than 560 mmHg Altitude lower than 2790 m 9150 ft Following DTC is not detected P0135 Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to...

Page 214: ...or in Section 6E2 Are they in good condition Go to Step 7 Faulty fuel injector s 7 Fuel Pressure inspection 1 Check fuel pressure referring to following Table B 3 in this section Is fuel pressure with...

Page 215: ...e is longer than 5 sec HO2S HO2S circuit ECM PCM WARNING When performing a road test select a place where there is no traffic or possibility of a traffic acci dent and very careful during to avoid occ...

Page 216: ...tem ECM PCM WARNING When performing a road test select a place where there is no traffic or possibility of a traffic acci dent and very careful during to avoid occurrence of an accident Road test shou...

Page 217: ...ition Go to Step 5 Repair or replace 5 Fuel Injector Circuit check 1 Check fuel injector circuit referring to Table B 2 in this section Is it in good condition Go to Step 6 Repair or replace 6 Fuel In...

Page 218: ...a traffic acci dent and very careful during to avoid occurrence of an accident Road test should be carried out with 2 person a driver and tester on a level road NOTE Check to make sure that following...

Page 219: ...install HO2S heater relay 2 With ignition switch ON leaving engine OFF check voltage between C51 3 6 and ground Is the voltage 10 14 V Substitute a known good ECM PCM and recheck Faulty HO2S heater re...

Page 220: ...ess side 2 HO2S 4 IG COIL fuse 1 HO2S heater relay 3 Main fuse DTC DETECTING CONDITION TROUBLE AREA Maximum HO2S voltage is higher than 2 0 V for 20 sec Maximum HO2S voltage is less than 0 35 V for 8...

Page 221: ...i dent and very careful during to avoid occurrence of an accident Road test should be carried out with 2 person a driver and tester on a level road Step Action Yes No 1 Was Engine Diag Flow Table perf...

Page 222: ...specified value HO2S HO2S circuit ECM PCM NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PRO CEDURE WARNING When performing a road test select a place...

Page 223: ...stall HO2S heater relay 2 With ignition switch ON leaving engine OFF check voltage between C51 3 17 and ground Is the voltage 10 14 V Substitute a known good ECM PCM and recheck Faulty HO2S heater rel...

Page 224: ...DETECTING CONDITION AND TROUBLE AREA A Terminal arrangement of ECM PCM coupler viewed from harness side 2 HO2S 4 IG COIL fuse 1 HO2S heater relay 3 Main fuse DTC DETECTING CONDITION TROUBLE AREA Minim...

Page 225: ...ring to avoid occurrence of an accident Road test should be carried out with 2 person a driver and tester on a level road Step Action Yes No 1 Was Engine DIag Flow Table performed Go to Step 2 Go to E...

Page 226: ...or in Section 6E2 Are they in good condition Go to Step 7 Faulty fuel injector s 7 Fuel Pressure inspection 1 Check fuel pressure referring to following Table B 3 in this section Is fuel pressure with...

Page 227: ...his step 6 Stop vehicle and check DTC and pending DTC by using scan tool DTC TROUBLESHOOTING DTC DETECTING CONDITION TROUBLE AREA Hi Low switch cycle average of HO2S voltage is longer than 5 sec HO2S...

Page 228: ...cle and check DTC and pending DTC by using scan tool DTC TROUBLESHOOTING DTC DETECTING CONDITION TROUBLE AREA HO2S voltage is lower than 0 5 V HO2S HO2S circuit Fuel injector Fuel pressure control sys...

Page 229: ...ondition Go to Step 5 Repair or replace 5 Fuel Injector Circuit check 1 Check fuel injector circuit referring to Table B 2 in this section Is it in good condition Go to Step 6 Repair or replace 6 Fuel...

Page 230: ...specified value HO2S HO2S circuit ECM PCM NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PRO CEDURE WARNING When performing a road test select a place...

Page 231: ...stall HO2S heater relay 2 With ignition switch ON leaving engine OFF check voltage between C51 3 5 and ground Is the voltage 10 14 V Substitute a known good ECM PCM and recheck Faulty HO2S heater rela...

Page 232: ...ess side 2 HO2S 4 IG COIL fuse 1 HO2S heater relay 3 Main fuse DTC DETECTING CONDITION TROUBLE AREA Maximum HO2S voltage is higher than 2 0 V for 20 sec Maximum HO2S voltage is less than 0 35 V for 8...

Page 233: ...ci dent and very careful during to avoid occurrence of an accident Road test should be carried out with 2 person a driver and tester on a level road Step Action Yes No 1 Was Engine Diag Flow Table per...

Page 234: ...specified value HO2S HO2S circuit ECM PCM NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PRO CEDURE WARNING When performing a road test select a place...

Page 235: ...install HO2S heater relay 1 2 With ignition switch ON leaving engine OFF check voltage between C51 3 16 and ground Is the voltage 10 14 V Substitute a known good ECM PCM and recheck Faulty HO2S heater...

Page 236: ...ssure out of specification Fuel injector malfunction Heated oxygen sensor malfunction MAF sensor malfunction ECT sensor malfunction Fuel level sensor malfunction NOTE Check to make sure that following...

Page 237: ...tisfactory Go to Step 8 Faulty fuel level sensor or its circuit 8 Check MAF sensor referring to MAF Sensor in Section 6E2 Is check result satisfactory Go to Step 9 Faulty MAF sensor or its circuit 9 C...

Page 238: ...ure out of specification Fuel injector malfunction Heated oxygen sensor malfunction MAF sensor malfunction ECT sensor malfunction Fuel level sensor malfunction NOTE Check to make sure that following c...

Page 239: ...tisfactory Go to Step 8 Faulty fuel level sensor or its circuit 8 Check MAF sensor referring to MAF Sensor in Section 6E2 Is check result satisfactory Go to Step 9 Faulty MAF sensor or its circuit 9 C...

Page 240: ...l if any 3 Operate vehicle within freeze frame data condition as noted for 1 min 4 Stop vehicle and check DTC and pending DTC by using scan tool DTC DETECTING CONDITION TROUBLE AREA P0300 Misfire whic...

Page 241: ...t mak ing operating sound If OK substitute a known good ECM PCM and recheck 5 Fuel Pressure inspection 1 Check fuel pressure referring to Table B 3 in this section Is check result satisfactory Go to S...

Page 242: ...function ECM malfunction Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 1 With engine running check voltage from C51 3 18 terminal of ECM connect...

Page 243: ...6 1 102 ENGINE GENERAL INFORMATION AND DIAGNOSIS H25 ENGINE A Fig 1 for Step 3 B Fig 2 for Step 3 1 Knock sensor 2 Knock sensor connector...

Page 244: ...10 sec 4 Check DTC by using scan tool A Terminal arrangement of ECM PCM coupler viewed from harness side 1 CKP sensor DTC DETECTING CONDITION TROUBLE AREA CKP sensor signal is not input for 3 sec afte...

Page 245: ...P Sensor Resistance check 1 With ignition switch OFF disconnect CKP sensor coupler 2 Check resistance between WHT wire ter minal and RED wire terminal of CKP sen sor coupler Is the resistance 485 655...

Page 246: ...360 pulses 1 revolution of camshaft Each of POS signals has equivalent wavelength Based on POS signal ECM PCM judges the wavelength of REF signals engine speed and piston position DTC DETECTING CONDIT...

Page 247: ...heck 1 With ignition switch OFF disconnect CMP sensor coupler 1 2 With ignition switch ON check voltage between BLU BLK wire terminal and GRY YEL wire terminal of CMP sensor coupler Is the voltage 10...

Page 248: ...ENGINE GENERAL INFORMATION AND DIAGNOSIS H25 ENGINE 6 1 107 Fig for Step 4...

Page 249: ...NE DTC P0400 Exhaust Gas Recirculation Flow Malfunction DTC No 51 SYSTEM WIRING DIAGRAM SYSTEM DESCRIPTION A Terminal arrangement of ECM PCM coupler viewed from harness side 2 Intake manifold 4 EGR va...

Page 250: ...r 3 min Throttle valve operating is kept constant in this step 6 Stop vehicle and check DTC and pending DTC by using scan tool DTC TROUBLESHOOTING DTC DETECTING CONDITION TROUBLE AREA The difference o...

Page 251: ...valve cou pler and ground Is each voltage 10 14 V Go to Step 5 Faulty BLU BLK wire 5 EGR Valve 2 Stepper Motor Coil Circuit check 1 With ignition switch OFF connect EGR cou pler and disconnect ECM PC...

Page 252: ...ing DTC by using scan tool A Terminal arrangement of ECM PCM coupler viewed from harness side 2 Main relay 4 Fuse box 1 Main fuse 3 EGR valve DTC DETECTING CONDITION TROUBLE AREA Low voltage is detect...

Page 253: ...Check 1 Connect connector to EGR valve 2 Remove ECM PCM cover and disconnect connector from ECM PCM 3 Check for proper connection to ECM PCM at system related terminals 4 If OK check for resistance be...

Page 254: ...the output voltage of HO2S 2 is main tained at specified level As TWC is in becomes deteriorated even when the above control is going on the exhaust gas which has passed TWC then passes HO2S 2 at the...

Page 255: ...pending DTC by using scan tool DTC TROUBLESHOOTING DTC DETECTING CONDITION TROUBLE AREA Output waveform of HO2S S 2 becomes similar to that of HO2S S 1 TWC converter Exhaust system HO2S SENSOR 2 HO2S...

Page 256: ...D DIAGNOSIS H25 ENGINE 6 1 115 5 1 Replace BANK 1 BANK 2 warm up TWC converter 2 Perform DTC confirmation procedure Is DTC P0420 P0430 detected Substitute a known good ECM PCM and recheck Replace TWC...

Page 257: ...g scan tool A Terminal arrangement of ECM PCM coupler viewed from harness side 2 Main relay 1 Main fuse 3 EVAP canister purge valve DTC DETECTING CONDITION TROUBLE AREA Monitor signal of EVAP canister...

Page 258: ...is section Is check result satisfactory Intermittent trouble or faulty ECM PCM Check for intermittent referring to Intermittent and Poor Connection in Section 0A Go to Step 3 3 Check EVAP canister pur...

Page 259: ...AP canister purge valve and its circuit are in good condition connect vacuum hoses securely If not proceed to Step 4 b Not using SUZUKI scan tool i Using service wire connect C51 2 1 terminal of ECM P...

Page 260: ...onnected blow into hose A Air should not come out of hose B If not replace EVAP canister purge valve 7 Connect 12 V battery to solenoid purge valve terminals In this state blow hose A Air should come...

Page 261: ...um is not felt there when engine is running at idle speed 6 Release parking brake lever set transfer in 2H and M T in 1st or A T in L 7 Also check that vacuum is felt when engine speed is increased to...

Page 262: ...nding DTC by using scan tool A Terminal arrangement of ECM PCM coupler viewed from harness side 1 Fuel level meter in combination meter 2 Fuel level sensor DTC DETECTING CONDITION TROUBLE AREA Fuel le...

Page 263: ...ignition switch OFF connect L15 cou pler floor harness to R01 coupler fuel tank harness 3 With ignition switch OFF disconnect G10 coupler instrument panel harness of com bination meter 4 Check resist...

Page 264: ...nt of ECM PCM coupler viewed from harness side 1 Vehicle speed sensor 2 Main relay 3 Speedometer DTC DETECTING CONDITION TROUBLE AREA Vehicle speed sensor signal is not inputted while fuel is cut for...

Page 265: ...ster on a level road Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Does speedometer indicate vehicle speed Faulty BLU YEL wire poor C51 3 1 conn...

Page 266: ...on switch OFF disconnect cou plers from combination meter 2 With ignition switch ON leaving engine OFF check voltage between BLU YEL wire ter minal and BLK YEL wire terminal of VSS coupler Is voltage...

Page 267: ...SIS H25 ENGINE DTC P0505 Idle Air Control System Malfunction SYSTEM WIRING DIAGRAM A Terminal arrangement of ECM PCM coupler viewed from harness side 2 Fast idle control system 4 Engine coolant 6 Cold...

Page 268: ...d ECM PCM NOTE Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PRO CEDURE Intake air temperature between 14 C and 70 C 6 8 F and 158 F Atmospheric pressure...

Page 269: ...g and air inhabit 2 Check fast idle up system referring to Throttle Valve in Section 6E2 Are they in good condition Go to Step 7 Repair or replace 7 VSS check 1 Perform DTC confirm procedure of VSS re...

Page 270: ...can tool 2 Turn ON ignition switch and clear DTC by using scan tool if any 3 Start engine and run it for 10 sec 4 Check DTC by using scan tool DTC TROUBLESHOOTING DTC DETECTING CONDITION TROUBLE AREA...

Page 271: ...continues more than 2 7 V for 5 sec under low load condition MAP sensor signal voltage continues less than 1 1 V for 5 sec under high load condition MAP sensor and its circuit ECM PCM NOTE Check to m...

Page 272: ...3 Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 MAP Sensor Signal check 1 Remove ECM PCM cover 2 Check voltage between C51 3 13 and C51 3 21 as...

Page 273: ...E Check to make sure that following conditions are satisfied when using this DTC CONFIRMATION PRO CEDURE Intake air temperature between 5 C and 70 C 6 8 F and 158 F Atmospheric pressure higher than 56...

Page 274: ...ENGINE GENERAL INFORMATION AND DIAGNOSIS H25 ENGINE 6 1 133 Fig and Table for Step 3...

Page 275: ...ngine starter circuit while engine cranking DTC DETECTING CONDITION AND TROUBLE AREA A Terminal arrangement of ECM PCM coupler viewed from harness side 2 Transmission range switch 1 Ignition switch DT...

Page 276: ...4 C and 70 C 6 8 F and 158 F Atmospheric pressure higher than 560 mmHg Altitude lower than 2790 m 9150 ft Step Action Yes No 1 Was Engine Diag Flow Table performed Go to Step 2 Go to Engine Diag Flow...

Page 277: ...ignition switch OFF connect scan tool 2 Turn ON ignition switch and clear DTC by using scan tool if any 3 Start engine and run it for 10 sec 4 Check DTC by using scan tool A Terminal arrangement of E...

Page 278: ...ow Table performed Go to Step 2 Go to Engine Diag Flow Table 2 Battery Voltage Supply Circuit check 1 Remove ECM PCM cover 2 While engine running check voltage between E61 35 and ground Is voltage 10...

Page 279: ...el pump relay is turned ON for 3 sec after ignition switch is turned ON while start engine signal is inputted while engine is running A Terminal arrangement of ECM PCM coupler viewed from harness side...

Page 280: ...OFF remove fuel pump relay 4 from connector 5 2 Using service wire 1 connect PNK BLK wire terminal 2 and BLU BLK wire termi nal 3 of relay connector Is fuel pump operation sound heard with ignition s...

Page 281: ...140 ENGINE GENERAL INFORMATION AND DIAGNOSIS H25 ENGINE Table B 2 Fuel Injector Circuit Check WIRING DIAGRAM A Terminal arrangement of ECM PCM coupler viewed from harness side 1 Fuel injector 2 Main r...

Page 282: ...s C51 2 6 C51 2 20 C51 2 7 C51 2 20 C51 2 18 C51 2 20 C51 2 19 C51 2 20 C51 2 27 C51 2 20 C51 2 28 C51 2 20 10 14 at 20 C Is check result as specified Fuel injector circuit is in good condition Go to...

Page 283: ...n Yes No 1 Fuel Pump Operation check 1 Remove fuel filler cap 2 Turn ON ignition switch Is fuel pump operation sound heard for 3 sec after ignition switch ON Go to Step 2 Go to B 1 flow table 2 Fuel P...

Page 284: ...nnect fuel return hose from fuel pipe and connect new hose to it 2 Put the other end of new return hose into approved gasoline container 3 Operate fuel pump Is fuel pressure 270 310 kPa Restricted fue...

Page 285: ...2 C51 3 25 C51 2 8 C51 3 26 C51 2 9 1 18 E61 21 7 E61 28 E61 13 E61 25 C51 2 3 E61 35 17 GRN BLK PNK WHT 3 A C 10 8 11 9 PPL RED 12 BB YEL WHT 12 v IG2 A C B B 2 4 15 16 IG1 YEL GRN RED BLK 6 5 M RED...

Page 286: ...HVAC control module 9 Heater blower motor relay 15 HTR 15 A fuse 12V E61 5 C51 2 2 C51 3 25 C51 2 8 C51 3 26 C51 2 9 1 18 E61 21 7 E61 28 E61 13 E61 25 C51 2 3 E61 35 17 GRN BLK PNK WHT 3 A C 10 8 11...

Page 287: ...ge between E61 5 and vehi cle body ground with engine running Is voltage 0 1 V Go to Step 4 Go to Step 5 4 A C Condenser Control Circuit check 1 Turn OFF ignition switch 2 Check for fuse blow at A C 2...

Page 288: ...E61 13 E61 25 C51 2 3 E61 35 17 GRN BLK PNK WHT 3 A C 10 8 11 9 PPL RED 12 BB YEL WHT 12 v IG2 A C B B 2 4 15 16 IG1 YEL GRN RED BLK 6 5 M RED BLU WHT RED BLK 13 14 A C51 3 C51 1 C51 2 1 2 3 4 5 6 7...

Page 289: ...Section 6E2 Is check result as specified RED BLK wire or WHT RED wire is open circuit If wire circuits are OK check A C compressor referring to Magnet Clutch Operation Check in Section 1B Faulty A C...

Page 290: ...int hose 09912 58490 4 Checking tool set 09912 58421 4 1 Tool body washer 4 2 Body plug 4 3 Body attachment 1 4 4 Holder 4 5 Return hose clamp 4 6 Body attachment 2 washer 4 7 Hose attachment 1 4 8 Ho...

Page 291: ...6 1 150 ENGINE GENERAL INFORMATION AND DIAGNOSIS H25 ENGINE...

Page 292: ...Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location Vie...

Page 293: ...gasoline unit equipped with its S O H C Single Overhead Camshaft valve mechanism arranged for V type valve configuration and 16 valves IN 2 and EX 2 one cylinder The single overhead camshaft is mounte...

Page 294: ...bearings is supplied to connecting rod bearings by means of intersecting passages drilled in crankshaft and then injected from a small hole provided on big end of connecting rod to lubricate pis ton r...

Page 295: ...nition coil assemblies and all spark plugs referring to Spark Plug and Ignition Coil Assembly Igniter and Igni tion Coil in Section 6F1 5 Install special tool Compression gauge into spark plug hole Sp...

Page 296: ...ector securely Engine Vacuum Check The engine vacuum that develops in the intake line is a good indi cator of the condition of the engine The vacuum checking proce dure is as follows 1 Warm up engine...

Page 297: ...m should be within following specification Vacuum specification at sea level 52 6 72 3 kPa 40 55 cmHg 15 7 21 6 in Hg at speci fied idling speed 4 After checking connect vacuum hose to intake manifold...

Page 298: ...min rpm 5 Stop engine and remove oil pressure gauge 6 Before reinstalling oil pressure switch be sure to wrap its screw threads with sealing tape 1 and tighten switch to specified torque Tightening to...

Page 299: ...lve lashes at valves 3 4 6 and 8 5 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 t...

Page 300: ...n 360 and check the same at valves 3 4 6 and 8 or 1 2 5 and 7 Adjust them as necessary 7 After checking and adjusting all valves reverse removal pro cedure for installation Air Cleaner Element REMOVAL...

Page 301: ...ignition coil assemblies with high tension cord 3 Disconnect PCV valve and breather hose from head cover 4 Detach accelerator cable from clamp 5 Remove cylinder head cover 1 with cylinder head cover g...

Page 302: ...PCV valve and breather hose to head cover 6 Connect negative cable at battery Throttle Body and Intake Manifold COMPONENTS NOTE When installing cylinder head cover use care so that cyl inder head cove...

Page 303: ...ect accelerator cable and A T throttle cable for A T from throttle body 7 Disconnect the following hoses Brake booster hose from intake manifold Canister purge hose from EVAP canister purge valve Engi...

Page 304: ...Reverse removal procedure for installation noting the followings Use new intake manifold gasket When installing intake manifold install clamps at positions as shown in figure Adjust accelerator cable...

Page 305: ...witch ON but engine OFF and check for fuel leaks Finally start engine and check for engine coolant leaks Exhaust Manifold COMPONENTS A Vehicle not equipped with warm up three way catalytic converter 3...

Page 306: ...and its gasket 2 from cylinder head INSTALLATION 1 Install new gasket 1 to cylinder head 2 Install exhaust manifold and stiffener if equipped 3 Install pipe gasket 1 and install exhaust No 1 pipe 2 t...

Page 307: ...st system for exhaust gas leakage Timing Belt and Belt Tensioner COMPONENTS 3 Engine hook 1 Timing belt 4 Tensioner spring 7 Pulley bolt 10 Inside cover 13 Tensioner stud 2 Tensioner 5 Camshaft timing...

Page 308: ...pulley water pump drive belt and fan shroud 5 Remove crankshaft pulley by removing 5 pulley bolts 1 6 Remove timing belt outside cover 7 For installation of timing belt align 4 timing marks as shown...

Page 309: ...er timing belt is removed never turn camshaft and crankshaft independently more than such an extent as shown in figure If turned interference may occur among piston and valves and parts related to pis...

Page 310: ...r and plate again and reinsert plate lug into tensioner hole 3 Check that timing mark E 2 on camshaft timing belt pulley is aligned with V mark 1 on cylinder head cover If not align two marks by turni...

Page 311: ...confirm again that two sets of marks are aligned respectively Tightening torque Tensioner stud a 11 N m 1 1 kg m 8 0 lb ft Tensioner bolt b 27 N m 2 7 kg m 19 5 lb ft 7 Install timing belt outside co...

Page 312: ...r inlet hose to radiator 12 Refill cooling system referring to Cooling System Flush and Refill in Section 6B 13 Connect negative cable to battery 14 Verify that there is no coolant leakage at hose con...

Page 313: ...rring to Dismounting in Section 7E 3 Disconnect CKP sensor coupler and remove CKP sensor by removing its bolt if equipped 4 Drain engine oil by removing drain plug 2 5 Remove clutch housing torque con...

Page 314: ...and cylinder block Remove oil old sealant and dusts from mating surfaces and oil pan inside Clean oil pump strainer screen INSTALLATION 1 Apply sealant to oil pan mating surface continuously as shown...

Page 315: ...et bolt b 11 N m 1 1 kg m 8 0 lb ft 4 After fitting oil pan to cylinder block run in securing bolts and start tightening at the center move wrench outward tighten ing one bolt at a time Tighten bolts...

Page 316: ...r oil referring to Main tenance Service in Section 7E 10 Refill engine with engine oil referring to Engine Oil and Filter Change in Section 0B 11 Verify that there is no engine oil leakage and differe...

Page 317: ...t pulley 3 To lock crankshaft engage special tool gear stopper with flywheel ring gear 1 drive plate ring gear for A T With crankshaft locked remove crankshaft timing belt pulley bolt 2 Special tool A...

Page 318: ...ASSEMBLY 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 INSPECTION Check oil seal lip for fault or other dam...

Page 319: ...1 and case using thickness gauge If clearance exceeds its limit replace outer rotor or case Radial clearance limit between outer rotor and case 0 310 mm 0 0122 in Side clearance Using straight edge an...

Page 320: ...n smoothly by hand Tightening torque Oil pump plate screw a 11 N m 1 1 kg m 8 0 lb ft 5 Apply engine oil to guide seal 3 and install guide seal and guide 2 Tighten oil level gauge guide bolt to specif...

Page 321: ...orque Crank timing belt pulley bolt a 130 N m 13 0 kg m 94 0 lb ft Special tool A 09927 56010 6 Install timing belt tensioner oil pump strainer oil pan and other parts referring to Timing Belt and Bel...

Page 322: ...mshaft oil seal 11 Clip 20 Camshaft housing No 6 Apply sealant 99000 31110 to mating surface of housing and cylinder head 3 Rocker arm shaft 12 Lock nut 21 CMP sensor case Apply sealant 99000 31110 to...

Page 323: ...timing belt pulley 1 by using special tool Special tool A 09917 68221 6 Remove cylinder head cover referring to Cylinder Head Cover in this section 7 Disconnect CMP sensor connector and remove CMP se...

Page 324: ...e rocker arm 1 with clip 2 from rocker arm shaft 3 12 Remove rocker arm shaft bolts 1 13 Push off rocker arm shaft end to CMP sensor case side and remove O ring 2 from shaft 1 NOTE To remove camshaft...

Page 325: ...er arm shaft Rocker arm shaft runout limit 0 20 mm 0 008 in Rocker Arm to Rocker Arm Shaft Clearance Using a micrometer and a bore gauge measure rocker shaft diameter and rocker arm inside diameter Di...

Page 326: ...eeds the limit replace camshaft Camshaft runout limit 0 10 mm 0 0039 in Camshaft Journal Wear Check camshaft journals and camshaft housings for pitting scratches wear or damage If any malcondition is...

Page 327: ...fied torque Tightening torque Camshaft housing bolt a 11 N m 1 1kg m 8 0 lb ft 6 Remove housing and using scale 2 on gaging plastic 1 envelope measure gaging plastic width at its widest point Camshaft...

Page 328: ...ing 1 3 With O ring groove in rocker arm shaft 1 exposed to trans mission side once install new O ring 2 to rocker arm shaft 4 Set rocker arm shaft so that its cut part faces down and becomes in paral...

Page 329: ...ion for installation Install housing as indicated by these marks As camshaft housing No 1 retains camshaft in proper posi tion as to thrust direction make sure to first fit No 1 housing to No 1 journa...

Page 330: ...ing torque Rocker arm shaft plug a 33 N m 3 3 kg m 24 0 lb ft 10 Install camshaft timing belt pulley 1 to camshaft while fitting pin 2 on camshaft into slot at E mark 11 Using special tool tighten pul...

Page 331: ...cylinder head cover 16 Install radiator and refill cooling system referring to Radia tor and Cooling System Flush and Refill in Section 6B 17 Install hood lock 1 to front upper member and adjust lock...

Page 332: ...spring 8 Cylinder head bolt Refer to Step 3 of Installation Tightening torque 4 Valve stem seal 9 Cylinder head TOP mark provided on gasket comes to crankshaft pulley side facing up Do not reuse 5 Val...

Page 333: ...lve Injector wires at the coupler Heated oxygen sensor 1 7 Disconnect the following hoses EVAP canister purge hose from EVAP canister purge valve Brake booster hose from intake manifold Engine coolant...

Page 334: ...head if equipped 14 Disconnect exhaust No 1 pipe 1 from exhaust manifold 2 and remove exhaust manifold stiffener 3 or exhaust pipe bracket bolt 15 Loosen cylinder head bolts in such order as indicated...

Page 335: ...s sec tion 3 Using special tool Valve lifter compress valve springs and then remove valve cotters 1 by using special tool Forceps as shown Special tool A 09916 14510 B 09916 14910 C 09916 84511 4 Rele...

Page 336: ...valve and valve guide Valve and valve guide specification If bore gauge is not available check end deflection of valve stem with a dial gauge instead Move stem end in directions 1 and 2 to measure end...

Page 337: ...ch that its chamfer is gone replace valve Seating contact width Create contact pattern on each valve in the usual manner i e by giving uniform coat of marking compound to valve seat and by rotatingly...

Page 338: ...exhaust valve seat 1 1 1 3 mm 0 0433 0 0511 in 2 INTAKE VALVE SEAT Cutting sequence is the same as for exhaust valve seats Seat width for intake valve seat 1 1 1 3 mm 0 0433 0 0511 in 3 VALVE LAPPING...

Page 339: ...to grind off high spots Should this fail to reduce thickness gauge readings to within limit replace cylinder head Leakage of combustion gases from this gasketed joint is often due to warped gasketed s...

Page 340: ...ed by decreased seating pressure Valve spring free length Standard 36 83 mm 1 4500 in Limit 35 67 mm 1 4043 in Valve spring preload Standard 10 7 12 5 kg for 31 5 mm 23 6 27 5 lb 1 24 in Limit 9 3 kg...

Page 341: ...ial tools Drive in new valve guide until special tool Valve guide installer contacts cylinder head After installing make sure that valve guide protrusions 1 by specified hight from cylinder head Speci...

Page 342: ...lve stem 7 Install valve spring and spring retainer Each valve spring has top end large pitch end 1 and bot tom end small pitch end 2 Be sure to position spring in place with its bottom end valve spri...

Page 343: ...em gradually as follows a Tighten all bolts to 35 N m 3 5 kg m 25 0 lb ft according to numerical order in figure b In the same manner as in 1 tighten them to 55 N m 5 5 kg m 40 0 lb ft c Loosen all bo...

Page 344: ...ry 12 Verify that there is no fuel leakage coolant leakage and exhaust gas leakage at each connection 13 Confirm that ignition timing is within specification referring to Ignition Timing Check in Sect...

Page 345: ...l or quick drying paint 5 Remove rod bearing caps 6 Install guide hose 1 over threads of rod bolts This is to pre vent damage to bearing journal and rod bolt threads when removing connecting rod 7 Dec...

Page 346: ...een thrust and axial measurements exceeds out of round limit Cylinder bore diameter limit 75 15 mm 2 9586 in Cylinder bore taper Limit 0 10 mm 0 0039 in Cylinder bore out of round Limit 0 10 mm 0 0039...

Page 347: ...Top 0 03 0 07 mm 0 0012 0 0027 in 2nd 0 02 0 06 mm 0 0008 0 0023 in Piston Pin 1 Check piston pin connecting rod small end bore and piston bore for wear or damage paying particular attention to con di...

Page 348: ...its limit replace con necting rod Connecting rod big end side clearance Standard 0 10 0 20 mm 0 0039 0 0079 in Limit 0 35 mm 0 0137 in 2 Connecting rod alignment Mount connecting rod on aligner to ch...

Page 349: ...tinguish them 0 25 mm undersize bearing has the stamped number US025 on its backside as indicated in figure but standard size one has no number 3 Rod bearing clearance a Before checking bearing cleara...

Page 350: ...od big end Regrind crankpin to following finished diameter Confirm that bearing clearance is within above standard value ASSEMBLY a Each piston 5 has stamped number 1 or 2 6 as shown It represents out...

Page 351: ...nd connect ing rod and install piston pin circlips 2 Install piston rings to piston 1st ring 1 differs from 2nd ring 2 in shape and marking Distinguish 1st ring from 2nd ring by referring to figure an...

Page 352: ...r bore point arrow mark on piston head to crankshaft pulley side 1 4 Install piston and connecting rod assembly into cylinder bore Use special tool Piston ring compressor to compress rings Guide conne...

Page 353: ...Adjust accelerator cable play and A T throttle cable for 4 A T model play referring to Accelerator Cable Adjustment and A T Throttle Cable Adjustment in Section 6E1 11 Check to ensure that all remove...

Page 354: ...t the following electric wires Ground wires from intake manifold Manifold differential pressure sensor Camshaft position sensor EGR valve EVAP canister purge valve Engine coolant temp sensor Throttle...

Page 355: ...e Fuel feed hose and return hose from each pipe A T fluid hose clamp from bracket 10 Disconnect accelerator cable and A T throttle cable if equipped from throttle body and each clamp 11 With hose conn...

Page 356: ...lock A T 17 Remove clutch housing torque converter housing lower plate 18 Remove torque converter bolts A T Special tool A 09927 56010 19 Remove nuts fastening cylinder block and transmission 20 Lower...

Page 357: ...ide and then carefully hoist engine assembly INSTALLATION 1 Lower engine assembly into engine compartment and con nect engine to transmission Hand tighten bolts and nuts fastening cylinder block and t...

Page 358: ...to specified torque Tightening torque Exhaust No 1 pipe bolt or nut a 50 N m 5 0 kg m 36 5 lb ft Tighten transmission stiffener bolts right side to specified torque A T Tightening torque Transmission...

Page 359: ...y parts which have not been rein stalled 10 Refill engine with engine oil referring to item Engine Oil and Filter Change in Section 0B 11 Refill cooling system referring to Cooling System Flush and Re...

Page 360: ...ENGINE MECHANICAL G16 ENGINE 6A1 69 Main Bearings Crankshaft and Cylinder Block COMPONENTS...

Page 361: ...ve oil pump 1 7 Remove oil seal housing 8 Remove connecting rod bearing caps 1 Cylinder block 6 Timing pulley key 11 Housing bolt short 16 Flywheel bolt 2 Front oil seal 7 Crankshaft 12 Oil seal housi...

Page 362: ...023 in Crankshaft thrust play Measure this play with crankshaft set in cylinder block in the nor mal manner that is with thrust bearing 1 and journal bearing caps installed Use a dial gauge to read di...

Page 363: ...ings are available in standardsize and 0 25 mm 0 0098 in undersize and each of them has 5 kinds of bearings differing in tolerance Upper half of bearing 2 has oil groove 3 as shown in fig ure Install...

Page 364: ...ading of clearance Tightening torque Crankshaft bearing cap bolt a 54 N m 5 4 kg m 39 0 lb ft 5 Remove cap and using scale 2 on gaging plastic 1 enve lope measure gaging plastic width at its widest po...

Page 365: ...nal dia at bearing cap 1 is within 51 9820 51 9879 mm 2 0466 2 0467 in and second one 1 indicate that jour nal dia at cap 2 is within 51 9940 52 0000 mm 2 0470 2 0472 in NOTE If bearing is in malcondi...

Page 366: ...fth rightmost alpha bet A indicates that cap bore dia of cap 5 is within 56 0000 56 0061 mm 2 2048 2 2049 in 3 There are five kinds of standard bearings differing in thick ness To distinguish them the...

Page 367: ...ck clearance UNDERSIZE BEARING 0 25 mm 0 00984 in 0 25 mm 0 00984 in undersize bearing is available in five kinds varying in thickness To distinguish them each bearing is painted in the following colo...

Page 368: ...above and alphabets stamped on mating surface of cylinder block select an undersize bearing by referring to table given below Check bearing clearance with newly selected undersize bearing Crankshaft...

Page 369: ...eds its limit replace flywheel Flywheel runout limit 0 2 mm 0 0078 in Cylinder Block Distortion of gasketed surface Using straightedge and thickness gauge check gasketed surface for distortion and if...

Page 370: ...der block and the other half without oil groove to bearing cap Make sure that two halves are painted in the same color 1 23 mm 0 91 in NOTE Before reboring install all main bearing caps in place and t...

Page 371: ...wn in figure a little at a time and repeat it till they are tightened to specified torque Tightening torque Crankshaft bearing cap bolt a 54 N m 5 4 kg m 39 0 lb ft 6 Apply sealant to mating surface o...

Page 372: ...p Strainer in this section 12 Install cylinder head assembly to cylinder block referring to Valves and Cylinder Head in this section 13 Install camshaft camshaft timing belt pulley timing belt cranksh...

Page 373: ...7 18211 09927 56010 09926 18210 09917 68221 Tappet adjuster wrench Gear stopper Oil seal guide Vinyl resin Camshaft pulley holder 09916 84511 09916 44910 09916 34542 See NOTE B Forceps Valve guide rem...

Page 374: ...64510 002 Connector 3 09915 64530 Hose 4 09915 67010 Attachment B 1 09916 14510 Valve lifter 2 09916 14910 Valve lifter attachment Material Recommended SUZUKI product Part Number Use Sealant SUZUKI B...

Page 375: ...late screw 11 1 1 8 0 Oil level gauge guide bolt 11 1 1 8 0 Oil pump bolt 11 1 1 8 0 Crankshaft timing belt pulley bolt 130 13 0 94 0 Oil pump plug 23 2 3 17 0 Camshaft housing bolt 11 1 1 8 0 Rocker...

Page 376: ...2 110 Required Service Material 6A2 112 Tightening Torque Specifications 6A2 113 WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system compo...

Page 377: ...inders 4 stroke cycle gasoline unit with its DOHC Double overhead camshaft valve mechanism arranged for V type valve configuration The double overhead camshaft is mounted over the cylinder head it is...

Page 378: ...rom the crankshaft journal bearings is supplied to the connecting rod bearings by means of intersecting passages drilled in the crankshaft and then injected from the big end of connecting rod to lubri...

Page 379: ...ct ignition coil har ness couplers 4 Remove all ignition coils 1 and spark plugs 2 5 Remove surge tank cover 6 Disconnect fuel injector wire harness at connector 7 Install special tool Compression gau...

Page 380: ...sure that engine idle speed is within specification 2 Stop engine and disconnect vacuum hoses from fuel pres sure regulator valve 3 or intake collector 1 to EVAP canis ter purge valve 2 3 Connect spe...

Page 381: ...plied in special tool A Special tool A 09915 77311 B 09915 76510 3 Start engine and warm it up to normal operating tempera ture NOTE Prior to checking oil pressure check the followings Oil level in oi...

Page 382: ...witch 1 be sure to wrap its screw threads with sealing tape and tighten switch to speci fied torque Tightening torque a 14 N m 1 4 kg m 10 0 lb ft 7 Start engine and check oil pressure switch for oil...

Page 383: ...ENGINE CLEAN Blow off dust by blowing compressed air from air outlet side of element i e the side facing up when installed in air cleaner case INSTALLATION 1 Install element to air cleaner box 2 Inst...

Page 384: ...ure in Section 6 1 2 Disconnect negative cable at battery 1 Air cleaner box 3 Intake air pipe 5 Intake manifold 7 Intake collector 9 Manifold absolute pressure MAP sensor 2 Intake air hose 4 Surge tan...

Page 385: ...e tank pipe 2 as one component Do not disassemble them when removing and reinstalling 9 Disconnect accelerator cable 1 and A T throttle cable for A T vehicle 2 from throttle body 10 Disconnect water h...

Page 386: ...bracket 5 from intake collector 16 Disconnect couplers from manifold absolute pressure MAP sensor EVAP canister purge valve 1 and EGR valve 2 17 Disconnect PCV hose 6 from cylinder head cover Disconn...

Page 387: ...1 and EVAP canister purge hose valve from intake collector 23 Remove throttle body 2 from intake collector 24 Remove IAC valve EGR valve and EVAP canister purge valve from intake collector 25 Remove i...

Page 388: ...e 3 manifold absolute pressure MAP sensor clamps 6 and each hoses to intake collector and throttle body if removed 5 Install throttle body and intake collector assembly to intake manifold with new int...

Page 389: ...e harness with clamps 11 Install clamp bracket 5 to intake collector 12 Connect earth terminal 4 to intake collector 13 Connect couplers of TP sensor 1 MAF sensor 2 and IAC valve 3 14 Connect brake bo...

Page 390: ...ng bolts a 50 N m 5 0 kg m 36 5 lb ft 23 Install fuse relay box 24 Check to ensure that all removed parts are back in place Reinstall any necessary parts which have not been rein stalled 25 Refill coo...

Page 391: ...manifold covers 2 from exhaust manifolds 1 7 Hoist vehicle A Vehicle not equipped with warm up three way catalytic converter 1 Exhaust manifold 3 Exhaust No 1 pipe 5 Exhaust No 1 pipe nut B Vehicle eq...

Page 392: ...d propeller shaft to facil itate their installation as shown in figure 9 For 4WD vehicle disconnect propeller shaft from front differ ential 10 Remove exhaust No 1 pipe 2 11 Detach exhaust manifold st...

Page 393: ...Tighten both manifold nuts and bolts to specified torque Tightening torque Exhaust manifold nut and bolt a 30 N m 3 0 kg m 22 0 lb ft 3 Attach exhaust manifold stiffener to transmission 4 Install exh...

Page 394: ...Front propeller shaft universal joint flange bolt c 55 N m 5 5 kg m 40 0 lb ft 6 Connect EGR pipe to left No 1 bank exhaust manifold 1 7 Install exhaust manifold covers 2 8 Install oil level gauge gui...

Page 395: ...anifold in this section for removal 2 Remove ignition coil covers 3 Disconnect ignition coil couplers and remove ignition coils 4 Remove cylinder head covers 1 1 Cylinder head cover 4 Cylinder head co...

Page 396: ...er gaskets to head covers 4 Install cylinder head covers 1 to cylinder heads 5 Using new seal washers 3 tighten nuts 2 to specified torque Tightening torque Cylinder head cover nut a 11 N m 1 1 kg m 8...

Page 397: ...assis if equipped Refer to Dismounting in Section 7E for removal 5 Drain engine oil by removing drain plug 3 6 Remove lower oil pan 2 from upper oil pan 1 7 Remove oil strainer bracket 8 Detach radiat...

Page 398: ...d lower crankcase and oil pump strainer mounting bolt removed remove oil pump strainer c Then remove upper oil pan from temporarily supported position CLEAN Inside of oil pan and oil pump strainer scr...

Page 399: ...member just beneath the lower crankcase At this point install oil pump strainer Tightening torque Oil pump strainer bolt a 11 N m 1 1 kg m 8 0 lb ft 5 Install upper oil pan 1 to lower crankcase Tight...

Page 400: ...10 Attach radiator outlet pipe to upper oil pan 11 Install front differential housing according to installation pro cedure described in Remounting of Section 7E if removed 12 Install rack and pinion a...

Page 401: ...ove radiator Refer to Radiator in Section 6B for removal 8 Remove thermostat cap Refer to Thermostat in Section 6B for removal 9 Remove P S pump A C compressor drive belt Refer to Section 3B1 for remo...

Page 402: ...are too long replace them with those of suitable length Special tool B 09944 36011 C 09926 58010 16 Disconnect CKP sensor connector and remove CKP sensor if necessary 17 Remove timing chain cover CLEA...

Page 403: ...sealing surface area as shown in figure A Sealant 99000 31250 Sealant amount f 3 mm 0 12 in g 2 mm 0 08 in Apply sealant B to mating surfaces of cylinder head 3 and cylinder block 4 as shown B Sealan...

Page 404: ...6 kg m 4 5 lb ft Install crankshaft pulley 1 To lock crankshaft pulley use special tool camshaft pulley holder with it at shown in figure Special tool A 09917 68221 Tightening torque Crankshaft pulley...

Page 405: ...r Refer to Timing Chain Cover in this section 1 OIl pump chain 5 Oil pump No 1 case 9 Case pin Tightening torque 2 Oil pump chain guide 6 Relief valve 10 Oil pump bolt 3 Oil pump drive sprocket 7 Reli...

Page 406: ...assembly 2 Oil pump chain guide 3 Oil pump chain CAUTION Do not remove oil pump sprocket or bolt Otherwise oil pump sprocket and or oil pump rotor shaft might be damaged CAUTION Do not remove oil pump...

Page 407: ...2 lb 2 05 in Measure clearance of oil pump rotor and oil pump case Radial Clearance Check radial clearance between outer rotor 2 and case 1 using thickness gauge 4 If clearance exceeds its limit repl...

Page 408: ...tening torque Oil pump bolt c 27 N m 2 7 kg m 19 5 lb ft 2 Hand tighten oil pump chain guide bolts 4 3 To take up slack of oil pump chain insert 1 2 1 5 mm 0 048 0 059 in thickness gauge 3 between cha...

Page 409: ...LH bank 2nd timing chain 5 Camshaft sprocket bolt 9 Timing chain tensioner adjuster No 3 bolt Tightening torque 2 Timing chain tensioner adjuster No 3 6 Timing chain guide No 4 10 Timing chain guide N...

Page 410: ...ng intake camshaft 2 counterclockwise a little while pushing back pad 7 Remove LH bank intake and exhaust camshaft sprocket bolts To remove it fit a spanner to hexagonal part 3 at the center of camsha...

Page 411: ...chain INSPECTION Timing chain guide No 4 and No 5 Check shoe 3 for wear or damage Camshaft sprocket Check teeth of sprocket 1 for wear or damage Timing chain Check timing chain 1 for wear or damage T...

Page 412: ...ALLATION 1 Check timing mark on crankshaft as shown in figure 2 Check timing mark on idler sprocket No 2 1 as shown in fig ure 3 Install timing chain guide No 4 4 Tightening torque Timing chain guide...

Page 413: ...stall it fit a spanner to hexagonal part at the center of camshaft to hold stationary Tightening torque Camshaft timing sprocket bolt b 80 N m 8 0 kg m 58 0 lb ft 8 With latch 2 of tensioner adjuster...

Page 414: ...gn timing mark on crankshaft and timing mark on cylinder block as shown in figure Check each other timing marks that align them shown in fig ure 2 Stopper 1 Crank timing pulley key 6 Timing mark of LH...

Page 415: ...kage at each connection 1st Timing Chain and Chain Tensioner COMPONENTS 1 1st timing chain 7 Idler sprocket No 1 13 Camshaft timing sprocket bolt 19 Timing chain tensioner spacer 2 Timing chain tensio...

Page 416: ...hain and Chain Ten sioner in this section for removal 7 Remove timing chain guide No 1 8 Remove timing chain guide No 2 9 Remove timing chain tensioner adjuster No 1 10 Remove idler sprocket No 1 and...

Page 417: ...ear or damage Timing Chain Tensioner Check shoe 1 for wear or damage 1st Timing Chain Crankshaft Sprocket Check teeth of sprocket 1 for wear or damage RH Bank 1st Timing Chain Intake Camshaft Sprocket...

Page 418: ...or wear or damage Idler Sprocket No 2 Check teeth of sprocket 2 for wear or damage 1st Timing Chain Check timing chain 1 for wear or damage Timing Chain Tensioner Adjuster No 1 Check that latch 1 and...

Page 419: ...RH bank intake camshaft as shown in figure 4 Install RH bank 1st timing chain intake camshaft sprocket 1 noting the following points The sprocket should be set in such way that its RH mark 4 can be se...

Page 420: ...ning match marks on LH sil ver plate 1 of 1st timing chain 10 Install crankshaft sprocket by aligning match marks on yel low plate 1 of 1st timing chain and crankshaft timing sprocket To install it fi...

Page 421: ...fter inserting it check to make sure that plunger will not come out 14 Install timing chain tensioner adjuster No 1 Tightening torque Timing chain tensioner adjuster No 1 bolt d 11 N m 1 1 kg m 8 0 lb...

Page 422: ...ts 21 Refill cooling system with coolant front differential with gear oil P S system with specified fluid and engine with engine oil 22 Check wheel alignment referring to Front End Alignment in Sectio...

Page 423: ...Timing chain tensioner adjuster No 2 7 RH bank exhaust camshaft housing 12 Timing chain tensioner adjuster No 2 bolt 3 RH bank exhaust camshaft sprocket 8 RH bank intake camshaft housing Tightening to...

Page 424: ...Ten sioner in this section for removal 3 Remove 1st timing chain Refer to 1st Timing Chain and Chain Tensioner in this sec tion for removal 4 Remove timing chain guide No 3 5 Loosen camshaft housing b...

Page 425: ...k shoe 1 for wear or damage RH Bank 2nd Timing Chain Sprockets Check teeth of sprocket for wear or damage RH Bank 2nd Timing Chain Check timing chain 1 for wear or damage Timing Chain Tensioner Adjust...

Page 426: ...aft journals 5 Install RH bank 2nd timing chain by aligning match marks on yellow plates 1 of RH bank 2nd timing chain RH bank 2nd timing chain intake camshaft sprocket and RH bank 2nd tim ing chain e...

Page 427: ...No 3 bolt c 11 N m 1 1 kg m 8 0 lb ft 10 Install 1st timing chain Refer to 1st Timing Chain and Chain Tensioner in this sec tion for installation 11 Install LH bank 2nd timing chain Refer to LH No 1 B...

Page 428: ...for removal 5 Remove LH bank 2nd timing chain Refer to LH No 1 Bank 2nd Timing Chain and Chain Ten sioner in this section for removal 6 Remove 1st timing chain Refer to 1st Timing Chain and Chain Ten...

Page 429: ...procket 2 8 Remove oil pump chain guide 9 Remove oil pump chain 10 Remove oil pump drive sprocket INSPECTION Oil Pump Chain Guide Check shoe 1 for wear or damage Oil Pump Drive Sprocket Check teeth of...

Page 430: ...3 Install oil pump chain guide 1 and hand tighten oil pump chain guide bolts 4 To take up slack of oil pump chain insert 1 2 1 5 mm 0 048 0 059 in thickness gauge 2 between chain guide and chain 3 and...

Page 431: ...g chain cover Refer to Timing Chain Cover in this section for installation 8 Install oil pan front differential housing P S system cooling system intake manifold with throttle body and other parts 9 R...

Page 432: ...5 2 RH bank exhaust camshaft 7 LH bank exhaust camshaft 12 Valve lash adjuster 3 RH bank intake camshaft 8 LH bank intake camshaft holder 13 Camshaft housing bolt 4 RH bank exhaust camshaft holder 9 L...

Page 433: ...and Chain Ten sioner in this section for removal 8 Remove CMP sensor Refer to CMP sensor in Section 6F2 for removal 9 Loosen LH bank camshaft housing bolts in such order as indicated in figure and re...

Page 434: ...ut exceeds below specified limit replace cam shaft Camshaft runout Limit 0 10 mm 0 0039 in Camshaft Journal Wear Check camshaft journals and camshaft housings for pitting scratches wear or damage If a...

Page 435: ...housing bolt 12 N m 1 2 kg m 9 0 lb ft 6 Remove housing and using scale 2 on gaging plastic 1 envelop measure gaging plastic width at its widest point Camshaft journal clearance Standard 0 045 0 099 m...

Page 436: ...re and adjuster outside diameter to determine cylinder head to adjuster clearance If clearance exceeds limit replace adjuster or cylinder head Hydraulic valve lash adjuster O D Standard 30 959 30 975...

Page 437: ...settle in place operating engine within half an hour after their installa tion may cause interference to occur between valves themselves or valves and piston If air is trapped in valve lash adjuster v...

Page 438: ...housing pins as shown in figure 7 Apply sealant A to LH bank exhaust camshaft housing No 5 sealing surface area as shown in figure A Sealant 99000 31250 8 Check position of LH bank camshaft housings...

Page 439: ...ank 2nd Timing Chain and Chain Ten sioner in this section for installation 12 Install timing chain cover Refer to Timing Chain Cover in this section for installation 13 Install oil pan front different...

Page 440: ...particular oil to be used refer to Engine in Section 0B Oil leaks If leak is found repair it Oil pressure refer to Oil Pressure Check in this section If defective pressure is found repair it 2 Run en...

Page 441: ...arved lot number on cylinder head gasket should face up toward cylinder head side 9 Outer valve spring Be sure to position spring in place with its bottom end small pitch end facing the bottom valve s...

Page 442: ...Refer to CMP Sensor in Section 6F2 for removal and Camshaft and Valve Lash Adjuster in this section for cam shaft and valve lash adjuster removal 6 Remove exhaust manifold Refer to Exhaust Manifold i...

Page 443: ...ial tool D Special tool A 09916 14510 B 09916 14910 C 09919 28610 D 09916 84511 2 Release special tool and remove spring retainer and valve spring 3 Remove valve from combustion chamber side 4 Remove...

Page 444: ...valve stem specification Valves Remove all carbon from valves Inspect each valve for wear burn or distortion at its face and stem and as necessary replace it Measure thickness of valve head If measur...

Page 445: ...eeds its limit replace valve Limit on valve head radial runout 0 08 mm 0 003 in Seating contact width Create contact pattern one each valve in the usual manner i e by giving uniform coat of marking co...

Page 446: ...T Use valve seat cutters to make three cuts as illustrated in figure Three cutters must be used the 1st for making 15 angle the 2nd for making 60 angle and 3rd for making 45 angle The 3rd cut 45 must...

Page 447: ...te and rub gasketed surface against paper to grind off high spots Should this fail to reduce thickness gauge readings to within limit replace cylinder head Leakage of combustion gases from this gasket...

Page 448: ...e plate to check each spring for squareness in terms of clearance between end of valve spring and square Valve springs found to exhibit a larger clearance than limit given below must be replaced Valve...

Page 449: ...ecial tools Drive in new valve guide until special tool Valve guide installer contacts cylinder head After installing make sure that valve guide protrusions 1 by specified height from cylinder head Sp...

Page 450: ...ve stem 7 Install valve springs inner and outer and spring retainer Each valve spring has top end large pitch end 1 and bot tom end small pitch end 2 Be sure to position spring in place with its botto...

Page 451: ...du ally as follows a Tighten all bolts to 53 N m 5 3 kg m 38 5 lb ft according to numerical order in figure b In the same manner as in a tighten them to 84 N m 8 4 kg m 61 0 lb ft c Loosen all bolts u...

Page 452: ...cover Refer to Cylinder Head Cover in this section for installation 14 Install exhaust manifold Refer to Exhaust Manifold in this section for installation 15 Install radiator outlet pipe radiator cool...

Page 453: ...differential housing with gear oil if drained refer ring to Maintenance Service in Section 7E 24 Connect negative cable at battery 25 Check ignition timing and adjust as necessary referring to Ignitio...

Page 454: ...der Heads in this section for removal 1 Top ring 5 Connecting rod Clean bearing installing surface when install 9 Piston pin circlip Tightening Torque 2 2nd ring 6 Connecting rod bearing cap Clean bea...

Page 455: ...rod bolt threads when removing connecting rod 9 Clean carbon from top of cylinder bore before removing pis ton from cylinder 10 Push piston and connecting rod assembly out through the top of cylinder...

Page 456: ...l measurements exceeds out of round limit Cylinder bore dia limit 84 050 mm 3 3090 in Cylinder bore taper Limit 0 10 mm 0 0039 in Cylinder bore out of round Limit 0 10 mm 0 0039 in Pistons Inspect pis...

Page 457: ...groove clearance Top 0 03 0 07 mm 0 0012 0 0027 in 2nd 0 02 0 06 mm 0 0008 0 0023 in Piston Pin Check piston pin connecting rod small end bore and piston bore for wear or damage paying particular atte...

Page 458: ...t replace con necting rod Connecting rod big end clearance Standard 0 25 0 35 mm 0 0099 0 0137 in Limit 0 45 mm 0 0177 in Connecting rod alignment Mount connecting rod on aligner to check it for bow a...

Page 459: ...nds of bearings differing in tolerance For identification of undersize bearing it is painted red at the position as indicated in figure undersize bearing thickness is 1 605 1 615 mm 0 0632 0 0635 in a...

Page 460: ...rought to within its limit even by using a new standard size bearing regrind crankpin to undersize and use 0 25 mm undersize bearing as follows Install 0 25 mm undersize bearing to connecting rod big...

Page 461: ...responding crankshaft pin diameter is 49 9940 50 0000 mm 1 9683 1 9685 in Crankshaft pin diameter Stamped numbers connecting rod big end inside diameter 1 53 0000 53 0060 mm 2 0867 2 0868 in 2 53 0061...

Page 462: ...painted in Black to its con necting rod big end inside Specification of new standard connecting rod bearing size 5 Check bearing clearance with newly selected standard bear ing referring to Selection...

Page 463: ...iston and connecting rod fit connecting rod to piston as shown in figure and insert piston pin to piston and connect ing rod and install piston pin circlips NOTE Two sizes of piston are available as s...

Page 464: ...ribute their end gaps as shown in figure INSTALLATION 1 Apply engine oil to pistons rings cylinder walls connecting rod bearings and crank pins NOTE Install circlip 6 with its cut part facing as shown...

Page 465: ...nkshaft Using a hammer handle tap piston head to install piston into bore Hold ring compressor firmly against cylinder block until all piston rings have entered cylinder bore Special tool A 09916 7731...

Page 466: ...n 16 Adjust water pump drive belt tension Refer to Cooling Fan Belt Tension Check and Adjustment in Section 6B for adjusting procedure 17 Adjust power steering pump drive belt tension Refer to Power S...

Page 467: ...an and radia tor reservoir Refer to Cooling Fan and Fan Clutch and Radiator in Section 6B for removal 7 Disconnect accelerator cable 1 and A T throttle cable for A T vehicle 2 from throttle body 8 Det...

Page 468: ...14 Disconnect following hoses Heater hose 9 from heater water pipe Heater hose 10 from water outlet cap EVAP canister hose from canister pipe Brake booster vacuum hose 15 Remove IAC valve 7 and EVAP c...

Page 469: ...bracket 2 for A T vehicle 26 Remove clutch housing lower plate 27 Remove torque converter bolts for A T vehicle 28 Remove starter motor 29 Lower vehicle 30 Support transmission For A T vehicle don t j...

Page 470: ...ne to transmission and engine side mounting brackets to engine mountings 2 Tighten nuts fastening engine side mounting brackets and engine mountings Tightening torque Engine side mounting bracket nut...

Page 471: ...Section 3B1 for details 11 Connect hoses cables and electric wires 12 Adjust accelerator cable and A T throttle cable for A T vehi cle according to procedure described in Accelerator Cable Adjustment...

Page 472: ...se bolt Tightening Torque 3 Crankshaft 9 O ring 15 Knock sensor Do not reuse 4 Main bearing Do not apply engine oil to outside sur faces 10 Timing chain oil jet 16 Flywheel or drive plate bolt Apply s...

Page 473: ...ead cover 6 Remove timing chain cover Refer to Timing Chain Cover in this section for removal 7 Remove timing chains and chain tensioners LH Bank 2nd timing chain 1st timing chain and RH Bank 2nd timi...

Page 474: ...thread diameter a 60 N m 6 0 kg m 43 5 lb ft Lower crankcase bolt 8 mm 0 315 in thread diameter b 27 N m 2 7 kg m 19 5 lb ft 2 Use a dial gauge to read displacement in axial thrust direc tion of crank...

Page 475: ...t journal out of round A B Limit 0 01 mm 0 0004 in Crankshaft taper a b Limit 0 01 mm 0 0004 in Main Bearings General information Service main bearings are available in standard size and 0 25 mm 0 009...

Page 476: ...torque is reduced to 0 in reverse order of tightening c In the same manner as in Step a tighten them to 42 N m 4 2 kg m 30 5 lb ft d In the same manner as in Step a again tighten them to specified to...

Page 477: ...ARING 1 First check journal diameter As shown in figure crank web 2 has stamped numbers and alphabet at the center Three kinds of numbers 1 2 and 3 represent the fol lowing journal diameters Crankshaf...

Page 478: ...ted in figure Each color indicates following thickness at the center of bearing Standard size main bearing specification Stamped alphabet Bearing cap bore diameter without bearing A 70 0000 70 0060 mm...

Page 479: ...ersize bearing is available in five kinds varying in thickness To distinguish them each bearing is painted in following col ors at such position as indicated in figure Each color represents following...

Page 480: ...inspect oil seal for wear or damage If lip portion is worn or damaged replace oil seal Flywheel If ring gear is damaged cracked or worn replace flywheel If the surface contacting clutch disc is damage...

Page 481: ...r Piston diameter 3 Using micrometer measure piston diameter 4 Calculate cylinder bore diameter to be rebored as follows D A B C D Cylinder bore diameter to be rebored A Piston diameter as measured B...

Page 482: ...to crankcase 1 mating surface area as shown in figure A Sealant 99000 31250 Sealant amount Width a 3 mm 0 12 in Height b 2 mm 0 08 in NOTE All parts to be installed must be perfectly clean Be sure to...

Page 483: ...pecified torque Tightening torque Lower crankcase bolt 10 mm 0 394 in thread diameter a 60 N m 6 0 kg m 43 5 lb ft Lower crankcase bolt 8 mm 0 315 in thread diameter b 27 N m 2 7 kg m 19 5 lb ft 7 Usi...

Page 484: ...tion 13 Install RH bank 2nd timing chain and tensioner RH No 2 Bank 2nd Timing Chain and Chain Tensioner in this section 14 Install 1st timing chain and tensioner 1st Timing Chain and Chain Tensioner...

Page 485: ...ssion gauge 09915 64530 09915 67010 09915 67311 09915 77311 Compression gauge hose Compression gauge attachment c Vacuum gauge Oil pressure gauge 09916 34542 09916 37810 09916 38210 See NOTE Reamer ha...

Page 486: ...installer Vacuum gauge hose joint 09919 28610 09924 17811 09926 58010 09944 36011 Protective sleeve Flywheel holder Bearing puller attachment Steering wheel remover 09911 97710 09915 76510 Oil seal g...

Page 487: ...oil pan To apply to mating surfaces of cylin der block and timing chain cover To apply to mating surfaces of cylin der head gasket and cylinder head To apply to mating surfaces of lower crankcase and...

Page 488: ...djuster No 3 nut 45 4 5 33 0 Timing chain tensioner adjuster No 3 bolt 11 1 1 8 0 Timing chain guide No 4 bolt 11 1 1 8 0 Timing chain tensioner nut 27 2 7 19 5 Idler sprocket No 1 bolt 45 4 5 32 5 Ti...

Page 489: ...6A2 114 ENGINE MECHANICAL H25 ENGINE...

Page 490: ...e Specifications 6A4 101 WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized...

Page 491: ...ycle gasoline unit with its DOHC Double overhead camshaft valve mechanism arranged for V type valve configuration and 16 valves 4 valves one cylinder The double overhead camshaft is mounted over the c...

Page 492: ...from the crankshaft journal bearings is supplied to the connecting rod bearings by means of intersecting passages drilled in the crankshaft and then injected from the big end of connecting rod to lubr...

Page 493: ...move all spark plugs 2 7 Disconnect fuel injector wires at the coupler 5 8 Install special tool Compression gauge into spark plug hole Special tool A 09915 64510 001 B 09915 64510 002 C 09915 64530 D...

Page 494: ...readings 12 After checking install spark plugs 2 and ignition coils 1 13 Connect ignition coil couplers 14 Connect accelerator cable 3 to clamp 4 For LH steering vehicle only NOTE For measuring compre...

Page 495: ...e manifold Special tool A 09915 67311 B 09918 08210 SUZUKI GENUINE PARTS C Hose 09355 35754 D 3 way joint 09367 04002 4 Start engine and run engine at specified idle speed see Idle Speed Idle Air Cont...

Page 496: ...m is hot When servicing be sure to perform it after exhaust sys tem has cooled down NOTE Prior to checking oil pressure check the followings Oil level in oil pan If oil level is low add oil up to full...

Page 497: ...reads with sealing tape 1 and tighten switch to specified torque Tightening torque Oil pressure switch a 14 N m 1 4 kg m 10 5 lb ft 7 Start engine and check oil pressure switch for oil leakage Air Cle...

Page 498: ...dy and Intake Manifold COMPONENTS REMOVAL 1 Relieve fuel pressure referring Fuel Pressure Relief Proce dure in Section 6 2 Disconnect negative cable at battery 1 Intake manifold 4 Fuel delivery pipe 7...

Page 499: ...om intake manifold Canister purge hose from EVAP canister purge valve Vacuum hose from intake manifold Water hoses from throttle body and water bypass pipe Breather hose from throttle body Fuel feed h...

Page 500: ...T throttle cable play for vehicle with A T referring to Accelerator Cable Adjustment and A T Throttle Cable Adjustment in Section 6E1 Check to ensure that all removed parts are back in place Reinstal...

Page 501: ...ed with warm up three way catalytic converter 3 Heated oxygen sensor 1 Tightening torque B Vehicle equipped with warm up three way catalytic converter 4 Exhaust manifold upper cover Do not reuse 1 Exh...

Page 502: ...manifold stiffener 1 if equipped 5 Remove exhaust No 1 pipe bolts or nuts and exhaust pipe bracket bolt if equipped 6 Remove exhaust manifold 1 and its gasket 2 from cylinder head INSTALLATION 1 Insta...

Page 503: ...sed Tighten pipe fasteners to specified torque Tightening torque Exhaust No 1 pipe bolt or nut a 50 N m 5 0 kg m 36 5 lb ft 4 Install exhaust manifold stiffener 1 if equipped Tighten exhaust manifold...

Page 504: ...in der head cover 7 Remove cylinder head cover INSTALLATION 1 Remove oil old sealant and dust from sealing surfaces on cylinder head and cover 2 Install O rings 3 and cylinder head cover gasket 2 to c...

Page 505: ...nect ignition coil couplers 7 Install oil level gauge 2 8 Connect breather hose and PCV hose to cylinder head cover 9 Connect accelerator cable to clamp For LH steering vehicle only Oil Pan and Oil Pu...

Page 506: ...sing 1 with differential 2 from chassis Refer to Dismounting in Section 7E 5 Drain engine oil by removing drain plug 6 Remove transmission stiffener if equipped 7 Remove clutch torque converter housin...

Page 507: ...3 to oil pump 1 Tighten strainer bolts first and then bracket bolt to specified torque Tightening torque Oil pump strainer bolt a 11 N m 1 1 kg m 8 0 lb ft Oil pump strainer bracket bolt b 11 N m 1 1...

Page 508: ...rential housing according to installation pro cedure described in Remounting in Section 7E 11 Refill front differential housing with gear oil referring to Main tenance Service in Section 7E 12 Install...

Page 509: ...Oil Pump Strainer in this section 4 Remove oil pump sprocket cover 1 5 Remove oil pump 2 from lower crankcase 1 1 Cylinder block 3 Oil pump sprocket 5 Oil pump bolt Tightening torque 2 Oil pump 4 Oil...

Page 510: ...gth and tension of oil relief spring Oil pump relief spring specification Measure clearance of oil pump rotor and oil pump case 1 Oil pump case No 1 4 Relief valve 2 Oil pump case No 2 5 Relief spring...

Page 511: ...all disassembled parts 2 Apply thin coat of engine oil to inner and outer rotors and inside surfaces of oil pump case 3 Install outer rotor to pump case No 1 4 Install relief valve 3 relief spring 2...

Page 512: ...ning torque Oil pump sprocket cover bolt a 11 N m 1 1 kg m 8 0 lb ft 3 Install oil pan and oil pump strainer Refer to Oil Pan and Oil Pump Strainer in this section 4 Refill engine with engine oil refe...

Page 513: ...mating surface of cylinder head and cylinder block 13 Oil pan bolt and nut 2 Cylinder head cover gasket 8 Crankshaft pulley 14 Timing chain cover bolt 3 Cylinder head side seal 9 Crankshaft pulley bo...

Page 514: ...cooling fan pulley 3 8 Remove generator belt referring to Generator Belt in Sec tion 6H 9 Remove water pump pulley 4 10 Remove generator belt tensioner 5 11 Remove generator belt idler pulley 1 12 Di...

Page 515: ...09926 58010 17 Remove timing chain cover CLEAN Clean sealing surface on timing chain cover crankcase cyl inder block and cylinder head Remove oil old sealant and dust from sealing surface INSPECTION C...

Page 516: ...ft pulley 1 To lock crankshaft pulley use special tool camshaft pulley holder with it at shown in figure Special tool A 09917 68221 Tightening torque Crankshaft pulley bolt a 150 N m 15 kg m 108 5 lb...

Page 517: ...ter pump pulley 3 10 Install generator belt referring to Generator belt in Section 6H 11 Install cooling fan belt fan pulley cooling fan and shroud 12 Install bypass pipe 1 and water bypass hose No 2...

Page 518: ...er No 2 bolt 2 Timing chain tensioner adjuster No 2 7 Tensioner adjuster No 2 gasket Tightening torque 3 Intake camshaft timing sprocket 8 Intake camshaft timing sprocket bolt Do not reuse 4 Exhaust c...

Page 519: ...h with marks on cylin der head Note that this step must be followed for reinstallation of timing chain 8 Remove timing chain tensioner adjuster No 2 1 To remove it slacken 2nd timing chain by turning...

Page 520: ...xhaust camshaft and crankshaft independently more than such an extent as shown If turned interfer ence may occur between piston and valves and valves themselves and parts related to piston and valves...

Page 521: ...that arrow mark on idler sprocket 1 faces upward as shown in figure 3 Check that knock pins of intake and exhaust camshafts are aligned with timing marks on cylinder head as shown in fig ure 4 Install...

Page 522: ...hold it with stopper 3 at the position by inserting stopper into body 8 Install timing chain tensioner adjuster No 2 1 with gasket Tightening torque Timing chain tensioner adjuster No 2 nut b 45 N m 4...

Page 523: ...Cover in this section 14 Install oil pan and oil pump strainer referring to Oil Pan and Oil Pump Strainer in this section 15 Install cooling system and other parts 16 Refill cooling system with coolan...

Page 524: ...rring to Cylinder Head Cover in this section 6 Remove timing chain cover referring to Timing Chain Cover in this section 1 1st timing chain 6 Timing chain tensioner adjuster No 1 11 Timing chain guide...

Page 525: ...igure 8 Remove 2nd timing chain referring to 2nd Timing Chain and Chain Tensioner in this section 9 Remove timing chain guide No 1 1 10 Remove timing chain tensioner adjuster No 1 2 11 Remove timing c...

Page 526: ...Chain Tensioner Check shoe 1 for wear or damage Crankshaft Timing Sprocket Check teeth of sprocket for wear or damage Idler Sprocket Check teeth and bush 1 of sprocket for wear or damage 1st Timing C...

Page 527: ...ing sprocket key 1 is in match with tim ing mark 2 on cylinder block 2 Install crankshaft timing sprocket 2 as shown in figure Match mark faces to chain cover side 3 Apply oil to bush of idler sprocke...

Page 528: ...tensioner adjuster No 1 returned and plunger 1 pushed back into body 3 hold it at the position by inserting stopper 4 between latch and body 9 Install timing chain tensioner adjuster No 1 1 Tightenin...

Page 529: ...ylinder head cover referring to Cylinder Head Cover in this section 16 Install oil pan and oil pump strainer referring to Oil Pan and Oil Pump Strainer in this section 17 Install cooling system and ot...

Page 530: ...ngine and remove cylinder head cover b Push adjuster downward by hand with less than 20 kg or 44 lbs Force when cam crest is not on adjuster to be check if clearance exists between cam and adjuster If...

Page 531: ...6 Valve lash adjuster Tightening torque 2 Exhaust camshaft 7 CMP sensor Apply engine oil to sliding surface of each part 3 Camshaft housing 8 Oil relief valve 4 Intake camshaft housing 9 Timing chain...

Page 532: ...ing chain cover referring to Timing Chain Cover in this section 7 Remove 2nd timing chain referring to 2nd Timing Chain and Chain Tensioner in this section 8 Remove CMP sensor referring to CMP Sensor...

Page 533: ...Limit 0 10 mm 0 0039 in NOTE Never disassemble hydraulic valve lash adjuster Don t apply force to body of adjuster oil in high pres sure chamber in adjuster will leak Immerse removed adjuster in clea...

Page 534: ...oved and install camshaft to cylinder head 3 Place a piece of gaging plastic the full width of journal of camshaft parallel to camshaft 4 Install camshaft housing 5 Tighten camshaft housing bolts in s...

Page 535: ...xhaust Standard 25 934 25 955 1 0211 1 0218 in Wear of Hydraulic Valve Lash Adjuster Check adjuster for pitting scratches or damage If any malcondition is found replace Measure cylinder head bore and...

Page 536: ...ad with engine oil according to fol lowing procedure Pour engine oil through oil holes 2 and check that oil comes out from oil holes in sliding part of valve lash adjuster Perform this check on both i...

Page 537: ...ndicated by these marks 8 After applying oil to housing bolts tighten them temporarily first Then tighten them by following sequence as indicated in figure Tighten a little at a time and evenly among...

Page 538: ...his section 13 Install oil pan and oil pump strainer referring to Oil Pan and Oil Pump Strainer in this section 14 Install cooling system and other parts 15 Refill cooling system with coolant front di...

Page 539: ...Valve spring outer 16 Cylinder head bolt 1 Cylinder block 9 Valve spring inner 17 Cylinder head bolt M6 2 Cylinder head 10 Valve spring retainer 18 Water outlet pipe bolt Apply lock cement 99000 31110...

Page 540: ...onnect accelerator cable and A T throttle cable for vehi cle with A T from throttle body 9 Disconnect the following hoses Brake booster hose from intake manifold Vacuum hose from intake manifold Canis...

Page 541: ...ndicated in fig ure and remove them 16 Check all around cylinder head for any other parts required to be removed or disconnected and remove or disconnect whatever necessary 17 Remove cylinder head wit...

Page 542: ...tools compress valve springs and then remove valve cotters 1 Special tool A 09916 14510 B 09916 14910 C 09919 28610 D 09916 84511 3 Release special tool and remove spring retainers and valve springs 4...

Page 543: ...ide Valve and calve guide specification Valves Remove all carbon deposits from valves Inspect each valve for wear burn or distortion at its face and stem replace as necessary Measure thickness of valv...

Page 544: ...ceeds its limit replace valve Limit on valve head radial runout 0 08 mm 0 003 in Seating contact width Create contact pattern on each valve in the usual manner i e by giving uniform coat of marking co...

Page 545: ...SEAT Use valve seat cutters to make three cuts as illustrated in figure Three cutters must be used the 1st for making 15 angle the 2nd for making 60 angle and 3rd for making 45 angle The 3rd cut 45 mu...

Page 546: ...ate and rub gasketed surface against paper to grind off high spots Should this fail to reduce thick ness gauge readings to within limit replace cylinder head Leakage of combustion gases from this gask...

Page 547: ...d of valve spring and square Valve springs found to exhibit a larger clearance than limit given below must be replaced Valve spring squareness limit 2 0 mm 0 079 in ASSEMBLY 1 Before installing valve...

Page 548: ...head After installing make sure that valve guide protrusions by specified height from cylinder head Special tool A 09916 58210 B 09917 87810 Valve guide oversize 0 03 mm 0 0012 in Valve guide protrusi...

Page 549: ...tem 7 Install valve springs inner and outer springs and spring retainer Each valve spring has top end large pitch end 1 and bot tom end small pitch end 2 Be sure to position spring in place with its b...

Page 550: ...es to crankshaft pulley side 4 facing up toward cylinder head side 4 Install cylinder head to cylinder block Apply engine oil to cylinder head bolts and tighten them gradually as follows a Tighten all...

Page 551: ...ttle Cable Adjustment in Section 6E1 9 Check to ensure that all removed parts are back in place Reinstall any necessary parts which have not been rein stalled 10 Refill engine with engine oil referrin...

Page 552: ...ing rod bearing cap nut 2 2nd ring 8 Piston pin 14 Oil pump bolt 3 Oil ring 9 Piston pin circlip 15 Oil pump sprocket cover bolt 4 Piston 10 Cylinder block Tightening torque 5 Connecting rod Do not ap...

Page 553: ...Mark cylinder number on all pistons connecting rods and connecting rod caps 8 Remove rod bearing caps 9 Install guide hose 1 over threads of rod bolts This prevents damage to bearing journal and rod b...

Page 554: ...axial directions at two positions as shown in figure If any of the following conditions is noted rebore cylinder a Cylinder bore dia exceeds limit b Difference of measurements at two positions exceeds...

Page 555: ...ameter to find their difference which is piston clearance Piston clearance should be within specification as given below If it is out of specification rebore cylinder and use oversize piston Piston cl...

Page 556: ...in clearance in small end Standard 0 003 0 014 mm 0 0001 0 0005 in Small end bore 21 003 21 011 mm 0 8269 0 8272 in Piston pin dia 20 997 21 000 mm 0 8267 0 8267 in Piston Rings To measure end gap ins...

Page 557: ...out of round or taper with a micrometer If crank pin is damaged or out of round or taper is out of limit replace crankshaft or regrind crank pin referring to following Step 6 Crank pin and connecting...

Page 558: ...all bearing in connecting rod and bearing cap 3 Place a piece of gaging plastic 1 to full width of crank pin as contacted by bearing parallel to crankshaft avoiding oil hole 4 Install rod bearing cap...

Page 559: ...ersize as follows Install 0 25 mm undersize bearing to connecting rod big end Measure bore diameter of connecting rod big end Regrind crank pin to following finished diameter Confirm that bearing clea...

Page 560: ...t pin diameter respectively For example stamped A indicates that corresponding crankshaft pin diameter is 49 9940 50 0000 mm 1 9683 1 9685 in Crankshaft pin diameter Stamped numbers connecting rod big...

Page 561: ...rd bearing painted in Black to its connecting rod big end inside Specification of new standard connecting rod bearing size 5 Check bearing clearance with newly selected standard bear ing referring to...

Page 562: ...not necessary to discriminate each piston by this letter NOTE Two sizes of piston are available as standard size spare part so as to ensure proper piston to cylinder clearance When installing a standa...

Page 563: ...h ring toward top of piston When installing oil ring 3 install spacer first and then two rails 3 After installing three rings 1st 2nd and oil rings distribute their end gaps as shown in figure INSTALL...

Page 564: ...l piston and connecting rod assembly into cylinder bore Use special tool Piston ring compressor to compress rings Guide connecting rod into place on crankshaft Using a hammer handle tap piston head to...

Page 565: ...not been rein stalled 10 Refill engine with engine oil referring to Engine Oil and Filter Change in Section 0B 11 Refill cooling system referring to Cooling System Flush and Refill in Section 6B 12 R...

Page 566: ...NE MECHANICAL J20 ENGINE 6A4 77 Engine Mountings COMPONENTS 1 Engine side mounting bracket nut and bolt 2 Engine mounting frame side bracket bolt 3 Engine mounting frame side bracket nut Tightening to...

Page 567: ...ine referring to Fuel Pressure Relief Procedure in Section 6 1 2 Disconnect negative cable at battery 3 Remove engine hood 4 Remove strut tower bar 5 Drain coolant 6 Remove radiator radiator fan shrou...

Page 568: ...mps Manifold differential pressure sensor Crankshaft position sensor EVAP canister air valve 9 Remove starter motor 10 Disconnect accelerator cable and A T throttle cable for A T vehicle from throttle...

Page 569: ...move right side transmission stiffener 1 if equipped 20 Remove clutch housing lower plate 21 Remove torque converter bolts for A T vehicle Special tool A 09927 56010 22 Lower vehicle 23 Support transm...

Page 570: ...g points 1 Lower engine assembly into engine compartment Connect engine to transmission and engine side mounting brackets to engine mountings 2 Tighten nuts fastening engine side mounting brackets and...

Page 571: ...o Cooling Fan Belt Tension Check and Adjustment in Section 6B 11 Adjust accelerator cable and A T throttle cable for A T vehi cle referring to Accelerator Cable Adjustment and A T Throttle Cable Adjus...

Page 572: ...ENGINE MECHANICAL J20 ENGINE 6A4 83 Main Bearings Crankshaft and Cylinder Block COMPONENTS...

Page 573: ...d diameter 3 Crankshaft 12 Blank 21 Water pump bolt 4 O ring 13 Engine side mounting bracket 22 Engine side mounting bracket bolt 5 Oil pump drive chain 14 Water pump Tightening torque 6 Main bearing...

Page 574: ...d oil pump strainer referring to Oil Pan and Oil Pump Strainer in this section for removal 5 Remove oil pump 6 Remove cylinder head cover 7 Remove timing chain cover referrimg to Timing Chain Cover in...

Page 575: ...hrust play Measure this play with crankshaft set in cylinder block in the nor mal manner that is with thrust bearing and lower crankcase 1 installed Tighten crankcase bolts referring to Step 6 Install...

Page 576: ...tion Service main bearings are available in standard size and 0 25 mm 0 0098 in undersize and each of them has 5 kinds of bearings differing in tolerance Upper half of bearing 1 has oil groove 2 as sh...

Page 577: ...m 19 5 lb ft 5 Remove lower crankcase and using scale 2 on gaging plastic 1 envelop measure gaging plastic width at its wid est point If clearance exceeds its limit replace bearing Always replace bot...

Page 578: ...nding journal diameter is 58 000 58 0060 mm 2 2835 2 2836 in NOTE If bearing is in malcondition or bearing clearance is out of specification select a new standard bearing according to following proced...

Page 579: ...earings differing in thick ness To distinguish them they are painted in following col ors at the position as indicated in figure Each color indicated the following thickness at the center of bearing C...

Page 580: ...recheck clearance UNDERSIZE BEARING 0 25 mm 0 009842 in 0 25 mm 0 009842 in undersize bearing is available in five kinds varying in thickness To distinguish them each bearing is painted in the followi...

Page 581: ...stamped on lower crankcase select an undersize bearing by referring to table given below Check bearing clearance with newly selected undersize bearing Crankshaft undersize bearing specification Oil Pu...

Page 582: ...heel Runout limit of flywheel 0 2 mm 0 0078 in Cylinder Block Distortion of gasketed surface Using straightedge and thickness gauge check gasketed surface for distortion and if flatness exceeds its li...

Page 583: ...1 26 5 mm 1 04 in NOTE Before reboring install lower crankcase and tighten to specification to avoid distortion of bearing bores NOTE All parts to be installed must be perfectly clean Be sure to oil c...

Page 584: ...the same color 2 Install O ring 2 to cylinder block 3 Fit thrust bearings 1 to cylinder block between No 2 and No 3 cylinders Face oil groove 2 sides to crank webs 4 Put crankshaft 1 with oil pump dri...

Page 585: ...torque e Tighten bolts 11 22 to the specified torque according to numerical order as shown Tightening torque Crankcase bolt with 10 mm thread diameter 1 10 a 60 N m 6 0 kg m 43 5 lb ft Crankcase bolt...

Page 586: ...p and Cooling Water Pipes or Hoses in Sec tion 6B 11 Install pistons and connecting rods referring to Pistons Pis ton Rings Connecting Rods and Cylinders in this section 12 Install oil pump referring...

Page 587: ...r Bearing installer Oil filter wrench 09915 67311 See NOTE A Vacuum gauge See NOTE B See NOTE C 09916 34542 09916 37810 09916 38210 09916 44910 Reamer handle Reamer 6 mm Reamer 11 mm Valve guide remov...

Page 588: ...Bearing puller attachment Steering wheel remover Gear stopper NOTE A This kit includes the following items 1 09915 64510 001 Compression gauge 2 09915 64510 002 Connector 3 09915 64530 Hose 4 09915 6...

Page 589: ...hain cover To apply to mating surfaces of cylinder head cover and cylinder head To apply to mating surfaces of exhaust cam shaft and housing and cylinder head To apply to mating surfaces of lower cran...

Page 590: ...ter No 1 bolt 11 1 1 8 0 Timing chain guide bolt 9 0 9 6 5 Oil pump sprocket cover bolt 11 1 1 8 0 Camshaft housing bolt 11 1 1 8 0 Oil relief valve 11 1 1 8 0 A C compressor bracket bolt 55 5 5 40 0...

Page 591: ...6A4 102 ENGINE MECHANICAL J20 ENGINE...

Page 592: ...1 Diagnosis Table 6B 11 Maintenance 6B 12 Coolant Level Check 6B 12 Cooling System Service 6B 13 Cooling System Flush and Refill 6B 14 Cooling Fan Belt Tension Check and Adjustment 6B 15 On Vehicle Se...

Page 593: ...ssary As long as there is pressure in the cooling system the temperature can be considerably higher than the boiling temperature of the solution in the radiator without causing the solution to boil Re...

Page 594: ...ipe 9 Radiator outlet hose 13 Heater outlet hose 2 Radiator inlet hose 6 O ring 10 Water outlet cap gasket 14 Heater inlet hose 3 Thermostat cap 7 Water inlet hose 11 Water outlet cap Do not reuse 4 T...

Page 595: ...eater hose 3 Water outlet pipe 9 Thermostat 15 Heater outlet hose 21 Water outlet pipe bolt Apply sealant 99000 31110 to all around thread part of bolt 4 Water outlet cap 10 Thermostat case 16 Water b...

Page 596: ...tion hose 3 Radiator inlet hose 9 O ring 15 Water head RH hose 21 Heater outlet hose 4 Water outlet cap 10 Water inlet pipe 16 Water outlet pipe 22 Heater inlet hose 5 Water outlet cap gasket 11 Therm...

Page 597: ...med up thermostat closed coolant circulates as follows 2 When coolant is warmed up to normal temperature and the thermostat opens coolant passes through the radiator core to be cooled as well as the a...

Page 598: ...ENGINE COOLING 6B 7...

Page 599: ...tor inlet way 9 Throttle body 13 Intake manifold Temp at which valve begins to open J20 and H25 engines 82 2 C 179 3 6 F G16 engine 88 2 C 190 3 6 F Temp at which valve becomes fully open J20 and H25...

Page 600: ...with a quality coolant that is a 50 50 mixture of water and eth ylene glycol antifreeze This 50 50 mixture coolant solution provides freezing protection to 36 C 33 F Maintain cooling system freeze pro...

Page 601: ...engine Itr 4 0 4 0 US pt 8 5 8 5 Imp pt 7 1 7 1 Engine radiator and heater Reservoir Total G16 engine ltr US lmp pt 4 6 9 7 8 1 0 9 1 9 1 6 5 5 11 6 9 7 J20 engine ltr US lmp pt 5 6 11 8 9 1 0 9 1 9 1...

Page 602: ...nough coolant Check coolant level and add as necessary Faulty thermostat Replace Faulty water pump Replace Dirty or bent radiator fins Clean or remedy Coolant leakage on cooling system Repair Defectiv...

Page 603: ...lant to reservoir to bring coolant level up to FULL mark 2 Then reinstall cap WARNING To help avoid danger of being burned Do not remove reservoir cap while coolant is boiling and Do not remove radiat...

Page 604: ...ent of cap is required use proper cap speci fied for this vehicle 5 Make sure that hose clamps are tightened securely and inspect all hoses Replace hoses whenever cracked swollen or otherwise deterior...

Page 605: ...r drain plug tightly 7 Disconnect hose from reservoir 1 Remove reservoir and pour out any fluid Scrub and clean inside of reservoir with soap and water Flush it well with clean water and drain Reinsta...

Page 606: ...eflection 10 kg 22 lbs Cooling fan belt tension for H25 engine model a 9 11 mm 0 35 0 43 in as deflection 10 kg 22 lbs 3 If belt is too tight or too loose adjust it to proper tension by displacing gen...

Page 607: ...it as follows a Loosen adjusting bolt 1 and pivot bolt 2 b Tighten adjusting bolt 1 during keeping fan belt in proper tension by tightening tension bolt 3 with wrench as shown in the figure c Tighten...

Page 608: ...cooling system 3 To remove these pipes or hoses loosen screw on each pipe or hose clip and pull hose end off For H25 engine 1 Disconnect negative cable at battery 2 Drain cooling system 3 Remove radia...

Page 609: ...l removed parts in reverse order of removal procedure not ing the following Tighten each clamp bolt securely When installing water outlet pipe 1 to cylinder head apply sealant to pipe bolt thread and...

Page 610: ...outlet cap 3 5 Connect ECT sensor 4 coupler 6 Install throttle body and intake manifold Refer to Throttle Body and Intake Manifold in Section 6A2 7 Install radiator outlet pipe 3 to thermostat case wi...

Page 611: ...thermostat cap 1 4 Remove thermostat 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 se...

Page 612: ...he recession of thermostat case J20 and H25 engines 2 Install thermostat cap to intake manifold G16 engine water pump J20 engine or thermostat case H25 engine 3 Install cooling fan and fan shroud and...

Page 613: ...Install belt to water pump pulley crankshaft pulley and gen erator pulley Install P S pump drive belt 2 Adjust belt tension as specified Refer to Cooling Fan Belt Tension Check and Adjustment in this...

Page 614: ...d H25 engines only 6 Remove radiator shroud securing clips 7 Then remove cooling fan clutch and radiator shroud INSPECTION Inspect fluid coupling for oil leakage If necessary replace fan clutch 2 asse...

Page 615: ...hen servicing A T vehicle place oil pan under radiator 1 and disconnect A T fluid hoses 2 3 from radiator 4 Loosen cooling fan clutch nuts 1 5 Disconnect radiator inlet hose from radiator 6 Remove P S...

Page 616: ...or cores INSTALLATION Reverse removal procedures noting the following Refill cooling system with proper coolant referring to Cool ant and Cooling System Flush and Refill in this section Adjust cooling...

Page 617: ...d tensioner referring to Timing Belt and Belt Tensioner in Section 6A1 4 Remove rubber seal 1 between oil pump and water pump 5 Remove oil level gauge guide 1 with oil level gauge 6 Remove generator a...

Page 618: ...ing tensioner pulley Refer to Generator Belt in Section 6H 6 Remove water pump assembly 1 by removing its 4 bolts 2 For H25 engine 1 Disconnect negative cable at battery 2 Drain engine oil 3 3 Drain c...

Page 619: ...er pump 1 impeller 2 for damage Replace as necessary For H25 engine Rotate water pump by hand to check for smooth operation If pump does not rotate smoothly or makes abnormal noise replace it Inspect...

Page 620: ...erring to Timing Belt and Belt Tensioner in Section 6A1 5 Install generator adjusting arm 1 6 With engine oil applied to O ring 2 install oil level gauge guide 1 7 Install crankshaft pulley water pump...

Page 621: ...all radiator outlet hose to thermostat cap 2 6 Fill coolant 7 Connect negative cable at battery For H25 engine 1 Install new O rings 3 to water pump 1 2 Install water pump to cylinder block Tightening...

Page 622: ...ry Engine Coolant Temperature ECT Sensor Refer to Engine Coolant Temperature ECT Sensor in Section 6E1 for G16 and J20 engine or 6E2 for H25 engine Required Service Materials Tightening Torque Specifi...

Page 623: ...6B 32 ENGINE COOLING...

Page 624: ...f the fuel system are fuel tank fuel pump fuel filter and fuel level gauge and it includes three lines fuel feed line fuel return line and fuel vapor line For the details of fuel flow and fuel vapor f...

Page 625: ...procedure described in Section 6 or Section 6 1 A small amount of fuel may be released after the fuel line is disconnected In order to reduce the chance of personal injury cover the fitting to be dis...

Page 626: ...t Fuel Filter REMOVAL 1 Relieve fuel pressure in fuel feed line referring to Section 6 or Section 6 1 2 Disconnect negative cable at battery 3 Hoist vehicle 4 Disconnect inlet and outlet hoses 2 3 fro...

Page 627: ...ng to Section 6 or Section 6 1 Fuel Lines 1 Fuel filter 2 Fuel filter outlet hose 3 Fuel filter inlet hose NOTE Due to the fact that fuel feed line is under high pressure this system requires special...

Page 628: ...6 1 2 Disconnect negative cable at battery 3 Insert fuel filler hose 1 of a hand operated pump into fuel filler hose and drain fuel in space A in the figure drain fuel through it till fuel stops 1 Fu...

Page 629: ...tank filler Use hand operated pump device to drain fuel tank 8 Disconnect fuel filter inlet hose 3 from fuel filter 1 9 Disconnect fuel vapor hose 1 and return hose 2 from pipes 10 Remove fuel tank pr...

Page 630: ...f deformed or damaged in any other way replace with a new one 4 Install fuel tank 1 by using fuel tank belts 10 and then install protector 9 to vehicle Tightening torque Fuel tank bolt a 50 N m 5 0 kg...

Page 631: ...lushing area 4 Fill tank with warm water or tap water and agitate vigorously and drain Repeat this washing until inside of tank is clean Replace tank if its inside is rusty 5 Completely flush out rema...

Page 632: ...47 WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to...

Page 633: ...absolute pressure MAP sensor 6E1 49 Fuel level sensor Sender gauge 6E1 51 Main relay 6E1 52 Fuel pump relay 6E1 54 A C compressor relay and condenser fan motor relay other than canvas top model 6E1 5...

Page 634: ...y system electronic control system and emission control system Air intake system includes air cleaner mass air flow sensor throttle body idle air control valve and intake mani fold Fuel delivery syste...

Page 635: ...6E1 4 ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINES ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM FOR G16 ENGINE...

Page 636: ...ehicle output speed sensor A T 48 Fuel filter 18 Shift solenoid valve A A T 49 Fuel pump with fuel level sensor 19 Shift solenoid valve B A T 50 EVAP canister 20 TCC solenoid valve A T 51 Data link co...

Page 637: ...6E1 6 ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINES ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM FOR J20 ENGINE...

Page 638: ...nverter if equipped 47 Stop lamp switch A T 17 Fuel pump with fuel level sensor 48 O D cut switch A T 18 Fuel feed line 49 POWER NORMAL change switch A T 19 Fuel filter 50 4WD low switch A T 20 Fuel p...

Page 639: ...nifold 7 The air by the amount corresponding to the throttle valve 5 opening and engine speed is filtered by the air cleaner passes through the throttle body is distributed by the intake manifold and...

Page 640: ...gine 9 Exhaust manifold 15 Fuel delivery pipe 21 EGR flow if equipped C Air 10 Bypass air flow 16 Engine 22 EVAP purge flow D Exhaust gas 11 Fresh air 17 PCV valve 23 To brake booster E Fuel vapor 12...

Page 641: ...the fuel pressure applied to the injector the fuel pressure in the fuel feed line 3 is always kept a certain amount higher than the pressure in the intake manifold 9 by the fuel pressure regulator 7 t...

Page 642: ...ons 2 ECM PCM which controls various devices according to the signals from the sensors and 3 various controlled devices Functionally it is divided into the following sub systems Fuel injection control...

Page 643: ...6E1 12 ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINES ELECTRONIC CONTROL SYSTEM COMPONENT LOCATION FOR G16 ENGINE...

Page 644: ...if equipped 6 Battery g Malfunction indicator lamp 7 TP sensor h Main relay 8 Transmission range switch A T only i EVAP canister purge valve 9 Camshaft position sensor CMP sensor j A C condenser fan...

Page 645: ...6E1 14 ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINES ELECTRONIC CONTROL SYSTEM COMPONENT LOCATION FOR J20 ENGINE...

Page 646: ...e if equipped f Fuel pump relay 6 Camshaft position sensor CMP sensor g Malfunction indicator lamp 7 ECT sensor h Injectors 8 TP sensor i EGR valve if equipped 9 Battery J A C compressor relay other t...

Page 647: ...61 30 E61 17 E61 8 E61 16 E61 15 E61 32 E61 28 E61 6 E61 34 E61 1 E61 3 PNK PNK BLK PNK GRN PNK BLU YEL BLU WHT BLU ORN BLU LT GRN LT GRN WHT LT GRN YEL LT GRN RED LT GRN BLK PPL BLK PPL YEL PPL RED G...

Page 648: ...enser fan motor if equipped 42 A C control module Amplifier if equipped 14 Monitor connector if equipped 43 ABS control module if equipped 15 Malfunction indicator lamp 44 Heated oxygen sensor 1 if eq...

Page 649: ...2 22 C51 2 21 C51 3 24 C51 1 26 C51 2 18 C51 3 20 C51 3 15 C51 3 18 C51 3 17 C51 2 28 C51 2 24 E61 5 E61 8 E61 7 E61 5 E61 2 E61 9 E61 14 E61 29 E61 23 E61 13 E61 31 E61 33 E61 20 E61 21 E61 19 E61 12...

Page 650: ...n sensor 1 if equipped 15 A C condenser fan relay if equipped 48 Heated oxygen sensor 2 if equipped 16 A C condenser fan motor if equipped 49 Intake air temp sensor 17 Monitor connector if equipped 50...

Page 651: ...d PPL RED other than canvas top model 12 shield ground Ground of shield wire for heated oxygen sensor 1 if equipped 14 WHT RED Test switch terminal if equipped 13 GRY RED Output of 5 V power source fo...

Page 652: ...1 if equipped 5 WHT GRN Fuel pump relay output with immobilizer control sys tem 6 7 RED 4WD air pump assembly output 8 PNK BLU Fuel injector No 4 output 9 PNK GRN Fuel injector No 3 output 10 PPL YEL...

Page 653: ...6E1 22 ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINES ENGINE AND EMISSION CONTROL SYSTEM FLOW CHART A Air B Exhaust gas C Vapor D Fuel...

Page 654: ...gine Diagnosis Table in Section 6 On Vehicle Service Engine and Emission Control System Description When hoses are disconnected and system components are removed for service reinstall components prope...

Page 655: ...le 12 Tank pressure control valve C Vehicle without immobilizer indicator lamp 6 PCV hose 13 Fuel tank D Vehicle with immobilizer indicator lamp 7 Breather hose 14 Air cap 1 Brake booster hose 8 Fuel...

Page 656: ...ver stopper throttle body 1 which should be within following specification If measured value is out of specification adjust it to specifi cation by changing height of pedal stopper bolt 3 Accelerator...

Page 657: ...y as follows 1 Connect SUZUKI scan tool to DLC 1 with ignition switch OFF Special tool A SUZUKI scan tool 2 Warm up engine to normal operating temperature 3 Check idle speed and IAC duty by using Data...

Page 658: ...cates idle mixture to be the cause of a driver performance complaint or emission failure the idle mixture can be adjusted using the following procedures 1 Check idle speed according to Idle Speed Idle...

Page 659: ...PECTION Check that throttle valve lever moves smoothly REMOVAL 1 Disconnect negative cable at battery 2 Drain cooling system 3 Disconnect accelerator cable 1 and or A T throttle cable 2 from throttle...

Page 660: ...ket to intake manifold Use new gasket 2 Install throttle body to intake manifold and tighten bolts and nuts to specified torque 3 Connect coolant hoses 3 to throttle body 4 Connect couplers to TP sens...

Page 661: ...rom throttle body 4 Connect connector to IAC valve 5 Check that plunger 1 of IAC valve moves once and then stops as soon as ignition switch is turned OFF after cranking engine for 2 seconds If plunger...

Page 662: ...nnect special tools fuel pressure gauge to delivery pipe Special tool A 09912 58441 B 09912 58431 C 09919 46010 3 Check that battery voltage is above 11 V 4 Turn ignition switch ON to operate fuel pum...

Page 663: ...witch ON check for fuel leaks CONDITION FUEL PRESSURE With fuel pump operating and engine stopped 250 300 kPa 2 5 3 0 kg cm2 35 6 42 7 psi At specified idle speed 210 260 kPa 2 1 2 6 kg cm2 29 8 37 0...

Page 664: ...el pressure is not felt advance to Diagnostic Flow Table B 3 in Section 6 REMOVAL 1 Remove fuel tank from body according to procedure described in Fuel Tank of Section 6C and remove fuel pump from fue...

Page 665: ...rn hose from fuel pressure regulator INSTALLATION For installation reverse removal procedure and note following precautions Use new O ring Apply thin coat of gasoline to O ring to facilitate installat...

Page 666: ...isconnect coupler from injector connect ohmmeter between terminals of injector and check resistance If resistance is out of specification replace Resistance of injector 13 16 at 20 C 68 F 3 Connect co...

Page 667: ...s hoses and attachment to hose and pipe of vehicle Special tool B 09912 58431 3 Connect special tool test lead to injector Special tool D 09930 88530 WARNING A small amount of fuel may be released whe...

Page 668: ...and measure injected fuel volume with graduated cylinder Test each injector two or three times If not within specification replace injector Injected fuel volume 42 52 cc 15 sec 1 42 1 48 1 75 1 83 US...

Page 669: ...moothly If not probable cause is incorrect installation of O ring Replace O ring with new one 4 Tighten delivery pipe bolts and make sure that injectors rotate smoothly Tightening torque Fuel delivery...

Page 670: ...ECM PCM cover 1 from bracket 4 Disconnect connectors from ECM PCM 5 Remove ECM PCM with bracket INSTALLATION 1 Install ECM PCM with bracket to vehicle 2 Connect connectors to ECM PCM securely 3 Instal...

Page 671: ...OFF and remove ECM PCM cover from bracket 4 Connect MAF sensor coupler to MAF sensor 5 Turn ignition switch ON and check voltage at MAF sensor output terminal MAF sensor output voltage 1 0 1 6 V 6 Sta...

Page 672: ...ll MAF sensor to air cleaner case 3 Install air cleaner outlet hose 4 Connect MAF sensor coupler securely 5 Connect battery negative cable to battery Intake air temperature IAT sensor REMOVAL 1 Discon...

Page 673: ...en sensor terminals while heating water gradually If measured resistance doesn t show such characteristic as shown in figure replace IAT sensor INSTALLATION 1 Clean mating surface of sensor and seal o...

Page 674: ...isconnect coupler from TP sensor 3 Remove TP sensor from throttle body INSTALLATION 1 Install TP sensor to throttle body Fit TP sensor to throttle body in such way that its holes are a little away fro...

Page 675: ...ler from ECT sensor 4 Remove ECT sensor 1 from intake manifold or water outlet cap 3 INSPECTION Immerse temperature sensing part of ECT sensor in water and measure resistance between sensor terminals...

Page 676: ...ENSOR 1 INSPECTION Inspect oxygen sensor and its circuit referring to DTC P0130 Diag Flow Table in Section 6 If malfunction is found replace OXYGEN SENSOR HEATER INSPECTION SENSOR 1 and 2 1 Disconnect...

Page 677: ...lowing Tighten oxygen sensor to specified torque Tightening torque Heated oxygen sensor a 45 N m 4 5 kg m 32 5 lb ft Connect coupler of oxygen sensor and fit connector to bracket After installing oxyg...

Page 678: ...tmeter should indicate deflection between 0 1 V and 8 14 V a few times while tire is turned one revolution If check result is not satisfactory proceed to Step 2 of DTC P0500 No 24 Diag Flow Table in S...

Page 679: ...Connect connector to it securely 5 Connect negative cable to battery Crankshaft position sensor G16 engine INSPECTION Check crankshaft position sensor referring to Steps 2 and 3 of DTC P0335 Diag Flo...

Page 680: ...1 3 Remove crankshaft position sensor from cylinder block 2 INSTALLATION Reverse removal procedure noting the following Check to make sure that crankshaft position sensor is free from any metal partic...

Page 681: ...o 400 mmHg by using vacuum pump 3 If check result is not satisfactory replace MAP sensor MAP sensor output voltage When sensor input voltage is 4 5 5 5 V ambient temp 20 30 C 68 86 F CAUTION Do not pu...

Page 682: ...ON 1 Confirm that vacuum passage on intake manifold is free from clog 2 Apply engine oil to O ring of sensor 3 Install sensor to intake manifold 4 Connect connector to sensor securely Fuel level senso...

Page 683: ...e cable at battery 2 Remove main relay 1 from connector A 1 Left hand steering vehicle except for canvas top model A 2 Right hand steering vehicle except for canvas top model B 1 Left hand steering ve...

Page 684: ...ecified proceed to next operation check If not replace Main relay resistance 4 Check that there is continuity between terminals A and B when battery is connected to terminals C and D If malfunction is...

Page 685: ...y is the same as that of main relay Check its resistance and operation using the same proce dure as that for main relay If malfunction is found replace A 1 Left hand steering vehicle except for canvas...

Page 686: ...ON 1 Disconnect negative cable at battery 2 Remove A C compressor relay 1 or A C condenser fan motor relay 2 from fuse relay box 3 3 Structure of A C compressor relay or A C condenser relay is the sam...

Page 687: ...USING SUZUKI SCAN TOOL 1 Connect SUZUKI scan tool to data link connector DLC 1 with ignition switch OFF Special tool A SUZUKI scan tool 2 Start engine and warm up it to normal operating tempera ture 3...

Page 688: ...each pair If found faulty replace EGR valve assembly EGR valve resistance 2 Remove carbon from EGR valve 1 gas passage 3 Inspect valve 2 valve seat 3 and rod for fault cracks bend or other damage If...

Page 689: ...w gasket 2 Evaporative emission control system VACUUM PASSAGE INSPECTION Start engine and run it at idle speed With finger placed against vacuum nozzle 1 check that vacuum is applied If it is not appl...

Page 690: ...2 Air should pass through valve smoothly from fuel tank side black side 3 of tank pressure control valve to orange side 2 when blown hard 3 From orange side even when blown softly air should come out...

Page 691: ...to check for vac uum If there is no vacuum check for clogged valve Replace as necessary 4 After checking vacuum stop engine and remove PCV valve 1 Shake valve and listen for the rattle of check needl...

Page 692: ...2 5 TP sensor screw 3 5 0 35 2 5 09917 47010 09930 88530 See NOTE A Vacuum pump gauge Injector test lead Tech 2 kit Suzuki scan tool See NOTE B NOTE A This kit includes the following items 1 Pressure...

Page 693: ...6E1 62 ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINES...

Page 694: ...oxygen sensor sensor 2 6E2 41 WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an autho...

Page 695: ...ft position sensor 6E2 43 Main relay 6E2 44 Fuel pump relay 6E2 45 A C compressor relay and condenser fan motor relay 6E2 45 Fuel cut operation 6E2 46 Emission Control System 6E2 46 EGR system if equi...

Page 696: ...system electronic control system and emission control system Air intake system includes air cleaner mass air flow sensor throttle body idle air control valve and intake mani fold Fuel delivery system...

Page 697: ...6E2 4 ENGINE AND EMISSION CONTROL SYSTEM H25 ENGINE ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM...

Page 698: ...unction indicator lamp 53 4WD low switch A T 13 Engine coolant temp sensor 32 Electric load Rear defogger if equipped Lighting switch 54 Transmission range switch A T 14 Heated oxygen sensor bank 1 se...

Page 699: ...ner passes through the throttle body is distributed by the intake manifold and finally drawn into each com bustion chamber When the idle air control valve is opened according to the signal from ECM PC...

Page 700: ...pipe As the fuel pressure applied to the injector the fuel pressure in the fuel feed line 4 is always kept a certain amount higher than the pressure in the intake manifold by the fuel pressure regulat...

Page 701: ...om the sensors and 3 various controlled devices Functionally it is divided into the following sub systems Fuel injection control system Heated oxygen sensor heater control system if equipped Idle air...

Page 702: ...sensor f Injectors F EVAP canister 7 Camshaft position sensor CMP sensor g Malfunction indicator lamp 8 ABS control module if equipped h Fuel pump relay 9 Crankshaft position sensor CKP sensor if equi...

Page 703: ...6E2 10 ENGINE AND EMISSION CONTROL SYSTEM H25 ENGINE Engine and Emission Control System Flow Chart A Air B Exhaust gas C Vapor D Fuel...

Page 704: ...14 C51 2 25 C51 2 24 C51 2 1 C51 2 13 C51 2 12 C51 2 11 C51 2 10 C51 2 23 C51 2 22 E61 1 E61 30 E61 17 E61 16 E61 23 E61 23 E61 20 E61 21 E61 34 E61 5 E61 7 E61 10 C51 1 7 C51 1 6 C51 1 1 C51 1 2 E61...

Page 705: ...ft position sensor 13 Ignition coil assembly for No 2 spark plug 38 TCC solenoid valve 63 CKP sensor if equipped 14 Ignition coil assembly for No 3 spark plug 39 Solenoid valve No 1 B 64 ECM PCM 15 Ig...

Page 706: ...Off for A T E61 15 BLK RED Electric load signal for rear defogger switch if equipped C51 3 12 RED GRN Throttle position TP sensor signal E61 16 WHT RED Test switch terminal if equipped C51 3 13 RED WH...

Page 707: ...n range selector switch A T C51 2 14 PPL BLK IAC valve output stepper motor coil 2 C51 2 15 LT GRN BLK IAC valve output stepper motor coil 1 C51 1 13 ORN BLU N position signal for transmission range s...

Page 708: ...ENGINE AND EMISSION CONTROL SYSTEM H25 ENGINE 6E2 15 ENGINE EMISSION CONTROL INPUT OUTPUT TABLE Diagnosis Diagnosis Table Refer to Engine Diagnosis Table in Section 6 1...

Page 709: ...fer to figure for proper routing of hoses 1 Brake booster hose pipe 8 EGR pipe 15 EVAP canister 2 Vacuum hose for fuel pressure regulator 9 Exhaust manifold 16 Tank pressure control valve 3 Fuel press...

Page 710: ...ollowing specification If measured value is out of specification adjust accelerator cable 1 to specification with cable adjusting nut 2 Accelerator pedal play a 2 5 mm 0 08 0 19 in 3 With accelerator...

Page 711: ...1 Before idle speed IAC duty check make sure of the follow ing Lead wires and hoses of engine emission control systems are connected securely Accelerator cable is adjusted Ignition timing is within s...

Page 712: ...peed is out of specifications check idle air control system referring to Diagnostic Flow Table DTC P0505 Idle Air Control System Malfunction in Section 6 1 Engine idle speed specification iv Check tha...

Page 713: ...le speed A C OFF 750 50 r min A C ON 800 50 r min IAC duty at specified idle speed 10 50 1 4 7 0 V when battery voltage is 14 V IAC duty to voltage relation NOTE If ECM PCM parts No ends with 0 ECM PC...

Page 714: ...ment should never be changed from the origi nal factory setting However if during diagnosis the check indi cates idle mixture to be the cause of a driver performance complaint or emission failure the...

Page 715: ...nt temp is 25 C 77 F Plunger protrusion a 26 6 27 4 mm 1 048 1 078 in 3 Warm up engine and check to make sure that fast control cam is off cam follower lever 1 at engine coolant temp is 52 68 C 126 15...

Page 716: ...y 6 Remove surge tank cover 7 Remove intake air pipe 1 and surge tank pipe 2 8 Disconnect connector of injector wire 9 Disconnect connectors of TP sensor 2 MAF sensor 1 and IAC valve 3 10 Disconnect g...

Page 717: ...8 Install clamp bracket to intake collector 9 Connect ground terminal to intake manifold 10 Connect connectors of TP sensor MAF sensor and IAC valve 11 Connect connector of injector wire 12 Install s...

Page 718: ...place IAC valve resistance 3 Remove IAC valve from intake collector 4 Connect connector to IAC valve 5 Check that plunger of IAC valve moves once and then stops as soon as ignition switch is turned OF...

Page 719: ...nnect special tools and hose 2 between fuel feed hose and fuel feed pipe as shown in figure and clamp hose securely to ensure no leaks occur during checking Special tool A 09912 58441 B 09912 58431 C...

Page 720: ...Remove fuel pressure gauge hose and 3 way joint 10 Connect fuel feed hose and clamp it securely 11 With engine OFF and ignition switch ON check for fuel leaks CONDITION FUEL PRESSURE With fuel pump o...

Page 721: ...tion switch ON If fuel pressure is not felt advance to Diagnostic Flow Table B 3 in Section 6 1 REMOVAL 1 Remove fuel tank from body according to procedure described in Fuel Tank of Section 6C and rem...

Page 722: ...om fuel delivery pipe 3 5 Disconnect fuel return hose 2 from fuel pressure regulator INSTALLATION For installation reverse removal procedure and note following precautions Use new O ring Apply thin co...

Page 723: ...g or cranking Cycle of operating sound should vary according to engine speed If no sound or an unusual sound is heard check injector cir cuit wire or coupler or injector 2 Disconnect connector from in...

Page 724: ...ol injector checking tool Special tool A 09912 58421 2 Connect special tools hoses and attachment to pipes of vehicle Special tool B 09912 58431 3 Connect special tool test lead to injector Special to...

Page 725: ...nector as shown in figure 8 Apply battery 5 voltage to injector for 15 seconds and mea sure injected fuel volume with graduated cylinder Test each injector two or three times If not within specificati...

Page 726: ...is replace with new one Install insulators and cushions 2 to intake manifold 3 Apply thin coat of fuel to O rings 1 and then install injectors into delivery pipes right and left and intake manifold Ma...

Page 727: ...sure regulator 8 Connect fuel feed hose 1 and fuel return hose 2 9 Connect connectors 3 to injectors 10 Install throttle body and intake collector refer to Throttle Body in this section 11 With engine...

Page 728: ...ct negative cable to battery Mass air flow sensor MAF sensor INSPECTION 1 Remove ECM PCM cover from bracket 2 With ignition switch OFF disconnect MAF sensor connector 1 3 Connect voltmeter to BLU BLK...

Page 729: ...ler from MAF sensor 2 2 Remove throttle body 1 referring to Throttle Body in this section INSTALLATION 1 Install throttle body referring to Throttle Body in this section 2 Connect coupler to MAF senso...

Page 730: ...LATION 1 Clean mating surface of sensor and seal on air cleaner case 2 Install IAT sensor 1 into seal 2 3 Connect connector to IAT sensor securely 4 Connect negative cable to battery Throttle position...

Page 731: ...throttle body lever 1 A should engage with B 2 Hand tighten TP sensor screws 3 Connect connector to TP sensor securely 4 Connect battery negative cable to battery 5 Adjust installation angle of TP sen...

Page 732: ...open TP sen sor voltage is as shown below TP sensor voltage when throttle is fully open 3 5 4 5 V 7 Install ECM PCM cover 8 Disconnect negative cable at battery for 30 sec or more and connect negative...

Page 733: ...ing Clean mating surfaces of sensor and water outlet cap 1 Use new O ring Tighten ECT sensor to specified torque Tightening torque ECT sensor a 15 N m 1 5 kg m 11 0 lb ft Connect coupler to sensor sec...

Page 734: ...r ness securely After installing oxygen sensor s start engine and check that no exhaust gas leakage exists Heated oxygen sensor sensor 2 REMOVAL 1 Disconnect negative cable from battery 2 Disconnect c...

Page 735: ...sor VSS ON VEHICLE INSPECTION 1 Hoist vehicle 2 Release parking brake lever set transmission in neutral and transfer in 2H 3 Remove ECM PCM cover 4 Connector voltmeter between VSS terminal C51 3 1 of...

Page 736: ...using vacuum pump 3 If check result is not satisfactory replace MAP sensor 1 MAP sensor output voltage Vin voltage 4 5 5 5 V ambi ent temp 20 30 C 68 86 F 4 Install MAP sensor 1 securely 5 Connect MAP...

Page 737: ...table below If check results are as specified proceed to next operation check If not replace Main relay resistance 4 Check that there is continuity between terminals A and B when battery is connected...

Page 738: ...ion is found replace A C compressor relay and condenser fan motor relay INSPECTION 1 Disconnect negative cable at battery 2 Remove A C compressor relay 1 or A C condenser fan motor relay 2 from fuse r...

Page 739: ...ON USING SUZUKI SCAN TOOL 1 Connect SUZUKI scan tool to data link connector DLC 1 with ignition switch OFF Special tool A SUZUKI scan tool 2 Start engine and warm up it to normal operating tempera tur...

Page 740: ...resistance 2 Remove carbon from EGR valve 1 gas passage 3 Inspect valve 2 valve seat and rod for fault cracks bend or other damage If found faulty replace EGR valve assembly INSTALLATION Reverse remov...

Page 741: ...wire harness and ECM PCM EVAP CANISTER PURGE VALVE INSPECTION Refer to EVAP Canister Purge Valve Inspection in Section 6E1 EVAP CANISTER INSPECTION Refer to EVAP Canister Inspection in Section 6E1 TAN...

Page 742: ...crew 2 5 0 25 1 8 09917 47010 09930 88521 See NOTE A Vacuum pump gauge Injector test lead Tech 2 kit SUZUKI scan tool See NOTE B NOTE A This kit includes the following items 1 Pressure gauge 09912 584...

Page 743: ...6E2 50 ENGINE AND EMISSION CONTROL SYSTEM H25 ENGINE...

Page 744: ...ription in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under...

Page 745: ...sensor and other sensors switches For their details refer to Electronic Control System in Section 6E1 Although this ignition system does not have a distributor it has two ignition coil assemblies one...

Page 746: ...nition coil for No 2 and No 3 cylinders 4 ECM or PCM 10 Spark plug 5 CMP sensor 11 High tension cord 6 Noise suppressor 12 Sensed information MAF sensor ECT sensor IAT sensor TP sensor CKP sensor Engi...

Page 747: ...6 High tension cord 10 Ignition label if equipped 3 Diagnosis connector canvas top model 7 Spark plug 11 Diagnosis connector other than canvas top model 4 CMP sensor 8 Noise suppressor 11 NOTE Above...

Page 748: ...rformed Go to Step 2 Go to Engine Diagnostic Flow Table in Section 6 2 Ignition Spark Test 1 Check all spark plug for condition and type referring to Spark Plug in this section 2 If OK perform ignitio...

Page 749: ...sfactory Malfunction of ignition coil assembly Go to Step 9 9 CMP Sensor Check 1 Check CMP sensor and signal rotor refer ring to Steps 6 and 7 of DTC P0340 No 42 Diag Flow table in Section 6 Is check...

Page 750: ...ect injector coupler Ignition timing Check 1 Start engine and warm it up to normal operating tempera ture 2 Make sure that all of electrical loads except ignition are switched off 3 Check to be sure t...

Page 751: ...re so that ignition timing is fixed on initial one 5 Set timing light to high tension cord for No 1 cylinder 6 Using timing light check that timing is within specification Initial ignition timing of v...

Page 752: ...ng it with 4 or N For vehicle not equipped with ignition timing adjusting resistor Check the followings CMP sensor and CKP sensor if equipped Signal rotor on camshaft TP sensor VSS Crankshaft pulley t...

Page 753: ...rom ignition coil assembly 1 while gripping its cap 2 Pull out high tension cord 2 from spark plug while gripping its cap INSPECTION Measure resistance of high tension cord by using ohmmeter High tens...

Page 754: ...l coupler 2 Disconnect high tension cord 3 from ignition coil assembly 2 3 Remove ignition coil bolt 1 and then pull out ignition coil assembly 2 INSPECTION Check for damage deterioration and terminal...

Page 755: ...en connect ignition coil coupler 3 Install high tension cord 3 to ignition coil assembly 2 while gripping its cap Spark Plug REMOVAL 1 Pull out high tension cord while gripping its cap 2 Remove igniti...

Page 756: ...fied torque Tightening torque Spark plug a 25 N m 2 5 kg m 18 0 lb ft 2 Install ignition coil assembly referring to Ignition Coil Assembly under On Vehicle Service earlier in this section 3 Install hi...

Page 757: ...by using ohmmeter If check result is not satisfactory replace ignition timing adjusting resistor INSTALLATION For installation reverse removal procedure CMP Sensor Refer to Camshaft Position Sensor C...

Page 758: ...noise suppressor 1 2 Remove noise suppressor 1 INSPECTION Using ohmmeter check to be sure that capacitor condenser in noise suppressor is not conductive If check result is not satisfactory replace noi...

Page 759: ...6420 Timing light Dry cell type Tech 2 kit SUZUKI scan tool See NOTE A NOTE A This kit includes the following items and substitutes for the Tech 1A kit 1 Tech 2 2 PCMCIA card 3 DLC cable 4 SAE 16 19 a...

Page 760: ...I dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag...

Page 761: ...primary current of the ignition coil according to the signal from ECM or PCM When the ignition coil primary current is turned OFF a high voltage is induced in the secondary wiring One ignition coil is...

Page 762: ...4 ECM or PCM 10 Ignition coil assembly for No 4 cylinder C51 2 23 BLK WHT BLK BLU WHT GRN BLK WHT BRN BLK BRN WHT BRN YEL BLK ORN BLU BRN BLK YEL BLU BLK RED BLU BLK BLU BLK BLU BLK PPL RED C51 2 26 E...

Page 763: ...Ignition coil assembly Igniter and ignition coil 3 Noise suppressor 5 Spark plug B H25 Engine 2 CMP sensor 4 ECM or PCM 6 Diagnosis connector NOTE Above figure shows left hand steering vehicle For rig...

Page 764: ...Test 1 Check all spark plug for condition and type referring to Spark Plug in this section 2 If OK perform ignition spark test referring to Ignition Spark Check in this section Is spark emitted from...

Page 765: ...51 2 13 and ground 7 CMP Sensor Check 1 Check CMP sensor Refer to Step 6 or 7 of DTC P0340 Diag Flow Table in Section 6 or 6 1 Is check result satisfactory Substitute a known good ECM or PCM and then...

Page 766: ...all spark plug referring to Spark Plug in this section 7 Connect injector coupler 1 8 For H25 engine install surge tank cover Ignition Timing Check and Adjustment 1 Start engine and warm it up to norm...

Page 767: ...osis coupler 1 by using service wire so that ignition timing is fixed on initial one 5 Set timing light to ignition harness for No 1 cylinder 6 Using timing light check that timing observed from viewp...

Page 768: ...n and vehicle stopped check that ignition timing is about BTDC 12 16 J20 engine 10 13 H25 engine with diagnosis connec tor 6 12 H25 engine without diagnosis connector shown in the figure Also check th...

Page 769: ...ne remove ignition coil cover 2 Disconnect ignition coil coupler 3 Remove ignition coil bolt 1 and then pull out ignition coil assembly 2 INSPECTION Check ignition coil assembly for the following Dama...

Page 770: ...rk plug cleaner or replace them with specified new plug Spark plug air gap a 1 0 1 1 mm 0 039 0 043 in Spark plug type DENSO K20PR U11 SK16PR11 NGK BKR6E 11 IFR5J11 A J20 Engine B H25 Engine CAUTION W...

Page 771: ...ignition coil assembly 2 securely 3 Tighten ignition coil bolt 1 and then connect ignition coil coupler 4 For H25 engine install ignition coil cover CMP Sensor REMOVAL 1 Disconnect CMP sensor coupler...

Page 772: ...P sensor coupling 2 into the slots of cam shaft when installing The dogs of CMP sensor coupling 2 are offset Therefore if the dogs can not be fitted into the slots turn the CMP sensor shaft by 180 deg...

Page 773: ...Tightening torque CMP sensor bolt a 15 N m 1 5 kg m 11 0 lb ft 4 Connect CMP sensor coupler 2 Noise Suppressor REMOVAL 1 Disconnect coupler of noise suppressor 1 2 Remove noise suppressor 1 A J20 Engi...

Page 774: ...ES 6F2 15 INSPECTION Using ohmmeter check to be sure that capacitor condenser in noise suppressor is not conductive If check result is not satisfactory replace noise suppressor INSTALLATION For instal...

Page 775: ...15 1 5 11 0 09930 76420 Timing light Dry cell type Tech 2 kit SUZUKI scan tool See NOTE NOTE This kit includes the following items and substitutes for the Tech 1A kit 1 Tech 2 2 PCMCIA card 3 DLC cabl...

Page 776: ...G 3 Diagnosis 6G 4 Unit Repair Overhaul 6G 6 Dismounting and Remounting 6G 6 Disassembly 6G 6 Reassembly 6G 9 Inspection 6G 11 Performance Test 6G 15 Specifications 6G 17 1 2 kW type 1 4 kW type 6G 17...

Page 777: ...movement causes the pinion to engage the engine flywheel gear and the magnetic switch main contacts to close and cranking takes place When the engine starts the pinion over running clutch protects the...

Page 778: ...d against possible dirt and water splash NOTE Make sure to apply grease before assembly where so indicated A in the figure below Spare parts have been lubricated 1 Front housing 7 Lever 13 Internal ge...

Page 779: ...djust switch Battery run down Recharge battery Battery voltage too low due to battery deteri oration Replace battery Poor contact in battery terminal connection Retighten or replace Loose grounding ca...

Page 780: ...running clutch Poor sliding of over running clutch Repair Over running clutch slipping Replace over running clutch Worn teeth of ring gear Replace flywheel M T or drive plate A T Noise Abnormally worn...

Page 781: ...ing motor 5 To install reverse the above procedure Disassembly 1 Remove protector if equipped and magnetic switch NOTE Before disassembling starting motor be sure to put match marks at two locations A...

Page 782: ...sembly 3 To overhaul reduction gear assembly remove packing and planetary gears 4 Remove seal rubber and plate 5 Remove shaft assembly with lever 6 Loosen pinion stop ring fixed by snap ring 1 Bolts 2...

Page 783: ...ol A 09900 06107 8 Remove rear bracket and brush holder 9 Remove armature from yoke and then ball from the end of armature shaft 10 Remove brush holder from rear bracket 11 Remove brush springs and br...

Page 784: ...nstall brush holder to armature while pushing 4 brushes out ward 6 Install rear bush and then rear bracket cap 7 Install rear bracket 8 Tighten brush holder screws 1 Rear bush 2 Rear bracket cap 3 Rea...

Page 785: ...cking align with holes for through bolts in front housing 12 Install plate and seal rubber to front housing 13 Apply grease to ball and install ball into shaft hole 14 Install yoke armature brush hold...

Page 786: ...rmance Test Refer to page 6G 16 Inspection 1 PLUNGER Inspect plunger for wear Replace if necessary 2 MAGNETIC SWITCH Push in plunger and release it The plunger should return quickly to its original po...

Page 787: ...or damage Replace if necessary 4 BRUSH Check brushes for wear Measure length of brushes and if below limit replace brush Brush length Install brushes to each brush holder and check for smooth movemen...

Page 788: ...should be replaced 7 ARMATURE Inspect commutator for dirt or burn Correct with sandpaper or lathe if necessary Check commutator for uneven wear with armature supported on V blocks If deflection of dia...

Page 789: ...n Ground Test Check commutator and armature core If there is continuity armature is grounded and must be replaced Open Circuit Test Check for continuity between segments If there is no conti nuity at...

Page 790: ...mage Replace if neces sary Inspect pinion for smooth movement 10 FRONT HOUSING BUSH Inspect bush for wear or damage Replace if necessary Performance Test Pull In Test Connect battery to magnetic switc...

Page 791: ...on Return Test Disconnect negative lead from switch body Check that plunger and pinion return inward If plunger and pinion don t return disassemble and inspect start ing motor No Load Performance Test...

Page 792: ...9 81 N m 0 98 kg m 7 0 lb ft minimum 1 000 rpm minimum Locked characteristic 4 0 V 760 A maximum 19 5 N m 1 95 kg m 14 1 lb ft minimum 980 A maximum 23 N m 2 3 kg m 16 5 lb ft minimum Magnetic switch...

Page 793: ...vice Material Special Tool Material Recommended SUZUKI product Part Number Use Lithium grease SUZUKI SUPER GREASE A 99000 25010 Front and rear bush Plunger Pinion drive lever Internal gear Planetary c...

Page 794: ...33 Generator 6H 33 Tightening Torque Specifications 6H 33 WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must b...

Page 795: ...e battery from shaking in its carrier the hold down bolts should be tight enough but not over tightened Electrolyte freezing The freezing point of electrolyte depends on its specific gravity Since fre...

Page 796: ...be charged before testing If there is a cranking complaint battery should be tested as described in Diagnosis section Charging and electrical sys tems should also be checked at this time Clear or Lig...

Page 797: ...attery cable connections clean The cable connections particularly at the positive termi nal post tend to become corroded The product of corrosion or rust on the mating faces of conductors resists the...

Page 798: ...justed The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication Two brushes carry current through the two slip rings to the field coil mounted on the rotor and...

Page 799: ...F Field coil terminal B 70 A type 2 Pulley nut 7 Regulator 12 Rear housing IG Ignition terminal C 80 A type 3 Rotor fan 8 Brush B Generator output Battery terminal L Lamp terminal 4 Stator coil 9 Rea...

Page 800: ...iods Electrical load exceeding generator output particularly with addition of aftermarket equipment Defects in charging system such as high resistance slipping drive belt loose generator output termin...

Page 801: ...ave to correct your S G reading taken with your hydrometer to the value at 20 C 68 F and apply the corrected S G value to the three point guide stated value For the manner of correction refer to the g...

Page 802: ...cting a charger or a booster battery to vehicle battery refer to this section describing battery charging A 60 A type E Ground B 70 A type F Field coil terminal C 80 A type IG Ignition terminal B Gene...

Page 803: ...battery cable connections at battery starting motor and ignition ground cable 5 Connect voltmeter and ammeter as shown in left figure Voltmeter Set between generator B terminal and ground Ammeter Set...

Page 804: ...A types If voltage is lower than standard value proceed to following check 2 Ground F terminal and start engine then measure voltage at B terminal as shown in left figure Voltage is higher than stand...

Page 805: ...wing of electrolyte measure generator B ter minal voltage at engine 2000 rpm 3 If measured voltage is higher than upper limit value proceed to disassembly section of generator service 4 Check ground o...

Page 806: ...off electrical accessories Then Start engine of the vehi cle with discharged battery 6 Disconnect jumper cables in the exact reverse order WITH CHARGING EQUIPMENT CAUTION If vehicle is manual transmis...

Page 807: ...the gas to ignite Battery fluid is highly acidic Avoid spilling on clothing or other fabric Any spilled electrolyte should be flushed with large quantity of water and cleaned immediately Remounting 1...

Page 808: ...Belt in Section 6B Engine Cooling J20 engine INSPECTION Refer to Water Pump Generator Power Steering and or A C Compressor If Equipped Drive Belt J20 Engine in section 0B 7 Maintenance and Lubrication...

Page 809: ...Dismounting 1 Disconnect negative cable at battery 2 Remove air cleaner outlet hose 3 Remove canister from its bracket WARNING Disconnect negative cable at battery before removing and installing gener...

Page 810: ...N m 4 8 kg m 35 0 lb ft 3 Install generator cooling fan belt Refer to Section 6B Engine Cooling G16 and H25 engines or Generator Belt J20 engine in this section 4 Install cooling fan belt J20 engine o...

Page 811: ...h marks on both front and rear housings as shown in left figure before separating them 2 Remove housing bolts from generator 1 Pulley 3 Bearing 5 Rotor 7 IC regulator 9 Rear housing 2 Front housing 4...

Page 812: ...t housing 6 When removing front bearing remove bearing retainer screws and retainer 1 Rear housing 2 Stator core 3 Front housing 4 Lever NOTE When using vise put clean cloth between rotor and vise so...

Page 813: ...e stator from rear housing and regulator assembly 10 To remove brush remove holder cover from brush holder and then disconnect brush wire from regulator terminal by using soldering iron 1 Rear bearing...

Page 814: ...CHARGING SYSTEM 6H 21 Disassembly 70 A and 80 A types...

Page 815: ...Pulley nut 9 End housing bearing 17 Brush 2 Pulley 10 Bearing cover 2 Pulley 10 Bearing cover 18 Brush holder 3 Drive end frame 11 Rear end frame 3 Drive end frame 11 Wave washer 19 Brush holder cove...

Page 816: ...stud bolts and then pull out stator CAUTION To hold shaft use hexagonal box Duodecimal box may cause slipping and consequential shaft or tool dam age Do not attempt to hold pulley by using vise or pi...

Page 817: ...ontinuity between slip ring and rotor core If there is continuity replace rotor 3 Check slip rings for roughness or scoring If rough or scored replace rotor Stator 1 Using an ohmmeter check all leads...

Page 818: ...tween each of upper and lower rectifier bodies and each diode lead Check both directions by reversing probes of ohmmeter and there should be only one way continuity in each case If check result is not...

Page 819: ...continuity between slip ring and rotor If there is continuity replace rotor Check slip rings for roughness or scoring If rough or scored replace rotor Using a vernier caliper measure the slip ring dia...

Page 820: ...er connect one tester probe to the B ter minal and the other to each rectifier terminal 2 Reverse the polarity of the tester probes and repeat Step 1 3 Check that one shows continuity and the other sh...

Page 821: ...cover and then brush holder 2 Unsolder and remove the brush and spring 3 Run the wire of a new brush through the spring and the hole in the brush holder and insert the spring and brush into the brush...

Page 822: ...using 4 After assembling generator make sure that rotor turns smoothly 1 Stator 2 Brush 3 Brush holder 4 Solder 5 Brush spring NOTE When using vise put clean cloth between rotor and vise so as not to...

Page 823: ...aring turns smoothly Tightening torque a 8 8 N m 0 88 kg m 6 5 lb ft b 2 6 N m 0 26 kg m 2 0 lb ft 6 Place drive end frame on pulley and then install rotor to drive end frame 7 Install rear end frame...

Page 824: ...ft 10 Install 4 rubber insulators 11 Install rectifier Tightening torque a 2 0 N m 0 2 kg m 1 5 lb ft b 3 9 N m 0 39 kg m 3 0 lb ft 12 Install brush holder cover to brush holder 1 Pulley 2 Hexagonal...

Page 825: ...N m 0 2 kg m 1 5 lb ft 15 Install rear end cover and terminal plate Tightening torque a 4 5 N m 0 45 kg m 3 5 lb ft b 3 8 N m 0 38 kg m 3 0 lb ft 80 A type only 16 Install insulator and tighten B term...

Page 826: ...000 r min No load speed 1 300 r min rpm 1 250 r min rpm 950 r min rpm Setting voltage 14 4 to 15 0 V 13 6 to 14 4 V Permissible ambient tem perature 30 to 90 C 22 to 194 F Polarity Negative ground Ro...

Page 827: ...6H 34 CHARGING SYSTEM...

Page 828: ...6K 2 Components 6K 2 Maintenance 6K 4 On Vehicle Service 6K 5 Exhaust Manifold 6K 5 Muffler 6K 5 CAUTION Be sure to use UNLEADED FUEL for the catalytic converter equipped vehicle Use of LEADED FUEL w...

Page 829: ...ce added to the exhaust system to lower the level of Hydrocarbon HC Carbon Monoxide CO and Oxides of Nitrogen NOx pollutants in the exhaust gas Components For G16 engine and J20 engine model 1 Exhaust...

Page 830: ...haust manifold 4 Gasket 7 Muffler Tightening torque A B 45 N m 4 5 kg m 50 N m 5 0 kg m 3 45 N m 4 5 kg m 50 N m 5 0 kg m 3 45 N m 4 5 kg m 3 45 N m 4 5 kg m 3 1 1 1 2 2 1 4 4 6 4 4 4 60 N m 6 0 kg m...

Page 831: ...Muffler in this section for torque data Check nearby body areas damaged missing or misposi tioned part open seam hole connection or any other defect which could permit exhaust fumes to seep into vehic...

Page 832: ...them as necessary Muffler Tighten bolts and nut referring to Components in this section WARNING To avoid the danger of being burned do not touch the exhaust system when the system is hot Any service...

Page 833: ...6K 6 EXHAUST SYSTEM...

Page 834: ...Prepared by 1st Ed Dec 2002 Printed in Japan 824...

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