SUZUKI eee USE THIS SUPPLEMENTARY SERVICE MANUAL Pee tae eR eed eas SUZUKI SANTANA MOTOR, S.AIMPORTANT WARNING/CAUTION/NOTE Please read this manual and follow its instruc- tions carefully. To emphasize special informa- tion, the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words WARNING: Indicates a potential hazard that could re- sult in death or injury. CAUTION: Indicates a potential hazard that could re- sult in vehicle damagi 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 se mechanics only. Inexperienced mechanics ‘or mechanics without the proper tools and equipment may not be able to prop: ly perform the services described in this manual. Improper repair may jury to the mechanic and may render the vehicle unsafe for the driver and passen- gers. oul is WARNING. an For vehicles equipped with a Supplemen- tal Inflatable Restraint Air Bag System: © Service on or around air bag system components or wiring must be per- formed only by an authorized Suzuki dealer. Please observe all WARNINGS and SERVICE PRECAUTIONS in Section * 9J under “On-Vehicle Service” and the Air Bag System Component and Wiring Location view in Section 9J before per- forming service on or around air bag system components or wiring. Failure to follow WARNINGS could result in unintended air bag deployment or could render the air bag inoperative. Ei ther of thase two conditions may result in severe injury. © If the air bag system and another ve- hicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag deployment. © Do not modity the steering wheel, dash- board, or any other air bag system com- ponent (on or around air bag system components or wiring). Modifications can adversely affect air bag system per- formance and lead to injury. @ If the vehicle will be exposed to temper- atures over 93°C, 200°F (for example, during a paint baking process), remove the air bag system components (air bag inflator module, sensing and diagnostic module, forward discriminating sensor) beforehand to avoid component dam- age or unintended deployment.FOREWORD This SUPPLEMENTARY SERVICE MANUALis a supplement to E416 SERVICE MANUAL. Applicable model: SE416 vehicles on and after following body No. GROUP 1 (X) JSAETA02C01200001 (x) (X) JSAETA02V01200001 (x) (X) JSAETDO1V01200001 (x) TD01V-200001 GROUP 2 Refer to body number mentioned in FORE- WORD of GROUP 2 When servicing a vehicle with a body number after the above listed number, refer to this Su- plementary Service Manual first And for any section, item or description not found in this service manual, refer to the right listed SERVICE MANUAL, When replacing parts or servicing by disas- sembling, it is recommended to use SUZUKI genuine parts, tools and service materials (Iu- bricants, sealants, etc.) as specified in each de- seription, Allinformation, illustrations and specifications contained in this literature are based on the lat- est product information available at the time of publication approval. And used 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 rightis reserved to make changes at any time without notice. SANTANA MOTOR, S.A. DEPARTAMENTO OE SERVICIO IMPRESO POR SANTANA MOTOR, S.A.- 107 Bea Reed STEERING, SUSPENSION | WHEELS AND TIRES Front Suspension ENGINE Electronic Fuel injection Sys-| tem (Sequential Multiport Fuel Injection) "Trans Automatic Transmission | HEATING AND AIR | conprmionnine BRAKES _ [aopy ELECTRICAL SYSTEM RELATED SERVICE MANUAL ‘¢ VITARA SERVICE MANUAL (99500-6010) *VITARA SUPPLEMENTARY SERVICE MANUAL (99501-60470) © VITARA SUPPLEMENTARY SERVICE MANUAL (99501-61410) © SE/SV/SZ/SY SERIES SUPPLEMENTA- RY SERVICE MANUAL (99501-60610) © SE416/SZ416 SUPPLEMENTARY SER- VICE MANUAL (99501-61420) * VITARA SUPPLEMENTARY SERVICE MANUAL (00000801231-5)A. ABS AC AF aT B. B+ C. CMP sensor ceu CTP switch D. DLC E. ECM ECT sensor EGR EVAP F awo G.GND |. IAC valve \AT sensor Ic M.MAF sensor MAP sensor MIL wr 0.0/0 PB. PCM PCV valve PSP switch 7. Tec TCM ‘TP sensor Vv. VES ABBREVIATIONS USED IN THIS MANUAL + Anti-lock Brake System : Air Conditioning : Air Fuel mixture ratio : Automatic Transmission : Battery Voltage : Camshaft Position Sensor Central Processing Unit : Closed Throttle Position switch :Data Link Connecter : Engine Control Module :Engine Coolant Temp. sensor Exhaust Gas Recirculation : Evaporative Emission : Four Wheel Drive : Ground Idle Air Control valve Intake Air Temp. sensor Ignition Control : Mass Air Flow sensor : Manifold Absolute Pressure sensor : Malfunction Indicator Lamp : Manual Transmission : Over Drive : Powertrain Control Module : Positive Crankcase Ventilation valve : Power Steering Pressure switch : Torque Converter Clutch : Transmission Control Module : Throttle Position sensor : Vehicle Speed SensorFRONT SUSPENSION 30-1 SECTION 3D SDs FRONT SUSPENSION CONTENTS FREE WHEEL DEVICE. General description ‘Manual ree wheel performance. ‘Automatic free wheel performance Free wheel types description Installation of "A" typo manual frae whool .. Installation of *B" type manual free wheet Instaltation of “A" type automatic tree wheel . Installation of *B" type automatic tree whet .. Replacement of “A” type manual free whee! .. Replacement of *B” type manual free whee! .. Heplacement of "A" type automatic free wheel Replacement of “B” type automatic free wheel... RECOMMENDED TOROUES....... SPECIAL TOOLS.FRONT SUSPENSION 30-2 FREE WHEEL DEVICE GENERAL DESCRIPTION The free wheel device allows the independence of the attachment of the front wheels with the input haif-axies, when the double drive is not going to be used, or couple both elements when four wheel drive is wished. This device is set at the ends of the front half-axles, coupled to the hubs and replacing the channeled flange. Its correct use avoids front tyre, in its movement from drafting the halt-axles, differential group and front drive, avoiding the wear of the elements and providing a reduction of the noise level and obtaining a tue! consumption save. ‘There are two types of free wheel, te manual driven one, which is coupled on the free wheel hub itselt and ine automatic one that works when the double drive 4H or 4l is selected MANUAL FREE WHEEL PERFORMANCE The free wheel device must be set at both ends of the front halt-axles. It consists of a knob located at the center that can be rotated and ite mark matched with the FREE or LOCK marks located outside. ‘When the knob i set in its FREE position the half-axle and the whee! will be disengaged and the front wheel rotation will be free. When itis set in its LOCK position the axle and the wheel will be engaged. For ils use refer to the Owner's, Manual, provided with the vehicle, AUTOMATIC FREE WHEEL PERFORMANCE ‘The automatic free wheel is located at the ends of the right and left front half-axlas ina si type. 1 Way to that of the manuat When a vehicle provided with automatic free wheel moves, when changing the transfer lever from 2H to 4H or 4L Position, the driving power is transmitted through the hall-axles to the free wheel internal mechanism. causing i to be linked with the whee! hub. This manoeuvre must be done with the vehicle stopped when the lever is for the frst time moved {rom 2H to 4H position. When the vehicle has moved 2 metres approx. the engagement of the free wheel is, accomplished. Later we can perform the change from 2H to 4H, or the contrary, with the vehicle moving, even not actuating on the clutch (Ihe vehicle being in a straight line trajectory). tn order to accomplish the disengagement of the free wheel device, simply set the transfer lever in 2H and the gear lever in MA position, approx. 2 metres later the locking device is disconnected. To engage the tree wheel in MA, simply set the transfer lever in 4H or 4L and move backward a shor track. Now, the unlocking will be produced by selecting 1" gear, the transter lever in 2H and moving forward some metres,FRONT SUSPENSION 30-3 FREE WHEEL TYPES DESCRIPTION There are two types of free wheel, a manual driven one and an automatic one, and for each type there are two versions, 50 that, in total there are four kinds of free wheels, ‘The installation of one or other type depends on the vehicle specification. The installation and maintenance method ‘changes from one to another; make certain you are ucing the adequate method by consulting up the corresponding section. ‘CAUTION: = Mako certain the wheel to be installed is identical by both sides. * For vehicle provided with manval tree wheel, the actuating knob must be in the same position. + Never unfit a tree wheel assy. Tho unfitting may alter ite correct perlormance. “A" Type manual free wheel LOCKED position wheel FREE position body clutch OFF clutch ON O-ring — 7 , SES} SSS knob Pal-avle hub “8 Type manual ree wheel corte a 0 Lockeo Ste 1 IRE f FREE 1. Knob 5. Internal driving gear 9. Retainer ring 13. Rear spring plate 2 Main spring 8.Clutch ring 10.0-ring 14. Free wheel assy 3. Knob screw 7. Return spring 11, Slotted nut 4. Knob nut 8. Bearing 12. Antirotation springFRONT SUSPENSION 30-4 ‘Type automatic tree wheel 4.Cover 6. Sliding gear 2.Cam 7. Driving gear 3. Retainer 8. Return spring 4 Screw 9. Change spring 5. Bearing 10. Susiaining spring “B" Type automatic free whee! 11.O-ring 42. Internal brake 13. Retaining ring 14. External brake. 15. Nedile bearing nn (asd 1. Wavy return spring 5. Wavy spring box 2. Bearing 6. clutch box ring 3. tnternal driving gear 7. retaining ring 4. Cluteh ring 8 follower cam 9. Mobile cam 10. Fix cam 11. O-ring 12. Slotted nut 16. Driving washer 47. Elastio ring 18. Retaining plate 19. O-ring 20. Wheel hub 21. Skid 13. Check spring 14, Plate 15. Assy NOTE: Some vehicles may incorporate the hub bearing ret safety washer. This mechanism is compatible with “A” type automatic ones. For “B” type automatic free wheel is compulsory the use of the Locking system consisting of slotted nut, check spring and plate, as shown above. ing system consisting of nut (not slotted) ‘and “B” manual driven free wheels and with ““A type manual free wheel Cone washer oning ap age peg SP Taree serew and] ; washer seiow 1. tntorocking finger FRONT SUSPENSION 30-5 ” TYPE MANUAL FREE INSTALLATION OF “ WHEEL Removal 1) Jack the vehicle and remove the tyre, if necessary. 2) Remove the half-axle and hub attaching flange. Installation 1) Align the “O° mark on the free wheel knob with FREE position. Detach from the body assy the free wheel cover assy. 2) Install the free wheel body assy on the wheel hub, Torque of attaching screws: 2,5 m g. (25 Nm) 3) Instati the cover assy on the body assy, so that the interlock finger of the driving roller adjust on the body assy channel NOTE: Before installing the cover assy check the following points: ‘+ The“O” mark of the knob is in FREE position. ‘+ The clutch is raised toward the cover side. If not (as shown in the figure), it may cause a defective performance. The hardware is correctly adjusted There are two interlocking fingers that may be freely adjusted.FRONT SUSPENSION 30-6 FREE position Between FREE LOCK Position ‘and LOCK positions 4) Altach the caver assy on the body assy by means of cover screws. ‘Torque of the cover attaching screws: 1 m Kg. (10 Nm) 5) To chack the performance of the Irae wheel, jack the front side of the vehicle and move the knob between FREE and LOCK posi- tions, checking it does softly. Also check, by hand turning. that the wheels remain attached to the half-axle in the LOCK position and. release from it in FREE position. MAINTENANCE SERVICE The vehicles provided with free wheel are subject to the following periodic checkings. Jn order to check the performance of the free wheel, jack the front side of ine vehicle, move the knob betwoen FREE and LOCK posi tions, and check it does softly. Also check if the wheel operates cor- rectly with the knob in FREE and LOGK positions by turing the wheel by hand, It the outcome of the check is not satisfactory, remove the free wheel cover end grease each sliding surace using lithium grease or grease after cleaning each sliding part, LITHIUM GREASE ‘SUZUKI SUPER GREASE A (99000-25010) If the performance goes on defective, alter the greasing operation, rework the damaged part or replace it by a new one. CAUTION ‘The hubs must not be grease coveredFigure: Manual free wheel FRONT SUSPENSION 30-7 INSTALLATION OF “B” TYPE MANUAL FREE WHEEL Removal 1) Jack the vehicle and remove the tyre 2) Remove axle and hub attaching flange Installation 1) Check the O-ring of the free wheel is not damaged and is cor- rectly placed. 2) Acting on the knob, place the free wheel in FREE position 3) Clean the contact surfaces of the hud and the free wheel and instal. 4) Torque the free wheel attaching screws (supplied wit cross way at the specified value. ina Torque of the free wheel screws: 3,3 m Kg (33 Nm). 5) Check the following: ‘= The knob actuates correctly and changes without difficulty from FREE to LOCK position and the other way round. ‘+ That once the knob isin its FREE position, the wheel turns freely ‘and iis not linked to the half-axle. + That once the knobiis in its LOCK position the free wheel assy is linked to the halt-axle.FRONT SUSPENSION 30-8 6) Install the tyre and torque the nuts to the specified value. Torque of attaching screws of wheet nuts: ,5 m Kg. (95. Nm). MAINTENANCE, Jack the vehicle and check that the tree wheel operates in FREE and LOCK positions, by turning the wheel. If any defective performance ts noted, replace the free wheel assy. CAUTION: Hubs must not be grease covered.‘A type 2 automatic freewheel > > 1 1. Free wheel subassy “7 2. Free wheel brake assy. 2. Brake spring 2. Dactutehing plate FRONT SUSPENSION 30-9 INSTALLATION OF “A” TYPE AUTOMATIC FREE WHEEL Removal 1) Jack the vehicle and remove the tyre, if required. 2) Remove hall-axte and tub allaching flange Installation 1) Check the O-ring of the free wheel is not damaged and is cor- rectly placed. 2) Install the tree wheel aligning it with free wheel brake assy cotter and with sleeve cotter. 3) Install the free wheel subassy matching the marks of the brake assy and subassy. CAUTION: Make certain the marks mentioned above are aligned, if not, they may interfere one on the others and cause damages. 4) Torque the free wheel screws to the specified value. Torque of the screws: 3,3 m Kg. (33 Nm). 5) Install front tyres, if removed and torque the attaching nuts to the specified value, Torque of tyre nuts : 9,5 m Kg. (95 Nm). 6) Low the vehicle from the jack and perform the checkings men- tioned in paragraph “performance checking”FRONT SUSPENSION 30-10 Performance checking Confirm the performance of the free whee! by means of the following tests: 1) Set the transfer box lever in 4H or 4L. and move slowly the vehicle 2 metres or more forward, 2) Jack the vehicle front part and check that the hall-axle moves together with the whee! whon it is actuated by hand clockwise {counterclockwise for the left wheel). 2) Low the vehicle for the wheal to settle on the ground. 4) Set the transfer lever in 2H and move slowly the vehicle 2 metres (or more backwards. Jack the vehicle front part and check that the half-axle does not move logether with the wheel when it is actuated by hand clock- wise (counterclockwise for the left wheel). Check for sure. that free wheel assy biocks itself backward and unlocks forward, actuating in inverse direction to that mentioned in steps 1) to 4) above. (Now, it must block backward and unblock forward. 5 6 ltany defective performance is detected, check the free whee! bracket or replace it, if required. MAINTENANCE Periodically check the performance of the tree wheel following the steps above and replace them if required.1. Interlocking plate 2. Screwariver FRONT SUSPENSION 30-11 INSTALLATION OF “B” TYPE AUTOMATIC FREE WHEEL Removal 1) Jack the vehicle and remove the wheel 2) Remove the axle and hub attaching flange. 3) Remove the hub bearing interlocking plate by loosening the four 4) Withdraw the hub bearing nut using the suitable tool. 5) Withdraw the hub bearing safety washer Installation 1) Install the spring washer supplied with the free whee! assy, on the sleeve; aligning the cotter with the channel. This washer may be installed in any position. 2) Install the antirotation spring washer, supplied with the free wheel assy, on the sleeve. The cotter of the washer must be housed on the channel and oriented outwardly. 3) Install the slotted nut, supplied with the free wheel assy, on the sleeve and tighten it by hand.FRONT SUSPENSION 90-12 4) _ Install the special too! consisting of two parts attaching it to the hub by means of three sciews and matching the edges of the wrench with the slotted nut channels. 5) Torque by hand the three tool attaching screws in the previous position. 6) While turning the wheel hub by hand, torque the slotted nut using the special to0I to the specified value. Nut Torque: 21 n Kg. (210 Nm) 7) Check that the O-ring of the free wheel is not damaged and is correctly located. 8) Check that the contact surfaces of the free wheel and the hub are clean. 9) Install the free wheel matching its edges with the channels of the slotted nut, already installed on the hub. 10) Torque the screws supplied with the free wheel, in a cross way, to the specified value. Torque of the free wheel attaching screws: 3,3 m Kg(33Nm) 11) Install the wheels and torque the attaching nuts to the specified value. Torque of wheel attaching nuts: 9,5 m Kg (95 Nm) Performance Checking ‘Accomplish a performance checking of the free wheel as previously described for the “A” type automatic free wheel.FRONT SUSPENSION 30-13 REPLACEMENT OF “A” TYPE MANUAL FREE Figures:*A” typemanial _-% WHEEL roe wheel ER Removal a a 2S 1) Jack the vehicle and remove the tyre if required. ef ENO 2) Set the actuating knob of the free wheel in its FREE position. gy 3) Remove the 6 screws attaching the wheel to the hub. RYE ey FREE position Installation 1) Refer to steps 1) to 5) indicated for the Installation of “A type manual free wheel, (Section 3D-5)FRONT SUSPENSION 30-14 REPLACEMENT OF “B" TYPE MANUAL FREE WHEEL Removal 1) Jack the vehicle and remove the wheel. 2) Set ire wheel actuating knob in *FREE" position. 3) Remove the 6 screws attaching the free wheel to the hub. Installation 1) Perform the operations 1) to 5) indicated in the installation of the “B" type manual free wheel (Section 30-7)‘Type 2. cuoyatie : free wheal. eS) FRONT SUSPENSION 30-15 REPLINCERENT OF “A” TYPE AUTOMATIC FREE WHEEL Removat 1) Set free wheels in FREE position (transfer lever to 2H position ‘and move the vehicle backwards 2 metres or more). 2) Jack the vehicle and , it necessary, remove the wheel. 3) Remove the free wheel subassy and free wheel assy. Installation 1) Reler to steps 1) to 6) of the installation of “A” type automatic free ‘wheel and the performance checking. (Pages 3D-9 and 30-10).FRONT SUSPENSION 30-16 “i 41. Slotted nut 2. Antirotation washer 3. Spring washer REPLACEMENT OF “B” TYPE AUTOMATIC FREE WHEEL Removal Free wheel assy 1) Jack the vehicle and remove the wheel. 2) Loose the six screws attaching the free wheel to the hub and withdraw it Bearing retaining system Remove (only if necessary) the slotted nut, the antirotation spring washer and the spring washer following the steps below: 1} Install the plate and slotted wrench assy {lool ref. 09943-06010) fon the wheel hub, aligning the edges of the wrench with the slot- ted nut channels 2) Torque the three plate attaching screws. Torque of plate attaching screws: 0,25 m Kg (2,5 Nm) 3) Loose (counterclockwise) 2 complete turns in order tothe stotted nut to be loosen from the antiotation spring washer. 4) Remove the special too! attached to the wheel hub. 5) Loose and withdraw the slotted nut, the antirotation spring washer and the spring washer. Installation 1) Perform the operations 1) to 6) indicated forthe installation of the “B" type automatic free wheel (Page 3D-11) (Only if the spring washer , retaining spring washer and slotted nut assy has been replaced). 2) Install he free whee! assy in accordance with indications on steps 7)10 14) ofthe installation of “B" type automatic free wheel (page 30-12 3) Bo peromance check cated on Hage 30-10FRONT SUSPENSION 30-17 SPECIFIED TORQUES ELEMENT Torque mKg. Nm. Hub attaching nuv/siotted nut 2 210 Fixing plate scrows 0.45 1S, ‘Attaching screws of the free wheel ("B° type manual and “A” and “B" types automatic) 3.3 33 ‘Atiaching screws of the flange and “A” type manual free wheel 25 2 HUB ATTACHING NUT FIXING PLATE SCREWS FREE WHEEL ATTACHING SCREWS @ % © FLANGE ATTACHING SCREWS. oo SLOTTED NUT SPECIAL TOOLS aos Oqpe (09951-16050 HUB NUT TORQUE TOOL Gp 09943-0610 1, SLOTTED NUT TORQUE TOOLELECTRONIC FUEL INJECTION SYSTEM_6EI-1 SECTION 6E1 ELECTRONIC FUEL INJECTION SYSTEM && (SEQUENTIAL MULTIPORT FUEL INJECTION) WARNING: For vehicles equipped with a Supplemental Inflatable Restraint Air Bag System: © Service on or around Air Bag System Components or Wiring must be performed only by an authorized Suzuki dealer. Please observe all WARNINGS and SERVICE PRECAUTIONS in Sec- tion 9J under “On-Vehicle Service” and the Air Bag System Component and Wiring Location view in Section 9J before performing service on or around Air Bag System Components or Wiring. Failure to follow WARNINGS could result in unintended air bag deployment or could render the air bag inoperative. Either of these two conditions may result in severe injury. © 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 air bags may be deployed by reserve energy in the Sensing and Diagnostic Module (SDM). NOTE: For the descriptions (items) not found in this section of this manual, refer to the same section of SE416/SZ416 supplementary service manual (99501-61A20). CONTENTS = GENERAL DESCRIPTION ..... 6513 ‘A22 Malfunction Indicator Lamp. ELECTRONIC CONTROL SYSTEM ........ 6E1- 6 ("CHECK ENGINE” Light) Circuit Engine Control Module (ECM) . 6E1-10 Check seeteees . +» BE1-22 Throttle Position Sensor 3 Malfunction indicator Lamp {TP Sensor)... . 6E1-12 ("CHECK ENGINE” Light) Circuit Engine Coolant Temperature Check 6E1-23 Sensor (ECT Sensor) ..... vos OE1-12 EGR System (For vehicle with EGR stepper motor) .... 6E1-13, EGR System (For vehicle with EGR valve, pressure transducer and solenoid vacuum valve) . . «+ BE1-14 DIAGNOSIS ............ 200. 6c1-15 Precautions in Diagnosing Troubles .... 6E1-15 DIAGNOSTIC FLOW CHART sess BEIGE Diagnostic Trouble Code Table . = BET A-1 ECM Power and Ground Circuit Check (Vehicle with Immobilizer) . ‘A-1 ECM Power and Ground Circuit Check (Vehicle without Immobilizer) ++ GE1-19 .. 6E1-21 Code No.13 Heated Oxygen Sensor Circuit (if equipped) 6E1-28 Code No.14 ECT Sensor Circuit =. BE1-25 Code No.15 ECT Sensor Circuit 651-26 Code No.21 TP Sensor Circuit -- 6E1-27 Code No.22 IP Sensor Circuit 6E1-28 Code No.24 VSS Circuit .. - 6E1-29, Code No.33 MAF Sensor Circuit . 6€1-30 Code No.34 MAF Sensor Circuit 6E1-31 Code No.42 CMP Sensor Circuit 661-32 Code No.4 CTP Switch Circuit 661-33 Code No.45 CTP Switch Circuit ......... 61-34 Code No.51 EGR Valve (Stepper Motor) .. =. GE1-356E1-2_ ELECTRONIC FUEL INJECTION SYSTEM B-1 Fuel Pump Circuit Check ........+.. 6£1-36 B-2 Fuel Injector Circuit Check ......... 661-37 8-3 Fuel Pressure Check .... - 8E1-39 8-4 Idle Air Control System Check ...... 61-41 B.S EGR System Check (Vehicle with EGR Stepper Motor) ............. 661-43 B-5 EGR System Check (Vehicle with EGR Solenoid Vacuum Valve) ..., 661-44 B-6 Evaporative Emission Control System Check . . ceseeee BETS, Inspection of ECM and Its Circuit ....... 61-46 Voltage Check . “ 6E1-46 Resistance Check .- 6E1-52 ON VEHICLE SERVICE . 6E1-55 ELECTRONIC CONTROL SYSTEM 6E1-55 MAF Sensor (Inspection) ... + 6E1-55ELECTRONIC FUEL INJECTION SYSTEM _6E1-3 GENERAL DESCRIPTION The Electronic Fuel Injection System in this ve- hicle supplies the combustion chambers with air/fuel mixture of optimized ratio under widely varying driving conditions. it uses the sequential multiport fuel injection system which injects fuel into each intake port of the cylinder head. This system has 3 major sub-systems: air intake system, fuel delivery system andelectroniccon- trot system. Air intake system includes air cleaner, mass air flow sensor, throttle body, fast idle air valve, idle air control valve and intake manifold. Fuel delivery system includes tue! pump, deliv- ery pipe, fuel pressure regulator, etc. Electronic control system includes ECM, vari ous sensors and controlled devices. This section explains the system related to the electronic fuel injection as well as such func- tions of ECM as listed below. © EGR system. (Stepper motor or solenoid vac- uum valve, if equipped) # Evaporative emission control system: © IC {Ignition Control) system.ELECTRONIC FUEL INJECTION SYSTEM _6E1-5 (uv) 14611 ,330/00. (Uy) YoUms MoLaMy (UW) yowas 19 C/O (UW) YatMs 101D2I8 Epo (Wy) Goums ayerg (wy) youms Bunyor (L/v) oajen paddinbs yt ‘2010s saddais) onjen YOR dwind jang 49181089 dyAa @afen jou3UOD ainssaud yue] * 4041; Jang 30)e)nBas esnssaud jong {paddinba 41 40suas uaBAxo pares}, aJO8 DIL (Uv) @ 8A/eA prousjos yIyS (UW) vaniea prousjos yus “o {paddinbs 4y JeuaAuod onAlered Aem aay, Josues ‘due! 1u2}009 euy6u3 Ployuews oyeVU} fur jong ep tend (pedainba 31) eaten yO3 {paddinbe 41) seonpsuen oinssaid YO3 Asneg sn uleny woums ule youms snoubew soueig $ aBued VoIsstUsUeN 10 (paddinbe JLIW) Yous wontsod jepad yan, NINA XO3HO.) uonsunyeyy (peddinba ») 4oisisax Bunsnipe 3 leujwuar yams “Beg [euler yous Ise, “ee ze “Le 0c ez 4 a 7 “sz 4 a4 ez We ‘02 e “BL {peddinbs 41) yous ainsseid Buyaais sam0g + ( (Uv) Yoimas oBued uorssiuusues JOsuas UONIsod yeyswED soyuBy aA” Josuas pads a| (paddinbe 31) aAjeA wiNNDeA plOUE|Os YOR 2nlen oB1nd saysiues d¥A3 Alen ADd sxo108 Bunsnipe ste 9p} Josuas uonisod amoryy AIGA se BIDE Sey Alea Jonuod ste ep) Apog emoiyy, Josuas moy sje sew Jauea[y styGE1-6 ELECTRONIC FUEL INJECTION SYSTEM. ELECTRONIC CONTROL SYSTEM The electronic control system consists of 1) vari- ous sensors which detect the state of engine and driving conditions, 2) ECM which controls various devices according to the signals from the sensors and 3) various controlled devices. Functionally, it is divided into the following sub systems: © Fuel injection control system @ Heated oxygen sensor heater control system {if equipped) ‘ ightnand storing vehicle 2. Teememiston range swites (Font) 8. Comshalt position sensor ICMP sensor) Gin ievbotor 29jusveatstor (vehicle without hosted ‘oxygen sensor) Nore: alle nthe other ede © Idle air control system © Fuel pump control system ‘© Evaporative emission control system © IC (Ignition Control) system © EGR system (stepper motor or solenoid vacu- um valve, if equipped) Also, with 4 A/T model, ECM controls A/T. efvnand steering vehicle INFORMATION SENSORS. ‘CONTROLLED DEVICES. omens 1. MAP ener 2 Fool pump relay A ECM 2.v58, b: itor 8: Mainretay 3. Heated oxygen sans faquisoed! ec: EGR valve stepper motor. iteaviooed) _C: Datalink connector {4 Powe stewring pressure switch 4: tal ircontalvaive (aesembiytine ag tink) {Waquipped) gota fn eisuibuter ° 6. eT sensor Matheneton indicator ome e ovpler Engine) 6 Batery (CHECK ENGINE” ight F eure transducer (if equipped) 7. TP sensor hh: EGR solenoid vacuum valve (itequippedl Gi: EGR valve equipped) ‘Above figure shows loft-hand steering vehicle. For right-hand steering vehicle, CO adjusting resister, combination meter, DLC ondELECTRONIC FUEL INJECTION SYSTEM _6E1-7 (peddmbo ») (2dsynbo 9) ES ANIA seB enews emp eng ap aw = 56E1-8_ ELECTRONIC FUEL INJECTION SYSTEM eS a we a las ae a7 BT aS IS OAS gy IN toe 2 ive {#1:Vehicle without immobilizer 12 Vehiote with immobilizer a cf ‘TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE) MIT VEHICLE AIT VEHICLE E1004” Gei008ELECTRONIC FUEL INJECTION SYSTEM _6E1-9 1. No.1 injector ‘Ten [POSITION Ter. [POSITION h 2, No.2 injector MINAL| ‘ercurr mance circu 3. No injector ret eae fag 4, No. injector BB | 811 | At0 | Fowar source for back up| GNDY | Av2 | A1z aoe Bi [ez{ian GNb2 | A26 | 425 | Ground 6 fgnitor Power source: 7. Noise suppressor ez [B21 | az Gwos | a13 [A26 8. Fusi pump retoy RG_| 82 [A13 | Main relay CO adjusting resistor (vor 8, Fuel pump co | a2r| 08 |hicte without heated oxy- 10, IAC volver cas [art] 09 [CMP censor [gen sensor) 11, EVAP canister purge valve ‘arm | as | 03 [MAF sensor ‘ans | era | or7 [ABS contotior (i 12, EGR colenoid vacuum valve ivocy | faailinaj| ronsreaest equipped) (if equipped |. [for sensors) 16 | are | os [ition switch (vohicle with immobilizer) 13. EGR valve (stepper motor, via | a7 [014 | TP eoncor itoqvipped) EGR valve (stepper mo, 14. Transmission range switch (A/T) 1D | B16 {019 {CTP switch EGR1 | AI} A7 | cor coil 1, if equipped) 15. “ODIOFF” indicator light (A/T) | Heated oxygen sensor EGR valve (stepper mo- 16. “POWER" indicator fight (A/T) OXH | AI7| A21 | eater (if equipped) EGR2 | A23 | A20 | ar coil. if equipped) 17. Lignting sten ested oxyoun sensor EGR valve (topper mo- 18, Small ight ox | A20] oe | eted onva cons | As | a6 eee fe ee 18, Broke swi 2 bosin Ta | as | 018 Ect arson EGR vive topper mo- rake fight EGR4 | A22 | A18 | or coil 4 if equipped) 21. Mattuntion indicator rnp SE_[ AIS] 01 [Sensor ground = (CHECK ENGINE light) | ~ [er | Tensmission noe roa nes | a2 | 07 [wceignat ewiten CR" range, AT) 23. Teimmobiize (f equipped sta | 610010 W| ~ [pra Fenemission range witch (ON range, AT) Transmission range switch (*D" ronge, A) 24. Data ink connector 25. Main relay 25. Ignition switch 27. Trensmission range switch (AT) 28. Startor magnetic swiren 29. CMP sensor pss | 815 | 018 pd | - Jars spo | as | 08 Transmission range in speedometer) 2 | - jaw inst | AS | 3 [Injector Not Transmission range 30. MAF sensor INJ2 | A16 | A16 | Injector No.2 t = {815 | witch CL" we, AT) 31 Teeonvor ; ; pees wma [Ar | As Injoaor Noa o> | ~ |e» [Ramisened on nated oxygen sanaor inae [ate [Av [ier Noa 38. Hosted onee sector No AF vahice apd enaor ECT contor ver _| 88 | a |igntor 8PG | - | 16 | inegatve, A/T) 38. CO. using reiter (voile concn carat ara | an Yori win 00 | = [a7 [op ewewien am lg ‘immobilizer Peel ABS controller {if equipped) FP : pump | LIGHT] = | 84 | Lighting switch (A/T) ‘AIC amolifi: (if eauinoed) 7 | as |Vohicle without | retay Power steering pressure switch © immobilizer iu i=] 120}) SAD Stow Seen ND) Utewippet we || a [cvabe TTT oe | ose sstecor wich 39. Vehicle speed sensor Veh ith 8s [iam inmost nel rote | EME, on] — [oer tenn Mode esectr etch (A) ro | ats or soloed vale 2. rasp wou] mua Ts, | — | ay sam eomnttvere a 4WD-fow switch (AT) —— - 48, ‘shineotenoi vow aia | ean [ere] a7 [ESReaienetdvacuum | se | - | ox [shit olencidvate 8 44. Shift solenoid valve B{A/T) jwatve (if equipped) 48, TEC solenoid vee AT) aincionindietor | 53_| ~ | 88 [Tec sonata vewo arn 46. A/T vehicle speed sensor (AT) hig aoe ‘CHECK ENGINE" “OD/OFF” indicator fight 47, ECM et opt | = | 83 lam ‘MON | a9 | 49 [Oury ouput tn “POWER? indicator ight we | = | & fia ON [oi7 TS | 86 | D16 | Test switch torminat ‘sou | Aze]| Azs | Data nx connector6€1-10_ ELECTRONIC FUEL INJECTION SYSTEM 2. intument main pane! 3. Steering whee! In engine oom 1. Mattunetion indicator tame Peneck ENGINE” hgh 2. Chater ewiteh termina 6 Sensedinformation 7 Output 8 Mein eelay 10 Vehicle without immobitzer 11, Vehicle with immobitizer E007 _ Engine Control Module (ECM) ECMis installed to the underside of the instrument panel at the driver's seat side. ECM is a precision unit consisting of microcomputer, A/D (Analog/Digital) converter, VO (Input/Output) unit, etc.. itis an essential part of the electronic contro! system, for its, functions include not only such a major function as to con- trol fuel injector, idle air control valve, fuel pump relay, etc. but also on-board diagnostic system (self-diagnosis func- tion) and fail-safe function as described in the following section On-board diagnostic system (Self-diagnosis function) ECM diagnoses troubles which may occur in the areas in- cluding the following parts when the ignition switch is ON orthe engine is running, and indicates the result by turning on or flashing malfunction indicator tamp ("CHECK EN- GINE” light). a © Heated oxygen sensor (if equipped) © Engine coolant temp. sensor ‘© Throttle position sensor (including idle * Vehicle speed sensor ‘= Mass air flow sensor ‘© Camshaft position sensor ‘© EGR stepper motor (if equipped) © CPU (Central Processing Unit) of ECM ECM and malfunction indicator lamp (“CHECK ENGINE” light) operate as follows. Malfunction indicator lamp ("CHECK ENGINE” light) lights when the ignition switch is turned ON (but the en- gine at stop) with the diagnosis switch terminal un- grounded regardless of the condition of Electronic Fuel Injection system. This is only to check the malfunction in- dicator lemp ("CHECK ENGINE” light) bulb and its circuit If the above areas of Electronic Fue! Injection system is free from any trouble after the engine start (while engine ie running), malfunction indicator tamp (“CHECK EN- GINE” light) turns OFF. * When ECM detects @ trouble which has occured in the above areas, it makes malfunction indicator lamp (“CHECK ENGINE” light) turn ON while the engine is run- ning to warn the driver of such occurrence of trouble and at the same time it stores the exact trouble area in ECM back-up memory. (The memory is kept as it is even if the trouble was only temporary and disappeared immodiately. And it is not erased unless the power to ECM is shut off for 20 seconds or longer.) ECM also indicates trouble area in memory by means of flashing of malfunction indicator lamp (“CHECK EN- GINE" light) at the time of inspection (i.e. when diagnosis switch terminal is grounded and ignition switch is turned ON).ELECTRONIC FUEL INJECTION SYSTEM _6E1.11 NOTE: ¢ Even whena trouble occurs in CMP sensor or CTP switch circuit {circuit open), ECM does not indicate it (or activate malfunction indicator lamp (“CHECK ENGINE” light)) while engine is running. And when that troubled circuit regains good condition, the memory of defective area will be erased automatical- ly even if the power circuit to ECM is not opened as de- scribed above. © For on-board diagnostic system and fail-safe function of A/T releat parts, refer to On-Board Diagnostic System in yn 7B1, the se Even when ¢ trouble has occurred in such areas of Electron- ic Fuel Injection system that include the following parts and a failure signal is sent to ECM, control over the injector, idle air control valve and other is maintained on the basis of the standard signals and/or back-up program prestored in the ECM while ignoring that failure signal and/or CPU. This function is called “fail-safe function”. Thus, with this func- tion, a certain level of engine performance is available even when some failure occurs in such areas so that disability in running is avoided. Engine coolant temp. sensor © Throttle position sensor © Mass air flow sensor © EGR stepper motor {if equipped) © CPU in ECM6E1-12 ELECTRONIC FUEL INJECTION SYSTEM > Throttle Position Sensor (TP Sensor) , The throttle position sensor consisting of a contact point s (CTP switch) and a potentiometer is installed on the throttle body, and detects the throttle valve opening The throttle opening in the idle state is detected by means of the contact point which turns ON in that state. But beyond that, the full opening is detected by the poten- tiometer as follows. ‘A5-volt reference voltage is applied to the sensor from ECM and as its brush moves over the print resictance according to the throttle valve opening, the output voltage varies ac- cordingly. 1. Refeercevotage | By mol 2. Outpervotage ring the ON/OFF signal and sensor output volt- 3. OWOFF signal age, ECM detects the throttle valve opening. ECM uses the signel from TP sensor as one of the signals to contro! fuel injector, idle air control valve, ignition timing, EVAP solenoid purge valve and EGR solenoid vacuum vaive (if equipped). Also for A/T model, ECM controls the automa sion. transmis- wipe voltage tow ———= ‘Smal -=—————» Large Thvotte vaive opening (oegreed ae jo08 ee v008 Engine Coolant Temperature Sensor (ECT Sensor) Located atthe side of intake manifold, this sensor measures the temperature of the engine coolant and converts its change into that in resistance through the thermister. By monitoring the resistance of the coolant temperature sensor, ECM detects the engine coolant temperature and that affects most systems under the control of ECM Also for A/T mode!, ECM control the automatic transmis- sion (TCC operation and gear shift to O/D gear). Resistance low ee High ohEXHAUST GAS RECIRCULATION (EGR) SYS- ‘TEM (For vehicle with EGR stepper motor) This system controls the formation of NOx emission by recirculating the exhaust gas into the combustion chamber through the intake manifold. The EGR system consists EGR valve and piping for exhaust gas. ‘The EGR valve is controlled by ECM according to the signals from CMP sensor, ECT sensor, MAF sensor and VSS. The EGR valve consists of a stepper motor, rods, valve, ete When the EGR valve stepper motor receives “open” signal from ECM, it turns in the “open” direction according to the number of steps and pushes out the rod which is in mesh with the worm of the stepper motor. As the rod installed ELECTRONIC FUEL INJECTION SYSTEM _6E1-13, to the EGR valve is pushed by this rod, the EGR valve opens by the amount corresponding to the number of steps of the “open” signal from ECM to let the exhaust gas flow from the ex- haust manifold to the intake manifold. To close the EGR valve, the stepper motor turns in the “close” direction according to the num- bar of steps of the “close” signal from ECM and pulls up the rod. in this way, the valve is closed by the spring force. Angin this state, the exhaust gas is not allowed to flow to the air intake system or the combus- tion chamber. Under any one of the following conditions, ECM closes the EGR valve. ‘# When engine coolant temperature is low © When throttle valve is at idle position ¢ When engine is running under high load 2 Rod fwith tad) 3 Roa 5 Spring 8 e101 610126E1-14 ELECTRONIC FUEL INJECTION SYSTEM pS SSS EEE EXHAUST GAS RECIRCULATION (EGR) SYS- TEM (For vehicle with EGR valve, pressure transducer and solenoid vacuum valve) This system controls the formation of NOx emission by recirculating the exhaust gas into the combustion chamber through the intake manifold. The EGR valve is controlled by EGR pressure transducer and EGR solenoid vacuum valve controlled by ECM according to signals from various sensors. The diaphragm mounted in the EGR pressure transducer is operated by back pressure of the exhaust gas to open and close the valve. By this ‘opening and closing action of the valve, the EGR pressure transducer controls the vacuum trans- mitted to the EGR valve. Under a low load condition such as tow speed driving, the exhaust pressure is low. In this stote, the diaphragm in the EGR pressure trans- ducer is pushed down by the spring force and the pressure transducer valve opens to allow the air into the vacuum passage from the out- side. As a result, the vacuum transmitted to the EGR valve becomes smaller and so does the opening of the EGR valve. Thus, less amount of exhaust gasis recirculated to the intake manifotd Under a high load condition such as high speed driving, on the other hand, the exhaust pressure is high. By the high exhaust pressure, the dia- phragm in the modulator is pushed up and closes its valve, As the air does not enter the vacuum passage in this state, the vacuum trans- mitted to the EGR valve grows larger and so does the opening of the EGR valve. Thus, larger amount of exhdust gas Is recircu- lated to the intake manifold. Under any one of the followinig conditions, ECM closes the vacuum passage of solenoid vacuum valve. In this state, as the vacuum is not transmitted to the EGR vaive, it remains closed. When engine coolant temperature is low © When throttle valve openingis less than spec- ification. © When engine is running under high load © When vehicle is stopped. Other than the above, EGR valve opens and closes in accordance with the EGR pressure transducer opere EGR eolencid vacuum valve EGR prossure transducer 7. EGR valve Intake manifla 2 4, Senaed information 5 6 ‘E1039Tie tsee.t ELECTRONIC FUEL INJECTION SYSTEM _6£1.15 DIAGNOSIS ECM has on-board diagnostic system (a system self-diag- nosis function) as described previously (p. 6E1-10). Investigate where the trouble is by referring to “DIAGNOS- TIC FLOW CHART” and “DIAGNOSTIC TROUBLE CODE TABLE” on later pages. Nort For diagnosis of A/T related part detected by ECM, refer to DIAGNOSIS in section 7B1. PRECAUTIONS IN DIAGNOSING TROUBLES [PRECAUTIONS IN IDENTIFYING DIAGNOSTIC TROUBLE coe} * Before identifying diagnostic trouble code indicated by malfunction indicator lamp (“CHECK ENGINE" light), don’t disconnect couplers from ECM, battery cable from battery, ECM ground wire harness from engine, Such dis- connection will erase memorized trouble in ECM memory # If abnormality or malfunction lies in two or more areas, malfunction indicator lamp ("CHECK ENGINE” light) in- dicates 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.6E1-16 ELECTRONIC FUEL INJECTION SYSTEM. ‘START DIAGNOSTIC FLOW CHART Does malfunction indicator } lamp ("CHECK ENGINE” light) tun ON when ignition switch is tuned ON (without starting engine. |? | Yes Using service wire, ground diagnosis switch terminal ‘and observe malfunction ia dicator tamp ("CHECK EN- GINE” light). Flashes. Is diagnostic trouble code No. 12 indicated? t No Check and repair according | to flow chart coresponding | to that code No. Hf engine fails to start, crank it for 2 seconds and thon while |__Remains ON ashes nO deeds Proceed to DIAGNOSIS of SECTION 8A. iO (emiaies OFF Does engine start? ub Proceed to chart ats ecm. power Lvs and ground ereut Proceed to chart nee | 2 (Melunction indicator tmp |_| ("CHECK ENGINE” gh seul chee Proceed to chart ‘A.(Malfunction keeping ignition switch ON (Don't turn it OFF) ground diag- nosis switch terminal. indicator lamp (CHECK EN: GINE™ light) cuit check). Yes ‘Are engine basic parts described in SECTION 6 *EN- | YES GINE DIAGNOSIS” in good condition? [ne Repair or replace, 1. After eapair, disconnect battery negative cable for longer than 20 sec. to erase diagnostic trouble code stored in ECM momoryendreconnectit. | 2, Start engine and warm it up to normal operating temperature. 3. With grounding diagno- sis switch terminal and ignition switch turned ON, make gure that mal function indicator tamp ("CHECK ENGINE” light) shows coda No. 12, 4. Remove service wire and reinstall cap. Is trouble corrected? 1. Monier sowsor 8: Disgnosis stenting) 0: Ground minal No Proceed to “TRO- UBLE — DIAGNO. SIS” (p. 6E1-62.) Cheek | Electro Fuo! Injection sys- tem parts thet are not indicated by on-board — dia wstic system (self-diagnosis function) YES END se1001Ge1018ELECTRONIC FUEL INJECTION SYSTEM _6E1-17 DIAGNOSTIC TROUBLE CODE TABLE (1 OF 2, M/T AND A/T) EXAMPLE: When throttle position sensor is dofective (Code No.21) Mattnction indicator _Co¥aNO2 Goat Code No.2 lamp COREE ENEINE? 4 ig ON et i - Tl rf__fi i i aslo3 0 0330 30 Time 306) 03 DIAGNOSTIC | MALFUNCTION INDICATOR TROUBLE | LAMP ("CHECK ENGINE” DIAGNOSTIC ITEM DIAGNOSIS. CODE NO. _| LIGHT) FLASHING PATTERN | 3 a ne Heated oxygen sensor 4 L if equipped) 7 r 4 ~ L Engine coolant temper- = B L ature sensor T a J Diagnose trouble according to z Throttle position sensor | “DIAGNOSTIC FLOW CHART” cor- 2 hl responding to each code No. z % 2 J Vehicle speed sensor 3 3 33 fl Mass air flow sensor 34 SALA z 5 a 1 Camshaft position sensor 44 Ann. Diagnose trouble according to a a CTP switch of throttle | | Wie terminals and body ground a. hrethay about 10-140? Yes Yes {No =BUB™ wire open Check voltage between EGR1, EGR2, EGA3 and EGR4 terminals of ECM coupler and body ground for about 1 second after ignition switch ON, Is each measured volt- ——=~1 REFERENCE (COM EGR?, EGR, EGR and EGR¢ terminal voltage) age abouts-8.4V? ones NO ves Check EGR valve. Intermittent trouble or Isit OK? faulty ECM. Recheck refer- ring to intermittent trouble. YES. “BriR”, “EW/Y™, “BrIB™ oF “Br/W" wire open or shorted to ground or poor EGR1, EGR2, EGR3 or EGR4 connec: tion of ECM coupler. Ifwiroherness andconnectionsare | «id NO OK, intermittent trouble or faulty ECM. Recheck referring to intermittent trouble. Faulty EGR valve cory fom, onilonswich OW — 661058 6E1059.6E1-26 ELECTRONIC FUEL INJECTION SYSTEM. B-1 FUEL PUMP CIRCUIT CHECK lonor ‘OND? ‘GNOS 2 8 86 vr venicue TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE) 2. Fuel pump relay ‘Fuel pume 5. Maia relay 2. Wehile with jmmobilisr B (e060 GE061 |s fuel pump heard to operate for 3 sec. after Ignition switch ON? NO jves 41. Turn OFF ignition switch 2. Using service wire, connect “P/B" and “BAV" wire terminals. 3. Is fuel pump heard to operate at ignition switch ON? . P18, aw 1. Fual pump: 2 Service wire Fuel pump cirenit in good condition. YES Lino Check fuel pump relay. fs it in good condition? “PIB” wire open, poor fuel pump coupler connection or fauity fuel pump. YES No Poor relay coupler connection, “P wire open or poor FP connection, If wire and connection are OK, substitute 8 known-good ECM and recheck NOTE: Before substituting a known-good ECM, ‘check to make sure that resistance of coil in relay is as specified. Faulty fuel pump relay. E02B-2 FUEL INJECTOR CIRCUIT CHECK ELECTRONIC FUEL INJECTION SYSTEM _ 61.37 TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE) MT VEHICLE secu 2. No. injector S.No. 2igeetor 4 No, Binjector 5. No. 4lojector 6. Mainrelay 7. Ignition twitch 8. Vehicle without immmosilzer 8. Vico with (enor AT VEHICLE eat Using sound scope, check each injector for ‘operating sound at engine cranking. Do all 4 injectors make operating sound? No ‘One or more of 4 injectors make(s} no operating. sound yes. in good condition. Fuel injector circuit Check coupler connection and wire harness of injector not making operating sound and injec- tor itself, I all above ary OK, substitute a known-good ECM and recheck. None of 4 injectors makes operating sound. To Oon next page.ELECTRONIC FUEL INJECTION SYSTEM. DNone of 4 injectors makes operating sound. 1. Disconnect coupler from No.1 with ignition ewitch OFF, 2. Check voltage at “BB wire terminal with ignition switch ON. Is it battery voltage? 1 Injector counter Disconnect ECM couplers with ignition ‘switch OFF check all 4 injectors for resistence respectively. No.1 injector :INJ1 and 81/82 No.2 injector :INJ2 and B1/82 No.3 injector : INJ3 and B1/B2 No. injector : INJ@ and B1/B2 If resistance is OK, substitute a known-good ECM and recheck. se1082 Power circuit open.B-3 FUEL PRESSURE CHECK JECTION SYSTEM ELECTRONIC FUEL 1 tnieeor 2 Baier ona 2 Fuel posse 4 ante 5 Fuel pumo 6. Ptsaion domper (ax Gauge (Hose (Ch:Anachment e085 NOTE: Bofore using following flow chart, check to ‘make sure that battery voltage Is higher than ‘14V. If battery voltage is low, pressure be- ‘comes lower than specification even if fuel pump ana ti in good condition. 1. Install fuel pressure gouge 2, Operate fuel pump. Is fuel pressure then 250 ~ 200 kPa (2.5 — 3.0 kgfem?, 35.6~ 427 psi? Also, is 180 kPa (1.8 ko/em?, 25.6 psil or higher tuel pressure retained for t mi ———= No pressure ‘mute after fuel pump is stopped? | To @ on next page. Pressure within spec. but not No tntained i To on next page. Low pressure To on next page, 1. Startengine andwarmituptonormalop- rating temperatue yen 2. Keep it running at specified idle speed. | fuel pressure then within 210 260 kPs (2.1 ~2.6 kglem?, 29.8 ~37.0 psi)? ves. mal fuel pressure. To® on next pane. No ‘© Clogged vacuum passage for fuel pres- sure reguletor or Faulty fuel pressure regulator.40_ ELECTRONIC FUEL INJECTION SYSTEM ee re STN B-3 FUEL PRESSURE CHECK (continued) No PRESSURE With fuel pump operated and fuel return hose blocked by pinching it, is fuel pres sure applied? ves No Shortage of fuel or fuel Pump or its circuit defective (Refer to “Diagnostic Flow Chart 8-1"). @ LOW PRESSURE 1. Operate fuel pump. 2. With fuel return hose blocked by pinching it, check fuel pressure. Is it 400 kPa (4.0 kg/em?, 56.9 psi) or more? Faulty fuel pressure regulator ‘¢ Fauity fuel pump or * Fuel leakage from hose ‘conneetion in fuel tank Faulty fuel Pressure regulator @ PRESSURE WITHIN SPEC. BUT NOT RETAINED Is there fuel leakage from fuel feed line hose, their joint? | ves 1. Disconnect fuel return hose from fuel pipe and connect new return hose toit 2. Put the other end of new Feturn hose into approved gasoline container. 3. Chock agoin if specified pressure is retained, ‘While doing so, does fuel come out of roturn hose? Fuel leakage from hose, pipe or icint. ‘¢ Fuel leakage from injector, Faulty fuel pump (Foulty ccheck valve in fuel pump) Fuel leakage from fuel prossure regulator dia phragm. @HIGH PRESSURE 1. Disconnect fuel return hose from fuel pipe and connect new return hose t 2. Put the other end of new re- turn hose into approved gasoline container. 3, Operate fuel pump. \s specified fuel pressure ob- tained then? No Faulty fuel preeeure Yes Faulty fuel pressure regulator. Restricted fuel return hose or pipe.B-4 IDLE AIR CONTROL SYSTEM CHECK ‘TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HAL a NESS SIDE) ELECTRONIC FUEL INJECTION SYSTEM_6E1-41 B: Diag. switch termina © Ground ermine! F: Dutyoutputterninat 1 leat contol valve {ine valve} 2. cM oa 2. Seated intoumation 3 Monto coupler To] 5 mainstay 1. Warm up engine to normal operating temperature and keep it idling. 2. Using service wire, ground diagnosis switch terminal 2. Is diagnostic trouble code No. 12 in- dicated? 6. Venice withoutimmabitier 7, Vebiele wit immobitzer 18: Diag switentermunat Ground verminl Duty output terminal VES. No Check idle air control duty (IAC duty) andiate speed. ‘Are they within specification? Yes ls engine idle speed kept at 750 ~ 850 ri ‘even with headlights turned ON. Yes System is in good condition. 1068 No High ile spe To O on next page. Go back to “Diagnostic Flow Chan” Low iale speed To @on next page. Tle speed is within specification but duty is not. 1. Adjust IAC duty ta specification. 2. Proceed to next step. No Proceed to system circuit check @ on next pege.6E1-42_ ELECTRONIC FUEL INJECTION SYSTEM B-4 DLE AIR CONTROL SYSTEM CHECK (continued) HIGH IDLE SPEED ‘Check (AC, tion. sistance andlor opers Isit in good condition? @ SYSTEM CIRCUIT CHECK 1. Disconnect ECM cou- plers with ignition ‘switch OFF 2.8 resistance between 1SC and B1/B2 11-1407 ves NO Poor coupler connec- tion. Hconnection is OK, sub- stitute 9 known-good ECM and recheck. good ECM and recheck. No ves Does duty meter in Faulty IAC valve, cate less than about 28% (or mote than ‘about 72% for OFF duty meter)? ves No Substitute a known: ‘Adjust idle speed and duty. NOTE: Hi not adjustable with idle speed adjusting screw, check fast idle ir valve for alr leak 9/8" elrcult ® LOW IDLE SPEED Cheek IAC tion, valve for its resistance and/or opers- Is itn good conaition? good ECM and recheck. No ves Does duty meter indi- Faulty 1A( ‘cate fess 90 - 100% (about 0 ~ 10% for OFF duty meter)? na YES Substitute a known- Proceed to system ci cuit check ©. NOTE: ‘> Feulty IAC valve *Poor coupler con- nection or © Open wire harness TAC duty ean be checkad by using analog type volt- ‘meter with high impedance (MQ/V minimum), al~ though not accura TAC duty to voltage relation estou, FDOT Sueven. | meren | VOUTMETER INDICATION | INDICATION 0 (%) 100 (%) lv) 0 3 o5xVe 708 2 ‘a ‘¢ “OFF DUTY METER” Is such duty moter that in- ficates approx. 100% when terminal voltage is. approx. “OV” © “Vp" ropresents battery voltage while engine of vehicle being checked is runniELECTRONIC FUEL INJECTION SYSTEM _6E1-43 B-5 EGR SYSTEM CHECK (Vehicle with EGR Stepper Motor) LEGRvatve 2. Ine mantels 3. From exhaust manitold eee 5. From mala ely oo ‘TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE) ar vencee eat f imac : T ben = ont Eons a2” Ta anvenc ee1069 | Ta —| Titan sach ON Ts 86 BUR ‘Test switch terminal ow Ignition switch ON : Test switch terminal grounded _ Fuel pump relay (ve| 0-1v | For3 seconds after ignition switch ON re | ar P| rote futhout immob Tee 70-14 | Ateriho above wine wr TW Tgnivon ech ON 5s ° Ignition wigger signa! eeiween O-V | While ‘engine cranking OR} Taro = : Engin sor switch —|_O= 120] Wii eigie ang STA B10 an (Engine start signal) ov Other than above o | en w_ _ | Fower ure Torback| ~Go.say__| Ignition switch ON and OFF an Tan 5 5 Ga ee u hicle with immobilizer) 10 = 14V After the above time mes | er | Pw | ABSconvoimodule | 10-1av | Sve" 8 secon afer anon Bch Four veal Toa [onion sach OF ower steering pres : Nae a pss | ors | avo | tur “awnas te With engine running at idle. space a o-w | tuning steering whet othe Aight or be left as far as it stops Ignition switch OW Closed throttl Z cane Throttle vaive at idle position | ars siw —_ | Closed throtle position ignition ewiteh ON 4-sv | Throtle vale opens larger thon idle postion T= [anton switch OW py | an suv | Oing. switch tamina ay anton ewih ON = Diag. switch terminal grounded oa = Tn = EGR lene van cor | B19 | caw —_| FoR Solenoid vasiim| 9 yay _ | wgntlon awiteh ON Malfunction _ indicator o-W Ignition switch ON owt | 820 vw | lame seHEcR EN GINE* igh 70-1av | Enaine unning [aR aa ; ea | eat BIT power source 10 14V | ignition switch ON TTERMIIWAL ARRANGEMENT OF EoM COURIER MEWED FROM HARNESS SIDE) alalsfalalafe(alatain fel elalatelalalalaP eek hatohobnledade ekaELECTRONIC FUEL INJECTION SYSTEM _6E1-49 AST VEHICLE TERMINAL NORMAL conomon NARIE”[ POSITION, VOLTAGE Ns [AT 70 14V_| Tgnition switch ON sc Az idle air control valve 10 14V_| “ition switch ON wat | As 70=14V_| Tgnition switch ON = Aa S = PRG Eee ames earee wake | 10-rav_| ignition switch ON FP as Fuel pump relay (vahicie | 0-1 __| For 3 seconds after ignition switch ON without immobilizer) T0= 14V_| After the above time rons |_A0 EGR avs EGR senpa [ao 1av | Over 1 second efter gion switch ON cam EGR valve (EGR sieppsi [9 iy | overt eecond ater ignition ewitch ON AT — EGR EGR golenaid vacuum | Go tav_| ignition switch ON O=1W_[Tonition switch ON wt | ae Ignition trigger signal Heme | wate engine cranking o3v MON} AS. Duty ouput terminal = = BR Alo Power source for back-up | 19_ say. | ignition switch ON and OFF 3a TO=14V_| Tonition switch ON GNOT[—ATz S 5 Jay_Wehiclo with | 0=1V___| Ignition switch ON ney 10 14v | Ignition switch OFF Telay (vahiclewithout] 9 ~ay | ignition ewiten ON ce [10 FeV] Teton awetch ON FP Fuel pump relay (vehicle For 3 seconds after ignition switch ON with immobilizer) 70 14V_| After the above time Ais EVAP canister purge valve PRG (ehicle withoutimmobite- | 10-14V | Ignition switch ON Taz Ave 10 14V_| Tonition switch ON ion ind = W__| Ignition switch ON ieataltar Malfunction indicatorlamp A (CHECK ENGINE" light) [“70-74V_| Engine running = Als i = o EGRa | 19 eae 1V__ | Over 1 second after ignition switch ON EGR valve (EGR stepper wert second after ignition Swit EGR2 ‘A20 motor coit 2, if equipped) 10-14v | Overt id after igniti itch ON, vested onyoen T= 14V_| Tgniton switch ON oxn | azt Hosted onygen dai | Over’ min. after engine Started Engine running at idle speed =e 5 5 SoL_| Aas Data link connector 4=5V_[Tghtion switch ON az | _ Aza To=14V | igativon switch ON GND | Aa ‘GNDS A26 - - TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE) ice6E1-50_ ELECTRONIC FUEL INJECTION SYSTEM. ee STEN AST VEHICLE TERMINAL NORMAL c WaMe [POSITION | WIRE COLLOR oa VOUTAGE eer s2_f Bt GA___| Shittsolenoid valve B o-W Tanition switch ON spoWER" indicator ght | Mode selector switch in Power mode PwL | 82 ° POWER idcnor tight | —————t tion gaeR OW Mode selector switch in Normal mode pe Tgnition switch ON o-2v ponore OD cut switch ON oo | 09 wo OOIOFr*indsstortahy cr eh ON ODeut switch OFF T=1V__[ Lighting switch OFF eal oe |encermocenaes 10= 14V_ Lighting switch ON Temall or head) Ooi | Waition switeh ON Mode selector switch in Power mode pwr | 65 ° Mode selector switch : 5 Toctav | Wgnition switch ON Mode selector switch in Normal mode rs rs cay | | ignition switch ON ele ae eee O-1V_| Transfer leverin 4L or N position Toniav | gnition switch ON ‘Transfer lever in 2K or 4H position Tgnition switch ON 0-1V | oD cut switch ON op | a 0G | OD cut switen 5 Jociav | Weaition switch ONT OD cut switch OFF Seeeca 7 TT vehicle speed seneer| 7 = GA] Tet solenoid valve O=7V | Tonttion switch OW 31] 810 G/O | Shift solenoid vaiveA | 10 14V_| lgntion switch ON Dar | Brition switch ON ale F Tranemission ronge switch Selector lever in other than “R* range (°R" range) Tontay | [nition awitch ON Selector lover in "A" range Ty anition switch ONT i O-1V | Selector lever in other than “N" elie su | Tensmission range switch { Selector lever in other than “N" range (IN range) Tanition switch ON y0-14v —MV_| Setectoriever in “N range Daa | ignition switch ON Blea 6 Transmission range switch Selector lever in other then “0° range ("0° range) Toc ia | ignition switch ON = HV _| Solector lever in “D" range ignition switch ON i O-1V | Solactor lover in other than “2° ran a on vig _ | Transmission range awiteh Selector k ther than "2" range (°2" range) Ton tav | [onition switch ON Selector lever in “2" renge daw | fetition switch ON a ee yor | Teanemission range awiteh Selector lever in other than “L* range (*L* range) To tay | [arition switch ON cane _ | 10-14 | Selector iever in *L* range sro | pie a ATT vate speed dentar | ~~ _ ~ TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE) 7 iy PERS By dada falefede elo esELECTRONIC FUEL INJECTION SYSTEM A/T VEHICLE TERMINAL NORMAL Post] WIRE circu CONDITION fae) | oor | eee VOLTAGE SE—[ or] Gv _| Sensor ground S = VeC~| Be | GR | Power soureo for Sensore | A76~626V | Ignition switch OW . T= 16V ignition switch ON ee fe oon eeaieentaal 1.7-=2.0V With engine running at idle speed Tndicotor deflection Heated oxygen sensor aor _GeFECTION | white engine running at 2,000 min for Ox | o4 | Ae | Gfequipped repeated | botween | minute of longer after warmed UP TW | OO adjusting resiator 7 ignition switch ON co LO | SM | itequinpes) foueunad CO resistor disconnected ena ipaition switch ON on | 06 | avy | diag. switeh terminal ov Tanition switch ON _ Jiang. witch terminal grounded ete iow Tgnition switch ON acs | or | va | At conditioning circuit With engine running {ifequipped) 0-1 pea Tndicotor dolisction | Ignition switch ON seo | os | y | Vetelespeed sensor | Tepeated between 0 | Hearlttietuined slowly with earrght in speedometer =1V and 4-5V tire locked. _ Tndicator deflection cas | 09 | w | caPsensor Tepeates “besween | fgntionswiteh ON repeated | be rank shaft turned slowly Engine stor switch 6-12 Wie engine cranking STA | B10 ey [Engine start signal) ov ‘Other than above ignition switch awit i eu) BWV | Wenicle with immobilizer) tay anition on = [pi |= Bian 5 = Engine coolantiemp. san- 5 Ignition switch ON wu [E8 a ‘sor amas Engine coolant temp.:80°C (176°F} Ignition switch ON 05-120 rottlevalve at ile posi via joi! cr | tesensor sorte valve ie aaa ignition switch ON Throttle valve at full open position pee [Tene = = T= ignition switch ON rs | ore | eum | tect ewiten torminat ignition ewitch ON a! Test switch terminal grounded BBE control maaule vgs ater Ignition swneh aes [ow | pw | Abscontol y0- 14 ‘Over 3 seconds ater Ign ON on ignition switch ON pss | 018 | avo | Power steering pressure With engine running at idle speed, ture BO | switeh (if equipped) o-w ing steering wheel to the right or left as far asit stops Ignition switeh ON Closed throttle position ow Throttle valve at idle position 10 Dis | BIY | viten bea Tgnition switch ON a-5v Tirottle valve opens terger then idle position a0 Blank = 5 ToT Brake pedal depressed a 1 f oat fad comes O-1W Brake pedul released = [pe T= fatane = = TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE} [a 4 score i orf caf eal [es cedar fs x fondo.ofp von6E1-52_ELECTRONIC FUEL INJECTION SYSTEM 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 pair of terminals of dis- connected couplers as listed in following table. CAUTION: © Be sure to connect ohmmeter probe from wire har- ness side of coupler. © Be sure to turn OFF ignition switch for this check. © Resistance in table represents that when parts tem- perature is 20°C (68°F). 1. ecw coupte aisconnected 2. Ohmmeter TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE) M/T VEHICLE mlelshaaalola apa ele[ale ofall debe fabtalakatated aE ad TERMINATPOSTION —] STANDARD cRcUT wr AT RESISTANCE Cty Noster = BEB | IATA | W270 = Reznor RI= BEVGRE [ATE ATURE | VE 7 = No.inestor T= Bave22 | A= RIVRGS | 12 7a = Rot recor AVa= BVT [AVE AIVARE| —V2= V7 = TAC ave z= BRVBEE | AE RIVROG [= Ta = EVAP Vehicle with AS ANIA2A cere ata g| MB caveze 20-260 . toe ean At5-ANT/Aze ear aae io Bn | Av-Anviaas | 2000 : EGR vaive (ol). eaipped [ADD BEVERE [AIO AVIARY | —20= 240 7 EGA valve (coil 4),f equipped | Aga 621/622 [AIS -Aiw/A24| 20-240 =ELECTRONIC FUEL INJECTION SYSTEM_ 661-53 TERMINAL POSTION ‘STANDARD, circuit a = eee CONDITION Teated oxygen sensor neater ~ = 7 {vehicte with immobilizer) eameel pelo eal Heated oxygan sensor neater (if equipped) and main relay AN? -B2, A21-Ai3 67.7- 98.32 - (vehicle without imenc Fuel pump relay 7 z - {vehicle with immobilizer he rnaueeet | etcencamnecnils et cect Fuel pump relay and main relay : ~ {vehicle without immobilizer) bALD ASHANS | 2" 168 : — lizer) ‘Main relay = = (vehicle with immobilizer) come saliiaate | checmoare Tontinully | Throtile valve at Tale position CTP switeh Bis~a2s | 19-1 ‘Throttle valve opens larger than sale position Throtile valve at idle position TP sensor ar-a2s | 014-01 Throttle valve at full open pose tion ECT sonser a5-Az | _o1a-01_ | aae-oaska | FABRE coOTNE Temp, BOC GO odjust resistor (vehicle For resistance of CO resistor, refer to TOLE Mi ut heated oxygen sensor only) | _A21~ A25 05-01 | TURE ADJUSTMENT hmmeterin- Vehicle speed sensor 85-Body | 08-Body | dicatorde- | Rear left wheel tumed siowly {in speedometer) ‘round ground | flects between | with rear right wheel locked and = Continuity | Selector lever in “A” range Tranamieion range eweh A? - Tangel Wenile wits immobiteed | ~ 81-011 | spout 10m | Sete ever fr oter than 7 TTanamiation Tenge ewich CP Conny — | Sees rer TaN range) and fuel pump relay {v - 811-5 elector lever in aR Hawhout motte Not continuity | Sesto" fever nother tan “R Conimuy ~| Selecor vara Tange Transmission range awit (-N* : = Ttansmigsion range swieh (-W| 812-011 rcomieen’ | Satsar lever hot an range TTone(nanon range ewan EWP Coninaky _ | Sener evar be ne ae Breas mon | Sear ha AF hicle without immobilizer) Not continuity | Selector lever in other thay Terarision ange aenen poe} paren [Senin Sees roe range) (venicte with immobilizer) Not continuity | Fenges ues ae Tana anon Tanga aetah POP Tontnatiy— | Geter Tovar in 7B Tans range) and fuel pump relay (ve- 7 BI3-A5. Selector lever in other than “D” ‘Not contini hicte without immobilizer) range Continuity _| Selector lever in “2” range Tanarison range auch 2° : ‘ Wo coninay | Ss range) and fuel pump relay {ve - BI4d- AS ie Selector lever in other than “2” hicle without immobilizer) Not continuity | range Canina —| Sessa lore Tae range} (vehicfe with immobilizer) - BIS O11 Tox comuinuity | Selector lever in other than “LU Traropiapy gage Sa CE Cant —| Seeger Bern" ana cereal line ay | | anes ener ar aT aed motte Not cosinuy | Sls ever oer tan AIT vehicle speed sensor = | 88-816 369-4512 7 ‘vo low ann ——)" geod [Cont —| Tater vari roan ground | Not continuity | Transferleverin ZH or 4H positionE1-54_ ELECTRONIC FUEL INJECTION SYSTEM TERMINAL POSTION 7 crRcuT SrANDARD ms MT T A RESISTANCE eee Sominany | ROSE iar wih OTe Mode selector switch - BS - Body, ER”. sound [mT Mode alae Bae To WOR Y | mat 00 cut switch - 87 - Body Continuity | OD cut switch ON ground [Rot continuiy | OD eat switch OFF Shit solenoid van ——hiio- 807, ~ oven ground ies Shit solenoid valve 8 : Bi eeay [4-150 : TCC solenoid valve - 88 - Body - ground louis[eno] (IEWED FROM HARNESS SIDE} (ww veracte) FS er venice! TERMINAL ARRANGEMENT OF ECM COUPLER usuo3. * e005 (VIEWED FROM HARNESS SIDE} dow verwcuey apis) 5 vr vente.) TERMINAL ARRANGEMENT OF ECM COUPLER FEE a eee ELECTRONIC FUEL INJECTION SYSTEM _ 661-55 ON VEHICLE SERVICE - ELECTRONIC CONTROL SYSTEM MASS AIR FLOW SENSOR (MAF SENSOR) Inspection NOTE: Use voltmeter with high-impedance (10k2/V minimum) or digital type voltmeter, 1) Remove ECM with bracket, relays, fuse box and wire har- ness previously outlined. 2} Connect couplers to ECM. 3) Connect voltmeter to “B +” terminal of MAF sensor cou- pler disconnected and ground. 4) Turn ignition switch ON and check that voltage is battery voltage. Ifnot, check if wire harness is open or connection is poor. 5) Turn ignition switch OFF and connect MAF sensor cou- pler to MAF sensor. 6} Turn ignition switch ON and check voltage at AFM termi- nal. Voltage: 1.0 -1.6V 7) Start engine and check that voltage is lower than 5V and rises as engine speed increases. (Reference data: 1.7 ~ 2.0V at specified idle speed) lf check result is not as specified above, cause may lie in wire harness, coupler connection, MAF sensor or ECM.AUTOMATIC TRANSMISSION 781-1 SECTION 7B1 AUTOMATIC TRANSMISSION (4 A/T) © Service on or around Air Bag System Components or Wiring must be performed only by an authorized Suzuki dealer. Please observe all WARNINGS and SERVICE PRECAUTIONS in Sec- tion 9J under “On-Vehicle Service” and the Air Bag System Component and Wiring Location view in Section 9J before performing service on of around Air Bag System Components or ring. Failure to follow WARNINGS could result in unintended air bag deployment or could Fender the air bag inoperative, Either of these two conditions may result in severe injury. © 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, tho air bags may be deployed 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 mentioned in FOREWORD of this manual. CONTENTS GENERAL DESCRIPTION ..... a 781-2 ELECTRONIC SHIFT CONTROL SYSTEM .. . +. 781 2 Powertrain (Engine) Control Module (PCM/ECM) . <. TBI 2 Automatic Gear Shift Diagram ..... - 781-6 DIAGNOSIS . 781 8 TRANSMISSION UNIT ..... +. 7B1- 8 Manual Road Test : -. 781-8 ELECTRONIC SHIFT CONTROL SYSTEM . - 781-9 On-Board Diagnostic System .. se - 781-9 Precaution in Identifying Diag. Trouble Code so 781 8 Precaution on Troubleshooting . + TBI 9 Diagnostic Flow Chart ..... : - 781-107B1-2_ AUTOMATIC TRANSMISSION GENERAL DESCRIPTION ELECTRONIC SHIFT CONTROL SYSTEM Engine -t+{ Torque convarter_J-——~|_ Planetary gear 4H Final gear ————— oii pump Clutch and brake = i Shik solenoid vaives A@]_——[__ Control valve Fcc solenoid valve ! AMT vehicle speed sensor_/===3 powersrain Engine) contol TT L_moauteweweenn Vehicle speed sensor Lt) {7 T T {in speedometer) i 4 4 4 || Pacer] anor | [row ‘Modo selector switch Throttle position concor — f=—~ | |_ENGINE® fight) | | tight Aight \ - Transfer 4WD-tow ewitch Engine coolant mp. eoneor Fr Ald pressure crear === Electric signal POWERTRAIN (ENGINE) CONTROL MODULE (PCM/ECM) The PCM is an electronic circuit component that controls gear shift and TCC lock-up according to the signal from each sensor. It is a microcomputer consisting of an IC. transistor, diode, etc. It is installed to the underside of the instrument panel at the driver's seat side. 1. Battery : 3 2. Ignition switeh 4 ECT aensor 5 TPsensor 8 v8 (in speedometer) 7. NTVSS tin AT 2 Lpmting etch Brake owen 10, Mode ttector switch 11 ODeutewith 12. a¥Diow etch 1. Tansmiasion range swith 1. MIL CCHECK ENGINE" ight 18, Monitor coupler 4. oue 18, “ODIOFF”inslestor ght 18, “POWER indicator ght 20. shitactenot vave 2, Shik solenoid valve 8 22. TCC solenaid valve 2 Zonor FP-cno2cnas ‘TERMINAL ARRANGEMENT OF PCM COUPLER (VIEWED FROM HARNESS SIDE) "7er002 783008432 1. Reference votags 2 Ouiputvotioge 53. ON/OFF ignat 44 Ground 5 Resitanee 6. brush 7. Rotor Tao 1 Venici speed sensor 2 Oilpen Tae TET AUTOMATIC TRANSMISSION _781 Throttle Position Sensor This sensor is installed to the throttle valve shaft. Throttle valve opening signal are transmitted from TP sensor to PCM as voltage signal, PCM uses it as one of the signals to control transmission gear shift. Vehicle Speed Sensor This sensor is a pulse generator type that detects revolution of the output shaft (vehicle speed) in the transmission case. The pulse generator is a noncontact sensor consisting of a permanent magnet, coil and gears. As the geer of the output shaft turns, the magneflux from the permanent magnet varies and a voltage of the frequen- cy corresponding to the rotor revolution occurs in the coil. This voltage is inputted to the PCM where PCM judges the output shaft revolution or the vehicle speed. The vehicle speed is also detected from the speed meter. Transmission Range Switch A transmission range switch is provided so that the engine can be started only when the shift lever is in the “P” or “N” position, e | oOAUTOMATIC TRANSMISSION 007 E1008 7a000 Brake Switch The same switch is used as the brake lamp switch. It disen- gages the TCC when the brake is depressed while the TCC is operating. Engine Coolant Temperature Sensor (ECT Sensor) The coolant temperature sensor is used and it prevents gear change to the O/D gear and TCC operation when the engine coolant temperature is 30°C (B6°F) or lower, O/D Cut Switch ‘The gear shift up or shift down to and from the O/D gear can be selected with this switch. ‘OD cut switch status | Switch position | “OD/OFF” light ON (continuity) Released ON OFF (not continuity) | Depressed OFF Transfer 4L Switch This switch detects that the 4-wheel drive low gear is en- gaged and prevents the gear change into O/D and lock-up.AUTOMATIC TRANSMISSION 781-5, Mode Selector Switch 2 The gear shift timing, normal or power, can be selected by using this switch. 1. Mode selector swien 2.Shittever Fail Safe Function This function is provided by the safe mechanism that assures safe driveability even when the shift so- lenoid valve or speed sensor fails. The table below shows the gear position in each shift under a normal/abnormal condition. Condition e = Shift solenoid Shift solenoid | Shift solenoid Normal valves-A & B ae valve'A abnormal | valve-B abnormal | Valves-A & 1 1st 2nd ard D O/D 3rd old o/D O1D 1st ist 2 ‘nd avd ard 3rd (3rd) ist Ist L | tet ist (2nd) (2nd) Change Mechanism P Shite set The same select pattern shift lever is used as the floor type j i tore ta | and frequently used “N” and “D" ranges are made select- R i able freely. ar Bo os shnesees ek can o}ea cme L TOE‘7B1-6_AUTOMATIC TRANSMISSION AUTOMATIC GEAR SHIFT DIAGRAM Automatic shift schedule as a result of shift control is shown below. In case that select lever shifted to L ata speed higher than 52 km/h (33 mile/h), 2nd gear operates first and then down shifts to 1st at a speed lower than that. No up shift is available in L. The same as, the select lever shifted to 2 at a speed higher than 100 km/h (63 mile/h), 3rd gear operates first and then down shifts to 2nd at a speed lower than that. No up shift is available in 2. Power Mode Unit: krvvh (mile/n) Shift Throttle opening i 1+2 | 243 | 3-4 | a43 | 3-2 21 ae 29 34 132 120 5 42 — (a1) (59) (63) (75) (53) (26) Closed throttle ue 3 48 36 23 7 av |e | eo | em | aa (a) Goor Shift Diagram TCC Lock-up Diagram : He coal a im) TOTS TBTOTEAUTOMATIC TRANSMISSION _ 781-7 Normal Mode Unit: keavh (mitem) ‘shift Throttle opening t-2 | 243 | 3-4 | 4-3 | 342 | 2-1 a 3 120 1 7 Ey Full throttle (28) (52) (75) 0 (48) (24) 14 32 45 35 2 i) Josed thrott Gt (9) (20) (23) (22) (18) (ay Gear Shift Diagram re venta paz aes vn —lonhed eee ce vai ed TCC Lockup Diagram ae osu * | T Ie | 3° 5 ae Lan ge ° [eco i tos veh aan ee, BOTS TaIOT7B1-8_ AUTOMATIC TRANSMISSION DIAGNOSIS TRANSMISSION UNIT MANUAL ROAD TEST This test checks the gears being used in “L", “2” or "O” range when driven with unoperated gear shift control sys- tem. Test drive vehicle on a level road. 1) Disconnect coupler of shift solenoid valves on transmis sion, WARNING: To avoid the danger of being burned, do not touch the hot exhaust system when disconnecting shift solenoid valves coupler. 2) With selector lever in “P” range, start engine and warm itup. 3) With select lever in “L" range, start vehicle and acceler ate to 20 km/h (12.5 mile/h). Check in this state that 1st gear is being used. 4) At 20 km/h (12.5 mile/h), shit accelerate to 40 km/h (25 3rd gear is being used. select lever to 2 range and /h). Check in this state that 5) At 40 km/h (25 mile/h), shift select lever to D range and check that O/D gear is used when speed is higher than 40 km/h (25 mile/h). 6) After above checks, stop vehicle then engine, and con- nect solenoid vaives coupler. WARNING: To avoid the danger of being burned, do not touch xhaust system when connecting shift sole- valves coupter. 7) Ground diagnosis switch terminal in monitor coupler, turn ON ignition switch and make sure that MIL ("CHECK ENGINE” light) indicates code No.12.Teo Reed at “Code No.2" os 03 a3 seconds seconds seconds on, Begining of next signal Beginning of sigael ort atk so 0330 second seconds seconds (Coe Ne.12 Norma TBI AUTOMATIC TRANSMISSION 781.9 ELECTRONIC SHIFT CONTROL SYSTEM The powertrain (engine) control module (P(E}CM) with on- board diagnostic system (self-diagnosis function) operates as described below. When diagnosing a trouble in the electronic shift control system, use “DIAGNOSTIC FLOW CHART” and “DIAGNOS- TIC TROUBLE CODE TABLE” on the following page. ON-BOARD DIAGNOSTIC SYSTEM {SELF-DIAGNOSIS FUNCTION) ‘© When the engine is OFF and the ignition switch is turned ON, the malfunction indicator lamp (“CHECK ENGINE” light) lights for its bulb check of malfunction indicator lamp (“CHECK ENGINE" light). © Should an abnormality have occurred in the electronic shift control system while the ignition switch is ON or the engine running, the area where the abnormality has oc- curred is stored in the P(EJCM memory and it remains in the memory till ignition switch is turned OFF. ‘© The affected area in the memory is indicated by flashing ‘of malfunction indicetor lamp (“CHECK ENGINE” light) when the diag. switch terminal is grounded. PRECAUTION IN IDENTIFYING DIAG. TROUBLE CODE © Before checking the diag. trouble code, be sure not to turn OFF the ignition switch, disconnect the P(E)CM or battery negative cable. Or the memory will be erased. © Each trouble code is indicated 3 times. Write it down so a8 not to forget it. When an abnormality exists in more than one oreo, their code Nos. are indicated from the smallest to larger numbers. PRECAUTION ON TROUBLESHOOTING © “Normal operating temperature” in the diagnostic flow chart means that the engine coolant temperature is 80°C (176°F) and A/T fluid temperature is 70-80°C (158-176°F). © Do not connect an ohmmeter, voltmeter, etc. directly (with the coupler disconnected) to the P{E)CM terminal. It may cause damage to the P(E)CM.7B1-10_ AUTOMATIC TRANSMISSION ——— DIAGNOSTIC FLOW CHART ‘STANT 1. Perform test driving. 2. After test driving, hold engine running in “P* position applied with parking brake 3. Using service wire, ground diag. switch terminal and ob- serve malfunction \dicator lamp ("CHECK ENGINE" light). co 1. Montiorcouoler 8: Diagnosis 2: Ground erin Malfunction indicator lemp Diagnostic trouble code indicated. No trouble code indi (CHECK ENGINE” light) doesn’t cated, (Code No. 12 only) Operate properly. (doesn't light. doesn't blink or doesn’t output code.) ‘Are they AIT related code (refer to Diagnostic Trouble Code Table) ‘Check according to flow only? chart for each symptom. Proceed to DIAGNOSTIC FLOW |__NO Sgrarann Ssaure cea insertion ee) Yes Proceed to Diag. flow chart A. Record trouble code No., turn OFF ignition switch to erase diag. wouble vode memory. Faulty shin point. Proceed to Diag. flow chan B. ‘Check wrouble coda orca and re- pair. Gear does not shift 10 On. Proceed to Diag. flow chart C. Is trouble corrected? No TCC lock-up occurs. Proceed to Diag. flow chart D. No ves END vowsAUTOMATIC TRANSMISSION 781-11 Diagnostic Trouble Code Table {A/T Related Code) Code No. Diagnostic Area Diagnosis 12 = Normal 61 Shift solenoid valve A or its circuit open or shorted to power Shift sotenoid valve A eircuit. 62 Shift solenoid vaive A or its circuit shorted to ground = Shift solenoid valve B or its circuit open or shorted to power Shift solenoid valve 8 cireuit 64 ‘Shift solenoid valve 8 or its circuit shorted to ground. ee TCC solenoid valve or its circuit open or shorted to power cir- ToC solenoid valve cuit. 66 ‘TCC solenoid vaive or its circuit shorted to ground, Defective switch or its circuit (more than two transmission fa Tronamission ange switch | T2ngeswitehes of "A", "N*, “D%, "2" and “L* turned ON s- multaneously or no transmission range switch turned ON while vehicle running). 5 ‘AMT vehicle speed sensor Defective sensor or its circuit, (open or short) Fail-Safe Tabl Code No. Diagnostic Area Fail-Safe Function 14 ecT eensor After 15 min. from engine start, TCM release inhibitions of 15 shift to OD gear and TCC lock-up. a mz TP sensor ‘Throttle opening is controlled as closed. a ‘Shift solenoid valve B. , : 1st, 2nd and 3rd gears ON, ath (0/0) gear OFF. Shift solenoic oe Se eaceeey For shift position refer to Fail-Safe Function in ELECTRONIC SHIFT CONTROL SYSTEM. a Shift solenoid valve A. Shift solenoid valve B Ist gear ON, 2nd 3rd and 4th (O/D) gears OFF. ue For shift position, refer to Fail-Safe Function in ELECTRONIC SHIFT CONTROL SYSTEM. 5 Fz — TCCsolenoid valve ~ ‘| TCC solenoid valve OFF Priority order le *L" > -2" = “NY "DRO ee Transmission range switeh | When two or more signals inputted same time) Transmission range switch is controlled es “D” range. (When no signal inputted) 75 ‘AIT vehicle speed sensor Signal from vehicle speed sensor (in speedometer) is used.7B1-12_AUTOMATIC TRANSMISSION ee ASN DIAGNOSTIC FLOW CHART A NO GEAR SHIFT OCCURS: i Warm up engine and transmission to normal operating temperature, Check diag. trouble code. No trouble code {_ indicates, Perform manual road test referring to p. 781-8, le it OK? OK With solenoid vaives coupler connected, turn ignition switch ON. . Conduct @ road test in “D" range and check voltage at each solenoid termini For relationship between vehicle ‘and each gear position, refer to gear shift diagram. Vehicio | tet_| and] ard | air speed | range | range | range | range Stenoia | Pamery |Banery| oy | gy EAtSa | Voltage | voltage Shift Battery | Battery solenoid | OV ov eoesa voltage | voltage NG ‘With P(E)CM coupler c: ver shifted to "D" range, check voltage at "L” and *2* range signal terminals. Voltage each torminel should be OV. oK Replace P(E)CM and recheck. onnectedand selectie- |_ NG OK NG a Go back to “DIAG. FLOW CHART” on page 781-10. Transmission or manual select control system faulty. Shift solenoid vaive-A, B or ‘transmission faulty. Shift switch or its circuit faulty Sy: Shih solenoid AS) terminal Se Shit solenoid 8 Sp) terminal 308 signal aren 2" range signa terminal ‘Terminal Arrangement of P(E}CM Coupler (Viewed from hamess side) =DIAGNOSTIC FLOW CHART B FAULTY SHIFT POINT AUTOMATIC TRANSMISSION 7B1-13 ‘Warm up engine and transmission to normal operating temperature. Check diag. trouble code. Trouble code indicated. No trouble code indicated. Go beck to “DIAG. CHART" on p. 781-10. FLOW TP sensor maladjusted or faulty signal circuit. OK Check throttle position sensor referring to NG section 6E1. 0K 1. With ignition switch OFF, connect P(E)CM coupler. 2. Check voltage at "PWR" terminal, Mode selector —_ op switch nS c position position position Voltage | Battery voltage | ov NG Replace P(EICM and recheck, Terminal Arrangement of PIE}CM Coupler (Viewed from harness side) PWR: “PORT terminal avo‘7B1-14_ AUTOMATIC TRANSMISSION DIAGNOSTIC CHART C NO GEAR SHIFT TO O/D i ‘Warm up engine and transmission to normal operating temperature, Check diag. trouble code, No trouble code indicated, 781-8. Does gear shift to O/0 {4th gear) occur in manual road test? oK 1. With ignition switch OFF, connect solenoid valves coupl 2. Conduct road test in “D” range and check voltage at euch solenoid terminal Perform manual road test referring to p. Troubte code indicated. Go back to “DIAG. FLOW CHART" in p. 781-10. NG Manual select contro! system or tranemiesion faulty. NG tion switch ON. 2. With select lever shifted to “O” range, check voltage at "L" and "2" range signal terminals, It should be OV. OK Vehicle | tet] and ] ard] ain speed | range | range | range | range Shit, | Batery [eatery] gy | oy selanolé | Vottage | votioge a Shi Battery | Battery felinoid | ov ov a voltage | vottage 1. With P(EJCM coupler connected, turn ign }NS_____ With coupler connected, check voltage at "00" terminal. O/B eut witch position OFF on Voltage | Battery voltage | ov oK To be continued Shift solenoid vaive-A, B or transmission faulty. NG Shift switch or its circuit faulty. NG Faulty O/D cut switch or its cir- cuit shorted.AUTOMATIC TRANSMISSION 781-15 Cominued | Check ECT sensor referring to section 6E1.15, NG fgeod conarton? I oK ECT sensor faulty With coupler connected, check voltage at NG Faulty 4WD-L switch or its cir- “LA” terminal. cuit shorted. Transfer | aroew | amoran pear, | postion | positon Battery Vonage Li iw voltage ox Replace P(EJCM and recheck. ‘Terminal Arrangement of P{EICM Coupler (Viewed from harness side) 9: Sti sled AS) tert & Sp: Shit solenoid B (6) terminal 2 ge gral erie 1: 0 hw ite ce °F range signal ternal (00:00 ext site termina Tai0r7B1-16 AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW CHART D NO TCC LOCK-UP OCCURS. ‘Warm up engine end transi operating temperature. Trouble code Indicated. Go back to “DIAG. FLOW Check diag. trouble code, Geant in 781-10. ‘No trouble code indicated, ion to normal Conduct roat test under following conditions ‘and chock if bettory voltage is obtained ot *Sy" terminal + G/D cut switch ON. (O/D OFF Hight turn ON.) _ ¢ Normal mode in “D* rang Solenoid vaive No.2 (TCC sole- © Transfer “2H” gear position. OK. Fold valve) oF transmission ‘© Accelerate till vehicle speed reaches about faulty 80 km/h and reduce throttle valve opening £0 that it is open lass than 20%. NG Check voltage at “BR” terminal Broke pedal | when, | wen NG Faulty brake peel switch ots Battery Voltage ow eset ox Check ECT sensor referring to section 6E7, ne Isit good condition? fp. NG_ rsensor fay ox Check voltage at “14” termina 7 TBear | ALorN | Horan NG Taulky 4WOL owitch or he ar pektyn | position | position ~-————"S$-——+} uit shorted casa Battery ed ov voltage oK Replace P{E)CM and recheck. Terminal Arrangement of P(E|CM Coupler (Viewed from harness side} BR: Broke switch terminal TeesGROUP2 ae 4} Ve Pasa 4 4 J 4 Gf GA OR q Brel Kinet bead aetiome sl Mec ch SUPPLEMENTARY SERVICE MANUALFOREWORD This SUPPLEMENTARY SERVICE MANUAL (GROUP 2) is a supplement to GROUP 1. BeAr EE} HEATING AND AIR eT eulod} Applicable model: SE416 vehicles on and after following body No. (x) JSAETA02C01300001 (x) {x) JSAETA0Z2V01300001 (x) (x) JSAETAO1CTV300001 (x) CONDITIONING Heating and Ventilation 1A BRAKES: 5 BODY ELECTRICAL SYSTEM AIR BAG SYSTEM 9 (SEE SUPPLEMENTARY SERVICE MANUAL 00000801281) (x) JSAETAO1VTV300001 (x) TAo1C-300001 RELATED SERVICE MANUAL TAO1V-300001 Therefore, whenever servicing applicable model, consult GROUP 2 first. And for any sec tion, item or description not found in GROUP. 2, refer to GROUP 1, When replacing parts or servicing by disas- sembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lu- bricants, sealants, etc.) as specified in each de- scription Allinformation, illustrations and specifications contained in this literature are based on the lat- est product intormation available at the time of. publication approval. And used as the main subject of descriptions the vehicle of standard specifications among others. Therefore, note that illustrations may differ from the vehicle being actually serviced. The rightis reservedto make changes at any time without notice. SANTANA MOTOR, S.A. DEPARTAMENTO DE SERVICIO Refer to FOREWORD of GROUP 1 IMPRESO POR SANTANA MOTOR, S.A. - 1997 g PaHEATER AN VENTILATION _1 SECTION 1A HEATER AND VENTILATION WARNING: For vehicles equipped with a Supplemental inflatable Restraint Air Bag System: © Service on or around Air Bag System Components ar Wiring must be performed only by an authorized Suzuki dealer. Please observe all WARNINGS and SERVICE PRECAU- TIONS in Section 9J under “On-Vehicle Service” and the Air Bag System Component and Wiring Location view in Section 9J before performing service on or around Air Bag ‘System Components or Wiring. Failure to follow WARNINGS could resutt in unintended air bag deployment or could render the air bag inoperative. Either of these two condi- tions may result in severe injury. © Technical service work must be started at least 90 seconds after the ignition switch is PE turned to the “LOCK” position and the negative cable is disconnected from the battery. Otherwise, the air bags may be deployed by reserve energy in the Sensing and Diagnos- tic module (SDM). NOTE: © For the descriptions {items) not found in this section, refer to SECTION 1A of the Service Manual mentioned in FOREWORD of this manual. ‘© The link mechanism of the heater varies depending on the specifications. CONTENTS GENERAL DESCRIPTION .. 5 HEATER CONTROL OPERATION ... TROUBLE DIAGNOSIS. WIRING CIRCUIT .. ‘ON-VEHICLE SERVICE . Mode Contro! Switch Mode Actuator Heater Control Lever Assembly Control Cables ........