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Suzuki GRAND VITARA -, Service Manual

The Suzuki GRAND VITARA Service Manual is a comprehensive guide for all maintenance and repair needs of this versatile SUV. Download the manual for free from manualshive.com to access detailed instructions and diagrams, ensuring your vehicle stays in top condition. Get your copy now and keep your Suzuki running smoothly.

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1-vi Table of Contents

Ignition Spark Test ..............................................1H-6

Repair Instructions ..............................................1H-7

High-Tension Cord Removal and Installation 

(For M16 Engine) ..............................................1H-7

High-Tension Cord Inspection (For M16 

Engine)..............................................................1H-7

Spark Plug Removal and Installation ..................1H-7
Spark Plug Inspection .........................................1H-8
Ignition Coil Assembly (Including ignitor) 

Removal and Installation...................................1H-8

Ignition Coil Assembly (Including ignitor) 

Inspection..........................................................1H-9

Ignition Timing Inspection ...................................1H-9

Specifications.....................................................1H-11

Tightening Torque Specifications......................1H-11

Special Tools and Equipment ...........................1H-11

Special Tool ......................................................1H-11

Starting System ......................................... 1I-1

Precautions............................................................ 1I-1

Cranking System Note ......................................... 1I-1

General Description .............................................. 1I-1

Cranking Circuit Introduction................................ 1I-1
Starting Motor Circuit Description ........................ 1I-1

Diagnostic Information and Procedures............. 1I-2

Cranking System Symptom Diagnosis................. 1I-2
Starting Motor Performance Test ......................... 1I-3

Repair Instructions ............................................... 1I-5

Starting Motor Dismounting and 

Remounting........................................................ 1I-5

Starting Motor Components ................................. 1I-6
Starting Motor Inspection ..................................... 1I-7

Specifications...................................................... 1I-10

Starting Motor Specifications ............................. 1I-10
Tightening Torque Specifications....................... 1I-10

Special Tools and Equipment ............................ 1I-10

Recommended Service Material ........................ 1I-10

Charging System...................................... 1J-1

General Description ............................................. 1J-1

Battery Description.............................................. 1J-1
Generator Description ......................................... 1J-2

Diagnostic Information and Procedures ............ 1J-3

Battery Inspection ............................................... 1J-3
Generator Symptom Diagnosis ........................... 1J-4
Generator Test (Undercharged Battery 

Check)............................................................... 1J-4

Generator Test (Overcharged Battery 

Check)............................................................... 1J-5

Repair Instructions .............................................. 1J-6

Jump Starting in Case of Emergency.................. 1J-6
Battery Dismounting and Remounting ................ 1J-7
Water Pump and Generator Drive Belt 

Removal and Installation (For M16 Engine)...... 1J-7

Water Pump and Generator Drive Belt 

Tension Inspection and Adjustment (For 
M16 Engine)...................................................... 1J-8

Water Pump and Generator Drive Belt 

On-Vehicle Inspection (For J20 Engine) ........... 1J-9

Water Pump and Generator Drive Belt 

Removal and Installation (For J20 Engine) ..... 1J-10

Generator Dismounting and Remounting.......... 1J-11
Generator Components..................................... 1J-12
Generator Inspection......................................... 1J-13

Specifications ..................................................... 1J-16

Charging System Specifications ....................... 1J-16
Tightening Torque Specifications...................... 1J-16

Exhaust System....................................... 1K-1

General Description .............................................1K-1

Exhaust System Description ...............................1K-1

Diagnostic Information and Procedures ............1K-1

Exhaust System Check .......................................1K-1

Repair Instructions ..............................................1K-1

Exhaust System Components.............................1K-1
Exhaust Manifold Removal and Installation 

(For M16 Engine Model) ...................................1K-4

Exhaust Manifold Removal and Installation 

(For J20 Engine Model).....................................1K-4

Exhaust Pipe and Muffler Removal and 

Installation .........................................................1K-5

Specifications .......................................................1K-6

Tightening Torque Specifications........................1K-6

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Summary of Contents for GRAND VITARA -

Page 1: ...tom Diagnosis 1A 48 Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop but Engine Can Be Started 1A 57 Malfunction Indicator Lamp Remains ON after Engine Starts 1A 59...

Page 2: ...1502 Electric Load Current Sensor Circuit Low High 1A 167 DTC P1510 ECM Back Up Power Supply Malfunction 1A 169 DTC P1603 TCM Trouble Code Detected For J20 Engine 1A 170 DTC P1674 CAN Communication Bu...

Page 3: ...tion For J20 Engine 1C 14 Electric Load Current Sensor On Vehicle Inspection For J20 Engine 1C 16 Electric Load Current Sensor Removal and Installation For J20 Engine 1C 16 Specifications 1C 17 Tighte...

Page 4: ...iming Chain and Chain Tensioner Inspection 1D 90 1st Timing Chain and Chain Tensioner Components 1D 91 1st Timing Chain and Chain Tensioner Removal and Installation 1D 92 1st Timing Chain and Chain Te...

Page 5: ...ipment 1F 14 Recommended Service Material 1F 14 Fuel System 1G 1 Precautions 1G 1 Precautions on Fuel System Service 1G 1 General Description 1G 1 Fuel System Description 1G 1 Fuel Delivery System Des...

Page 6: ...on 1J 1 Generator Description 1J 2 Diagnostic Information and Procedures 1J 3 Battery Inspection 1J 3 Generator Symptom Diagnosis 1J 4 Generator Test Undercharged Battery Check 1J 4 Generator Test Ove...

Page 7: ...System Caution Refer to Exhaust System Check in Section 1K Precaution for CAN Communication System Refer to Precaution for CAN Communication System in Section 00 Precautions for Catalytic Converter R...

Page 8: ...ights on When checking ECM for DTC keep in mind that DTC is displayed on the scan tool as follows depending on the scan tool used SUZUKI scan tool displays DTC detected by ECM OBD generic scan tool di...

Page 9: ...formation refer to Description of Electric Throttle Body System Calibration For the procedure to register such data in ECM refer to Electric Throttle Body System Calibration in Section 1C To shut off...

Page 10: ...to the catalyst and stores the malfunction area in its memory If it detects that continuously 3 driving cycles are normal after detecting a malfunction however it makes MIL 1 turn OFF although DTC sto...

Page 11: ...ng Cycle Detection Logic The malfunction detected in the first driving cycle is stored in ECM memory in the form of pending DTC but the malfunction indicator lamp does not light at this time It lights...

Page 12: ...Air bag SDM immobilizer control module in ECM BCM Body electrical Control Module TCM Transmission Control Module for A T model 4WD control module for J20 engine and ABS hydraulic unit control module a...

Page 13: ...BCM 4 4WD control module for J20 engine 5 combination meter 6 and keyless start control module if equipped 7 of this vehicle communicate control data between each control module Communication of each...

Page 14: ...y to engage air conditioning compressor Top gear inhibit Torque converter clutch control inhibit Lock up slip control inhibit signal Immobilizer indication Engine emissions related malfunction Engine...

Page 15: ...ght active if equipped with DRL Air conditioning switch ON if equipped with A C A T mode status Electric load active low beam Electric load active high beam Electric load active tail light Electric lo...

Page 16: ...ld Tuning System For J20 Engine in Section 1D and intake manifold 5 The air by the amount corresponding to throttle valve 6 opening and engine speed is filtered by the air cleaner distributed by the i...

Page 17: ...o of throttle actuator control to about 15 to maintain the throttle valve opening In this way the throttle valve 17 is opened and closed to achieve the optimum throttle valve opening In this system as...

Page 18: ...ranking time or slow rise of revolution speed immediately after start up may occur However turning OFF the ignition switch once and restarting will set correct registration Generator Control System De...

Page 19: ...ed its impedance drops to the specified value approx 30 by its characteristic When a certain voltage about 0 4 V is applied between sensor elements in this state circuit current corresponding to the s...

Page 20: ...F sensor heater control system if equipped Oxygen sensor heater control system if equipped A C control system if equipped with A C Camshaft position control system for M16 engine Immobilizer control s...

Page 21: ...CCELERATOR PEDAL POSITION APP SENSOR A C COMPRESSOR CLUTCH IF EQUIPPED WITH A C HEATER CONTROL GENERATOR IMMOBILIZER COIL ANTENNA IF EQUIPPED KEYLESS START CONTROL MODULE IF EQUIPPED POWER STEERING PU...

Page 22: ...8 63 67 69 71 C37 12 16 WHT 2 C37 56 BRN 54 C37 21 55 BRN BLK C37 20 32 BLU ORN GRN C37 53 C37 54 C37 40 C37 41 C37 45 C37 44 WHT BLK RED BLU RED BLU YEL E23 17 E23 50 WHT WHT BLU ORN ORN BLU BLU GRN...

Page 23: ...62 DOME fuse 12 O2 HTR fuse 37 Fuel injector No 1 63 FI fuse 13 HO2S heater relay 38 Fuel injector No 2 64 Ignition switch 14 HO2S 2 39 Fuel injector No 3 65 IGN fuse 15 A F sensor 40 Fuel injector N...

Page 24: ...C37 24 C37 57 RED C37 25 47 PNK E23 49 48 16 55 59 17 C37 12 15 WHT 2 C37 56 BRN 49 C37 21 50 BRN BLK C37 20 27 BLU ORN GRN C37 53 C37 54 C37 40 C37 41 C37 45 C37 44 WHT BLK RED BLU RED BLU YEL E23 1...

Page 25: ...motor control relay 18 ABS hydraulic unit control module assembly 39 Fuel pump relay 61 Starting motor 19 BCM 40 Fuel pump 62 Diagnosis connector if equipped 20 Combination meter 41 Radiator cooling...

Page 26: ...nd No 3 for M16 engine 50 Ignition coil No 2 for J20 engine 21 BRN Ignition coil No 1 and No 4 for M16 engine 51 WHT BLU CKP sensor signal for M16 engine Ignition coil No 1 for J20 engine BLU Cranksha...

Page 27: ...active low signal to ABS hydraulic unit control module assembly 49 PNK A C compressor relay output if equipped with A C 20 GRN WHT Stop lamp switch signal 50 BLU ORN Throttle actuator control relay ou...

Page 28: ...SSURE SWITCH TP SENSOR THROTTLE ACTUATOR FUEL PUMP RELAY FUEL INJECT IMT VACUUM SOLENOID VALVE for J20 engine GENERATOR CONTROL THROTTLE ACTUATOR CONTROL RELAY OR A F SENSOR HEATER HO2S HEATER IGNITIO...

Page 29: ...m Engine and Emission Control System Diagram S5JB0A1102001 48 37 25 42 35 33 34 24 43 18 26 10 9 7 8 14 13 23 11 15 12 2 6 1 3 30 29 38 16 17 36 31 22 21 40 27 41 32 4 28 44 5 45 20 19 46 47 39 49 I5J...

Page 30: ...frigerant pressure sensor if equipped with A C 8 EVAP canister 25 Electric load 42 Accelerator pedal position APP sensor 9 Tank pressure control valve built in fuel pump 26 Fuel level sensor 43 Thrott...

Page 31: ...d valve G TCM for A T model 8 CMP sensor h Ignition coil assembly with ignitor H BCM 9 MAP sensor i Main relay I Immobilizer coil antenna if equipped 10 CKP sensor j Integration relay No 2 built in HO...

Page 32: ...p pressure switch n Immobilizer indicator lamp if equipped 14 Accelerator pedal position APP sensor o Throttle actuator control relay 15 Rear wheel speed sensor RH LH VSS Step Action Yes No 1 Customer...

Page 33: ...ion and Engine Symptom Diagnosis Are check and repair complete Go to Step 11 Check and repair malfunction part s and go to Step 11 9 Troubleshooting for DTC 1 Check and repair according to applicable...

Page 34: ...agnosis Customer problem inspection form Example NOTE This form is a standard sample It should be modified according to conditions characteristic of each market I2RH01110010 01 www CarGarage ir www Ca...

Page 35: ...bleshooting for DTC See each DTC Diag Flow Based on the DTC indicated in Step 6 or 7 and referring to the applicable DTC diag flow locate the cause of the trouble namely in a sensor switch wire harnes...

Page 36: ...F and disconnect scan tool from data link connector Without Using Scan Tool Vehicle Equipped with Diagnosis Connector 1 Turn ignition switch to OFF position 2 Using service wire ground diagnosis switc...

Page 37: ...ing MIL P0010 Camshaft position actuator circuit for M16 engine Oil control valve circuit open or short 1 driving cycle P0011 Camshaft position timing over advanced or system performance for M16 engin...

Page 38: ...on 1 driving cycle U P0131 O2 sensor HO2S circuit low voltage Sensor 1 Output voltage or sensor current of A F sensor is less than specification 2 driving cycles U P0132 O2 sensor HO2S circuit high vo...

Page 39: ...2 output variation is more than specification 2 driving cycles P0443 Evaporative emission system purge control valve circuit Monitor signal of EVAP canister purge valve is different from command signa...

Page 40: ...than specified time continuously 1 driving cycle P1678 CAN communication reception error for BCM Reception error of communication data for BCM is detected for longer than specified time continuously...

Page 41: ...sor voltage is more than specification 1 driving cycle UP1614 Transponder response error Refer to Diagnostic Trouble Code DTC Table in Section 10C UP1615 ID code does not registered vehicle equipped w...

Page 42: ...h circuit stuck on P0751 Shift solenoid A No 1 performance or stuck off P0752 Shift solenoid A No 1 stuck on P0756 Shift solenoid B No 2 performance or stuck off P0757 Shift solenoid B No 2 stuck on P...

Page 43: ...letely closed position default opening ECM controls fuel cut at specified engine speed ECM stops air fuel ratio control P0131 O2 sensor HO2S circuit low voltage Sensor 1 ECM stops air fuel ratio contr...

Page 44: ...control relay and throttle valve is fixed at the opening of about 7 from its completely closed position default opening ECM controls fuel cut at specified engine speed P2138 Pedal position sensor main...

Page 45: ...idle speed after warming up 0 20 0 10 mA FUEL CUT Engine at fuel cut condition ON Engine at other than fuel cut condition OFF O2S B1 S2 ACT HEATED OXYGEN SENSOR 2 At specified idle speed after warmin...

Page 46: ...ead position OFF At specified idle speed and steering wheel turned to the right or left as far as it stops ON RADIATOR FAN LOW RADIATOR COOLING FAN CONTROL RELAY No 1 Ignition switch ON Engine coolant...

Page 47: ...etectable range of fuel level sensor is set as 0 to 100 however with some models whose fuel tank capacity is smaller indicated fuel level may be only 70 even when fuel tank is full BATTERY VOLTAGE V T...

Page 48: ...pe pre catalyst FUEL CUT ON OFF ON Fuel being cut output signal to injector is stopped OFF Fuel not being cut O2S B1 S2 ACT HEATED OXYGEN SENSOR 2 ACTIVE INACTIVE This parameter indicates activation c...

Page 49: ...es throttle valve opening information in the form of voltage APP SENSOR 1 VOLT ACCELERATOR PEDAL POSITION APP SENSOR MAIN OUTPUT VOLTAGE V The Accelerator Pedal Position APP Sensor Main reading provid...

Page 50: ...ction looseness deterioration bend Vacuum Hose and Purge Valve Chamber Inspection in Section 1B Connectors of electric wire harness disconnection friction Fuses burning Parts installation bolt loosene...

Page 51: ...ction if equipped keyless start control system 1 Check keyless start control system referring to Keyless Start System Operation Inspection in Section 10E Is check result satisfactory Go to Step 5 Keyl...

Page 52: ...at specified idle speed Go to Engine Symptom Diagnosis Check ignition control related parts referring to Ignition Timing Inspection in Section 1H 9 Check immobilizer system malfunction if equipped imm...

Page 53: ...Was fuel pump operating sound heard from fuel filler for about 2 seconds after ignition switch ON and stop Go to Fuel Pressure Check Go to Fuel Pump and Its Circuit Check 12 Check ignition spark 1 Dis...

Page 54: ...njector connectors 2 Using sound scope 1 check operating sound of each injector 2 when cranking engine Was injector operating sound heard from all injectors Go to Engine Symptom Diagnosis Go to Fuel I...

Page 55: ...ne with VVT in Section 1D or Compression Check For J20 Engine in Section 1D Poor spark plug tightening or faulty gasket Spark Plug Removal and Installation in Section 1H Compression leak from valve se...

Page 56: ...m Inspection For J20 Engine in Section 1D or Camshaft Tappet and Shim Inspection For M16A Engine with VVT in Section 1D Worn valve stem and guide Valves and Valve Guides Inspection For J20 Engine in S...

Page 57: ...ings Connecting Rods and Cylinders Removal and Installation For M16A Engine with VVT in Section 1D Low oil pressure Condition Low oil pressure Engine noise Crankshaft noise NOTE Before checking mechan...

Page 58: ...vy deposits and burned electrodes etc Spark Plug Inspection in Section 1H Malfunctioning EGR valve EGR Valve Inspection in Section 1B High idle speed Condition Improper engine idling or engine fails t...

Page 59: ...tion For J20 Engine in Section 1D or Valves and Valve Guides Inspection For M16A Engine with VVT in Section 1D Worn valve stem Valves and Valve Guides Inspection For J20 Engine in Section 1D or Valves...

Page 60: ...ing Faulty spark plug Spark Plug Inspection in Section 1H Loose connection of high tension cord for M16 engine High Tension Cord Removal and Installation For M16 Engine in Section 1H Engine overheatin...

Page 61: ...Intake Air Temperature IAT Sensor Inspection in Section 1C Faulty electric throttle body assembly Electric Throttle Body Assembly On Vehicle Inspection in Section 1C Faulty accelerator pedal position...

Page 62: ...electric throttle body assembly Electric Throttle Body Assembly On Vehicle Inspection in Section 1C Faulty accelerator pedal position APP sensor assembly Accelerator Pedal Position APP Sensor Assembly...

Page 63: ...ture Clogged air cleaner Air Cleaner Filter Inspection and Cleaning For J20 Engine in Section 1D or Air Cleaner Filter Inspection and Cleaning For M16A Engine with VVT in Section 1D Vacuum leaks Engin...

Page 64: ...4 E23 1 E23 60 E23 19 E23 16 10 12 11 A E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43...

Page 65: ...nown good combination meter and recheck If MIL still remains OFF substitute a known good ECM and recheck 5 CAN communication line circuit check 1 Check CAN communication circuit between combination me...

Page 66: ...to ECM and or the ECM connectors referring to Inspection of ECM and Its Circuits 8 Combination meter circuit check 1 Turn ignition switch to OFF position 2 Measure resistance between G28 15 terminal o...

Page 67: ...YEL C37 60 C37 59 3 2 1 E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 2...

Page 68: ...uit check for ground short 1 Disconnect connector from oil control valve with ignition switch turned OFF 2 Measure resistance between C37 60 terminal of ECM connector and engine ground Is resistance i...

Page 69: ...dition for 5 minutes or longer until engine is warmed up to normal operating temperature 3 Stop vehicle 4 Run engine at idle speed for 1 minute 5 Start vehicle and increase vehicle speed up to 80 km h...

Page 70: ...s 0 5 Is it OK Substitute a known good ECM and recheck Go to Step 5 5 Oil control circuit visual inspection 1 Remove cylinder head cover referring to Cylinder Head Cover Removal and Installation For M...

Page 71: ...53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30...

Page 72: ...A F sensor connector and ECM connector Is each measured wire resistance lower than 1 Go to Step 4 Repair or replace defective wire circuit 4 Sensor circuit insulation check 1 Measure resistance betwe...

Page 73: ...nd Emission Control System Check performed Go to Step 2 Go to Engine and Emission Control System Check 2 A F sensor heater circuit check 1 Disconnect connector from A F sensor with ignition switch tur...

Page 74: ...2 Check for proper connection to relay connector 3 If connection are OK measure voltage between each relay power terminal of relay connector and vehicle body ground with ignition switch tuned ON For...

Page 75: ...k 1 Disconnect connector from ECM with ignition switch turned OFF 2 Check for proper connection of A F sensor heater circuit terminal to ECM connector 3 If connection are OK measure each wire resistan...

Page 76: ...4 3 9 RED GRN PNK BLK C37 47 C37 11 C37 57 6 2 7 10 BLK BLU WHT BLK RED GRY GRN 1 8 5 5V BLK WHT BLK PNK GRN I5JB0A110032 01 1 HO2S heater relay 4 O2 HTR fuse 7 Heater 10 To other sensors 2 Shield wi...

Page 77: ...onnector and vehicle body ground with ignition switch turned ON Is measured voltage 10 14 V Go to Step 9 Go to Step 3 3 HO2S heater fuse check 1 Check for O2 HTR fuse 1 blown For J20 engine For M16 en...

Page 78: ...ection in Section 1C Is it in good condition Go to Step 7 Replace relay 7 HO2S 2 heater circuit check 1 Measure insulation resistance between heater terminals of HO2S 2 connector Is measured resistanc...

Page 79: ...d resistance infinity Substitute a known good ECM and recheck Repair or replace short wire Step Action Yes No E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 5...

Page 80: ...ge 6 Release accelerator pedal to decrease vehicle speed to 40 km h 25 mile h 7 Stop vehicle and run it idle for 1 min 8 Check DTC and pending DTC DTC Troubleshooting NOTE Before this trouble shooting...

Page 81: ...and recheck Go to Step 5 5 MAF sensor power supply voltage check 1 Disconnect connector from MAF and IAT sensor with ignition switch turned OFF 2 Turn ON ignition switch measure voltage between engin...

Page 82: ...l of MAF and IAT sensor connector and engine ground Is resistance infinity Go to Step 10 RED wire is shorted to ground circuit 10 MAF sensor signal circuit check 1 Measure resistance between RED wire...

Page 83: ...inal of MAF and IAT sensor connector and engine ground Is resistance below 3 Go to Step 6 Go to Step 5 5 Ground circuit check 1 Remove ECM from its bracket with ECM connectors connected 2 Measure resi...

Page 84: ...ignition switch turned OFF 2 Measure voltage between C37 26 and C37 27 terminals of ECM connector referring to Mass Air Flow MAF and Intake Air Temperature IAT Sensor On Vehicle Inspection in Section...

Page 85: ...ion switch measure resistance between BLU wire terminal of MAF and IAT sensor connector and engine ground Is resistance below 5 Go to Step 6 Go to Step 5 5 Ground circuit check 1 Remove ECM from its b...

Page 86: ...34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45...

Page 87: ...k 1 Connect scan tool to DLC with ignition switch turned OFF 2 Turn ON ignition switch 3 Check DTC Is there DTC P0107 or DTC P0108 Go to applicable DTC diag flow Go to Step 3 3 MAP sensor output signa...

Page 88: ...connector from MAP sensor with ignition switch turned OFF 2 Check for proper connection of MAP sensor at GRY RED RED WHT and GRY GRN wire terminals 3 Turn ON ignition switch measure voltage between en...

Page 89: ...vehicle body ground Is resistance infinity Go to Step 7 RED WHT wire is shorted to ground circuit 7 MAP sensor output signal check 1 Check MAP sensor according to Manifold Absolute Pressure MAP Sensor...

Page 90: ...h resistance circuit ECM grounds C37 58 C37 48 C37 30 C37 29 and or C37 15 circuit are open or high resistance If wires are OK substitute a known good ECM and recheck 6 MAP sensor signal circuit check...

Page 91: ...ure ECT approx 90 95 C 194 203 F 4 Run engine at idle speed for 10 min or more 5 Check DTC and pending DTC E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 6...

Page 92: ...heck 1 Disconnect MAF and IAT sensor connector 1 with ignition switch turned OFF 2 Check for proper connection to MAF and IAT sensor connector 1 at LT GRN and GRY GRN wire terminals 3 If OK then with...

Page 93: ...istance below 3 Go to Step 8 LT GRN wire is high resistance circuit 8 Ground circuit check 1 Connect connectors to ECM 2 Check for proper connection of MAF and IAT sensor connector at GRY GRN wire ter...

Page 94: ...n Trouble area DTC will be set when all of following conditions are detected for 0 5 seconds continuously Engine is running Voltage of IAT sensor output is less than specified value High intake air te...

Page 95: ...r connector and vehicle body ground Is resistance infinity Go to Step 5 LT GRN wire is shorted to ground circuit If wire is OK substitute a known good ECM and recheck 5 IAT short circuit check 1 Turn...

Page 96: ...cautions For DTC Troubleshooting DTC detecting condition Trouble area DTC will be set when all of following conditions are detected for 0 5 seconds continuously Engine is running Voltage of IAT sensor...

Page 97: ...wire and connection are OK go to Step 5 Go to Step 5 5 Wire circuit check 1 Disconnect connectors from ECM with ignition switch turned OFF 2 Turn ON ignition switch 3 Measure voltage between LT GRN wi...

Page 98: ...and recheck Replace MAF and IAT sensor Step Action Yes No C37 57 GRY GRN GRY GRN 3 1 2 5V C37 24 PPL YEL E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60...

Page 99: ...oting referring to Precautions For DTC Troubleshooting Step Action Yes No 1 Was Engine and Emission Control System Check performed Go to Step 2 Go to Engine and Emission Control System Check 2 DTC che...

Page 100: ...to Step 7 Go to Step 7 7 Wire circuit check 1 Disconnect connectors from ECM with ignition switch turned OFF 2 Turn ignition switch to ON position 3 Measure voltage between PPL YEL wire terminal of E...

Page 101: ...K substitute a known good ECM and recheck 11 ECT sensor check 1 Check ECT sensor according to Engine Coolant Temperature ECT Sensor Inspection in Section 1C Is it in good condition Substitute a known...

Page 102: ...ehicle body ground Is resistance infinity Go to Step 5 PPL YEL wire is shorted to ground circuit If wire is OK substitute a known good ECM and recheck 5 ECT sensor short circuit check 1 Turn ON igniti...

Page 103: ...Intermittent trouble Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 3 ECT voltage check 1 Disconnect connector from ECT sensor with ignition switch turn...

Page 104: ...und circuit check 1 Connect connectors to ECM 2 Check for proper connection of ECT sensor connector at GRY GRN wire terminal 3 Measure resistance between GRY GRN wire terminal of ECT sensor connector...

Page 105: ...U E23 1 E23 60 C37 15 C37 29 C37 48 BLK ORN C37 58 BLU ORN GRN BLU RED BLU YEL BLU RED E23 16 E23 50 E23 17 C37 45 C37 44 1 1 1 2 1 3 3 4 5 8 6 7 10 9 E23 29 BLK YEL BLK WHT WHT GRN C37 30 BLK ORN BLK...

Page 106: ...nition switch turned OFF 2 Turn ON ignition switch check TP Sensor 1 Volt displayed on scan tool when accelerator pedal is idle position and fully depressed Is displayed TP sensor value as described v...

Page 107: ...4 6 V Go to Step 9 Go to Step 7 7 Wire harness check 1 Disconnect connectors from ECM with ignition switch turned OFF 2 Check for proper connection of ECM connector at C37 54 and C37 41 terminals 3 If...

Page 108: ...ons for DTC troubleshooting referring to Precautions For DTC Troubleshooting DTC detecting condition Trouble area Output voltage of throttle position sensor main is more than specified value for speci...

Page 109: ...engine ground with ignition switch turned ON Is voltage 0 V Substitute a known good ECM and recheck WHT wire is shorted to power circuit 5 Wire harness check 1 Measure voltage between BLK wire termin...

Page 110: ...nd Is resistance below 5 Go to Step 11 Go to Step 10 10 Ground circuit check 1 Remove ECM from its bracket with ECM connectors connected 2 Check for proper connection of ECM connector at C37 41 termin...

Page 111: ...L RED BLU PNK BLU BLK YEL 10 7 11 5 V 5 V I5JB0A110044 02 1 HO2 heater relay 4 O2 HTR fuse 7 Heater 10 Adjusting resistor 2 Shield wire 5 IG COIL fuse 8 To HO2S 2 heater 11 Sensor 3 Ignition switch 6...

Page 112: ...and keep it at 2000 r min for 60 sec 3 Repeat racing engine Repeat depressing accelerator pedal 5 to 6 times continuously to enrich A F mixture and take foot off from pedal to enlean it Does A F sens...

Page 113: ...plied keep vehicle coasting with fuel cut for 3 sec or more and then stop vehicle 7 Check if DTC and pending DTC exist by using scan tool If not check if oxygen sensor monitoring test has been complet...

Page 114: ...ay 4 O2 HTR fuse 7 Heater 10 To other sensors 2 Shield wire 5 IG COIL fuse 8 To A F sensor heater For M16 engine 3 Ignition switch 6 HO2S 2 9 ECM DTC detecting condition Trouble area DTC P0137 HO2S 2...

Page 115: ...or 12 sec or more then stop vehicle and run engine at idle speed for 60 sec or more 6 Repeat Step 4 7 Keep above vehicle speed for 8 min or more Throttle valve opening is kept constant in this step 8...

Page 116: ...n RED wire terminal of HO2S 2 connector and vehicle body ground Is resistance infinity Go to Step 7 RED wire is shorted to ground circuit 7 HO2S 2 signal circuit check 1 Measure voltage between RED wi...

Page 117: ...ferring to Precautions For DTC Troubleshooting DTC detecting condition Trouble area HO2S 2 voltage is higher than specified value after warming up engine circuit open 2 driving cycle detection logic H...

Page 118: ...d Oxygen Sensor HO2S 2 Heater On Vehicle Inspection in Section 1C Is it in good condition Substitute a known good ECM and recheck Replace HO2S 2 Step Action Yes No E23 C37 3 4 18 19 5 6 7 10 11 17 20...

Page 119: ...nd warm up to normal operating temperature 5 Operate vehicle with condition as noted freeze frame data for 5 min 6 Stop vehicle and check DTC and pending DTC DTC detecting condition Trouble area DTC P...

Page 120: ...injectors referring to Fuel Injector Inspection in Section 1G Is check result satisfactory Go to Step 6 Faulty injector s or its circuit 6 Visual inspection 1 Check MAF sensor and air intake system Ob...

Page 121: ...usting resistor circuit wire between A F sensor connector and ECM connector is less than 3 continuity check Resistance between A F sensor adjusting resistor circuit wires are infinity no continuity ch...

Page 122: ...LU E23 1 E23 60 C37 15 C37 29 C37 48 BLK ORN C37 58 BLU ORN GRN BLU RED BLU YEL BLU RED E23 16 E23 50 E23 17 C37 45 C37 44 1 1 1 2 1 3 3 4 5 8 6 7 10 9 E23 29 BLK YEL BLK WHT WHT GRN C37 30 BLK ORN BL...

Page 123: ...gnition switch turned OFF 2 Turn ON ignition switch check TP Sensor 2 Volt displayed on scan tool when accelerator pedal is idle position and fully depressed Is displayed TP sensor value as described...

Page 124: ...proper connection of ECM connector at C37 40 and C37 41 terminals 3 If OK measure resistance between RED and GRN wire terminals of electric throttle body assembly connector Is resistance infinity Go t...

Page 125: ...ons for DTC troubleshooting referring to Precautions For DTC Troubleshooting DTC detecting condition Trouble area Output voltage of throttle position sensor sub is more than specified value for specif...

Page 126: ...engine ground with ignition switch turned ON Is voltage 0 V Substitute a known good ECM and recheck WHT wire is shorted to power circuit 5 Wire harness check 1 Measure voltage between RED wire termin...

Page 127: ...round Is resistance below 3 Go to Step 11 Go to Step 10 10 Ground circuit check 1 Remove ECM from its bracket with ECM connectors connected 2 Check for proper connection of ECM connector at C37 41 ter...

Page 128: ...connect scan tool 2 Turn ON ignition switch and print Freeze Frame Data or write them down using scan tool 3 Clear DTC using scan tool 4 Drive vehicle under freeze frame data condition as noted for 1...

Page 129: ...Replace defective injector 8 Ignition timing check 1 Check ignition timing referring to Ignition Timing Inspection in Section 1H Is check result satisfactory Go to Step 9 Check related sensors 9 EGR...

Page 130: ...49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24...

Page 131: ...gnition switch measure voltage between C37 56 terminal of ECM connector and engine ground Is voltage 4 6 V WHT wire is open circuit Go to Step 5 5 Knock sensor circuit for short check 1 Disconnect con...

Page 132: ...E23 60 E23 16 7 BLK YEL BLK YEL BLK YEL C37 22 BLK WHT BLK YEL BLK YEL BLK YEL A BLK RED B BLK 6 12 11 14 WHT GRN WHT RED 8 BLK RED 10 BLK BLU BLK 9 C37 15 C37 29 C37 48 BLK ORN C37 58 C37 30 BLK ORN...

Page 133: ...2 Check for proper connection to ECM at C37 36 and C37 51 terminals 3 If OK measure resistance between engine ground and each C37 36 and C37 51 terminals of ECM connector Is each resistance infinity...

Page 134: ...WHT GRN WHT RED BLK RED 10 E23 1 BLK 9 C37 15 C37 29 C37 48 BLK ORN C37 58 C37 30 BLK ORN BLK YEL BLK YEL BLK YEL 15 BLU BLK E23 16 1 C37 51 5V 2 BLK YEL WHT BLU BLU BLK BLU BLK BLU BLK 8 I5JB0A110048...

Page 135: ...lled properly and connector connected securely Go to Step 3 Correct 3 Wire harness and connection check 1 Disconnect connector from CKP sensor with ignition switch turned OFF 2 Check for proper connec...

Page 136: ...re OK substitute a known good ECM and recheck 7 Engine start signal check 1 Check starting motor circuit for opening and short referring to Step 2 of DTC P0616 Starter Relay Circuit Low and Step 3 and...

Page 137: ...25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59...

Page 138: ...alled properly and connector connected securely Go to Step 3 Correct 3 Wire harness and connection check 1 Disconnect connector from CMP sensor 2 Check for proper connection to CMP sensor at BLU BLK W...

Page 139: ...e ground Is measured resistance value less than 3 Go to Step 6 BLK YEL wire is open or high resistance circuit 6 Was terminal B voltage in Step 3 within specification Go to Step 7 BLU BLK wire is open...

Page 140: ...ected Excessive Detected S5JB0A1104042 System and Wiring Diagram I5JB0A110051 01 1 EGR valve 4 Sensed information 7 IG COIL fuse 10 Main relay 2 Intake manifold 5 Fresh air 8 Fuse box No 2 11 FI fuse...

Page 141: ...an tool 3 Start engine and warm up to normal operating temperature 4 Run engine at idle for 10 min 5 Drive vehicle and increase engine speed 3000 rpm in 3rd gear 6 Release accelerator pedal and with e...

Page 142: ...Inspection in Section 1C Is check result satisfactory Intermittent trouble or faulty ECM Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 Replace MAP sens...

Page 143: ...oting is performed read the precautions for DTC troubleshooting referring to Precautions For DTC Troubleshooting DTC detecting condition Trouble area EGR valve output voltage is different from output...

Page 144: ...R valve control circuit wire Is each resistance infinity Go to Step 6 Faulty wire s are short circuit 6 EGR valve stepper motor coil circuit check 1 With ignition switch turned OFF connect EGR valve c...

Page 145: ...ensor Description Refer to A F Sensor Description DTC Detecting Condition and Trouble Area C37 11 C37 38 C37 57 WHT BRN 1 3 2 4 5 V YEL BLU WHT BLU WHT C37 37 BLK 5 5 V I5JB0A110053 02 1 A F sensor 3...

Page 146: ...exists using scan tool If not check if catalyst monitoring test has been completed using scan tool If not in both of above checks i e no DTC pending DTC and catalyst monitoring test not completed che...

Page 147: ...With ignition switch OFF connect scan tool to DLC 2 Turn ON ignition switch and clear DTC using scan tool 3 Start engine and warm up normal operating temperature 4 Drive vehicle at more than 40 km h...

Page 148: ...ECM connector and vehicle body ground Is resistance infinity Go to Step 4 GRN BLK wire is shorted to ground circuit 4 Wire circuit check 1 Measure voltage between C37 13 terminal of ECM connector and...

Page 149: ...2 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 12 V 1 5 E23 24 YEL RED BLK YEL YEL GRN PNK BLK WHT GRN E23 15 BLK WHT BLU B...

Page 150: ...y ground Is voltage about 3 5 V or less Go to Step 5 Intermittent trouble Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 5 Fuel level sensor output signa...

Page 151: ...e E empty Replenish fuel tank with fuel and go to Step 3 Go to Step 3 3 Do you have SUZUKI scan tool Go to Step 4 Go to Step 5 4 Fuel level sensor output signal check with SUZUKI scan tool 1 Connect S...

Page 152: ...nd Is voltage 10 14 V YEL RED wire is open circuit Substitute a known good ECM and recheck 10 Fuel level sensor ground circuit check 1 Disconnect connector from sub fuel lever sensor with ignition swi...

Page 153: ...45 43 41 33 1 12 13 23 8 5V RED BLK E23 46 E23 47 BLU RED BLU YEL BLU BLK E23 48 PPL YEL GRY GRN C37 24 C37 57 1 2 10 3 4 8 5 9 BLK RED YEL GRN C37 15 C37 29 C37 48 BLK ORN C37 58 C37 30 BLK ORN BLK Y...

Page 154: ...nect connectors to ECM with ignition switch turned OFF 2 Run engine until ECT is over 97 5 C 207 5 F 3 Measure voltage between E23 46 terminal of ECM connector and vehicle body ground Is voltage below...

Page 155: ...10 9 Radiator cooling fan control No 2 check 1 Connect connectors to ECM with ignition switch turned OFF 2 Run engine until ECT is over 102 5 C 216 5 F 3 Measure voltage between E23 47 terminal of ECM...

Page 156: ...ctors to ECM with ignition switch turned OFF 2 Run engine until ECT is over 102 5 C 216 5 F 3 Measure voltage between E23 48 terminal of ECM connector and vehicle body ground Is voltage below 1 5 V In...

Page 157: ...on Yes No E23 4 E23 19 WHT RED WHT BLU WHT RED WHT BLU E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42...

Page 158: ...e than 3700 rpm for 10 sec 7 Check pending DTC and DTC DTC Troubleshooting NOTE Before this trouble shooting is performed read the precautions for DTC troubleshooting referring to Precautions For DTC...

Page 159: ...6 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 5...

Page 160: ...4 Check related fuse and repair defective circuit 4 Stop lamp brake pedal switch signal circuit check 1 Disconnect connectors from ECM with ignition switch turned OFF 2 Check for proper connection of...

Page 161: ...3 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 4 1 2 3...

Page 162: ...connector and C37 14 terminal of ECM connector Is resistance below 3 Go to Step 4 GRY RED wire is open circuit 4 A C refrigerant pressure sensor power supply circuit check 1 Measure resistance between...

Page 163: ...tem Check performed Go to Step 2 Go to Engine and Emission Control System Check 2 A C refrigerant pressure sensor power supply circuit check 1 Disconnect connector from A C refrigerant pressure sensor...

Page 164: ...ound and GRY GRN wire terminal of A C refrigerant pressure sensor connector Is resistance below 5 Go to Step 7 Go to Step 6 6 ECM ground circuit check 1 Remove ECM from its bracket with ECM connectors...

Page 165: ...5 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 2...

Page 166: ...e and Emission Control System Check 2 Signal circuit check 1 Turn OFF ignition switch 2 Remove ECM from its bracket with ECM connectors connected 3 Measure voltage at terminal C37 22 of ECM connector...

Page 167: ...ctor and vehicle body ground Is voltage 0 1 V Intermittent trouble Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 If OK substitute a known good ECM and r...

Page 168: ...DTC and pending DTC IG L C FR E 4 2 BRN BLK C37 8 BRN BLK C37 28 B E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35...

Page 169: ...generator control circuit wire of generator connector and vehicle body ground is infinity ground circuit short check Voltage between generator control circuit wire of generator connector and vehicle b...

Page 170: ...prox 90 95 C 193 203 F 5 Turn ON following accessory switch Head lights switch Blower motor switch max position Rear defogger switch 6 Increase engine speed to 4000 rpm and keep it for 10 sec or more...

Page 171: ...coil monitor wire between generator connector and ECM connector is less than 1 continuity check Resistance between generator control wire and field coil monitor wire of generator connector is infinity...

Page 172: ...warm up normal operating temperature 4 Run engine at idle speed for 3 min or more 5 Check DTC I5JB0A110064 02 1 IMT vacuum solenoid valve 4 Fuse box No 2 7 FI fuse 2 Main relay 5 Ignition switch 8 IGN...

Page 173: ...e is shorted to ground circuit 4 Wire circuit check 1 Measure voltage between C37 33 terminal of ECM connector and vehicle body ground with ignition switch turned ON Is voltage 0 V Go to Step 5 GRY RE...

Page 174: ...idle 8 Check DTC and pending DTC 1 C37 9 BLU GRN GRY GRN GRY GRN C37 14 GRY RED GRY RED E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15...

Page 175: ...nected sensors to this circuit 3 Electric load current sensor output circuit check 1 Disconnect connector from ECM with ignition switch turned OFF 2 Check for proper connection of electric load curren...

Page 176: ...peed for 1 min 3 Check DTC and pending DTC E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45...

Page 177: ...1 Turn OFF ignition switch 2 Remove ECM from its bracket with ECM connectors connected 3 With engine running measure voltage between E23 2 terminal of ECM connector and engine ground Is voltage 10 14...

Page 178: ...19 8 7 18 1 E93 2 1 E23 C37 3 4 18 19 5 6 7 10 11 17 20 4746 49 50 51 21 22 52 16 25 9 24 14 29 55 57 5453 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 3938 44 45 43 41 33 1 12 13 23 8 3 4...

Page 179: ...cuit junction connector 1 ECM DTC detecting condition Trouble area Transmission error that is inconsistent between transmission data and transmission monitor CAN bus monitor data is detected more than...

Page 180: ...control module assembly and 4WD control module for J20 engine and or DTC No 33 in keyless start control module if equipped Go to Step 6 Go to Step 7 6 DTC check in ECM bus off 1 Disconnect connectors...

Page 181: ...f wires are OK substitute a known good 4WD control module and recheck 12 ABS hydraulic unit control module check 1 Measure resistance at following connector terminals Between E03 8 terminal and E03 6...

Page 182: ...nnector if equipped G28 8 terminal of combination meter connector Between G31 2 terminal of BCM connector and RED wire terminal of DLC Between G31 4 terminal of BCM connector and WHT wire terminal of...

Page 183: ...ground Between E03 12 terminal of ABS hydraulic unit control module connector and vehicle body ground Between E03 6 terminal of ABS hydraulic unit control module connector and vehicle body ground Betw...

Page 184: ...s there DTC P1674 Go to DTC P1674 CAN Communication Bus Off Error Go to Step 4 4 ECM ABS hydraulic unit control module and TCM for A T model connector check 1 Check for proper connection at each ECM A...

Page 185: ...C P1676 Go to Step 11 G28 10 or G28 8 circuit wire between combination meter and CAN circuit junction connector is open or high resistance If wires are OK substitute a known good combination meter or...

Page 186: ...Repair insulation of CAN communication line circuit referring to Precaution for CAN Communication System in Section 00 15 CAN communication line circuit ground short check 1 Measure resistance at foll...

Page 187: ...of communication data for BCM is detected for longer than specified time continuously 1 driving detection logic but MIL does not light up ECM BCM CAN communication line circuit Step Action Yes No 1 W...

Page 188: ...ubstitute a known good BCM and recheck 8 DTC check in ECM 1 Disconnect connectors from TCM for A T model and connect connector to ABS hydraulic unit control module with ignition switch turned OFF 2 Ch...

Page 189: ...rminal of ECM connector and E03 10 terminal of ABS hydraulic unit control module connector Between E23 19 terminal of ECM connector and E03 8 terminal of ABS hydraulic unit control module connector Be...

Page 190: ...tor and vehicle body ground Between G31 1 terminal of BCM connector and vehicle body ground Between G31 2 terminal of BCM connector and vehicle body ground Between G31 3 terminal of BCM connector and...

Page 191: ...eck 1 Connect scan tool to DLC with ignition switch turned OFF 2 Check ECM TCM for A T model ABS hydraulic unit control module assembly 4WD control module for J20 engine keyless start control module i...

Page 192: ...eck ECM for DTC Is there DTC P1685 Go to Step 9 E92 17 or E92 7 circuit wire between TCM and CAN circuit junction connector is open or high resistance If wires are OK substitute a known good TCM for A...

Page 193: ...recaution for CAN Communication System in Section 00 14 CAN communication line circuit ground short check 1 Measure resistance at following connector terminals Between E23 4 terminal of ECM connector...

Page 194: ...11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 12V 5V BLU BLK BLU BLK BLK RED 1 2 BLK RED BLK...

Page 195: ...it Electric throttle body assembly ECM Step Action Yes No 1 Was Engine and Emission Control System Check performed Go to Step 2 Go to Engine and Emission Control System Check 2 Throttle actuator circu...

Page 196: ...D wire terminal of electric throttle body assembly connector and engine ground Is resistance infinity Go to Step 4 BLU YEL wire and or BLU RED wire is shorted to ground circuit 4 Throttle actuator cir...

Page 197: ...ator control relay from relay box with ignition switch turned OFF 2 Check for proper connection to throttle actuator control relay at BLU BLK BLU RED BLU ORN and GRN wire terminals 3 Measure voltage b...

Page 198: ...tep Action Yes No 1 Was Engine and Emission Control System Check performed Go to Step 2 Go to Engine and Emission Control System Check 2 Throttle actuator control relay circuit check 1 Remove throttle...

Page 199: ...hrottle valve and throttle body housing referring to Throttle Valve Visual Check under Electric Throttle Body Assembly On Vehicle Inspection in Section 1C Is it in good condition Go to Step 3 Take it...

Page 200: ...e measured actual throttle valve opening angle and the target throttle valve opening angle which is calculated based on accelerator pedal opening angle and engine condition is more than specification...

Page 201: ...5 terminal of ECM connector Between BLU RED wire terminal of electric throttle body assembly connector and C37 44 terminal of ECM connector Is each resistance below 3 Go to Step 4 BLU YEL wire and or...

Page 202: ...0 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 E23 56 E23 55 E23 54 E23 53 E23 52 E23 51 5 V 5 V WHT W...

Page 203: ...on scan tool Is displayed voltage below 0 1 V Go to Step 4 Intermittent trouble Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 4 ECM voltage check 1 Dis...

Page 204: ...1 Measure resistance between E23 55 and each E23 54 E23 51 terminals of ECM connector with ignition switch turned OFF Is each resistance infinity Go to Step 9 WHT BLU wire is shorted to ORN wire and o...

Page 205: ...or pedal position APP sensor main circuit Accelerator pedal position APP sensor assembly ECM Incorrect mounting of accelerator pedal position APP sensor assembly Step Action Yes No 1 Was Engine and Em...

Page 206: ...orted to power circuit 6 Wire harness check 1 Disconnect connectors from ECM with ignition switch turned OFF 2 Check for proper connection of ECM connector at E23 56 E23 55 and E23 53 terminals 3 If O...

Page 207: ...4 terminal of ECM connector and engine ground Is resistance below 3 ORN wire is open or high resistance circuit Faulty ECM ground circuit If circuit is OK substitute a known good ECM and recheck 10 Ac...

Page 208: ...tool Is displayed voltage below 0 1 V Go to Step 4 Intermittent trouble Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 4 ECM voltage check 1 Disconnect...

Page 209: ...minals of ECM connector with ignition switch turned OFF Is each resistance infinity Go to Step 9 BLU GRN wire is shorted to ORN wire and or BLU YEL wire circuit 9 Wire harness check 1 Measure resistan...

Page 210: ...rator pedal position APP sensor assembly properly referring to Accelerator Pedal Position APP Sensor Assembly Removal and Installation in Section 1C 3 Accelerator pedal position sensor sub and its cir...

Page 211: ...engine ground Is voltage 0 V Go to Step 8 BLU GRN wire is shorted to power circuit 8 Ground circuit check 1 Connect connectors to ECM with ignition switch turned OFF 2 Measure resistance between BLU Y...

Page 212: ...3 1 12 13 23 8 12V 5V BLU BLK BLU BLK BLK RED 1 2 BLK RED BLK RED BLU E23 1 E23 60 C37 15 C37 29 C37 48 BLK ORN C37 58 BLU ORN GRN BLU RED BLU YEL BLU RED E23 16 E23 50 E23 17 C37 45 C37 44 1 1 1 2 1...

Page 213: ...intermittent referring to Intermittent and Poor Connection Inspection in Section 00 Go to Step 3 3 ECM voltage check 1 Disconnect connector from electric throttle body assembly with ignition switch tu...

Page 214: ...terminal of ECM connector and engine ground between C37 40 terminal of ECM connector and engine ground Is each voltage 0 V Go to Step 8 BLK wire or RED wire is shorted to other circuit 8 Wire harness...

Page 215: ...1 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 E23 56 E23 55 E23 54 E23 53 E23 52 E23 51 5 V 5 V WHT WHT BLU ORN ORN...

Page 216: ...or from accelerator pedal position APP sensor assembly with ignition switch turned OFF 2 Check for proper connection to accelerator pedal position APP sensor assembly at BLU YEL BLU GRN ORN BLU ORN WH...

Page 217: ...ach resistance infinity Go to Step 7 WHT BLU wire or BLU GRN wire is shorted to other circuit 7 Wire harness check 1 Turn ON ignition switch 2 Measure voltage between E23 55 terminal of ECM connector...

Page 218: ...ch turned OFF 2 Turn ON ignition switch clear DTC by using scan tool and run engine for 1 min 3 Check DTC and pending DTC by using scan tool DTC Troubleshooting NOTE Before this trouble shooting is pe...

Page 219: ...lloscope 3 NOTE As each terminal voltage is affected by battery voltage confirm that it is 11 V or more when ignition switch is turned ON Voltage with asterisk cannot be measured with voltmeter becaus...

Page 220: ...on switch is turned to ST cranking position Output signal is active low duty pulse Number of pulse generated times varies depending on vehicle condition C37 5 YEL BLK EGR valve stepper motor coil 1 10...

Page 221: ...800 kPa 116 psi 2 15 2 38 V Engine running A C switch ON and blower selector at 1st position or more A C refrigerant pressure 1400 kPa 203 psi 2 67 2 95 V Engine running A C switch ON and blower selec...

Page 222: ...ch turned ON 0 0 6 V 3 5 V Reference waveform No 12 and Reference waveform No 14 Engine running at idle after warmed up engine Output signal is active high pulse Pulse frequency varies depending on en...

Page 223: ...turned ON C37 30 BLK ORN Ground for ECM Below 0 3 V Ignition switch turned ON C37 31 BLK YEL Ground for A F sensor heater Below 0 3 V Ignition switch turned ON C37 32 PNK BLU Heater output of A F sen...

Page 224: ...1 V 10 14 V Reference waveform No 22 and Reference waveform No 23 Ignition switch turned ON and accelerator pedal at full depressed position after warmed up engine C37 45 BLU YEL Output of throttle ac...

Page 225: ...1 camshaft revolution C37 53 WHT Output for 5 V power source of throttle position sensor 4 5 5 5 V Ignition switch turned ON C37 54 BLK Throttle position sensor main signal 0 72 1 04 V Ignition switc...

Page 226: ...r frequency which varies depending on engine condition E23 5 PPL WHT Serial communication line of data link connector 12 V 8 14 V Ignition switch turned ON E23 6 BLK WHT Cruise control main switch sig...

Page 227: ...n E23 20 GRN WHT Stop lamp switch signal 0 1 V Ignition switch turned ON stop lamp not lit up 10 14 V Ignition switch turned ON stop lamp lit up E23 21 BLK YEL Cruise control command switch ground if...

Page 228: ...Ignition switch turned ON engine coolant temp 102 5 C 216 5 F or higher or A C refrigerant pressure 1600 kPa 232 psi or higher with A C switch turned on while engine is running E23 48 RED YEL Radiato...

Page 229: ...r sub 4 5 5 5 V Ignition switch turned ON E23 54 ORN Ground for accelerator pedal position APP sensor main Below 0 3 V Ignition switch turned ON E23 55 WHT BLU Accelerator pedal position APP sensor ma...

Page 230: ...ngine at specified idle speed 1 Cylinder reference signal CMP reference signal 3 720 crank angle I5JB0A110074 01 I5JB0A110075 01 Measurement terminal CH1 C37 52 to C37 58 CH2 C37 2 to C37 58 Oscillosc...

Page 231: ...oscope setting CH1 5 V DIV CH2 5 V DIV TIME 20 ms DIV Measurement condition After warmed up to normal operating temperature Engine at specified idle speed For a few sec from headlight switch turned ON...

Page 232: ...y cycle 4 10 14 V Measurement terminal CH1 C37 52 to C37 58 CH2 C37 16 to C37 58 Oscilloscope setting CH1 5 V DIV CH2 20 V DIV TIME 40 ms DIV Measurement condition After warmed up to normal operating...

Page 233: ...3 Ignition coil pulse width I5JB0A110083 02 Measurement terminal CH1 C37 52 to C37 58 CH2 C37 18 to C37 58 Oscilloscope setting CH1 2 V DIV CH2 2 V DIV TIME 40 ms DIV Measurement condition After warm...

Page 234: ...V DIV CH2 2 V DIV TIME 40 ms DIV Measurement condition After warmed up to normal operating temperature Engine at specified idle speed A For J20 engine B For M16 engine 3 Cylinder reference signal CMP...

Page 235: ...ent terminal CH1 C37 38 to C37 58 CH2 C37 37 to C37 58 CH3 C37 32 to C37 31 Oscilloscope setting CH1 500 mV DIV CH2 500 mV DIV CH3 10 V DIV TIME 100 ms DIV Measurement condition After warmed up to nor...

Page 236: ...B For M16 engine 1 Cylinder reference signal CMP reference signal 2 CKP signal 3 360 crank angle 4 4 5 V 5 36 6 30 CKP pulse I5JB0A110091 01 Measurement terminal CH1 C37 52 to C37 58 CH2 C37 51 to C3...

Page 237: ...drive signal C37 44 terminal 3 ON signal 4 OFF signal 5 One duty cycle I4RS0B110081 02 Measurement terminal CH1 C37 45 to C37 58 CH2 C37 44 to C37 58 Oscilloscope setting CH1 5 V DIV CH2 5 V DIV TIME...

Page 238: ...ne racing 2 Throttle position sensor main signal 3 Racing 4 Idle Measurement terminal CH1 C37 56 to C37 58 Oscilloscope setting CH1 1 V DIV TIME 10 ms DIV Measurement condition After warmed up to norm...

Page 239: ...5 OFF signal Measurement terminal CH1 E23 4 to C37 58 CH2 E23 19 to C37 58 Oscilloscope setting CH1 1 V DIV CH2 1 V DIV TIME 40 s DIV Measurement condition Ignition switch turned ON Signal pattern is...

Page 240: ...1 2 I4RS0A110086 02 Terminals Circuit Standard resistance Condition E23 60 to E23 29 Main relay 160 240 Battery disconnected and ignition switch turned ON E23 15 to E23 29 Fuel pump relay 160 240 C37...

Page 241: ...1 WHT E23 2 WHT GRN GRY RED BLU RED WHT GRY GRN C37 14 C37 9 C37 55 C37 57 GRY BLK C37 12 E23 55 BLU YEL BLU RED C37 45 C37 44 5 C37 15 C37 29 C37 48 BLK ORN C37 58 C37 30 BLK ORN BLK YEL BLK YEL BLK...

Page 242: ...nnectors referring to Inspection of ECM and Its Circuits Step Action Yes No 1 Circuit fuse check 1 Disconnect connectors from ECM with ignition switch turned OFF 2 Check for proper connection to ECM c...

Page 243: ...o Step 6 6 ECM ground circuit check 1 Turn ignition switch to OFF position 2 Disconnect connectors from ECM 3 Measure resistance between each C37 15 C37 30 C37 29 C37 48 and C37 58 terminals of ECM co...

Page 244: ...asure voltage between BLK RED wire terminal of main relay connector and body ground Is voltage 10 14 V Go to Step 10 BLK RED wire is open circuit 10 Main relay check 1 Check main relay referring to Co...

Page 245: ...and or ORN BLU wire is shorted to ground circuit Step Action Yes No BLK WHT BLU BLK BLU BLK WHT GRN BLK RED BLK RED BLK RED BLK YEL BLU 12V 5V 9 2 8 3 E23 29 E23 1 E23 60 10 E23 C37 3 4 18 19 5 6 7 10...

Page 246: ...en each BLU BLK wire terminal of fuel injector connector and engine ground with ignition switch turned ON Is voltage 10 14 V Go to Step 5 BLU BLK wire is open or shorted to ground circuit If it is in...

Page 247: ...15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37...

Page 248: ...itch measure voltage between BLK WHT wire terminal of fuel pump relay connector and engine ground Is voltage 10 14 V Go to Step 3 BLK WHT wire is open or shorted to ground circuit 3 Fuel pump relay po...

Page 249: ...vehicle body ground Is resistance infinity Go to Step 8 PNK wire is shorted to ground 8 Fuel pump circuit check 1 Connect service wire between E23 15 terminal of ECM connector and vehicle body ground...

Page 250: ...Check S5JB0A1104067 System Diagram Special tool A 09912 58442 B 09912 58432 C 09912 58490 4 C B A 1 2 3 I2RH01110133 01 1 Injector 2 Delivery pipe 3 Fuel pressure regulator 4 Fuel filter and fuel pump...

Page 251: ...about the same value as Step 2 Go to Step 4 Go to Step 8 4 Fuel line check 1 Check fuel pipe fuel hose and joint for fuel leakage Are they in good condition Go to Step 5 Repair or replace defective pa...

Page 252: ...LK RED YEL GRN RED YEL BLK BLU BLU BLU WHT YEL GRN 5V WHT BLU WHT RED E23 4 E23 19 RED WHT WHT BLU WHT RED RED WHT 5V PNK GRN YEL RED WHT BLK BLK RED 12V PNK RED GRY RED GRY BLK C37 14 C37 12 WHT RED...

Page 253: ...running A C switch OFF OFF Engine running A C switch ON and blower speed selector turned 1st position or more ON Is check result satisfactory Go to Step 4 Check HVAC control module and its circuit 4...

Page 254: ...following conditions respectively Voltage between E23 49 terminal of ECM connector and ground While engine running and A C switch turned OFF 10 14 V While engine running A C and blower speed selector...

Page 255: ...19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 E23 4 E23 19 1 RED WHT E03 12 E03 6...

Page 256: ...LIST mode on scan tool 2 Check electric load signal under following conditions respectively A C switch signal Engine running A C switch OFF OFF Engine running A C switch ON and blower speed selector t...

Page 257: ...3 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 1...

Page 258: ...ector and vehicle body ground Is voltage 10 14 V Go to Step 4 BLU WHT wire is open circuit 4 Radiator cooling fan control check 1 Disconnect connector from radiator cooling fan motor No 1 and connect...

Page 259: ...5 C 207 5 F 3 Measure voltage between BLU wire terminals of radiator cooling fan motor No 2 connector and vehicle body ground Is voltage 10 14 V Go to Step 14 Go to Step 11 11 Wire circuit check 1 Dis...

Page 260: ...ute a known good ECM and recheck Replace radiator cooling fan motor Step Action Yes No Step Action Yes No 1 Is there DTC s of ECT sensor circuit DTC P0116 P0117 P0118 and or radiator cooling fan circu...

Page 261: ...or cooling fan relay No 3 connector and radiator cooling fan motor No 2 connector with ignition switch turned OFF Is resistance below 3 Go to Step 7 BLU wire is open or high resistances 7 Wire circuit...

Page 262: ...gear shift lever in Neutral shift selector lever to P range for A T vehicle and set parking brake and block drive wheels 1 Connect SUZUKI scan tool to DLC 1 with ignition switch turned OFF Special too...

Page 263: ...uel pressure gauge set 09912 58413 09912 58490 09930 76420 3 way joint hose Timing light dry cell type 09933 06320 SUZUKI scan tool ECM check harness 120P This kit includes following items 1 Tech 2 2...

Page 264: ...le cause is clogged EGR gas passage stuck or faulty EGR valve Repair Instructions EVAP Canister Purge Inspection S5JB0A1206001 NOTE Before inspection check to make sure that gear shift lever is in neu...

Page 265: ...ctor referring to Inspection of ECM and Its Circuits in Section 1A iv Turn ON ignition switch Using service wire ground C37 13 terminal circuit of special tool valve ON B and unground it valve OFF A 2...

Page 266: ...ster purge valve If resistance is not as specified replace EVAP canister purge valve EVAP canister purge valve resistance 30 34 at 20 C 68 F 4 With coupler disconnected apply vacuum 60 kPa 8 7 psi to...

Page 267: ...and cylinder head Use new gaskets EGR Valve Inspection S5JB0A1206008 1 Check resistance between following terminals of EGR valve 1 in each pair If found faulty replace EGR valve assembly EGR valve re...

Page 268: ...ening for obstructed PCV valve or hose hampers its accurate adjustment 1 Remove PCV valve referring to PCV Valve Removal and Installation 2 Connect PCV valve to hose and install plug to cylinder head...

Page 269: ...g part Tightening torque Note N m kgf m lb ft PCV valve 27 2 7 19 5 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No 1207F P No 99000 31250 09917 47011 SUZUKI scan tool...

Page 270: ...ld Absolute Pressure MAP Sensor Inspection S5JB0A1306005 1 Disconnect connector from MAP sensor 2 Remove MAP sensor from intake manifold 3 Arrange 3 new 1 5 V batteries 2 in series check that total vo...

Page 271: ...or M16 engine 2 Check that there isn t any foreign matter caught between throttle valve and throttle body housing If there is take it out after removing throttle body referring to Electric Throttle Bo...

Page 272: ...ody assembly If measured resistance is out of specified value replace electric throttle body assembly Throttle actuator motor resistance 0 3 100 at 20 C 68 F Throttle Position Sensor Performance Check...

Page 273: ...system as follows 1 If electric throttle body assembly and or accelerator pedal position APP sensor assembly are replaced perform following steps a Disconnect negative cable at battery for 20 seconds...

Page 274: ...to expose sensor section of accelerator pedal position APP sensor assembly to water NOTE After replacing accelerator pedal position APP sensor assembly perform calibration of throttle valve referring...

Page 275: ...e or does not vary linearly as the following graph replace accelerator pedal position APP sensor assembly Accelerator pedal position APP sensor output voltage Accelerator pedal position APP sensor mai...

Page 276: ...nnector 2 Using ohmmeter measure resistance of Sensor heater between terminals VB and GND at sensor connector If found faulty replace A F sensor NOTE Temperature of sensor affects resistance value lar...

Page 277: ...onnector of A F sensor and or heated oxygen sensor 3 Remove A F sensor 1 and or heated oxygen sensor 2 from exhaust No 1 pipe Installation Reverse removal procedure noting the following Tighten A F se...

Page 278: ...5 while keeping approximately 1 mm 0 03 in gap with respect to end face of CMP sensor If resistance does not vary as specified below replace CMP sensor CMP sensor resistance Resistance varies from le...

Page 279: ...bolt a 10 N m 1 0 kgf m 7 5 lb ft 2 Connect connector to CKP sensor securely 3 Adjust generator drive belt tension referring to Water Pump and Generator Drive Belt Tension Inspection and Adjustment Fo...

Page 280: ...inal of battery by passing magnetic substance iron 5 while keeping approximately 1 mm 0 03 in gap with respect to end face of CKP sensor If resistance does not vary as specified below replace CKP sens...

Page 281: ...ay No 2 For J20 Engine 1 Disconnect negative cable at battery 2 Remove included in integration relay No 2 1 from fuse box No 2 2 3 Check that there is no continuity between terminals E41 1 and E37 8 o...

Page 282: ...and IAT sensor with ignition switch turned ON 0 5 1 0 V 7 Start engine and check that voltage is lower than 5 V and it rises as engine speed increases MAF signal voltage between C37 26 terminal circui...

Page 283: ...esistance between sensor terminals while heating air gradually If measured resistance does not show such characteristic as shown replace MAF and IAT sensor Intake air temperature sensor resistance 20...

Page 284: ...ot as described replace intake manifold tuning vacuum solenoid valve 7 Connect vacuum hoses to intake manifold tuning valve and vacuum tank 8 Connect intake manifold tuning vacuum solenoid valve conne...

Page 285: ...rminal of ECM connector and vehicle body ground referring to Inspection of ECM and Its Circuits in Section 1A If check result is satisfactory electric load current sensor is in good condition If check...

Page 286: ...ightening torque Note N m kgf m lb ft Accelerator pedal position APP sensor assembly nut 6 0 0 6 4 5 APP sensor assembly bracket nut 6 0 0 6 4 3 ECT sensor 12 5 1 25 9 0 A F sensor 45 4 5 32 5 Heated...

Page 287: ...stroke cycle gasoline unit with its DOHC Double overhead camshaft valve mechanism arranged for V type valve configuration and 16 valves 4 valves one cylinder The double overhead camshaft is mounted o...

Page 288: ...tem operation the intake valve timing is varied by the cam timing sprocket 1 which varies the rotational phase between the intake camshaft 3 and sprocket The rotor 2 in the cam timing sprocket is actu...

Page 289: ...s to the left opposite direction against the coil 5 By this spool valve movement the pressurized oil 1 is led into the chambers for timing advancing and the oil in the chambers for timing retarding is...

Page 290: ...g loss Improvement of the fuel efficiency Lowering of the exhaust emission Light engine load range To the retarded side To shorten the valve opening overlap in order to prevent the exhaust gas counter...

Page 291: ...0 Carry out Steps 7 through 9 on each cylinder to obtain 4 readings 11 After checking install spark plugs and ignition coil assemblies 2 with high tension cord 3 12 Connect ignition coil couplers 1 13...

Page 292: ...cular to shim faces at valves to be checked in this case 3 and 8 if not adjust it by turning crankshaft Check valve lashes d In the same manner as b c check valve lashes at valves 4 and 6 e In the sam...

Page 293: ...ess of new shim with the following formula and table Shim thickness specification Intake side A B C 0 20 mm 0 008 in Exhaust side A B C 0 30 mm 0 012 in A Thickness of new shim B Thickness of removed...

Page 294: ...tallation S5JB0A1416001 Removal 1 Open air cleaner case 1 by unhooking its clamps 2 2 Remove air cleaner filter from case Installation Reverse removal procedure for installation Thickness mm in Shim N...

Page 295: ...ition coil assemblies 2 with high tension cord 3 7 Remove wire harness clamp from cylinder head cover 8 Remove oil level gauge 1 9 Disconnect PCV hose 2 from PCV valve 3 and disconnect breather hose 4...

Page 296: ...linder head cover gasket or spark plug hole gaskets will not get out of place or fall off 4 Tightening bolts in such order as indicated in the figure a little at a time till they are tightened to spec...

Page 297: ...On Vehicle Inspection in Section 1C I5JB0A141005 05 A Installing location of intake manifold bolt and nut 7 EVAP canister purge valve 14 Intake manifold bolt short 1 Intake manifold 8 EVAP canister p...

Page 298: ...nector 2 to electric throttle body assembly securely 4 Connect engine coolant hoses 3 to electric throttle body assembly 1 5 Connect air intake pipe 1 and breather union 2 6 Tighten air intake pipe bo...

Page 299: ...5 Remove EVAP canister purge valve 7 6 Remove intake manifold bracket 8 7 Remove delivery pipe referring to Fuel Injector Removal and Installation in Section 1G 8 Remove intake manifold 1 and EGR pipe...

Page 300: ...e Oil and Filter Change in Section 0B 4 Drain coolant referring to Cooling System Draining in Section 1F 5 Disconnect breather hose 1 from air intake pipe 2 6 Remove air intake pipe 2 I5JB0A141015 02...

Page 301: ...owing hoses Brake booster hose 22 from intake manifold Radiator inlet and outlet hoses 26 from each pipe Heater inlet and outlet hoses 23 from each pipe Fuel hoses 24 from fuel pipes EVAP canister pur...

Page 302: ...Dismounting and Remounting in Section 5B if necessary 25 Remove engine with engine front mounting bracket 1 from engine front mounting 2 if necessary 26 Remove clutch cover and clutch disc referring t...

Page 303: ...and Installation for M16 Engine Model in Section 6C 14 Adjust P S pump and A C compressor if equipped drive belt tension referring to P S Pump and A C Compressor If Equipped Drive Belt Inspection and...

Page 304: ...face of cylinder and cylinder head Apply sealant 99000 31260 to the mating surface of timing chain cover referring to the figure of Step 5 of Installation under Timing Chain Cover Removal and Installa...

Page 305: ...olt To lock crankshaft pulley 1 use special tool with it as shown in the figure Special tool A 09917 68221 5 Remove crankshaft pulley 1 If it is hard to remove use special tools as shown in the figure...

Page 306: ...linder head and B to mating surface of timing chain cover as shown in the figure A Water tight sealant 99000 31140 SUZUKI Bond No 1207B B Sealant 99000 31260 SUZUKI Bond No 1217G Sealant amount for ti...

Page 307: ...ion for M16 Engine Model in Section 6C 16 Install engine assembly to vehicle referring to Engine Assembly Removal and Installation For M16A Engine with VVT Timing Chain Cover Inspection S5JB0A1416016...

Page 308: ...in Section 6C 7 Adjust P S pump and A C compressor drive belt tension referring to P S Pump and A C Compressor If Equipped Drive Belt Inspection and Adjustment for M16 Engine Model in Section 6C 8 Ref...

Page 309: ...exhaust camshaft timing sprocket marks 1 with notches 2 of cylinder head respectively and align crankshaft sprocket key 3 with notch of cylinder block 4 3 Remove timing chain tensioner adjuster assemb...

Page 310: ...in the figure 4 Fit crankshaft timing sprocket to timing chain by aligning gold plate 3 of timing chain and circle mark 4 on crankshaft timing sprocket Then install crankshaft timing sprocket fitted w...

Page 311: ...nkshaft timing sprocket is in match with gold plate 4 of timing chain 8 Screw in plunger 1 by turning body 2 in arrow direction and install a retainer 3 wire to hold plunger in place 9 Install timing...

Page 312: ...oval and Installation For M16A Engine with VVT 12 Perform Steps 3 to 8 of Installation of Timing Chain Cover Removal and Installation For M16A Engine with VVT Timing Chain and Chain Tensioner Inspecti...

Page 313: ...ith spanner or the like loosen mounting bolt of intake cam timing sprocket assembly 3 and remove it CAUTION Never attempt to loosen mounting bolt with intake cam timing sprocket assembly held stationa...

Page 314: ...shaft bearing 1 to cylinder head CAUTION Do not apply engine oil to camshaft bearing back Only a upper half bearing of intake camshaft bearing No 1 has some holes Other bearings 3 Install intake camsh...

Page 315: ...camshaft 2 held stationary with spanner or the like tighten bolt of intake cam timing sprocket assembly 3 to specification Tightening torque Intake cam timing sprocket bolt a 60 N m 6 0 kgf m 43 5 lb...

Page 316: ...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 found replace camshaft or cylinder head with housing...

Page 317: ...eplace camshaft or cylinder head assembly whichever the difference from specification is greater Camshaft journal diameter A Camshaft journal bearing bore B Standard Limit Intake side No 1 housing 0 0...

Page 318: ...ine cylinder head to tappet clearance If clearance exceeds limit replace tappet or cylinder head Cylinder head to tappet clearance Standard 0 025 0 066 mm 0 0010 0 026 in Limit 0 15 mm 0 0059 in Tappe...

Page 319: ...ecified procedure 3 Valve spring 9 Cylinder head bolt M10 Check cylinder head bolt M10 plastic deformation tightening bolt for deformation referring to Cylinder Head Bolt under Valves and Valve Guides...

Page 320: ...Remove exhaust manifold referring to Exhaust Manifold Removal and Installation For M16 Engine Model in Section 1K if necessary 10 Remove cylinder head with intake manifold and exhaust manifold Use li...

Page 321: ...erring to Cylinder Head Cover Removal and Installation For M16A Engine with VVT 10 Install oil pan referring to Oil Pan and Oil Pump Strainer Removal and Installation For M16A Engine with VVT in Secti...

Page 322: ...cylinder head Heat cylinder head uniformly at a temperature of 80 to 100 C 176 to 212 F so that head will not be distorted and drive new valve guide into hole with special tools Drive in new valve gu...

Page 323: ...lve stem 7 Install valve spring and spring retainer Each valve spring has top end large pitch end 1 and bottom end small pitch end 2 Be sure to position spring in place with its bottom end small pitch...

Page 324: ...ion Remove all carbon from valves Inspect each valve for wear burn or distortion at its face and stem end as necessary replace it Inspect valve stem end face for pitting and wear If pitting or wear is...

Page 325: ...contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping 1 Exhaust valve seat Use valve seat cutters 1 to make two cuts as illustrated...

Page 326: ...bide abrasive paper place abrasive paper on and over surface plate and rub gasketed surface against paper to grind off high spots Should this fail to reduce thickness gauge readings to within limit re...

Page 327: ...sound condition free of any evidence of breakage or weakening Remember weakened valve springs can cause chatter not to mention possibility of reducing power output due to gas leakage caused by decrea...

Page 328: ...der bore before removing piston from cylinder 7 Push piston and connecting rod assembly out through the top of cylinder bore A 1 Tighten all nuts to 15 N m 1 5 kgf m 2 Then retighten all nuts by turni...

Page 329: ...against cylinder block until all piston rings have entered cylinder bore Special tool A 09916 77310 5 Install bearing cap 1 Point arrow mark 2 on cap to crankshaft pulley side After applying engine o...

Page 330: ...in the figure c Insert piston pin to piston and connecting rod d Install piston pin circlips 3 NOTE Circlip should be installed with its cut part facing as shown in the figure Install so that circlip...

Page 331: ...ameter Standard 78 00 78 014 mm 3 0709 3 0714 in Limit 78 114 mm 3 075 in Cylinder taper and out of round Limit 0 10 mm 0 004 in NOTE If any one of four cylinders has to be rebored rebore all four to...

Page 332: ...n ring and ring land by using thickness gauge 2 If clearance is out of specification replace piston Ring groove clearance Piston Ring Piston ring end gap To measure end gap insert piston ring 2 into c...

Page 333: ...20 in Piston pin clearance in piston Standard 0 006 0 017 mm 0 00024 0 00067 in Limit 0 05 mm 0 0020 in Small end bore 20 003 20 011 mm 0 7875 0 7878 in Piston pin dia 19 997 20 000 mm 0 7873 0 7874 i...

Page 334: ...B 0 1 mm 0 004 in Crank Pin and Connecting Rod Bearings Inspection S5JB0A1416034 Crank Pin Diameter Inspect crank pin for uneven wear or damage Measure crank pin for out of round or taper with a micro...

Page 335: ...rod When installing cap be sure to point arrow mark 2 on cap to crankshaft pulley side as shown in the figure After applying engine oil to rod bolts tighten cap nuts 3 gradually as follows a Tighten...

Page 336: ...meter 2 Next check crankshaft pin diameter On crank web No 3 four alphabets are stamped as shown in the figure Three kinds of alphabet A B and C represent the following crankshaft pin diameter respect...

Page 337: ...and its cap is 1 and alphabet stamped on crank web No 3 is B install a new standard bearing painted in Black to its connecting rod big end inside Specification of new standard connecting rod bearing s...

Page 338: ...1D 52 Engine Mechanical For M16A Engine with VVT Main Bearings Crankshaft and Cylinder Block Components S5JB0A1416035 I5JB0A141026 02 www CarGarage ir www CarGarage ir w w w C a r G a r a g e i r...

Page 339: ...wheel 22 N m 2 2 kgf m 16 0 lb ft 5 Main bearing See B 14 Main bearing cap 5 N m 0 5 kgf m 4 0 lb ft 6 Sensor plate 15 Flywheel mounting bolt 70 N m 7 0 kgf m 51 0 lb ft 7 Crankshaft timing sprocket k...

Page 340: ...t to cylinder block 6 Install bearing cap to cylinder block making sure to point arrow mark on each cap to crankshaft pulley side Fit them sequentially in ascending order 1 2 3 4 and 5 starting from p...

Page 341: ...ial tool A 09911 97720 Tightening torque Rear oil seal housing bolt 11 N m 1 1 kgf m 8 0 lb ft 10 Install flywheel for M T Using special tool lock flywheel and tighten flywheel bolts to specified torq...

Page 342: ...o 1 Bolt under Main Bearings Inspection For M16A Engine with VVT a Tighten bolts 1 10 to 30 N m 3 0 kgf m 22 0 lb ft according to numerical order in the figure b In the same manner as in Step a tighte...

Page 343: ...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 shown in the figure...

Page 344: ...mit replace bearing Always replace both upper and lower inserts as a unit A new standard bearing may produce proper clearance If not it will be necessary to regrind crankshaft journal for use of 0 25...

Page 345: ...stamped on cylinder block is B install a new standard bearing painted in Brown to its journal New standard size crankshaft main bearing specification 5 Using scale 1 on gauging plastic 2 check bearing...

Page 346: ...51 732 51 750 mm 2 0367 2 0374 in b Using micrometer measure regrind journal diameter Measurement should be taken in two directions perpendicular to each other in order to check for out of round c Us...

Page 347: ...9 Check sensor plate for crack damage If malcondition is found replace it Rear Oil Seal Inspection S5JB0A1416040 Carefully inspect oil seal 1 for wear or damage If its lip is worn or damaged replace i...

Page 348: ...20 in Honing or Reboring Cylinders 1 When any cylinder needs reboring all other cylinders must also be rebored at the same time 2 Select oversized piston according to amount of cylinder wear Oversize...

Page 349: ...shaft housing bolt 11 1 1 8 0 Cylinder head cover bolt 8 0 8 6 0 Air intake pipe bolt 3 0 3 2 5 Starting motor terminal nut 11 1 1 8 0 Generator terminal nut 7 0 7 5 0 Timing chain cover bolt and nut...

Page 350: ...gine with VVT Main Bearings Crankshaft and Cylinder Block Components For M16A Engine with VVT Special Tool S5JB0A1418002 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond N...

Page 351: ...09916 58210 09916 67020 Valve guide installer handle Tappet holder Overseas 09916 67021 09916 77310 Tappet holder Piston ring compressor 50 125 mm 09916 84511 09917 68221 Forceps Camshaft pulley holde...

Page 352: ...soline unit with its DOHC Double overhead camshaft valve mechanism arranged for V type valve configuration consisting of 16 valves 4 valves one cylinder The double overhead camshaft is mounted over th...

Page 353: ...Engine Mechanical For J20 Engine 1D 67 I5JB0A142069 02 www CarGarage ir www CarGarage ir w w w C a r G a r a g e i r...

Page 354: ...tuning system consists of the following items IMT valve 5 fixed on intake manifold 1 IMT valve actuator 4 IMT vacuum solenoid valve 2 Vacuum tank 3 Vacuum tank contains the one way check valve 6 to ma...

Page 355: ...orque between middle and high engine speed ranges is improved whilst it drops between low and middle engine speed ranges When IMT valve is totally closed B The effective intake pipe length is longer E...

Page 356: ...the negative pressure The effective intake pipe length therefore becomes longer Diagnostic Information and Procedures Compression Check S5JB0A1424001 Check compression pressure on all 4 cylinders as f...

Page 357: ...r of the condition of the engine The vacuum checking procedure is as follows 1 Warm up engine to normal operating temperature and make sure that engine idle speed is within specification NOTE After wa...

Page 358: ...4 according to the following procedure a Check valve lashes of cylinder No 1 b Turn crankshaft pulley by 180 clockwise c Check valve lashes of cylinder No 3 d In the same manner as b c check valve la...

Page 359: ...not to contact the shim by installing special tool on camshaft housing with housing bolt 1 tighten housing bolts to specified torque Special tool A 09916 66510 Tightening torque Camshaft housing bolt...

Page 360: ...l camshaft housing 1 and tighten bolts to specified torque Tightening torque Camshaft housing bolt a 11 N m 1 1 kgf m 8 0 lb ft 10 Turn crankshaft pulley more than 4 rotations 11 Check valve clearance...

Page 361: ...breather hose 1 to air cleaner outlet hose 2 Air Cleaner Filter Removal and Installation S5JB0A1426002 Removal 1 Remove air cleaner upper case 1 from lower case after hooking clamps 2 from upper case...

Page 362: ...ative cable at battery 2 Drain coolant referring to Cooling System Draining in Section 1F 3 Disconnect breather hose 1 from air cleaner outlet hose 2 4 Disconnect air cleaner outlet hose 2 from air cl...

Page 363: ...r Electric Throttle Body Assembly On Vehicle Inspection in Section 1C Intake Manifold Removal and Installation S5JB0A1426012 CAUTION Never disassemble intake manifold Disassembly will spoil its origin...

Page 364: ...elt referring to Water Pump and Generator Drive Belt On Vehicle Inspection For J20 Engine in Section 1J Refill cooling system referring to Cooling System Flush and Refill in Section 1F Upon completion...

Page 365: ...efore installation and replace if found defective 6 Install cylinder head cover to cylinder head 7 Tighten cylinder head cover nuts in such order as indicated in the figure a little at a time till the...

Page 366: ...ront mounting 6 Engine splash cover 2 Engine front mounting right bracket 7 Engine front mounting nut 3 Engine front mounting left bracket 8 Engine rear mounting member bolt 4 Engine rear mounting mem...

Page 367: ...ition coil assembly 6 Injectors 7 HO2S 8 A F sensor 9 Engine oil pressure switch 10 CKP sensor 11 Back up light switch For M T model 12 Generator 13 Starting motor 14 Ground terminal Magnet clutch swi...

Page 368: ...member using jack 2 18 Carry out Step 1 to 12 of Removal under Front Suspension Frame Stabilizer Bar and or Bushings Removal and Installation in Section 2B in order to lower engine with front suspensi...

Page 369: ...emoval and Installation for J20 Engine Model in Section 7B 11 Install P S pump to its bracket referring to P S Pump Removal and Installation for J20 Engine Model in Section 6C 12 Return disconnected h...

Page 370: ...ns in order to fix crankshaft pulley by special tool Bolt size M8 P1 25 L 25 mm 0 98 in Strength 7T 2 9 d 6 b 3 5 1207B 1207F 4 1 a 7 8 10 c I5JB0A142021 01 1 Crankshaft pulley bolt 6 Timing chain cov...

Page 371: ...hain cover 1 bolts 3 and nut 2 Installation 1 Clean sealing surfaces on timing chain cover cylinder block and cylinder head Remove oil oil sealant and dust from sealing surface 2 Install new oil seal...

Page 372: ...lt idler pulley 1 Tighten nut to specified torque Tightening torque Idler pulley nut a 42 N m 4 2 kgf m 30 5 lb ft 6 Install belt tensioner 2 Tighten bolts to specified torque Tightening torque Genera...

Page 373: ...sealing surface Inspection Check oil seal lip for fault or other damage Replace as necessary 2nd Timing Chain and Chain Tensioner Components S5JB0A1426023 2 Bolt 3 Wrench I2RH01140060 01 10 4 9 5 1 9...

Page 374: ...he following conditions Key on crankshaft match with mark on cylinder block I Arrow mark on idler sprocket points upward II Marks on cam sprockets match with marks on cylinder head III Mark on crank s...

Page 375: ...by aligning yellow plate 1 of 2nd timing chain and match marks on idler sprocket 5 Install sprockets to intake and exhaust camshafts by aligning dark blue plate of 2nd timing chain match marks on inta...

Page 376: ...k arrow mark 9 on idler sprocket faces upward as shown in figure 11 Apply oil to timing chains tensioner tensioner adjusters sprockets and guides 12 Install timing chain cover Refer to Timing Chain Co...

Page 377: ...I2RH01140077 01 I2RH01140078 01 OIL c 10 b 9 a 8 4 7 OIL 3 OIL 1 OIL 2 OIL 5 6 I5JB0A142027 01 1 1st timing chain 6 Timing chain tensioner adjuster No 1 25 N m 2 5 kgf m 18 0 lb ft 2 Idler sprocket 7...

Page 378: ...ocket 4 and 1st timing chain 5 6 Remove crankshaft timing sprocket 6 Installation 1 Install crankshaft timing sprocket 2 as shown in figure 2 Check that match mark 1 on crankshaft timing sprocket is i...

Page 379: ...ith match marks on sprockets respectively 13 Install 2nd timing chain Refer to 2nd Timing Chain and Chain Tensioner Removal and Installation For J20 Engine for installation 14 Install timing chain cov...

Page 380: ...ket for wear or damage Idler Sprocket Check teeth and bush 1 of sprocket for wear or damage 1st Timing Chain Check timing chain for wear or damage Timing Chain Tensioner Adjuster No 1 Check that latch...

Page 381: ...figure and remove them 3 Remove camshaft housings 4 Remove camshafts 5 Remove tappets with shims Installation 1 Apply engine oil around tappet 1 and then install tappets with shims to cylinder head NO...

Page 382: ...enly among bolts and repeat tightening sequence two or three times before they are tightened to specified torque Tightening torque Camshaft housing bolt a 11 N m 1 1 kgf m 8 0 lb ft 7 Turn crankshaft...

Page 383: ...amshaft journals and camshaft housings for pitting scratches wear or damage If any malcondition is found replace camshaft or cylinder head with housing Never replace cylinder head without replacing ho...

Page 384: ...ylinder head to tappet clearance If clearance exceeds limit replace tappet or cylinder head Cylinder head bore and tappet outside diameter Oil Relief Valve Check oil relief valve for clogging and ball...

Page 385: ...ain Tensioner Removal and Installation For J20 Engine for removal 6 Remove camshafts tappets and shims Refer to Camshafts Tappet and Shim Removal and Installation For J20 Engine for removal I5JB0A1420...

Page 386: ...head gasket 1 to cylinder block Identification number 6 provided on gasket comes to crankshaft pulley side 4 facing up toward cylinder head side 5 Install cylinder head to cylinder block Apply engine...

Page 387: ...For J20 Engine for installation 9 Install timing chain cover Refer to Timing Chain Cover Removal and Installation For J20 Engine for installation 10 Check intake and exhaust valve lashes referring to...

Page 388: ...e into cylinder head ream guide hole with special tool 11 mm reamer so as to remove burrs and make it truly round Special tool A 09916 34542 B 09916 38210 2 Install valve guide to cylinder head Heat c...

Page 389: ...a hammer or else Install seal to guide only by pushing special tool by hand Tapping or hitting special tool may cause damage to seal 6 Install valve to valve guide Before installing valve to valve gui...

Page 390: ...and guide If clearance exceeds limit replace valve and valve guide Valve stem and valve guide specification Valve stem end deflection If bore gauge is not available check end deflection of valve stem...

Page 391: ...mit 1 1 mm 0 04 in Valve head radial runout Check each valve for radial runout with a dial gauge and V block To check runout rotate valve slowly If runout exceeds its limit replace valve Valve head ra...

Page 392: ...with fine size compound each time using valve lapper according to usual lapping method Cylinder Head Inspection S5JB0A1426047 Remove all carbon deposits from combustion chambers NOTE Do not use any s...

Page 393: ...kened valve springs can cause chatter not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure Valve spring free length Standard 51 13 mm 2 013 in Li...

Page 394: ...and bearing or between bearing cap and bearing 2 When installing piston and connecting rod assembly into cylinder bore point front mark 3 on piston head to crankshaft pulley side 1 1 Top ring TOP mar...

Page 395: ...s 3 c Tighten all connecting rod bolts to 15 N m 1 5 kgf m 11 0 lb ft d Retighten them by turning through 45 e Repeat step d once again Tightening torque Connecting rod bolt a Tighten 15 N m 1 5 kgf m...

Page 396: ...2 stamped piston to cylinder which is identified with blue painted or 2 stamped and a number 1 piston to cylinder with red painted or 1 stamped Also a letter A or B is stamped on piston head but ordin...

Page 397: ...lling these piston rings to piston direct marked side of each ring toward top of piston 1st ring 1 differs from 2nd ring 2 in thickness shape and color of surface contacting cylinder wall Distinguish...

Page 398: ...replaced Piston diameter As indicated in figure piston diameter should be measured at a position 26 5 mm 1 04 in a from piston skirt end in the direction perpendicular to piston pin Piston diameter P...

Page 399: ...7 mm 0 00024 0 00067 in Small end bore 21 003 21 011 mm 0 8269 0 8272 in Piston pin diameter B 20 997 21 000 mm 0 8267 0 8268 in Piston bore A 21 006 21 014 mm 0 8270 0 8273 in Piston rings To measure...

Page 400: ...nd crank pin referring to the following step 6 Connecting rod bearing and crank pin Out of round A B Taper a b Out of round and taper limits 0 01 mm 0 0004 in Connecting rod bearing general informatio...

Page 401: ...g plastic 1 width at the widest point clearance If clearance exceeds its limit select connecting rod bearing referring to Pistons Piston Rings Connecting Rods and Cylinders Inspection and Cleaning For...

Page 402: ...9940 50 0000 mm 1 9683 1 9685 in Crank pin diameter c There are 5 kinds of standard bearings differing in thickness To distinguish them they are painted in the following colors at the position as ind...

Page 403: ...hicker bearing and recheck clearance Connecting rod bolt Measure each thread diameter of connecting rod bolts 1 at A on 28 5 mm 1 12 in from bolt mounting surface and B on 42 0 mm 1 65 in from bolt mo...

Page 404: ...1D 118 Engine Mechanical For J20 Engine Main Bearings Crankshaft and Cylinder Block Components S5JB0A1426040 I5JB0A142056 02 www CarGarage ir www CarGarage ir w w w C a r G a r a g e i r...

Page 405: ...mating surface 10 Flywheel Tighten 40 N m 4 0 kgf m 29 0 lb ft 0 N m 0 kgf m 0 lb ft 40 N m 4 0 kgf m 29 0 lb ft and 58 N m 5 8 kgf m 42 0 lb ft by the specified procedure 3 Crankshaft 11 Water pump T...

Page 406: ...has oil groove 3 Install this half with oil groove to cylinder block and another half without oil groove to lower crankcase Make sure that two halves are painted in the same color 2 Install new O ring...

Page 407: ...ft 40 N m 4 0 kgf m 29 0 lb ft and 58 N m 5 8 kgf m 42 0 lb ft by the specified procedure Crankcase bolt with 8 mm thread diameter 11 22 Tighten 26 N m 2 6 kgf m 19 0 lb ft by the specified procedure...

Page 408: ...ion For J20 Engine 18 Install timing chain sprockets timing chains timing chain tensioner tensioner adjusters timing chain guides timing chain cover crankshaft pulley water pump pulley Refer to Timing...

Page 409: ...termined by taking micrometer readings If any one of journals is badly damaged or if amount of uneven wear in the sense exceeds its limit regrind or replace crankshaft Limit on out of round and taper...

Page 410: ...ce Standard 0 032 0 050 mm 0 0013 0 0019 in Limit 0 063 mm 0 0024 in Selection of main bearings STANDARD BEARING If engine is under the following conditions select a new standard bearing as followings...

Page 411: ...following colors at the position as indicated in figure Each color indicates the following thickness at the center of bearing Standard size main bearing thickness Stamped alphabet Journal bore diamete...

Page 412: ...xt thicker bearing and recheck clearance UNDERSIZE BEARING 0 25 mm 0 25 mm undersize bearing is available in five kinds varying in thickness To distinguish them each bearing is painted 1 in the follow...

Page 413: ...Check bearing clearance with newly selected undersize bearing Undersize bearing specification Crankshaft Position Sensor Plate Check teeth of plate for damage If any damage is found replace crankshaf...

Page 414: ...at the same time Oversize piston specification 2 Using micrometer measure piston diameter 3 Calculate cylinder bore diameter to be rebored as follows D A B C D Cylinder bore diameter to be rebored A P...

Page 415: ...chain cover bolt and nut 11 1 1 8 0 Idler pulley nut 42 4 2 30 5 Generator belt tensioner bolt 25 2 5 18 5 Crankshaft pulley bolt 150 15 0 108 5 Camshaft timing sprocket bolt 80 8 0 57 5 Timing chain...

Page 416: ...Rings Connecting Rods and Cylinders Components For J20 Engine Main Bearings Crankshaft and Cylinder Block Components For J20 Engine Special Tool S5JB0A1428002 Material SUZUKI recommended product or Sp...

Page 417: ...r attachment 09916 57350 09916 66510 Valve guide installer handle 6 mm Tappet holder 09916 77310 09916 84511 Piston ring compressor 50 125 mm Forceps 09917 68221 09917 98221 Camshaft pulley holder Val...

Page 418: ...1D 132 Engine Mechanical For J20 Engine 09944 36011 Steering wheel remover www CarGarage ir www CarGarage ir w w w C a r G a r a g e i r...

Page 419: ...crankshaft journal bearings Oil 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...

Page 420: ...1E 2 Engine Lubrication System For M16A Engine with VVT I3RH0B150001 01 www CarGarage ir www CarGarage ir w w w C a r G a r a g e i r...

Page 421: ...cial tool A 09915 77310 B 09915 78211 4 Start engine and warm engine up to normal operating temperature NOTE Be sure to shift transaxle gear shift lever in Neutral set parking brake and block drive wh...

Page 422: ...Pan and Oil Pump Strainer Components S5JB0A1516001 1 I5JB0A151003 01 I5JB0A151005 01 1 Oil pan Apply sealant 99000 31260 to mating surface 6 Strainer bolt 11 N m 1 1 kgf m 8 0 lb ft 2 Strainer 7 Oil...

Page 423: ...ner 1 from cylinder block Installation 1 Install new O rings 2 in the position as shown in the figure and install oil pump strainer 1 Tighten strainer bolt 3 to specified torque Tightening torque Oil...

Page 424: ...engine bolt c 85 N m 8 5 kgf m 61 5 lb ft 9 Install clutch housing lower plate No 1 1 and clutch housing lower plate No 2 2 Tightening torque Clutch housing lower plate No 1 bolt a 11 N m 1 1 kgf m 8...

Page 425: ...A1516006 Disassembly 1 Remove rotor plate 1 by removing its mounting bolts 2 Remove outer rotor 1 and inner rotor 2 3 Remove relief valve 1 spring 2 and retainer 3 by removing circlip 4 I4RS0A150010 0...

Page 426: ...to specified torque After installing plate check to be sure that rotors turn smoothly by hand 0 3 N m 0 03 kgf m 0 25 lb ft torque or below Tightening torque Oil pump rotor plate bolt a 11 N m 1 1 kg...

Page 427: ...ce exceeds its limit replace oil pump assembly Side clearance for oil pump inner rotor Limit 0 15 mm 0 0059 in Relief valve spring free length and load Check relief valve spring free length and load a...

Page 428: ...ollowing Oil Pan and Oil Pump Strainer Components For M16A Engine with VVT Oil Pump Components For M16A Engine with VVT Special Tool S5JB0A1518002 Fastening part Tightening torque Note N m kgf m lb ft...

Page 429: ...one path oil reaches the crankshaft journal bearings Oil from the crankshaft journal bearings is supplied to the connecting rod bearings by means of intersecting passages drilled in the crankshaft In...

Page 430: ...1E 12 Engine Lubrication System For J20 Engine I5JB0A151013 01 www CarGarage ir www CarGarage ir w w w C a r G a r a g e i r...

Page 431: ...areful not to make special tool touch Exhaust manifold when installing because Exhaust manifold becomes very hot 4 Start engine and warm it up to normal operating temperature NOTE Be sure to place tra...

Page 432: ...Oil pan Apply sealant 99000 31260 to mating surface 8 Gasket 2 Oil pump strainer 9 Baffle plate 3 O ring 11 N m 1 1 kgf m 8 0 lb ft 4 Oil pump strainer bolt 85 N m 8 5 kgf m 61 5 lb ft 5 Oil pan bolt...

Page 433: ...000 31250 SUZUKI Bond No 1207F Sealant amount for oil pan Width a 3 mm 0 12 in Height b 2 mm 0 08 in 2 Install new O rings 2 to oil pump strainer 1 securely as shown in figure Tighten strainer bolts t...

Page 434: ...g surface of oil pan and cylinder block Remove oil old sealant and dust from mating surfaces and oil pan inside Clean oil pump strainer screen Oil Pump Components S5JB0A1526004 a 1 2 c b I5JB0A152009...

Page 435: ...t 3 Install oil pan and oil pump strainer Refer to Oil Pan and Oil Pump Strainer Removal and Installation For J20 Engine 4 Install front suspension frame referring to Front Suspension Frame Stabilizer...

Page 436: ...valve set Measure free length and tension of oil relief spring If the measured values of length or tension is less than the specification replace oil pump relief valve set Oil relief spring Measure cl...

Page 437: ...Reference For the tightening torque of fastener not specified in this section refer to Fastener Information in Section 0A 1 Oil pump case No 1 3 Inner rotor 2 Outer rotor I2RH01150025 01 Fastening pa...

Page 438: ...scribed in the following Oil Pan and Oil Pump Strainer Components For J20 Engine Special Tool S5JB0A1528002 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No...

Page 439: ...wed to the reservoir When the system cools down the coolant is drawn back into the radiator The cooling system has been filled with a quality coolant that is a 50 50 mixture of water and ethylene glyc...

Page 440: ...tor inlet hose 5 Thermostat 9 Heater core inlet hose 2 Radiator outlet hose 6 Water pump 10 Heater core outlet hose 3 Throttle body inlet hose 7 Throttle body 11 Heater core 4 Throttle body outlet hos...

Page 441: ...replace as necessary Poor generation generator Check and repair ECT sensor faulty Check and replace as necessary Radiator cooling fan relay No 2 and or No 3 faulty Check and replace as necessary Radia...

Page 442: ...1F 4 Engine Cooling System Repair Instructions Cooling System Components S5JB0A1606001 I5JB0A161003 03 www CarGarage ir www CarGarage ir w w w C a r G a r a g e i r...

Page 443: ...se 4 Drain plug 19 Radiator outlet pipe 34 Water bypass No 1 hose 5 Radiator outlet hose 20 Heater outlet No 2 hose 35 Main fan motor 6 Radiator inlet No 1 hose 21 Heater pipe 36 Sub fan motor 7 Water...

Page 444: ...se Engine Cooling System Inspection and Cleaning S5JB0A1606003 WARNING To help avoid danger of being burned do not remove radiator cap while engine and radiator are still hot Scalding fluid and steam...

Page 445: ...ter until system is filled and run engine until upper radiator hose is hot again 5 Repeat Steps 3 and 4 several times until drained liquid is nearly colorless 6 Close radiator drain plug 1 tightly 7 R...

Page 446: ...ing to Intake Manifold Removal and Installation For M16A Engine with VVT in Section 1D 3 Disconnect water inlet hose 1 and heater outlet No 2 hose 2 from each pipe 4 Remove thermostat case 3 with ther...

Page 447: ...bleed valve 1 of thermostat is clean Should this valve be clogged engine would tend to overheat Check to make sure that valve seat 2 is free from foreign matters which would prevent valve from seatin...

Page 448: ...1 1 and No 3 2 as follows a Check that there is no continuity between terminals C and D If there is continuity replace relay b Connect battery positive terminal to terminal B of relay c Connect batter...

Page 449: ...Installation Reverse removal procedure for installation noting the following Refill cooling system referring to Step 7 to 17 of Cooling System Flush and Refill After installation verify there is no co...

Page 450: ...ooling System Flush and Refill After installation verify there is no coolant leakage each connection Refill A T fluid referring to A T Fluid Change in Section 5A Water Pump Removal and Installation Fo...

Page 451: ...Engine Model S5JB0A1606023 Removal 1 Disconnect negative cable at battery 2 Drain coolant referring to Cooling System Draining 3 Remove water pump and generator drive belt referring to Water Pump and...

Page 452: ...torque is also described in the following Cooling System Components Reference For the tightening torque of fastener not specified in this section refer to Fastener Information in Section 0A Special T...

Page 453: ...sure to connect and clamp each hose correctly referring to Fuel Hose Disconnecting and Reconnecting After connecting make sure that it has no twist or kink When installing injector or fuel feed pipe...

Page 454: ...pump passes the venturi 5 Schematic and Routing Diagram Fuel Delivery System Diagram S5JB0A1702001 I5JB0A171001 03 20 7 10 6 9 13 15 14 2 12 11 19 17 18 16 1 4 5 3 8 I5JB0A171002 03 1 Fuel tank 6 Fuel...

Page 455: ...to Fuel Pressure Check in Section 1A and check each possibly defective part Replace if found defective a Turn ignition switch ON to operate fuel pump and after 2 seconds turn it OFF Repeat this 3 or...

Page 456: ...witch ON check for fuel leaks Fuel Cut Operation Inspection S5JB0A1704002 NOTE Before inspection make sure that gear shift lever is in neutral position shift select lever is P range for A T vehicle A...

Page 457: ...Fuel System 1G 5 Repair Instructions Fuel System Components S5JB0A1706001 I5JB0A170001 03 www CarGarage ir www CarGarage ir w w w C a r G a r a g e i r...

Page 458: ...1G 6 Fuel System 5 2 26 1 11 3 4 8 14 b 13 a 12 b 23 c 16 25 27 21 10 9 10 20 15 18 17 19 29 28 21 6 7 B 22 30 I5JB0A170002 03 www CarGarage ir www CarGarage ir w w w C a r G a r a g e i r...

Page 459: ...ing oil 99000 25320 to O ring 4 Fuel tank filler hose 17 Fuel injector 30 Fuel suction hose 5 Fuel filler cap 18 Injector cushion 31 Fuel pipe bolt Tighten bolts as alphabetical order a through d 6 Fu...

Page 460: ...ly as shown in figure For Normal Clamp Fuel tank system NOTE Be sure to install hose to spool of pipe surely I5JB0A170003 01 1 Pipe 6 Vehicle backward for M16 engine model Vehicle forward for J20 engi...

Page 461: ...isconnected by hand I3RM0A170001 01 A With short pipe fit hose as far as it reaches pipe joint as shown B With the following type pipe fit hose as far as its peripheral projection as shown C With bent...

Page 462: ...wheels 3 Remove fuse box No 2 cover 4 Disconnect fuel pump relay 1 from fuse box No 2 2 5 Remove fuel filter cap in order to release fuel vapor pressure in fuel tank and then reinstall it 6 Start engi...

Page 463: ...6 Remove clamp 1 from pipes 2 Installation 1 Install clamps to marked location on pipes If clamp is deformed its claw is bent or broken replace it with new one 2 Install pipes with pipe clamps to vehi...

Page 464: ...s 3 Installation Reverse removal procedure for installation noting the following Replace injector O ring 1 with new one using care not to damage it Check if cushion 2 is scored or damaged If it is rep...

Page 465: ...or fire and personal injury 1 Install injector to special tool injector checking tool 2 Install pressure regulator to special tool injector checking tool Special tool A 09912 58421 B 09912 58442 3 Co...

Page 466: ...e CAUTION Check to make sure that connection is made between correct terminals Wrong connection can cause damage to ECM wire harness etc iii Turn ignition switch ON 8 Apply battery voltage to injector...

Page 467: ...allation noting the following Replace O ring with new one using care not to damage it Apply thin coat of fuel to O ring and then install fuel pressure regulator 1 to delivery pipe Tighten fuel pressur...

Page 468: ...personal injury Removal 1 Remove fuel filler cap 2 Insert hose of a hand operated pump into fuel filler hose 1 and drain fuel in space A as shown in figure CAUTION Do not force pump hose into fuel tan...

Page 469: ...ng to Propeller Shaft Removal and Installation in Section 3D 6 With cable connected detach parking brake cable clamp from fuel tank cover referring to Parking Brake Cable Location in Section 4D 7 Disc...

Page 470: ...before installing fuel tank to vehicle 2 Raise fuel tank 1 with jack and connect connectors of fuel pump and sub fuel level gauge and clamp wire harness 3 Install fuel tank to vehicle Tightening torqu...

Page 471: ...l tank inside will get corrosion The following procedure are used for purging fuel tank 1 After removing fuel tank remove all hoses pipes sub fuel level gauge and fuel pump assembly from fuel tank 2 D...

Page 472: ...e surface of pipe where joint is to be inserted push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely or fuel leak may occur 1 Clean mating surfaces of fuel...

Page 473: ...it in the arrow direction as shown in figure Installation Reverse removal procedure for installation Fuel Pump Inspection S5JB0A1706021 Check fuel pump assembly for damage Check fuel suction filter fo...

Page 474: ...ensor 1 refer to Fuel Level Sensor Inspection in Section 9C Specifications Tightening Torque Specifications S5JB0A1707001 NOTE The specified tightening torque is also described in the following Fuel S...

Page 475: ...y attachment 1 4 Holder 5 Return hose and clamp 6 Body attachment 2 and washer 7 Hose attachment 1 8 Hose attachment 2 09912 58442 09912 58490 Fuel pressure gauge 3 way joint hose This tool is include...

Page 476: ...ression stroke detects the crank angle and adjusts initial ignition timing automatically TP sensor ECT sensor MAP sensor MAF sensor IAT sensor knock sensor wheel speed sensor VSS and other sensors swi...

Page 477: ...17 5 6 BLK YEL C37 51 5V 5V C37 52 WHT RED WHT BLU 5V 5V BLK WHT BLK WHT BRN BLK BRN C37 20 C37 21 BLK ORN BLK ORN C37 30 BLK ORN BLK YEL BLK YEL BLK YEL C37 58 A B 3 4 7 8 9 10 12 E23 60 E23 29 12V 5...

Page 478: ...information MAP sensor ECT sensor MAF and IAT sensor TP sensor Knock sensor wheel speed signal ABS Electric load signal Engine start signal Torque reduction signal TCM 19 Ignition coil assembly for No...

Page 479: ...t No spark Blown fuse for ignition coil Replace Loose connection or disconnection of high tension cord s for M16 engine or lead wire Connect securely Faulty high tension cord s for M16 engine Replace...

Page 480: ...tisfactory Go to Step 8 Replace ignition coil assembly 8 CKP sensor check 1 Check CKP sensor referring to Crankshaft Position CKP Sensor Inspection in Section 1C Is check result satisfactory Go to Ste...

Page 481: ...ks 6 If no spark is emitted inspect the related parts as described in Ignition System Symptom Diagnosis 13 Knock sensor check 1 Confirm that knock sensor circuit is in good condition referring to DTC...

Page 482: ...Inspection For M16 Engine S5JB0A1806002 Measure resistance of high tension cord 1 by using ohmmeter If resistance exceeds specification replace high tension cord s High tension cord resistance No 1 c...

Page 483: ...gs replace them with new plugs Spark plug air gap a 1 0 1 1 mm 0 040 0 043 in Spark plug type NGK BKR6E 11 Nickel for M16 and J20 engine models IFR6J11 Iridium for M16 engine IFR5J11 Iridium for J20 e...

Page 484: ...Measure secondary coil for resistance If resistance is out of specification replace ignition coil assembly Secondary coil resistance 7 6 10 2 k at 20 C 68 F For J20 Engine Check ignition coil assembl...

Page 485: ...ion order 1 3 4 2 Special tool A 09930 76420 7 If ignition timing is out of specification check the followings CKP sensor CKP sensor plate TP sensor CMP sensor CMP sensor rotor tooth of camshaft Wheel...

Page 486: ...ote N m kgf m lb ft Spark plug 25 2 5 18 0 Ignition coil bolt for M16 engine 10 1 0 7 5 Ignition coil bolt for J20 engine 6 5 0 65 5 0 09930 76420 SUZUKI scan tool Timing light dry cell type This kit...

Page 487: ...the ignition switch is closed The resulting plunger and pinion drive lever movement causes the pinion to engage the engine flywheel gear and the magnetic switch main contacts to close and cranking tak...

Page 488: ...tery deterioration Replace battery Poor contact in battery terminal connection Retighten or replace Loose grounding cable connection Retighten Fuse set loose or blown off Tighten or replace Poor conta...

Page 489: ...motor running but not cranking engine Worn pinion tip Replace over running clutch Poor sliding of over running clutch Repair Over running clutch slipping Replace over running clutch Worn teeth of ring...

Page 490: ...r and pinion return inward If plunger and pinion don t return replace the magnetic switch No Load Performance Test 1 Connect battery and ammeter to starter as shown 2 Check that starter rotates smooth...

Page 491: ...ting motor mount bolts 3 5 Remove starting motor 4 Remounting Reverse the dismounting procedure noting the following Tighten battery cable nut 5 to specified torque Tightening torque Starting motor ba...

Page 492: ...water splash NOTE Spare parts have been lubricated I5JB0A190002 01 1 Front housing 7 Plate 13 Planetary gear 19 Rear bush 2 Bush 8 Seal rubber 14 Packing 11 N m 1 1 kgf m 8 0 lb ft 3 Pinion stop ring...

Page 493: ...nd coil case If no continuity exists coil is open and should be replaced Rear Bracket Bush Inspect bush for wear or damage Replace if necessary Brush Check brushes for wear Measure length of brushes a...

Page 494: ...f deflection of dial gauge 4 pointer exceeds limit repair or replace NOTE The following specification presupposes that armature is free from bend Bent armature must be replaced Commutator out of round...

Page 495: ...rmal conditions Replace if necessary Pinion and Over Running Clutch Inspect pinion for wear damage or other abnormal conditions Check that clutch locks up when turned in direction of drive and rotates...

Page 496: ...nts Voltage 12 volts Output 1 2 kW 1 4 kW Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length Standard 12 3 mm 0 48 in Limit 5 5 mm 0 22 in Number of pinion teeth...

Page 497: ...y ruin a battery it should be protected against freezing by keeping it in a fully charged condition If a battery is frozen accidentally it should not be charged until it is warmed Sulfation If the bat...

Page 498: ...cal systems need to be checked If there is a trouble in cranking and its cause lies in the battery it should be replaced Generator Description S5JB0A1A01002 The basic charging system is the IC integra...

Page 499: ...ast indefinitely however with proper care it will provide many years of service If the battery performs satisfactorily during test but fails to operate properly for no apparent reason the following ar...

Page 500: ...ime 2 Check drive belt for proper tension 3 If battery defect is suspected refer to Battery Description 4 Inspect wiring for defects Check all connections for tightness and cleanliness battery cable c...

Page 501: ...light and heater motor 2 Measure current and if it is less than 30 A repair or replace generator Generator Test Overcharged Battery Check S5JB0A1A04003 1 To determine battery condition refer to Batter...

Page 502: ...nd any other metal on vehicle because a short circuit could occur Batteries should always be kept out of reach of children 1 Set parking brake and place automatic transmission in PARK NEUTRAL on manua...

Page 503: ...nel by terminal Water Pump and Generator Drive Belt Removal and Installation For M16 Engine S5JB0A1A06011 Removal 1 Disconnect negative cable at battery 2 If vehicle equipped with A C remove compresso...

Page 504: ...or drive belt tension a 7 0 8 5 mm 0 28 0 33 in as deflection 10 kg 22 lbs NOTE When replacing belt with a new one adjust belt tension to 5 5 6 5 mm 0 22 0 26 in 3 If belt is too tight or too loose ad...

Page 505: ...for cracks cuts deformation wear and cleanliness If any of these conditions are found replace belt referring to Water Pump and Generator Drive Belt Removal and Installation For J20 Engine Check to mak...

Page 506: ...nerator belt 1 Installation 1 Loosen tensioner by turning the tensioner pulley 2 clockwise 2 While holding the tensioner install generator belt 1 NOTE Make sure that the belt fits each pulley s groove...

Page 507: ...ting bolt For M16 Engine 9 Generator B For J20 Engine 5 Generator mounting bolt For J20 Engine 7 0 N m 0 7 kgf m 5 0 lb ft 1 B terminal wire 6 Generator pivot bolt 52 5 N m 5 25 kgf m 38 0 lb ft 2 cou...

Page 508: ...ified torque For J20 Engine 3 Install generator belt Refer to Water Pump and Generator Drive Belt Removal and Installation For M16 Engine or Water Pump and Generator Drive Belt Removal and Installatio...

Page 509: ...or regulator Using ohmmeter check for continuity between slip rings of rotor If there is no continuity replace rotor 1 Resistance between slip rings of rotor 1 7 2 0 Using ohmmeter check that there i...

Page 510: ...een coil leads 2 and stator core 1 If there is continuity replace stator Brush and brush holder Check each brush for wear by measuring its length If brush is found worn down to service limit replace b...

Page 511: ...uld be only one way continuity in each case If check result is not satisfactory replace rectifier 1 2 In the same manner as described in above Step 1 check that there is only one way continuity betwee...

Page 512: ...fied in this section refer to Fastener Information in Section 0A Battery type 55B24R S 55D23L Rated Capacity AH 5HR 12 Volts 36 48 Electrolyte L US Imp pt 3 1 6 55 5 46 3 9 8 24 6 86 Electrolyte S G 1...

Page 513: ...hicle is raised for other service check exhaust system as follows Check rubber mountings for damage deterioration and out of position Check exhaust system for leakage loose connection dent and damage...

Page 514: ...anifold 11 Muffler 20 Exhaust center pipe gasket 3 Exhaust pipe No 1 bracket 12 Mounting 45 N m 4 5 kgf m 32 5 lb ft 4 HO2S 13 A F sensor 50 N m 5 0 kgf m 36 5 lb ft 5 Exhaust pipe No 1 gasket 14 Exha...

Page 515: ...racket 13 A F sensor 23 Exhaust manifold cover 4 HO2S 14 Exhaust manifold bolt 24 Heat protector panel 5 Exhaust pipe No 1 gasket 15 Exhaust manifold nut 25 Heat protector rear panel 6 No 1 seal ring...

Page 516: ...nents 2 Install exhaust pipe No 1 bracket 1 Tightening torque Exhaust pipe No 1 bracket bolt and nut a 50 N m 5 0 kgf m 36 5 lb ft 3 Connect negative cable at battery 4 Check exhaust system for exhaus...

Page 517: ...em referring to Cooling System Flush and Refill in Section 1F 7 Connect negative cable at battery 8 Verify that there is no fuel leakage coolant leakage and exhaust gas leakage at each connection Exha...

Page 518: ...ponents Reference For the tightening torque of fastener not specified in this section refer to Fastener Information in Section 0A Fastening part Tightening torque Note N m kgf m lb ft Exhaust manifold...

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