Important manual safety warnings

IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions
carefully. To emphasize special information, the
words WARNING, CAUTION and NOTE have
special meanings. Pay special attention to the
messages highlighted by these signal words.
WARNING:
Indicates a potential hazard that could result
in death or injury.
CAUTION:
Indicates a potential hazard that could result
in vehicle damage.
NOTE:
Indicates special information to make
maintenance easier or instructions clearer.
WARNING:
This service manual is intended for
authorized Maruti dealers and qualified
service mechanics only. Inexperienced
mechanics or mechanics without the proper
tools and equipment may not be able to
properly perform the services described in
this manual. Improper repair may result in
injury to the mechanic and may render the
vehicle unsafe for the driver and
passengers.
FOREWORD
This manual contains procedures for diagnosis, maintenance, adjustments, minor service
operations, replacement of components (Service) and for disassembly and assembly of major
components (Unit Repair-Overhaul).
Applicable model: MB308 (BS-III)

The contents are classified into sections each of which is given a section number as indicated in the
Table of Contents on next page. And on the first page of each individual section is an index of that
section.
This manual should be kept in a handy place for ready reference of the service work.
Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
When replacing parts or servicing by disassembling, it is recommended to use MARUTI genuine
parts, tools and service materials (lubricant, sealants, etc.) as specified in each description.
All information, illustrations and specifications contained in this literature are based on the latest
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 right is reserved to make changes at any time without notice.
Related Manual
Manual Name Manual No.
MB-308 SERVICE MANUAL 99500M84401-74E
MB308 WIRING DIAGRAM MANUAL 99512M84451-74E
MARUTI UDYOG LIMITED

SERVICE DEPARTMENT
TABLE OF CONTENTS SECTION TABLE OF CONTENTS SECTION
GENERAL INFORMATION ENGINE
General Information 0A Engine Diagnosis 6-1 0A 6
Maintenance and Lubrication 0B Engine Mechanical 6A1 0B 6A
(F8B Engine)
HEATING AND AIR CONDI-
Engine Mechanical 6A1 6A1
TIONING
(F8D Engine)
Heater and Ventilation 1A 1A
Engine Cooling 6B 6B
Air Conditioning 1B 1B
Engine Fuel 6C 6C
(If Equipped)
Engine and Emission Control 6E2 6E2
STEERING, SUSPENSION, System
WHEELS AND TIRES Ignition System 6F 6F
Steering, Suspension, Wheels 3 Cranking System 6G 3 6G
and Tires Charging System 6H 6H
Front End Alignment 3A Exhaust System 6K 3A 6K
Manual Rack and Pinion 3B 3B
TRANSMISSION, CLUTCH
Steering Wheel and Column 3C 3C
AND DIFFERENTIAL
Front Suspension 3D 3D
Manual Transmission 7A 7A
Rear Suspension 3E 3E
(4-speed)
(Leaf Spring Type)
Manual Transmission 7A1 7A1
Rear Suspension 3E1 3E1
(5-speed)
(Coil Spring Type)
Clutch 7C 7C
Wheels and Tires 3F 3F
ELECTRICAL SYSTEM
DRIVE SHAFT AND PROPEL-
Electrical System 8
8B 8
LER SHAFT
Wiring Diagram 8A 8A
Front Drive Shaft 4 4
BODY SERVICE 9 9
BRAKE SYSTEM
Brakes 5 RESTRAINT SYSTEM 5
Restraint System 10 10
NOTE:
The screen toned Section 8A WIRING DIAGRAM is not contained in this manual.
The Section 8A is contained in WIRING DIAGRAM MANUAL mentioned in FOREWORD of this manual.
GENERAL INFORMATION 0A-1
SECTION 0A 0A
GENERAL INFORMATION
NOTE : For the descriptions (items) not found in this section of this manual, refer to the same section of Service Manual
mentioned in the FOREWORD of this manual.
CONTENTS
HOW TO USE THIS MANUAL ........................................................................................................................... 0A-

PRECAUTIONS ................ 0A-
General Precautions ..... 0A-
Precautions for Catalytic Converter .............................................................................................................. 0A-
Precautions for Electrical Circuit Service ...................................................................................................... 0A-
Electrical Circui 0A-
Intermittent and P 0A-
Precaution for Installing Mobile Communication Equipment ......................................................................... 0A-
IDENTIFICATION INFORMATION .................................................................................................................... 0A-
Vehicle Identificatio 0A-
Engine Identification 0A-
Transmission Iden 0A-
VEHICLE LIFTING POINTS ............................................................................................................................. 0A-
ABBREVIATIONS MAY BE USED IN THIS MANUAL ...................................................................................... 0A-
METRIC INFORMATION ... 0A-
Metric Fasteners ........... 0A-
Fasteners Strength I 0A-
Standard Tightening T 0A-
MAINTENANCE AND LUBRICATION 0B-1
SECTION 0B
0B
MAINTENANCE AND LUBRICATION
CONTENTS
PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B- 2
MAINTENANCE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-
Emission Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B- 5
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-
Chassis and Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-
Final Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-
RECOMMENDED FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-
0B-2 INSPECTION AND MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE

This table includes services as scheduled up to 80,000 km mileage.
Interval: Beyond 80,000 km, carry out the same services at the same intervals
This inter val should be judged by respectively.
odometer reading or months, which- Km (x 1,000) 1 5 10 20 30 40 50 60 70 80
ever comes first.
Months 1 6 12 24 36 48 60 72 84 96
ENGINE
1. Water pump drive belt (tension, wear) A I I I I I I R A I
2. Engine coolant (level, leakage) I I I R I R I R I R
3. Engine oil (API GRADE SF, SG, SH) & Oil filter R I R R R R R R R R
4. Cooling system hoses and connections
(leakage, damage) I I I I I I I I I I
5. Engine bolts (All cyli nder head and manifold fixings) T T T T
I
6. Engine mounting (loose, damage) T T T T
I
I
7. Valve clearance I A A A A A
I
I I I I
I
I
8. Camshaft timing belt (dam age, wear)
Replace every 1,00 ,000 km
9. Exhaust system (noise , leakage or othe rwise defective) I I I I I
I
I
10. Positive crankcase ventilation System
I I I I I
I
I
(Hoses, connections and valve)
IGNITION
1. Ignition wiring, (dam age, deterioration) I I I I
I
I
2. Distr ibutor cap and rotor (wear, deterioration) I I I I
I
I
3. Spark plugs (clean and adjust the gap) Ñ Ñ I R I R I R I R
FUEL
Paved-road Clean every 5,000 km. Replace every 40,000 km.
1. Air cleaner Clean every 2,500 km. or as required. Replace every 40,000
Dusty condition
km. More frequent replacement if dust condi tion is severe.
2. Accelerator cable and Throttle shafts I&L I&L I&L I&L I&L I&L I&L I&L I&L
I
3. Fuel tank cap, fuel lines & connections

I I I
I
(leakage, damage)
4. Fuel filter (leakage) I I I I I R I I I R
CLUTCH AND TRANSMISSION
1. Clutch pedal (play) I I I I I I I I I I
2. Clutch slipping (dragging or excessive damage) I I I I I I I I I I
3. Manual Transmission/Transfer and Differential oil
(level, leakage) I I I R I R I R I R
Notes:
"A" : Adjust.
"I" : Inspect and correct or replace if necessary
"T" : Tighten to specified torque.
"C" : Clean.
"R" : Replace or change.
"O" : Rotate.
"L" : Lubricate.
INSPECTION AND MAINTENANCE 0B-3

ever comes first.
Months 1 6 12 24 36 48 60 72 84 96
DRIVE SHAFTS
1. Drive shaft boots (Bent of boot damage) I I I I I I I I I I
BRAKE
1. Brake fluid (level, leakage) I I I R I R I R I R
2. Brake pedal (pedal-to-wall clearance) I I I I I I I I I I
3. Parking brake lever and cable (play, damage) I I I I I I I I I I
4. Brake discs & pads (wear) I I I I I I I I I
I
5. Brake drums & shoes I I I I I I I I
I
I
6. Master cylinder and wheel cylinder
I I I I I R I I I R
(oil leakage, boot kit)
7. Brake hoses and pipes (leakage, damage) I I I I I I I I I I
WHEEL
1. Tyres (air pressure, abnormal wear, crack, ROTATION) Rotat e and inspe ct every 5,000 km
2. Wheels (dam age) I I I I I I I I I I
3. Front wheel bearings (loose , damage) I I I I I I I I I
I
4. Rear wheel bearings (loose , damage) I I I I I I I I I

I
FRONT AND REAR SUSPENSION

1. Suspen sion strut (oil leaka ge, damage) I I I I I I I I I I
2. Suspen sion arms and knuckle supp orts (loose,damage) I I I I I I I I I
I
3. Rear spr ing (damage) I I I I I I I I I

I
4. Shock abso rber s (oil leaka ge, damage) I I I I I I I I I I

5. All bolt s and nuts (loose) T T T T T T T T T
I
6. Suspen sion arms and Tension rods I I I I I I I I I

I
Notes:
"A" : Adjust.
"C" : Clean.
"O" : Rotate.
"L" : Lubricate.
0B-4 INSPECTION AND MAINTENANCE

ever comes first.
Months 1 6 12 24 36 48 60 72 84 96
STEER ING
1. Steer ing wheel (play, loose) I I I I I I I I I I
2. Power Steering fluid (level, leakage)/Connections I I I I I I I I I I
3. All rods and arms (loose, damage, wear) I I I I I I I I I I
ELECTRICAL
1. Battery electrolyte (level, leakage) I I I I I I I I I I
2. Wiring harness connection (looseness, damage) I I I I I I I I I
I
3. Lighting system (operation, stains, damage) I I I I I I I I I I
4. Horn (operation) I I I I I I I I I I
5. System voltage I I I I I I I I I
I
BODY
1. All chassis bolts and nuts (tighten) I T T T T T T T T
I
2. All Latches, Hinges & Locks (function) I I&L I&L I&L I&L I&L I&L I&L I&L I&L
ROAD TEST
1. Operation of Brakes, Gear shifting & speedometer I I I I I I I I I I
2. Body and Chassis noise I I I I I I I I I I
AIR CONDITIONER (if equi pped)
1. Chec k belt tensi on I I I I I I I I I I
2. Chec k recei ver drier bubbles I I I I I I I I I I
3. Tighten compres sor mount ing bolts T T T T T T T T T
I
4. Chec k all hose joints, tighten if neces sar y I I I I I I I I I I

5. Chec k funct ioning of Reci r flap I I I I I I I I I I
6. Clean condens er with low pressu re water I C C C C C C C C C
7. Check belt for frayed edges, change if necessary I I I I I I I I I
I
8. Chec k all mount ing bolts I I I I I I I I I

I
Notes:
"A" : Adjust.
"C" : Clean.
"O" : Rotate.
"L" : Lubricate.
INSPECTION AND MAINTENANCE 0B-5
EMISSION CONTROL SYSTEM
PCV (Positive Crankcase Ventilation) Valve Inspec-

tion
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.
1
2
Fuel Evaporative Emission Control System (if
3
equipped)
Check EVAP (Evaporative Emission) canister for damage, clog
and operation referring to Section 6E2.
HEATER AND VENTILATION 1A-1
SECTION 1A
HEATER (OPTIONAL) AND VENTILATION 1A
CONTENTS
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-

DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-
Diagnosis Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-
Wiring Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A- 2
ON VEHICLE SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-
Heater Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-
Blower Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-
Blower Fan Motor Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-
Heater Control Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-
Blower Fan Motor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-
Air Inlet Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-
1A-2 HEATER AND VENTILATION
WIRING CIRCUIT
1. Blower fan motor

2. Blower fan motor resistor
3. Blower fan motor switch
4. Ignition switch
5. To A/C switch (if equipped)
6. To ECM (Idle up signal)
AIR CONDITIONING (OPTIONAL) 1B-1
SECTION 1B
AIR CONDITIONING (OPTIONAL)

1B
CAUTION:
The air conditioning system of this vehicle uses refrigerant CFC-12 (R-12).
None of refrigerant, compressor oil and component parts is interchangeable between two
types of A/C: one using refrigerant CFC-12 (R-12) and the other using refrigerant HFC-134a (R-
134a).
Be sure to check which refrigerant is used before any service work including inspection and
maintenance. For identification between these two types, refer to the description in page 1B-2.
When replenishing or changing refrigerant and compressor oil and when replacing parts,
make sure that the material or the part to be used is appropriate to the A/C installed in the
vehicle being serviced. Use of incorrect one will result in leakage of refrigerant, damage in
parts or other faulty condition.
For basic servicing method of the air conditioning system that is not described in this section, refer to AIR
CONDITIONING BASIC MANUAL (99520-02130).
CONTENTS
GENERAL DESCRIPTION ...............................1B- A/C Condenser Assembly ..............................1B-
Refrigerant Flow of Air Conditioning Receiver/Dryer ................................................1B-
System.........................................................1B- Radiator (and Condenser) Cooling Fan
Major Components and Location ...................1B- Motor ...........................................................1B-
DIAGNOSIS ......................................................1B- Cooling Unit ....................................................1B-
General Diagnosis Table.................................1B- A/C Evaporator Thermistor .............................1B-
Quickly Checking of Refrigerant Charge........1B- Expansion Valve..............................................1B-
Diagnosis Test.................................................1B- Dual Pressure Switch......................................1B-
Wiring Circuit...................................................1B- 2 A/C Switch.......................................................1B-
A/C System Inspection of ECM and Radiator (and Condenser) Cooling Fan
Its Circuits....................................................1B- 3 Relay and Compressor Relay .....................1B-
A/C Compressor Drive Belt Inspection...........1B- Compressor ....................................................1B-
Magnet Clutch.................................................1B-
RECOVERY, EVACUATION AND Disassembly of Compressor ..........................1B-
CHARGING.......................................................1B- Checking Components...................................1B-
Refrigerant Recovery ......................................1B- Assembly of Compressor ...............................1B-
Evacuating and Charging ...............................1B- Assembly of Magnetic Clutch .........................1B-
ON-VEHICLE SERVICE....................................1B- REQUIRED SERVICE MATERIALS .................1B-
SPECIAL TOOLS .............................................1B-
1B-2 AIR CONDITIONING (OPTIONAL)
WIRING CIRCUIT
1. Blower fan motor

2. Blower fan motor resistor
4. Dual pressure switch
5. A/C Switch
6. Fuse box
7. Radiator (and condenser) cooling fan relay
8. Radiator (and condenser) cooling fan motor
9. Compressor
10. Main relay
11. Ignition switch
12. A/C evaporator thermistor
13. ECT sensor
14. Compressor relay
AIR CONDITIONING (OPTIONAL) 1B-3
A/C SYSTEM INSPECTION OF ECM AND ITS

CIRCUITS
ECM and its Circuits can be checked at ECM wiring couplers by
measuring voltage.
CAUTION:
ECM cannot be checked by itself. It is strictly prohibited
to connect voltmeter or ohmmeter to ECM with couplers
disconnected from it.
Voltage Check
1) Remove ECM from vehicle.
2) Connect ECM couplers (2) to ECM (1).
3) Check voltage at each terminal of couplers connected.
Refer to "Inspection of ECM and its circuit" in ENGINE AND
EMISSION CONTROL SYSTEM section.
NOTE:
As each terminal voltage is affected by the battery voltage,
confirm that it is 11V or more when ignition switch is ON.
1. Blower fan motor

2. ECM
4. A/C switch
6. ECT sensor
7. Radiator fan relay
8. Radiator fan
9. Compressor
10. Main relay
11. Engine earth
13. Compressor relay
A. To HTR fuse 15A

B. To A/C fuse 10A
C. To RDTR fuse 30A
D. To FI fuse 15A
(HARNESS SIDE)
E 53 E 54 E 55 E 56
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 15 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 23 23 22 21 20 19 18 17 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 35 34 32 32 31 30 29 28 35 34 33 32 31 30 29 28 31 30 29 28 27 26
1B-4 AIR CONDITIONING (OPTIONAL)
ECM VOLTAGE VALUES TABLE FOR RELATION OF A/C CONTROL

Measurement
Terminal Wire Circuit Normal value Condition
ground
Ground to
E54-01 B ECM main ground –0.4 – 0 volt Engine running
body
Main power supply Ground to Ignition switch ON with engine
E54-02 B/R 10 – 14 volts
for ECM engine stopped
ECM ground for Ground to
E53-06 B/Or –0.4 – 0 volt Engine running
power circuit body
Power supply for Ground to Ignition switch ON with engine
E54-03 B/R 10 – 14 volts
ECM power circuit engine stopped
Ignition switch ON with engine
Ground to 0.5 – 1.2 volt
E53-15 V/R Main relay drive stopped
engine
0 volt Ignition switch OFF
Blower fan motor switch and A/C
switch ON or engine coolant temp
Radiator (condens- 0 – 1 volt
Ground to sensor more than 100 C (212 F)
E53-12 Bl er) cooling fan relay
engine with engine running
output
out ut
Except the above-mentioned with
10 – 14 volts
engine running
ECM ground for Ground to
E53-07 B/Or –0.4 – 0 volt Engine running
power circuit body
Blower fan motor switch ON with en-
0 – 1 volt
Blower load for Ground to gine running
E56-02
- P/B
blower fan input engine Blower fan motor switch OFF with
10 – 14 volts
engine running
0 – 1 volts
Ground to switch ON with engine running
E54-31
- Or/B A/C switch input
engine Blower fan motor switch or A/C
10 – 14 volt
switch OFF with engine running
Sensor common Ground to
E54-05 B/G –0.4 – 0 volt Engine running
ground Body
Evaporator thermistor temperature at
2.0 – 2.5 volts
Evaporator thermis- approx. 15°C (59°F) with engine
(2100 – 2580 )
tor temperature Ground to running
E56-08
- V/R
(EVAP temp sen- Engine Evaporator thermistor temperature at
3.1 – 3.3 volts
sor) input approx. 0°C (32°F) with engine
(4600 – 5100 )
running
Engine coolant temperature at
0.71 – 0.76 volts
approx. 80°C (176°F) with engine
Engine coolant (290 – 320 )
Ground to running
E54-15
- Lg/B temperature sensor
Engine Engine coolant temperature at
input 0.35 – 0.37 volts
approx. 110°C (230°F) with engine
(136 – 144 )
running
Compressor mag- 0 – 1 volt
Ground to switch ON with engine running
E53-11
- P/B net clutch relay
Engine Except the above-mentioned with
output 10 – 14 volts
engine running
STEERING, SUSPENSION, WHEELS AND TIRES 3-1
SECTION 3
STEERING, SUSPENSION, WHEELS AND TIRES
NOTE : For the descriptions (items) not found in this section of this manual, refer to the same section of Service
Manual mentioned in the FOREWORD of this manual.
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-
FRONT END ALIGNMENT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A
MANUAL RACK AND PINION SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B
STEERING WHEEL AND COLUMN SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C
FRONT SUSPENSION SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D
REAR SUSPENSION (LEAF SPRING TYPE) SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E
REAR SUSPENSION (COIL SPRING TYPE) SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E1
WHEELS AND TIRES SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F
CONTENTS
DIAGNOSIS
GENERAL DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-
DIAGNOSIS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-
TIRE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-
Irregular and/or Premature Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-
Wear Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-
Tire Waddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-
Tire Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-
VIBRATION DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-
FRONT DRIVE SHAFT 4-1
SECTION 4
FRONT DRIVE SHAFT
CONTENTS
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-
Diagnosis table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-
Drive shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-
REQUIRED SERVICE MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-
4
BRAKES 5-1
SECTION 5
BRAKES
NOTE:
All brake fasteners are important attaching parts in that they could affect the performance of vital parts
and systems, and/or could result in major repair expense. They must be replaced with one of same part
number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to assure
proper retention of all parts. There is to be no welding as it may result in extensive damage and weakening
of the metal.
CONTENTS
GENERAL DESCRIPTION.................................. 5- Brake Hose and Pipe Inspection ..................... 5-
Front Disc Brake Caliper Assembly ................. 5- Bleeding Brakes .............................................. 5-
Rear Drum Brake Assembly ............................ 5- Brake Hose/Pipe and Parking Brake
Master Cylinder Assembly ............................... 5- Cable .......................................................... 5- 5
DIAGNOSIS ........................................................ 5- FRONT DISC BRAKE ........................................ 5-
Diagnosis Table ............................................... 5- Brake Pad ....................................................... 5-
Caliper Assembly ............................................ 5-
ON-VEHICLE SERVICE ..................................... 5- Brake Disc ....................................................... 5-
Brake pedal Free Height Adjustment ............... 5- REAR DRUM BRAKE ......................................... 5-
Brake Pedal Play Inspection ............................ 5- Brake Drum ..................................................... 5-
Stop Light Switch Adjustment .......................... 5- Brake Shoe ...................................................... 5-
Excessive Pedal Travel Check ......................... 5- Wheel Cylinder ................................................ 5-
Front Brake Pad Inspection ............................. 5- Brake Back Plate ............................................. 5-
Brake Disc Inspection ...................................... 5- MASTER CYLINDER ...................................... 5-
Rear Drum Brake Shoe Adjustment ................ 5- Master Cylinder Reservoir ............................... 5-
Parking Brake Inspection and Master Cylinder Assembly ............................... 5-
Adjustment ................................................. 5-
Flushing Brake Hydraulic System .................... 5- REQUIRED SERVICE MATERIALS ................... 5-
Master Cylinder and Brake Fluid SPECIAL TOOLS ............................................... 5
Level Inspection .......................................... 5-
ENGINE DIAGNOSIS 6-1
SECTION 6 6
ENGINE DIAGNOSIS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 1
ENGINE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 5
On-Board Diagnostic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 5
Precaution in Diagnosing Troubles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 5
Engine Diagnostic Flow Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 6
Engine Diagnosis Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
GENERAL INFORMATION
STATEMENT ON CLEANLINESS AND CARE
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances
that are measured in the thousands of an millimeter (ten thousands of inch). Accordingly, when any internal
engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood
that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is
considered standard shop practice even if not specifically stated.
A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the
surfaces on initial operation.
Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should be retained in order. At the time of installation, they
should be installed in the same locations and with the same mating surfaces as when removed.
Battery cables should be disconnected before any major work is performed on the engine. Failure to
disconnect cables may result in damage to wire harness or other electrical parts.
6-2 ENGINE DIAGNOSIS
Throughout this manual, the four cylinders of the engine are

identified by numbers: No.1, No.2, and No.3 as counted from
crankshaft pulley side to flywheel side.
1. No.1 cylinder
2. No.2 cylinder
3. No.3 cylinder
GENERAL INFORMATION ON ENGINE

SERVICE
THE FOLLOWING INFORMATION ON ENGINE SERVICE
SHOULD BE NOTED CAREFULLY, AS IT IS IMPORTANT IN
PREVENTING DAMAGE, AND IN CONTRIBUTING TO RELI-
ABLE ENGINE PERFORMANCE.
When raising or supporting engine for any reason, do not use a
jack under oil pan. Due to small clearance between oil pan and
oil pump strainer, jacking against oil pan may cause it to be bent
against strainer resulting in damaged oil pick-up unit.
It should be kept in mind, while working on engine, that 12-volt
electrical system is capable of violent and damaging short cir-
cuits.
When performing any work where electrical terminals could
possibly be grounded, ground cable of the battery should be dis-
connected at battery.
Any time the air cleaner, air intake hose, throttle body or intake
manifold is removed, the intake opening should be covered. This
will protect against accidental entrance of foreign material which
could follow intake passage into cylinder and cause extensive
damage when engine is started.
When disconnecting couplers, don’t pull wire harness but make
sure to hold coupler itself. With lock type coupler, be sure to un-
lock before disconnection. Attempt to disconnect coupler with-
out unlocking may result in damage to coupler. When
connecting lock type coupler, insert it till clicking sound is heard
and connect it securely.
PRECAUTION ON FUEL SYSTEM SERVICE

Work must be done with no smoking, in a well-ventilated area
and away from any open flames.
As fuel feed line (between fuel pump and fuel pressure regula-
tor) is still under high fuel pressure even after engine was
stopped, loosening or disconnecting fuel feed line directly may
cause dangerous spout of fuel to occur where loosened or dis-
connected.
Before loosening or disconnecting fuel feed line, make sure to
release fuel pressure according to FUEL PRESSURE RELIEF
PROCEDURE.
A small amount of fuel may be released after the fuel line is dis-
connected.
In order to reduce the chance of personal injury, cover the fitting
to be disconnected with a shop cloth. Put that cloth in an ap-
proved container when disconnection is completed.
Never run engine with fuel pump relay disconnected when en-
gine and exhaust system are hot.
Fuel or fuel vapor hose connection varies with each type of pipe.
When reconnecting fuel or fuel vapor hose, be sure to connect
and clamp each hose correctly referring to left figure.
After connecting, make sure that the hose has no twist or kink.
When installing fuel union bolt gasket, always use new gasket
and tighten union bolt to specified torque. See Section 6C for
specified torque.
When installing injector, fuel feed pipe or fuel pressure regulator,
lubricate its O-ring with gasoline.
When connecting fuel pipe flare nut, first tighten flare nut by
hand and then tighten it to specified torque.
FUEL PRESSURE RELIEF PROCEDURE
CAUTION:
This work must not be done when engine is hot. If done
so, it may cause adverse effect to catalyst.
After making sure that engine is cold, relief fuel pressure as follows.
1) Place transmission gear shift lever in ªNeutralº, set parking
brake, and block drive wheels.
2) Remove fuel pump relay (1) from connector.
3) Remove fuel filler cap to release fuel vapor pressure in fuel tank
and then reinstall it.
4) Start engine and run it till it stops for lack of fuel. Repeat crank-
ing engine 2 – 3 times of about 3 seconds each time to dissipate
fuel pressure in lines. Fuel connections are now safe for servic-
ing.
5) Upon completion of servicing, install fuel pump relay to relay
box.
FUEL LEAKAGE CHECK PROCEDURE

After performing any service on fuel system, check to make sure
that there are no fuel leakages as follows.
1) Turn the ignition switch ON position for 3 seconds (to operate
fuel pump) and then turn it OFF position.
Repeat this (ON and OFF) 3 or 4 times and apply fuel pressure
to fuel line (till fuel pressure is felt by hand placed on fuel return
hose).
2) In this state, check to see that there are no fuel leakages from
any part of fuel system.
ENGINE DIAGNOSIS
This vehicle is equipped with an engine and emission control system, which controls the A /F mixture, ignition tim-
ing, emission, etc. suitably to engine conditions by ECM. ECM has an On-Board Diagnostic system which detects
a malfunction in this system.
When diagnosing a trouble in the engine including this system, be sure to have understanding of the outline of “On-
Board Diagnostic system” and each item in “Precaution in Diagnosing Trouble” and follow “ENGINE DIAGNOSTIC
FLOW TABLE” given below to obtain correct result smoothly.
ON-BOARD DIAGNOSTIC SYSTEM

Refer to “On-Board Diagnostic System” in Section 6E2.
PRECAUTION IN DIAGNOSING TROUBLES

Be sure to read “Precaution in Diagnosing Troubles” in Section 6E2
and observe what is written there.
ENGINE DIAGNOSTIC FLOW TABLE

Refer to the following pages for the details of each step.
STEP ACTION YES NO

1 Customer Complaint Analysis Go to Step 2. Perform customer
1) Perform customer complaint analysis. complaint analysis.
Was customer complaint analysis performed?
2 Diagnostic Trouble Code (DTC) Check, Record and 1) Print DTC or Go to Step 4.
Clearance write it down and
1) Check for DTC referring to “DTC Check” in clear it by refer-
Section 6E2. ring to “DTC
Is there any malfunction DTC(s)? Clearance” in
section 6E2.
2) Go to Step 3.
3 Visual Inspection 1) Repair or replace Go to Step 5.
1) Perform visual inspection referring to the “Visual malfunction part.
Inspection” in this section. 2) Go to Step 11.
Is there any faulty condition?
4 Visual Inspection Go to Step 8.
1) Perform visual inspection referring to the “Visual
Inspection” in this section.
Is there any faulty condition?
5 Trouble Symptom Confirmation Go to Step 6. Go to Step 7.
1) Confirm trouble symptom referring to the “Trouble-
Symptom Confirmation” in this section.
Is trouble symptom identified?
6 Rechecking and Record of DTC Go to Step 9. Go to Step 8.
1) Recheck for DTC referring to “DTC Check” in
Section 6E2.
Is there any DTC(s)?
7 Rechecking and Record of DTC Go to Step 10.
1) Recheck for DTC referring to “DTC Check” in
Section 6E2.
Is there any malfunction DTC(s)?
8 Engine Basic Inspection and Engine Diagnosis Table Go to Step 11. 1) Check and repair
1) Check and repair according to “Engine Basic Check” malfunction
and “Engine Diagnosis Table” in this section. part(s).
Are check and repair complete? 2) Go to Step 11.
9 Trouble shooting for DTC
1) Check and repair according to applicable DTC diag.
flow table in Section 6E2.
Are check and repair complete?
10 Check for Intermittent Problems 1) Repair or replace Go to Step 11.
1) Check for intermittent problems referring to “Check for malfunction
Intermittent Problem” in this section. part(s).
Is there any faulty condition? 2) Go to Step 11.
11 Final Confirmation Test Go to Step 6. End.
1) Clear DTC if any.
2) Perform final confirmation test referring to “Final
Confirmation Test” in this section.
Is there any problem symptom, malfunction DTC or abnor-
mal condition?
1. CUSTOMER COMPLAINT ANALYSIS

Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this
purpose, use of such an inspection form will facilitate collecting information to the point required for proper anal-
ysis and diagnosis.
CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE)
User name: Model: VIN:

Date of issue: Date of Reg.: Date of problem: Mileage:
PROBLEM SYMPTOMS
Difficult Starting Poor Driveability
No cranking Hesitation on acceleration
No initial combustion Back fire/ After fire
No combustion Lack of power
Poor starting at Surging
( cold warm always) Abnormal knocking
Other Other
Poor idling Engine Stall when
Poor fast idle Immediately after start
Abnormal idling speed Axal. pedal is depressed
( High Low) ( r/min.) Accel. pedal is released
Unstable Load is applied
Hunting ( r/min. to r /min.) A/ C Electric load P/ S
Other Other
Other
OTHERS:
VEHICLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS

Environmental Condition
Weather Fair Cloudy Rain Snow Always Other
Temperature Hot Warm Cool Cold ( °F/ °C Always
Frequency Always Sometimes ( times/ day, month) Only once Under certain condition
Road Urban Suburb Highway Mountainous ( Uphill Downhill) Tarmacadam
Gravel Other
Vehicle Condition
Engine Cold Warming up phase Warmed up Always Other at starting
Condition Immediately after start Racing without load Engine speed ( r/min)
Vehicle During driving: Constant speed Accelerating Decelerating
condition Right hand corner left hand corner When shifting (Lever position ) At stop
Vehicle speed when problem occurs ( km/h, Mile /h) Other
Malfunction indicator
Always ON Sometimes ON Always OFF Good condition
lamp condition
Diagnostic
g trouble First check: No code Normal code Malfunction code ( )
code Second check: No code Normal code Malfunction code ( )
NOTE:
The above form is a standard sample. It should be modified according to conditions characteristic of each
market.
2. DIAGNOSTIC TROUBLE CODE (DTC) CHECK, RECORD AND CLEARANCE

First, check DTC referring to “DTC Check” in Section 6E2. If DTC is indicated, print it or write it down and then
clear it by referring to “DTC Clearance” in Section 6E2. DTC indicates malfunction that occurred in the system
but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored
now. To check which case applies, check the symptom in question according to Step 5 and recheck DTC accord-
ing to Step 6 or 7.
Attempt to diagnose a trouble based on DTC in this step only or failure to clear the DTC in this step will lead
to incorrect diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting.
3. and 4. VISUAL INSPECTION

Be sure to perform visual check of the following items that support proper function of the engine.
INSPECTION ITEM REFERRING SECTION

Engine oil – – – – – level, leakage Section 0B
Engine coolant – – – – – level, leakage Section 0B
Fuel – – – – – level, leakage Section 0B
Air cleaner element – – – – – dirt, clogging Section 0B
Battery – – – – – fluid level, corrosion of terminal
Water pump belt and/or cooling fan belt – – – – – tension, damage Section 0B
Throttle cable – – – – – play, installation Section 6E1
Vacuum hoses of air intake system – – – – – disconnection, looseness,
deterioration, bend
Connectors of electric wire harness – – – – – disconnection, friction
Fuses – – – – – burning Section 8
Parts – – – – – installation, bolt – – – – – looseness
Parts – – – – – deformation
Other parts that can be checked visually
Also check following items at engine start, if possible
Malfunction indicator lamp Section 6E2
Charge warning lamp Section 6H
Engine oil pressure warning lamp Operation Section 8
Engine coolant temp. meter Section 8
Fuel lever meter Section 8
Abnormal air being inhaled from air intake system
Exhaust system – – – – – leakage of exhaust gas, noise
Other parts that can be checked visually
5. TROUBLE SYMPTOM CONFIRMATION

Based on information obtained in Step 1 customer complaint analysis and Step 2 DTC check, confirm trouble
symptoms. Also, reconfirm DTC according to “DTC Confirmation Procedure” in Section 6E2.
6. and 7. RECHECKING AND RECORD OF DTC

Refer to “DTC Check” in section 6E2 for checking procedure.
8. ENGINE BASIC INSPECTION AND ENGINE DIAGNOSIS TABLE

Perform basic engine check according to the “Engine Basic Inspection Flow Table” first. When the end of the
flow table has been reached, check the parts of the system suspected as a possible cause referring to ENGINE
DIAGNOSIS TABLE and based on symptoms appearing on the vehicle (symptoms obtained through steps of
customer complaint analysis, trouble symptom confirmation and/or basic engine check) and repair or replace
faulty parts, if any.
ENGINE BASIC INSPECTION FLOW TABLE
STEP ACTION YES NO

1 Was “ ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE
DIAG. FLOW
TABLE”.
2 Check battery voltage. Go to Step 3. Charge or replace
Is it 11 V or more? battery.
3 Is engine cranked? Go to Step 4. Go to “DIAGNOSIS”
in section 6G.
4 Does engine start? Go to Step 5. Go to Step 7.
5 Check engine idle speed/IAC duty referring to “Idle Go to Step 6. Go to “ENGINE
Speed /IAC Duty Inspection” in section 6E2. DIAGNOSIS TABLE”
Is check result as specified? in this section.
6 Check ignition timing referring to “Ignition Timing Inspec- Go to “ENGINE Adjust ignition
Tion” in section 6F1. DIAGNOSIS TABLE” timing.
Is check result as specified? in this section.
7 Check fuel supply as follows: Go to Step 9. Go to Step 8.
1) Check to make sure that enough fuel is filled in fuel
tank.
2) Turn the ignition switch ON position for 3 seconds and
then turn it OFF position.
Repeat this a few times.
Is fuel return pressure (returning sounds) felt from fuel
return hose when the ignition switch is turned ON posi-
tion?
8 Check fuel pump for operating. Go to “Diag. Flow Go to “Diag. Flow
1) Was fuel pump operating sound heard from fuel filler Table B-3” in section Table B-1” in section
for about 3 seconds after turning the ignition switch ON 6E2. 6E2.
position and stop?
9 Check ignition spark referring to “Ignition Spark Test” Go to Step 10. Go to “DIAGNOSIS”
in section 6F. in section 6F.
Is it in good condition?
10 Check fuel injector referring to “Fuel Injector Inspection” in Go to “ENGINE Go to “Diag. Flow
section 6E1. DIAGNOSIS TABLE” Table B-2 in section
Is it in good condition? in this section. 6E2.
9. TROUBLESHOOTING FOR DTC

Based on the DTC indicated in Step 6 or 7 and referring to the applicable DTC diag. flow table in Section 6E1,
locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ECM or other
part and repair or replace faulty parts.
10. CHECK FOR INTERMITTENT PROBLEM

Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to
ªINTERMITTENT AND POOR CONNECTIONº in Section 0A and related circuit of DTC recorded in step 2.
11. FINAL CONFIRMATION TEST

Confirm that the problem symptom has gone and the engine is free from any abnormal conditions. If what has
been repaired is related to the DTC, clear the DTC once, perform DTC confirmation procedure and confirm
that no malfunction DTC (a normal code) is indicated.
ENGINE DIAGNOSIS TABLE
Condition Possible Cause Reference Item

Hard starting Engine and emission control system
(Engine cranks OK) out of order.
Faulty CMP sensing rotor CMP sensing rotor inspection in section
6E1.
Faulty idle air control system Diag. Flow Table B-4 in Section 6E2.
Faulty ECT sensor or MAP sensor ECT sensor or MAP sensor in Section
6E2.
Faulty ECM Inspection of ECM and its circuit in Sec-
tion 6E2.
Low compression. Compression check in Section 6A or 6A1.
Compression leak from valve seat Valves inspection in Section 6A or 6A1.
Sticky valve stem Valves inspection in Section 6A or 6A1.
Weak or damaged valve springs Valves spring inspection in Section 6A or
6A1.
Compression leak at cylinder head gasket Cylinder head inspection in Section 6A or
6A1.
Sticking or damaged piston ring Piston ring inspection in Section 6A or
6A1.
Worn piston, ring or cylinder Cylinders, pistons and piston rings
inspection in Section 6A or 6A1.
Others
Malfunctioning PCV valve PCV system inspection in Section 6E1.

Engine has no power Engine overheating. Refer to “Overheating” Section.
Ignition system out of order.
Defective spark plug Spark plugs in Section 6F1.
Faulty ignition coil Ignition coil in Section 6F.
Fuel system out of order.

Fuel pressure out of specification Diag. Flow Table B-3 in Section 6E2.
– Dirty fuel filter
– Dirty or clogged fuel hose or pipe
– Malfunctioning fuel pressure regulator
– Malfunctioning fuel pump
Engine and emission control system

out of order.
Faulty injector Fuel injector in Section 6E1.
Faulty TP sensor, ECT sensor or TP sensor, ECT sensor or MAP
MAP sensor sensor in Section 6E1.
Faulty ECM Inspection of ECM and its circuit in
Section 6E2.
Low compression. Previously outlined.

Others
Dragging brakes Diagnosis in Section 5.
Slipping clutch Diagnosis in Section 7C.
Improper engine Ignition system out of order.
idling or engine fails Faulty spark plug Spark plugs in Section 6F1.
to idle Faulty ignition coil Ignition coil in Section 6F.
Fuel system out of order.

– Malfunctioning fuel pressure regulator
Engine overheating. Refer to “Overheating” Section.

out of order.
Faulty idle air control system Diag. Flow Table B-4 in Section 6E2.
Faulty evaporative emission control system Diag. Flow Table B-5 in Section 6E2.
Faulty ECT sensor, TP sensor or ECT sensor, TP sensor or MAP
MAP sensor sensor in Section 6E1.
Section 6E2.
Low compression. Previously outlined.

Others
Malfunctioning PCV valve PCV system inspection in Section
6E1.

Engine hesitates Ignition system out of order.
(Momentary lack of Spark plug faulty or plug gap as out Spark plugs in Section 6F.
response as the of adjustment
accelerator is
depressed. Fuel system out of order.
Can occur at all Fuel pressure out of specification Diag. Flow Table B-3 in Section 6E2.
vehicle speeds. – Clogged fuel filter
Usually most severe – Faulty fuel pressure regulator
when first trying to Clogged fuel filter, hose or pipe Fuel pressure check in Section 6E1.
make the vehicle
move, as from a Engine overheating Refer to “ Overheating” Section.
stop sign.) Engine and emission control system out
of order.
Faulty TP sensor, ECT sensor or MAP TP sensor, ECT sensor or MAP
sensor sensor in Section 6E1.
Faulty ECM . Inspection of ECM and its circuit in
Section 6E2.
Low compression Previously outlined.
Surges Ignition system out of order.
(Engine power variation Defective spark plug (excess carbon Spark plugs in Section 6F1.
under steady deposits, improper gap, and burned
throttle or cruise. electrodes, etc.)
Feels like the vehicle
speeds up and down Fuel system out of order.
with no change in Variable fuel pressure Diag. Flow Table B-3 in Section 6E2.
the accelerator – Clogged fuel filter
pedal.) – Kinky or damaged fuel hose and line
– Faulty fuel pressure regulator
Engine and emission control system out

of order.
Faulty MAP sensor MAP sensor in Section 6E1.
Section 6E2.

Excessive detonation Engine overheating Refer to “Overheating” Section.
(The engine makes Ignition system out of order.
sharp metallic knocks Faulty spark plug Spark plugs in Section 6F1.
that change with Improper ignition timing Ignition timing in Section 6F1.
throttle opening.
Sounds like pop corn Fuel system out of order.
popping.) Clogged fuel filter and fuel lines Fuel pressure check in Section 6E1.

out of order.
Faulty ECT sensor or MAP sensor ECT sensor or MAP sensor in Section
6E1.
tion 6E2.
Others
Excessive combustion chamber deposits Piston and cylinder head cleaning in
Section 6A or 6A1.
Overheating Inoperative thermostat Thermostat in Section 6B.
Poor water pump performance Water pump in Section 6B.
Clogged or leaky radiator Radiator in Section 6B.
Improper engine oil grade Engine oil and oil filter change in
Section 0B.
Clogged oil filter or oil strainer Oil pressure check in Section 6A or 6A1.
Poor oil pump performance Oil pressure check in Section 6A or 6A1.
Blown cylinder head gasket Cylinder head inspection in Section 6A
or 6A1.
Poor gasoline Ignition system out of order.
mileage Faulty spark plug (improper gap, heavy Spark plugs in Section 6F1.
deposits, and burned electrodes, etc.)

out of order.
Faulty TP sensor, ECT sensor or MAP TP sensor, ECT sensor or MAP
sensor sensor in Section 6E1.
tion 6E2.

Others
Poor valve seating Valves inspection in Section 6A or 6A1.
Thermostat out of order Thermostat in Section 6B.
Improper tire pressure

Excessive engine oil Oil entering combustion chamber
consumption Sticky piston ring Piston cleaning in Section 6A or 6A1.
Worn piston and cylinder Cylinders, pistons and piston rings
inspection in Section 6A or 6A1.
Worn piston ring groove and ring Pistons and piston rings inspection in Sec-
tion 6A or 6A1.
Improper location of piston ring gap Pistons installation in Section 6A or 6A1.
Worn or damaged valve stem seal Valves and cylinder head in Section 6A
or 6A1.
Worn valve stem Valves inspection in Section 6A or 6A1.
Low oil pressure Improper oil viscosity Engine oil and oil filter change in
Section 0B.
Malfunctioning oil pressure switch Oil pressure switch inspection in
Section 8.
Clogged oil strainer Oil pan and oil pump strainer
cleaning in Section 6A or 6A1.
Functional deterioration of oil pump Oil pump in Section 6A or 6A1.
Worn oil pump relief valve Oil pump in Section 6A or 6A1.
Excessive clearance in various sliding
parts
Engine noise Valve noise
Note: Before check- Improper valve lash Valve lash in Section 6A or 6A1.
ing the mechanical Worn valve stem and guide Valves inspection in Section 6A or 6A1.
noise, make sure Weak or broken valve spring Valve springs inspection in Section 6A or
that: 6A1.
Ignition timing is Warped or bent valve Valves inspection in Section 6A or 6A1.
properly adjusted. Loose camshaft housing bolts Camshafts in Section 6A or 6A1.
Specified spark
plug is used. Piston, ring and cylinder noise
Specified fuel is Worn piston, ring and cylinder bore Pistons and cylinders inspection in Sec-
used. tion 6A or 6A1.
Connecting rod noise
Worn crankpin bearing Crankpin and connecting rod bearing in-
spection in Section 6A or 6A1.
Worn crankpin Crankpin and connecting rod bearing in-
spection in Section 6A or 6A1.
Loose connecting rod nuts Connecting rod installation in Section 6A
or 6A1.
Low oil pressure Previously outlined.
Crankshaft noise
Low oil pressure Previously outlined.
Worn crankshaft journal bearing Crankshaft and bearing inspection in
Section 6A or 6A1.
Worn crankshaft journal Crankshaft and bearing inspection in
Section 6A or 6A1.
Loose lower crankcase Crankshaft installation in Section 6A or
(bearing cap) bolts 6A1.
Excessive crankshaft thrust play Crankshaft inspection in Section 6A or
6A1.
Condition Possible Cause Referring Item

Excessive Ignition system out of order
hydrocarbon (HC) Defective spark plug
emission or
Excessive carbon Fuel system out of order
monoxide (CO) Fuel pressure out of specification Fuel pressure check in Section 6E1.
emission
Engine and Emission control system
out of order.
Lead contamination of three way catalytic Check for absence of filler neck
converter (if equipped) restrictor.
Malfunctioning PCV valve PCV valve in Section 6E1.
Faulty EVAP control system EVAP control system check in
Section 6E2.
Closed loop system (A/F feed back Check Heated oxygen sensor output
compensation) fails voltage referring to DTC No.14 Diag.
– Faulty TP sensor Flow Table in Section 6E2.
– Faulty ECT sensor or MAP sensor
– Faulty Heated O2 sensor
Section 6E2.

Excessive nitrogen Fuel system out of order
oxides (NOx) Fuel pressure out of specification Fuel pressure check in Section 6E1.
emission
Engine and emission control system Check for absence of filler neck
Lead contamination of three way catalytic restrictor.
converter (if equipped) Check Heated oxygen sensor output
Closed loop system (A/F feed back voltage referring to DTC No.14 Diag.
compensation) fails (vehicle with O2 sensor) Flow Table in Section 6E2.
– Faulty TP sensor
– Faulty ECT sensor or MAP sensor
– Faulty Heated O2 sensor
Faulty injector Fuel injector Section 6E1.
Section 6E2.
ENGINE MECHANICAL (F8B ENGINE) 6A-1
SECTION 6A
6A
ENGINE MECHANICAL
(F8B ENGINE)
CONTENTS
GENERAL DESCRIPTION ................................. 6A- Connecting Rods .............................................. 6A-
Engine ................................................................. 6A- Oil Pump Strainer ............................................. 6A-
Engine Lubrication .............................................. 6A- Oil Pan .............................................................. 6A-
ENGINE SERVICES NOT REQUIRING Flywheel ............................................................ 6A-
Cylinder Head ................................................... 6A-
ENGINE REMOVAL ............................................ 6A-
Camshaft .......................................................... 6A-
DISMOUNTING ENGINE .................................... 6A- Rocker-Arm Shafts ........................................... 6A-
ENGINE DISASSEMBLY .................................... 6A- Timing Belt Inside Cover Stud Bolts ................. 6A-
Crankshaft Timing Belt Guide ........................... 6A-
INSPECTION OF ENGINE COMPONENTS ...... 6A-
Camshaft and Crankshaft Timing Belt
Cylinder Head .................................................. 6A-
Rocker-Arm Shaft and Rocker Arms ................ 6A- Pulleys .......................................................... 6A-
Valve Guides .................................................... 6A- Timing Belt ........................................................ 6A-
Valves ............................................................... 6A- Distributor Gear Case ....................................... 6A-
Valve Seats ....................................................... 6A- Fuel Pump ......................................................... 6A-
Valve Springs .................................................... 6A- Generator .......................................................... 6A-
Camshaft .......................................................... 6A- Clutch Disc and Cover ...................................... 6A-
Throttle Body and Intake Manifold .................... 6A- 2
1 Distributor ......................................................... 6A-
Exhaust Manifold .............................................. 6A- 4 Valve Lash (Clearance) Adjustment .................. 6A-
Cylinder Block ................................................... 6A- MOUNTING ENGINE .......................................... 6A-
Piston and Piston Rings .................................... 6A- MAINTENANCE SERVICES ............................... 6A-
Connecting Rods .............................................. 6A- Water Pump Belt ............................................... 6A-
Connecting-Rod Big End Bearings ................... 6A- Ignition Timing ................................................... 6A-
Crankshaft ........................................................ 6A- Valve Clearance (Lash) ..................................... 6A-
Crankshaft Journal Bearings ............................ 6A- Oil Pump Discharge Pressure
Flywheel ........................................................... 6A-
Oil Seals ........................................................... 6A- Measurement ................................................ 6A-
Timing Belt and Timing Pulleys ........................ 6A- Compression Pressure Measurement .............. 6A-
Oil Pump ........................................................... 6A- Vacuum Measurement ...................................... 6A-
Engine Oil ......................................................... 6A-
ENGINE REASSEMBLY .................................... 6A- Engine Oil Filter ................................................ 6A-
Crankshaft ........................................................ 6A- Engine Coolant ................................................. 6A-
Oil Seal Housing ............................................... 6A- Exhaust Line and Muffler .................................. 6A-
Oil Pump ........................................................... 6A- Oil Filter Cap ..................................................... 6A-
Piston and Piston Rings ................................... 6A-
REQUIRED SERVICE MATERIALS ................... 6A-
6A-2 ENGINE MECHANICAL (F8B ENGINE)
THROTTLE BODY AND INTAKE MANIFOLD
1. Intake manifold
2. Throttle body
3. Gasket
4. Fuel pressure regulator
5. Fuel delivery pipe
6. Fuel injector
7. Stiffener
: Tightening Torque
: Do not reuse
REMOVAL
1) Relieve fuel pressure according to fuel pressure relief proce-
dure described in Section 6.
2) Disconnect negative cable at battery.
3) 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.
4) Remove air cleaner case (1).

5) Disconnect following electric lead wires:
Injectors lead wires at the coupler
Canister purge control valve
Throttle position sensor/Idle air control valve
Pressure sensor
6) Disconnect accelerator cable from throttle body.

7) Disconnect following hoses:
Canister purge hose from canister purge control valve
Engine cooling water (coolant) hoses from throttle body
PCV hose from intake manifold
Fuel return and inlet hoses from each pipe
8) Remove intake manifold stiffener (1).

9) Remove intake manifold (2) with throttle body (3) from cylinder
head, and then its gasket (4).
INSPECTION
Using a straight edge and thickness gauge, check surface at a
total of 6 locations. If distortion limit, given below, is exceeded,
correct gasketed surface or replace intake manifold.
Limit of distortion: 0.05 mm (0.002 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): 11 N·m (1.1 kg-m, 8.0 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.
Adjust water pump drive belt tension, referring to Section 6B.
Upon completion of installation, turn ignition switch ON but en-
gine OFF and check for fuel leaks.
Finally, start engine and check for engine coolant leaks.
6A-4 ENGINE MECHANICAL (F8B ENGINE)
EXHAUST MANIFOLD
4 1
23 N-m
3
(2.3 Kg-m)
1. Exhaust manifold
2. Gasket
3. Heated Oxygen sensor
4. Exhaust manifold bolt and nut
5. Exhaust pipe bolt
5 55 N-m (5.5 Kg-m) : Tightening Torque
: Do not reuse
WARNING:
To avoid danger of being burned, do not service exhaust
system while it is still hot. Service should be performed
after system cools down.
REMOVAL
2) Disconnect Heated oxygen sensor coupler (if equipped).
3) Remove exhaust manifold covers of exhaust manifold.
4) Remove exhaust pipe from exhaust manifold.
5) Remove exhaust manifold and its gasket from cylinder head.
INSTALLATION
1) Install new gasket (1) to cylinder head.
2) Install exhaust manifold (2).
Tighten bolts and nuts to specified torque.
Tightening Torque
(a): 23 N.m (2.3 kg-m, 17.0 lb-ft)
3) Install pipe gasket and install exhaust pipe to exhaust manifold.
Before installing pipe gasket, check it for deterioration or dam-
age, and replace as necessary.
Tighten pipe fasteners to specified torque.
(a)
Tightening Torque
(b): 55 N.m (5.5 kg-m, 40.0 lb-ft)
4) Install upper cover (3) to exhaust manifold.
5) Connect Heated oxygen sensor connector (4) and fit
connector tobracket.
6) Connect negative cable at battery.
7) Check exhaust system for exhaust gas leakage.
(b)
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, various sen-
tem. sors 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
1. Air Cleaner 23. ECM

2. EVAP canister purge valve 24. Radiator fan
3. IAT sensor 25. Radiator fan control relay
4. TP sensor 26. VSS in combination meter
5. IAC valve 27. A/C compressor control relay
6. MAP sensor 28. Malfunction indicator lamp in combination meter
7. A/C evaporator temp. sensor (if equipped) 29. Blank
8. EVAP canister 30. Ignition switch
31. Starter magnetic switch
9. Tank pressure control valve
32. Main fuse
10. Fuel pressure regulator
33. Battery
11. A/C dual pressure switch (if equipped)
34. Blank
12. PCV valve
35. Blank
13. Fuel injector
36. Monitor connector
14. Heated Oxygen sensor
36-1. Diagnosis switch terminal
15. Fuel pump 36-2. Test switch terminal
16. Stop light switch 36-3. Duty output terminal
17. ECT sensor 37. Blank
18. Three way catalytic convertor 38. Heater blower fan switch
19. CMP sensor 39. Electric load (blower fan and small light)
20. Main relay 40. Data link connector (DLC)
21. Ignitor 41. Fuel pump relay
22. Blank 42. Fuel filter
AIR INTAKE SYSTEM

The main components of the air intake system are air uted by the intake manifold and finally drawn into each
cleaner, air cleaner outlet hose, throttle body, IAC combustion 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, the air bypasses the throttle valve through
valve opening and engine speed) is filtered by the air bypass passage and is finally drawn into the intake
cleaner, passes through the throttle body, is distrib- manifold.
1. Air cleaner 5. Throttle valve 9. Exhaust manifold

2. IAT sensor 6. IAC valve 10. Air flow
3. Air cleaner outlet hose 7. Intake manifold 11. MAP sensor
4. Throttle body 8. Cylinder head
FUEL DELIVERY SYSTEM

The fuel delivery system consists of the fuel tank, fuel the fuel feed line) is always kept a certain amount
pump, fuel filter, fuel pressure regulator, delivery pipe higher than the pressure in the intake manifold by the
and fuel injectors. fuel pressure regulator, the fuel is injected into the in-
take port of the cylinder head when the injector opens
The fuel in the fuel tank is pumped up by the fuel according to the injection signal from ECM.
pump, filtered by the fuel filter and fed under pressure
to each injector through the delivery pipe. As the fuel The fuel relieved by the fuel pressure regulator re-
pressure applied to the injector (the fuel pressure in turns through the fuel return line to the fuel tank.
1. Fuel injector 5. EVAP canister 9. Fuel vapor line

2. Delivery pipe 6. EVAP canister purge valve 10. Fuel filter
3. Fuel pressure regulator 7. Fuel feed line 11. Fuel tank
4. Intake manifold 8. Fuel return line 12. Fuel pump
ELECTRONIC CONTROL SYSTEM

The electronic control system consists of 1) various Fuel injection control system
sensors which detect the state of engine and driving Idle speed control system
conditions, 2) ECM which controls various devices Fuel pump control system
according to the signals from the sensors and 3) vari- Ignition control system
ous controlled devices. Radiator fan control system
Functionally, it is divided into the following sub sys- Evaporative emission control system
tems: A/C control system (if equipped)
i g
c
INFORMATION SENSORS CONTROL DEVICES OTHERS

1. MAP sensor a : Fuel injectors A : ECM
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 : Igniter D : Monitor connector
5. Heated Oxygen sensor e : Blank E : DLC
6. VSS f : Malfunction indicator lamp F : Tank pressure control valve
7. Battery g : Radiator fan control relay
8. CMP sensor h : IAC valve
9. Blank i : A/C compressor control relay
10. A/C evaporator temp. sensor (if equipped) (if equipped)
11. A/C dual pressure switch (if equipped) j : Main relay
TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE)
E 53 E 54 E 55 E 56
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 15 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 23 23 22 21 20 19 18 17 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 35 34 32 32 31 30 29 28 35 34 33 32 31 30 29 28 31 30 29 28 27 26
Terminal Circuit Terminal Circuit

E53-01 Engine starter switch(Engine E54-22 Blank
starter signal) E54-23 Blank
E53-02 Blank E54-24 Blank
E53-03 Fuel Injector No.3 E54-25 Blank
E53-06 Ground E54-28 Blank
E53-07 Ground E54-29 Ground
1. Fuel injector No.1 E53-08 IAC valve E54-30 Ground
2. Fuel injector No. 2 E53-09 Duty output terminal E54-31 A/C ON signal from A/C switch (if
3. Fuel injector No.3 E53-10 Fuel pump relay equipped)
E53-11 A/C compressor magnetic clutch E54-32 CMP sensor (+)
4. Blank
(if equipped) E54-33 CMP sensor (-)
5. Idle air control (IAC) valve E53-12 Radiator fan control relay E54-34 Blank
6. EVAP canister purge valve E53-13 Blank E54-35 Blank
7. Fuel pump relay E53-14 Blank E55-01
8. Fuel pump E53-15 Main Relay to Blank
9. Radiator fan control relay E53-16 Blank E55-35
10. Radiator fan motor E53-17 Blank E56-01 Blank
11. Malfunction indicator light E53-18 Blank E56-02 Electric Load signal for blower fan
E53-19 Blank motor
E53-20 Blank E56-03 Blank
13. Igniter E56-04 Stop light switch
E53-21 Blank
14. Blank E56-05 Ignition signal
E53-22 Blank
15. Engine coolant temp. (ECT) sensor E53-23 Blank E56-06 Blank
with gauge E56-07 Power source for back-up
E53-24 Blank
16. ECT sensor E53-25 Blank E56-08 A/C evaporator temp. sensor (with
17. ECT gauge E53-26 Blank A/C)
18. A/C compressor control relay E53-27 Blank E56-09 Blank
(if equipped) E53-28 Blank E56-10 Blank
19. Blank E53-29 Test switch terminal E56-11 Electric Load signal for small light
20. Main relay switch
E53-30 Diagnosis switch terminal
E56-12 Blank
21. Starter magnetic switch E53-31 Blank
E56-13 Blank
22. Camshaft position (CMP) sensor E53-32 Igniter
E56-14 VSS
23. To Combination meter E53-33 Blank
E56-15 Blank
24. Vehicle speed sensor (VSS) E53-34 Blank
E56-16 Malfunction indicator light
(reed switch) E54-01 Ground
E56-17 Data link connector
25. Manifold absolute pressure (MAP) E54-02 Power source
E56-18 Blank
sensor E54-03 Power source
E56-19 Blank
26. Throttle position (TP) sensor E54-04 Blank
E56-20 Blank
E54-05 Sensor ground
27. Blank E56-21 Blank
E54-06 Blank
28. Intake air temp.(IAT) sensor E56-22 Blank
E54-07 Oxygen sensor heater
29. A/C evaporator temp. sensor E56-23 Blank
E54-08 Power supply for sensor
(if equipped) E56-24 Blank
E54-09 Blank
30. Heated Oxygen sensor E56-25 Blank
E54-10 Blank
31. Blank E56-26 Blank
E54-11 MAP sensor
32. Stop light switch E56-27 Blank
E54-12 TP sensor
E56-28 Blank
33. Small light switch E54-13 Heated Oxygen sensor
E56-29 Blank
34. Heater blower motor switch E54-14 Blank
E56-30 Blank
35. Heater blower motor E54-15 ECT sensor
E56-31 Blank
36. A/C dual pressure switch (if equipped) E54-16 IAT sensor
37. A/C switch (if equipped) E54-17 Blank
38. Blank E54-18 EVAP canister purge valve
E54-19 Blank
39. Data link connector
E54-20 Blank
E54-21 Blank
Air
IAC
Fuel
valve
Exhaust gas
AIR
EXHAUST 3 WAY
CLEANER THROTTLE INTAKE
ENGINE CATALYTIC
OUTLET BODY MANIFOLD MANIFOLD
CONVERTER
HOSE
IAT
TP sensor ECT CMP
sensor Heated Oxygen sensor
sensor sensor
FUEL
INJECTOR
Camshaft and
each piston
position
Pressure in
Intake air Throttle valve
intake
temp. opening
manifold Engine coolant Exhaust oxygen
temp. concentration Battery voltage
Vehicle speed
Engine start signal
Fuel pump Diagnosis signal
Test signal
Electric load signal
Fuel pump
ECM
relay
Fuel injection control EVAP A / C compressor

Malfunction
canister control relay
indicator lamp
Idle air control purge valve (if equipped)
Radiator fan
control relay
ENGINE & EMISSION CONTROL INPUT/OUTPUT TABLE

INFORMATION
VSS
CMP sensor
MAP sensor
TP sensor
ECT sensor
IAT sensor
Heated O2 sensor
Electric load signal
Starter switch
Battery voltage
Stop lamp switch
A/C switch
Diagnosis switch
Test switch
SENSORS
(input)
CONTROL
DEVICE
(output)
Fuel injector
IAC valve
Fuel pump relay
Igniter
EVAP canister purge valve
MIL
Radiator fan relay
A/C compressor relay
DIAGNOSIS
The engine and emission control system in this vehicle are con-
trolled by ECM. ECM 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 diag-
nosis according to ENGINE DIAGNOSTIC FLOW TABLE in SEC-
TION 6.
ON-BOARD DIAGNOSTIC SYSTEM

ECM 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 is free from any trouble after the
engine start (while engine is running), malfunction indicator
lamp turns OFF.
When ECM detects a trouble which has occurred in the areas,it
makes malfunction indicator lamp turn ON while the engine is
running 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.
PRECAUTIONS IN DIAGNOSING TROUBLES

Before identifying diagnostic trouble code, don’t disconnect cou-
plers from ECM , battery cable from battery, ECM ground wire
harness from engine. Such disconnection will erase memorized
trouble in ECM memory.
Be sure to read PRECAUTIONS FOR ELECTRICAL CIRCUIT
SERVICE in SECTION 0A before inspection and observe what
is written there.
ECM replacement
When substituting a known-good ECM , check for following
conditions. Neglecting this check may cause damage to known-
good ECM.
– Resistance value of all relays, actuators is as specified re-
spectively.
– TP sensor and MAP sensor are in good condition and none
of power circuits of these sensors is shorted to ground.
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 driver’s seat side.
Special Tool
(A): 99000M24120-426 (SUZUKI scan tool)
4) Turn ignition switch ON.
1
5) Read DTC according to instructions displayed on SUZUKI scan
tool and print it or write it down. Refer to SUZUKI scan tool oper-
(A)
ator’s manual for further details.
If communication between SUZUKI scan tool and ECM is not
possible, check if SUZUKI scan tool is communicable by con-
necting it to ECM in another vehicle. If communication is pos-
sible in this case, SUZUKI scan tool is in good condition. Then
check data link connector and serial data line (circuit) in the ve-
hicle 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).
[Not using SUZUKI scan tool]

1) Check malfunction indicator lamp (1) referring to MALFUNC-
1
TION INDICATOR LAMP (MIL) CHECK in this section.
2) Using service wire, ground diagnosis switch terminal in monitor
coupler (2).
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 (3) 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)

DIAGNOSTIC TROUBLE CODE (DTC)

CLEARANCE
2) Connect SUZUKI scan tool to data link connector (DLC) in the
same manner as when making this connection for DTC check.
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
disconnect SUZUKI scan tool from data link connector (DLC).
1) Turn OFF ignition switch.
2) Disconnect battery negative cable for specified time below to
erase diagnostic trouble code stored in ECM memory and re-
connect it.
Time required to erase DTC:
Ambient temperature Time to cut power to ECM
o o
Over 0 C (32 F) 30 sec. or longer
Not specifiable.
Under 0oC (32oF) Select a place with higher than
0oC (32oF) temperature.
DIAGNOSTIC TROUBLE CODE (DTC) TABLE

DIAGNOSTIC
TROUBLE
CODE NO. MALFUNCTION INDICATOR
DIAGNOSTIC ITEM DETECTING CONDITION
SUZUKI LAMP FLASHING PATTERN
SCAN MIL
TOOL
1 2
12 Normal .................
1 1
P0107 Manifold absolute pressure Low Pressure-high vacuum-low voltage
11
P0108 sensor circuit malfunction High Pressure-low vacuum-high voltage
P0122 1 3 Throttle position circuit low input

13 Throttle position sensor
P0123 circuit malfunction Throttle position circuit high input
Terminal Voltage is lower than specification
P0031
1 4 HO2S heater circuit malfunction when heater is “OFF”
P0032 14 Terminal Voltage is higher when heater is “ON”
P0134 HO2S malfunction Oxygen Sensor malfunction
1 5
P0340 15 Camshaft position sensor No signal for 2 sec during engine cranking
circuit malfunction
1 6
P0500 16 Vehicle speed sensor
malfunction
P0112 1 8
Intake Air Temp circuit Intake Air Temp circuit low input
18
malfunction
P0113 Intake Air Temp circuit high input
P0117 1 9 Engine coolant temperature Engine coolant temp. Circuit low input
19
P0118 sensor circuit malfunction Engine coolant temp. Circuit high input
A-1 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK

(MALFUNCTION INDICATOR LAMP DOES NOT LIGHT AT IGNITION SWITCH ON.)
B/Or
B/Or
1. Battery positive voltage

2. Blank
3. Ignition switch
4. Fuse
E 53 E 54 E 55 E 56 5. Malfunction indicator lamp
7. ECM
8. Main relay
STEP ACTION YES NO

1 Test switch terminal circuit check: Go to Step 2. "P/W" wire (test switch terminal)
1) With the ignition switch ON position, check shorted to ground circuit.
voltage between E53-29 terminal of ECM If OK, substitute a known good
coupler and ground. ECM and recheck.
Is voltage 10-14V?
2 MIL bulb and circuit check: Go to TABLE A-4. MIL bulb burned out.
1) Using service wire, ground E56-16 termi- "IG-COIL METERº fuse(s)
nal of ECM coupler. blown.
Does MIL turn ON at ignition ON position? Ignition switch malfunction.
"V/Y" wire open.
"B/W" wire open.
Fig. for STEP 1 Fig. for STEP 2
E 53 E 54 E 55 E 56
E56-16
1. ECM (PCM) coupler connected

2. Body ground
1. ªIG-COIL METERº fuse 3. Service wire

(MALFUNCTION INDICATOR LAMP FLASHES AT IGNITION SWITCH ON.)
E56-16
E53-15
E54-02
E54-03
E54-01
B/Or E53-06
B/Or E53-07
E53-30

E53-29 2. Blank
3. Ignition switch
4. Fuse
5. Malfunction indicator lamp
E 53 E 54 E 55 E 56 6. Monitor connector
7. ECM
8. Main relay
STEP ACTION YES NO

1 MIL Flashing Pattern Check Go to Step 2. Substitute a known-good
1) Turn ignition switch ON. ECM and recheck.
Does lamp flashing pattern indicate diagnostic trouble
code?
2 Diag. Switch Circuit Check System is in good "V/G" circuit shorted to
Is diag. switch terminal connected to ground via ser- condition. ground. If circuit is OK,
vice wire? substitute a known-good
ECM and recheck.

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

2. Blank
3. Ignition switch
4. Fuse
E 53 E 54 E 55 E 56 6. Monitor connector
7. ECM
8. Main relay
STEP ACTION YES NO

1 MIL Circuit Check "V/Y" circuit shorted Go to Step 2.
1) Turn ignition switch OFF and disconnect connec- to ground.
tors from ECM.
Does MIL turn ON at ignition switch ON?
2 ECM Connection Check Go to Step 3. Poor connector connection.
Is connector (E53-30 connection) connected to ECM
properly?
3 Diag. Switch Terminal Circuit Check "V/G" or "Bl/B" cir- Substitute a known-good
1) Connect connectors to ECM. cuit open. ECM and recheck.
2) Using service wire, ground E53-30 terminal with
connectors connected to ECM.
Does MIL flash?
Fig. for STEP 3 E 53 E 54 E 55 E 56
E53-30
1. ECM (PCM) coupler connected

2. Body ground
3. Service wire
A-4 ECM 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.)
B/Or
B/Or

2. Blank
3. Ignition switch
4. Fuse
7. ECM
8. Main relay
E 53 E 54 E 55 E 56
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 relay.
1) Turn OFF ignition switch and remove main 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 Power Circuit Check Go to Step 5. "V/R" or "B/Y" cir-
1) Turn OFF ignition switch, disconnect connectors from ECM cuit open.
and install main relay.
2) Check for proper connection to ECM at terminals E53-15
E54-2 and E54-3
3) If OK, then measure voltage between terminal E53-15 and
ground with ignition switch ON.
Is each voltage 10 – 14 V?
A-4 ECM POWER AND GROUND CIRCUIT CHECK (Page 2 of 2)

STEP ACTION YES NO
5 ECM Power Circuit Check Check ground circuits Go to Step 6.
1) Using service wire, ground terminal E53-15 and "Bl/B" and "B" for open.
measure voltage between terminal E54-2 If OK, then substitute a
(E54-3) and ground at ignition switch ON. known-good ECM and re-
Is it 10 – 14 V? check.
6 Is operating sound of main relay heard in Step 1? Go to Step 7. "B/Y" or "B/R" wire
open.
7 Main Relay Check "B/Y" or "B/R" wire open. Replace main relay.
1) Check main relay according to procedure in Step
3.
Is main relay in good condition?
1. “FI” fuse 1. Main relay
Fig. for STEP 4

E 53 E 54 E 55 E 56
E53-15 E54-3 E54-2
1. ECM coupler
2. Body ground
CODE NO.11 (P0107/P0108) MAP SENSOR CIRCUIT

(SIGNAL VOLTAGE LOW, HIGH OR PERFORMANCE PROBLEM)
NOTE:
When Code No.11 (P0107/P0108), 13 (P0122/P0123),
18 (P0112/P0113) and19 (P0117/P0118) are indicated
together, it is possible that " B/G" wire is open or
"E54-05" terminal connections are poor.
1. ECM
2. ECM coupler
E 53 E 54 E 55 E 56
3. MAP sensor
4. MAP sensor coupler
5. To TP sensor
6. To other sensors
E54-05
STEP ACTION YES NO

1 1) Disconnect MAP sensor coupler with igni- Go to Step 2. "Lbl" wire open or short.
tion switch OFF. Poor "E54-08" connection.
2) Check voltage between "c" wire terminal of If wire and connection are OK,
MAP sensor coupler and ground with igni- substitute a known-good ECM
tion switch ON. and recheck.
Is voltage about 4 – 5 V?
2 1) Check voltage between "a" wire terminal of Go to Step 3. "Lg/R" wire open or short.
MAP sensor coupler and ground with igni- Poor "E54-11" connection.
tion switch ON. If wire and connection are OK,
Is voltage about 4 – 5 V? substitute a known-good ECM
and recheck.
3 1) Connect "a" and "b" wire terminals of MAP Go to Step 4. "B/G" wire open.
sensor coupler using service wire. Poor "E54-05" connection.
2) Check voltage between "Lg/R" wire termi- If wire and connection are OK,
nal of MAP sensor coupler and ground. substitute a known-good ECM
Is voltage about 0 V? and recheck.
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 coupler
Is MAP sensor in good condition? terminals.
If connection is OK,
substitute a known-
good ECM and re-
check.
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
6E2-33 to confirm that the trouble has been corrected.
CODE NO.13 (P0122/P0123) TP SENSOR CIRCUIT

(SIGNAL VOLTAGE HIGH OR LOW)
NOTE:
When Code No.11 (P0107/P0108), 13 (P0122/P0123),
18 (P0112/P0113) and19 (P0117/P0118) are indicated
together, it is possible that " B/G" wire is open or
"E54-05" terminal connections are poor.
2 1
3 4
5
5V 5V
Lbl E54-8
Gr E54-12
B/G E54-05
6
1. ECM
2. ECM coupler
E 53 E 54 E 55 E 56 3. TP sensor
4. TP sensor coupler
5. To MAP sensor
6. To other sensors
STEP ACTION YES NO

1 1) Disconnect TP sensor coupler with ignition Go to Step 2. l “Lbl” wire open or short.
switch OFF. l Poor “E54-08” connection.
2) Check voltage between “a” wire terminal If wire and connection are OK,
Of TP sensor coupler and ground with substitute a known-good ECM
Ignition switch ON. and recheck.
2 1) Check voltage between “b” wire terminal Go to Step 3. l “Gr” wire open or short.
Of TP sensor coupler and ground with l Poor “E54-12” connection.
Ignition switch ON. If wire and connection are OK,
Is voltage about 4 – 5 V? substitute a known-good ECM
and recheck.
3 1) Connect “b” and “c” wire terminal of TP Go to Step 4. l “B/G” wire open.
sensor coupler using service wire. l Poor “E54-05” connection.
2) Check voltage between “b” wire terminal If wire and connection are OK,
of TP sensor coupler and ground with substitute a known-good ECM
Ignition switch ON. and recheck.
Is voltage about 0 V?
4 1) Perform TP SENSOR INSPECTION in this Poor connection of Faulty TP sensor.
section. TP sensor coupler
Is TP sensor in good condition? Terminals.
substitute a known-
good ECM and re-
check.
Fig. for STEP 1 Fig. for STEP 2 Fig. for STEP 3
NOTE:
DTC 14 (P0031/P0032) Heated Oxygen Sensor (HO2S)

Heater Control Circuit High/Low
CIRCUIT DESCRIPTION
3 4
B/G E54-29
2
6
B/W sW E54-13
7
B/W R/Bl E54-07
5
E56-05
1
E53 E54 E55 E56

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 “E54-07” when engine is HO2Sheater characteristics malfunction
running at high load. ECN (PCM) malfunction
B:
High voltage at terminal “E54-07” 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.

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.
INSPECTION
Step Action Yes No

1 Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG.
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
E54-07 and E56-05.
3) If wire and connection are OK, measure
voltage between “E56-05” 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 “E56-05” wire
terminal in HO2S connector and E56-05
terminal wire in ECM connector.
Is resistance below 5 W?
4 Check HO2S heater drive circuit. Go to Step 5. “R/Bl” wire shorted to

1) Check that there is insulating between
“E54-07” wire terminal and vehicle body ground circuit.
ground.
Is there insulating?
5 Check HO2S heater drive circuit. Go to Step 6. “R/Bl” wire shorted to

1) Turn ON ignition switch. power circuit.
2) Measure voltage between “E54-07” wire
terminal and vehicle body ground.
Is voltage 0 V?
6 Check HO2S heater drive circuit. Go to Step 7. “R/Bl” wire open circuit.
1) Connect connector to HO2S with ignition
switch turn OFF.
2) Trun ON ignition switch.
3) Measure voltage “E54-07” 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 “R/Bl” 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 “E54-07” ECM (PCM) and
terminal wire and “E56-05” terminal wire. recheck.
Is resistance below 10W?
DTC P0134 Heated Oxygen Sensor (HO2S)

CIRCUIT DESCRIPTION
DTC CONFIRMATION PROCEDUR
B/G E54-29
6 7
sW E54-13
R/Bl E54-07
5
E56-05
E53 E54 E55 E56

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 malfunction
running at specified vehicle speed, HO2S output voltage “B/G” or “sW” circuit open (poor
connection)
does not go below 0.3 V or over 0.6 V. or 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 O O
– Intake air temp. : 70°C, 158°F or lower O O
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.
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.
3 Check HO2S signal. Intermittent trouble. Go to Step 4.

1) Connect scan tool to DLC with Check for intermittent
ignition switch OFF. referring to “Intermittent
2) Warm up engine to normal and Poor Connection” in
operating temperature and keep it
at 2000 r/min. for 60 sec. Section 0A.
3) Repeat racing engine (Repeat If they are OK, go to Step
depressing accelerator pedal 5 to 8.
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. “B/G” wire open circuit.

1) Disconnect connector from HO2S Poor “E54-29” terminal
sensor with ignition switch turn OFF. connection.
2) Check proper connection to HO2S Faulty ECM (PCM)
sensor ground.
at “sW”, “B/G” and “R/Bl”. If they are OK, substitute a
3) If wire and connection are OK,
known good ECM and
check there is continuity between
“B/G” wire terminal and engine recheck.
ground.
Is there continuity?
5 Check HO2S sensor ground. Go to Step 6 “B/G” wire high resistance

1) With ignition switch turn ON, check circuit.
voltage between “B/G” wire Poor “E54-29” terminal
connection.
terminal and engine ground. Faulty ECM (PCM)
Is voltage about 0.1 V or less? ground.
If they are OK, substitute a
known good ECM and
recheck.
6 Check wire circuit. Go to Step 7 “sW” wire high resistance

circuit or open circuit.
1) Measure resistance between “sW”
Poor “E54-13” terminal
wire terminal and engine ground. connection.
Is resistance less than 1.6 MW? Faulty ECM (PCM)
ground.
If they are OK, substitute a
known good ECM and
recheck.
Step Action Yes No

7 Check wire circuit. Go to Step 8. “sW” wire shorted to ground
1) Disconnect connector from ECM circuit.
(PCM) with ignition switch turn OFF.
2) Check that there is insulating
between “sW” wire terminal and
body ground.
Is there insulating?
8 Check HO2S heater circuit. Check HO2S referring Replace Heated O2 sensor
1) Check HO2S heater circuit, to “HEATED OXYGEN
referring to SENSOR” in Section 6E2.
DTC P0031/P0032 diagnosis flow If it in good condition,
table. substitute a known-good
Is result in good condition? ECM (PCM) and recheck.
Fig. 1 for Step 3
Normal NG NG NG
0.6 V
0.3 V
CODE NO.15 (P0340) CMP SENSOR CIRCUIT

(SENSOR SIGNAL NOT INPUTTED FOR 2 SECONDS AT ENGINE CRANKING)
Bl
1. ECM
2. CMP sensor
3. Rotor
B/W
4. CMP sensor coupler
E 53 E 54 E 55 E 56
E54-33 E54-32
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. Go to Step 2. “Bl” wire open or short.
2) Measure resistance between “E54-32” “B/W” wire open or
and “E54-33” terminals of ECM coupler. short.
CMP sensor resistance: 185 – 275 Poor terminal connec-
at --10 -- 50°C (14 -- 122°F) tion of CMP sensor cou-
3) Measure resistance betwee “E54-32” pler.
terminal of ECM coupler and ground. If wire and connection are
Insulation resistance: 1WM or more OK, replace CMP sensor.
Were measured resistance values in above
2) and 3) as specified?
2 1) Check CMP sensor referring to Poor “E43-32” or Faulty CMP sensor.
Section 6F1. “E54-33” terminal con-
Is it in good condition? nection of ECM coupler.
substitute a known-good
ECM and recheck.
Fig. for STEP 1
E 53 E 54 E 55 E 56
E54-33 E54-32
1. ECM coupler disconnected
NOTE:
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)
E 53 E 54 E 55 E 56
1. ECM
2. Speedometer
3. Meter coupler (G01)
E56-14
STEP ACTION YES NO

1 Does speedometer indicate vehicle “V” wire open. Broken speed meter cable.
speed? Poor “E56-14” connec- If if it OK, go to Step 2.
tion.
If OK, substitute a known-
good ECM and recheck.
2 1) Disconnect ECM coupler with ignition Poor E56-14 connection. If Go to Step 3.
switch at OFF position. connection is OK, intermit-
2) Connect ohmmeter between E56-14 tent trouble or faulty ECM.
terminal of ECM coupler and body Recheck referring to IN-
ground. TERMITTENT TROUBLE.
3) Hoist front end of car and lock front
right tire.
4) Turn front left tire slowly. Does ohm-
meter indicator deflect between 0 and
a few times while tire is turned one
revolution?
3 1) Remove combination meter. Faulty speedometer. “V” wire open, “B/Bl” wire
2) Check speed sensor referring to VE- open, poor coupler-to-meter
HICLE SPEED SENSOR (VSS) IN- connection or poor “B/Bl”
SPECTION under ON-VEHICLE SER- wire ground.
VICE. If OK, substitute a known-
Is it good condition? good ECM and recheck.
NOTE:
CODE NO.18 (P0112/P0113) IAT SENSOR CIRCUIT

NOTE
b When Code No. 11 (P0107/P0108), 13 (P1022/P0123),
18 (P0112/P0113) and 19 (P0114/P0118) are
a
indicated together, it is possible that "B/G" wire is
open or "E56-02" terminal connections are poor.
E54-05
E 53 E 54 E 55 E 56
1. ECM
2. IAT sensor
3. IAT sensor coupler
4. To other sensors
E54-16
STEP ACTION YES NO

1 1) Disconnect IAT sensor coupler with ignition Go to Step 2. “Lg/W” wire open or short.
switch OFF. Poor “E54-16” connection.
2) Check voltage between “Lg/W” wire termi-
nal of IAT sensor coupler and ground with
ignition switch ON.
2 1) Connect IAT sensor coupler terminals b and Go to Step 3. “B/G” wire open or poor
c using service wire. “E54-05” connection.
2) Check voltage between “Lg/W” wire termi- If wire and connection are OK,
nal of IAT sensor coupler and ground with substitute a known-good ECM
ignition switch ON. and recheck.
Is voltage 0.15 V or less?
3 1) Perform IAT SENSOR INSPECTION in this Poor connection of IAT Faulty IAT sensor.
section. sensor coupler termi-
Is IAT sensor in good condition? nals.
substitute a known-
good ECM and re-
check.
1. IAT sensor coupler disconnected

1. IAT sensor coupler disconnected 2. Service wire
2. Engine ground 3. Engine ground
NOTE:
CODE NO.19 (P0117/P0118) ECT SENSOR CIRCUIT

NOTE
When Code No. 11 (P0107/P0108), 13
b (P1022/P0123), 18 (P0112/P0113) AND 19
a
(P0117/P0118) are indicated together, it is possible
that "B/G" wire is open or "E54-05" terminal
connection is poor.
E54-05
E54-05
E 53 E 54 E 55 E 56 1. ECM
2. ECT sensor
3. ECT sensor coupler
4. To other sensors
5. To combination meter
E54-15
STEP ACTION YES NO

1 1) Disconnect ECT sensor coupler with Go to Step 2. “Lg/W” wire open or short.
Ignitionswitch OFF. Poor “C54-15” connection.
2) Check voltage between “Lg/B” wire terminal
of ECT sensor coupler and ground with igni-
tion switch ON.
2 1) Connect ECT sensor coupler terminals "b" Go to Step 3. “B/G” wire open or poor
and "c" using service wire. “E54-05” connection.
2) Check voltage between “Lg/B” wire terminal If wire and connection are OK,
of ECT sensor coupler and ground with igni- substitute a known-good ECM
tion switch ON. and recheck.
Is voltage 0.15 V or less?
3 1) Perform ECT SENSOR INSPECTION in this Poor connection of Faulty ECT sensor.
section. ECT sensor coupler
Is ECT sensor in good condition? terminals.
substitute a known-
good ECM and re-
check.
1. ECT sensor coupler disconnected

1. ECT sensor coupler disconnected 2. Service wire
2. Engine ground 3. Engine ground
NOTE:
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.
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 operating
temperature.
2) Increase vehicle speed to 31 to 37 mile/h (50 – 60
km/h) in 5th gear.
3) Keep driving at above vehicle speed for 25 to 30 se-
conds.
4) Release accelerator pedal and with engine brake ap-
plied, 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 (P0130) 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.
3) Select “DTC” mode on scan tool and check DTC.
4) Check pending DTC in “PENDING DTC” mode and DTC in “DTC” mode.
B-1 FUEL PUMP AND ITS CIRCUIT CHECK
1. ECM
2. Fuel pump relay
3. Fuel pump
a 4. Main relay
d 5. Ignition switch
c b
STEP ACTION YES NO

1 Is fuel pump heard to operate 2 se- Fuel pump and its circuit are in good Go to Step 2.
conds after ignition switch ON? condition.
2 1) Remove fuel pump relay from relay Go to Step 3. “B/R” or “P” wire open,
box with ignition switch OFF. poor fuel pump relay-
2) Connect two terminals (a and b) of to-coupler connection
relay connector as shown in figure or faulty fuel pump.
using service wire.
Is fuel pump heard to operate with
ignition switch ON?
3 1) Check fuel pump relay, referring to Poor fuel pump relay-to-coupler con- Faulty fuel pump relay.
p.6E2-68. nection, “Br/B”, “B/W” wire open or
Is it in good condition? poor E53-10 connection.
If wire and connection are OK, substi-
tute a known-good ECM and recheck.
Fig. for STEP 2
1. Fuel pump relay coupler

2. Service wire
B-2 FUEL INJECTOR AND ITS CIRCUIT CHECK

2. Blank
E53-05 3. “FI” fuse in fuse/relay box
E54-02 4. Main relay
E53-04 5. ECM
E54-03 6. No.1 injector
E53-06
E53-07
E54-01
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 3 injector make operating sound?
2 Does none of 3 injectors make operating sound at Go to Step 4. Go to Step 3.
Step 1?
3 Check fuel injector(s) referring to p. 6E2-58. Check coupler connection Faulty fuel injector(s).
Is it in good condition? and wire harness
of injector not making
operating sound.
4 Check power circuit of injectors for open and short. Check all 3 injectors for Power circuit open or
Is it in normal condition? resistance respectively. short.
If resistance is OK,
substitute a known-good
ECM and recheck.
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/cm2, 28.4 psi) or higher fuel pres- Go to Step 3. Go to Step 4.
sure 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?
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 fuel
by pinching it, is fuel pressure applied? regulator. 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/cm2, 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
Special Tool
(A) Gauge
(B) Hose
(C) 3-way joint
B-4 IDLE AIR CONTROL SYSTEM CHECK
E54-8
E54-12
E54-5
E53-8

2. Blank
3. "FI" fuse in fuse/relay box
4. Main relay
5. ECM
6. IAC valve
7. Throttle body
8. Bypass air
9. TP sensor
STEP ACTION YES NO

1 IAC valve function check: Go to Step 2. Go to Step 5.
1) Check IAC valve referring to IAC VALVE INSPEC-
TION in this section.
Is check result in good condition?
2 Closed throttle position check: Check for following: Go to Step 3.
1) Connect SUZUKI scan tool to DLC. EVAP canister purge valve
2) With the ignition switch ON position, check Accessory engine load PCV
"CLOSED THROT POS" in parameter data list. system
Throttle valve fully close : ON Idle air passage
Throttle valve slight open : OFF A/C signal
Is each check result as specified?
3 Closed throttle position recheck: Recheck engine idle speed. Go to Step 4.
1) With the ignition switch OFF position disconnect
negative battery cable for 30 seconds and con-
nect it.
2) Recheck closed throttle position referring to Step
2.
4 TP sensor signal voltage check: Substitute a known good Check TP sensor
1) With the ignition switch ON position, check volt- ECM and recheck. referring TP SEN-
age between E54-12 and ground. SOR INSPEC-
Throttle valve fully close: 0.78 – 0.83V TION in this sec-
Is each check result as specified? tion.
5 IAC valve circuit check: Go to Step 6. Repair or replace.
1) Check "O", "B/R" and "B" wire for open and short.
Are they in good condition?
6 IAC valve substitution: IAC valve malfunction. Substitute a
1) Substitute a known good IAC valve. known good ECM
2) Check IAC valve referring to IAC VALVE INSPEC- and recheck.
TION in this section.
Is check result in good condition?
B-5 EVAPORATIVE EMISSION CONTROL SYSTEM CHECK
9
8
TP sensor Or/Y
MAP sensor E54-18
CMP sensor 5
ECT sensor E53-06
VSS sensor E53-07 Bl/B
IAT sensor
B
E53-15 E54-02/03
V/R
B/R 10
B/Y
1. To throttle body 6. EVAP canister purge valve

2. To fuel tank 7. Main relay
3. EVAP canister 8. Sensed information
4. Air 9. ECM
5. Air and vapor 10. Fuel tank
STEP ACTION YES NO

1 Check canister purge system for opera- Check EVAP canister referring to Go to Step 2.
tion referring to p.E54-18. p.E54-18 and fuel filler cap referring
Is it in good condition? to Section 6C.
If OK, system is in good condition.
2 Check vacuum passage, hoses and “O/Y” wire open, Vacuum passage
EVAP canister purge valve referring to “O/Y” wire shorted to ground, clogged,
p.E54-18. Poor EVAP canister purge valve Vacuum leakage or
Are they in good condition? coupler connection, Faulty EVAP canister
Poor "E54-18" connection, purge valve
Poor performance of ECT sensor
or MAP sensor or TP sensor
If none of the above exists, substi-
tute a known-good ECM and re-
check.
B-6 ENGINE START SIGNAL CHECK
1. ECM
2. ECM coupler
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 or
2) Is 6 – 12 V voltage applied to E53-01 terminal of coupler signal circuit is Poor “E53-01”
only when cranking engine. in good condition. connection
Fig. for STEP 1
E 53 E 54 E 55 E 56
E53-01

2. Body ground
B-7 RADIATOR FAN CONTROL SYSTEM CHECK
1. Radiator fan motor

2. Radiator fan control (RFC) relay
3. ECM
4. Main relay
5. Engine coolant temp. (ECT) sensor
6. Vehicle speed sensor
7. A/C signal
STEP ACTION YES NO

1 Check radiator fan control system referring to RFC system is in good Go to Step 2.
p. 6E2-71. condition.
2 Check RFC relay referring to p. 6E2-71. Go to Step 3. Faulty RFC relay.
3 Check wire harnesses and connections for open Poor performance of ECT Wire open or short
or short. sensor. If ECT sensor is OK, Poor connection or
Are they in good condition? substitute a known-good Faulty radiator fan
ECM and recheck. motor
B-8 A/C CONTROL SIGNAL CHECK (IF EQUIPPED)
1. Battery
2. Main fuse box
3. Ignition switch
4. “HEATER” fuse
5. Blower fan motor
6. Blower fan switch
7. A/C switch
10. A/C compressor
11. ECM
12. A/C compressor control relay
STEP ACTION YES NO

1 1) Check voltage at “E54-31” terminal under each A/C control signal is “G/B” wire open or short
condition given in table below. in good condition. Poor “E54-31” terminal
Ignition switch ON connection
A/C switch OFF If wire and connection are
10 – 14 V
Blower fan switch OFF OK, check dual pressure
switch and A/C switch re-
Ignition switch ON
ferring to Section 1B.
A/C switch ON 2 V or less
Blower fan switch ON
2) Is check result satisfactory?
Fig. for STEP 1

E 53 E 54 E 55 E 56
E54-31
1. ECM coupler connected

2. Body ground
B-9 ELECTRIC LOAD SIGNAL CIRCUITS CHECK
1. Ignition switch
2. Blower fan motor
3. Blower fan switch
4. Heater blower register
5. Clearance light
6. From battery
7. Clearance light switch
STEP ACTION YES NO

1 Check voltage at E56-11 terminal under each condition given Go to Step 2. “Br/R” wire open or
below. short
Small light turned OFF :0V Poor “E56-11” ter-
Small light turned ON : 10 – 14 V minal connection
2 Check voltage at E56-02 terminal under each condition given Electric load “P/B” wire open or
below. signal circuit short
Ignition switch ON and are in good Poor “E56-02” termi-
heater blower fan turned OFF : 10 – 14 V condition. nal connection
Ignition switch ON and
heater blower fan turned ON : 2 V or less
Fig. for STEP 1 and 2
E 53 E 54 E 55 E 56
E56-11 E56-02
1. ECM coupler connected

2. Body ground
B-10 FUEL CUT OPERATION CHECK
1. ECM
2. ECM coupler
3. TP sensor
STEP ACTION YES NO

1 Check fuel cut operation referring FUEL CUT OPERA- Fuel cut operation is Go to step 2.
TION 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 Tech-1 to DLC. good ECM and re-
2) With the ignition switch ON position, check “CLOSED check.
THROT POS” in parameter data list.
Throttle valve fully close : ON
Throttle valve slight open : OFF
3 Closed throttle position recheck: Recheck fuel cut op- Go to step 4.
1) With the ignition switch OFF position disconnect neg- eration.
ative battery cable for 30 seconds and connect it.
2) Recheck closed throttle position referring to Step 2.
4 TP sensor signal voltage check: Substitute a known Check TP sensor re-
1) With the ignition switch at ON position, check voltage good ECM and referring to TP SEN-
between E54-12 and ground. check fuel cut opera- SOR INSPECTION in
Throttle valve fully close: 0.78 – 0.83V tion. this section.
Throttle valve fully open: 3.7 – 4.7V
INSPECTION OF ECM AND ITS CIRCUITS

ECM and its circuits can be checked at ECM wiring couplers by
measuring voltage and resistance.
CAUTION:
ECM cannot be checked by itself. It is strictly prohibited
to connect voltmeter or ohmmeter to ECM with couplers
disconnected from it.
VOLTAGE CHECK
1) Remove ECM from body with ignition switch OFF referring to
ECM REMOVAL.
2) Connect ECM couplers to ECM.
3) Check voltage at each terminal of couplers connected.
NOTE:
As each terminal voltage is affected by the battery voltage,
confirm that it is 11V or more when ignition switch is ON.
2
3
1. ECM
2. Couplers
3. Body ground
TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE)
E 53 E 54 E 55 E 56
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 15 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 23 23 22 21 20 19 18 17 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 35 34 32 32 31 30 29 28 35 34 33 32 31 30 29 28 31 30 29 28 27 26
TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION

E53-01 Engine starter switch 1.5 V or less Ignition switch ON
(Engine starter signal) 6 - 12 V While engine cranking
E53-02 Blank -
E53-03 Fuel Injector No.3 10 - 14 V Ignition switch ON
E53-06 Ground -
E53-07 Ground -
E53-08 IAC valve -
E53-09 Duty output terminal 1 V or less Ignition switch ON
E53-10 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 with
engine stopped.
E53-11 A/C compressor magnetic 1 V or less Engine running, A/C compresor: ON
clutch (if equipped) 10 - 14 V Engine running, A/C compresor: OFF
E53-12 Radiator fan control relay 10 - 14 V Ignition switch ON
1 V or less Engine cooling fan ON
E53-13 Blank -
E53-14 Blank -
E53-15 Main Relay 1 V or less Ignition switch ON
E53-16 Blank -
E53-17 Blank -
E53-18 Blank -
E53-19 Blank -
E53-20 Blank -
E53-21 Blank -
E53-22 Blank -
E53-23 Blank -
E53-24 Blank -
E53-25 Blank -
E53-26 Blank -
E53-27 Blank -
E53-28 Blank -
E53-29 Test switch terminal 10 - 14 V Ignition switch ON
1 V or less Ignition switch ON, Test switch terminal
grounded
E53-30 Diagnosis switch terminal 10 - 14 V Ignition switch ON
1 V or less Ignition switch ON, Test switch terminal
grounded
E53-31 Blank -
E53-32 Igniter 1 V or less Ignition switch ON
E53-33 Blank -
E53-34 Blank

E54-01 Ground -
E54-02 Power source 10 - 14 V Ignition switch ON
E54-03 Power source 10 - 14 V Ignition switch ON
E54-04 Blank -
E54-05 Sensor ground -
E54-06 Blank -
E54-07 Oxygen sensor heater 10 - 14 V Ignition switch ON
E54-08 Power supply for sensor 4.5 - 5.5 V Ignition switch ON
E54-09 Blank -
E54-10 Blank -
E54-11 MAP sensor About 3.6 V Ignition switch ON, engine stop
About 1 - V Engine runningat idel speed, A/C OFF
E54-12 TP sensor 0.78 - 0.83 V Throttle valve at idle position
3.7 - 4.7 V Throttle valve at full open position
E54-13 Heated Oxygen sensor 0.3 - 0.6 V deflection When engine is running at idle
E54-14 Blank -
E54-15 ECT sensor 2.5 - 3.0 V Engine coolant temp.: at 20 C
o
0.6 - 0.9 V Engine coolant temp.: at 80 C

o
E54-16 IAT sensor 2.0 - 2.5 V IAT sensor ambient temp.: at 20 C

o
0.4 - 0.6 V IAT sensor ambient temp.: at 80 C

o
E54-17 Blank -
E54-18 EVAP canister purge valve 10 - 14 V Ignition switch ON
E54-19 Blank -
E54-20 Blank -
E54-21 Blank -
E54-22 Blank -
E54-23 Blank -
E54-24 Blank -
E54-25 Blank -
E54-26 Blank -
E54-27 Blank -
E54-28 Blank -
E54-29 Ground -
E54-30 Ground -
E54-31 A/C ON signal from A/C 10 - 14 V Ignition switch ON,A/C switch OFF, Blower fan
switch (if equipped) switch OFF
2 V or less Ignition switch ON,A/C switch ON, Blower fan
switch ON
E54-32 CMP sensor (+) 1 V or less Ignition switch ON
E54-33 CMP sensor (-) About 0 V
E54-34 Blank -
E54-35 Blank -
Terminal CIRCUIT NORMAL VOLTAGE CONDITION
E55-01 -
to Blank -
E55-35 -
E56-01 Blank -
E56-02 Electric Load signal for 2 V or less Ignition switch ON,Blower fan switch : High or
blower fan motor Middle position
4.0 - 14.0 V Ignition switch ON,Blower fan switch : OFF or
Low position
E56-03 Blank -
E56-04 Stop light switch (Brake 1.5 V or less Brake pedal released (swtich OFF), Ignition
pedal switch) switch ON
10 - 14 V Brake pedal Depressed (swtich ON), Ignition
switch ON
E56-05 Ignition signal 10 - 14 V Ignition switch ON
E56-06 Blank -
E56-07 Power source for back-up 10 - 14 V
E56-08 A/C evaporator temp. 2.0 - 2.5 V A/C ventilator outlet temp.: at 20 C
o
Sensor (with A/C)

E56-09 Blank -
E56-10 Blank -
E56-11 Electric Load signal for 1V or less Ignition switch ON,and Small light turned OFF
small light switch
10 - 14 V Ignition switch ON,and Small light turned ON
E56-12 Blank -
E56-13 Blank -
E56-14 VSSIndicator deflection 0 - 1 Vand 4 - 14 V Ignition switch ON,Front left tire turned quickly
repeate between with front right tire locked.
E56-15 Blank -
E56-16 Malfunction indicator light About 0.5 V or less Ignition switch ON, Engine stops
10 - 14 V Engine running
E56-17 Data link connector 10 - 14 V Ignition switch ON
E56-18 Blank -
E56-19 Blank -
E56-20 Blank -
E56-21 Blank -
E56-22 Blank -
E56-23 Blank -
E56-24 Blank -
E56-25 Blank -
E56-26 Blank -
E56-27 Blank -
E56-28 Blank -
E56-29 Blank -
E56-30 Blank -
E56-31 Blank -
ENGIINE AND EMISSION CONTROL SYSTEM 6E2-49
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 discon-

nected 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 below represents that when
parts temperature is 20°C (68°F)

2. Ohmmeter
NORMAL
TERMINAL CIRCUIT CONDITION
RESISTANCE
E53-05 – E54-02 Fuel Injector No.1 11.3 – 13.8 W
E53-04 – E54-02 Fuel injector No.2 11.3 – 13.8 W
E53-03 – E54-02 Fuel Injector No.3 11.3 – 13.8 W
EVAP canister duty
E54-18 – E54-02 purge valve 28 – 36 W
90 – 110 W omron made

E53-12 E54-02 Radiator fan control relay
60 – 88 W interface made
E54-32 – E54-33 CMP sensor 185 – 275 W –10 – 50°C (14 –122°F)
E53-10 – E56-05 Fuel pump relay 80 – 100 W Battery disconnected and ignition switch ON
E53-15 – E53-05 Main relay 80 – 100 W Battery disconnected and ignition switch ON
E54-01/53-06/53-07-
Ground Continuity
Body ground
ON-VEHICLE SERVICE
1. MAP sensor
2. EVAP canister
3. EVAP canister purge valve (if equipped)
4. PCV valve
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 service.
Air cleaner has been properly installed and is in good condition.
No abnormal air inhaling from air intake system.
ECM 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.

1) Connect SUZUKI scan tool to DLC (1) with ignition switch OFF.
Special Tool
2) Start engine and warm it up to normal operating temperature.
When using SUZUKI scan tool: 3) Check idle speed and IAC duty by using "DATA LIST" mode of
SUZUKI scan tool.
NOTE:
Check to ensure that radiator fan is not running and then
measure IAC-duty.
Duty values with (*) are applicable to vehicle used at high
1 place (higher than 2000 in or 6560 ft.)
ENGINE IDLE SPEED AND IAC DUTY

(A) A/C OFF A/C ON
900±50r/min
1000± 50 r/min.
3 – 30 or *40%
6E2-52 ENGIINE AND EMISSION CONTROL SYSTEM

1) Using service wire, ground diagnosis switch terminal in monitor
connector.
2) Connect duty meter between duty output terminal and ground
terminal of monitor connector.
3) Set tachometer.
5) Confirm that all accessories (light, A/C, blower fan, etc.) are out
of service.
6) Check idle speed and IAC duty.
NOTE:
Check to ensure that radiator fan is not running and then
measure IAC-duty.
If duty and/or idle speed is out of specifications, inspect idle air
1. Monitor connector A: Blank
control system referring to "B-4 Idle Air Control System Check"
2. Service wire B: Diagnosis switch terminal in this section.
3. Duty meter C: Blank
D: Ground terminal
E: Test switch terminal
F: Duty output terminal
ENGINE IDLE SPEED AND IAC DUTY

A/C OFF A/C ON
900±50 r/min.
1000±50 r/min.
3 – 30 or *40%
NOTE:
Duty values with (*) are applicable to vehicle used at high
place (higher than 2000 m or 6560 ft.)
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 VB
100 0 VB
– "OFF DUTY METER" is such duty meter that indicates

approx. 100% when terminal voltage is approx. "0V".
– "VB" represents battery voltage while engine of vehicle
being checked is running.
AIR INTAKE SYSTEM

THROTTLE BODY
CAUTION:
Do not remove or adjust
throttle stop screw as it is
factory adjusted precisely
: Tightening torque
: Do not reuse
CAUTION:
Do not disassemble IAC 1. Throttle body
valve. Disassembly spoils 2. Throttle stop screw
its original performance 3. TP sensor
4. O-ring
5. IAC valve
6. MAP sensor
ON-VEHICLE INSPECTION
Check that throttle valve lever moves smoothly.
REMOVAL
2) Drain cooling system referring to Section 6B.
3) Disconnect accelerator cable from throttle body.
4) Remove air cleaner outlet hose (1).

5) Disconnect couplers from TP sensor, MAP sensor and IAC

valve.
6) Remove throttle body from intake manifold.
4 3 1 7) Disconnect EVAP canister purge valve hose from throttle
body.
1. TP sensor
2. IAC valve
3. MAP sensor
4. EVAP canister purge valve hose
5. Throttle body
DISASSEMBLY
NOTE:
While disassembling and assembling throttle body, use spe-
cial care not to deform levers on throttle valve shaft or cause
damage to any other parts.
1) Remove TP sensor, MAP sensor and IAC valve from throttle
body.
CLEANING
Clean throttle body bore and idle air passage by blowing com-
pressed air.
CAUTION:
TP sensor, IAC valve, MAP sensor or other compo-
nents containing rubber must not be placed in a sol-
vent or cleaner bath. A chemical reaction will cause
these parts to swell, harden or get distorted.
Do not blow compressed air through bypass air pas-
1. Throttle body bore sage with IAC valve installed to throttle body. This will
2. Idle bypass passage
cause IAC valve to malfunction.
REASSEMBLY
1) Install IAC valve to throttle body referring to IAC valve Installa-
tion section.
2) Install TP sensor to throttle body referring to TP sensor Installa-
tion section.
3) Install MAP sensor to throttle body referring to MAP sensor
Installation section.
INSTALLATION
1) Clean mating surfaces and install throttle body gasket to intake
manifold.
Use new gasket.
2) Install throttle body to intake manifold.

3) Connect EVAP canister purge valve hose.
4) Connect couplers to TP sensor, MAP sensor and IAC valve se-

curely.
4 3 1
1.TP sensor
2. IAC valve
3. MAP sensor
4. EVAP canister purge valve hose
5. Throttle body
5) Install air cleaner outlet hose (1).
6) Connect accelerator cable and adjust cable play to specification.

7) Refill cooling system.
8) Connect negative cable at battery.
ELECTRONIC CONTROL SYSTEM

ECM
CAUTION:
As ECM consists of precision parts, be careful not to ex-
pose it to excessive shock.
REMOVAL
1) Disconnect battery negative cable at battery.
2) Remove ECM from body.
3) Disconnect couplers from ECM.
INSTALLATION
1) Install ECM to body.
2) Connect couplers to ECM securely.
3) Connect battery negative cable at battery.
E54-08
MAP SENSOR
OUTPUT VOLTAGE CHECK
E 53 E 54 E 55 E 56 1) Remove ECM according to previously outlined.
2) Connect couplers (1) to ECM securely.
3) With coupler connected to ECM, connect digital type voltmeter
(2) as shown and check that ECM supply voltage 4.75 – 5.25
V is applied to coupler terminal E54-08.
4) Check output voltage at coupler terminal E54-11.

Note that it varies with atmospheric pressure and altitude. Also,
start engine, it it can, and check if output voltage varies.
Output voltage (ECM supply voltage 4.75 – 5.25 V, ambient
temp. 10 – 40°C, 50 – 104°F)
ALTITUDE BAROMETRIC OUTPUT

(Reference) PRESSURE VOLTAGE
(ft) (m) (kPa(mmHg)) (V)
0 0 101.3 (760) 3.3 – 3.9
1000 305 97.7 (733) 3.2 – 3.8
2000 610 94.3 (707) 3.1 – 3.7
3000 914 90.9 (682) 3.0 – 3.6
4000 1219 87.7 (658) 3.0 – 3.5
5000 1524 84.5 (634) 2.9 – 3.4
6000 1829 81.5 (611) 2.8 – 3.3
7000 2133 78.5 (589) 2.7 – 3.2
8000 2438 75.6 (567) 2.6 – 3.1
9000 2743 72.8 (546) 2.5 – 3.0
10000 3048 70.1 (526) 2.5 – 3.0
NOTE:
Note that atmospheric pressure varies depending on weather
conditions as well as altitude.
Take that into consideration when performing above check.
If check result is not satisfactory in previous step 3) or 4), check
MAP sensor and its circuit according to Diagnostic Flow Table for
Code No. 11 (P0107/P0108).
NOTE:
If output voltage does not vary when engine is started, it is
possible that vacuum passage is clogged. Clean them.
Another possibility is that filter in MAP sensor is clogged from
freezing. If it is suspected, leave it at room temperature (20 C,
68 F) for a while and recheck.
5) Upon completion of checking, install ECM and connect ECM
couplers securely.
TP SENSOR
INSPECTION
1) Disconnect negative cable at battery and coupler from TP

sensor
2) Using ohmmeter, check resistance between terminals under
each condition given in table below.
Vcc
Terminal Resistance
Between "Vcc" and 4—6kW
Vout "GND" terminals
Throttle valve is
0.6 — 1.2 k W
GND Between "Vout" and at idle position
"GND" terminals Throttle valve is
3.2 — 5.4 k W
fully opened
NOTE:
There should be more than 1.5k resistance difference
between when throttle valve is st idle position and when it
fully open.
Vcc
GND If check result is not satisfactory, replace TP sensor.
3) Connect TP sensor coupler securely.
Vout
4) Connect negative cable to battery.
"GND" : Ground terminal

"Vcc" : Reference voltage terminal
"Vout" : Output voltage terminal
REMOVAL
1) Disconnect battery negative cable at battery.
2) Disconnect coupler from TP sensor.
2 3) Remove TP sensor from throttle body.
INSPECTION
3
1. Install TP sensor (1) to throttle body.
Fit TP sensor to throttle body in such way that its holes (3) are a
little away from TP sensor screw holes (2) as shown and turn
TP sensor clockwise (4) so that those holes align.
Tightening Torque
4 (a) : 2.5 N.m (0.25 kg-m, 2.0 lb-ft)
1
2) Connect coupler to tp sensor securely.
(a) 3) Connect battery negative cable to battery.
ADJUSTMENT
1) Warm up engine to normal operating temperature.
1) Loosen TP sensor screws.
[Not using SUZUKI scan tool] 3) [Using SUZUKI scan tool]

Connect SUZUKI scan tool to DLC with ignition switch OFF and
TERMINAL ARRANGEMENT OF ECM
COUPLER (VIEWED FROM HARNESS SIDE)
check "TP SENSOR VOLT" value displayed on scan tool by us-
ing "DATA LIST" mode.
Remove ECM as previously outlined and with couplers con-
nected to ECM, connect digital type voltmeter between
"E54-12" and "E54-05" terminal.
E54-05 E54-12
4) Turn TP sensor (1) clockwise or counterclockwise and tighten

TP sensor screw at a position where voltage as specified below
is obtained.
TP sensor output voltage when throttle is fully close:
0.805± 0.025 V
5) Tighten TP sensor screw to specified torque.
Tightening Torque
(a): 2.0 N·m (0.20 kg-m, 2.0 lb-ft)
6) Check to make sure that TP sensor voltage is as shown below
when throttle is fully open.
TP sensor output voltage when throttle is fully open:
4.2± 0.5 V
7) Install ECM as previously outlined.
8) With ignition switch at OFF position, disconnect negative cable
at battery for 30 seconds and connect it.
Heated Oxygen Sensor

OXYGEN SENSOR HEATER INSPECTION
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 heater
HO2S 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.
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.
c) Remove HO2S from exhaust manifold.
1
INSTALLATION
Reverse removal procedure noting the following.
l 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
1
l Connect coupler of heated oxygen sensor and clamp wire
harness securely.
l After installing heated oxygen sensor, start engine and
check that no exhaust gas leakage exists.
E 53 E 54 E 55 E 56
EVAP 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. EVAP canister purge valve

2. EVAP canister
1) Warn up engine to normal operating temperature.

2) Disconnect purge hose (1) 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.
B 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, 1-way valve (if equipped)
(2), wire harness and ECM.
Refer to TABLE 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 dis-
connected, 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.
EVAP CANISTER PURGE VALVE INSPECTION

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:
28 – 36W 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.
4) Connect SUZUKI scan tool to DLC (1) with ignition switch OFF.
Special Tool
(A): 99000 M 24120-426 (SUZUKI SCAN TOOL)
1
(A)
5) Disconnect vacuum hoses from intake manifold.

Blow into hose (1). Air should not come out of nozzle (2).
6) Open EVAP canister purge valve using "MISC TEST" mode of

SUZUKI scan tool with ignition switch ON. In this state, blow
hose "A".
Air should come out of nozzle "B".
WARNING:
Do not suck the air through valve. Fuel vapor inside
valve is harmful.
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.
7) Connect vacuum hoses.

1) With ignition switch OFF, disconnect coupler from EVAP canis-
ter purge valve (1).
2) Check resistance between two terminals of EVAP canister
purge valve (1).
Resistance of EVAP canister purge valve:
28 – 36° at 20°C (68F) F8B engine
If resistance is as specified, proceed to next operation check.

If not, replace.
3) Disconnect vacuum hoses from intake manifold.

4) With coupler disconnected, blow into hose "A". Air should not
come out of hose "B".
5) Connect 12V-battery to EVAP canister purge valve terminals. In

this state, blow hose "A".
Air should come out of hose "B".
WARNING:
Do not suck the air through valve. Fuel vapor inside
valve is harmful.
If check result is not as described, replace EVAP canister purge

valve.
6) Connect vacuum hoses.

7) Connect EVAP canister purge valve coupler securely.
"A" EVAP CANISTER/1-WAY VALVE INSPECTION

"B" "C"
WARNING:
DO NOT SUCK nozzles on canister/1-way valve. Fuel va-
por inside canister/1-way valve is harmful.
1) Disconnect vacuum hoses from EVAP canister.

2) When air is blown into pipe "A", there should be no restriction
of flow through purge pipes "B" and "C".
3) If operation differs from above description, EVAP canister must
be replaced.
4) Disconnect vacuum hoses from 1-way valve.
5) Air should pass through valve smoothly from EVAP canister
side (green side of valve) (1) when blown hard.
6) Air should not pass through valve from EVAP canister purge
valve (2) side to EVAP canister side.
7) If operation differs from above description, 1-way valve must be
replaced.
8) Connect hoses to canister (2) and canister purge valve (1).

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
99000M24120-426
09917-47910 09930-88530
Tech 2 kit (SUZUKI scan tool) (See Note : “A”)
Vacuum pump gauge Injector test lead
“A” :This kit incluses the following items and substitutes for the Tech 1A kit.
1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback adapter,
7. Battery power cable, 8. RS232 cable, 9. RS232 adapter, 10. RS 232 loopback connector, 11. Storage case,
12. Power supply.
IGNITION SYSTEM 6F1-1
SECTION 6F1
IGNITION SYSTEM
6F1
CONTENTS
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . 6F- 2 Spark Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F- 6
Components . . . . . . . . . . . . . . . . . . . . . . . . . 6F- 2 Noise suppressor . . . . . . . . . . . . . . . . . . . . . . . 6F-
System Wiring . . . . . . . . . . . . . . . . . . . . . . . . 6F- 3 Igniter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F- 4 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-
Diagnostic Flow Table . . . . . . . . . . . . . . . . . . 6F- 4 Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-
Ignition Spark Test . . . . . . . . . . . . . . . . . . . . . 6F- Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . 6F- 7
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 6F- 6 DISTRIBUTOR UNIT . . . . . . . . . . . . . . . . . . . . . . 6F-
High-Tension Cords. . . . . . . . . . . . . . . . . . . . 6F- SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 6F- 9
6F1-2 IGNITION SYSTEM
GENERAL DESCRIPTION
The ignition system used for this vehicle has an electronic ignition control system and consists of the following
parts.
ECM
It detects the engine condition 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 igniter.
Igniter
It turns ON and OFF the primary current of the ignition coil according to the signal from ECM.
Ignition coil
When the ignition coil primary current is turned OFF, a high voltage is induced in the secondary winding.
Distributor
It distributes a high voltage current to each plug.
High-tension cords, spark plugs and noise suppressor.
CMP sensor (Camshaft position Sensor)
Located in the distributor, it converts the crank angle into voltage variation and sends it to ECM. For its details,
refer to SECTION 6E1.
TP sensor, ECT sensor and MAP sensor
For their details, refer to SECTION 6E.
COMPONENTS
1. CMP sensor
2. Noise suppressor
3. Monitor coupler
4. Spark plug
5. Distributor
6. High-tension cord
7. Ignition coil
8. Igniter
SYSTEM WIRING
1. Battery 7. Noise suppressor
2. Main fuse box 8. Distributor
3. Ignition switch 9. Distributor rotor
4. Main relay 10. Signal rotor
5. Ignition coil 11. CMP sensor
6. Igniter 12. Spark plug
B/Or
DIAGNOSIS
Condition Possible Cause Correction
Engine cranks, but will Blown fuse for ignition coil Replace
not start or hard to start Loose connection or disconnection of lead wire or Connect securely
high-tension cord(s)
Faulty high-tension cord(s) Replace
Faulty spark plug(s) Adjust, clean or replace
Cracked rotor or cap Replace
Maladjusted signal rotor air gap Adjust
Faulty ignition coil Replace
Faulty noise suppressor Replace
Faulty CMP sensor Replace
Faulty igniter Replace
Faulty ECM Replace
Maladjusted ignition timing Adjust
Poor fuel economy or Incorrect ignition timing Adjust
engine performance Faulty spark plug(s) or high-tension cord(s) Adjust, clean or replace
Faulty ECM Replace
DIAGNOSTIC FLOW TABLE
STEP ACTION YES NO

1 Was ENGINE DIAGNOSTIC FLOW TABLE in SEC- Go to Step 2. Go to ENGINE DIAG-
TION 6 performed? NOSTIC FLOW
TABLE in SECTION 6.
2 Ignition Spark Test Go to Step 11 on the Go to Step 3.
1) Check all spark plug for condition and type, refer- next page.
ring to SPARK PLUG in this section.
2) If OK, perform ignition spark test, referring to IGNI-
TION SPARK TEST in this section.
Is spark emitted from all spark plugs?
3 Diagnostic Trouble Code (DTC) Check Go to applicable flow Go to Step 4.
1) Check DTC stored in ECM, referring to DIAGNOS- table corresponding to
TIC TROUBLE CODE (DTC) CHECK in SECTION that code No. in SEC-
6E2. TION 6E2.
Is DTC stored?
4 Electrical Connection Check/Noise Suppressor Check Go to Step 5. Connect securely.
1) Check ignition coil for electrical connection. Replace noise sup-
2) Check noise suppressor referring to NOISE SUP- pressor.
PRESSOR.
Are they in good condition?
5 High-tension Cord Check Go to Step 6. Replace high-tension
1) Check high-tension cord for resistance, referring to cord(s).
HIGH-TENSION CORDS in this section.
6 Igniter Check Go to Step 7. Replace igniter.
1) Check igniter, referring to IGNITER in this section.
STEP ACTION YES NO

7 Ignition Coil Power Supply And Ground Circuit Check Go to Step 8. Repair or replace.
1) Check ignition coil power supply (“B/W” wire) circuit
for open and short.
Are circuits in good condition?
8 Ignition Coil Check Go to Step 9. Replace ignition coil
1) Check ignition coil for resistance, referring to IGNI- assembly.
TION COIL in this section.
9 CMP Sensor Check Go to Step 10 on the Adjust or replace.
1) Check CMP sensor and signal rotor, referring to next page.
DISTRIBUTOR in this section.
10 Ignition Trigger Signal Circuit Check Go to Step 11. Repair or replace.
1) Check ignition trigger signal (“Br/W” wire) circuit for
open, short and poor connection.
Are circuits in good condition?
11 Ignition Timing Check Substitute a known- Go to Step 12.
1) Check initial ignition timing and ignition timing ad- good ECM and then
vance, referring to IGNITION TIMING in this sec- repeat STEP 2.
tion.
12 Ignition Timing Adjustment And Recheck System is in good Substitute a known-
1) Adjust initial ignition timing, referring to IGNITION condition. good ECM and then
TIMING in this section. repeat STEP 2.
2) Recheck initial ignition timing and ignition timing
advance, referring to IGNITION TIMING in this sec-
tion.
ON-VEHICLE SERVICE
SPARK PLUGS
REMOVAL
1) Remove high-tension cords, referring to HIGH-TENSION
CORDS under ON-VEHICLE SERVICE earlier in this section.
2) Remove spark plugs.
INSPECTION
1) Inspect them for:
Electrode wear
Carbon deposits
Insulator damage
2) If any abnormality is found, adjust air gap, clean with spark plug
cleaner or replace them with specified new plugs.
F8B engine
Spark plug air gap “a”: 0.8 -0.9 mm
Spark plug type: CHAMPION RN10YC
MICO WR8DC
INSTALLATION
1) Install spark plugs and torque them to specification.
Tightening Torque for spark plug
25 N·m (2.5 kg-m, 18.0 lb-ft) . . . .

2) Install high-tension cords, referring to HIGH-TENSION CORDS
under ON-VEHICLE SERVICE earlier in this section.
IGNITION TIMING
NOTE:
Before starting engine, place transmission gear shift lever in
“Neutral” and set parking brake.
INSPECTION AND ADJUSTMENT

1) When using SUZUKI scan tool, connect SUZUKI scan tool to
DLC with ignition switch OFF.
Special Tool (when using SUZUKI scan tool)
1
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
(A) to SECTION 6E2).
5) Set timing light to No.1 high-tension cord.

6) Fix ignition timing to initial one as follows:
When using SUZUKI scan tool:
a) Select “MISC” mode on SUZUKI scan tool and fix ignition
timing to initial one.
When not using SUZUKI scan tool:
a) Disconnect scan tool from DLC if connected and connect
A and B terminals of monitor coupler by using service wire
so that ignition timing is fixed on initial one.
7) Using timing light (1), check that timing is within specification.
Initial ignition timing (Test switch terminal grounded or

fixed by scan tool):
5 ± 1° BTDC (at idle speed)
Ignition order 1-3-2
8) If ignition timing is out of specification, remove air cleaner as-

sembly then loosen flange bolts (1), adjust timing by turning
distributor assembly (2) while engine is running, and then
tighten bolts (1).
Tightening Torque
(a): 23 N·m (2.3 kg-m, 14.0 lb-ft)
9) After tightening distributor flange bolts, recheck that ignition
timing is within specification.
10) After checking and/or adjusting initial ignition timing, release
ignition timing fixation by SUZUKI scan tool or disconnect ser-
vice wire from monitor coupler.
11) With engine idling (test switch terminal ungrounded, vehicle
stopped), check that ignition timing is about 8 BTDC
(Constant variation within a few degrees from 8 indicates no
abnormality but proves operation of electronic timing control
system). Also, check that increasing engine speed advances
ignition timing.
If above check results are not satisfactory, check test switch
terminal circuit and ECM.
SPECIAL TOOLS
09900-25002 09900-27301 09930-76420 99000M24120-426

Pocket tester Timing light (DC 12 V) Timing light (Dry cell type) Tech 2 kit (SUZUKI scan tool)
(See Note : “A”)
"A" :This kit incluses the following items and substitutes for the Tech 1A kit.
1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback adapter,
7. Battery power cable, 8. RS232 cable, 9. RS232 adapter, 10. RS232 loopback connector, 11. Storage case,
12. Power supply.
EXHAUST SYSTEM 6K1-1
SECTION 6K1
EXHAUST SYSTEM
CONTENTS
GENERAL DESC 6K1-2 6K1

MAINTENANCE ........ 6K1-3
ON-VEHICLE SERV 6K1-4
CAUTION:
THE ENGINE OF THIS VEHICLE REQUIRES THE USE OF UNLEADED FUEL ONLY. USE OF LEADED
AND/OR LOW LEAD FUEL CAN RESULT IN DAMAGE AND REDUCE THE EFFECTIVENESS OF THE
CATALYTIC CONVERTER.
6K1-2 EXHAUST SYSTEM
GENERAL DESCRIPTION
The exhaust system consists of an exhaust manifold with catalytic contertor (Manivertor), exhaust pipes, a catalyst
case a muffler and seal, gaskets and etc., and catalyst case has the three-way catalytic converter (TWC).
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.
23N-m (2.3 Kg-m)

10N-m (1.0 Kg-m) 11 10
2
23N-m (2.3 Kg-m)

6 10
1
14
16
23N-m 4
(2.3 Kg-m) 15
12 55N-m (5.5 Kg-m)
7
11 23N-m (2.3 Kg-m)
10
8 55N-m (5.5 Kg-m)
1. Exhaust manifold cover 10. Rubber mounting

2. Exhaust manifold cover bolt 11. Mounting bolt
3. Exhaust manifold gasket 12. Exhaust pipe nut
4. Exhaust manifold 13. Gasket
5. Heated Oxygen sensor 14. Muffler
6. Exhaust manifold nut 15. Manivertor cover
7. Seal ring 16. Exhaust manifold bolt : Tightening Torque
8. Exhaust pipe bolt 17. Catalyst case
9. Exhaust pipe : Do not reuse
EXHAUST SYSTEM 6K1-3
MAINTENANCE
WARNING:
To avoid the danger of being burned, do not touch the ex-
haust system when the system is hot. Any service on the
exhaust system should be performed when the system
is cool.
At every interval of periodic maintenance service, and when ve-

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

damage.
If bolts or nuts are loosened, tighten them to specified torque.
Refer to GENERAL DESCRIPTION in this section for torque
data.
Check nearby body areas for damaged, missing, or misposi-

tioned part, open seam, hole, loose connection or any other de-
fect which could permit exhaust fumes to seep into vehicle.
Make sure that exhaust system components have enough clear-
ance from underbody to avoid overheating and possible dam-
age to passenger compartment carpet.
Any defect should be fixed at once.
6K1-4 EXHAUST SYSTEM
ON-VEHICLE SERVICE
WARNING:
To avoid the danger of being burned, do not touch the ex-
haust system when the system is hot. Any service on the
exhaust system should be performed when the system
is cool.
EXHAUST MANIFOLD
Refer to Section 6A for removal and installation procedures of ex-
haust manifold.
Check gasket and seal for deterioration or damage.
Replace them as necessary.
EXHAUST PIPE
For replacement of exhaust pipe, be sure to hoist vehicle and ob-
serve WARNING under ªMaintenanceº and the following.
CAUTION:
Exhaust pipe have three way catalytic converter in it, it
should not be exposed to any impulse.
Be careful not to drop it or hit it against something.
Tighten bolts and nuts to specified torque when reassembling.

Refer to GENERAL DESCRIPTION in this section for location of
bolts and nuts.
After installation, start engine and check each joint of exhaust
system for leakage.
BODY ELECTRICAL SYSTEM 8-1
SECTION 8
BODY ELECTRICAL SYSTEM
NOTE : For the descriptions (items) not found in this section of this manual, refer to the same section of Service
Manual mentioned in the FOREWORD of this manual.
CONTENTS
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- *
Combination Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- *
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-*
Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- *
Head Light levelling, Front Fog Lamp, Rear Fog Lamp, Rear Defogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 1
8
8-2 BODY ELECTRICAL SYSTEM
HEADLIIGHTS LEVELING SYSTEM

Trouble Possible Cause Correction
Both headlights do not "Wiper Washer" fuse blown Check circuit and replace fuse
move Head light leveling switch faulty Check switch or replace it as
necessary.
Wiring or grounding faulty Repair circuit.
One of headlights (either Wiring or grounding faulty Repair circuit.
Right or Left) does not Head light leveling actuator faulty Replace actuator
Move
Headlight assembly deformed Replace headlight
HEADLIGHT LEVELING SWITCH

1 INSPECTION
Check for resistance between terminals at each switch
2 position as shown below. If check is not specified, replace.
3 1
Headlight leveling switch resistance
0
4
Position Terminals Resistance (KW)

- VCC and GND 5.30 - 5.86
0 4.77 - 5.27
1 3.99 - 4.41
2 SIG and GND 3.71 - 4.10
3 3.06 - 3.38
4 2.28-2.52
GND VCC
LEVELING ACTUATOR
SIG INSPECTION
1. Headlight leveling switch All headlight system couples connected including leveling
actuator and switch, and at ignition switch ON, listen to the
leveling actuator sound on both actuators according to the
movement of the leveling switch. If no sound heard with the
movement of the leveling switch, replace headlight assembly.

Important manual safety warnings

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IMPORTANT

Applicable model: MB308 (BS-III)

Manual Name Manual No.

MB-308 SERVICE MANUAL 99500M84401-74E

MB308 WIRING DIAGRAM MANUAL 99512M84451-74E

MARUTI UDYOG LIMITED

HOW TO USE THIS MANUAL ........................................................................................................................... 0A-

MAINTENANCE AND LUBRICATION

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B- 2

MAINTENANCE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-

PERIODIC MAINTENANCE SCHEDULE

5. Engine bolts (All cyli nder head and manifold fixings) T T T T

3. Fuel tank cap, fuel lines & connections

This table includes services as scheduled up to 80,000 km mileage.

4. Rear wheel bearings (loose , damage) I I I I I I I I I

FRONT AND REAR SUSPENSION

3. Rear spr ing (damage) I I I I I I I I I

4. Shock abso rber s (oil leaka ge, damage) I I I I I I I I I I

6. Suspen sion arms and Tension rods I I I I I I I I I

This table includes services as scheduled up to 80,000 km mileage.

4. Chec k all hose joints, tighten if neces sar y I I I I I I I I I I

8. Chec k all mount ing bolts I I I I I I I I I

EMISSION CONTROL SYSTEM

PCV (Positive Crankcase Ventilation) Valve Inspec-

HEATER (OPTIONAL) AND VENTILATION 1A

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-

1. Blower fan motor

AIR CONDITIONING (OPTIONAL)

1. Blower fan motor

A/C SYSTEM INSPECTION OF ECM AND ITS

1. Blower fan motor

A. To HTR fuse 15A

ECM VOLTAGE VALUES TABLE FOR RELATION OF A/C CONTROL

STEERING, SUSPENSION, WHEELS AND TIRES

FRONT DRIVE SHAFT

Throughout this manual, the four cylinders of the engine are

GENERAL INFORMATION ON ENGINE

PRECAUTION ON FUEL SYSTEM SERVICE

FUEL PRESSURE RELIEF PROCEDURE

FUEL LEAKAGE CHECK PROCEDURE

ON-BOARD DIAGNOSTIC SYSTEM

PRECAUTION IN DIAGNOSING TROUBLES

ENGINE DIAGNOSTIC FLOW TABLE

STEP ACTION YES NO

1. CUSTOMER COMPLAINT ANALYSIS

User name: Model: VIN:

VEHICLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS

2. DIAGNOSTIC TROUBLE CODE (DTC) CHECK, RECORD AND CLEARANCE

3. and 4. VISUAL INSPECTION

INSPECTION ITEM REFERRING SECTION

5. TROUBLE SYMPTOM CONFIRMATION

6. and 7. RECHECKING AND RECORD OF DTC

8. ENGINE BASIC INSPECTION AND ENGINE DIAGNOSIS TABLE

ENGINE BASIC INSPECTION FLOW TABLE

STEP ACTION YES NO

9. TROUBLESHOOTING FOR DTC

10. CHECK FOR INTERMITTENT PROBLEM

11. FINAL CONFIRMATION TEST

ENGINE DIAGNOSIS TABLE

Condition Possible Cause Reference Item

Condition Possible Cause Reference Item

Fuel system out of order.

Engine and emission control system