TABLE OF CONTENTS SECTION 0A

FOREWORD
GENERAL INFORMATION
0B
This SUPPLEMENTARY SERVICE MANUAL is a General Information 0A
supplement to MT308 SERVICE MANUAL and has Maintenance and Lubrication 0B
been prepared exclusively for the following model. 6
ENGINE
General Information and 6 6A
Applicable model: MG413W (BS-III)
Diagnosis
Engine Mechanical 6A 6C
Therefore, whenever servicing the above applicable
Engine Fuel 6C
model, consult this supplement first. And for any sec-
Engine and Emission Control 6E2 6E2
tion, item or description not found in this supplement,
System
refer to the RELATED MANUAL below.
Ignition System 6F1 6F
Charging System 6H
When replacing parts or servicing by disassembling,
Exhaust System 6K1 6H
it is recommended to use MARUTI genuine parts,
Body Electrical System 8
tools and service materials (lubricants, sealants, etc.)
as specified in each description. 6K

All information, illustrations and specifications con-

tained in this literature are based on the latest product
information available at the time of publication ap-
proval. And use as the main subject of description is
the vehicle of standard 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 MANUAL:

99510M 82C02-74E Supplementary Service Manual

99500M80302-74E Service Manual

99512M82C00-74E
Wiring Diagram Manual
99512M82C01-74E

MARUTI UDYOG LIMITED

SERVICE DIVISION

© COPYRIGHT MARUTI UDYOG LIMITED 2005

 MAINTENANCE AND LUBRICATION 0B-1

SECTION 0B
0B

MAINTENANCE AND LUBRICATION

CONTENTS

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-

MAINTENANCE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-
Emission Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B- 2
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-
Chassis and Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-
Final Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-
RECOMMENDED FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-
0B-2 MAINTENANCE AND LUBRICATION

Fuel Tank Inspection

Check fuel tank for damage, cracks, fuel leakage, corrosion and
tank bolts looseness.
If a problem is found, repair or replace.

Fuel Tank Cap Inspection

Check fuel filler cap (1) for malfunction and damage, gasket (2) for
even filler neck imprint, deterioration and damage. Replace if faulty.

EMISSION CONTROL SYSTEM

PCV (Positive Crankcase Ventilation) Valve,

Crankcase Ventilation Hoses and Connections
Inspection
Check crankcase ventilation hoses and PCV hoses for leaks,
cracks or clog, and PCV valve (1) for stick or clog. Refer to Section
6E1 for PCV valve checking procedure.

Fuel Evaporative Emission Control System

(if equipped)
Check EVAP (Evaporative Emission) canister for damage, clog and
operation referring to Section 6E1.
 ENGINE MECHANICAL 6A-1

SECTION 6A

ENGINE MECHANICAL
6A

CONTENTS

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
Compression Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
Engine Vacuum Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
Oil Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
Valve Lash (Clearance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
Air Cleaner Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
Throttle Body and Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A- 2
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A- 4
Timing Belt and Belt Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
Oil Pan and Oil Pump Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
Rocker Arms, Rocker Arm Shaft and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
Valves and Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
Piston, Piston Rings, Connecting Rods and Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
UNIT REPAIR OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
Main Bearings, Crankshaft and Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-
REQUIRED SERVICE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-

NOTE:
For what each abbreviation stands for (i.e., full term), refer to SECTION 0A.
6A- 2 ENGINE MECHANICAL

THROTTLE BODY AND INTAKE MANIFOLD

1 8

1. Intake manifold
2. Gasket
3. NIL
4. Engine hook
5. Fuel delivery pipe
6. Throttle body
: Tightening Torque 7. Throttle body gasket
: Do not reuse 8. EGR
9. EGR Gasket

REMOVAL
1) Relieve fuel pressure according to fuel pressure relief procedure
described in Section 6.
2) Disconnect negative cable at battery.
3) Remove engine under cover.
4) Drain cooling system.
WARNING:
To help avoid danger of being burned, do not remove
drain plug and radiator cap while engine and radiator are
still hot. Scalding fluid and steam can be blown out under
pressure if plug and cap are taken off too soon.

5) Remove intake manifold stiffener (1).

6) Disconnect IAT sensor coupler and breather hose and remove

air cleaner outlet hose.
7) Disconnect following electric lead wires:
Ground wires from intake manifold
ECT sensor
Injectors lead wires at the coupler
EVAP canister purge valve
TP sensor
MAP sensor
IAC valve
EGR valve
and then release wire harness from clamps.
 ENGINE MECHANICAL 6A- 3

8) Disconnect accelerator cable from throttle body.

9) Disconnect following hoses:
Brake booster hose from intake manifold
Canister purge hose from EVAP canister purge valve bracket
Engine cooling water (coolant) hose (outlet side) from throttle
body
Radiator inlet hose from thermostat cap
PCV hose from intake manifold
Fuel feed hose and return hose from each pipe
Heater inlet hose from thermostat cap
10) Remove heater pipe from intake manifold by removing 2 bolts.
11) Remove intake manifold with throttle body and thermostat cap
from cylinder head, and then its gasket.

INSPECTION
Using a straight edge and thickness gauge, check surface at a to-
tal of 6 locations. If distortion limit, given below, is exceeded, cor-
rect gasketed surface or replace intake manifold.

Limit of distortion: 0.07 mm (0.003 in.)

INSTALLATION
Reverse removal procedure for installation noting the followings.
Use new intake manifold gasket.
Tighten bolts and nuts to specified torque.

Tightening Torque
(a): 25 N´m (2.5 kg-m, 18.0 lb-ft)

Adjust accelerator cable play, referring to Section 6E.

Check to ensure that all removed parts are back in place. Rein-
stall any necessary parts which have not been reinstalled.
Refill cooling system, referring to Section 6B.
Upon completion of installation, turn ignition switch ON but en-
gine OFF and check for fuel leakage.
Finally, start engine and check for engine coolant leakage.
6A- 4 ENGINE MECHANICAL

EXHAUST MANIFOLD
WARNING:
To avoid danger of being burned, do not service exhaust
5
system while it is still hot. Service should be performed af-
2 ter system cools down.

REMOVAL
1) Disconnect negative cable at battery.
4
2) Disconnect heated oxygen sensor (4) coupler (if equipped).
3) Remove exhaust manifold cover (2) of exhaust manifold.
3
4) Disconnect exhaust pipe (7) from exhaust manifold.
6 5) Remove exhaust manifold (1) and its gasket (3) from cylinder
1
head.
7

5. Engine hook
6. Seal ring

INSTALLATION
1) Install new gasket (1) to cylinder head.
2) Install exhaust manifold.
Tighten nuts to specified torque.

Tightening Torque
(a): 23 N.m (2.3 kg-m, 17.0 lb-ft)

3) Install seal ring (2) and install exhaust pipe to exhaust manifold.
Before installing seal ring, check it for deterioration or damage,
and replace as necessary.
Tighten pipe fasteners to specified torque.

Tightening Torque
1 (a)
2 (b): 50 N.m (5.0 kg-m, 36.5 lb-ft)

4) Install exhaust manifold cover to exhaust manifold.

(b) 5) Connect heated oxygen sensor connector and fit connector to
bracket. (if equipped)
6) Connect negative cable at battery.
7) Check exhaust system for exhaust gas leakage.
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-1

SECTION 6E2

ENGINE AND EMISSION CONTROL SYSTEM

CONTENTS

GENERAL DESCRIPTION . . . . . . . . . . . . . 6E2- 2 B-10 Fuel Cut Operation Check . . . . . . . . 6E2-41 6E2
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . 6E2- 4 B-11 EGR Check . . . . . . . . . . . . . . . . . . . 6E2-42
FUEL DELIVERY SYSTEM . . . . . . . . . . . 6E2- 4 Inspection of ECM (PCM) and Its
ELECTRONIC CONTROL SYSTEM . . . . 6E2- 5 Circuits . . . . . . . . . . . . . . . . . . . . . . . . 6E2-43
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . 6E2- 9 Voltage Check . . . . . . . . . . . . . . . . . . . . . 6E2-43
On-Board Diagnostic System . . . . . . . . . . 6E2- 9 Resistance Check . . . . . . . . . . . . . . . . . . 6E2-47
Precautions in Diagnosing Troubles . . . . . 6E2- 9 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 6E2-48
MIL Check . . . . . . . . . . . . . . . . . . . . . . . . 6E2-10 General . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2-
DTC Check . . . . . . . . . . . . . . . . . . . . . . . 6E2-10 Accelerator Cable Adjustment . . . . . . . . . 6E2-
DTC Clearance . . . . . . . . . . . . . . . . . . . . 6E2-12 Idle Speed/Idle Air Control (IAC)
DTC Table . . . . . . . . . . . . . . . . . . . . . . . . 6E2-13 Duty Inspection . . . . . . . . . . . . . . . . . . 6E2-48
A-1 MIL Circuit Check . . . . . . . . . . . . . . . 6E2-14 Air Intake System . . . . . . . . . . . . . . . . . . . 6E2-
A-2 MIL Circuit Check . . . . . . . . . . . . . . . 6E2-15 Throttle Body . . . . . . . . . . . . . . . . . . . . . . 6E2-
A-3 MIL Circuit Check . . . . . . . . . . . . . . . 6E2-16 Idle Air Control Valve (IAC Valve) . . . . . . . 6E2-
A-4 ECM (PCM) Power and Ground Fuel Delivery System . . . . . . . . . . . . . . . . 6E2-
Circuit Check . . . . . . . . . . . . . . . . . . . . 6E2-17 Fuel Pressure Inspection . . . . . . . . . . . . . 6E2-
Code No.11 (P0107/P0108) MAP Sensor Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . 6E2-
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 6E2-19 Fuel Pressure Regulator . . . . . . . . . . . . . 6E2-
Code No.13 (P0122/P0123) TP Sensor Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . 6E2-
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 6E2-21 Electronic Control System . . . . . . . . . . . . 6E2-
Code No.14 (P031/32/0134) Heated O2 Sensor ECM (PCM) . . . . . . . . . . . . . . . . . . . . . . . 6E2-
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 6E2-23 MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . 6E2-
Code No.15 (P0340) CMP Sensor TP Sensor . . . . . . . . . . . . . . . . . . . . . . . . 6E2-
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 6E2-28 IAT Sensor . . . . . . . . . . . . . . . . . . . . . . . . 6E2-
Code No.16 (P0500) VSS Circuit . . . . . . . 6E2-29 ECT Sensor . . . . . . . . . . . . . . . . . . . . . . . 6E2-
Code No.18 (P0112/P0113) IAT Sensor Main Relay . . . . . . . . . . . . . . . . . . . . . . . . 6E2-
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 6E2-30 Heated Oxygen Sensor . . . . . . . . . . . . . . 6E2-50
Code No.19 (P0117/P0118) ECT Sensor Fuel Pump Relay . . . . . . . . . . . . . . . . . . . 6E2-
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 6E2-31 Fuel Cut Operation . . . . . . . . . . . . . . . . . 6E2-
DTC Confirmation Procedure . . . . . . . . . 6E2-32 CMP Sensor . . . . . . . . . . . . . . . . . . . . . . 6E2-
B-1 Fuel Pump and Its Circuit Check . . . 6E2-33 VSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2-
B-2 Fuel Injector and Its Circuit Check . . 6E2-34 EVAP Emission Control System . . . . . . . 6E2-51
B-3 Fuel Pressure Check . . . . . . . . . . . . 6E2-35 EVAP Canister Purge Valve . . . . . . . . . . . 6E2-52
B-4 Idle Air Control System Check . . . . . 6E2-37 EVAP Canister . . . . . . . . . . . . . . . . . . . . . 6E2-54
B-5 Evaporative Emission Control Tank Pressure Control Valve . . . . . . . . . . 6E2-
System Check . . . . . . . . . . . . . . . . . . . 6E2-38 PCV System . . . . . . . . . . . . . . . . . . . . . . 6E2-
B-6 Engine Start Signal Check . . . . . . . . 6E2-39 PCV Hose. . . . . . . . . . . . . . . . . . . . . . . . . 6E2-
B-9 Electric Load Signal Circuits PCV Valve . . . . . . . . . . . . . . . . . . . . . . . . 6E2-
Check . . . . . . . . . . . . . . . . . . . . . . . . . 6E2-40 EGR System . . . . . . . . . . . . . . . . . . . . . . . 6E2-55
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . 6E2-56
6E2-2 ENGINE AND EMISSION CONTROL SYSTEM

GENERAL DESCRIPTION

The engine and emission control system has 4 major Fuel delivery system includes fuel pump, delivery
sub-systems: air intake system, fuel delivery system, pipe, fuel pressure regulator, fuel injectors, etc.
electronic control system and emission control sys- Electronic control system includes ECM (PCM), vari-
tem. ous sensors and controlled devices.
Air intake system includes air cleaner, MAP sensor,
throttle body, IAC valve and intake manifold. Emission control system includes EVAP and PCV
systems.
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-3

43

1. Air Cleaner 23. ECM (PCM)

2. EVAP canister Duty purge valve 24. Blank
3. IAT sensor 25. Blank
4. TP sensor 26. Reed switch in combination meter (VSS)
5. IAC valve 27. Blank
6. MAP sensor 28. Malfunction indicator lamp in combination meter
7. Blank 29. Blank
8. EVAP canister 30. Ignition switch
9. Tank pressure control valve 31. Starter magnetic switch
10. Fuel pressure regulator 32. Main fuse
11. Blank 33. Battery
12. PCV valve 34. Blank
13. Fuel injector 35. Blank
14. Heated Oxygen sensor 36. Monitor connector
15. Fuel Pump 36-1. Diagnosis switch terminal
16. Stop light switch 36-2. Test switch terminal
17. ECT sensor 36-3. Duty output terminal
18. Three way catalytic convertor 37. Blank
19. CMP sensor 38. Blank
20. Main relay 39. Electric load (blower fan, small light and rear de-
21. Ignition coil assembly fogger)
(For No.1 and No.4 spark plugs) 40. Data link connector (DLC)
22. Ignition coil assembly 41. Fuel pump relay
(For No.2 and No.3 spark plugs) 42. Fuel filter
43. EGR
6E2-4 ENGINE AND EMISSION CONTROL SYSTEM

AIR INTAKE SYSTEM

The main components of the air intake system are air by the intake manifold and finally drawn into each com-
cleaner, air cleaner outlet hose, throttle body, IAC bustion chamber.
valve and intake manifold. When the IAC valve is opened according to the signal
The air (by the amount corresponding to the throttle from ECM (PCM), the air bypasses the throttle valve
valve opening and engine speed) is filtered by the air through bypass passage and is finally drawn into the
cleaner, passes through the throttle body, is distributed intake manifold.

1. Air cleaner
2. IAT sensor
3. Air cleaner outlet hose
4. Throttle body
5. Throttle valve
6. IAC valve
7. Intake manifold
8. Cylinder head
9. Exhaust manifold
10. Air flow
11. MAP sensor

FUEL DELIVERY SYSTEM

The fuel delivery system consists of the fuel tank, fuel line) is always kept a certain amount higher than the
pump, fuel filter, fuel pressure regulator, delivery pipe pressure in the intake manifold by the fuel pressure
and fuel injectors. regulator, the fuel is injected into the intake port of the
cylinder head when the injector opens according to the
The fuel in the fuel tank is pumped up by the fuel pump,
injection signal from ECM (PCM).
filtered by the fuel filter and fed under pressure to each
injector through the delivery pipe. As the fuel pressure The fuel relieved by the fuel pressure regulator returns
applied to the injector (the fuel pressure in the fuel feed through the fuel return line to the fuel tank.

1. Fuel injector
2. Delivery pipe
3. Fuel pressure regulator
4. Intake manifold
5. EVAP canister
6. EVAP canister purge valve
7. Fuel feed line
8. Fuel return line
9. Fuel vapor line
10. Fuel filter
11. Fuel tank
12. Fuel pump
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-5

ELECTRONIC CONTROL SYSTEM

The electronic control system consists of 1) various
sensors which detect the state of engine and driving
conditions, 2) ECM (PCM) which controls various de-
vices according to the signals from the sensors and
3) various controlled devices. Evaporative emission control system
Functionally, it is divided into the following sub sys-
tems:

INFORMATION SENSORS CONTROL DEVICES OTHERS

1. MAP sensor a : Fuel injectors A : ECM (PCM)
2. TP sensor b : EVAP canister purge valve B : PCV valve
3. IAT sensor c : Fuel pump relay C : EVAP canister
4. ECT sensor d : Ignition coil assembly D : Monitor connector
5. Oxygen sensor e : Malfunction indicator lamp E : DLC
6. VSS f : IAC valve F : EGR
7. CMP sensor g : Main relay
6E2 -6 ENGINE AND EMISSION CONTROL SYSTEM

1
RED/WHT
G02-05
16
YEL G01-32 2
GRN/ORN
G02-04

WHT/GRN 3
BRN G01-33 G02-03
G01-30
4
WHT/BLK
G02-02
17
BRN/YEL RED/WHT 5
E03-15 G02-08

GRY 6
G02-17
GRY/RED
18 Lg/RED G02-34
GRY/BLU
G01-08 G02-16
Lg GRY/BLK
G02-33
G01-12
PNK
19 G01-09
7
1K

Lg/YEL BLU/GRN
G01-11 G01-18

20 Lg
G01-16

21 Lg/WHT
G01-15

BLK/BLU
G01-05

22
YEL
G01-29
RED
G01-13
G01-07 8
YEL/RED VIO/YEL
E03-16
9
PNK
G02-10

10
23 GRN/WHT
E03-04 VIO
G02-09 11
24
RED/YEL
E03-11 BLU/YEL
G02-30
BLU
G02-29
12
#2

#3 13
BRN/BLK
G02-31
#4

#1
BRN/WHT
G02-32 PLUG
25

H M2 M1 L
BLU/
26 E03-02
WHT WHT
E03-07

IG
BLK/WHT IGI SW
E03-05
ST

14
BLU
G02-15
EPI
BLU/BLK 15A
G01-02
27
BLU/BLK
G01-03 MAIN
BLK/YEL
G02-01 15

BLK/BLU
E03-17 G02-07
YEL/BLK BLK/BLU
G02-06
G01-01 BLK/BLU
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-7

TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE)

G02 G01 G03 E03

E01 E02 #1 #2 #3 #4 STA OXH E24 +BP PM PM +BB 1GS SLS2 EL3

EGR1 EGR3 MR FPR MON 15C PRG THA THW OX VTA PM VCC2 VCC ST DNL SPD2 EL+

EGR2 EGR4 1GT1 1GT2 DN T5 N- N+ E22 E21

1. Fuel injector No.1 Terminal Circuit Terminal Circuit

2. Fuel injector No.2
3. Fuel injector No.3 G02-1 Engine Starting Signal G01-17 Blank
4. Fuel injector No.4 G02-2 Fuel Injector no. 4 G01-18 EVAP canister purge valve
5. Idle air control (IAC) valve G02-3 Fuel Injector no. 3 G01-19 Blank
G02-4 Fuel Injector no. 2 G01-20 Blank
6. EGR Valve
G01-21 Blank
7. EVAP canister purge valve G02-5 Fuel Injector no. 1
G01-22 Blank
8. Malfunctioning indicator lamp G02-6 Engine Ground
G01-23 Blank
9. Fuel pump relay G02-7 Engine Ground G01-24 Blank
10. Fuel pump G02-8 IAC Valve G01-25 Blank
11. Diagnostic Connector G02-9 Duty Output Terminal G01-26 Blank
12. Ignition coil assembly for No.2 G02-10 Fuel Pump Relay G01-27 Blank
and 3 spark plugs G01-28 Blank
G02-11 AC Relay
13. Ignition coil assembly for No.1 G01-29 Power Supply for HO2S sensor
G02-12 Radiator Fan Relay G01-30 Sensor Ground
and 4 spark plugs
G02-13 Blank G01-31 A/C ON signal from A/C switch
14. Main relay
G02-14 Blank (if equipped)
15. Starter magnetic switch G01-32 CMP sensor (+)
G02-15 Main Relay
16. Camshaft position (CMP) G01-33 CMP sensor (–)
sensor G02-16 EGR Terminal 3
G01-34 Blank
17. VSS (reed switch) G02-17 EGR Terminal 1 G01-35 Blank
18. Throttle position (TP) sensor G02-19 Blank G03-01
19. Manifold absolute pressure G02-20 Blank to Blank
(MAP) sensor G02-21 Blank G03-35
E03-1 Electric load signal for small
20. Intake air temp.(IAT) sensor G02-22 Blank
light switch and rear defogger
21. Engine coolant temp. (ECT) G02-23 Blank E03-2 Electric load signal for blower
22. Heated Oxygen sensor G02-24 Blank fan motor
23. Stop light switch G02-25 Blank E03-3 Blank
24. Position light switch G02-26 Blank E03-4 Stop light switch (brake pedal
25. Heater blower motor switch switch)
G02-27 Blank E03-5 Ignition switch
26. Heater blower motor
G02-28 Blank E03-6 Blank
27. Data link connector
G02-29 Test Switch Terminal E03-7 Power source for back-up
G02-30 Diagnosis Switch Terminal E03-8 A/C evaporator temp sensor
(with A/C)
G02-31 Igniter-2
E03-9 Blank
G02-32 Igniter-1 E03-10 Blank
G02-33 EGR Terminal 4 E03-11 Position lamp switch
G02-34 EGR Terminal 2 E03-12 Blank
G01-1 Ground E03-13 Blank
G01-2 Power Source E03-14 VSS
E03-15 Vehicle speed signal to EPS
G01-3 Power Source
E03-16 Malfunctioning Indicator Lamp
G01-4 Blank E03-17 Data Link Connector
G01-5 Sensor Ground E03-18 Blank
G01-6 Blank E03-19 Blank
G01-7 Oxygen Sensor Heater E03-20 Blank
E03-21 Blank
G01-8 Power Supply for TP Sensor
E03-22 Blank
G01-9 Power Supply for MAP Sensor
E03-23 Blank
G01-10 Blank E03-24 Blank
G01-11 MAP sensor E03-25 Blank
G01-12 TP sensor E03-26 Sensor ground
G01-13 Heated Oxygen Sensor E03-27 Blank
E03-28 Blank
G01-14 Blank
E03-29 Blank
G01-15 ECT sensor E03-30 Blank
G01-16 IAT sensor E03-31 Blank
6E2-8 ENGINE AND EMISSION CONTROL SYSTEM

Air
IAC
valve Fuel
Exhaust gas

AIR IN-
3 WAY
CLEANER TAKE EXHAUST
THROTTL ENGINE CATALYTIC
OUTLET MAN- MANIFOLD
E BODY CONVERTER
HOSE IFOLD
IAT Heated
TP sensor ECT CMP Oxygen
sensor
sensor sensor sensor
FUEL
INJECTOR Camshaft and
each piston
Pressure position
Intake Throttle valve
in intake
air temp. opening Engine Exhaust Battery voltage
manifold
coolant oxygen Vehicle speed
temp. concentration Engine start signal
Diagnosis signal
Fuel pump
Test signal
Electric load signal

Fuel pump ECM (PCM)

relay

Fuel injection control EVAP

Malfunction
canister EGR
indicator
purge
Idle air control lamp
valve
CMP sensor

MAP sensor

TP sensor

ECT sensor

IAT sensor

Heated Oxygen sensor

VSS

Lighting switch

Ignition switch

Start siwtch

Stop lamp switch

Diagnosis switch

Test switch
INFORMATION
SENSORS AND
SWITCH (INPUT)

CONTROL
DEVICE
(OUTPUT)
Fuel injector
IAC valve
Fuel pump
Ignition coil
EVAP canister purge valve
MIL
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-9

DIAGNOSIS
The engine and emission control system in this vehicle are con-
trolled by ECM (PCM). ECM (PCM) has an On-Board Diagnostic
system which detects a malfunction in this system.
When diagnosing troubles, be sure to have full understanding of the
outline of ON-BOARD DIAGNOSTIC SYSTEM and each item in
PRECAUTION IN DIAGNOSING TROUBLE and execute diagno-
sis according to ENGINE DIAGNOSTIC FLOW TABLE in SEC-
TION 6.

ON-BOARD DIAGNOSTIC SYSTEM

ECM (PCM) performs on-board diagnosis (self-diagnosis) on the
system and operates malfunction indicator lamp as follows.
Malfunction indicator lamp lights when the ignition switch is
turned ON (but the engine at stop) regardless of the condition of
engine and emission control system. This is only to check the
malfunction indicator lamp bulb and its circuit.
If the areas monitored by ECM (PCM) is free from any trouble af-
ter the engine start (while engine is running), malfunction indica-
tor lamp turns OFF.
When ECM (PCM) detects a trouble which has occurred in the
areas,it makes malfunction indicator lamp turn ON while the en-
gine is running to warn the driver of such occurrence of trouble
and at the same time it stores the exact trouble area in ECM
(PCM) back-up memory.

PRECAUTIONS IN DIAGNOSING TROUBLES

Before identifying diagnostic trouble code, don’t disconnect cou-
plers from ECM (PCM) , battery cable from battery, ECM (PCM)
ground wire harness from engine. Such disconnection will erase
memorized trouble in ECM (PCM) memory.
Be sure to read PRECAUTIONS FOR ELECTRICAL CIRCUIT
SERVICE in SECTION 0A before inspection and observe what is
written there.
ECM (PCM) replacement
When substituting a known-good ECM (PCM) , check for follow-
ing conditions. Neglecting this check may cause damage to
known-good ECM (PCM).
– Resistance value of all relays, actuators is as specified respec-
tively.
– TP sensor and MAP sensor are in good condition and none of
power circuits of these sensors is shorted to ground.
6E2-10 ENGINE AND EMISSION CONTROL SYSTEM

MALFUNCTION INDICATOR LAMP (MIL)

CHECK
1) Turn ON ignition switch (but engine at stop) and check that mal-
function indicator lamp lights up.
If lamp does not light up, go to DIAGNOSTIC FLOW TABLE A-1
in this section.
If lamp flashes, go to DIAGNOSTIC FLOW TABLE A-2 in this
section.
2) Start engine and check that malfunction indicator lamp turns
OFF.
If lamp remains ON, go to DTC CHECK NOT USING SUZUKI
SCAN TOOL in this section.

DIAGNOSTIC TROUBLE CODE (DTC) CHECK

[Using SUZUKI scan tool]
1) Check malfunction indicator lamp referring to MALFUNCTION
INDICATOR LAMP (MIL) CHECK in this section.

2) Turn ignition switch OFF.

3) After setting cartridge to SUZUKI scan tool, connect it to data link
connector (DLC) (1) located on underside of instrument panel at
passenger seat side.
4) Turn ignition switch ON.
5) Read DTC according to instructions displayed on SUZUKI scan
tool and print it or write it down. Refer to SUZUKI scan tool opera-
tor’s manual for further details.
If communication between SUZUKI scan tool and ECM (PCM)
is not possible, check if SUZUKI scan tool is communicable by
connecting it to ECM (PCM) in another vehicle. If communica-
tion is possible in this case, SUZUKI scan tool is in good condi-
tion. Then check data link connector and serial data line (circuit)
in the vehicle with which communication was not possible.
6) After completing the check, turn ignition switch OFF and discon-
nect SUZUKI scan tool from data link connector (DLC).
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-11

[Not using SUZUKI scan tool]

1) Check malfunction indicator lamp referring to MALFUNCTION
INDICATOR LAMP (MIL) CHECK in this section.
2) Using service wire (2), ground diagnosis switch terminal in moni-
tor connector (1).
3) Read DTC from flashing pattern of malfunction indicator lamp.
Refer to DTC TABLE.
If lamp remains ON, go to Table A-3 in this section.

NOTE:
If abnormality or malfunction lies in two or more areas,
malfunction indicator lamp indicates applicable codes
three times each.
And flashing of these codes is repeated as long as diag-
nosis terminal is grounded and ignition switch is held at
ON position.
Take a note of diagnostic trouble code indicated first.

4) After completing the check, turn ignition switch OFF and discon-
nect service wire from monitor connector.

EXAMPLE: When throttle position sensor is defective (Code No.13)

Code No.13 Code No.13 Code No.13

ON
Malfunction indicator
lamp
OFF
6E2-12 ENGINE AND EMISSION CONTROL SYSTEM

DIAGNOSTIC TROUBLE CODE (DTC)

CLEARANCE
[Using SUZUKI scan tool]
1) Turn ignition switch OFF.
2) Connect SUZUKI scan tool to data link connector (DLC) in the
same manner as when making this connection for DTC check.
3) Turn ignition switch ON.
4) Erase DTC according to instructions displayed on SUZUKI scan
tool.
Refer to SUZUKI scan tool operator’s manual for further details.
5) After completing the clearance, turn ignition switch OFF and dis-
connect SUZUKI scan tool from data link connector (DLC).

[Not using SUZUKI scan tool]

1) Turn OFF ignition switch.
2) Disconnect battery negative cable for specified time below to
erase diagnostic trouble code stored in ECM (PCM) memory
and reconnect it.

Time required to erase DTC:

Ambient temperature Time to cut power to ECM (PCM)
Over 0° C (32°F) 30 sec. or longer
Not specifiable.
Under 0° C (32°F) Select a place with higher than
0° C (32° F) temperature.
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-13

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

DIAGNOSTIC
TROUBLE
MALFUNCTION
CODE NO.
INDICATOR LAMP DIAGNOSTIC ITEM DIAGNOSIS
SUZUKI
FLASHING PATTERN
SCAN MIL
TOOL
P0107
Manifold absolute
11
P0108 pressure sensor

P0122
13 Throttle position sensor
P0123
P0031 Heated Oxygen sensor HTR Low
HeatedOxygen sensor HTR High
P0032 14
Heated Oxygen sensor Character-
P0134 istic failure
Diagnose trouble according to
P0340 15 Camshaft position sensor DIAGNOSTIC FLOW TABLE
corresponding to each code No.

P0500 16 Vehicle speed sensor

P0112 Intake air temperature

18
sensor
P0113
P0117 Engine coolant
19
P0118 temperature sensor

This code appears when none of the

0000 12 Normal other codes (above codes) are
identified.
6E2-14 ENGINE AND EMISSION CONTROL SYSTEM

A-1 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK

(MALFUNCTION INDICATOR LAMP DOES NOT LIGHT AT IGNITION SWITCH ON.)

G02-30

G02-29

G02-09
G02-07
G02-06
E03-17

1. Battery positive voltage

2. Blank
3. Ignition switch
4. "IG. COIL" fuse
5. Malfunction indicator lamp
6. Combination meter
7. ECM (PCM)
8. Diagnosis switch terminal
9. Monitor connector

STEP ACTION YES NO

1 Test Switch Terminal Circuit Check: Go to Step 2. "Bl" wire (test switch terminal)
1) With the ignition switch ON position, check shorted to ground circuit. If OK,
voltage between G02-29 terminal of ECM substitute a known-good ECM
coupler and ground. and recheck.

2 MIL Bulb and Circuit Check: Go to TABLE A-4. MIL bulb burned out.
1) Using service wire, ground E03-17 Fuse (s) blown.
terminal of ECM coupler. Ignition switch malfunction.
Does MIL turn ON at ignition switch ON "V/Y" wire open.
position? "B/W" wire open.
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-15

A-2 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK

(MALFUNCTION INDICATOR LAMP FLASHES AT IGNITION SWITCH ON.)

G02-30

G02-29

G02-09
G02-07
G02-06
E03-17

1. Battery positive voltage

2. Blank
3. Ignition switch
4. "IG. COIL" fuse
5. Malfunction indicator lamp
6. Combination meter
7. ECM (PCM)
8. Diagnosis switch terminal
9. Monitor connector

STEP ACTION YES NO

1 MIL Flashing Pattern Check Go to Step 2. Substitute a known-good
1) Turn ignition switch ON. ECM (PCM) and recheck.
Does lamp flashing pattern indicate diagnostic
trouble code?
2 Diag. Switch Circuit Check System is in good "Bl/Y" circuit shorted to
Is diag. switch terminal connected to ground via condition. ground. If circuit is OK,
service wire? substitute a known-good
ECM (PCM) and recheck.
6E2-16 ENGINE AND EMISSION CONTROL SYSTEM

A-3 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK

(MALFUNCTION INDICATOR LAMP DOES NOT FLASH OR JUST REMAINS ON EVEN WITH GROUND-
ING DIAGNOSIS SWITCH TERMINAL.)

G02-30

G02-29

G02-09
G02-07
G02-06
E03-17

1. Battery positive voltage

2. Blank
3. Ignition switch
4. "IG. COIL" fuse
5. Malfunction indicator lamp
6. Combination meter
7. ECM (PCM)
8. Diagnosis switch terminal
9. Monitor connector

STEP ACTION YES NO

1 MIL Circuit Check "V/Y" circuit shorted Go to Step 2.
1) Turn ignition switch OFF and disconnect to ground.
connectors from ECM (PCM).
Does MIL turn ON at ignition switch ON?
2 ECM (PCM) Connection Check Go to Step 3. Poor connector
1) Turn ignition switch OFF. connection.
Is connector (G02-30 connection) connected to ECM
(PCM) properly?
3 Diag. Switch Terminal Circuit Check "Bl/Y" or "B" circuit Substitute a known-good
1) Connect connectors to ECM (PCM). open. ECM (PCM) and recheck.
2) Using service wire, ground G02-8 terminal with
connectors connected to ECM (PCM).
3) Turn ignition switch ON.
Does MIL flash?
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-17

A-4 ECM (PCM) POWER AND GROUND CIRCUIT CHECK (Page 1 of 2)

(MALFUNCTION INDICATOR LAMP DOES NOT LIGHT AT IGNITION SWITCH ON AND ENGINE DOES
NOT START THOUGH IT IS CRANKED UP.)

G01-03
G01-02

G02-15

1. Battery positive voltage

G02-07 2. Fuse box
3. Ignition switch
G02-06 4. "IG. COIL" fuse
5. "FI" fuse
E03-17 6. Main relay
7. ECM (PCM)
8. Malfunction indicator lamp
9. Combination meter

STEP ACTION YES NO

1 Main Relay Operating Sound Check Go to Step 5. Go to Step 2.
Is operating sound of main relay heard at ignition switch ON?
2 Fuse Check Go to Step 3. Check for short in
Is main "FI" fuse in good condition? circuits connected
to this fuse.
3 Main Relay Check Go to Step 4. Replace main
1) Turn OFF ignition switch and remove main relay. relay.
2) Check for proper connection to main relay at terminal "A"
and "B".
3) If OK, check main relay for resistance and operation
referring to MAIN RELAY INSPECTION in this section.
Is check result satisfactory?
4 ECM (PCM) Power Circuit Check Go to Step 5. "Bl" or "B/W"
1) Turn OFF ignition switch, disconnect connectors from circuit open.
ECM (PCM) and install main relay.
2) Check for proper connection to ECM (PCM) at terminals
G01-03, G01-02 and G02-15.
3) If OK, then measure voltage between terminal G02-15 and
ground with ignition switch ON.
Is voltage 10 14 V?
6E2-18 ENGINE AND EMISSION CONTROL SYSTEM

A-4 ECM (PCM) POWER AND GROUND CIRCUIT CHECK (Page 2 of 2)

STEP ACTION YES NO
5 ECM (PCM) Power Circuit Check Check ground circuits Go to Step 6.
1) Using service wire, ground terminal G02-15 and "B/Bl" for open.
measure voltage between terminal G01-03 If OK, then substitute a
(G01-02) and ground at ignition switch ON. known-good ECM (PCM)
Is it 10 14 V? and recheck.
6 Is operating sound of main relay heard in Step 1? Go to Step 7. "W " or "Bl/B" wire
open.
7 Main Relay Check "W" or "Bl/B" wire Replace main relay.
1) Check main relay according to procedure in Step open.
3.
Is main relay in good condition?
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-19

CODE NO.11 (P0107/P108) MAP SENSOR CIRCUIT

(SIGNAL VOLTAGE LOW, HIGH OR PERFORMANCE PROBLEM)

NOTE:
When Code No.11 (P0107/P0108), 13 (P0122/P0123)
and 19 (P0117/P0118) are indicated together, it is
possible that "B / Bl" wire is open or "G03-9" terminal
connection is poor.

PNK
G01-09

G01-11 1. ECM (PCM)

2. ECM (PCM) connector
G01-05 3. MAP sensor
4. MAP sensor connector
5. To other sensors
5

STEP ACTION YES NO

1 1) Disconnect MAP sensor connector with Go to Step 2. "PNK" wire open or short.
ignition switch OFF. Poor "G01-09" connection.
2) Check voltage between "PNK " wire If wire and connection are
terminal of MAP sensor connector and OK, substitute a known-good
ground with ignition switch ON. ECM (PCM) and recheck.
Is voltage about 4 5 V?
2 1) Check voltage between "Lg/Y" wire Go to Step 3. "Lg/Y" wire open or short.
terminal of MAP sensor connector and Poor "G01-11" connection.
ground with ignition switch ON. If wire and connection are
Is voltage about 4 5 V? OK, substitute a known-good
ECM (PCM) and recheck.
3 1) Connect "Lg/Y" and "B/Bl" wire terminals of Go to Step 4. "B/Bl" wire open.
MAP sensor connector using service wire. Poor "G01-05" connection.
2) Check voltage between "Lg/Y" wire If wire and connection are
terminal of MAP sensor connector and OK, substitute a known-good
ground. ECM (PCM) and recheck.
Is voltage about 0 V?
4 1) Remove MAP sensor. Clean air passage or Go to Step 5.
2) Visually inspect air pressure inlet passage replace as necessary.
of MAP sensor for clogging.
Is there any blockage?
5 1) Perform MAP SENSOR INSPECTION in Poor connection of Faulty MAP sensor.
this section. MAP sensor connector
Is MAP sensor in good condition? terminals.
If connection is OK,
substitute a known-
good ECM (PCM) and
recheck.
6E2-20 ENGINE AND EMISSION CONTROL SYSTEM

Fig. for STEP 1 Fig. for STEP 2 Fig. for STEP 3

NOTE:
Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page
6E2-32 to confirm that the trouble has been corrected.
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-21

CODE NO.13 (P0122/P0123) TP SENSOR CIRCUIT

(SIGNAL VOLTAGE HIGH OR LOW)

NOTE:
When Code No.11 (P0107/P0108), 13 (P0122/P0123)
and 19 (P0117/P0118) are indicated together, it is
possible that "B / Bl" wire is open or "G01-05" terminal
connection is poor.

G01-08

1. ECM (PCM)
G01-12 2. ECM (PCM) connector
3. TP sensor
G01-05 4. TP sensor connector
5. To other sensors

STEP ACTION YES NO

1 1) Disconnect TP sensor connector with Go to Step 2. "Lg/R" wire open or short.
ignition switch OFF. Poor "G01-8" connection.
2) Check voltage between "Lg/R" wire If wire and connection are OK,
terminal of TP sensor coupler and ground substitute a known-good
with ignition switch ON. ECM (PCM) and recheck.
Is voltage about 4 5 V?
2 1) Check voltage between "Lg" wire terminal Go to Step 3. "Lg" wire open or short.
of TP sensor coupler and ground with Poor "G01-12" connection.
ignition switch ON. If wire and connection are OK,
Is voltage about 4 5 V? substitute a known-good
ECM (PCM) and recheck.
3 1) Connect "Lg" and "B/Bl" wire terminal of Go to Step 4. "B/Bl" wire open.
TP sensor connector using service wire. Poor "G01-05" connection.
2) Check voltage between "Lg" wire terminal If wire and connection are OK,
of TP sensor connector and ground with substitute a known-good
ignition switch ON. ECM (PCM) and recheck.
Is voltage about 0 V?
4 1) Perform TP SENSOR INSPECTION in this Poor connection of TP Faulty TP sensor.
section. sensor connector
Is TP sensor in good condition? terminals.
If connection is OK,
substitute a known-
good ECM (PCM) and
recheck.
6E2-22 ENGINE AND EMISSION CONTROL SYSTEM

Fig. for STEP 1 Fig. for STEP 2 Fig. for STEP 3

NOTE:
Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page
6E2-32 to confirm that the trouble has been corrected.
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-23

DTC P0031/P0032 Heated Oxygen Sensor (HO2S)

Heater Control Circuit High/Low
CIRCUIT DESCRIPTION

3 4
Y G01-29
2
6
B/W R G01-13

7
B/W Y/R G01-07

5
E03-05
1

G02 G01 G03 E03

7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1

17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8

27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17 25 24 23 22 21 20 19 18

34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 31 30 29 28 27 26

1. Main fuse 4. “IG METER” fuse 7. ECM (PCM)

2. Ignition switch 5. Heater
3. Fuse box 6. HO2S

DTC DETECTING CONDITION POSSIBLE CAUSE

DTC will set when A or B condition is met. • HO2S heater circuit open or shorted to
A: ground
• Low voltage at terminal “G01-07” when engine is • HO2Sheater characteristics malfunction
running at high load. • ECN (PCM) malfunction
B:
• High voltage at terminal “G01-07” when engine is
running under condition other than above.
*2 driving cycle detection logic, Continuous monitoring

DTC CONFIRMATION PROCEDURE

WARNING:
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident
And be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out with 2 persons, a driver and a tester.

1) Turn ignition switch OFF.

2) Clear DTC with ignition switch ON, check vehicle and environmental condition for :
3) Start vehicle and depress accelerator pedal fully for 5 sec. or longer
4) Stop vehicle.
5) Check DTC in “DTC” mode and pending DTC in “ON BOARD TEST” or “PENDING DTC” mode.
6E2-24 ENGINE AND EMISSION CONTROL SYSTEM

INSPECTION

Step Action Yes No

1 Was “ENGINE DIAG. FLOW TABLE” Go to Step 2. Go to “ENGINE DIAG.
performed? FLOW TABLE”.

2 Check HO2S heater power circuit. Go to Step 3. “B/W” wire open circuit or
1) Disconnect connector from HO2S sensor shorted to ground circuit.
with ignition switch turn OFF.
2) Check proper connection to HO2S sensor at
G01-07 and E03-05.
3) If wire and connection are OK, measure
voltage between “B/W” wire terminal and
engine ground with ignition switch turn ON.
Is voltage over 10 V?

3 Check HO2S heater power circuit. Go to Step 4. “B/W” wire high

1) Disconnect connector from ECM (PCM) with resistance circuit
ignition switch turn OFF.
2) Measure resistance between “B/W” wire
terminal in HO2S connector and E03-05
terminal wire in ECM connector.
Is resistance below 5 W?

4 Check HO2S heater drive circuit. Go to Step 5. “Y/R” wire shorted to

1) Check that there is insulating between “Y/R” ground circuit.
wire terminal and vehicle body ground.
Is there insulating?

5 Check HO2S heater drive circuit. Go to Step 6. “Y/R” wire shorted to

1) Turn ON ignition switch. power circuit.
2) Measure voltage between “Y/R” wire terminal
and vehicle body ground.
Is voltage 0 V?

6 Check HO2S heater drive circuit. Go to Step 7. “Y/R” wire open circuit.
1) Connect connector to HO2S with ignition
switch turn OFF.
2) Trun ON ignition switch.
3) Measure voltage “G01-07” terminal wire and
vehicle body ground with disconnect
connector from ECM (PCM).
Is it result over 10 V?

7 Check heater sensor Go to Step 8. Replace HO2S.

1) Disconnect HO2S coupler with ignition
switch OFF.
2) Check HO2S heater resistance.
Is it 5.0 - 6.4 W at 20°C, 68°F?

8 Check HO2S heater power circuit. HO2S heater circuit “Y/R” wire high
1) Disconnect connecter from ECM (PCM) with are OK. resistance circuit.
ignition switch turn OFF. Sustitute a known-good
2) Measure resistance between “G01-07” ECM (PCM) and
terminal wire and “E03-05” terminal wire. recheck.
Is resistance below 10W?
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-25

DTC P0134 Heated Oxygen Sensor (HO2S)

CIRCUIT DESCRIPTION
DTC CONFIRMATION PROCEDUR

Y G01-29
6 7
R G01-13

Y/R G01-07

E03-05

G02 G01 G03 E03

7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1

17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8

27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17 25 24 23 22 21 20 19 18

34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 31 30 29 28 27 26

1. Main fuse 4. “IG METER” fuse 6. HO2S

2. Ignition switch 5. Heater 7. ECM (PCM)
3. Fuse box

DTC DETECTING CONDITION POSSIBLE CAUSE

• When running at idle speed after engine warmed up and • Heated oxygen sensor-1 malfunction
running at specified vehicle speed, HO2S output voltage • “Or” or “R” circuit open (poor connection) or
does not go below 0.3 V or over 0.6 V. short
*2 driving cycle detection logic, Monitoring once/1 driving. • Fuel system malfunction
• Exhaust gas leakage

DTC CONFIRMATION PROCEDURE

WARNING:
• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident
and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out with 2 persons, a driver and a tester.

1) Turn ignition switch OFF. Clear DTC with ignition switch ON, check vehicle and environmental condition for :
– Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)
– Ambient temp. : –10°C, 14°F or higher
– Intake air temp. : 70°C, 158°F or lower
2) Warm up engine to normal operating temperature.
3) Drive vehicle at 30 – 40 mph, 50 – 60 km/h for 2 min.
4) Stop vehicle and run engine at idle for 2 min.
5) Check DTC in “DTC” mode and pending DTC in “ON BOARD TEST” or “PENDING DTC” mode.
6E2-26 ENGINE AND EMISSION CONTROL SYSTEM

INSPECTION

Step Action Yes No

1 Was “ENGINE DIAG. FLOW TABLE” Go to Step 2. Go to “ENGINE DIAG.
performed? FLOW TABLE”.

2 Is there DTC(s) other than HO2S (DTC Go to applicable DTC Go to Step 3.

P0031/P0032)? Diag. Flow Table.

Intermittent trouble. Go to Step 4.

3 Check HO2S signal. Check for intermittent
1) Connect scan tool to DLC with referring to “Intermittent
ignition switch OFF. and Poor Connection” in
2) Warm up engine to normal Section 0A.
operating temperature and keep it If they are OK, go to Step
at 2000 r/min. for 60 sec. 8.
3) Repeat racing engine (Repeat
depressing accelerator pedal 5 to 6
times continuously and take foot off
from pedal to enrich and enlean
A/F mixture).
Does HO2S output voltage deflect
between 0.35 V and over 0.6 V
repeatedly?

4 Check HO2S sensor ground. Go to Step 5 "Y" wire open circuit.

1) Disconnect connector from HO2S Poor “G01-29” terminal
sensor with ignition switch turn connection.
OFF. Faulty ECM (PCM)
2) Check proper connection to HO2S ground.
sensor If they are OK, substitute a
at "Y", "R" and "Y/R". known good ECM and
3) If wire and connection are OK, recheck.
check there is continuity between
"Y" wire terminal and engine
ground.
Is there continuity?

5 Check HO2S sensor ground. Go to Step 6 "Y" wire high resistance

1) With ignition switch turn ON, check circuit.
voltage between "Y" wire terminal Poor “G01-29” terminal
and engine ground. connection.
Is voltage about 0.1 V or less? Faulty ECM (PCM)
ground.
If they are OK, substitute a
known good ECM and
recheck.

6 Check wire circuit. Go to Step 7 "R" wire high resistance

1) Measure resistance between "R" wire circuit or open circuit.
terminal and engine ground. Poor “G01-13” terminal
Is resistance less than 1.6 MW? connection.
Faulty ECM (PCM)
ground.
If they are OK, substitute a
known good ECM and
recheck.
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-27

Step Action Yes No

7 Check wire circuit. Go to Step 8. "Y" wire shorted to ground

1) Disconnect connector from ECM circuit.
(PCM) with ignition switch turn OFF.
2) Check that there is insulating
between "Y" wire terminal and body
ground.
Is there insulating?

8 Check HO2S heater circuit. Check HO2S referring Repair or replace

1) Check HO2S heater circuit, to “HEATED OXYGEN Heated O2 sensor
referring to SENSOR” in Section 6E2.
DTC P0031/P0032 diagnosis If it in good condition,
flow table. substitute a known-good
ECM (PCM) and recheck.

Fig. 1 for Step 3

Normal NG NG NG
0.6 V

0.3 V
6E2-28 ENGINE AND EMISSION CONTROL SYSTEM

CODE NO.15 (P0340) CMP SENSOR CIRCUIT

(SENSOR SIGNAL NOT INPUTTED FOR 2 SECONDS AT ENGINE CRANKING)

YEL
G01-32
1. ECM (PCM)
2. CMP sensor
BRN 3. Rotor
G01-33 4. CMP sensor connector

NOTE:
If starter circuit is open (i.e., start signal circuit is OK but starter fails to run), this DTC is stored in memory
at starter switch ON, even through CMP sensor is in good condition.
When starter motor fails to run and this DTC appears, check starter circuit first.

STEP ACTION YES NO

1 1) Disconnect couplers from ECM (PCM). Go to Step 2. "YEL" wire open or
2) Measure resistance between "G01-32" and short.
"G01-33" terminals of ECM (PCM) coupler. "BRN" wire open or
CMP sensor resistance: about 230 W at short.
20°C (68°F) Poor terminal
3) Measure resistance between "G01-32" connection of CMP
terminal of ECM (PCM) coupler and ground. sensor coupler.
Insulation resistance: 1 MW or more If wire and connection
Were measured resistance values in above are OK, replace CMP
2) and 3) as specified? sensor.
2 1) Check CMP sensor referring to Section 6F1. Poor "G01-32" or Faulty CMP sensor.
Is it in good condition? "G01-33" terminal
connection of ECM
(PCM) coupler.
If connection is OK,
substitute a known-good
ECM (PCM) and recheck.

NOTE:
Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page
6E2-32 to confirm that the trouble has been corrected.
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-29

CODE NO.16 (P0500) VSS CIRCUIT

(VSS SIGNAL NOT INPUTTED ALTHOUGH FUEL IS KEPT CUT AT LOWER THAN
4000 R/MIN. FOR LONGER THAN 4 SECONDS)

E03-15

1. ECM
2. VSS (Reed switch)
3. Speedometer

STEP ACTION YES NO

1 Does speedometer indicate vehicle Go to Step 2. Faulty speedometer cable.
speed?
2 1) Connect couplers to ECM with ignition Poor E03-15 connection. Go to Step 3.
switch OFF. If connection is OK,
2) Connect voltmeter between E03-15 intermittent trouble or
terminal of ECM coupler and body faulty ECM.
ground.
3) Hoist rear end of vehicle and lock
rear right tire.
4) Turn rear left tire quickly with ignition
switch ON.
Does voltmeter indicate deflection
between 0 and 4 5V a few times
while tire is turned one revolution?
3 Check VSS refer to VSS INSPECTION in "Br/Y" wire open or short. Faulty speedometer VSS.
this section. "B" wire open.
Is it in good condition? If wire and connection are
OK, substitute a known-
good speedometer and
recheck.

NOTE:
Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page
6E2-32 to confirm that the trouble has been corrected.
6E2-30 ENGINE AND EMISSION CONTROL SYSTEM

CODE NO.18 (P0112/P0113) IAT SENSOR CIRCUIT

(SIGNAL VOLTAGE HIGH OR LOW)

G01-16

G01-05 1. ECM (PCM)

2. IAT sensor
3. IAT sensor connector
4. To Heated oxygen sensor

STEP ACTION YES NO

1 1) Disconnect IAT sensor connector with Go to Step 2. "Lg/B" wire open or short.
ignition switch OFF. Poor "G01-16" connection.
2) Check voltage between "Lg /B" wire
terminal of IAT sensor connector and
ground with ignition switch ON.
Is voltage about 4 5 V?
2 1) Connect IAT sensor connector terminals Go to Step 3. "B /Bl" wire open or poor
using service wire. "G01-05" connection.
2) Check voltage between "Lg /B" wire If wire and connection are OK,
terminal of IAT sensor connector and substitute a known-good
ground with ignition switch ON. ECM (PCM) and recheck.
Is voltage 0.15 V or less?
3 1) Perform IAT SENSOR INSPECTION in Poor connection of Faulty IAT sensor.
this section. IAT sensor coupler
Is IAT sensor in good condition? terminals.
If connection is OK,
substitute a known-
good ECM (PCM) and
recheck.

Fig. for STEP 1 Fig. for STEP 2

1. IAT sensor connector disconnected 1. IAT sensor connector disconnected

2. Engine ground 2. Service wire
3. Engine ground

NOTE:
Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page
6E2-32 to confirm that the trouble has been corrected.
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-31

CODE NO.19 (P0117/P0118) ECT SENSOR CIRCUIT

(SIGNAL VOLTAGE HIGH OR LOW)

NOTE:
When Code No.11 (P0107/P0108), 13 (P0122/P0123) and
19 (P0117/P0118) are indicated together, it is possible
that "G / R" wire is open or "G03-9" terminal connection
is poor.
G01-15

G01-05
1. ECM (PCM)
2. ECT sensor
3. ECT sensor connector
4. To other sensors
5. To combination meter

STEP ACTION YES NO

1 1) Disconnect ECT sensor connector with Go to Step 2. "Lg/W" wire open or short.
ignition switch OFF. Poor "G01-15" connection.
2) Check voltage between "Lg /W" wire
terminal of ECT sensor connector and
ground with ignition switch ON.
Is voltage about 4 5 V?
2 1) Connect ECT sensor connector terminals Go to Step 3. "B /Bl" wire open or poor
using service wire. "G01-05" connection.
2) Check voltage between "Lg /W" wire If wire and connection are OK,
terminal of ECT sensor connector and substitute a known-good
ground with ignition switch ON. ECM (PCM) and recheck.
Is voltage 0.15 V or less?
3 1) Perform ECT SENSOR INSPECTION in Poor connection of Faulty ECT sensor.
this section. ECT sensor
Is ECT sensor in good condition? connector terminals.
If connection is OK,
substitute a known-
good ECM (PCM)
and recheck.

Fig. for STEP 1 Fig. for STEP 2

1. ECT sensor connector disconnected

1. ECT sensor connector disconnected 2. Service wire
2. Engine ground 3. Engine ground

NOTE:
Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page
6E2-32 to confirm that the trouble has been corrected.
6E2-32 ENGINE AND EMISSION CONTROL SYSTEM

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE

WARNING:
When performing a road test, select a safe place where there is not traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.

1) Clear DTC stored in ECM memory referring to DTC CLEARANCE in this section.
2) Perform DTC confirmation test under the following conditions.
3) Check DTC referring to DTC CHECK in this section.

Test Condition for Code No. 13 (P0122/P0123), 18 (P0112/P0113), 19 (P0117/P0118)

Turn ignition switch ON.

Test Condition for Code No. 15 (P0340)

Crank engine for 3 sec.

Driving Test Condition for Code No. 16 (P0500)

1) Start engine and warm up engine to normal operating

temperature.
2) Increase engine speed to 4,000 r /min. in 3rd gear in case
of M/T model and "2" range in case of A/T model.
3) Release accelerator pedal and with engine brake applied,
keep vehicle coasting for 5 to 8 seconds till engine speed
reaches 2,000 r/ min.
4) Repeat above steps 2) and 3) 3 times or more.
5) Stop vehicle.

Driving Test Condition for Code No. 14 (P0031/P0032/P0134)

1) Start engine and warm up engine to normal operat-
ing temperature.
2) Increase vehicle speed to 31 to 37 mile/h (50 – 60
km/h) in 5th gear of M/T or in 4th of "D" range of A/T.
3) Keep driving at above vehicle speed for 25 to 30 se-
conds.
4) Release accelerator pedal and with engine brake
applied, decrease vehicle speed to about 18 mile/h
(30 km/h).
5) Repeat above steps 2) to 4) 3 times or more.
NOTE: 6) Stop vehicle.
If the above driving test can not be performed, check oxygen sensor for voltage referring to Step 1 and
2 of Code No. 14 (P0031/P0032/P0134) Diag. Flow Table and confirm that oxygen sensor and its circuit
(Closed Loop System) are in good condition.

Test Condition for Code No. 11 (P0107 / P0108)

1) Start engine.
2) Maintain engine speed at 2000RPM for 5 seconds.
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-33

B-1 FUEL PUMP AND ITS CIRCUIT CHECK

1. ECM (PCM)
2. Fuel pump relay
3. Fuel pump
4. Main relay
5. "IG. COIL" fuse
6. "FI" fuse
G02-10

G01-02/
G01-03
G02-15

STEP ACTION YES NO

1 Is fuel pump heard to operate 2 Fuel pump and its circuit are in good Go to Step 2.
seconds after ignition switch ON? condition.
2 1) Remove fuel pump relay from Go to Step 3. "Bl/B" or "P/B" wire
relay box with ignition switch OFF. open, poor fuel pump
2) Connect two terminals of relay relay-to-coupler
connector as shown in figure using connection or faulty
service wire. fuel pump.
Is fuel pump heard to operate with
ignition switch ON?
3 1) Check fuel pump relay, referring to Poor fuel pump relay-to-coupler Faulty fuel pump relay.
p.6E1-68. connection, "P " or " B / W" wire open
Is it in good condition? or poor G02-10 connection.
If wire and connection are OK,
substitute a known-good ECM (PCM)
and recheck.

Fig. for STEP 2

6E2-34 ENGINE AND EMISSION CONTROL SYSTEM

B-2 FUEL INJECTOR AND ITS CIRCUIT CHECK

1. Battery positive voltage

G02-05 2. "IG. COIL" fuse
G01-03 3. "FI" fuse
G02-04 4. Main relay
G01-02 5. ECM (PCM)
G02-03 6. No.1 injector
G02-15 7. No.3 injector
8. No.4 injector
G02-02 9. No.2 injector

G02-07
G02-06

STEP ACTION YES NO

1 Check each injector for operating sound at engine Fuel injector circuit is in Go to Step 2.
cranking using sound scope. good condition.
Do all 4 injector make operating sound?
2 Does none of 4 injectors make operating sound at Go to Step 4. Go to Step 3.
Step 1?
3 Check fuel injector(s) referring to p. 6E1-57. Check coupler Faulty fuel injector(s).
Is it in good condition? connection and wire
harness of injector not
making operating sound.
4 Check power circuit of injectors for open and short. Check all 4 injectors for Power circuit open or
Is it in normal condition? resistance respectively. short.
If resistance is OK,
substitute a known-good
ECM (PCM) and
recheck.
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-35

B-3 FUEL PRESSURE CHECK (Page 1 of 2)

1. Fuel Injector
2. Delivery pipe
3. Fuel regulator
4. Fuel filter
5. Fuel pump

Special Tool
(A) Gauge (09912-58441)
(B) Hose (09912-58431)
(C) 3-way joint (09912-58490)

STEP ACTION YES NO

1 1) Release fuel pressure from fuel feed line. Go to Step 2. Go to Step 5.
2) Install fuel pressure gauge.
3) Check fuel pressure by repeating ignition switch
ON and OFF.
Is fuel pressure then 270 310 kPa
(2.7 3.1 kg/cm2, 38.4 44.0 psi)?
2 Is 200 kPa (2.0 kg/cm 2, 28.4 psi) or higher fuel Go to Step 3. Go to Step 4.
pressure retained for 1 minute after fuel pump is
stopped at Step 1?
3 1) Start engine and warm it up to normal operating Normal fuel pressure. Clogged vacuum
temperature. passage for fuel
2) Keep it running at specified idle speed. pressure regulator or
Is fuel pressure then within 200 240 kPa faulty fuel pressure
(2.0 2.4 kg /cm2, 28.4 34.1 psi)? regulator.
4 Is there fuel leakage from fuel feed line hose, pipe or Fuel leakage from Go to Step 10.
their joint? hose, pipe or joint.
5 Was fuel pressure higher than spec. in Step 1? Go to Step 6. Go to Step 7.
6 1) Disconnect fuel return hose from fuel pressure Restricted fuel return Faulty fuel pressure
regulator and connect new return hose to it. hose or pipe. regulator.
2) Put the other end of new return hose into approved
gasoline container.
3) Operate fuel pump.
Is specified fuel pressure obtained then?
6E2-36 ENGINE AND EMISSION CONTROL SYSTEM

B-3 FUEL PRESSURE CHECK (Page 2 of 2)

STEP ACTION YES NO
7 Was no fuel pressure applied in step 1? Go to Step 8. Go to Step 9.
8 With fuel pump operated and fuel return hose blocked Faulty fuel pressure Shortage of fuel or
by pinching it, is fuel pressure applied? regulator. fuel pump or its circuit
malfunction.
9 1) Operate fuel pump. Faulty fuel pressure Clogged fuel filter,
2) With fuel return hose blocked by pinching it, check regulator. restricted fuel feed
fuel pressure. hose or pipe, Faulty
Is it 450 kPa (4.5 kg/cm 2, 63.9 psi) or more? fuel pump or fuel
leakage from hose
connection in fuel
tank.
10 1) Disconnect fuel return hose from pressure Faulty fuel pressure Fuel leakage from
regulator and connect new return hose to it. regulator. injector, Fuel leakage
2) Insert the other end of new return hose into from between injector
approved gasoline container. and delivery pipe,
3) Check again if specified pressure is obtained. Faulty fuel pump
While doing so, does fuel come out of return hose? (faulty check valve in
fuel pump) or Fuel
leakage from fuel
pressure regulator
diaphragm.

Fig. for STEP 1

1. Fuel feed hose

2. Fuel delivery pipe

Special Tool
(A) Gauge
(B) Hose
(C) 3-way joint
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-37

B-4 IDLE AIR CONTROL SYSTEM CHECK

G01-03 G01-08
G01-12
G01-02
G01-05
G02-15
G02-08
G02-06

G02-07
1. Battery positive voltage
2. "IG. COIL" fuse
3. "FI" fuse
4. Main relay
5. ECM (PCM)
6. IAC valve
7. Throttle body
8. Engine coolant
9. Bypass air
10. TP sensor

STEP ACTION YES NO

1 Check engine idle speed and IAC duty referring to System is in good Go to Step 2.
IDLE SPEED/IAC DUTY INSPECTION on condition.
P.6E1-48.
Is idle speed within specification?
2 1) Check IAC valve referring to IAC VALVE Go to Step 3. Go to Step 6.
INSPECTION in this section.
Is check result in good condition?
3 1) Connect SUZUKI scan tool to DLC. Check for following: Go to Step 4.
2) With the ignition switch ON position, check EVAP canister purge valve
"CLOSED THROT POS" in parameter data list. Accessory engine load
Throttle valve fully close: ON PCV system
Throttle valve slight open: OFF Idle air passage.
Is each check result as specified?
4 1) With the ignition switch OFF position Recheck engine idle Go to Step 5.
disconnect negative battery cable for 30 speed.
seconds and connect it.
2) Recheck closed throttle position referring to
Step 3.
Is each check result as specified?
5 1) With the ignition switch ON position, check Substitute a known-good Check TP sensor
voltage between G01-12 and ground. ECM and recheck. referring TP SENSOR
Throttle valve fully close: 0.78 – 0.83 V INSPECTION in this
Is each check result as specified? section.
6 1) Check "R/W", "Bl/B" and "B/Bl" wire for open Go to Step 7. Repair or replace.
and short.
Are they in good condition?
7 1) Substitute a known-good IAC valve. IAC valve malfunction. Substitute a known-
2) Check IAC valve referring to IAC VALVE good ECM and
INSPECTION in this section. recheck.
Is check result in good condition?
6E2-38 ENGINE AND EMISSION CONTROL SYSTEM

B-5 EVAPORATIVE EMISSION CONTROL SYSTEM CHECK

TP sensor
MAP sensor
CMP sensor
ECT sensor
VSS
IAT sensor

G01-18
G01-07/
G01-06

G02-06/
G02-15 G02-07

1. To intake manifold 6. EVAP canister purge valve

2. Tank pressure control valve 7. Main relay
3. EVAP canister 8. Sensed information
4. Air 9. ECM (PCM)
5. Air and vapor 10. Fuel tank

STEP ACTION YES NO

1 Check canister purge system for Check EVAP canister referring to Go to Step 2.
operation referring to p. 6E1-71. p. 6E1-75 and fuel filler cap
Is it in good condition? referring to Section 6C.
If OK, system is in good condition.
2 Check vacuum passage, hoses and "Bl/G" wire open, Vacuum passage
EVAP canister purge valve referring to "Bl/G" wire shorted to ground, clogged,
p.6E1-72. Poor EVAP canister purge valve Vacuum leakage or
Are they in good condition? coupler connection, Faulty EVAP canis-
Poor "G01-18" connection, ter purge valve
Poor performance of ECT sensor
or MAP sensor or TP sensor
If none of the above exists,
substitute a known-good ECM
(PCM) and recheck.
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-39

B-6 ENGINE START SIGNAL

1. ECM (PCM)
G02-01 2. ECM (PCM) connector
3. Main switch
4. To starting motor

STEP ACTION YES NO

1 1) With ignition switch OFF, disconnect couplers from ECM Engine starter "B /Y" wire open
(PCM). signal circuit is in or
2) Is 6 – 12 V voltage applied to G02-01 terminal of coupler good condition. Poor "G02-01"
only when cranking engine. connection
6E2-40 ENGINE AND EMISSION CONTROL SYSTEM

B-9 ELECTRIC LOAD SIGNAL CIRCUITS CHECK

E03-11 3

E03-02 4 1. ECM (PCM)

2. ECM (PCM) connector
3. From lighting switch (small)
4. From heater blower switch
5. Rear defogger switch (if equipped)

STEP ACTION YES NO

1 Check voltage at "E03-02" and "E03-11" terminal under Electric load "R/Y" wire open or
each condition given below. signal circuit short
are in good "Bl/W" wire open or
Small light turned OFF 1 V or less
condition. short
Small light turned ON 10 14 V
Poor "E03-02"
Is check result satisfactory? terminal connection
Poor "E03-11"
terminal connection
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-41

B-10 FUEL CUT OPERATION CHECK

1. ECM
2. ECM connector
3. TP sensor

G01-08

G01-12

G01-05

STEP ACTION YES NO

1 Check fuel cut operation referring FUEL CUT Fuel cut operation is Go to Step 2.
OPERATION INSPECTION in this section. in good condition.
Does fuel injector operate as specified?
2 Closed throttle position check: Substitute a known- Go to Step 3.
1) Connect SUZUKI scan tool to DLC. good ECM and
2) With the ignition switch ON position, check recheck.
"CLOSED THROT POS" in parameter data list.
Throttle valve fully close: ON
Throttle valve slight open: OFF
Is each check result as specified?
3 Closed throttle position check: Recheck fuel cut Go to Step 4.
1) With the ignition switch OFF position disconnect operation.
negative battery cable for 30 seconds and connect
it.
2) Recheck closed throttle position referring to Step 2.
Is each check result as specified?
4 TP sensor signal voltage check: Substitute a known- Check TP sensor
1) With the ignition switch at ON position, check voltage good ECM and referring to TP
between G01-12 and ground. recheck fuel cut SENSOR
Throttle valve fully close: 0.78 0.83 V operation. INSPECTION in this
Throttle valve slight open: 3.7 4.7 V section.
Is each check result as specified?
6E2-42 ENGINE AND EMISSION CONTROL SYSTEM

B-11 EGR CHECK

1 5
1. ECM
Gr 2. Main Relay
G02-17 3. Tail Fuse
4. Main Fuse
Gr/R 5. EGR
G02-34

Gr/Bl
G02-16

Gr/B
G02-33

ECM

G02-15 Bl

Bl/B
G01-02
Bl/B
G01-03

STEP ACTION YES NO

1 1) Check EGR system referring to EGR system is in good condition. Go to step 2.

p.6E2-61
If wire and connection are OK, "Gr", "Gr/R" wire open.
2) is it in good condition? intermittent trouble or faulty ECM.
"Gr/Bl","Gr/B" wire
Recheck, referring to open.
“Intermittent Trouble” in
Poor "EGR" terminal
SECTION 0A.
connection
If wire and connection are
OK, substitute a known-
good ECM
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-43

INSPECTION OF ECM (PCM) AND ITS

CIRCUITS
ECM (PCM) and its circuits can be checked at ECM (PCM) wiring
couplers by measuring voltage and resistance.

CAUTION:
ECM (PCM) cannot be checked by itself. It is strictly prohib-
ited to connect voltmeter or ohmmeter to ECM (PCM) with
couplers disconnected from it.

VOLTAGE CHECK
1) Remove ECM (PCM) from body with ignition switch OFF refer-
ring to ECM (PCM) REMOVAL.
2) Connect ECM (PCM) connectors to ECM (PCM).
3) 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.

TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE)

G02 G01 G03 E03

E01 E02 #1 #2 #3 #4 STA OXH E24 +BP PM PM +BB 1GS SLS2 EL3

EGR1 EGR3 MR FPR MON 15C PRG THA THW OX VTA PM VCC2 VCC ST DNL SPD2 EL+

EGR2 EGR4 1GT1 1GT2 DN T5 N- N+ E22 E21

6E2-44 ENGINE AND EMISSION CONTROL SYSTEM

TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION

G02-1 Engine Starting Signal 1.5 v or less Ignition switch ON
6 - 12 V While engine cranking
G02-2 Fuel Injector no. 4 10 - 14 V Ignition switch ON
G02-3 Fuel Injector no. 3 10 - 14 V Ignition switch ON
G02-4 Fuel Injector no. 2 10 - 14 V Ignition switch ON
G02-5 Fuel Injector no. 1 10 - 14 V Ignition switch ON
G02-6 Engine Ground ---------
G02-7 Engine Ground ---------
G02-8 IAC Valve ---------
G02-9 Duty Output Terminal 10 -14 V Ignition switch ON
1 V or less Ignition switch ON
G02-10 Fuel Pump Relay 1 V or less For 3 seconds after ignition switch ON or while
engine running
10 - 14 V After 3 seconds from ignition switch ON
G02-11 ACCompressor magnet with engine stopped
clutch relay and condensor 1 V or less Engine running, A/C compressor and A/C
fan control relay (with condensor fan : ON
A/C Relay 10 - 14 V Engine running, A/C compressor and A/C
condensor fan : OFF
G02-12 Radiator Fan Control Relay 1 V or less Engine cooling fan ON
G02-13 Blank
G02-14 Blank
G02-15 Main Relay
G02-16 EGR Terminal 3 10 - 14 V Ignition switch ON
G02-17 EGR Terminal 1 10 - 14 V Ignition switch ON
G02-19 Blank
G02-20 Blank
G02-21 Blank
G02-22 Blank
G02-23 Blank
G02-24 Blank
G02-25 Blank
G02-26 Blank
G02-27 Blank
G02-28 Blank
G02-29 Test Switch Terminal 10 - 14 V Ignition switch ON
1 V or less Ignition switch ON, Test switch terminal grounded
G02-30 Diagnosis Switch Terminal 10 - 14 V Ignition switch ON
1 V or less Ignition switch ON, Test switch terminal grounded
G02-31 Igniter-2
G02-32 Igniter - 1
G02-33 EGR Terminal 4 10 - 14 V Ignition switch ON
G02-34 EGR Terminal 2 1 V or less Ignition switch ON
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-45

TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION

G01-1 Ground
G01-2 Power Source 10 - 14 V Ignition switch ON
G01-3 Power Source 10 - 14 V Ignition switch ON
G01-4 Blank
G01-5 Sensor Ground
G01-6 Blank
G01-7 Oxygen Sensor Heater 10 - 14 V Ignition switch ON
G01-8 Power Supply for TP Sensor 4.5 - 5.5 V Ignition switch ON
G01-9 Power Supply for MAP Sensor 4.5 - 5.5 V Ignition switch ON
G01-10 Blank
G01-11 MAP sensor About 3.6 V Ignition switch ON, engine stop
About 1 - 3 V Engine running at idle speed, A/C OF
G01-12 TP sensor 0.78 - 0.83 Throttle valve at idle position
3.7 - 4.7 V Throttle valve at full open position
G01-13 Heated Oxygen Sensor 0.3 - 0.6 V deflection When engine is running at idle
G01-14 Blank
G01-15 ECT sensor 2.5 - 3.0 V Engine coolant temp : at 20 degree C
0.6 - 0.9 V Engine coolant temp : at 80 degree C
G01-16 IAT sensor 2.0 - 2.5 V IAT sensor ambient temp :at 20 degree C
0.4 - 0.6 IAT sensor ambient temp :at 80 degree C
G01-17 Blank

G01-18 EVAP canister purge valve 10 - 14 V Ignition switch ON

G01-19 Blank
G01-20 Blank
G01-21 Blank
G01-22 Blank
G01-23 Blank
G01-24 Blank
G01-25 Blank
G01-26 Blank
G01-27 Blank
G01-28 Blank
G01-29 Heated oxygen sensor ground ---------
G01-30 CMP sensor Ground ---------
G01-31 A/C ON signal from A/C switch 10 - 14 V Ignition switch ON, A/C switch OFF,
equipped) Blower fan (if switch OFF
2 V or less Ignition switch ON, A/C switch OFF,
Blower fan switch ON
G01-32 CMP sensor (+) 1 V or less Ignition switch ON
G01-33 CMP sensor (–) About 0 V ---------
G01-34 Blank
G01-35 Blank
6E2-46 ENGINE AND EMISSION CONTROL SYSTEM

TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION

G03-01
To Blank
G03-35

E03-1 Electric load signal for small 1 V or less Ignition switch ON, Small light turned OFF and
Rear defogger turned light switch and OFF
10 - 14 V Ignition switch ON, Small light turned OFF and
Rear defogger turned ON
E03-2 Electric load signal for 2 V or less Ignition switch ON, Blower fan switch : High,
blower fan motor Middle or Low position
10 - 14 V Ignition switch ON, Blower fant switch :
OFF position
E03-3 Blank
E03-4 Stop light switch 1.5 or less Brake pedal released (seitch OFF),
(brake pedal switch) ignition switch ON
10-14 V Brake pedal released (seitch OFF),
ignition switch ON
E03-5 Ignition switch 10 - 14 V Ignition switch ON
E03-6 Blank
E03-7 Power source for back-up 10 - 14 V
E03-8 A/C evaporator temp sensor 2.0 - 2.5 V A/C ventilator outlet temp : at 20 degree C
(with A/C)
E03-9 Blank
E03-10 Blank
E03-11 Position lamp switch 1 V or less Ignition switch ON, Position light turned OFF
10 - 14 V Ignition switch ON, Position light turned ON
E03-12 Blank
E03-13 Blank
E03-14 VSS (Reed switch) Indicator deflection Ignition switch ON, Front left tire turned
repeated between quickly with front right tire locked.
0-1 V and 4-14 V
E03-15 Vehicle speed signal to EPS
E03-16 Malfunctioning Indicator Lamp About 0.5 or less Ignition switch ON, engine stops
10 - 14 V Engine running
E03-17 Data Link Connector 10 - 14 V Ignition switch ON
E03-18 Blank
E03-19 Blank
E03-20 Blank
E03-21 Blank
E03-22 Blank
E03-23 Blank
E03-24 Blank
E03-25 Blank
E03-26 Sensor ground
E03-27 Blank
E03-28 Blank
E03-29 Blank
E03-30 Blank
E03-31 Blank
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-47

RESISTANCE CHECK
1) Disconnect ECM (PCM) couplers from ECM (PCM) with ignition
switch OFF.

CAUTION:
Never touch terminals of ECM (PCM) itself or connect
voltmeter or ohmmeter.

2) Check resistance between each pair of terminals of discon-

nected couplers as listed in following table.

CAUTION:
• Be sure to connect ohmmeter probe from wire harness
side of coupler.
• Be sure to turn OFF ignition switch for this check.
• Resistance in table below represents that when parts
temperature is 20° C (68°F).

1. ECM (PCM) coupler disconnected

2. Ohmmeter

NORMAL
TERMINAL CIRCUIT CONDITION
RESISTANCE
G02-05 - G01-02 Fuel Injector No.1 11.3 - 13.8 W
G02-04 - G01-02 Fuel injector No.2 11.3 - 13.8 W
G02-03 - G01-02 Fuel Injector No.3 11.3 - 13.8 W
G02-02 - G01-02 Fuel injector No.4 11.3 - 13.8 W
G01-18 - G01-02 EVAP canister purge valve 30 - 34 W
G01-32 - G01-33 CMP sensor About 230 W -10 - 50° C (14 - 122° F)
G02-10 - E03-07 Fuel pump relay 60 - 150 W Battery disconnected and ignition switch ON
G02-15 - E03-07 Main relay 60 - 150 W Battery disconnected and ignition switch ON
G01- 01 / G02-06 / G02-07 -
Ground Continuity
Body ground
6E2-48 ENGINE AND EMISSION CONTROL SYSTEM

ON VEHICLE SERVICE
IDLE SPEED/IAC DUTY INSPECTION
Before idle speed/IAC duty check, make sure of the following.
Lead wires and hoses of Electronic Fuel Injection system is con-
nected securely.
Accelerator cable has some play, that is, it is not tight.
Valve lash is checked and adjusted according to maintenance
schedule.
Ignition timing is within specification.
All accessories (wipers, heater, lights, A/C, etc.) are out of ser-
vice.
Air cleaner has been properly installed and is in good condition.
No abnormal air inhaling from air intake system.
ECM (PCM) does not detect any malfunction DTC.
After above items are all confirmed, check idle speed and IAC duty
as follows.
NOTE:
Before starting engine, place transmission gear shift lever in
"Neutral" and, set parking brake and block drive wheels.

[Using SUZUKI scan tool]

1) Connect SUZUKI scan tool to DLC (1) with ignition switch OFF.
2) Start engine and warm it up to normal operating temperature.
3) Check idle speed and IAC duty by using "DATA LIST" mode of
SUZUKI scan tool.

ENGINE IDLE SPEED AND IAC DUTY

750 ± 50 r/min.
5 35 %
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-49

[Not using SUZUKI scan tool]

1) Using service wire (1), ground diagnosis switch terminal in moni-
tor connector.
2) Connect duty meter between duty output terminal (2) and
ground terminal (3) of monitor connector.
3) Set tachometer.
DUTY
METER 4) Start engine and warm it up to normal operating temperature.
5) Confirm that all accessories (light, A /C, blower fan, etc.) are out
of service.
6) Check idle speed and IAC duty.
If duty and/or idle speed is out of specifications, inspect idle air
control system referring to B-4 IDLE AIR CONTROL SYSTEM
CHECK in this section.

ENGINE IDLE SPEED AND IAC DUTY

750 ± 50 r/min.
5 35 %

NOTE:
Above duty values are on duty meter indications (high
voltage rate).
IAC duty can be checked roughly by using voltmeter. IAC
duty to voltage relation is as follows.

ON DUTY OFF DUTY VOLTMETER

METER INDICATION METER INDICATION INDICATION
(%) (%) (V)
0 100 0
50 50 0.5 x V
100 0

– "OFF DUTY METER" is such duty meter that indicates

approx. 100% when terminal voltage is approx. "0 V".
– "VB" represents battery voltage while engine of vehicle
being checked is running.
6E2-50 ENGINE AND EMISSION CONTROL SYSTEM

Heated Oxygen Sensor

OXYGEN SENSOR HEATER INSPECTION
Inspect heated oxygen sensor referring to flow table of
diagnostic trouble code No. 14 (P0130).

1) Disconnect sensor connector.

2) Using ohmmeter, measure resistance between terminals
“VB” and “GND” of sensor connector.
If found faulty, replace oxygen sensor.
NOTE:
Temperature of sensor affects resistance value largely.
Make sure that sensor heater is at correct temperature.
Resistance of oxygen sensor heaterHO2S 5.0 – 6.4 W at
20°C (68°F)
1. Viewed from terminal side

3) Connect sensor connector securely.

REMOVAL
WARNING:
To avoid danger of being burned, do not touch exhaust
system when system is hot. Oxygen sensor removal
should be performed when system is cool.
1) Disconnect negative cable at battery.
2) Remove HO2S (1) as follows.
a) Disconnect connector of HO2S and release its wire
harness from clamps, then remove exhaust manifold
cover.
b) Remove front bumper, if necessary.

INSTALLATION
Reverse removal procedure noting the following.
• Tighten heated oxygen sensor to specified torque.
Tightening torque
Heated oxygen sensor: 45 N·m (4.5 kg-m, 32.5 lb-ft)
1. HO2S

• Connect coupler of heated oxygen sensor and clamp wire

harness securely.
• After installing heated oxygen sensor, start engine and
check that no exhaust gas leakage exists.
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-51

EVAP EMISSION CONTROL SYSTEM

EVAP CANISTER PURGE INSPECTION
NOTE:
Before inspection, check to make sure that gear shift lever is
in neutral position (with A/T model, selector lever in "P" range)
and that parking brake lever is pulled all the way up.

1) Warn up engine to normal operating temperature.

2) Disconnect purge hose from EVAP canister.
3) Place finger against the end of disconnected hose and check
that vacuum is not felt there when engine is running at idle
speed.
4) Also check that vacuum is felt when engine speed is increased
to higher than about 3000 r/min.
If check result is not satisfactory, check vacuum passage,
hoses, EVAP canister purge valve, wire harness and ECM
(PCM).
Refer to B-5 EVAPORATIVE EMISSION CONTROL SYSTEM
CHECK.

VACUUM PASSAGE INSPECTION

Start engine and run it at idle speed. Disconnect vacuum hose from
EVAP canister purge valve. With finger placed against hose discon-
nected, check that vacuum is applied.
If it is not applied, clean vacuum passage by blowing compressed
air.

VACUUM HOSE INSPECTION

Check hoses for connection, leakage, clog and deterioration.
Replace as necessary.
6E2-52 ENGINE AND EMISSION CONTROL SYSTEM

EVAP CANISTER PURGE VALVE

INSPECTION
[Using SUZUKI scan tool]

WARNING:
Do not suck the air through valve. Fuel vapor inside valve
is harmful.

1) With ignition switch OFF, disconnect coupler from EVAP canis-

ter purge valve.
2) Check resistance between two terminals of EVAP canister
purge valve.

Resistance of EVAP canister purge valve:

W at 20° C (68°F)

If resistance is as specified, proceed to next operation check. If

not, replace.

3) Connect coupler to EVAP canister purge valve.

5) Disconnect vacuum hoses from intake manifold.

Blow into hose "A". Air should not come out of nozzle "B".

6) Open EVAP canister purge valve by executing "CANI PURGE

VAL" under "MISC TEST" mode of SUZUKI scan tool with igni-
tion switch ON. In this state, blow hose "A".
Air should come out of nozzle "B".
If check result is not as described, check wire harnesses for
open or short. If it is in good condition, replace EVAP canister
purge valve and recheck.
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-53

7) Connect vacuum hoses.

[Not using SUZUKI scan tool]

WARNING:
Do not suck the air through valve. Fuel vapor inside valve
is harmful.

1) With ignition switch OFF, disconnect coupler from EVAP canis-

ter purge valve.
2) Check resistance between two terminals of EVAP canister
purge valve.

Resistance of EVAP canister purge valve:

30 – 34 W at 20° C (68°F)

If resistance is as specified, proceed to next operation check. If

not, replace.

3) Disconnect vacuum hoses from intake manifold and its pipe.

4) Blow into hose "A". Air should not come out of hose "B".

5) Disconnect connecter from EVAP canister purge valve.

Connect 12 V-battery to EVAP canister purge valve terminals.
In this state, blow hose "A".
Air should come out of hose "B".
If check result is not as described, replace EVAP canister purge
valve.
6E2-54 ENGINE AND EMISSION CONTROL SYSTEM

6) Connect vacuum hoses.

7) Connect EVAP canister purge valve coupler securely.

EVAP CANISTER
INSPECTION
1
2
WARNING:
3 DO NOT SUCK nozzles on EVAP canister. Fuel vapor inside
EVAP canister is harmful.

1) Outside of EVAP canister visually.

2) Disconnect vacuum hoses from EVAP canister.
3) Check that there should be no restriction of flow through
purge pipe (1) and air pipe (2) when air is blown into tank pipe
(3).
If any faulty condition is found in above inspection replace.
 ENGINE AND EMISSION CONTROL SYSTEM 6E2-55

A D 2
B A
B
C
F
E
D
E

F 1. EGR valve
C 1 2. Connector

1
2
6E2-56 ENGINE AND EMISSION CONTROL SYSTEM

SPECIAL TOOLS

1. Pressure gauge
09912-58441
2. Pressure hose
09912-58431
3. 3-way joint & hose
09912-58490
4. Checking tool set
09912-58421
4-1. Tool body & washer
4-2. Body plug
4-3. Body attachment
4-4. Holder
4-5. Return hose & clamp
4-6. Body attachment-2 & washer
4-7. Hose attachment-1
4-8. Hose attachment-2

Tech 2 kit (SUZUKI scan tool)

99000M24120-426
This kit includes following items :
1. Tech2
2. PCMCIA
3. DLC cable
4. SAE 16/19 adapter
5. Cigarette
6. DLC loopback adapter
7. Battery power
8. RS232 cable
9. RS232 adapter

10. RS232 loop back connector

09917-47010 09930-88530 11. Storage case
Vacuum pump gauge Injector test lead 12. Power supply
 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) 6F1-1

SECTION 6F1

IGNITION SYSTEM
(ELECTRONIC IGNITION SYSTEM)

CONTENTS

GENERAL DESCRIPTION . . . . . . . . . . . . . . 6F1- 2 Ignition Coil Assembly . . . . . . . . . . . . . . . . . . 6F1-

DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F1- Camshaft Position Sensor . . . . . . . . . . . . . . 6F1-
Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . 6F1- 6
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 6F1-
Ignition Spark Test . . . . . . . . . . . . . . . . . . . . 6E1- SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 6F1- 8
6F1
High-Tension Cords . . . . . . . . . . . . . . . . . . . 6F1-
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . 6F1- 5
6F1-2 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM)

GENERAL DESCRIPTION
The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below and
has an electronic ignition control system.
ECM
It detects the engine and vehicle conditions through the signals from the sensors, determines the most suitable
ignition timing and time for electricity to flow to the primary coil and sends a signal to the ignitor (power unit) in
the ignition coil assembly.
Ignition coil assembly (including an ignitor)
The ignition coil assembly has a built-in ignitor which turns ON and OFF the current flow to the primary coil accord-
ing to the signal from ECM. When the current flow to the primary coil is turned OFF, a high voltage is induced
in the secondary coil.
High tension cords and spark plugs.
CMP sensor (Camshaft position sensor)
Using signals from this sensor, ECM identifies the specific cylinder whose piston is in the compression stroke
and detects the crank angle.
TP sensor, ECT sensor, MAP sensor and other sensors/switches
Refer to section 6E2 for details.
Although this ignition system does not have a distributor, it has two ignition coil assemblies (one is for No.1 and
No.4 spark plugs and the other is for No.2 and No.3 spark plugs). When an ignition signal is sent from ECM to the
ignitor in the ignition coil assembly for No.1 and No.4 spark plugs, a high voltage is induced in the secondary coil
and that passes through the high-tension cords and causes No.1 and No.4 spark plugs to spark simultaneously.
Likewise, when an ignition signal is sent to the ignitor in the other ignition coil assembly, No.2 and No.3 spark plugs
spark simultaneously.
 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) 6F1-3

SYSTEM COMPONENTS

1. ECM 6. ECT sensor

2. Ignition coil assembly 7. IAT sensor
for No.1 and No.4 spark plugs 8. TP sensor
3. Ignition coil assembly 9. VSS
for No.2 and No.3 spark plugs 10. High-tension cords
4. CMP sensor 11. Monitor connector
5. MAP sensor
6F1-4 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM)

SYSTEM WIRING DIAGRAM

G02-32

G02-31

G02-09
G02-15
G02-30
G01-2
G02-29
G01-3

G01-1
G01-32 Y/Bl
G02-7

G02-6 G01-33 Br

1. Ignition switch 5. CMP sensor 11. Sensed information Electric load signal
2. Main relay 6. No.1 spark plug MAP sensor Engine start signal
3. Ignition coil assembly for 7. No.2 spark plug ECT sensor Test switch terminal
No.1 and No.4 spark plugs 8. No.3 spark plug IAT sensor
4. Ignition coil assembly for 9. No.4 spark plug TP sensor
No.2 and No.3 spark plugs 10. Monitor connector VSS
 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) 6F1-5

SPARK PLUGS
1) Pull out high-tension cords by gripping their caps and then re-
move ignition coil assemblies referring to IGNITION COIL AS-
SEMBLY in this section.
2) Remove spark plugs.
3) Inspect them for:
Electrode wear
Carbon deposits
Insulator damage
4) If any abnormality is found, adjust air gap, clean with spark plug
cleaner or replace them with specified new plugs.

Spark plug air gap "a" : 0.8 - 0.9 mm ( 0.028 - 0.031 in.)
Spark plug type : MICO FR6DC4
: CHAMPION RC8YC

5) Install spark plugs and torque them to specification.

Tightening Torque for spark plug

28 N.m (2.8 kg-m, 20.0 lb-ft)

6) Install ignition coil assemblies referring to IGNITION COIL AS-

SEMBLY in this section.
7) Install high-tension cords securely by gripping their caps.
6F1- 6 IGNITION SYSTEM ELECTRONIC
( IGNITION SYSTEM )

IGNITION TIMING
NOTE:
Before starting engine, place transmission gear shift lever in
ª Neutralº and set parking brake.

INSPECTION/ADJUSTMENT
1) When using SUZUKI scan tool, connect SUZUKI scan tool to
DLC with ignition switch OFF.

Special Tool
(A): 99000M24120-426 (SUZUKI scan Tool)

2) Start engine and warm it up to normal operating temperature.

3) Make sure that all of electrical loads except ignition are switched
off.
4) Check to be sure that idle speed is within specification.
(Refer to SECTION 6E1)

5) Fix ignition timing to initial one as follows:

When using SUZUKI scan tool:
Select ªMISCº mode on SUZUKI scan tool and fix ignition timing
to initial one.
When not using SUZUKI scan tool:
Disconnect scan tool from DLC, and connect D and E terminals
of monitor connector (1) or E to body ground by using service
wire so that ignition timing is fixed on initial one.
 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) 6F1- 7

6) Set timing light to high-tension cord (1) of No.1 ignition coil.

7) Using timing light (2), check that ignition timing is within specifi-
cation.

Initial ignition timing

(Test switch terminal
grounded or fixed with
SUZUKI scan tool : 5 ± 1 BTDC at idle speed
Ignition order : 1-3-4-2

8) If ignition timing is out of specification, loosen flange bolt (1),

adjust timing by turning CMP sensor assembly (2) while engine
is running, and then tighten bolt.

Tightening Torque
(a): 13 N.m (1.3 kg-m, 9.5 lb-ft)

9) After tightening bolt, recheck that ignition timing is within speci-

fication.

10) After checking and/or adjusting, disconnect service wire from

monitor connector or release fixed ignition timing and discon-
nect SUZUKI scan tool from DLC.

CAUTION:
Driving with test switch terminal grounded will cause
damage to catalyst. Be sure to disconnect service wire
after adjustment.

11) With engine idling (test switch terminal ungrounded, vehicle

stopped), check that ignition timing vary more or less of initial
ignition timing (about 8 ).
Also, check that increasing engine speed advances ignition
timing.
If above check results are not satisfactory, check TP sensor,
test switch terminal circuit and ECM.
6F1-8 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM)

SPECIAL TOOLS
Tech 2 kit (SUZUKI scan tool)
99000M24120-426
This kit includes following items :
1. Tech2
2. PCMCIA
3. DLC cable
4. SAE 16/19 adapter
5. Cigarette
6. DLC loopback adapter
7. Battery power
8. RS232 cable
9. RS232 adapter

10. RS232 loop back connector

11. Storage case
12. Power supply
 EXHAUST SYSTEM 6K1-1

SECTION 6K-1

EXHAUST SYSTEM

CONTENTS

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6K1- 2

6K1
6K1-2 EXHAUST SYSTEM

GENERAL DESCRIPTION
The exhaust system consists of a exhaust manifold, an exhaust pipes, a muffler, gasket and etc., and the system
have three way catalytic converter.

The three way catalytic converter is an emission control device added to the exhaust system to lower the levels
of Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.

THE CATALYTIC CONVERTER REQUIRES USE OF UNLEADED FUEL ONLY.

3 45N-m (4.5 kg-m)

4
2

1. Exhaust manifold cover

2. Exhaust manifold
3. Oxygen sensor
4. Gasket
5. To exhaust manifold
6. Gasket
7. Exhaust pipe (with three way catalytic converter)
8. Spring
9. Exhaust pipe bolt
10. Exhaust pipe No.1 bracket
11. Mounting
12. Exhaust pipe No.2 bracket
13. Heater Protector
14. Muffler
 BODY ELECTRICAL SYSTEM 8-1

SECTION 8

BODY ELECTRICAL SYSTEM

CONTENTS

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Head Light Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

GENERAL DESCRIPTION
The body electrical components of this vehicle are designed to operate on 12 Volts power supplied by the battery.
The electrical system utilizes negative ground polarity.
8

4.9 – 5.4
0.8 - 0.9
3.1 - 3.4
3.3 - 3.7
3.7 - 4.0
4.8 - 5.3