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8 - Tradebit

1. Vehicle Condition Cold Immedi Engine condition Vehicle condition During dr Vehicle Right hand corner Warming up phase ately after start Warmed up iving Constant speed Left hand corner speed when problem occurs Sometimes ON Always ON Malfunction indicator lamp condition S econd check No code Always UOther at starting Racing without load Accelerating When shifting Lever position Always OFF Engine speed r min Decelerating km h Other Mile h Good condition Diagnostic trouble First check No code Malfunction code code NOTE Malfunction code The above form is a standard sample It should be modified according to conditions characteristic of each market 6 12 ENGINE GENERAL INFORMATION AND DIAGNOSIS MALFUNCTION INDICATOR LAMP MIL CHECK 1 Turn ON ignition switch but the engine at stop and check that MIL lights for 2 3 sec and then goes out If MIL does not light up or MIL dims go to Diagnostic Flow Table A 1 for troubleshooting 2 If MIL remains ON and no DTC is stored in ECM go to Diagnos tic Flow Table A 2 for troubleshooting DIAGNOSTIC TR
2. 1 Crankshaft pulley 2 P S pump pulley 3 Generator 4 A C compressor if equipped 1 P S pump POWER STEERING P S SYSTEM 3B1 3 POWER STEERING P S PUMP The power steering pump is a vane type and is driven by the V ribbed belt from the crankshaft Relieved Hydraulic 8 400 kPa 84 0 kg cm or 1 194 psi pressure trol Control Flow control valve con device Relief valve 760 850 cm 1 61 1 34 1 80 1 50 US Imp pt Fluid capacity of system 3B1 4 POWER STEERING P S SYSTEM ON VEHICLE SERVICE INSPECTION DRIVE BELT INSPECTION Refer to SECTION 6H DRIVE BELT ADJUSTMENT Refer to SECTION 6H FLUID LEAKAGE Start engine and turn steering wheel fully to the right and left so that maximum hydraulic pressure is provided Then visually check gear box P S pump and fluid reservoir themselves and each joint of their connecting pipes for leak age CAUTION Never keep steering wheel turned fully for longer than 10 seconds POWER STEERING P S SYSTEM 3B1 5 HYDRAULIC PRESSURE IN P S CIRCUIT 1 After cleaning joint of high pressure hose and P S pump thor oughly disconnect hose from pump and install special tool oil pressure gauge attachment and hose Tighten bolt and attachment to specified torque Tightening torque a 55 N m 5 5 kg m 40 0 Ib ft Special Tool A 09915 77410 Oil pressure gauge B 09915 77420 Attachment amp
3. Before draining engine oil check engine for oil leakage If any evi dence of leakage is found make sure to correct defective part be fore performing the following work 1 Drain engine oil by removing drain plug 2 After draining oil wipe drain plug clean Reinstall drain plug and tighten it securely as specified below Tightening Torque Gite ee a 30 N m 3 0 kg m 21 5 Ib ft 2 Oil drain plug MAINTENANCE AND LUBRICATION 0B 7 1 Oil filter 1 Oil filter 1 LOW level mark 2 FULL level mark 3 Oil filler inlet 3 4 5 2 g 9 Loosen oil filter by using oil filter wrench Special tool Special Tool A 09915 46510 Apply engine oil to new oil filter O ring Screw new filter on oil filter stand by hand until filter O ring con tacts with mounting surface Tighten filter to specified torque Special Tool A 09915 46510 Tightening Torque a 14 N m 1 4 kg m 10 5 Ib ft Remove dipstick and oil filler cap Replenish oil through oil filler inlet until oil level is brought to FULL level mark on dipstick Amount of oil about 3 5 liters or 7 4 6 2 US Imp pt NOTE Note that amount of oil required when actually changing oil may somewhat differ from this data depending on various conditions temperature viscosity etc Install oil filler cap and dipstick Start engine and run it for three minutes Stop it and wa
4. 2 Coat special tool F surface with compressor oil and install it to the shaft Special Tool F 09991 06040 3 Install O ring to case 4 Apply compressor oil to lip type seal and O ring 5 Install front head assembly 6 Tighten front head bolt as specified torque Tightening Torque a 14 N m 1 4 kg m 10 5 Ib ft b 23 N m 2 3 kg m 17 0 lb ft NOTE e Be sure to use new front head bolt and washer e Tighten bolt a first and next b 1B 16 AIR CONDITIONING OPTIONAL REQUIRED SERVICE MATERIALS RECOMMENDED MATERIAS SUZUKI PRODUCT REFRIGERANT DRUM 200 g 95794 50G00 0000 Refrigerant e Refrigerant charge USE EERENS COMPRESSOR OIL RS 20 150 cc e O ring P 99000 99088 00D0 e Each component SPECIAL TOOLS 09900 06107 Snap ring pliers 09991 06030 09991 06040 09991 06050 Opening type Armature plate remover Lip type seal protector Lip type seal installer SD 09991 06020 09991 06010 Armature plate spanner Magnet clutch pulley installer POWER STEERING P S SYSTEM 3B1 1 SECTION 3B1 POWER STEERING P S SYSTEM WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to System Components and Wiring Location View under General Description in air bag system section in order to co
5. ENGINE BASIC INSPECTION DIAGNOSIS IN TERMS OF SYMPTOM AND ENGINE DIAGNOSIS TABLE Perform basic engine check according to the Engine Basic Inspection Flow Table first When the end of the flow table has been reached check the parts of the system suspected as a possible cause referring to ENGINE DIAGNOSIS TABLE DIAGNOSIS IN TERMS OF SYMPTOM and based on symptoms appearing on the ve hicle symptoms obtained through steps of customer complaint analysis trouble symptom confirmation and or basic engine check and repair or replace faulty parts if any TROUBLESHOOTING FOR DTC See each DTC Diag Flow Table Based on the DTC indicated in Step 5 and referring to the applicable DTC diag flow table in this section locate the cause of the trouble namely in a sensor switch wire harness connector actuator ECM or other part and repair or replace faulty parts CHECK FOR INTERMITTENT PROBLEM Check parts where an intermittent trouble is easy to occur e g wire harness connector etc referring to INTERMITTENT AND POOR CONNECTION in Section OA and related circuit of DTC recorded in Step 2 FINAL CONFIRMATION TEST Confirm that the problem symptom has gone and the engine is free from any abnormal conditions If what has been repaired is related to the DTC clear the DTC once perform DTC confirmation procedure and confirm that no DTC is indicated ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 11 CUSTOMER PROBLEM INSPECTION F
6. o 1 Diameter 2 Pitch GENERAL INFORMATION 0A 3 FASTENER INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are metric When replac ing any fasteners it is most important that replacement fasteners be the correct diameter thread pitch and strength CAUTION Note that both ISO and JIS type bolts and nuts are used for the engine assembly and related parts Even when the diameter of the thread is the same its pitch may vary be tween these two types Installing a mismatched bolt or nut will cause damage to the thread As the first step make sure to tighten it by hand temporarily and if it feels tight check the thread pitch for correct matching MAINTENANCE AND LUBRICATION OB 1 SECTION 0B MAINTENANCE AND LUBRICATION EE WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View un der General Description in air bag system section in order to confirm whether you are perform ing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precautions under On Vehicle Service in air bag system section before perform ing service on or around the air bag system components or wiring Failure to follow WARNINGS could
7. ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 21 Condition Possible Cause Reference Item Poor fuel mileage Injection system out of order e Faulty fuel injection pump static timing e Clogged fuel filter or lines e Faulty fuel injection pump e Faulty injector Static timing in ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FORE WORD of this manual Fuel filter in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Fuel injection pump in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANU AL listed in FOREWORD of this manual Fuel injector in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Engine and emission control system out of order e Air cleaner element clogged e Faulty ECT sensor and TP sensor e Faulty fuel injection timing control ac tuator e Faulty ECM e Malfunctioning EGR valve Low compression Others e Dragging brakes e Slipping clutch e Thermostat out of order e Improper tire pressure ITEM 3 1 Air cleaner element inspection in Section 0B ECT sensor and TP sensor in Section 6E3 Fuel injection timing control actuator in Section 6E3 Inspection of ECM and its circuit EGR system inspection in Section 6E3 Previously outlined Diagnosis in Section 5 Diagnosis in Section 7C Thermostat in Section 6B Refer to Section 3F 6 22 ENGINE GENERAL INFORMATION AND DIAGNOSIS Condition Excessiv
8. circuit in 1 Turn ignition switch OFF glow plug relay 2 Check continuity between B Or terminal in double relay coupler open coupler and body ground Is it continuity 1 Turn ignition switch ON Go to Step 7 Double relay mal 2 Measure voltage between G Y G W terminals in double function relay coupler with connect it coupler Is it 10 to 14 V ECM Power Circuit Check Substitute a G Y or G W cir 1 Turn OFF ignition switch disconnect connectors from known good ECM cuit open ECM and install double relay and recheck 2 Check for proper connection to ECM at terminals E92 16 and E92 33 3 If OK then measure voltage between terminal E92 16 and ground E92 33 and ground with ignition switch ON Is each voltage 10 14 V Fig 1 for Step 3 Main fuse Battery fuse HA Fusible link 6 36 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC No 1 CRANKSHAFT POSITION CKP SENSOR CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION 1 CKP sensor 2 ECM DTC DETECTING CONDITION POSSIBLE CAUSE e No CKP sensor signal for 2 seconds at engine e CKP sensor circuit open or short cranking e Signal teeth damaged e CKP sensor malfunction foreign material being attached or improper installation e ECM malfunction Reference Connect oscilloscope between terminals E92 8 and E92 25 of ECM connector connected to ECM and body ground then check CKP sensor signal Oscillo
9. Be careful not to damage fins of condenser and radiator 10 Remove receiver dryer from condenser INSTALLATION WARNING After installing hood latch be sure to perform its adjust mentaccording to procedure described in Service Manu al Failure to perform this adjustment may cause hood to be unlatched resulting in an accident 1 Receiver dryer 2 Receiver outlet pipe 3 Receiver dryer bracket bolt 4 Receiver outlet pipe bolt Reverse removal sequence to install condenser noting the follow ing point e When replacing condenser add 20 30 cm 20 30 cc of com pressor oil from compressor suction side e Evacuate and charge system according to previously described procedure e Regulate hood latch referring to HOOD in Section 9 of the Ser vice Manual mentioned in FOREWORD of this manual RECEIVER DRYER INSPECTION Use aleak tester to check for gas leakage at sight glass and fittings REMOVAL 1 Recover refrigerant by using recovery and recycling equip ment Be sure to follow the instruction manual for the equip ment The amount of compressor oil removed must be measured and the same amount added to the system 2 Remove front bumper referring to FRONT BUMPER in Sec tion 9 of the Service Manual mentioned in FOREWORD of this manual 3 Disconnect receiver outlet pipe 4 Remove receiver dryer from its holder 1B 8 AIR CONDITIONING OPTIONAL 1 Manif
10. CENTER SHAFT REMOVAL 1 Hoist vehicle 2 Drain engine coolant and transmission oil 1 3 Remove right side drive shaft 4 Remove engine rear mounting and its bracket 5 Remove water inlet pipe bolts 6 Remove center shaft 1 Engine rear mounting 2 Engine rear mounting bracket INSTALLATION 1 Install center shaft CAUTION e Protect differential side oil seal from any damage preventing them from unnecessary contact while installing e Make sure that differential side joint is inserted fully Ne 3 Water inlet pipe and its snap ring is seated as it was 4 Bolt 2 Install water inlet pipe with new O ring 3 Install engine rear mounting and its bracket 4 Install right side drive shaft 5 Fill transmission oil and engine coolant 6 Lower vehicle 5 Center shaft assembly BRAKES 5 1 SECTION 5 BRAKES WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to System Components and Wiring Location View under Gen eral Description in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precautions under ON VEHICLE SERVICE in air bag system section before performing service on or a
11. Fuel filter in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Fuel injection pump in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Fuel injector in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Engine overheating Refer to Overheating of this table Engine and emission control system out of order e Faulty ECM e Faulty fuel injection timing control ac tuator e Malfunctioning EGR valve Inspection of ECM and its circuit Fuel injection timing control actuator in Section 6E3 EGR system inspection in Section 6E3 Others e Excessive combustion chamber de posits Inoperative thermostat Faulty radiator fan motor or its circuit Poor water pump performance Clogged or leaky radiator Improper engine oil grade Clogged oil filter or oil strainer Poor oil pump performance Dragging brakes Slipping clutch Blown cylinder head gasket Piston and cylinder head in Section 6A4 Thermostat in Section 6B Radiator fan control system in Section 6B Water pump in Section 6B Radiator in Section 6B ITEM 1 3 Engine oil and oil filter change in Section 0B Oil pressure check in Section 6A4 Oil pressure check in Section 6A4 Diagnosis in Section 5 Diagnosis in Section 7C Valves and cylinder head in OVERHAUL CHECKING TUNING MANUAL listed be low in FOREWORD of this manual
12. ITEM 3 1 Air cleaner filter 1 ITEM 3 3 Fuel filter ITEM 6 2 Wheel bearings ITEM 6 3 Propeller shafts 4WD and drive shafts ITEM 6 6 and 6 7 a 5 een p BCD H B E H tial oil 4WD ITEM 6 8 Automatic transmission fluid NOTES R Replace or change I Inspect and correct or replace if necessary 1 Inspect or replace more frequently if necessary Manual transmission oil and differen Every 15 000km 9 000 miles or 12 months Every 45 000km 27 000 miles or 36 months a Every 75 000km 45 000 miles pon Every 5 000km 3 000 miles or 4 months Every 2 500km 1 500 miles Every 30 000km 18 000 miles or 24 months Every 10 000km 6 000 miles or 8 months Every 15 000km 9 000 miles or 12 months Every 15 000km 9 000 miles or 12 months Every 30 000km 18 000 miles or 24 months Every 30 000km 18 000 miles or 24 months MAINTENANCE AND LUBRICATION 0B 5 1 Air cleaner 2 Air cleaner suction pipe xe 1 Accessory drive belt 2 Dynamic roller tensioner 3 Roller tensioner 1 Radiator outlet pipe 2 Radiator outlet pipe bolt 1 Accessory drive belt 2 Dynamic roller tensioner 3 Roller tensioner MAINTENANCE SERVICE ENGINE ITEM 1 1 Accessory Drive Belt Inspection and Replacement Inspection 1 Remove air cleaner and air cleaner suction pipe 2 Inspect belt for
13. Suspension system tighteness damage rattle breakage 6 5 Steering system tighteness damage breakage rattle 6 6 Manual transmission oil l 1st 15 000 km only 6 7 Rear differential oil 4WD R 1st 15 000 km only 6 8 Automatic transmission Fluid level Fluid change Replace every 165 000 km 99 000 miles Fluid hose 6 9 All latches hinges and locks 6 10 Power steering if equipped NOTES e R Replace or change e I Inspect and correct or replace if necessary OB 4 MAINTENANCE AND LUBRICATION MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS If the vehicle is usually used under the conditions corresponding to any severe condition code given below it is recommended that applicable maintenance operation be performed at the particular interval as given in the chart below Severe condition code A Repeated short trips B Driving on rough and or muddy roads C Driving on dusty roads D Driving in extremely cold weather and or salted roads E Repeated short trips in extremely cold weather F Leaded fuel use G Town use Towing a trailer Sustained high speed driving Hot climates above 30 C 86 F Low quality lubricants or fuel H Trailer towing if admitted Severe Condition Code Maintenance Maintenance Maintenance Interval Operation ITEM 1 1 Accessory drive belt ITEM 1 2 Camshaft timing belt ITEM 1 3 Engine oil and filter A CDE G A CDEFGH
14. ee engine Fig B 1 volt Engine running Ground to E92 33 ECM power source engine Fig B 10 14 volts Ignition switch ON position Ground to 0 5 0 5 E92 34 B Or ECM ground engine Fig A volt Ignition switch ON position Ground to 0 5 0 5 E92 35 B Or ECM ground engine Fig A volt Ignition switch ON position 6 30 ENGINE GENERAL INFORMATION AND DIAGNOSIS RESISTANCE CHECK 1 Disconnect ECM couplers from ECM with ignition switch OFF CAUTION Never touch terminals of ECM itself or connect volt meter or ohmmeter 2 Check resistance between each terminal of couplers discon nected CAUTION e Be sure to connect ohmmeter probe from wire har ness side of coupler e Be sure to turn OFF ignition switch for this check e Resistance in table below represents that when parts temperature is 20 C 68 F 1 ECM coupler disconnected 2 Ohmmeter TERMINALS CIRCUIT STANDARD RESISTANCE E92 7 to E92 24 Injector needle sensor 85 Q 130 Q 530 Q 590 Q at 60 C 140 F E92 4 to E92 24 ECT sensor 220 Q 240 Q at 90 C 194 F E92 1 to E92 19 1 4KQ 2 1 KQ TP sensor 950 Q 1 5 KQ ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 31 COMPONENT LOCATION 1 Fuel injection pump 9 ECT sensor 2 Glow plug 10 Vacuum pump 3 Fuel injector 11 EGR No 2 valve 4 Injection needle sensor 12 Fuel filter 5 Regulator 13 EGR No 1 solenoid valve 6 EGR No
15. hose 2 Check each connection for fluid leakage and bleed air P S fluid reservoir Gauge valve fully open P S pump P S gear box High pressure side Low pressure side oahwWwn 3 With engine idling warm up engine till temperature of fluid in reservoir rises to 50 60 C 122 140 F 4 Check back pressure by measuring hydraulic pressure with gauge valve fully open engine idling and hands off steering wheel Back pressure Lower than 0 1500 kPa 0 15 kg cm2 0 213 psi 1 P S fluid reservoir 4 P S gear box When back pressure is higher than specified values check con 2 Gauge valve fully open 5 High pressure side a 3 P S pump 6 Low pressure side trol valve and piping for clogging 3B1 6 POWER STEERING P S SYSTEM 1 P S fluid reservoir 2 Gauge valve fully close 3 Oil pressure gauge 4 P S pump 5 P S gear box 1 P S fluid reservoir 2 Gauge valve fully open 3 Oil pressure gauge 4 P S pump 5 P S gear box 5 Check relief pressure e Increase engine speed to about 1 500 r min rpm Close gauge valve gradually while watching pressure increase indi cated by gauge and take reading of relief pressure maxi mum hydraulic pressure Relief pressure 8 200 8 900 kPa 82 89 kg cm2 1167 1265 psi e When it is higher than specified values possible cause is malfunction of relief valve e Wh
16. High engine coolant temperature Low voltage Low resistance Br W circuit open e ECT sensor malfunction e ECM malfunction NOTE e Before inspecting be sure to check that coolant temp meter in combination meter indicates normal op erating temperature Engine is not overheating DTC CONFIRMATION PROCEDURE 1 Clear DTC start engine and keep it at idle for 1 min 2 Select DTC mode on scan tool and check DTC 6 40 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION STEP ACTION 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE Check ECT Sensor and Its Circuit Go to Step 3 Intermittent trouble 1 Connect scan tool with ignition switch OFF Check for intermittent 2 Turn ignition switch ON referring to Intermittent 3 Check engine coolant temp displayed on scan and Poor Connection in tool See Fig 1 Section 0 A Is 40 C 40 F or 130 C 266 F indicated Check Wire Harness Replace ECT sensor Br wire shorted to 1 Disconnect ECT sensor connector ground 2 Check engine coolant temp displayed on scan If wire is OK substitute tool a known good ECM and Is 40 C 40 F indicated recheck Does scan tool indicate 40 C 40 F at Step 2 Go to Step 6 Go to Step 5 Check Wire Harness Go to Step 4 Br wire open or 1 Disconnect ECT sensor connector with ignition shorted to power or switch OFF poor E92 4
17. While turn ON ignition switch for 12 volts E92 06 Glow plug control relay Ground to several seconds Engine running volt E92 07 Injector needle Sensor au 3 4 5 volts Ignition switch ON position positive input engine Fig B CKP sensor positive Ground to E92 08 ee engine Fig B 2 3 volts Ignition switch ON position Data link connector Ground to E92 10 K line engine Fig B 2 3 volts Ignition switch ON position E92 11 Br Engine speen signal Ground io 4 6 volts Ignition switch ON position output engine Fig B PS 8 12 volts While turn ON ignition switch for E92 12 Glow plug indicator lamp Ground to several seconds output engine Fig B Ground to E92 13 e A C CUT signal output engine Fig B 10 14 volts 10 14 volts Ignition switch ON position E92 14 BIW EGR valve No 2 output eine et CELTI n gt a i fer o cove ia c n a ie ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 29 i aor Measurement wa Data link connector Ground to 0 5 0 5 E92 27 L line engine Fig B Ignition switch ON position 0 1 volt While turn ON ignition switch for E92 29 B R Glow plug control relay Ground to ae several seconds output engine Fig B eo 0 1 volt While turn ON ignition switch for E92 30 y Malfunction indicator Ground to o several seconds lamp output engine Fig B per ane 10 14 volts Engine running 10 14 volts Ignition switch ON position E92 32 R Y EGR valve No 1 output ane to
18. connection 2 Check for proper connection to ECT sensor at If wire and connection Br W and Br wire terminals are OK substitute a 3 If OK then with ignition switch ON is voltage known good ECM and applied to Br wire terminal about 4 6 V recheck See Fig 2 Check Wire Harness Replace ECT sensor Br W wire open or 1 Using service wire connect ECT sensor poor E92 21 connection connector terminals See Fig 3 If wire and connection 2 Turn ignition switch ON and check engine are OK substitute a coolant temp displayed on scan tool known good ECM and Is 130 C 266 F indicated recheck Fig 1 for Step 2 Fig 2 for Step 5 Fig 3 for Step 6 N ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 41 DTC No 4 THROTTLE POSITION CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION BI R BI B 1 TP sensor 2 ECM 18 17 46 15 14 43 12 41 10 3 7 lelali 35 34 33 32 30 29 27 25 24 23 24 19 DTC DETECTING CONDITION POSSIBLE CAUSE e Signal voltage high e Bl Or circuit open or shorted to power e Signal voltage low e BI B circuit open or shorted to ground e BI R circuit open or shorted to power or ground e TP sensor malfunction e ECM malfunction DTC CONFIRMATION PROCEDURE 1 Clear DTC start engine and keep it at idle for 1 min 2 Select DTC mode on scan tool and check DTC 6 42 ENGINE GENERAL INFORMATION AND DIAGNO
19. cracks cuts deformation wear and cleanliness If any of above conditions are found replace accessory drive belt 3 Using special tool A check that dynamic roller tensioner hole and generator mount bracket hole are aligned If they are not aligned perform following items Special Tool A 09919 56520 OUT0000075 i Remove engine right side under cover ii Remove radiator outlet pipe tightening bolts iii Adjust belt tension by referring to step 3 to 7 of Accessory Drive Belt Installation in SECTION 6H If belt tension can not be adjusted within specified tension replace the generator belt OB 6 MAINTENANCE AND LUBRICATION Replacement Replace drive belt with new one Refer to Accessory Drive Belt in SECTION 6H for replacement procedure ITEM 1 2 Camshaft Timing Belt Replacement Replace belt with new one Refer to Timing Belt in SECTION 6A4 for replacement procedure CAUTION e Do not bend or twist timing belt e Do not allow timing belt to come into contact with oil water etc 1 Camshaft timing belt FG ITEM 1 3 Pee E Engine Oil and Oil Filter Change E PO It is recommended to use engine oil of ACEA B2 96 CCMC PD 2 elelelelie ofefelefelele or API CF except CF 2 or higher quality level oils a 2eEEEEE Select the appropriate oil viscosity according to the left chart Al ways change oil and oil filter as soon as possible after driving ina dust storm
20. from engine assembly NOTE Plug each port of removed pump to prevent dust or any oth er foreign matter from entering 1 P S pump POWER STEERING P S SYSTEM 3B1 9 INSTALLATION Reverse removal procedure Tightening Torque a 35 N m 3 5 kg m 25 5 Ib ft NOTE e Fill specified power steering fluid after installation and bleed air without failure e Refer to structural diagram on previous page for tightening torque e Check each connection for fluid leakage TIGHTENING TORQUE SPECIFICATIONS Tightening Torque Fastening parts ib High amp low pressure pipe nut bolt pipe to gear box sss 25 5 Pipe clamp boli High pressure pipe bolt pipe to pump s s l oo P S pump mounting bolt REQUIRED SERVICE MATERIALS RECOMMENDED Power steerino fluid An equivalent of DEXRON II e To fill power steering fluid reservoir DEXRON IE or DEXRON M e Parts lubrication when installing SPECIAL TOOLS 09915 77420 09915 77410 Oil pressure gauge Oil pressure gauge attachment and hose set FRONT DRIVE SHAFT 4 1 SECTION 4 FRONT DRIVE SHAFT NOTE For the descriptions items not found in this section of this manual refer to the same section of Service Manual mentioned in FOREWORD of this manual CONTENTS ON VEHICLE SERVICE CENTER SHAFT REMOVal INStAllatiOn sersa niens iaa Back wand ala asd ea a ea PAO y a ae a al a a a AIS al weed ade ae 4 1 ON VEHICLE SERVICE an
21. of DTC No 3 Engine Coolant Temperature ECT Black Smoke Engine Warm and Cold 6 61 Circuit Malfunction 0005 6 39 The Engine Will Not Start with Emission of DTC No 4 Throttle Position Circuit Clear Smoke Engine Cold 6 62 Malfunction 0 cee eee eee 6 41 The Engine Is Difficult to Start When Cold DTC No 13 Barometric Pressure Sensor with Emission of Black Smoke 6 63 Low High Input 00e eee eee 6 43 The Engine Starts Then Stops 6 64 DTC No 14 Injector Needle Sensor Circuit Unstable Idling 0 oeenn 6 65 MATENON aigarada epasu make St Vibration at Idle 00 0 0 eee essen 6 66 DTC No 16 Injection Timing Actuator Control Unwanted Acceleration 6 67 Malfunction 00 cece e eee eee 6 46 The Engine Stalls on Overrun DTC No 34 Injection Timing Actuator Circuit Slow Return to Idle e0ee sees 6 68 Malfunction a aan 6 46 Engine Miss fire Irregular Operation 6 69 DTC No 17 ECM Power Supply Circuit The Engine Starts with Difficulty Malfunction 00 cece eee ee 6 48 Engine Hot cececeeeeeeeeeeees 6 70 DTC No 22 Glow Plug Relay Control Vehicle Lacks of Power Malfunction FeedBack Low Voltage 6 49 with or without Emission of Smoke 6 71 DTC No 23 Glow Plug Relay Control Circuit Excessive Diesel Consumption 6 73 Malfunction 0 0 ccc
22. proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure This is considered standard shop practice even if not specifically stated ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 3 e A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surfaces on initial operation e Whenever valve train components pistons piston rings connecting rods rod bearings and crankshaft journal bearings are removed for service they should be retained in order At the time of installation they should be installed in the same locations and with the same mating surfaces as when removed e Battery cables should be disconnected before any major work is performed on the engine Failure to disconnect cables may result in damage to wire harness or other electrical parts e Throughout this manual the four cylinders of the engine are identified by numbers No 1 No 2 No 3 and No 4 as counted from flywheel side to crankshaft pulley side GENERAL INFORMATION ON ENGINE SER VICE THE FOLLOWING INFORMATION ON ENGINE SERVICE SHOULD BE NOTED CAREFULLY AS IT IS IMPORTANT IN PREVENTING DAMAGE AND IN CONTRIBUTING TO RELI ABLE ENGINE PERFORMANCE e When raising or supporting engine for any reason do not use a jack under oil pan Due to small clearance between oil pan and oil pump strainer jacking against oil pan may cause it to be bent against strainer
23. result in unintentional activation of the system or could render the system inoperative Ei ther of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the sys tem may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE For the descriptions items not found in this section refer to the same section of the Service Manual men tioned in FOREWORD of this manual CONTENTS MAINTENANCE SCHEDULE 3 0352 sccwiceiahebered nin a See bahar be bea seh E A need etd ad ea ees OB 2 Normal Condition Schedule 00 0 cece een tented eee aiaia a OB 2 Maintenance Recommended Under Severe Driving Conditions 0 00 c cece eee ee eee OB 4 MAINTENANCE SERVICE 0 2 2 c cnie cies eden reneis ka Gna a bs bee dent ekobveivadw hides aden ed eee OB 5 EO e Ar ERN EAEE AE T eee Goins amt EE Cre he cA tea cette eres Soak A ade Seeks ERT OB 5 FUCISYSIOM aasaran bidder adaws Joke dae Gree he eat eda i a Saa ded ead Paes coed OB 10 RECOMMENDED FLUIDS AND LUBRICANTS 0 000 OB 11 0B 2 MAINTENANCE AND LUBRICATION MAINTENANCE SCHEDULE NORMAL CONDITION SCHEDULE This table includes services as scheduled up to 90 000 km 54 000 miles Interval mileage Beyond 90 000 km 54 000 miles carry out the same
24. resulting in damaged oil pick up unit e t should be kept in mind while working on engine that 12 volt electrical system is capable of violent and damaging short cir cuits When performing any work where electrical terminals could possibly be grounded ground cable of the battery should be dis connected at battery e Any time the air cleaner air intake hose turbo charger or intake manifold is removed the intake opening should be covered This will protect against accidental entrance of foreign material which could follow intake passage into cylinder and cause extensive damage when engine is started 6 4 ENGINE GENERAL INFORMATION AND DIAGNOSIS With short pipe fit hose as far as it reaches pipe joint as shown Hose LM dL Pipe U LLLA Clamp securely at a position 3 to 7 mm 0 12 0 27 in from hose end With following type pipe fit hose as far as its peripheral projection as shown Clamp securely at a position 3 to 7 mm 0 12 0 27 in from hose end With bent pipe fit hose as far as its bent part as shown or till pipe is about 20 30 mm 0 79 1 18 in into the hose WLOX Clamp securely at a position 3 to 7 mm 0 12 0 27 in from hose end With straight pipe fit hose till pipe is about 20 to 30 mm 0 79 1 18 in into the hose Hose Wii ppypyy atts 20 to 30 mm 0 79 1 18 in Clamp Clamp securely at a position 3 to 7 mm 0 12
25. signal in ECM faulty A C controller faulty Sub radiator fan motor condenser fan motor inoperative e Fuse blown e Sub radiator fan motor relay faulty e Wiring or grounding faulty e Sub radiator fan motor faulty Blower motor inoperative e Fuse blown Blower fan motor relay faulty Blower fan motor resistor faulty Blower fan motor switch faulty Wiring or grounding faulty Blower fan motor faulty Check A C and DEF fuses and check for short circuit Check compressor relay Check magnet clutch Tighten or replace drive belt Check compressor Check A C ON permission signal Check A C controller Check SUB RD FAN and DEF fuses and check for short circuit Check sub radiator fan motor relay Repair as necessary Check sub radiator fan motor Check DEF fuse and cassette fuse and check for short circuit Check blower fan motor relay Check blower fan motor resistor Check blower fan motor switch Repair as necessary Check blower fan motor AIR CONDITIONING OPTIONAL 1B 5 Trouble Possible Cause Measure Cool air does not come out or insufficient cooling A C system normal operative Insufficient or excessive charge of re frigerant Refrigerant leak in system Condenser clogged Evaporator clogged or frosted A C evaporator thermistor faulty A C controller faulty Expansion valve faulty Drive belt slipping Magnetic clutch faulty Compressor faulty Air in A C sy
26. the engine and emission control system in their structure and operation In case of an engine trouble even when the malfunction indicator lamp MIL doesn t turn ON it should be diagnosed according to this flow table 1 Malfunction indicator lamp 2 Data link connector DLC 3 SUZUKI scan tool SUZUKI serial data line B L line of ISO 9141 Body ground ECM ground K line of ISO 9141 13 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 7 ON BOARD DIAGNOSTIC SYSTEM ECM diagnosis troubles which may occur in the area including the following parts when the ignition switch is ON and the engine is run ning and indicates the result by turning on malfunction indicator lamp 1 for marked following items e Injection timing actuator Glow plug relay CKP sensor ECT sensor TP sensor Barometric pressure sensor Injector needle sensor Power supply EGR No 1 solenoid valve EGR No 2 solenoid valve MIL CPU Central Processing Unit of ECM ECM and malfunction indicator lamp 1 operate as follows e Malfunction indicator lamp 1 lights for 2 to 3 seconds when the ignition switch is turned ON but the engine at stop This is only to check the malfunction indicator lamp 1 bulb and its circuit e fthe above areas of Engine and Emission Control system is free from any trouble malfunction indicator lamp 1 turns OFF after 2 to 3 seconds from ignition switch turn ON e When EC
27. vide eta deen ap aa Sake 5 2 TIGHTENING TORQUE SPECIFICATIONS 0 000 ccc eee eee eee 5 4 SPEGIAL TOOLS oore adhe atits dice wind tite been betel aaa Gena a seston ae atlas 5 4 5 2 BRAKES 1 Air bleeder plug 2 Weight ON VEHICLE SERVICE EXCESSIVE PEDAL TRAVEL CHECK 1 Start engine 2 Depress brake pedal a few times 3 With brake pedal depressed with approximately 30 kg 66 Ibs load measure brake pedal to wall clearance c Clearance c Over 70 mm in 4 If clearance c is less than specification the most possible cause is either rear brake shoes are worn out beyond limit or air is in lines Should clearance c remain less than specification even after replacement of brake shoes and bleeding of system other pos sible but infrequent cause is malfunction of rear brake shoe ad justers or booster push rod length out of adjustment FLUID PRESSURE TEST Test procedure for LSPV assembly is as follows Before testing confirm the following e Fuel tank is filled with fuel fully e Vehicle is equipped with spare tire tools jack and jack handle 1 Place vehicle on level floor and set 200 kg 442 Ibs weight slow ly on axle housing center 2 Install special tool to front and rear brake NOTE Pressure gauge should be connected to breather of front left side brake and rear right side brake After testing front left side and rear right side test front
28. 0 27 in from hose end e When disconnecting couplers don t pull wire harness but make sure to hold coupler itself With lock type coupler be sure to un lock before disconnection Attempt to disconnect coupler with out unlocking may result in damage to coupler When connecting lock type coupler insert it till clicking sound is heard and connect it securely PRECAUTION ON FUEL SYSTEM SERVICE e Work must be done with no smoking in a well ventilated area and away from any open flames e As fuel feed line between fuel injection pump and fuel pipe is still under high fuel pressure even after engine was stopped loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened or discon nected A small amount of fuel may be released after fuel line is discon nected In order to reduce the chance of personal injury cover fitting to be disconnected with a shop cloth Put that cloth in an approved container when disconnection is completed e Fuelhose connection varies with each type of pipe When recon necting fuel hose be sure to connect and clamp each hose cor rectly referring to figure Hose Connection After connecting make sure that it has no twist or kink e When installing fuel filter union bolt or plug bolt on union bolt al ways use new gasket and tighten it to specified torque a om 1 Diameter 2 Pitch ENGINE GENERAL INFORMATION AN
29. 1 valve 14 EGR No 2 solenoid valve 7 Coolant temp gauge 15 Double relay 8 Coolant temp switch 16 Glow plug control relay 6 32 ENGINE GENERAL INFORMATION AND DIAGNOSIS TABLE A 1 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK LAMP DOES NOT COME ON AT IGNITION SWITCH ON BUT ENGINE AT STOP CIRCUIT DESCRIPTION y A To immobilizer B To EGR No 1 and No 2 solenoid valve C To injection actuator S aa UL Main fuse Ignition switch ae mer e epa en oLTs 17 le bT4 Tels Deckers 3534 33 52 90 29 127 LT EAR EAEAN in combination meter Fusible link IG fuse IG METER fuse Generator ECM akNM SCOMND When the ignition switch is turned ON ECM causes the double relay to turn ON close the contact point Then ECM being supplied with the main power turns ON the malfunction indicator lamp MIL When the engine starts to run and no malfunction is detected in the system MIL goes OFF but if a malfunction was or is detected MIL remains ON even when the engine is running INSPECTION ACTION MIL Power Supply Check Go to Step 2 IG fuse blown main fuse 1 Turn ignition switch ON blown ignition switch malfunc Do other indicator warning lights in combina tion B W circuit between IG tion meter comes ON fuse and combination meter or poor coupler connection at combination meter ECM Power and Ground Circuit Check Go to Step 3 Go to TABL
30. 26 ENGINE GENERAL INFORMATION AND DIAGNOSIS SCAN TOOL DATA DEFINITIONS CALC LOAD CALCULATED LOAD VALUE mg sir Engine load value calculated from throttle position and engine speed Load is referred to in terms of fuel quantity per stroke COOLANT TEMP VOLTAGE ENGINE COOLANT TEMPERATURE VOLTAGE V It is detected by engine coolant temp sensor ENGINE SPEED rpm It is computed by reference pulses from crankshaft position sensor INJECTION TIMING START OF INJECTION Start of injection control is performed by calculating an optimal desired start of injection and closing the loop on it ECM controls the injection start timing THROTTLE POSITION SENSOR VOLTAGE TP SENSOR VOLT V The Throttle Position Sensor reading provides throttle valve opening information in the form of voltage This in formation is used for correction such as enrichment correction during acceleration The voltage reading should increase as the throttle is opened 0 V indicates a broken or shorted sensor BATTERY VOLTAGE V This parameter indicates battery positive voltage inputted from main relay to ECM NEEDLE SENSOR VOLTAGE V The ECM detects the start of needle movement by triggering on the rising edge of the needle movement sensor signal BAROMETRIC SENSOR VOLTAGE V This parameter represents a measurement of barometric air pressure and is used for altitude correction of the fuel injection quantity ENGINE GENERAL INFORMATION AND DIAGNOSIS 6
31. 27 A Fig A B Fig B 1 ECM 2 Couplers 3 Body ground 4 Terminal E92 18 for engine ground INSPECTION OF ECM AND ITS CIRCUITS ECM and its circuits can be checked at ECM wiring connectors by measuring voltage and resistance CAUTION ECM cannot be checked by itself It is strictly prohibited to connect voltmeter or ohmmeter to ECM with connec tor disconnected from it VOLTAGE CHECK 1 Remove ECM from body referring to Section 6E 2 Check voltage at each terminal of connectors connected NOTE As each terminal voltage is affected by the battery voltage confirm that it is 11 V or more when ignition switch is ON 1 ECM connectors Viewed from harness side 6 28 ENGINE GENERAL INFORMATION AND DIAGNOSIS ECM VOLTAGE VALUES TABLE ee Measurement Pe f TP sensor power supply Ground to E92 01 BI R engine Fig B 4 6 volts Ignition switch ON position Ignition switch ON position and Ground to 0 6 1 0 volts throttle lever at idle position E92 02 BI B TP sensor input gt f 7 engine Fig B 54 28 volts nition switch ON position and throttle lever at fully open position 0 25 0 28 Ignition switch ON position at en volt ine coolant temp 60 C 140 F E92 04 Br ECT sensor signal input Ground oe I l engine Fig B 0 14 0 12 Ignition switch ON position at en volt gine coolant temp 90 C 194 F
32. 6 9 E92 33 SAH Ignition switch IG METER fuse Double relay EGR No 2 solenoid valve for intake pipe EGR No 1 solenoid valve for intake manifold ECM Main fuse Fusible link Generator DPONOARON gt DTC DETECTING CONDITION POSSIBLE CAUSE EGR No 1 or No 2 solenoid valve circuit is opened or e R Y BI W circuit open or short shorted e BI Y circuit open or short e EGR solenoid valve malfunction DTC CONFIRMATION PROCEDURE 1 Clear DTC with ignition switch ON 2 Select DTC mode on scan tool and check DTC INSPECTION STEP ACTION Check EGR No 1 No 2 solenoid valve for resistance R Y BI Y circuit Replace EGR No 1 or 1 With ignition switch OFF disconnect coupler from open or short No 2 solenoid valve canister purge valve 2 Check resistance of EGR No 1 No 2 solenoid valve Resistance between two terminals See Fig 1 23 40 Q at 20 C 68 F Resistance between terminal and body 1M Q or higher Is it as specified Fig 1 for Step 1 6 52 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC NO 37 A C CUT OFF CONTROL CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION G Or P 1 A C controller 2 A C switch 3 A C compressor relay 4 Condenser fan relay R BI Y 7 an B Or 5 A C compressor 5 os 6 Condenser fan 77T 7 Dual pressure switch 6 BIB BI B 8 Ignition switch B 9 ECM 10 Main fuse box hy 11 Relay box 12 Circuit fuse bo
33. BLE CODE DTC TABLE DTC will set when detecting circuit malfunction Sensor circuit voltage high input function Sensor circuit voltage high input Barometric pressure sensor mal No lights function Sensor circuit in ECM voltage high Implausible signal during engine running Injector needle sensor circuit mal Sensor circuit is open function Sensor circuit is short to ground or battery volt age line Injection timing actuator control Implausible injection timing during engine run Lights malfunction ning ee Battery voltage is low Lights when P l t malfunct Battery voltage is high undervoltage Glow plug relay diagnostig teed Low input when should be turn ON glow plug Lights back malfunction Relay circuit is open Relay circuit is short to ground or battery volt No lights No lights Glow plug relay control circuit mal ert Laie eas oa tagar High input when should be turn OFF glow plug Lights Solenoid valve circuit is open Solenoid valve circuit is short to ground or bat No lights tery voltage line EGR No 1 solenoid valve circuit malfunction Actuator circuit is open Actuator circuit is short to ground or battery Lights voltage line Injection timing actuator circuit mal function Solenoid valve circuit is open Solenoid valve circuit is short to ground or bat No lights tery voltage line EGR No 2 solenoid valve circuit malfunction Control circuit is open Control circuit is short to ground or battery volt No light
34. D DIAGNOSIS 6 5 METRIC INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are metric When replac ing any fasteners it is most important that replacement fasteners be the correct diameter thread pitch and strength CAUTION Note that both ISO and JIS type bolts and nuts are used for the engine assembly and related parts Even when the diameter of the thread is the same its pitch may vary be tween these two types Installing a mismatched bolt or nut will cause damage to the thread As the first step make sure to tighten it by hand temporarily and if it feels tight check the thread pitch for correct matching 6 6 ENGINE GENERAL INFORMATION AND DIAGNOSIS ENGINE DIAGNOSIS GENERAL DESCRIPTION This vehicle is equipped with an engine and emission control system which are under control of ECM The engine and emission control system in this vehicle are controlled by ECM ECM has an On Board Diagnostic system which detects a malfunction in this system and abnormality of those parts that influence the engine exhaust emission When diagnosing engine troubles be sure to have full understanding of the outline of On Board Diag nostic System and each item in Precaution in Diagnosing Trouble and execute diagnosis according to ENGINE DIAGNOSTIC FLOW TABLE There is a close relationship between the engine mechanical engine cooling system immobilizer system exhaust system etc and
35. E A 3 ECM POW Does engine start ER AND GROUND CIRCUIT CHECK If these circuits are OK go to DIAGNOSIS in SECTION 8G MIL Circuit Check Substitute a known Bulb burned out V wire cir 1 Turn ignition switch OFF and disconnect good ECM and re cuit open connectors from ECM check 2 Check for proper connection to ECM at terminal E92 30 3 If OK then using service wire ground ter minal E92 30 in connector disconnected Does MIL turn on at ignition switch ON ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 33 TABLE A 2 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK LAMP REMAINS ON WITH IGNITION SWITCH ON WIRING DIAGRAM CIRCUIT DESCRIPTION Refer to table A 1 INSPECTION Diagnostic Trouble Code DTC check Go to Step 2 of ENGINE Go to Step 2 1 Check DTC referring to DTC CHECK section DIAG FLOW TABLE Is there any DTC s DTC check Go to Step 3 Start engine and recheck DTC while engine running Is there any DTC s MIL Circuit check V wire circuit shorted to Substitute a known good 1 Turn OFF ignition switch ground ECM and recheck 2 Disconnect connectors from ECM Does MIL turn ON at ignition switch ON 6 34 ENGINE GENERAL INFORMATION AND DIAGNOSIS TABLE A 3 ECM POWER AND GROUND CIRCUIT CHECK MIL DOESN T LIGHT AT IGNITION SWITCH ON AND ENGINE DOESN T START THOUGH IT IS CRANKED UP CIRCUIT DESCRIPTION y A To immobilizer B To EGR No 1 and No 2 solenoid
36. IMPORTANT WARNING CAUTION NOTE Please read this manual and follow its instructions carefully To emphasize special information the words WARNING CAUTION and NOTE have special mean ings Pay special attention to the messages high lighted by these signal words WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in vehicle damage NOTE Indicates special information to make mainte nance easier or instructions clearer WARNING This service manual is intended for autho rized SUZUKI dealers and qualified service mechanics only Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly per form the services described in this manual Improper repair may result in injury to the mechanic and may render the vehicle un safe for the driver and passengers WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on or around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under Gener al Description in air bag system section in order to confirm whether you are per forming service on or near the air bag sys tem components or wiring Please observe all WARNINGS and Precau tions in air bag system section before perfo
37. LE per Check injection timing actuator connector for proper installation Is injection timing actuator connector connected securely Check injection timing actuator operation as fol lows 1 With ignition switch OFF disconnect coupler from injection timing actuator 2 Check injection riming actuator resistance Refer to INJECTOR TIMING ACTUATOR in Section 6E3 Is it as specified Check ECM terminal voltage as follows 1 Disconnect ECM coupler 2 Connect injection timing actuator coupler 3 Turn ignition switch ON 4 Measure voltage between E92 15 terminal in ECM coupler and body ground Is it over 10 V Check injection timing actuator circuit voltage as follows 1 Disconnect injection timing actuator coupler 2 Turn ignition switch ON 3 Measure voltage between E92 15 terminal in ECM coupler and body ground Is it 0 V Check injection pump static timing Refer to FUEL INJECTION PUMP in Section 6E3 Is it as specified Substitute a known good ECM and recheck Is DTC detected ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 47 Go to Step 6 Go to Step 7 Remove the injection pump and have it checked by BOSCH dealer Refer to FUEL INJEC TION PUMP in Section 6E3 Go to ENGINE DIAG NOSIS FLOW TABLE Correct Remove the injection pump and have it checked by BOSCH dealer Refer to FUEL INJEC TION PUMP in Section 6E3 G and G R circuits open or shorte
38. M detects a trouble which has occurred in the above areas with marked it makes malfunction indicator lamp 1 stay ON after 2 to 3 seconds from ignition switch turn ON including while the engine is running to warn the driver of such occurrence of trouble and at the same time it stores the trouble area in ECM back up memory The memory is kept as it is even if the trouble was only temporary and disappeared immediately Data Link Connector DLC DLC 1 is in compliance with SAEJ1 962 in its installation position the shape of connector and pin assignment Serial data line K line and L line of ISO 9141 is used for SUZUKI scan tool Tech 1 to communicate with ECM Air Bag SDM and ABS control module SUZUKI serial data line is used for SUZUKI scan tool to communi cate with immobilizer control module 6 8 ENGINE GENERAL INFORMATION AND DIAGNOSIS PRECAUTION IN DIAGNOSING TROUBLE e Don t disconnect couplers from ECM battery cable at battery ECM ground wire harness from engine or main fuse before con firming diagnostic information DTC etc stored in ECM memory Such disconnection will erase memorized information in ECM memory Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan tool Before using scan tool read its Operator s Instruction Manual carefully to have good understanding as to what functions are available and how to use it Priorities for diagnosing troub
39. METRIC PRESSURE SENSOR LOW HIGH INPUT WIRING DIAGRAM CIRCUIT DESCRIPTION Barometric pressure sensor is installed in ECM e ECM barometric pressure sensor malfunction DTC CONFIRMATION PROCEDURE 1 Turn ignition switch OFF 2 Clear DTC with ignition switch ON 3 Turn ignition switch ON for 2 sec crank engine for 2 sec and run it at idle for 1 min 4 Check DTC in DTC mode INSPECTION Substitute a known good ECM and recheck 6 44 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC No 14 INJECTOR NEEDLE SENSOR CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION 1 Injector needle sensor 2 ECM 18 17 16 15 14 43 12 41 10 8 7 6 4 lAl 35 34 33 32 30 29 27 25 24 23 21 19 DTC DETECTING CONDITION POSSIBLE CAUSE e No injector needle sensor signal for 2 seconds at engine e Injector needle sensor circuit open or short cranking e Injector damaged e Injector needle sensor malfunction e ECM malfunction Reference Connect oscilloscope between terminals E92 7 E92 24 of ECM connector connected to ECM and check CKP sen sor signal Oscilloscope Waveforms 1V DIV 1V DIV 4V 4V GND E E E E E E A E E E N GND PoJ ir hmas 1ms DIV Waveform at idle speed Waveform at 2500 rpm DTC CONFIRMATION PROCEDURE 1 Clear DTC and crank engine for 2 sec 2 Select DTC mode on scan tool and check DTC ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 45 INS
40. ON 1 Fuel filter FUEL SYSTEM ITEM 3 1 Air Cleaner Filter Replacement 1 Unclamp air cleaner case clamps 2 Replace air cleaner filter with new one 3 Clamp case securely Air Cleaner Filter Inspection 1 Visually check that air cleaner filter is not excessively dirty dam aged or oily 2 Clean filter with compressed air from air outlet side of filter i e the side facing up when installed ITEM 3 2 Fuel lines Inspection Check fuel lines for loose connection deterioration or damage which could cause leakage Make sure all clamps are secure Replace any damaged or deteriorated parts There should be no sign of fuel leakage or moisture at any fuel con nection ITEM 3 3 Fuel Filter Replacement WARNING This work must be performed in a well ventilated area and away from any open flames such as gas hot water heaters Replace fuel filter with new one referring to FUEL FILTER in Sec tion 6E3 Water Draining of Fuel Filter Bleed fuel filter of water referring to FUEL FILTER in Section 6E3 MAINTENANCE AND LUBRICATION OB 11 ITEM 3 4 Fuel Tank Inspection Check fuel tank for corrosion deterioration or damage which could cause leakage If a problem is found repair or replace RECOMMENDED FLUIDS AND LUBRICANTS Minimum quality level required is ACEA B2 96 CCMC PD 2 or Engine oil API CF except CF 2 Refer to engine oil viscosity chart in
41. ORM EXAMPLE Date Fog Dat of problem PROBLEM SYMPTOMS Difficult Starting No cranking No initial combustion No combustion Poor starting at LJcold LJwarm Other Poor Idling Poor fast idle Abnormal idling speed High Low Unstable Hunting Other r min OTHERS always Poor Driveability Hesitation on acceleration Back fire LAfter fire Lack of power Surging abnormal knocking Other Engine Stall when Immediately after start Accel pedal is depressed r min Accel pedal is released Load is applied to r min A C OElectric load Other Other VEHICLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental Condition Weather Fair Cloudy Rain Snow Always Other Hot Temperature Warm Cool Cold F Frequency Always times Sometimes Road Urban Suburb Highway Other Mountainous C LiAlways day month LJOnly once Uphill Downhill Under certain condition Tarmacadam Gravel
42. OUBLE CODE DTC CHECK 1 Prepare SUZUKI scan tool Tech 1 2 With ignition switch OFF connect it to data link connector DLC 1 located on underside of instrument panel at driver s seat side Special Tool A SUZUKI scan tool B Mass storage cartridge C 16 14 pin DLC cable Turn ignition switch ON and confirm that MIL lights Read DTC according to instructions displayed on scan tool and print it or write it down Refer to scan tool operator s manual for further details If communication between scan tool and ECM is not possible check if scan tool is communicable by connecting it to ECM in another vehicle If communication is possible in this case scan tool is in good condition Then check data link connector and se rial data line circuit in the vehicle with which communication was not possible After completing the check turn ignition switch off and discon nect scan tool from data link connector DIAGNOSTIC TROUBLE CODE DTC CLEARANCE 1 Connect SUZUKI scan tool Tech 1 to data link connector in the same manner as when making this connection for DTC check 2 Turn ignition switch ON 3 Erase DTC according to instructions displayed on scan tool Refer to scan tool operator s manual for further details 4 After completing the clearance turn ignition switch off and dis connect scan tool from data link connector ee a ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 13 DIAGNOSTIC TROU
43. OVERHAUL CHECKING TUN ING MANUAL listed below in FOREWORD of this manual Refer to Section 6A4 and OVERHAUL CHECKING TUNING MANUAL listed below in FOREWORD of this manual Condition Engine noise Note Before check ing the mechanical noise make sure that e Ignition timing is proper e Specified fuel is used ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 23 Possible Cause Valve noise e Improper valve lash e Worn valve stem and guide Weak or broken valve spring Warped or bent valve Loose camshaft housing bolts Reference Item Valve clearance in Section 6A4 Valves and cylinder head in OVERHAUL CHECKING TUNING MANUAL listed below in FOREWORD of this manual Valve spring in OVERHAUL CHECKING TUNING MANUAL listed below in FORE WORD of this manual Valves and cylinder head in OVERHAUL CHECKING TUNING MANUAL listed below in FOREWORD of this manual Camshaft in OVERHAUL CHECKING TUN ING MANUAL listed below in FOREWORD of this manual Piston ring and cylinder noise e Worn piston ring and cylinder bore Connecting rod noise e Worn crankpin bearing e Worn crankpin e Loose connecting rod nuts e Low oil pressure Crankshaft noise e Low oil pressure e Worn crankshaft journal bearing Worn crankshaft journal Loose lower crankcase bearing cap bolts Excessive crankshaft thrust play Valves and cylinder head in OVERHAUL CHECKING TUNING MANUAL liste
44. PECTION se oon J s J o SOS 1 Was ENGINE DIAGNOSIS FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed NOSIS FLOW TABLE 2 Check injector needle sensor and connector for Go to Step 3 Correct proper installation Is injector needle sensor installed properly and con nector connected securely Check injector needle sensor resistance as follows Go to Step 4 Replace injector needle 1 Disconnect injector needle sensor connector with sensor ignition switch OFF 2 Measure resistance between sensor terminals Refer to INJECTOR NEEDLE SENSOR in Sec tion 6E3 Is measured resistance value as specified Check ECM terminal voltage as follows Go to Step 5 Injector needle sensor 1 Turn ignition switch OFF circuit shorted to pow 2 Disconnect ECM connector er 3 Check for proper connection to ECM at each sen sor terminals 4 If check is OK then turn ignition switch ON and measure voltage between sensor terminal of ECM and body ground Is it 0 V Check continuity of injector needle sensor circuit as Go to Step 6 Circuit open or shorted follows to ground 1 Turn ignition switch OFF 2 Connect injector needle sensor coupler 3 Measure resistance between the following points e Both ECM connector terminals of the injector needle sensor continuity e Either terminal of injector needle sensor cou pler and body ground no continuity Are both check results satisfactory Check injector damage as follow
45. SIS INSPECTION STEP ACTION 1 Was ENGINE DIAG FLOW TABLE Go to Step 2 Go to ENGINE DIAG performed FLOW TABLE Check TP Sensor and Its Circuit Go to Step 3 Intermittent trouble 1 Connect scan tool to DLC with ignition Check for intermittent switch OFF and then turn ignition switch referring to Intermittent ON and Poor Connection in 2 Check throttle valve opening percentage Section 0 A displayed on scan tool See Fig 1 Is it displayed 0 or 100 3 Check Wire Harness Go to Step 4 BI R wire open BI R 1 Disconnect connector from TP sensor wire shorted to ground with ignition switch OFF circuit or power circuit or 2 Check for proper connection to TP sensor BI Or wire BI B wire at BI R BI B and BI Or wire terminal open or shorted to ground 3 If OK then with ignition switch ON check circuit or poor E92 1 or voltage at each of BI R and BI B wire E92 2 connection terminals and body ground See Fig 2 If wire and connection are Is voltage about 4 6 V at each terminal OK substitute a known good ECM and recheck 4 Check TP Sensor Bl Or wire open or poor Replace TP sensor Refer to TP SENSOR in Section 6E3 E92 19 connection Is it in good condition If wire and connection are OK substitute a known good ECM and recheck Fig 1 for Step 2 Fig 2 for Step 3 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 43 DTC NO 13 BARO
46. TABLE OF CONTENTS GENERAL INFORMATION General Information Maintenance and Lubrication HEATING AND AIR CONDITIONING SECTION Heater and Ventilation Air Conditioning STEERING SUSPENSION WHEELS AND TIRES Steering Suspension Wheels and Tires Front End Alignment Power Steering P S System Steering Wheel and Column Front Suspension Rear Suspension Wheel and Tires DRIVE SHAFT Front Drive Shaft BRAKE SYSTEM Brakes Antilock Brake System ABS ENGINE Engine General Information and Diagnosis Engine XUD9 BSD Engine Engine Cooling Engine Fuel Engine and Emission Control System XUD9 BSD Engine Cranking System Charging System Exhaust System TRANSMISSION AND CLUTCH Manual Transmission Clutch Hydraulic Type BODY ELECTRICAL SERVICE IMMOBILIZER CONTROL SYSTEM WIRING DIAGRAM BODY SERVICE AIR BAG SYSTEM NOTE The screen toned sections are included in SY413 SY416 SY418 SERVICE MANUAL GENERAL INFORMATION 0A 1 SECTION 0A Ox GENERAL INFORMATION NOTE For the descriptions items not found in this section refer to the same section of the Service Manual men tioned in FOREWORD of this manual CONTENTS IDENTIFICATION INFORMATION 2 000 cece eee e eee eens OA 1 Engine Identification NUMBER cc sce ekaeng cee ahaa wines a Rn
47. ce ees 6 49 Engine Knocking ee Pe ee EEEE 6 74 DTC No 32 Glow Plug Relay Control Hesitation at Steady Speed 6 75 Malfunction FeedBack High Voltage 6 49 Hesitation on Re acceleration 6 76 DTC No 33 EGR No 1 Control Valve Circuit With Emission of Black Smoke at Idle Malfunction 2 000 Akis 6 51 after Starting ccccceceeeeeveeeeee 6 77 DTC No 36 EGR No 2 Control Valve Circuit Emission of Blue Smoke at Idle on Overrun Malfunction 0 00 c cee eee ees 6 51 at Low Load st dss le cdi ho en ee eee 6 78 BTC NOSTAN LUON Control Circuit With Emission of Black Smoke at Load 6 80 Malfunction 0 c eee eee eee ee 6 52 No Re acceleration No Liveliness DTC No 38 Malfunction Indicator Lamp Circuit with or without Emission of Smoke 6 81 Malfunction es Ce ne 7 oe 6 54 The Vehicle Moves off with Difficulty DTC No 39 Glow Plug Indicator Lamp Circuit with or without Emission of Smoke 6 82 Malfunction 00 cee eee eee ee 6 56 SPECIAL TOOLS 00005 6 83 GENERAL INFORMATION STATEMENT ON CLEANLINESS AND CARE An automobile engine is a combination of many machined honed polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter ten thousands of inch Accordingly when any internal engine parts are serviced care and cleanliness are important Throughout this section it should be understood that
48. d below in FOREWORD of this manual Crankpin and connecting rod in OVERHAUL CHECKING TUNING MANUAL listed below in FOREWORD of this manual Crankpin and connecting rod in OVERHAUL CHECKING TUNING MANUAL listed below in FOREWORD of this manual Connecting rod in OVERHAUL CHECKING TUNING MANUAL listed below in FORE WORD of this manual Previously outlined Previously outlined Crank shaft and bearing in OVERHAUL CHECKING TUNING MANUAL listed below in FOREWORD of this manual Crank shaft and bearing in OVERHAUL CHECKING TUNING MANUAL listed below in FOREWORD of this manual Crankshaft in OVERHAUL CHECKING TUN ING MANUAL listed below in FOREWORD of this manual Crankshaft in OVERHAUL CHECKING TUN ING MANUAL listed below in FOREWORD of this manual 6 24 ENGINE GENERAL INFORMATION AND DIAGNOSIS Condition Possible Cause Referring Item Excessive hydrocar bon HC emission or excessive carbon monoxide CO emis sion Injection system out of order e Faulty fuel injection pump static timing e Clogged fuel filter or lines Faulty fuel injection pump e Faulty injector Static timing in ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FORE WORD of this manual Fuel filter in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Fuel injection pump in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANU AL listed in FOREWORD of th
49. d data range Therefore judgment as abnormal should not be made by checking with these data alone Also conditions in the below table that can be checked by the scan tool are those detected by ECM and output from ECM as commands and there may be cases where the engine or actuator is not operating in the condition as indicated by the scan tool NOTE e When checking the data with the engine running at idle or racing be sure to shift M T gear to the neutral gear position and pull the parking brake fully Also if nothing or no load is indicated turn OFF A C all electric loads P S and all the other necessary switches SCAN TOOL DATA CONDITION REFERENCE VALUES At specified idle speed with no load after CALCULATED ENGINE LOAD VALUE At 2000 r min with no load after warming 6 7 up 7 mg str COOLANT TEMP SENSOR VOLTAGE 0 1V ENGINE COOLANT TEMPERATURE At specified idle speed after warming up 80 100 C SENSOR 176 212 F ENGINE SPEED At idling with no load after warming up ley ir ata At specified idle speed with no load after INJECTION TIMING A ii r min with no load after warming 6 7 deg THROTTLE POS SENSOR VOLTAGE Throttle valve fully closed 0 6 1 0 V THROTTLE POSITION SENSOR Throttle valve fully open 2 4 2 8 V BATTERY VOLTAGE Ignition switch ON engine stop 12 15V n Display the barometric BAROMETRIC PRESSURE VOLTAGE Ignition switch ON pressure voltage At specified idle speed with no load after 6
50. d to ground G R circuit shorted to power supply Adjust injection pump static timing Refer to FUEL INJEC TION PUMP in Section 6E3 Faulty ECM 6 48 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC No 17 ECM POWER SUPPLY CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION T A To immobilizer ae B To EGR No 1 and No 2 solenoid valve C To injection actuator Ignition switch IG METER fuse Double relay ECM Fusible link Main fuse Generator Battery DTC DETECTING CONDITION POSSIBLE CAUSE e ECM power supply circuit is 6 V or lower e Poor charge battery e ECM power supply circuit is 16 V or higher e Fuse blown e G Y and G W circuit open or shorted to ground e B W and P circuit open or shorted to ground e Double relay ground open or shorted to power supply e Generator malfunction e Double relay malfunction ODNOARON DTC CONFIRMATION PROCEDURE 1 Clear DTC 2 Start engine and run it at 3000 r min 3 Select DTC mode on scan tool and check DTC INSPECTION STEP ACTION 1 Was ENGINE DIAGNOSIS FLOW TABLE per Go to Step 2 Go to ENGINE DIAG formed NOSIS FLOW TABLE 2 Check battery voltage Go to Step 3 Battery poor charge or Is it over 12 V malfunction 3 Check ECM power circuit Go to Step 4 ECM power circuit mal Go to TABLE A 2 ECM POWER AND GROUND function CIRCUIT CHECK Is check results OK 4 Check generator volta
51. daa adele ER AREA NEARNE OA 1 WARNING CAUTION AND INFORMATION LABELS 0 00 cece eect eetee nee ees 0A 2 FASTENER INFORMATION ooo aaaeeeaa 0A 3 Metric Fasteners 2 vicadsicie crew vientibenveidw bide wiieeeandeee deeead dived oe ei de ede ee deed 0A 3 IDENTIFICATION INFORMATION ENGINE IDENTIFICATION NUMBER a The number is punched on cylinder block 0A 2 GENERAL INFORMATION WARNING CAUTION AND INFORMATION LABELS The figure below shows main labels among others that are attached to vehicle component parts When servicing and handling parts refer to WARNING CAUTION instructions printed on labels If any WARNING CAUTION label is found stained or damaged clean or replace it as necessary NOTE Air bag CAUTION WARNING labels are attached on the vehicle equipped with air bag system only N VEU 1 Air bag caution label 8 Engine cooling fan warning label 2 Smoke level label 9 Air bag warning label on driver air bag inflator module 3 Tire information placard 10 Air bag warning label on combination switch and contact coil assembly 4 Child lock caution label 11 Air bag caution label on steering column 5 Seat belt pretensioner warning label if equipped 12 Air bag warning label on passenger air bag inflator module 6 Fuel limitation label 13 Air bag warning label on SDM 7 Coolant degassing tank cap radiator cap warning label 14 Child seat warning label if equipped
52. e engine oil consumption Low oil pressure Possible Cause Oil entering combustion chamber e Sticky piston ring Worn piston and cylinder Worn piston ring groove and ring Improper location of piston ring gap Worn or damaged valve stem seal Worn valve stem Improper oil viscosity Malfunctioning oil pressure switch Clogged oil strainer Functional deterioration of oil pump Worn oil pump relief valve Excessive clearance in various slid ing parts Reference ltem Valves and cylinder head in OVERHAUL CHECKING TUNING MANUAL listed below in FOREWORD of this manual Valves and cylinder head in OVERHAUL CHECKING TUNING MANUAL listed below in FOREWORD of this manual Valves and cylinder head in OVERHAUL CHECKING TUNING MANUAL listed below in FOREWORD of this manual Valves and cylinder head in OVERHAUL CHECKING TUNING MANUAL listed below in FOREWORD of this manual Valves and cylinder head in OVERHAUL CHECKING TUNING MANUAL listed below in FOREWORD of this manual Valves and cylinder head in OVERHAUL CHECKING TUNING MANUAL listed below in FOREWORD of this manual ITEM 1 3 Engine oil and oil filter change in Section 0B Oil pressure switch in Section 8 Oil pan and oil pump strainer in OVERHAUL CHECKING TUNING MANUAL listed below in FOREWORD of this manual Oil pump in OVERHAUL CHECKING TUN ING MANUAL listed below in FOREWORD of this manual Oil pump in
53. e with special tool A and remove clutch plate bolt Special Tool A 09991 06020 NOTE Do not reuse clutch plate bolt 3 Using special tool B remove clutch plate Special Tool B 09991 06030 4 Disconnect clutch coil lead wire from thermal switch 5 Remove diode component from compressor body by loosening attaching bolt 6 Remove shims from shaft 7 Using special tool C remove circlip Special Tool C 09900 06107 1 Puller 2 Compressor 1 Circlip 2 Clutch coil 3 Compressor 1 Circlip 2 Clutch coil 3 Compressor 1 Clutch pulley AIR CONDITIONING OPTIONAL 1B 13 8 Remove clutch pulley with puller NOTE Be careful not to damage pulley when tapping clutch pulley 9 Remove circlip by using special tool C 10 Remove clutch coil from compressor Special Tool C 09900 06107 INSTALLATION 1 Install clutch coil Protrusion on under side of clutch coil must match hole in com pressor to prevent movement and correctly locate lead wire 2 Using special tool C install circlip to compressor as shown Special Tool C 09900 06107 3 Clamp covering portion of read wire 4 Install clutch pulley a Set clutch pulley squarely over clutch pulley installation boss b Place special tool D onto clutch bearing Ensure that edge rests only on inner race of bearing Special Tool D 09991 06010 CAUTION Be careful not to scra
54. ect DTC mode on scan tool and check DTC 6 50 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION ACTION NO 1 Was ENGINE DIAGNOSIS FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG NOSIS FLOW TABLE Check glow plug relay and connector for proper installa Go to Step 3 Correct tion Is glow plug relay installed properly and connector con nected securely Check glow plug relay operation as follows Go to Step 4 Glow plug relay mal 1 Disconnect negative cable terminal at battery function 2 Disconnect coupler and terminals from glow plug relay and remove it 3 Check glow plug relay Refer to GLOW PLUG RELAY in Section 6E3 Is check results as specified Check glow plug relay power supply circuit as follows Go to Step 5 C57 1 and C57 2 cir 1 Insulate C57 1 and C57 2 terminals in glow plug har cuits open or shorted to ness ground 2 Connect negative cable to battery terminal 3 Turn ignition switch ON 4 Measure voltage between C57 1 terminal in glow plug harness terminal and ground C57 2 terminal in glow plug harness terminal and ground Is voltage at each terminal over 10 V Check glow plug relay circuit continuity as follows Go to Step 6 C58 1 circuit open 1 Turn ignition switch OFF 2 Check continuity between C58 1 terminal in glow plug relay coupler and body ground Is it continuity Check glow plug relay circuit insulation as follows Go to Step 7 C57 2 circuit open or 1 Disconn
55. ect coupler from ECM glow plug malfunction 2 Check continuity between C57 2 terminal in glow plug harness and body ground Is it continuity Check terminal E92 29 circuit voltage as follows Go to Step 8 E92 29 circuit open or 1 Connect coupler and terminal to glow plug relay shorted to ground 2 Disconnect coupler from ECM 3 Turn ignition switch ON 4 Measure voltage between E92 29 terminal in ECM coupler and body ground Is voltage over 10 V Check terminal E92 29 circuit voltage as follows Go to Step 9 E92 29 circuit shorted 1 Disconnect coupler from glow plug relay to power supply 2 Measure voltage between E92 29 terminal in ECM coupler and body ground with ignition switch ON Is it 0 V Check terminal E92 6 circuit voltage as follows Go to Step 10 E92 6 circuit open or 1 Connect shorting harness between E92 29 terminal in shorted to ground ECM coupler and body ground 2 Measure voltage between E92 6 terminal in ECM coupler and body ground with ignition switch ON Is it over 6 V 1 Disconnect shorting harness in Step 7 Substitute a E92 6 circuit shorted to 2 Measure voltage E92 6 terminal in ECM coupler and known good ECM power supply body ground with ignition switch ON and recheck Is it over 0 V ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 51 DTC NO 33 EGR NO 1 CONTROL VALVE CIRCUIT MALFUNCTION DTC NO 36 EGR NO 2 CONTROL VALVE CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION 7 2 B BI oe B W j p E92 1
56. en it is lower than specified values possible cause is ei ther failure of P S pump or settling of relief valve spring CAUTION Be sure not to close gauge valve for longer than 10 seconds e Next open gauge valve fully and increase engine speed to about 1 500 r min rpm Then turn steering wheel to the left or right fully and take reading of relief pressure Relief pressure 8 200 8 900 kPa 82 89 kg cm 1167 1265 psi e When it is higher than specified values possible cause is malfunction of relief valve e When itis lower than specified values possible cause is fail ure in steering gear box Replace gear box CAUTION Be sure not to hold steering wheel at fully turned position for longer than 10 seconds POWER STEERING P S SYSTEM 3B1 7 REMOVAL AND INSTALLATION POWER STEERING GEAR BOX REMOVAL 1 Perform steps 1 to 6 written in REMOVAL POWER STEER ING GEAR BOX SECTION 3B1 in service manual mentioned in FOREWORD of this manual 2 Remove engine mounting member and then remove engine rear mounting bracket together with its mounting from engine 3 Perform steps 9 to 11 written in REMOVAL POWER STEER ING GEAR BOX SECTION 3B1 in service manual mentioned in FOREWORD of this manual 1 Engine rear mounting 3 Mounting member 2 Mounting bracket 4 Suspension frame INSTALLATION Reverse removal procedure for installation of steering gear box noting the follo
57. ge as follows Substitute a known Generator malfunction 1 Run engine at 3000 rpm good ECM and recheck 2 Measure battery voltage Is it 12 to 16 V ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 49 DTC No 22 GLOW PLUG RELAY CONTROL MALFUNCTION FEEDBACK LOW VOLTAGE DTC No 23 GLOW PLUG RELAY CONTROL CIRCUIT MALFUNCTION DTC No 32 GLOW PLUG RELAY CONTROL MALFUNCTION FEEDBACK HIGH VOLTAGE CIRCUIT DESCRIPTION SAE Ignition switch IG METER fuse Glow plug control relay ECM Glow plug Main fuse Generator Battery ANOaARWN ITEM DTC DETECTING CONDITION POSSIBLE CAUSE Glow plug relay control malfunction e Bl circuit short to ground Glow plug relay feedback voltage is low when e Glow plug relay malfunction E92 29 terminal on ECM output voltage is low e Glow plug relay C57 1 C58 3 terminal circuit open or short to ground e Glow plug relay C57 2 terminal circuit short to ground DTC No 23 Glow plug relay control circuit open or short e B R circuit open or short to ground Glow plug relay control malfunction e BI circuit short to power supply Glow plug relay feedback voltage is high when e Glow plug relay malfunction E92 29 terminal on ECM output voltage is high Glow plug relay C57 2 terminal circuit short to power supply DTC No 22 DTC No 32 DTC CONFIRMATION PROCEDURE 1 Clear DTC start engine and keep it at idle for 1 min 2 Sel
58. gher than specification move bolt A rearward and if it is lower forward e Repeat steps 3 and 4 until rear brake pressure is within specification e After adjustment be sure to torque nut to specification g Upon completion of fluid pressure test bleed brake system and perform brake test 5 4 BRAKES TIGHTENING TORQUE SPECIFICATIONS TIGHTENING TORQUE FASTENING PARTS bi Front caliper 15 Brake bleeder plu pan Rear wheel cylinder and caliper 6 0 LSPV bolt LSPV bracket bolt LSPV adjusting nut 17 0 SPECIAL TOOLS ye A 09950 78210 09952 36310 09952 36320 Flare nut wrench 09956 02310 Fluid pressure gauge Fluid pressure gauge 10 mm Fluid pressure gauge attachment 7 mm attachment ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 1 SECTION 6 ENGINE GENERAL INFORMATION AND DIAGNOSIS WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to System Components and Wiring Location View under Gen eral Description in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Precau tions in air bag system section before performing service on or around the air bag system compo nents or wiring Failure to follo
59. ing bracket 2 Spacer 3 Washer COMPRESSOR MOUNT INSPECTION 1 Remove compressor Refer to COMPRESSOR in this section 2 Check mounting bolts and nuts for looseness 3 Check mounting bracket for crack and deformation If there is defect for its bracket replace compressor mounting bracket REMOVAL 1 Remove compressor Refer to COMPRESSOR in this section 2 Loosen mounting bolts and nuts and then remove compressor mounting bracket and its spacer INSTALLATION Reverse removal procedure noting the following point e Tighten compressor mounting bracket bolts and nuts as below order Compressor mounting bracket bolts and nuts tightening order a b gt c d e Tighten mounting bolts and nuts as specified torque Tightening Torque a b c and d 50 N m 5 0 kg m 36 0 Ib ft e When flange bolt e f is attached be careful to kinds of flange bolt Flange bolt e Wide angle flange bolt Flange bolt f Narrow angle flange bolt DRIVE BELT Refer to ACCESSORY DRIVE BELT in Section 6H for detail AIR CONDITIONING OPTIONAL 1B 11 MAGNET CLUTCH Clutch plate bolt Clutch plate Circlip Clutch pulley Washer Shims Diode component Clutch coil Lip type seal 10 Compressor front head 11 Compressor body assembly 12 O ring 13 Compressor thermal switch 14 Magnet clutch assembly DNDAPONM INSPECTION Clutch plate and pu
60. injection pump static timing Static timing in ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FORE WORD of this manual e Clogged fuel filter or lines Fuel filter in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual e Faulty fuel injection pump Fuel injection pump in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANU AL listed in FOREWORD of this manual e Faulty injector Fuel injector in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Engine overheating Refer to Overheating of this table Engine and emission control system out of order e Faulty CKP sensing rotor CKP sensing rotor in Section 6E3 e Faulty CKP sensor injector needle CKP sensor injector needle sensor ECT sensor ECT sensor and TP sensor sensor and TP sensor in section 6E3 Faulty fuel injection timing control ac Fuel injection timing control actuator in tuator Section 6E3 Faulty ECM Inspection of ECM and its circuit Malfunctioning EGR valve EGR system inspection in section 6E3 Maladjusted accelerator cable play Adjustment injection pump in ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Low compression Previously outlined ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 19 Possible Cause Reference Item Engine hesitates Momentary lack of res ponse as the accelerator is depressed Can occur at all vehicle speeds Usually
61. is manual Fuel injector in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Engine and Emission control system out of order e Air cleaner element clogged e Faulty ECT sensor and TP sensor e Faulty fuel injection timing control ac tuator e Faulty ECM e Malfunctioning EGR valve Low compression ITEM 3 1 Air cleaner element inspection in Section 0B ECT sensor and TP sensor in Section 6E3 Fuel injection timing control actuator in Section 6E3 Inspection of ECM and its circuit EGR system inspection in Section 6E3 Previously outlined Excessive nitrogen ox ides NOx emission Engine and emission control system out of order e Air cleaner element clogged Faulty ECT sensor and TP sensor Faulty fuel injection timing control ac tuator Faulty ECM Malfunctioning EGR valve ITEM 3 1 Air cleaner element inspection in Section 0B ECT sensor and TP sensor in Section 6E3 Fuel injection timing control actuator in Section 6E3 Inspection of ECM and its circuit EGR system inspection in Section 6E3 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 25 SCAN TOOL DATA As the data values given below are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool use them as reference values Even when the vehicle is in good condition there may be cases where the checked value does not fall within each specifie
62. it another 5 minutes before checking oil level Add oil as necessary to bring oil level to FULL level mark on dipstick Check oil filter and drain plug for oil leakage OB 8 MAINTENANCE AND LUBRICATION ITEM 1 4 Engine Coolant Change WARNING To help avoid danger of being burned do not remove de gassing tank cap while engine and radiator are still hot Scalding fluid and steam can be blown out under pres sure if cap is taken off too soon CAUTION When changing engine coolant use mixture of 50 wa ter and 50 ethylene glycol base coolant Anti freeze Anti corrosion coolant for the market where ambient temperature falls lower than 16 C 3 F in winter and mixture of 70 water and 30 ethylene glycol base coolant for the market where ambient temperature doesn t fall lower than 16 C 3 F Even ina market where no freezing temperature is antici pated mixture of 70 water and 30 ethylene glycol base coolant should be used for the purpose of corro sion protection and lubrication 1 Remove degassing tank cap when engine is cool 2 Loosen radiator drain plug to drain coolant 3 Tighten drain plug securely 1 Radiator 2 2 Radiator drain plug 4 Fill cooling system with specified coolant through degassing tank filler inlet until coolant level reaches FULL level mark Run engine until radiator upper hose is hot and then for 2 min utes at about 2 000 r min while rep
63. it occurred as described by the customer For this purpose use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis DIAGNOSTIC TROUBLE CODE DTC CHECK RECORD AND CLEARANCE First check DTC referring to DTC check section If DTC is indicated print it or write them down and then clear them by referring to DTC clearance section DTC indicates malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored now To check which case applies check the symptom in question according to Step 4 and recheck DTC ac cording to Step 5 Attempt to diagnose a trouble based on DTC in this step only or failure to clear the DTC in this step will lead to incorrect diagnosis trouble diagnosis of a normal circuit or difficulty in troubleshooting 3 and 4 VISUAL INSPECTION As apreliminary step be sure to perform visual check of the items that support proper function of the engine referring to Visual Inspection section TROUBLE SYMPTOM CONFIRMATION Based on information obtained in Step 1 Customer complaint analysis and Step 2 DTC check confirm trouble symptoms Also reconfirm DTC according to DTC Confirmation Procedure described in each DTC Diagno sis section 6 and 7 RECHECKING AND RECORD OF DTC 10 11 Refer to DTC check section for checking procedure
64. item 1 3 Ethylene glycol base coolant E l Antifreeze Anticorrosion coolant Brake fluid DOT 3 See oil chart on Section 7A AIR CONDITIONING OPTIONAL 1B 1 SECTION 1B AIR CONDITIONING OPTIONAL WARNING For vehicles equipped with Supplement Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are per forming service on or near the air bag system components or wiring Please observe all WARN INGS and Service Precautions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM CAUTION The air conditioning system of this vehicle uses refrigerant HFC 134a R 134a NOTE e For the descriptions items not found in thi
65. l air being inhaled from air intake system Exhaust system leakage of exhaust gas noise Other parts that can be checked visually ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 15 ENGINE BASIC INSPECTION This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found in visual inspection Follow the flow table carefully Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE Check battery voltage Go to Step 3 Charge or replace Is it 11 V or more battery Is engine cranked Go to Step 4 Go to DIAGNOSIS in Section 6G Does engine start Go to Step 5 Go to Step 7 Check idle speed as follows Go to Step 6 Go to IDLE SPEED 1 Warm up engine to normal operating temp INSPECTION AND 2 Shift transmission to neutral position ADJUSTMENT in 3 All of electrical loads are switched off Section 6E3 4 Check engine idle speed with scan tool See Fig 1 Is it 845 895 r min Check ignition pump static timing referring to FUEL IN Go to DIAGNOSIS Adjust injection pump JECTION PUMP STATIC TIMING ADJUSTMENT AND IN TERMS OF static timing referring CHECKING in Section 6E3 SYMPTOM to Section 6E3 Is injection pump static timing correct Check immobilizer DTC with scan tool referring to Section Goto DIAGNOSIS Go to Step 8 8G in Section 8G Is it indicated the trouble code Perform air evacuation in the f
66. lacement becomes necessary Do not use a replace ment part of lesser quality or substitute design Torque values must be used as specified during reas sembly to assure proper retention of these parts CONTENTS GENERAL DESCRIPTION 0 0 eect eee e nents 3B1 2 Power Steering P S PUMP 00 0 tn eee eet a nee 3B1 3 ON VEHICLE SERVICE coii ciii deci tee ceeded AY s aaa a aaee arda aa a dita E a i 3B1 4 Mo oeU aa a a ke ae gle ce cage a oe cee Re a e e e 3B1 4 Removal and installation power steering gear DOX 16 ett eens 3B1 7 Removal and installation power steering PUMP 6 0c ett 3B1 8 TIGHTENING TORQUE SPECIFICATIONS 00 cece nent eee eens 3B1 9 REQUIRED SERVICE MATERIAL 00 ccc cect aaraa 3B1 9 SSPE GIA TOOLS ah caer eens hp ag te Beare a aga te asec cg tapes ns epee tet E ena A a Ea de 3B1 9 3B1 2 POWER STEERING P S SYSTEM GENERAL DESCRIPTION The power steering P S system in this vehicle reduces the driver s effort needed in turning the steering wheel by utilizing the hydraulic pressure generated by the power steering P S pump which is driven by the engine The steering gear box consists of the rack and pinion gears and the control valve unit hydraulic pressure cylinder unit 1 Power steering gear box 2 Power steering pump 3 P S fluid reservoir Pump Valve section Fluid reservoir l 4 Rack 6 Pinion Cylinder Dny
67. lenishing coolant This drives out any air which may still be trapped within cooling sys tem Add coolant as necessary until coolant level reaches FULL level 1 Degassing tank mark Reinstall degassing tank cap 2 FULL level mark 3 4 egassingitantcap Refer to Section 6B of this manual for Coolant Capacity 3 LOW level mark Radiator cap 1 Heater Glow plug MAINTENANCE AND LUBRICATION 0B 9 ITEM 1 5 Exhaust System Inspection WARNING To avoid danger of being burned do not touch exhaust system when it is still hot Any service on exhaust system should be performed when it is cool Check exhaust system as follows Check rubber mountings for damage and deterioration Check exhaust system for leakage loose connections dents and damages If bolts or nuts are loose tighten them to specification Refer to SECTION 6K for torque specification of bolts and nuts Check nearby body areas for damaged missing or misposi tioned parts open seams holes loose connections or other de fects which could permit exhaust fumes to seep into vehicle Make sure that exhaust system components have enough clear ance from underbody to avoid overheating and possible dam age to floor carpet Any defects should be fixed at once ITEM 1 6 Heater Glow Plugs Inspection Check for external damage such as deformation scratch crack etc 0B 10 MAINTENANCE AND LUBRICATI
68. les If multiple diagnostic trouble codes DTCs are stored Troubleshoot diagnostic trouble codes according to the follow ing priorities 1 DTC No 16 No 32 No 34 and DTC No 127 2 Diagnostic trouble codes DTCs other than DTC No 16 No 32 No 34 and DTC No 127 Be sure to read Precautions for Electrical Circuit Service in Section 0A before inspection and observe what is written there ECM Replacement When substituting a known good ECM check for following conditions Neglecting this check may cause damage to a known good ECM Resistance value of all relays actuators is as specified re spectively ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 9 ENGINE DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step STEP ACTION Customer Complaint Analysis Go to Step 2 Perform customer 1 Perform customer complaint analysis referring to the complaint analysis next page Was customer complaint analysis performed Diagnostic Trouble Code DTC Check Record and 1 Print DTC or write Goto Step 4 Clearance them down and 1 Check for DTC referring to the next page clear them by re Is there any DTC s ferring to DTC Clearance sec tion Go to Step 3 Visual Inspection Repair or replace Go to Step 5 1 Perform visual inspection referring to the next page malfunction part Is there any faulty condition 2 Go to Step 11 Visual Inspection Go to Step 8 1 Perform visual inspec
69. lley 1 Check clutch plate and clutch pulley for wear and oil soaked conditions respectively 2 Check clutch pulley bearing for noise wear and grease leak age If there is any defect for clutch plate and clutch pulley replace magnet clutch component 2 Thermal switch 1 Disconnect thermal switch lead wire from clutch coil lead wire 2 Use an ohmmeter to check thermal switch for continuity If it is no continuity replace thermal switch 1 Thermal switch lead wire 2 Ohmmeter 3 Thermal switch Clutch coil 1 Connect battery and ammeter to compressor as shown 2 Check that steadily locks between clutch plate and clutch pulley 3 Check that ammeter indicates specified current If check result is without specified current replace magnet clutch assembly 1 Battery 2 Ammeter 3 Compressor Specified current of magnet clutch 4 A MAX at 12 V 1B 12 AIR CONDITIONING OPTIONAL 1 Ohmmeter 2 Diode component 1 Clutch plate 2 Clutch plate bolt 3 Washer 1 Clutch plate 1 Diode component 2 Compressor body 3 Attaching bolt Diode component Check both directions by reversing probes of ohmmeter and there should be only one way continuity for diode component If check result is not satisfactory replace magnet clutch compo nent REMOVAL 1 Remove compressor Refer to COMPRESSOR in this section 2 Fix clutch plat
70. m cooling unit or air duct Blower motor faulty Wiring or grounding faulty Check condenser Check charge of refrigerant Replace receiver dryer and evacua tion and charging Check or replace drive belt Check compressor Check charge refrigerant Check evaporator and A C evaporator thermistor Check evaporator Repair as necessary Check blower motor Repair as necessary 1B 6 AIR CONDITIONING OPTIONAL ON VEHICLE SERVICE REFRIGERATING SYSTEM CONDENSER REMOVAL 1 Disconnect negative cable at battery 2 Recover refrigerant by using recovery and recycling equip ment Be sure to follow the instruction manual for the equip ment The amount of compressor oil removed must be measured and the same amount added to the system 3 Remove front bumper referring to FRONT BUMPER in Sec tion 9 of the Service Manual as mentioned in FOREWORD of this manual 4 Disconnect compressor discharge hose from condenser inlet fittings NOTE As soon as above hose and pipe are disconnected cap opened fittings so that moisture and dust do not enter into condenser 5 Remove horn 6 Remove hood latch and hood lock member 1 Horn 2 Hood lock member 7 Disconnect coupler from dual pressure switch 8 Remove receiver outlet pipe 1 Receiver outlet pipe 2 Joint AIR CONDITIONING OPTIONAL 1B 7 9 Remove condenser with receiver dryer NOTE
71. most severe when first trying to make the vehicle move as from a stop sign Injection system out of order e Clogged fuel filter or lines e Faulty fuel injection pump e Faulty injector e Faulty fuel injection pump static timing Static timing in ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FORE WORD of this manual Fuel filter in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Fuel injection pump in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANU AL listed in FOREWORD of this manual Fuel injector in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Engine overheating Refer to Overheating of this table Engine and emission control system out of order Faulty CKP sensing rotor Faulty CKP sensor injector needle sensor ECT sensor and TP sensor Faulty fuel injection timing control ac tuator Faulty ECM Malfunctioning EGR valve Maladjusted accelerator cable play CKP sensing rotor in Section 6E3 CKP sensor injector needle sensor ECT sensor and TP sensor in section 6E3 Fuel injection timing control actuator in section 6E3 Inspection of ECM and its circuit EGR system inspection in section 6E3 Adjustment injection pump in ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Low compression Previously outlined Surges Engine power variation under steady throttle o
72. nd in this manual refer to the related manuals mentioned below The contents are classified into sections each of which is given a section number as indicated in the Table of Con tents on the next page And on the first page of each individual section is an index of that section This manual should be kept in a handy place for ready reference of the service work Strict observance of the so specified items will enable one to obtain the full performance of the vehicle When replacing parts or servicing by diassembling it is recommnded to use SUZUKI genuine parts tools and ser vice materials lubricant sealants etc as specified in each description Allinformation illustrations and specifications contained in this literature are based on the latest product informa tion available at the time of publication approval And used as the main subject of description is the vehicle of stan dard specifications among others Therefore note that illustrations may differ from the vehicle being actually serviced The right is reserved to make changes at any time without notice RELATED MANUALS SY413 SY416 SY418 Service Manual 99500 60G20 01E SY413 SY416 SY418 SY419 Wiring Diagram Manual 99512 60G60 015 All Models Deisel Diagnosis Manual 99501 66G10 01E 967 GB 04 97 Overhaul Checking Tuning Manual 99501 66G21 01E 9608GB 15 06 2000 SUZUKI MOTOR CORPORATION OVERSEAS SERVICE DEPARTMENT COPYRIGHT SUZUKI MOTOR CORPORATION 2000
73. nfirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precautions under ON VEHICLE SERVICE in air bag system section before per forming service on or around the air bag system components or wiring Failure to follow WARN INGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE e For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in FOREWORD of this manual e Some parts in the Power Steering Gear Box cannot be disassembled or adjusted For detailed informa tion refer to the description of POWER STEERING GEAR BOX COMPONENTS under REMOVE AND INSTALL POWER STEERING GEAR BOX in same section of the service manual mentioned in FORE WORD of this manual e Allsteering gear fasteners are important attaching parts in that they could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of the same part number or with an equivalent part if rep
74. ntinuity Are both check results satisfactory Check CKP sensor damage as follows Go to Step 7 1 Remove CKP sensor 2 Check sensor for damage or foreign material at tached Is it in good condition Check CKP sensor voltage waveform as follows Substitute a known 1 Install CKP sensor good ECM and recheck 2 Check for voltage waveform as shown in refer ence of previous page Is specified voltage and waveform obtained Check sensor rotor with flywheel for the following Replace CKP sensor e Rotor teeth neither missing nor damaged See Fig 2 e No foreign material being attached e Rotor being eccentric Are they in good condition NO Go to ENGINE DIAG NOSIS FLOW TABLE Correct Replace CKP sensor CKP sensor circuit shorted to power Circuit open or shorted to ground Clean repair or re place Go to Step 8 Clean repair or replace sensor rotor 6 38 ENGINE GENERAL INFORMATION AND DIAGNOSIS Fig 1 for Step 4 Fig 2 for Step 8 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 39 DTC No 3 ENGINE COOLANT TEMPERATURE ECT CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION Br W 1 ECT sensor 2 ECM 18 17 16 lis 14 43 12 11 10 8 7 6 l1 211 35 34 33 32 30 29 27 25 24 23 24 19 DTC DETECTING CONDITION POSSIBLE CAUSE e Low engine coolant temperature High voltage High resistance Br circuit open or shorted to power e
75. ol actuator e Faulty ECM e Faulty glow plug control relay Low compression e Improper valve lash e Improper valve timing Compression leak from valve seat Sticky valve stem Weak or damaged valve spring Compression leak at cylinder head gasket Sticking or damaged ring Worn piston ring or cylinder CKP sensing rotor in Section 6E3 CKP sensor injector needle sensor ECT sensor and TP sensor in Section 6E3 Fuel injection timing control actuator in sec tion 6E3 Inspection of ECM and its circuit Glow plug control relay in Section 6E3 Compression check in section 6A4 Valve clearance in section 6A4 Valve timing in OVERHAUL CHECKING TUNING MANUAL listed below in FORE WORD of this manual Valve seats in OVERHAUL CHECKING TUNING MANUAL listed below in FORE WORD of this manual Valves in OVERHAUL CHECKING TUN ING MANUAL listed below in FOREWORD of this manual Valve spring in OVERHAUL CHECKING TUNING MANUAL listed below in FORE WORD of this manual Cylinder head in OVERHAUL CHECKING TUNING MANUAL listed in FOREWORD of this manual Piston and Connecting Rod in section 6A4 Piston and Connecting Rod in section 6A4 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 17 Condition Possible Cause Reference Item Engine has no power Engine overheating Injection system out of order e Faulty fuel injection pump static timing e Clogged fuel filter or lines Faulty fuel injection pum
76. old gauge set 2 High pressure side Discharge side hose 3 Low pressure side Suction side hose 1 Manifold gauge set 2 High pressure side Discharge side hose 3 Low pressure side Suction side hose 4 Recovery and recycling equipment INSTALLATION Reverse removal sequence to install receiver dryer noting the fol lowing points e When replacing receiver dryer add 10 cm3 10 cc of compres sor oil from compressor suction side e Blind plugs of receiver dryer should not be removed until just be fore receiver dryer is installed e Evacuate and charge system according to previously described procedure COMPRESSION SYSTEM COMPRESSOR INSPECTION 1 Install manifold gauge set referring to TROUBLESHOOTING PROCEDURE USING MANIFOLD GAUGE SET in the same section of the Service Manual mentioned in FOREWORD of this manual 2 Run engine at fast idle 3 Check compressor for the following e High pressure gauge reading is not low and low pressure gauge reading is not higher than normal referring to COR RECTIVE MEASURES FOR MALFUNCTION SYMPTOMS under DIAGNOSIS in the same section of the Service Manual as mentioned in FOREWORD of this manual e Metallic sound e Leakage from shaft seal If any of the above checks indicates a defect repair compres sor REMOVAL 1 Run engine at idle with air conditioning on for 10 minutes 2 Disconnect negative cable at battery 3 Recover
77. or relay A C evaporator thermistor Compressor Dual pressure switch Sub radiator fan motor Radiator fan switch B BI Y B 13 AIR CONDITIONING OPTIONAL 1B 3 FUNCTION OF EACH CONTROL COMPONENT ECM ECM output A C control signal to A C amplifier when ECM detect the following conditions e Engine coolant temperature above 113 C 235 F eere serenererers OFF below 111 C 232 F 242 2steceietas ON e Engine speed below 500 r min 002 0005 OFF above 500 r min 000 ON 1B 4 AIR CONDITIONING OPTIONAL GENERAL Trouble Cool air does not come out A C system improper op erative DIAGNOSIS Possible Cause A C system inoperative e No refrigerant e Fuse blown A C switch faulty Blower motor switch faulty A C thermistor faulty Dual pressure switch faulty Wiring or grounding faulty A C controller and its circuit faulty A C ON permission signal in ECM faulty Measure Recover evacuation and charging Check BACK DEF RD FAN SUB and A C fuses and check for short circuit Check A C switch Check blower motor switch Check A C thermistor Check dual pressure switch Repair as necessary Check A C controller and its circuit Check A C ON permission signal Compressor inoperative dose not ro tate e Fuse blown Compressor relay faulty Magnet clutch faulty Drive belt loose or broken Compressor faulty A C ON permission
78. p e Faulty injector Refer to Overheating of this table Static timing in ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FORE WORD of this manual Fuel filter in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Fuel injection pump in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANU AL listed in FOREWORD of this manual Fuel injector in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Engine and emission control system out of order e Faulty CKP sensing rotor e Faulty CKP sensor injector needle sensor ECT sensor and TP sensor Faulty fuel injection timing control ac tuator Faulty ECM Malfunctioning EGR valve Maladjusted accelerator cable play Low compression Others e Dragging brakes e Slipping clutch CKP sensing rotor in Section 6E3 CKP sensor injector needle sensor ECT sensor and TP sensor in section 6E3 Fuel injection timing control actuator in sec tion 6E3 Inspection of ECM and its circuit EGR system inspection in section 6E3 Adjustment injection pump in ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Previously outlined Diagnosis in Section 5 Diagnosis in Section 7C 6 18 ENGINE GENERAL INFORMATION AND DIAGNOSIS Condition Possible Cause Reference Item Improper engine idling Injection system out of order or engine fails to idle Faulty fuel
79. r cruise PECIS IKE INE vene Clogged fuel filter or lines speeds up and down with no change in the acceler ator pedal Injection system out of order e Faulty fuel injection pump e Faulty injector e Faulty fuel injection pump static timing Static timing in ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FORE WORD of this manual Fuel filter in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Fuel injection pump in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Fuel injector in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Engine and emission control system out of order e Faulty ECM e Faulty fuel injection timing control ac tuator e Malfunctioning EGR valve Inspection of ECM and its circuit Fuel injection timing control actuator in section 6E3 EGR system inspection in section 6E3 6 20 ENGINE GENERAL INFORMATION AND DIAGNOSIS Possible Cause Reference Item Excessive detonation The engine makes sharp metallic knocks that change with throttle opening Sounds like pop corn popping Overheating Injection system out of order e Faulty fuel injection pump static timing e Clogged fuel filter or lines e Faulty fuel injection pump e Faulty injector Static timing in ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FORE WORD of this manual
80. refrigerant from refrigeration system using recovery and recycling equipment 4 Remove drive belt Refer to Section 6H CHARGING SYSTEM section in this manual for removal 5 Disconnect magnet clutch lead wire from engine wire harness 6 Disconnect suction and discharge flexible hoses from compres sor NOTE Cap open fittings immediately to keep moisture out of sys tem AIR CONDITIONING OPTIONAL 1B 9 7 Loosen compressor mounting bolt then remove compressor from its mounting bracket 1 1 Compressor mounting bolt 2 Magnet clutch assembly 8 Drain compressor oil from compressor and measure its amount NOTE When removing compressor be careful not to damage fins of condenser INSTALLATION Reverse removal procedure noting the following point e Tighten compressor mounting bolt as below order Compressor mounting bolt tightening order a b gt c e Tighten compressor mounting bolt as specified torque Tightening Torque a b and c 26 N m 2 6 kg m 19 0 Ib ft 1 Compressor mounting bolt 1 b 1 c e Pour new compressor oil with the same amount as that drained from compressor e Evacuate and charge system according to previously described procedure NOTE Compressor supplied from factory is filled up with speci fied amount of compressor oil Compressor oil amount 120 cm 120 cc 1B 10 AIR CONDITIONING OPTIONAL 1 Compressor mount
81. right side and rear left side in the same way Special Tool Front brake A 09956 02310 B 09952 36320 C 09360 10026 Union bolt as spare part D 09161 10009 Washer as spare part Rear brake A 09956 02310 E 09952 36310 F 55473 82030 Air bleeder plug as a spare part NOTE Special tool B or E is used instead of thread diameter 10 mm attachment of special tool A So remove the attachment from A and install B or E as shown in figure 1 LSPV lever A a 2 LSPV spring 3 LSPV stay BRAKES 5 3 3 Depress brake pedal gradually till fluid pressure of front brake becomes as specified below and check corresponding pres sure of rear brake then It should be within specification given below Front brake 3 900 4 300 kPa 39 43 kg cm 555 611 psi 5 000 kPa 50 kg cm 711 psi 4 800 5 200 kPa 48 52 kg cm 683 739 psi As done above apply 100 kg cm pressure to front brake and check that rear brake pressure then is within specification as given below Front brake 5 400 5 800 kPa 54 58 kg cm 768 825 psi 7 200 7 600 kPa 72 76 kg cm 1024 1081 psi If rear brake pressure is not within specification adjust it by changing bolt A tightening position as follows 10 000 kPa 100 kg cm 1 422 psi Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft e f rear brake pressure is hi
82. rming service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Ei ther of these two conditions may result in serve injury e If the air bag system and another vehicle system both need repair SUZUKI recom mends that the air bag system be repaired first to help avoid unintentional air bag system activation e Do not modify the steering wheel instru ment panel or any other air bag system component on or around air bag system components or wiring Modifications can adversely affect air bag system perfor mance and lead to injury e If the vehicle will be exposed to tempera tures over 93 C 200 F for example dur ing a paint baking process remove the air bag system components air bag infla tor modules sensing and diagnostic module SDM seat belt pretensioner if equipped beforehand to avoid compo nent damage or unintended activation FOREWORD This manual contains procedures for diagnosis maintenance adjustments minor service operations replace ment of components service and for disassembly and assembly of major components Units Repair Overhaul Applicable model SY419 on and after the following VIN No SEDAN JSAEGC51S00300001 WAGON x JSAEGC51W00300001 x Whenever servicing the above applicable model consult this manual And for any section item or descripton not fou
83. round the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the sys tem may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE e For the descriptions items not found in this section refer to the same section of Service Manual Sa mentioned in FOREWORD of this manual e All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary Do not use a replace ment part of lesser quality or substitute design Torque values must be used as specified during reas sembly to assure proper retention of all parts There is to be no welding as it may result in extensive damage and weakening of the metal CONTENTS ON VEHICLE SERVICE 00 0 eee e nee e eee n eee 5 2 Excessive Pedal Travel Check 0 000000 ccc ccc nee eee nee a a eee eee 5 2 FIuic Pressure lest larsen ee breedule a tae aay deeug Berta aun a apeea ieee eae ee ere apa ave ati ap aed
84. s Go to Step 7 Clean repair or re 1 Remove needle sensor with injector place 2 Check injector for damage pollution and clogs Refer to INJECTOR in Section 6A4 Is it in good condition Check voltage waveform for injector needle sensor Substitute a known Replace injector as follows good ECM and recheck 1 Install needle sensor with injector 2 Check for voltage waveform as shown in refer ence of previous page Is specified voltage and or waveform obtained 6 46 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC No 16 INJECTION TIMING ACTUATOR CONTROL MALFUNCTION DTC No 34 INJECTION TIMING ACTUATOR CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION Ignition switch IG METER fuse Double relay Injection timing actuator ECM Fusible link Generator T 2 3 4 5 6 7 A To EGR solenoid valve ITEM DTC DETECTING CONDITION POSSIBLE CAUSE Injection timing actuator improper operative e Injection pump static timing is displacement DTC No 16 e Injection pump malfunction e ECM malfunction Injection timing actuator circuit is opened or e G circuit open or short DTC No 34 shorted e G R circuit open or short e Injection timing actuator malfunction DTC CONFIRMATION PROCEDURE 1 Clear DTC with ignition switch ON 2 Select DTC mode on scan tool and check DTC INSPECTION ACTION Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 5 Was ENGINE DIAGNOSIS FLOW TAB
85. s age line MIL circuit is open MIL circuit malfunction MIL circuit is short to ground or battery voltage No lights line A C cut off control circuit malfunc Lamp circuit is open Lamp circuit is short to ground or battery volt No lights age line Internal control module memory Data write error or check sum error when writ Lights check sum error ten into ECM 3 Glow plug indicator lamp malfunc tion DTC NO 3 a function age line E Ea Ea Ea p pe 6 14 ENGINE GENERAL INFORMATION AND DIAGNOSIS VISUAL INSPECTION Visually check following parts and systems INSPECTION ITEM REFERRING SECTION Engine oil level leakage Section 0B Engine coolant level leakage Section 0B level leakage Section 0B Air cleaner element dirt clogging Section 0B Battery fluid level corrosion of terminal Water pump belt tension damage Section 0B Throttle cable play installation Section 6E Vacuum hoses disconnection looseness deterioration bend Connectors of electric wire harness disconnection friction burning Section 8 installation bolt looseness deformation Other parts that can be checked visually Also check following items at engine start if possible Malfunction indicator lamp Section 6 Charge warning lamp Section 6H Engine oil pressure warning lamp Operation Section 8 section 6A4 for pressure check Engine coolant temp meter Section 8 Fuel level meter Section 8 Tachometer Abnorma
86. s section refer to the same section of the Service Manual mentioned in the FOREWORD of this manual e For basic servicing method of the air conditioning system that is not described in this section refer to AIR CONDITIONING BASIC MANUAL Part number 99520 02130 CONTENTS GENERAL DESCRIPTION 1B 2 Compression System 1B 8 Wiring Circuit caisgeas diia i eee eee 1B 2 Compressor 0 0c cece eee eee 1B 8 Function of Each Control Component 1B 3 Compressor Mount 45 1B 10 DIAGNOSIS 20 200 o eee eee eee 1B 4 PING IDEN anesse Anota inca eek hence ss 16710 Magnet CIUtCh cu irada roe iona iat akiita ao 1B 11 ON VEHICLE SERVICE 1B 6 Lip Type Seal o u ioio 1B 14 Refrigerating System 005 1B 6 Condenser 2iscdacceia fica eir eae 1B 6 REQUIRED SERVICE MATERIALS 1B 16 Receiver Dryer 00 2 eee 1B 7 SPECIAL TOOLS 02005 1B 16 1B 2 AIR CONDITIONING OPTIONAL WIRING CIRCUIT GENERAL DESCRIPTION 4 2 3 4 5 6 Fi 8 9 0 Main fuse box Fuse and relay box Cassette fuse Junction box J B Ignition switch Generator Blower fan motor relay Blower fan motor Blower fan motor resistor Blower fan switch Ti 12 13 14 16 17 18 19 20 Mode controller A C amplifier ECM Sub radiator fan motor relay Compress
87. scope Waveforms 35 ms 860 rpm 14 ms 2150 rpm 10V DIV afar 5V DIV Ee E T R 5ms DIV 2ms DIV Waveform at idle speed Waveform at 2150 rpm DTC CONFIRMATION PROCEDURE 1 Clear DTC and crank engine for 2 sec 2 Select DTC mode on scan tool and check DTC ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 37 INSPECTION ACTION Was ENGINE DIAGNOSIS FLOW TABLE per Go to Step 2 formed Check CKP sensor and connector for proper instal Go to Step 3 Go to Step 4 lation Go to Step 5 Is CKP sensor installed properly and connector connected securely Check CKP sensor resistance as follows 1 Disconnect CKP sensor connector with ignition switch OFF 2 Measure resistance between sensor terminals Refer to CKP SENSOR in Section 6E3 Is measured resistance value as specified Check ECM terminals voltage as follows 1 Turn ignition switch OFF 2 Disconnect ECM connector 3 Check for proper connection to ECM at each sen sor terminals 4 If check is OK then turn ignition switch ON and measure voltage between sensor terminal E92 8 E92 25 of ECM and body ground See Fig 1 Is it 0 V Check continuity of CKP sensor circuit as follows Go to Step 6 1 Turn ignition switch OFF 2 Connect CKP sensor coupler 3 Measure resistance between the following points e Both ECM connector terminals of the CKP sen sor circuit continuity e Either terminal of CKP sensor coupler and body ground no co
88. services at This interval should be judged by the same intervals respectively odometer reading or months km x 1 000 15 30 45 60 75 90 whichever comes first Miles x 1 000 9 18 27 36 45 54 Months 12 24 36 48 60 72 1 ENGINE 1 1 Accessory drive belt 1 2 Camshaft timing belt Replace every 120 000 km 72 000 miles 1 3 Engine oil and oil filter Replace every 10 000 km 6 000 miles or 8 months 1 4 Engine coolant am R s Brasse CPP Pt PK 1 6 Heater Glow plugs Leje te Dusty condition Refer to Severe Driving Condition schedule 3 2 Fuel lines 3 3 Fuel filter Replace at 1st 10 000 km 6 000 miles and then every 20 000 km 12 000 miles Drain water every 10 000 km 6 000 miles 34 Fueltank ee ear MAINTENANCE AND LUBRICATION 0B 3 This table includes services as scheduled up to 90 000 km 54 000 miles mileage Beyond 90 000 km 54 000 miles carry out the same services at Interval This interval should be judged by odometer reading or months x 1 000 the same intervals respectively whichever comes first x 1 000 5 BRAKE 5 1 Brake discs and pads thickness wear damage Brake drums and shoes wear damage 5 2 Brake hoses and pipes leakage damage clamp 5 3 Brake fluid 5 4 Brake lever and cable damage stroke operation 6 CHASSIS AND BODY 6 3 Propeller shafts 4WD and drive shafts 6 4
89. stem Air leaking from cooling unit or air duct Heater and ventilation system faulty Blower motor faulty Excessive compressor oil existing in A C system Check charge of refrigerant Check system for leaks Check condenser Check evaporator Check A C evaporator thermistor Check A C controller Check expansion valve Check or replace drive belt Check magnetic clutch Check compressor Replace receiver dryer and evacua tion and charging Repair as necessary Check air inlet box assembly blower unit Check heater control lever assembly Check heater assembly Check blower motor Pull out compressor oil in A C system and replenish compressor oil and re place compressor Cool air does not come out only intermittently Wiring connection faulty Expansion valve faulty Excessive moisture in A C system A C controller faulty Magnetic clutch faulty Excessive charge of refrigerant Repair as necessary Check expansion valve Replace receiver dryer and evacua tion and charging Check A C controller Check magnetic clutch Check charge of refrigerant Cool air comes out only at high speeds Cool air does not come out only at high speeds Insufficient velocity of cooled air Condenser clogged Insufficient charge of refrigerant Air in A C system Drive belt slipping Compressor faulty Excessive charge of refrigerant Evaporator frosted Evaporator clogged or frosted Air leaking fro
90. ta Definitions 6 26 ENGINE DIAGNOSIS 6 6 Inspection of ECM and Its Circuits 6 27 General Description 6 6 voltage Check sees eee 6 27 On Board Diagnostic System ETER 6 7 Resistance Check ere Te ene ee ee ee ee 6 30 Precaution in Diagnosing Trouble 6 8 Component Location 00 6 31 Engine Diagnostic Flow Table 6 9 Table A 1 Malfunction Indicator Lamp Circuit Customer Problem Inspection Form 6 11 Check Lamp Does Not Come ON at Malfunction Indicator Lamp Check 6 12 Ignition Switch ON 00000 6 32 Diagnostic Trouble Code Check 6 12 Table A 2 Malfunction Indicator Lamp Circuit Diagnostic Trouble Code Clearance 6 12 Check Lamp Remains ON at Ignition Diagnostic Trouble Code Table Sa shane es 6 13 Switch ON Ce 6 33 6 2 ENGINE GENERAL INFORMATION AND DIAGNOSIS Table A 3 ECM Power and Ground Circuit Check MIL Doesn t Start at Ignition Switch ON and Engine Doesn t Start Though It is DTC No 127 Internal Control Module Memory Check Sum Error 0 000 cece eaee 6 58 DIAGNOSIS IN TERMS OF SYMPTOM 6 59 Cranked Up Edla a i adi case oa i BS ATi cad eal cae de 6 34 The Engine Will Not Start with No Emission DTC No 1 Crankshaft Position CKP Sensor of Smoke Engine Warm and Cold ree 6 60 Circuit Maruneuan A a E E ae 6 36 The Engine Will Not Start with Emission
91. tch bearing seal 1B 14 AIR CONDITIONING OPTIONAL 1 Clutch plate 2 Clutch pulley 1 Clutch plate 2 Clutch plate bolt 3 Washer 1 Case 2 Front head 1 Front head 2 Cylinder shaft 3 Cylinder 4 Case 5 O ring 5 Install circlip by using special tool C Special Tool C 09900 06107 CAUTION Be careful not to scratch bearing seal 6 Adjust clearance between clutch plate and clutch pulley by putting shim s on compressor shaft Standard clearance a 0 3 0 5 mm 0 012 0 020 in 7 Tighten new clutch plate bolt as specified below Tightening Torque a 14 N m 1 4 kg m 10 5 Ib ft Special Tool A 09991 06020 LIP TYPE SEAL REMOVAL 1 Remove magnet clutch referring to MAGNET CLUTCH in this section 2 Remove front head mounting screws 8 pcs 3 Remove front head by pushing cylinder shaft NOTE Be careful not to remove cylinder from case 4 Remove O ring 1 Front head 2 Bearing puller 1 Lip type seal 2 Front head 1 Front head 2 O ring 1 Case 2 Front head AIR CONDITIONING OPTIONAL 1B 15 5 Remove lip type seal from front head INSTALLATION 1 Press fit lip type seal into front head using special tool E Special Tool E 09991 06050 CAUTION Do not reuse lip type seal once removed from com pressor
92. tion referring to the next page Is there any faulty condition Trouble Symptom Confirmation Go to Step 6 Go to Step 7 1 Confirm trouble symptom referring to the next page Is trouble symptom identified Rechecking and Record of DTC Go to Step 9 Go to Step 8 1 Recheck for DTC referring to DTC Check section Is there any DTC s Rechecking and Record of DTC Go to Step 10 1 Recheck for DTC referring to DTC Check section Is there any DTC s Engine Basic Inspection Diagnosis in Terms of Symp Go to Step 11 1 Check and repair tom and Engine Diagnosis Table malfunction part s 1 Check and repair according to Engine Basic Check 2 Go to Step 11 Diagnosis in Terms of Symptom and Engine Diag nosis Table section Are check and repair complete Trouble shooting for DTC 1 Check and repair according to applicable DTC diag flow table Are check and repair complete Check for Intermittent Problems 1 Repair or replace Go to Step 11 1 Check for intermittent problems referring to the next malfunction part s page 2 Go to Step 11 Is there any faulty condition Final Confirmation Test Go to Step 6 End 1 Clear DTC if any 2 Perform final confirmation test referring to the next page Is there any problem symptom DTC or abnormal condition 10 6 10 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1 CUSTOMER COMPLAINT ANALYSIS Record details of the problem failure complaint and how
93. uel circuit as follows Go to ENGINE Go to DIAGNOSIS 1 Pump the priming pump on fuel filter over 30 times DIAGNOSTIC IN TERMS OF 2 Carry out cranking the engine over 3 times for 5 se FLOW TABLE SYMPTOM conds Does engine start Fig 1 for Step 5 Select DATA LIST mode 6 16 ENGINE GENERAL INFORMATION AND DIAGNOSIS ENGINE DIAGNOSIS TABLE Perform troubleshooting referring to following table when ECM has no DTC and no abnormality found in visual inspection and engine basic inspection previously Possible Cause Referring Item Hard Starting Engine cranks Ok Injection system out of order e Faulty fuel injection pump static timing e Clogged fuel filter or lines e Faulty fuel injection pump e Faulty ignitor Static timing in ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FORE WORD of this manual Fuel filter in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Fuel injection pump in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANU AL listed in FOREWORD of this manual Fuel injector in Section 6E3 and ALL MODEL DIESEL DIAGNOSIS MANUAL listed in FOREWORD of this manual Immobilizer control system out of order Immobilizer control system in Section 8G Engine and emission control system out of order e Faulty CKP sensing rotor e Faulty CKP sensor injector needle sensor ECT sensor and TP sensor e Faulty fuel injection timing contr
94. valve C To injection actuator S aa UL Main fuse Ignition switch Double relay Malfunction indicator lamp 18 17 16 15 14 13 i2 11 10 8 7 6 LALA in combination meter 35 34 33 32 30 29 P 27 25 24 23 P 21 19 Fusible link ee IG fuse IG METER fuse Generator ECM AN SCOMDND When the ignition switch tuned ON the double relay turns ON the contact point closes and the main power is supplied to ECM INSPECTION STEP ACTION 1 Double Relay Operating Sound Check Go to Step 3 Go to Step 2 Is operating sound of double relay heard at ignition switch ON 2 Double Relay Check Go to Step 3 Replace double Refer to DOUBLE RELAY in Section 6E3 relay Is double relay in good condition 3 Fuse Check Go to Step 4 Check for short in Is Fusible link and IG METER fuse in good condition circuits connected See Fig 1 to this fuse 4 Double Relay Power Circuit Check Go to Step 5 B W or P cir 1 Turn ignition switch OFF and disconnect coupler from cuit in glow plug double relay relay coupler open 2 Turn ignition switch ON measure voltage between B W or shorted to terminal in double relay coupler and body ground and P ground terminal in double relay coupler and body ground Is each terminal voltage 10 to 14 V ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 35 Double Relay Ground Circuit Check Go to Step 6 B Or
95. w WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the sys tem may be activated by reserve energy in the Sensing and Diagnostic Module SDM GENERAL INFORMATION AND ENGINE DIAGNOSIS 0 cece en teens 6 ENGINE MECHANICAL 2 2 2003 seeeeie ae deeedieriesiiee tlie a ae a a geneween ed 6A4 ENGINE COOLING 2c rete dais cubis irois cede ened en esas ei bes ba Med Pa bee cake dv ey bea w ei Ea 6B ENGINE AND EMISSION CONTROL SYSTEM CRANKING SYSTEM 22 0 30 5ec0 beivededepherte borer ead aver dened Meas Dra eevee ade EE CHARGING SYSTEM c0 jscceteiddinie dete hinaa eb a nae ha dbdaeee dee beeede i 6H EXHAUST SYSTEM ragio eireta coho ia a Ge ee pe boe amas ee eae eee eT Ge ween Ada nad ee ead 6K CONTENTS GENERAL INFORMATION 6 2 Visual Inspection 00e eee 6 14 Statement on Cleanliness and Care 6 2 Engine Basic Inspection 6 15 General Information on Engine Service 6 3 Engine Diagnosis Table 6 16 Precaution on Fuel System Service 6 4 Scan Tool Data i iccieec aieew auch adaaals 6 25 Metric Information 2 0000 6 5 Scan Tool Da
96. wing points CAUTION Be sure to confirm that steering wheel and front tires wheels are in straight position when inserting steering lower joint into steering pinion shaft e f a plug was put to disconnected pipe when removing steering gear box remove that plug before reconnecting pipe e Use specified torque as given below Tightening Torque a 55 N m 5 5 kg m 40 0 Ib ft b 20 N m 2 0 kg m 14 5 lb ft c 35 N m 3 5 kg m 25 5 Ib ft d 35 55 N m 3 5 5 5 kg m 25 5 39 5 Ib ft e 25 N m 2 5 kg m 18 0 Ib ft f 55 N m 5 5 kg m 40 0 Ib ft g 45 N m 4 5 kg m 32 5 lb ft 3B1 8 POWER STEERING P S SYSTEM REMOVAL AND INSTALLATION POWER STEERING PUMP Tightening Torque a 35 N m 3 5 kg m 25 5 Ib ft b 6 5 N m 0 65 kg m 5 0 Ib ft c 55 N m 5 5 kg m 40 0 Ib ft 1 Power steering pump assembly 5 Rack and pinion 2 Power steering fluid reservoir 6 Low pressure return hose Tank side 3 Accessory drive belt 7 Low pressure return hose amp pipe Gear box side 4 High pressure hose amp pipe REMOVAL NOTE Be sure to clean each joint of suction and discharge sides thoroughly before removal 1 Remove drive belt referring to SECTION 6H 2 Disconnect high pressure hose and low pressure return hose from pump As fluid flows out of disconnected joints put a con tainer under joints or a plug to hose 3 Remove P S pump
97. x 13 Generator 14 Battery DTC DETECTING CONDITION POSSIBLE CAUSE e Low voltage at terminal E92 13 when ECM doesn t e P circuit open or short output A C ON signal to A C amplifier or when engine Each engine emission control sensor faulty coolant temp is not 110 C 230 F or more e ECM malfunction DTC CONFIRMATION PROCEDURE 1 Clear DTC with ignition switch ON 2 Select DTC mode on scan tool and check DTC ENGINE GENERAL INFORMATION AND DIAGNOSIS 6 53 DTC NO 37 INSPECTION s orion es o ia Was ENGINE DIAGNOSIS FLOW TABLE performed NOSIS FLOW TABLE 2 Check A C Cut Signal Circuit Substitute a known P circuit open or short 1 Check voltage at terminal E92 13 good ECM and recheck A C cut signal specification While engine running 0 1 5V Ignition switch turn ON or while cranking engine 10 14V Are check results as specified

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