Get Body Electrical System -> On-Vehicle Service Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

ON-VEHICLE SERVICE

HEADLIGHT

HEADLIGHT SWITCH

INSPECTION

1) Disconnect negative cable at battery.

2) Disconnect combination switch lead wire coupler.

3) Check for continuity between terminals at each switch position

shown below. If check result is not as specified, replace.

REMOVAL AND INSTALLATION

Refer to COMBINATION SWITCH ASSEMBLY in section 3C.

Terminal

Switch Position

Mating side (front) view of combination

switch coupler

Terminal

Switch Position

HEADLIGHT

REMOVAL

1) Disconnect negative cable at battery.

2) Remove front grille.

3) Remove garnish (1) installed under the headlight.

4) Remove headlight mounting bolts.

5) Detach headlight assembly (2) from vehicle.

6) Disconnect couplers from headlight assembly.

7) Remove headlight assembly.

INSTALLATION

Reverse removal procedure for installation.

BODY ELECTRICAL SYSTEM 8-9

Lighting switch

K L M R J

OFF

SMALL

HEAD

Dimmer and passing switch

R H J G

PASS

BULB REPLACEMENT

WARNING:

To avoid danger of being burned, don’t touch when the

bulb is hot.

1) Disconnect negative cable at battery.

2) Disconnect harness from bulb.

3) Remove socket cover (1) and bulb (2).

4) Replace bulb and assemble all removed parts.

HEADLIGHT AIMING WITH SCREEN

NOTE:

D Unless otherwise obligated by local regulations, adjust

headlight aiming according to following procedure.

D After replacing headlight, be sure to adjust aiming.

Before adjustment, make sure the following.

a) Place vehicle on a flat surface in front of blank wall (screen)

ahead of headlight surface.

Clearance “a”: 10 m (32.8 ft.)

b) Adjust air pressure of all tires to a specified value respectively.

c) Bounce vehicle body up and down by hand to stabilize suspen-

sion.

d) Carry out with one driver aboard.

Driver’s weight: 75 kg (165 Ib)

Adjustment

1) Check to see if hot spot (high intensity zone) of each main (low)

beam axis falls as illustrated.

Clearance “H”: Approx. 130 mm (5.15 in.)

2) If headlight aiming is not set properly, align it to specification by

adjusting aiming screw and aiming gear.

X - X: Horizontal center line of headlights bulb

A - A: Vertical center line of left headlight bulb

B - B: Vertical center line of right headlight bulb

1. Headlight assembly

2. Aiming (for up/down adjustment)

3. Aiming (for right/left adjustment)

1. Screen

8-10 BODY ELECTRICAL SYSTEM

TURN SIGNAL AND HAZARD WARNING

LIGHT

TURN SIGNAL LIGHT SWITCH

INSPECTION

1) Disconnect negative cable at battery.

2) Disconnect combination switch lead wire coupler.

3) Check for continuity between terminals at each switch position

shown below. If check result is not as specified, replace.

Terminal

Turn

Signal

Hazard

REMOVAL AND INSTALLATION

Refer to COMBINATION SWITCH ASSEMBLY in Section 3C.

Mating side (front) view of combination

switch coupler

TURN SIGNAL/HAZARD RELAY

The turn signal/hazard relay (1) is located on the fuse box (2).

INSPECTION

Connect battery and tester as shown left.

Unless a continued click sound is heard, replace relay (1).

Reference flashing cycle : 60 – 120 cycle/minute

BODY ELECTRICAL SYSTEM 8-11

A B C D E F

OFF

IGNITION SWITCH

INSPECTION

1) Disconnect negative cable at battery.

2) Disconnect ignition main switch lead wire coupler.

3) Check for continuity between terminals at each switch position

shown below. If check result is not as specified, replace.

Terminal

Position

key

Mating side (front) view of ignition main

switch coupler

REMOVAL AND INSTALLATION

Refer to STEERING LOCK ASSEMBLY (IGNITION SWITCH) in

section 3C.

COMBINATION METER

REMOVAL

1) Disconnect negative cable at battery.

2) Remove heater control knobs (1) and mounting bolts.

3) Disconnect heater control lead wire couplers (2).

4) Loosen steering column mounting nuts of upper side, and lower

steering column.

5) Remove meter cluster (3).

6) Pull out combination meter (4), and disconnect speedometer

cable and combination meter lead wire couplers.

INSTALLATION

Reverse removal procedure for installation.

8-12 BODY ELECTRICAL SYSTEM

+B ACC IG ST

OUT

LOCK

ACC

START

FUEL METER/FUEL GAUGE UNIT

FUEL METER

INSPECTION

1) Remove rear seat cushion. Refer to REAR SEAT in Section 9.

2) Disconnect Y/R lead wire coupler under the rear seat cushion.

3) Turning switch ON, and check that fuel meter indicates E.

4) Turn ignition switch OFF.

5) Ground Y/R lead through a 3.4 W test bulb (1) as illustrated.

6) Turn ignition switch ON and check that bulb light up and pointer

(2) moves to F side.

7) If fuel meter shows no operation, repair or replace defective

parts.

FUEL SENDER GAUGE

INSPECTION

1) Remove fuel tank referring to FUEL TANK REMOVAL in Sec-

tion 6C.

2) Remove fuel gauge unit (1) from tank.

3) Check resistance between terminal (a) and gauge unit (ground)

in individual each float position below.

If the measured value is out of specification, replace.

BODY ELECTRICAL SYSTEM 8-13

Float Position Resistance (W)

Full Upper “a” 40.9 mm (1.61 in.) 1 - 5

Middle (1/2) “b” 106.2 mm (4.18 in.) 28.5 - 36.5

Full Lower “c” 169.5 mm (6.67 in.) 103 - 117

ENGINE COOLANT TEMPERATURE (ECT)

METER AND SENSOR UNIT

ENGINE COOLANT TEMPERATURE (ECT) METER

INSPECTION

1) Disconnect Y/W lead wire going to ECT sensor.

2) Turn ignition switch ON, and check that ECT meter indicates

COOL.

3) Turn ignition switch OFF.

4) Ground Y/W lead wire through a 3.4 W test bulb (1) as illus-

trated.

5) Turn ignition switch ON, and check that bulb light up and pointer

(2) moves to hot side.

6) If ECT meter shows no operation, repair or replace defective

parts.

ENGINE COOLANT TEMPERATURE (ECT) SENSOR

FOR METER

REMOVAL AND INSTALLATION

Refer to ENGINE COOLANT TEMPERATURE SENSOR in sec-

tion 6E1.

WARNING:

D Make sure that engine coolant temperature is cold be-

fore removing any part of cooling system.

D Also be sure to disconnect negative cable from battery

terminal before removing any part.

1. ECT sensor

INSPECTION

Warm up ECT sensor (1) observing resistance between sensor ter-

minal (2) and sensor unit (1). Resistance should be decreased with

increase of its temperature.

8-14 BODY ELECTRICAL SYSTEM

Temperature Resistance

505C (1225F) 136 - 216 W

1205C (2485F) 16.4 - 19.4 W

OIL PRESSURE WARNING LIGHT

OIL PRESSURE SWITCH

INSPECTION

1) Disconnect oil pressure switch (1) lead wire.

2) Check for continuity between oil pressure switch terminal (2)

and cylinder block (3) as shown.

If check result is not as specified, replace oil pressure switch (1).

REMOVAL AND INSTALLATION

Refer to OIL PRESSURE CHECK in Section 6A1.

BRAKE AND PARKING BRAKE WARNING

LIGHT

INSPECTION

D BRAKE FLUID LEVEL SWITCH

Check switch (1) for continuity.

If check result is not as specified, replace switch.

D PARKING BRAKE SWITCH

Check switch (1) for continuity.

If check result is not as specified, replace switch.

BODY ELECTRICAL SYSTEM 8-15

During Engine Running No continuity

At Engine Stop Continuity

OFF position (float up) No continuity

ON position (float down) Continuity

OFF position

(parking brake released)

No continuity

ON position

(parking brake lever pulled up)

Continuity

COMPONENTS

FRONT WIPER

FRONT WASHER

WIPERS AND WASHERS

FRONT WIPER/WASHER SWITCH

INSPECTION

1) Disconnect negative cable at battery.

2) Disconnect combination switch lead wire coupler.

3) Check for continuity between terminals at each switch position

as shown below. If check result is not as specified, replace

switch.

REMOVAL AND INSTALLATION

Refer to COMBINATION SWITCH ASSEMBLY in Section 3C.

Wiper SW

Terminal

Washer

OFF

Mating side (front) view of combination

switch coupler

8-16 BODY ELECTRICAL SYSTEM

N P O S

OFF

INT

INTERMITTENT WIPER RELAY CIRCUIT

INSPECTION

1) Disconnect negative cable at battery.

2) Disconnect combination switch lead wire coupler.

3) Turn the front wiper switch to INT position.

4) Connect battery positive terminal to terminal “N” and battery

negative terminal to terminal “R”.

5) Connect voltmeter positive lead to terminal “O” and negative

lead to terminal “R”

Check that the voltmeter indicates the battery voltage (10 –

14V).

6) Connect terminal “S” and terminal “N” by a jumper wire. Then

move jumper wire end connected to terminal “N” to terminal “R”.

Observe the voltmeter voltage drops to 0V right after connect-

ing the jumper wire from terminal “N” to “R”. Then the voltage

rises to battery voltage (10 – 14 V) within the time shown below.

Mating side (front) view of combination

switch coupler

BODY ELECTRICAL SYSTEM 8-17

WASHER LINKED OPERATION

INSPECTION

1) Disconnect negative cable at battery.

2) Disconnect combination switch lead wire coupler.

3) Make sure that front wiper switch is at OFF position.

4) Connect battery positive terminal to terminal “N” and battery

negative terminal to terminal “R”.

5) Connect voltmeter positive lead to terminal “O” and negative

lead to terminal “R”.

6) Push washer switch and check that voltage changes as shown

in the diagram.

Mating side (front) view of combination

switch coupler

FRONT WIPER MOTOR

INSPECTION

1) As illustrated left, have a 12V battery and connect its (+) termi-

nal to terminal “A”, and its (–) terminal to bracket (1) (wiper

ground). If motor (2) rotates at a low revolution speed of 45 to

55 rpm, it is proper. As for high speed check, connect battery (+)

terminal to terminal “B”, and its (–) terminal to bracket (1) (wiper

ground). If motor (2) rotates at a high revolution speed of 67 to

83 rpm, it is proper.

2) Testing automatic stop action

a) Connect 12V battery (+) terminal to terminal “A” of wiper mo-

tor (2) and (–) terminal to bracket (1) (wiper ground) and let

the motor turn.

b) Disconnect terminal “A” from battery, and let the motor stop.

c) Connect terminal “A” and “D” with a jumper wire (3), and con-

nect terminal “C” to battery (+) terminal. Observe the motor

turns once again then stops at a given position.

d) Repeat a) thru c) several times and inspect if the motor stops

at the given position every time.

8-18 BODY ELECTRICAL SYSTEM

FRONT WASHER PUMP

REMOVAL

1) Disconnect negative cable at battery.

2) Remove washer tank fitting screws.

3) Disconnect pump lead wire and hoses.

4) Remove washer tank (1).

5) Remove pump (2) from tank.

INSPECTION

Connect battery (+) and (–) terminals to pump (+) and (–) terminals

respectively to check pumping rate.

Check for front washer pump.

Pumping Rate:

More than 1.0 l/min (2.1 US pt./min, 1.76 Imp pt./min)

Installation

Reverse removal procedure for installation.

DOOR SWITCH

INSPECTION

Pull out door switch from body and check switch for continuity.

If found defective, replace switch.

BODY ELECTRICAL SYSTEM 8-19

Body Electrical System -> On-Vehicle Service for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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