1998-2003 Suzuki Alto 4 Door Engine and Emission Control System User Manual
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Engine and Emission Control System for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

6E1
ENGINE AND EMISSION CONTROL SYSTEM 6E1-1
SECTION 6E1
ENGINE AND EMISSION CONTROL SYSTEM
CONTENTS
GENERAL DESCRIPTION 6E1- 2. . . . . . . . . . . . . .
Air Intake System 6E1- 4. . . . . . . . . . . . . . . . . . . .
Fuel Delivery System 6E1- 4. . . . . . . . . . . . . . . . .
Electronic Control System 6E1- 5. . . . . . . . . . . . .
DIAGNOSIS 6E1-10. . . . . . . . . . . . . . . . . . . . . . . . . . .
On-Board Diagnostic System 6E1-10. . . . . . . . . .
Precautions in Diagnosing Troubles 6E1-10. . . .
MIL Check 6E1-11. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC Check 6E1-11. . . . . . . . . . . . . . . . . . . . . . . . .
DTC Clearance 6E1-13. . . . . . . . . . . . . . . . . . . . . .
DTC Table 6E1-14. . . . . . . . . . . . . . . . . . . . . . . . . .
A-1 MIL Circuit Check 6E1-15. . . . . . . . . . . . . . . .
A-2 MIL Circuit Check 6E1-16. . . . . . . . . . . . . . . .
A-3 MIL Circuit Check 6E1-17. . . . . . . . . . . . . . . .
A-4 ECM Power and Ground
Circuit Check 6E1-18. . . . . . . . . . . . . . . . . . . . . . .
Code No.11 (P0105) MAP Sensor Circuit 6E1-20
Code No.13 (P0120) TP Sensor Circuit 6E1-22.
Code No.14 (P0130) O2 Sensor Circuit 6E1-24.
Code No.15 (P0340) CMP Sensor Circuit 6E1-26
Code No.16 (P0500) VSS Circuit 6E1-27. . . . . . .
Code No.18 (P0110) IAT Sensor Circuit 6E1-28.
Code No.19 (P0115) ECT Sensor Circuit 6E1-29
DTC Confirmation Procedure 6E1-30. . . . . . . . . .
B-1 Fuel Pump and Its Circuit Check 6E1-31. . .
B-2 Fuel Injector and Its Circuit Check 6E1-32. .
B-3 Fuel Pressure Check 6E1-34. . . . . . . . . . . . .
B-4 Idle Air Control System Check 6E1-36. . . . .
B-5 Evaporative Emission Control
System Check 6E1-37. . . . . . . . . . . . . . . . . . . . . .
B-6 Engine Start Signal Check 6E1-38. . . . . . . . .
B-7 Radiator Fan Control System Check 6E1-39
B-8 A/C Control Signal Check
(If equipped) 6E1-40. . . . . . . . . . . . . . . . . . . . . . .
B-9 Electric Load Signal Circuits Check 6E1-41.
B-10 Fuel Cut Operation Check 6E1-42. . . . . . . .
Inspection of ECM and Its Circuits 6E1-43. . . . . .
Voltage Check 6E1-43. . . . . . . . . . . . . . . . . . . . .
Resistance Check 6E1-46. . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 6E1-47. . . . . . . . . . . . . . . .
General 6E1-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accelerator Cable Adjustment 6E1-48. . . . . . . . .
Idle Speed/Idle Air Control (IAC)
Duty Inspection 6E1-49. . . . . . . . . . . . . . . . . . . . .
AIR INTAKE SYSTEM 6E1-51. . . . . . . . . . . . . . . . . .
Throttle Body 6E1-51. . . . . . . . . . . . . . . . . . . . . . . .
Idle Air Control Valve (IAC Valve) 6E1-54. . . . . .
FUEL DELIVERY SYSTEM 6E1-55. . . . . . . . . . . . . .
Fuel Pressure Inspection 6E1-55. . . . . . . . . . . . . .
Fuel Pump 6E1-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pressure Regulator 6E1-7. . . . . . . . . . . . . . .
Fuel Injector 6E1-58. . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRONIC CONTROL SYSTEM 6E1-61. . . . . .
ECM 6E1-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAP Sensor 6E1-61. . . . . . . . . . . . . . . . . . . . . . . .
TP Sensor 6E1-64. . . . . . . . . . . . . . . . . . . . . . . . . .
IAT Sensor 6E1-66. . . . . . . . . . . . . . . . . . . . . . . . . .
ECT Sensor 6E1-67. . . . . . . . . . . . . . . . . . . . . . . . .
Main Relay/Fuel Pump Relay 6E1-68. . . . . . . . . .
Oxygen Sensor 6E1-69. . . . . . . . . . . . . . . . . . . . . .
Fuel Cut Operation 6E1-70. . . . . . . . . . . . . . . . . . .
A/C Compressor Control Relay
(If equipped) 6E1-70. . . . . . . . . . . . . . . . . . . . . . .
CMP Sensor 6E1-70. . . . . . . . . . . . . . . . . . . . . . . .
Radiator Fan Control System 6E1-71. . . . . . . . . .
VSS 6E1-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAP Control System 6E1-73. . . . . . . . . . . . . . . .
PCV System 6E1-78. . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 6E1-79. . . . . . . . . . . . . . . . . . . . . .
6E1-2 ENGINE AND EMISSION CONTROL SYSTEM
GENERAL DESCRIPTION
The engine and emission control system has 4 major
sub-systems: air intake system, fuel delivery system,
electronic control system and emission control sys-
tem.
Air intake system includes air cleaner, MAP sensor,
throttle body, IAC valve and intake manifold.
Fuel delivery system includes fuel pump, delivery
pipe, fuel pressure regulator, fuel injectors, etc.
Electronic control system includes ECM, various sen-
sors and controlled devices.
Emission control system includes EVAP and PCV
systems.
ENGINE AND EMISSION CONTROL SYSTEM 6E1-3
1. Air Cleaner
2. EVAP canister purge valve
3. IAT sensor
4. TP sensor
5. IAC valve
6. MAP sensor
7. A/C evaporator temp. sensor (if equipped)
8. EVAP canister
9. Tank pressure control valve
10. Fuel pressure regulator
11. A/C dual pressure switch (if equipped)
12. PCV valve
13. Fuel injector
14. Oxygen sensor
15. Fuel pump
16. Stop light switch
17. ECT sensor
18. Three way catalytic convertor
19. CMP sensor
20. Main relay
21. Ignitor
22. Blank
23. ECM
24. Radiator fan
25. Radiator fan control relay
26. VSS in combination meter
27. A/C compressor control relay
28. Malfunction indicator lamp in combination meter
29. Blank
30. Ignition switch
31. Starter magnetic switch
32. Main fuse
33. Battery
34. Blank
35. Blank
36. Monitor connector
36-1. Diagnosis switch terminal
36-2. Test switch terminal
36-3. Duty output terminal
37. Blank
38. Heater blower fan switch
39. Electric load (blower fan and small light)
40. Data link connector (DLC)
41. Fuel pump relay
42. Fuel filter
6E1-4 ENGINE AND EMISSION CONTROL SYSTEM
AIR INTAKE SYSTEM
The main components of the air intake system are air
cleaner, air cleaner outlet hose, throttle body, IAC
valve and intake manifold.
The air (by the amount corresponding to the throttle
valve opening and engine speed) is filtered by the air
cleaner, passes through the throttle body, is distrib-
uted by the intake manifold and finally drawn into each
combustion chamber.
When the IAC valve is opened according to the signal
from ECM, the air bypasses the throttle valve through
bypass passage and is finally drawn into the intake
manifold.
1. Air cleaner
2. IAT sensor
3. Air cleaner outlet hose
4. Throttle body
5. Throttle valve
6. IAC valve
7. Intake manifold
8. Cylinder head
9. Exhaust manifold
10. Air flow
11. MAP sensor
12. Engine coolant
FUEL DELIVERY SYSTEM
The fuel delivery system consists of the fuel tank, fuel
pump, fuel filter, fuel pressure regulator, delivery pipe
and fuel injectors.
The fuel in the fuel tank is pumped up by the fuel
pump, filtered by the fuel filter and fed under pressure
to each injector through the delivery pipe. As the fuel
pressure applied to the injector (the fuel pressure in
the fuel feed line) is always kept a certain amount
higher than the pressure in the intake manifold by the
fuel pressure regulator, the fuel is injected into the in-
take port of the cylinder head when the injector opens
according to the injection signal from ECM.
The fuel relieved by the fuel pressure regulator re-
turns through the fuel return line to the fuel tank.
1. Fuel injector
2. Delivery pipe
3. Fuel pressure regulator
4. Intake manifold
5. EVAP canister
6. EVAP canister purge valve
7. Fuel feed line
8. Fuel return line
9. Fuel vapor line
10. Fuel filter
11. Fuel tank
12. Fuel pump
ENGINE AND EMISSION CONTROL SYSTEM 6E1-5
ELECTRONIC CONTROL SYSTEM
The electronic control system consists of 1) various
sensors which detect the state of engine and driving
conditions, 2) ECM which controls various devices
according to the signals from the sensors and 3) vari-
ous controlled devices.
Functionally, it is divided into the following sub sys-
tems:
D Fuel injection control system
D Idle speed control system
D Fuel pump control system
D Ignition control system
D Radiator fan control system
D Evaporative emission control system
D A/C control system (if equipped)
INFORMATION SENSORS
1. MAP sensor
2. TP sensor
3. IAT sensor
4. ECT sensor
5. Oxygen sensor
6. VSS
7. Battery
8. CMP sensor
9. Blank
10. A/C evaporator temp. sensor (if equipped)
11. A/C dual pressure switch (if equipped)
CONTROL DEVICES
a : Fuel injectors
b : EVAP canister purge valve
c : Fuel pump relay
d : Igniter
e : Blank
f : Malfunction indicator lamp
g : Radiator fan control relay
h : IAC valve
i : A/C compressor control relay
(if equipped)
j : Main relay
OTHERS
A : ECM
B : PCV valve
C : EVAP canister
D : Monitor connector
E : DLC
F : Tank pressure control valve
6E1-6 ENGINE AND EMISSION CONTROL SYSTEM
ENGINE AND EMISSION CONTROL SYSTEM 6E1-7
TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE)
1. Fuel injector No.1
2. Fuel injector No.2
3. Fuel injector No.3
4. Blank
5. Idle air control (IAC) valve
6. EVAP canister purge valve
7. Fuel pump relay
8. Fuel pump
9. Radiator fan control relay
10. Radiator fan motor
11. Malfunction indicator light
12. Monitor connector
13. Igniter
14. Capacitor (noise suppressor)
15. Engine coolant temp. (ECT) sensor
with gauge
16. ECT sensor
17. ECT gauge
18. A/C compressor control relay
(if equipped)
19. Blank
20. Main relay
21. Starter magnetic switch
22. Camshaft position (CMP) sensor
23. To Combination meter
24. Vehicle speed sensor (VSS)
(reed switch)
25. Manifold absolute pressure (MAP)
sensor
26. Throttle position (TP) sensor
27. Blank
28. Intake air temp.(IAT) sensor
29. A/C evaporator temp. sensor
(if equipped)
30. Oxygen sensor
31. Blank
32. Stop light switch
33. Small light switch
34. Heater blower motor switch
35. Heater blower motor
36. A/C dual pressure switch (if equipped)
37. A/C switch (if equipped)
38. Blank
39. Data link connector
TERMINAL
CIRCUIT
E34-1
E34-2
E34-3
E34-4
E34-5
E34-6
E34-7
E34-8
E34-9
E34-10
E34-11
E34-12
E34-13
E34-14
E34-15
E34-16
E34-17
E34-18
E34-19
E34-20
E34-21
E34-22
E33-201
E33-202
E33-203
E33-204
E33-205
E33-206
E33-207
E33-208
E33-209
E33-210
E33-211
E33-212
E33-213
E33-214
E33-215
E33-216
Blank
IAC valve
Blank
Blank
Blank
Blank
Test switch terminal
Diagnosis switch terminal
Electric load signal for blower
fan motor
Stop light switch
(brake pedal switch)
Blank
Data link connector
Engine starter switch
(engine starter signal)
Blank
Blank
Blank
Duty output terminal
Electric load signal for small
light switch and rear defogger
A/C ON signal from A/C switch
(if equipped)
Blank
Blank
Sensor ground
Power supply for sensor
Blank
CMP sensor (+)
VSS
MAP sensor
TP sensor
A/C evaporator temp. sensor
(with A/C)
ECT sensor
Blank
Blank
CMP sensor (–)
Blank
Oxygen sensor
IAT sensor
Blank
A/C compressor magnet clutch
(with A/C)
CIRCUIT
E32-301
E32-302
E32-303
E32-304
E32-305
E32-306
E32-307
E32-308
E32-309
E32-310
E32-311
E32-312
E32-313
E32-314
E32-315
E32-316
E32-317
E32-318
E32-319
E32-320
E32-321
E32-322
E32-323
E32-324
E32-325
E32-326
Ground
Power source
Blank
Blank
Blank
Blank
EVAP canister purge valve
Blank
Blank
Igniter
Fuel injector No. 3
Fuel injector No. 1
Ground
Power source for backup
Power source
Blank
Malfunction indicator light
Fuel pump relay
Main relay
Radiator fan control relay
Blank
Blank
Blank
Blank
Fuel injector No. 2
Ground
TERMINAL
6E1-8 ENGINE AND EMISSION CONTROL SYSTEM
IAC
valve
INTAKE
MANIFOLD
THROTTLE
BODY
AIR
CLEANER
OUTLET
HOSE
TP sensor
ENGINE
EXHAUST
MANIFOLD
ECT
sensor
CMP
sensor
Oxygen sensor
3 WAY
CATALYTIC
CONVERTER
Camshaft and
each piston
position
FUEL
INJECTOR
Intake air
temp.
Throttle valve
opening
Fuel pump
Engine coolant
temp.
Exhaust oxygen
concentration
D Battery voltage
D Vehicle speed
D Engine start signal
D Diagnosis signal
D Test signal
D Electric load signal
ECM
Fuel pump
relay
Fuel injection control
Idle air control
EVAP
canister
purge valve
Radiator fan
control relay
Malfunction
indicator lamp
A/C compressor
control relay
(if equipped)
Air
Fuel
Exhaust gas
Pressure in
intake
manifold
IAT
sensor
Igniter
AIR
CLEANER
MAP sensor
INFORMATION
SENSORS
(input)
CONTROL
DEVICE
(output)
ENGINE AND EMISSION CONTROL SYSTEM 6E1-9
ENGINE & EMISSION CONTROL INPUT/OUTPUT TABLE
CMP sensor
MAP sensor
TP sensor
ECT sensor
IAT sensor
O2 sensor
VSS
Electric load signal
Starter switch
Battery voltage
Stop lamp switch
A/C switch
Diagnosis switch
Test switch
Fuel injector f f f f f f f f
IAC valve f f f f f f f f
Fuel pump relay f f
Igniter f f f f f f
EVAP canister purge valve f f f f f f
MIL f f f f f f f f
Radiator fan relay f f
A/C compressor relay f f f f f
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.
D 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.
D If the areas monitored by ECM is free from any trouble after the
engine start (while engine is running), malfunction indicator
lamp turns OFF.
D 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
D 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.
D Be sure to read PRECAUTIONS FOR ELECTRICAL CIRCUIT
SERVICE in SECTION 0A before inspection and observe what
is written there.
D 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.
6E1-10 ENGINE AND EMISSION CONTROL SYSTEM
MALFUNCTION INDICATOR LAMP (MIL)
CHECK
1) Turn ON ignition switch (but engine at stop) and check that mal-
function indicator lamp lights up.
If lamp does not light up, go to DIAGNOSTIC FLOW TABLE A-1
in this section.
If lamp flashes, go to DIAGNOSTIC FLOW TABLE A-2 in this
section.
2) Start engine and check that malfunction indicator lamp turns
OFF.
If lamp remains ON, go to DTC CHECK NOT USING SUZUKI
SCAN TOOL in this section.
DIAGNOSTIC TROUBLE CODE (DTC) CHECK
[Using SUZUKI scan tool]
1) Check malfunction indicator lamp referring to MALFUNCTION
INDICATOR LAMP (MIL) CHECK in this section.
2) Turn ignition switch OFF.
3) After setting cartridge to SUZUKI scan tool, connect it to data
link connector (DLC) (1) located on underside of instrument
panel at driver’s seat side.
Special Tool
(A): 09931-76011 (SUZUKI scan tool)
(B): Mass storage cartridge
(C): 09931-76030 (16/14-pin DLC adapter)
4) Turn ignition switch ON.
5) Read DTC according to instructions displayed on SUZUKI scan
tool and print it or write it down. Refer to SUZUKI scan tool oper-
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).
ENGINE AND EMISSION CONTROL SYSTEM 6E1-11
[Not using SUZUKI scan tool]
1) Check malfunction indicator lamp (1) referring to MALFUNC-
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:
D 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.
D 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.
6E1-12 ENGINE AND EMISSION CONTROL SYSTEM
EXAMPLE: When throttle position sensor is defective (Code No. 13)
DIAGNOSTIC TROUBLE CODE (DTC)
CLEARANCE
[Using SUZUKI scan tool]
1) Turn ignition switch OFF.
2) Connect SUZUKI scan tool to data link connector (DLC) in the
same manner as when making this connection for DTC check.
3) Turn ignition switch ON.
4) Erase DTC according to instructions displayed on SUZUKI
scan tool.
Refer to SUZUKI scan tool operator’s manual for further details.
5) After completing the clearance, turn ignition switch OFF and
disconnect SUZUKI scan tool from data link connector (DLC).
[Not using SUZUKI scan tool]
1) Turn OFF ignition switch.
2) Disconnect battery negative cable for specified time below to
erase diagnostic trouble code stored in ECM memory and re-
connect it.
Time required to erase DTC:
ENGINE AND EMISSION CONTROL SYSTEM 6E1-13
Ambient temperature Time to cut power to ECM
Over 0_C (32_F) 30 sec. or longer
Under 0_C (32_F)
Not specifiable.
Select a place with higher than
0_C (32_F) temperature.
6E1-14 ENGINE AND EMISSION CONTROL SYSTEM
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DIAGNOSTIC
TROUBLE
CODE NO.
MALFUNCTION INDICATOR
DIAGNOSTIC ITEM
DIAGNOSIS
SUZUKI
SCAN
TOOL
MIL
LAMP FLASHING PATTERN
DIAGNOSTIC
ITEM
DIAGNOSIS
P0105 11
Manifold absolute pressure
sensor
P0120 13 Throttle position sensor
P0130 14 Oxygen sensor
P0340 15 Camshaft position sensor
Diagnose trouble according to DIAG-
NOSTIC FLOW TABLE corresponding to
each code No.
P0500 16 Vehicle speed sensor
P0110 18 Intake air temperature sensor
P0115 19
Engine coolant temperature
sensor
––– 12 Normal
This code appears when none of the oth-
er codes (above codes) are identified.
ENGINE AND EMISSION CONTROL SYSTEM 6E1-15
A-1 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK
(MALFUNCTION INDICATOR LAMP DOES NOT LIGHT AT IGNITION SWITCH ON.)
1. Battery positive voltage
2. Blank
3. Ignition switch
4. Fuse
5. Malfunction indicator lamp
6. Monitor connector
7. ECM
8. Main relay
STEP
ACTION YES NO
1
Test switch terminal circuit check:
1) With the ignition switch ON position, check
voltage between E34-7 terminal of ECM
coupler and ground.
Is voltage 4-5V?
Go to Step 2. “P/W” wire (test switch terminal)
shorted to ground circuit.
If OK, substitute a known good
ECM and recheck.
2
MIL bulb and circuit check:
1) Using service wire, ground E32-317 termi-
nal of ECM coupler.
Does MIL turn ON at ignition ON position?
Go to TABLE A-4. MIL bulb burned out.
“IG-COIL METER” fuse(s)
blown.
Ignition switch malfunction.
“V/Y” wire open.
“B/W” wire open.
Fig. for STEP 1
1. ECM coupler disconnected
2. Body ground
3. Service wire
Fig. for STEP 2
1. “IG-COIL METER” fuse
6E1-16 ENGINE AND EMISSION CONTROL SYSTEM
A-2 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK
(MALFUNCTION INDICATOR LAMP FLASHES AT IGNITION SWITCH ON.)
1. Battery positive voltage
2. Blank
3. Ignition switch
4. Fuse
5. Malfunction indicator lamp
6. Monitor connector
7. ECM
8. Main relay
STEP
ACTION YES NO
1
MIL Flashing Pattern Check
1) Turn ignition switch ON.
Does lamp flashing pattern indicate diagnostic trouble
code?
Go to Step 2. Substitute a known-good
ECM and recheck.
2
Diag. Switch Circuit Check
Is diag. switch terminal connected to ground via ser-
vice wire?
System is in good
condition.
“V/G” circuit shorted to
ground. If circuit is OK,
substitute a known-good
ECM and recheck.
ENGINE AND EMISSION CONTROL SYSTEM 6E1-17
A-3 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK
(MALFUNCTION INDICATOR LAMP DOES NOT FLASH OR JUST REMAINS ON EVEN WITH GROUND-
ING DIAGNOSIS SWITCH TERMINAL.)
1. Battery positive voltage
2. Blank
3. Ignition switch
4. Fuse
5. Malfunction indicator lamp
6. Monitor connector
7. ECM
8. Main relay
STEP
ACTION YES NO
1
MIL Circuit Check
1) Turn ignition switch OFF and disconnect connec-
tors from ECM.
Does MIL turn ON at ignition switch ON?
“V/Y” circuit shorted
to ground.
Go to Step 2.
2
ECM Connection Check
1) Turn ignition switch OFF.
Is connector (E34-8 connection) connected to ECM
properly?
Go to Step 3. Poor connector connection.
3
Diag. Switch Terminal Circuit Check
1) Connect connectors to ECM.
2) Using service wire, ground E34-8 terminal with
connectors connected to ECM.
3) Turn ignition switch ON.
Does MIL flash?
“V/G” or “Bl/B” cir-
cuit open.
Substitute a known-good
ECM and recheck.
Fig. for STEP 3
1. ECM coupler connected
2. Body ground
3. Service wire
6E1-18 ENGINE AND EMISSION CONTROL SYSTEM
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.)
1. Battery positive voltage
2. Blank
3. Ignition switch
4. Fuse
5. Malfunction indicator lamp
6. Monitor connector
7. ECM
8. Main relay
STEP
ACTION YES NO
1
Main Relay Operating Sound Check
Is operating sound of main relay heard at ignition switch ON?
Go to Step 5. Go to Step 2.
2
Fuse Check
Is main “FI” fuse in good condition?
Go to Step 3. Check for short in
circuits connected
to this fuse.
3
Main Relay Check
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?
Go to Step 4. Replace main relay.
4
ECM Power Circuit Check
1) Turn OFF ignition switch, disconnect connectors from ECM
and install main relay.
2) Check for proper connection to ECM at terminals 302, 315
and 319 of E32.
3) If OK, then measure voltage between terminal E32-319 and
ground with ignition switch ON.
Is each voltage 10 – 14 V?
Go to Step 5. “V/R” or “B/Y” cir-
cuit open.
ENGINE AND EMISSION CONTROL SYSTEM 6E1-19
A-4 ECM POWER AND GROUND CIRCUIT CHECK (Page 2 of 2)
STEP
ACTION YES NO
5
ECM Power Circuit Check
1) Using service wire, ground terminal E32-319 and
measure voltage between terminal E32-302
(E32-315) and ground at ignition switch ON.
Is it 10 – 14 V?
Check ground circuits
“Bl/B” and “B” for open.
If OK, then substitute a
known-good ECM and re-
check.
Go to Step 6.
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
1) Check main relay according to procedure in Step
3.
Is main relay in good condition?
“B/Y” or “B/R” wire open. Replace main relay.
Fig. for STEP 2
Fig. for STEP 3
1. “FI” fuse
1. ECM coupler
2. Body ground
Fig. for STEP 4
1. Main relay
6E1-20 ENGINE AND EMISSION CONTROL SYSTEM
CODE NO.11 (P0105) MAP SENSOR CIRCUIT
(SIGNAL VOLTAGE LOW, HIGH OR PERFORMANCE PROBLEM)
NOTE:
When Code No.11 (P0105), 13 (P0120), 18 (P0110) and
19 (P0115) are indicated together, it is possible that
“B/G” wire is open or “E34-22” terminal connections
are poor.
1. ECM
2. ECM coupler
3. MAP sensor
4. MAP sensor coupler
5. To TP sensor
6. To other sensors
STEP ACTION YES NO
1
1) Disconnect MAP sensor coupler with igni-
tion switch OFF.
2) Check voltage between “c” wire terminal of
MAP sensor coupler and ground with igni-
tion switch ON.
Is voltage about 4 – 5 V?
Go to Step 2. D “Lbl” wire open or short.
D Poor “E33-201” connection.
If wire and connection are OK,
substitute a known-good ECM
and recheck.
2
1) Check voltage between “a” wire terminal of
MAP sensor coupler and ground with igni-
tion switch ON.
Is voltage about 4 – 5 V?
Go to Step 3. D “Lg/R” wire open or short.
D Poor “E33-205” connection.
If wire and connection are OK,
substitute a known-good ECM
and recheck.
3
1) Connect “a” and “b” wire terminals of MAP
sensor coupler using service wire.
2) Check voltage between “Lg/R” wire termi-
nal of MAP sensor coupler and ground.
Is voltage about 0 V?
Go to Step 4. D “B/G” wire open.
D Poor “E34-22” connection.
If wire and connection are OK,
substitute a known-good ECM
and recheck.
4
1) Remove MAP sensor.
2) Visually inspect air pressure inlet passage
of MAP sensor for clogging.
Is there any blockage?
Clean air passage or
replace as necessary.
Go to Step 5.
5
1) Perform MAP SENSOR INSPECTION in
this section.
Is MAP sensor in good condition?
Poor connection of
MAP sensor coupler
terminals.
If connection is OK,
substitute a known-
good ECM and re-
check.
Faulty MAP sensor.
ENGINE AND EMISSION CONTROL SYSTEM 6E1-21
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
6E1-30 to confirm that the trouble has been corrected.
6E1-22 ENGINE AND EMISSION CONTROL SYSTEM
CODE NO.13 (P0120) TP SENSOR CIRCUIT
(SIGNAL VOLTAGE HIGH OR LOW)
1. ECM
2. ECM coupler
3. TP sensor
4. TP sensor coupler
5. To MAP sensor
6. To other sensors
NOTE:
When Code No.11 (P0105), 13 (P0120), 18 (P0110) and
19 (P0115) are indicated together, it is possible that
“B/G” wire is open or “E34-22” terminal connection are
poor.
STEP
ACTION YES NO
1
1) Disconnect TP sensor coupler with ignition
switch OFF.
2) Check voltage between “a” wire terminal of
TP sensor coupler and ground with ignition
switch ON.
Is voltage about 4 – 5 V?
Go to Step 2. D “Lbl” wire open or short.
D Poor “E33-201” connection.
If wire and connection are OK,
substitute a known-good ECM
and recheck.
2
1) Check voltage between “b” wire terminal of
TP sensor coupler and ground with ignition
switch ON.
Is voltage about 4 – 5 V?
Go to Step 3. D “Gr” wire open or short.
D Poor “E33-206” connection.
If wire and connection are OK,
substitute a known-good ECM
and recheck.
3
1) Connect “b” and “c” wire terminal of TP
sensor coupler using service wire.
2) Check voltage between “b” wire terminal of
TP sensor coupler and ground with ignition
switch ON.
Is voltage about 0 V?
Go to Step 4. D “B/G” wire open.
D Poor “E34-22” connection.
If wire and connection are OK,
substitute a known-good ECM
and recheck.
4
1) Perform TP SENSOR INSPECTION in this
section.
Is TP sensor in good condition?
Poor connection of TP
sensor coupler termi-
nals.
If connection is OK,
substitute a known-
good ECM and re-
check.
Faulty TP sensor.
ENGINE AND EMISSION CONTROL SYSTEM 6E1-23
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
6E1-30 to confirm that the trouble has been corrected.
6E1-24 ENGINE AND EMISSION CONTROL SYSTEM
CODE NO.14 (P0130) OXYGEN SENSOR CIRCUIT
(SIGNAL VOLTAGE DOESN’T CHANGE)
NOTE:
D Before diagnosing trouble according to flow table
given below, check to make sure that following sys-
tem and parts other than Electronic Fuel Injection
system are in good condition.
– Air cleaner (clogged)
– Vacuum leaks (air inhaling)
– Spark plugs (contamination, gap)
– High-tension cords (crack, deterioration)
– Ignition timing
– Engine compression
– Any other system and parts which might affect A / F
mixture or combustion.
D If code No.14 (P0130) and another code No. are indi-
cated together, the latter has priority. Therefore,
check and correct what is represented by that code
No. first and then proceed to the following check.
D Be sure to use a voltmeter with high impedance
(MW /V minimum) or digital type voltmeter for accu-
rate measurement.
1. ECM
2. Oxygen sensor
3. Coupler
STEP
ACTION YES NO
1
1) Warm up engine to normal operat-
ing temperature.
2) Connect voltmeter between
E33-213 terminal of ECM coupler
and body ground.
3) Maintain engine speed at 2000 rpm
and after 60 seconds, check volt-
meter.
Does the voltage deflect between
above and below 0.45 V repeatedly?
Oxygen sensor and its circuit (closed
loop system, A/F ratio feed back sys-
tem) are in good condition.
Intermittent trouble or faulty ECM.
Recheck, referring to INTERMITTENT
AND POOR CONNECTION in SEC-
TION 0A.
Go to Step 2.
2
Does the voltage remain unchanged at
0.45 V above?
“W” circuit shorted to power circuit or
rich A/F mixture.
If circuit is OK, check MAP sensor,
ECT sensor, fuel pressure, injectors
and their circuit. If all above are OK,
check ECM and its circuit.
Go to Step 3.
3
1) Maintain engine speed at 2000 rpm
for 60 seconds.
2) Check voltmeter while repeating
racing engine.
Does it indicate 0.45 V or more even
once?
Poor E33-213 connection or lean A/F
mixture.
If connection is OK, check MAP sen-
sor, ECT sensor, fuel pressure, injec-
tors and their circuit.
If all above are OK, check ECM and its
circuit.
“W” circuit open/short
or oxygen sensor mal-
function.
If wire and connection
are OK, replace oxy-
gen sensor and re-
check.
6E1-26 ENGINE AND EMISSION CONTROL SYSTEM
CODE NO.15 (P0340) CMP SENSOR CIRCUIT
(SENSOR SIGNAL NOT INPUTTED FOR 2 SECONDS AT ENGINE CRANKING)
1. ECM
2. CMP sensor
3. Rotor
4. CMP sensor coupler
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.
2) Measure resistance between “E33-203”
and “E33-211” terminals of ECM coupler.
CMP sensor resistance: 185 – 275 W
at –10 – 50 5C (14 – 122 5F)
3) Measure resistance between “E33-203” ter-
minal of ECM coupler and ground.
Insulation resistance: 1 MW or more
Were measured resistance values in above 2)
and 3) as specified?
Go to Step 2. D “Bl” wire open or short.
D “B/W” wire open or
short.
D Poor terminal connec-
tion of CMP sensor cou-
pler.
If wire and connection are
OK, replace CMP sensor.
2
1) Check CMP sensor referring to Section 6F.
Is it in good condition?
D Poor “E33-203” or
“E33-211” terminal con-
nection of ECM coupler.
If connection is OK,
substitute a known-good
ECM and recheck.
Faulty CMP sensor.
Fig. for STEP 1
1. ECM coupler disconnected
NOTE:
Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page
6E1-30 to confirm that the trouble has been corrected.
ENGINE AND EMISSION CONTROL SYSTEM 6E1-27
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)
1. ECM
2. Speedometer
3. Meter coupler (G01)
STEP
ACTION YES NO
1
Does speedometer indicate vehicle
speed?
D “V” wire open.
D Poor “E33–204” connec-
tion.
If OK, substitute a known-
good ECM and recheck.
Broken speed meter cable.
If if it OK, go to Step 2.
2
1) Disconnect ECM coupler with ignition
switch at OFF position.
2) Connect ohmmeter between E33-204
terminal of ECM coupler and body
ground.
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
R a few times while tire is turned one
revolution?
Poor E33-204 connection. If
connection is OK, intermit-
tent trouble or faulty ECM.
Recheck referring to IN-
TERMITTENT TROUBLE.
Go to Step 3.
3
1) Remove combination meter.
2) Check speed sensor referring to VE-
HICLE SPEED SENSOR (VSS) IN-
SPECTION under ON-VEHICLE SER-
VICE.
Is it good condition?
Faulty speedometer. “V” wire open, “B/Bl” wire
open, poor coupler-to-meter
connection or poor “B/Bl” wire
ground.
If OK, substitute a known-
good ECM and recheck.
NOTE:
Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page
6E1-30 to confirm that the trouble has been corrected.
6E1-28 ENGINE AND EMISSION CONTROL SYSTEM
CODE NO.18 (P0110) IAT SENSOR CIRCUIT
(SIGNAL VOLTAGE HIGH OR LOW)
1. ECM
2. IAT sensor
3. IAT sensor coupler
4. To other sensors
NOTE:
When Code No.11 (P0105), 13 (P0120), 18 (P0110) and
19 (P0115) are indicated together, it is possible that
“B/G” wire is open or “C52-9” terminal connections
are poor.
STEP
ACTION YES NO
1
1) Disconnect IAT sensor coupler with ignition
switch OFF.
2) Check voltage between “Lg/W” wire termi-
nal of IAT sensor coupler and ground with
ignition switch ON.
Is voltage about 4 – 5 V?
Go to Step 2. D “Lg/W” wire open or short.
D Poor “E33-214” connection.
2
1) Connect IAT sensor coupler terminals using
service wire.
2) Check voltage between “Lg/W” wire termi-
nal of IAT sensor coupler and ground with
ignition switch ON.
Is voltage 0.15 V or less?
Go to Step 3. “B/G” wire open or poor
“E34-22” connection.
If wire and connection are OK,
substitute a known-good ECM
and recheck.
3
1) Perform IAT SENSOR INSPECTION in this
section.
Is IAT sensor in good condition?
Poor connection of IAT
sensor coupler termi-
nals.
If connection is OK,
substitute a known-
good ECM and re-
check.
Faulty IAT sensor.
Fig. for STEP 1 Fig. for STEP 2
1. IAT sensor coupler disconnected
2. Engine ground
1. IAT sensor coupler disconnected
2. Service wire
3. Engine ground
NOTE:
Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page
6E1-30 to confirm that the trouble has been corrected.
ENGINE AND EMISSION CONTROL SYSTEM 6E1-29
CODE NO.19 (P0115) ECT SENSOR CIRCUIT
(SIGNAL VOLTAGE HIGH OR LOW)
1. ECM
2. ECT sensor
3. ECT sensor coupler
4. To other sensors
5. To combination meter
NOTE:
When Code No.11 (P0105), 13 (P0120), 18 (P0110)
and 19 (P0115) are indicated together, it is pos-
sible that “B/G” wire is open or “E34-22” terminal
connection is poor.
STEP
ACTION YES NO
1
1) Disconnect ECT sensor coupler with ignition
switch OFF.
2) Check voltage between “Lg/B” wire terminal
of ECT sensor coupler and ground with igni-
tion switch ON.
Is voltage about 4 – 5 V?
Go to Step 2. D “Lg/W” wire open or short.
D Poor “C52-8” connection.
2
1) Connect ECT sensor couple terminals using
service wire.
2) Check voltage between “Lg/B” wire terminal
of ECT sensor coupler and ground with igni-
tion switch ON.
Is voltage 0.15 V or less?
Go to Step 3. “B/G” wire open or poor
“C51-22” connection.
If wire and connection are OK,
substitute a known-good ECM
and recheck.
3
1) Perform ECT SENSOR INSPECTION in this
section.
Is ECT sensor in good condition?
Poor connection of
ECT sensor coupler
terminals.
If connection is OK,
substitute a known-
good ECM and re-
check.
Faulty ECT sensor.
Fig. for STEP 1 Fig. for STEP 2
1. ECT sensor coupler disconnected
2. Engine ground
1. ECT sensor coupler disconnected
2. Service wire
3. Engine ground
NOTE:
Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page
6E1-30 to confirm that the trouble has been corrected.
6E1-30 ENGINE AND EMISSION CONTROL SYSTEM
DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE
WARNING:
D 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.
D 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 (P0120), 18 (P0110), 19 (P0115)
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 (P0130)
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.
6) Stop vehicle.
NOTE:
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 (P0105)
1) Start engine.
2) Maintain engine speed at 2000RPM for 5 seconds.
ENGINE AND EMISSION CONTROL SYSTEM 6E1-31
B-1 FUEL PUMP AND ITS CIRCUIT CHECK
1. ECM
2. Fuel pump relay
3. Fuel pump
4. Main relay
5. Ignition switch
STEP
ACTION YES NO
1 Is fuel pump heard to operate 2 se-
conds after ignition switch ON?
Fuel pump and its circuit are in good
condition.
Go to Step 2.
2 1) Remove fuel pump relay from relay
box with ignition switch OFF.
2) Connect two terminals (a and b) of
relay connector as shown in figure
using service wire.
Is fuel pump heard to operate with
ignition switch ON?
Go to Step 3. “B/R” or “P” wire open,
poor fuel pump relay-
to-coupler connection
or faulty fuel pump.
3 1) Check fuel pump relay, referring to
p.6E1-68.
Is it in good condition?
Poor fuel pump relay-to-coupler con-
nection, “Br/B”, “B/W” wire open or
poor E32-318 connection.
If wire and connection are OK, substi-
tute a known-good ECM and recheck.
Faulty fuel pump relay.
Fig. for STEP 2
1. Fuel pump relay coupler
2. Service wire
6E1-32 ENGINE AND EMISSION CONTROL SYSTEM
B-2 FUEL INJECTOR AND ITS CIRCUIT CHECK
1. Battery positive voltage
2. Blank
3. “FI” fuse in fuse/relay box
4. Main relay
5. ECM
6. No.1 injector
7. No.2 injector
8. No.3 injector
STEP
ACTION YES NO
1
Check each injector for operating sound at engine
cranking using sound scope.
Do all 3 injector make operating sound?
Fuel injector circuit is in
good condition.
Go to Step 2.
2
Does none of 3 injectors make operating sound at
Step 1?
Go to Step 4. Go to Step 3.
3
Check fuel injector(s) referring to p. 6E1-58.
Is it in good condition?
Check coupler connection
and wire harness
of injector not making
operating sound.
Faulty fuel injector(s).
4
Check power circuit of injectors for open and short.
Is it in normal condition?
Check all 3 injectors for
resistance respectively.
If resistance is OK,
substitute a known-good
ECM and recheck.
Power circuit open or
short.
ENGINE AND EMISSION CONTROL SYSTEM 6E1-33
Blank
6E1-34 ENGINE AND EMISSION CONTROL SYSTEM
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.
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/cm
2
, 38.4 – 44.0 psi)?
Go to Step 2. Go to Step 5.
2
Is 200 kPa (2.0 kg/cm
2
, 28.4 psi) or higher fuel pres-
sure retained for 1 minute after fuel pump is stopped at
step 1?
Go to Step 3. Go to Step 4.
3
1) Start engine and warm it up to normal operating
temperature.
2) Keep it running at specified idle speed.
Is fuel pressure then within 200 – 240 kPa
(2.0 – 2.4 kg/cm
2
, 28.4 – 34.1 psi)?
Normal fuel pressure. Clogged vacuum
passage for fuel
pressure regulator or
faulty fuel pressure
regulator.
4
Is there fuel leakage from fuel feed line hose, pipe or
their joint?
Fuel leakage from
hose, pipe or joint.
Go to Step 10.
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
regulator and connect new return hose to it.
2) Put the other end of new return hose into approved
gasoline container.
3) Operate fuel pump.
Is specified fuel pressure obtained then?
Restricted fuel return
hose or pipe.
Faulty fuel pressure
regulator.
ENGINE AND EMISSION CONTROL SYSTEM 6E1-35
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
by pinching it, is fuel pressure applied?
Faulty fuel pressure
regulator.
Shortage of fuel or fuel
pump or its circuit
malfunction.
9
1) Operate fuel pump.
2) With fuel return hose blocked by pinching it, check
fuel pressure.
Is it 450 kPa (4.5 kg/cm
2
, 63.9 psi) or more?
Faulty fuel pressure
regulator.
Clogged fuel filter,
restricted fuel feed
hose or pipe, Faulty
fuel pump or fuel
leakage from hose
connection in fuel
tank.
10
1) Disconnect fuel return hose from pressure
regulator and connect new return hose to it.
2) Insert the other end of new return hose into
approved gasoline container.
3) Check again if specified pressure is obtained.
While doing so, does fuel come out of return hose?
Faulty fuel pressure
regulator.
Fuel leakage from
injector, Fuel leakage
from between injector
and delivery pipe,
Faulty fuel pump
(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
6E1-36 ENGINE AND EMISSION CONTROL SYSTEM
B-4 IDLE AIR CONTROL SYSTEM CHECK (Page 1 of 2)
1. Battery positive voltage
2. Blank
3. “FI” fuse in fuse/relay box
4. Main relay
5. ECM
6. IAC valve
7. Throttle body
8. Engine coolant
9. Bypass air
10. TP sensor
STEP
ACTION YES NO
1
IAC valve function check:
1) Check IAC valve referring to IAC VALVE INSPEC-
TION in this section.
Is check result in good condition?
Go to Step 2. Go to Step 5.
2
Closed throttle position check:
1) Connect SUZUKI scan tool to DLC.
2) With the ignition switch ON position, check
“CLOSED THROT POS” in parameter data list.
Throttle valve fully close : ON
Throttle valve slight open : OFF
Is each check result as specified?
Check for following:
EVAP canister purge valve
Accessory engine load PCV
system
Idle air passage
A/C signal
Go to Step 3.
3
Closed throttle position recheck:
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.
Is each check result as specified?
Recheck engine idle speed. Go to Step 4.
4
TP sensor signal voltage check:
1) With the ignition switch ON position, check volt-
age between E33-206 and ground.
Throttle valve fully close: 0.78 – 0.83V
Is each check result as specified?
Substitute a known good
ECM and recheck.
Check TP sensor
referring TP SEN-
SOR INSPEC-
TION in this sec-
tion.
5
IAC valve circuit check:
1) Check “O”, “B/R” and “B” wire for open and short.
Are they in good condition?
Go to Step 6. Repair or replace.
6
IAC valve substitution:
1) Substitute a known good IAC valve.
2) Check IAC valve referring to IAC VALVE INSPEC-
TION in this section.
Is check result in good condition?
IAC valve malfunction. Substitute a
known good ECM
and recheck.
ENGINE AND EMISSION CONTROL SYSTEM 6E1-37
B-5 EVAPORATIVE EMISSION CONTROL SYSTEM CHECK
1. To throttle body
2. To fuel tank
3. EVAP canister
4. Air
5. Air and vapor
6. EVAP canister purge valve
7. Main relay
8. Sensed information
9. ECM
10. Fuel tank
STEP
ACTION YES NO
1
Check canister purge system for opera-
tion referring to p.6E1-73.
Is it in good condition?
Check EVAP canister referring to
p.6E1-76 and fuel filler cap referring
to Section 6C.
If OK, system is in good condition.
Go to Step 2.
2
Check vacuum passage, hoses and
EVAP canister purge valve referring to
p.6E1-74.
Are they in good condition?
D “O/Y” wire open,
D “O/Y” wire shorted to ground,
D Poor EVAP canister purge valve
coupler connection,
D Poor “E32-307” connection,
D 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.
D Vacuum passage
clogged,
D Vacuum leakage or
D Faulty EVAP canister
purge valve
6E1-38 ENGINE AND EMISSION CONTROL SYSTEM
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.
2) Is 6 – 12 V voltage applied to E34-13 terminal of coupler
only when cranking engine.
Engine starter
signal circuit is
in good condition.
D “B/Y” wire open or
D Poor “E34-13”
connection
Fig. for STEP 1
1. ECM coupler disconnected
2. Body ground
ENGINE AND EMISSION CONTROL SYSTEM 6E1-39
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
p. 6E1-71.
Is it in good condition?
RFC system is in good
condition.
Go to Step 2.
2
Check RFC relay referring to p. 6E1-71.
Is it in good condition?
Go to Step 3. Faulty RFC relay.
3
Check wire harnesses and connections for open
or short.
Are they in good condition?
Poor performance of ECT
sensor. If ECT sensor is OK,
substitute a known-good
ECM and recheck.
D Wire open or short
D Poor connection or
D Faulty radiator fan
motor
6E1-40 ENGINE AND EMISSION CONTROL SYSTEM
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
8. Dual pressure switch
9. A/C evaporator thermistor
10. A/C compressor
11. ECM
12. A/C compressor control relay
STEP
ACTION YES NO
1
1) Check voltage at “E34-19” terminal under each
condition given in table below.
2) Is check result satisfactory?
Ignition switch ON
A/C switch OFF
Blower fan switch OFF
Ignition switch ON
A/C switch ON
Blower fan switch ON
10 – 14 V
2 V or less
A/C control signal is
in good condition.
D “G/B” wire open or short
D Poor “E34-19” terminal
connection
If wire and connection are
OK, check dual pressure
switch and A/C switch re-
ferring to Section 1B.
Fig. for STEP 1
1. ECM coupler connected
2. Body ground
ENGINE AND EMISSION CONTROL SYSTEM 6E1-41
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 E34-18 terminal under each condition given
below.
Small light turned OFF : 0 V
Small light turned ON : 10 – 14 V
Is check result satisfactory?
Go to Step 2. D “Br/R” wire open or
short
D Poor “E34-18” ter-
minal connection
2
Check voltage at E34-9 terminal under each condition given
below.
Ignition switch ON and
heater blower fan turned OFF : 10 – 14 V
Ignition switch ON and
heater blower fan turned ON : 2 V or less
Is check result satisfactory?
Electric load
signal circuit
are in good
condition.
D “P/B” wire open or
short
D Poor “E34-9” termi-
nal connection
Fig. for STEP 1 and 2
1. ECM coupler connected
2. Body ground
6E1-42 ENGINE AND EMISSION CONTROL SYSTEM
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-
TION INSPECTION in this section.
Does fuel injector operate as specified?
Fuel cut operation is
in good condition.
Go to step 2.
2
Closed throttle position check:
1) Connect Tech-1 to DLC.
2) With the ignition switch ON position, check “CLOSED
THROT POS” in parameter data list.
Throttle valve fully close : ON
Throttle valve slight open : OFF
Is each check result as specified?
Substitute a known
good ECM and re-
check.
Go to step 3.
3
Closed throttle position recheck:
1) With the ignition switch OFF position disconnect neg-
ative battery cable for 30 seconds and connect it.
2) Recheck closed throttle position referring to Step 2.
Is each check result as specified?
Recheck fuel cut op-
eration.
Go to step 4.
4
TP sensor signal voltage check:
1) With the ignition switch at ON position, check voltage
between E33-206 and ground.
Throttle valve fully close: 0.78 – 0.83V
Throttle valve fully open: 3.7 – 4.7V
Is each check result as specified?
Substitute a known
good ECM and re-
check fuel cut opera-
tion.
Check TP sensor re-
ferring to TP SEN-
SOR INSPECTION in
this section.
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.
1. ECM
2. Couplers
3. Body ground
TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE)
ENGINE AND EMISSION CONTROL SYSTEM 6E1-43
6E1-44 ENGINE AND EMISSION CONTROL SYSTEM
TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION
E34-1 Blank — —
E34-2 IAC valve — —
E34-3 Blank — —
E34-4 Blank — —
E34-5 Blank — —
E34-6 Blank 10 – 14 V Ignition switch ON, selector lever: “L” range
Test switch terminal
4.5 – 5.5 V Ignition switch ON
-
Test
switch
terminal
1 V or less Ignition switch ON, Test switch terminal grounded
Diagnosis switch terminal
4.5 – 5.5 V Ignition switch ON
-
Diagnosis
switch
terminal
1 V or less Ignition switch ON, Test switch terminal grounded
Electric load signal for blow-
2 V or less
Ignition switch ON, Blower fan switch : High or Middle
position
-
g
er fan motor
4.0 – 14.0 V
Ignition switch ON, Blower fan switch : OFF or Low posi-
tion
Stop lamp switch
1.5V or less Brake pedal released (switch OFF), Ignition switch ON
-
(brake pedal switch)
10 – 14 V Brake pedal depressed (switch ON), Ignition switch ON
E34-11 Blank — —
E34-12 Data link connector 10 – 14 V Ignition switch ON
Engine starter switch
1.5V or less Ignition switch ON
-
g
(engine starter signal)
6 – 12 V While engine cranking
E34-14 Blank 10 – 14 V Ignition switch ON, selector lever: “L” range
E34-15 Blank — —
E34-16 Blank — —
E34-17 Duty output terminal 1 V or less Ignition switch ON
Electric load signal for small
1 V or less Ignition switch ON and Small light turned OFF
-
g
light switch
10 – 14 V Ignition switch ON and Small light turned ON
A/C ON signal from A/C
10 – 14 V
Ignition switch ON, A/C switch OFF, Blower fan switch
OFF
-
g
switch (if equipped)
2 V or less
Ignition switch ON, A/C switch ON, Blower fan switch
ON
E34-20 Blank — —
E34-21 Blank — —
E34-22 Sensor ground — —
TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION
E33-201 Power supply for sensor 4.5 – 5.5 V Ignition switch ON
E33-202 Blank — —
E33-203 CMP sensor (+) 1 V or less Ignition switch ON
E33-204 VSS
Indicator deflection
repeated between
0 – 1 V and 4 – 14 V
Ignition switch ON, Front left tire turned quickly with front
right tire locked
MAP sensor
About 3.6 V Ignition switch ON, engine stop
-
MAP
sensor
About 1 – 3 V Engine running at idle speed, A/C OFF
TP sensor
0.78 – 0.83 V Throttle valve at idle position
-
TP
sensor
3.7 – 4.7 V Throttle valve at full open position
E33-207
A/C evaporator temp. sen-
sor (with A/C)
2.0 – 2.5 V A/C ventilator outlet temp.: at 205C
ECT sensor
2.5 – 3.0 V Engine coolant temp.: at 205C
-
ECT
sensor
0.6 – 0.9 V Engine coolant temp.: at 805C
E33-209 Blank — —
E33-210 Blank — —
ENGINE AND EMISSION CONTROL SYSTEM 6E1-45
TERMINAL CONDITIONNORMAL VOLTAGECIRCUIT
E33-211 CMP sensor (–) About 0 V —
E33-212 Blank — —
E33-213 Oxygen sensor
Deflect between 0
and 1 V
Engine running, after engine warmed up
IAT sensor
2.0 – 2.5 V IAT sensor ambient temp.: at 205C
-
IAT
sensor
0.4 – 0.6 V IAT sensor ambient temp.: at 805C
E33-215 Blank — —
A/C compressor magnet
1 V or less Engine running, A/C compressor: ON
-
g
clutch (with A/C) relay
10 – 14 V Engine running, A/C compressor: OFF
TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION
E32-301 Ground — —
E32-302 Power source 10 – 14 V Ignition switch ON
E32-303 Blank — —
E32-304 Blank — —
E32-305 Blank — —
E32-306 Blank — —
E32-307 EVAP canister purge valve 10 – 14 V Ignition switch ON
E32-308 Blank — —
E32-309 Blank — —
E32-310 Ignition coil assembly 1 V or less Ignition switch ON
E32-311 Fuel injector No.3 10 – 14 V Ignition switch ON
E32-312 Fuel injector No.1 10 – 14 V Ignition switch ON
E32-313 Ground — —
E32-314 Power source for backup 10 – 14 V —
E32-315 Power source 10 – 14 V Ignition switch ON
E32-316 Blank — —
Malfunction indicator light
About 0.5 V or less Ignition switch ON, engine stops
-
Malfunction
indicator
light
10 – 14 V Engine running
Fuel
p
um
p
relay
1 V or less
For 3 seconds after ignition switch ON or while engine
running
-
Fuel
um
relay
10 – 14 V
After 3 seconds from ignition switch ON with engine
stopped
E32-319 Main relay 1 V or less Ignition switch ON
Radiator fan control relay
10 – 14 V Ignition switch ON
-
Radiator
fan
control
relay
1 V or less Engine cooling fan ON
E32-321 Blank — —
E32-322 Blank — —
E32-323 Blank — —
E32-324 Blank — —
E32-325 Fuel injector No.2 10 – 14 V Ignition switch ON
E32-326 Ground — —
RESISTANCE CHECK
1) Disconnect ECM couplers from ECM with ignition switch OFF.
2) Check resistance between each pair of terminals of discon-
nected couplers as listed in following table.
1. ECM coupler disconnected
2. Ohmmeter
CAUTION:
Never touch terminals of ECM itself or connect volt-
meter or ohmmeter.
CAUTION:
D Be sure to connect ohmmeter probe from wire har-
ness side of coupler.
D Be sure to turn OFF ignition switch for this check.
D Resistance in table below represents that when
parts temperature is 20_C (68_F).
6E1-46 ENGINE AND EMISSION CONTROL SYSTEM
TERMINAL CIRCUIT
NORMAL
RESISTANCE
CONDITION
E32-312 – E32-302 Fuel Injector No.1 11.3 – 13.8 W
E32-325 – E32-302 Fuel injector No.2 11.3 – 13.8 W
E32-311 – E32-302 Fuel Injector No.3 11.3 – 13.8 W
E32-307 – E32-302
EVAP canister
p
urge valve
37 – 44 W F8D engine
E32
-
307
–
E32
-
302
EVAP
canister
urge
valve
28 – 36 W F8B engine
E32-320 E32-302
Radiator fan control relay
90 – 110 W omron made
E32
-
320
–
E32
-
302
Radiator
fan
control
relay
60 – 88 W interface made
E33-302 – E32-311 CMP sensor 185 – 275 W –10 – 50 _C (14 – 122 _F)
E32-318 – E32-314 Fuel pump relay 80 – 100 W Battery disconnected and ignition switch ON
E32-318 – E32-314 Main relay 80 – 100 W Battery disconnected and ignition switch ON
E32-301/313/326 –
Body ground
Ground Continuity
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-47
ON-VEHICLE SERVICE
1. MAP sensor
2. EVAP canister
3. EVAP canister purge valve (if equipped)
4. PCV valve
GENERAL
When hoses are disconnected and system components are re-
moved for service, reinstall components properly, and route and
connect hoses correctly after service. Refer to figure on previous
page for proper routing of hoses.
ACCELERATOR CABLE ADJUSTMENT
1) With throttle valve closed, check accelerator pedal play which
should be within the following specification.
Pedal play “a” : 2 – 7 mm (0.08 – 0.27 in.)
If measured value is out of specification, adjust it to specification
with cable adjusting nut.
1. Accelerator cable
2. Adjusting nut
3 Lock nut
2) With accelerator pedal depressed fully, check clearance be-
tween throttle lever (2) and lever stopper (1) (throttle body)
which should be within following specification.
Clearance “b” : 0.5 – 2.0 mm (0.02 – 0.07 in.)
(With pedal depressed fully)
6E1-48 ENGIINE AND EMISSION CONTROL SYSTEM
IDLE SPEED/IAC DUTY INSPECTION
Before idle speed/IAC duty check, make sure of the following.
D Lead wires and hoses of Electronic Fuel Injection system is con-
nected securely.
D Accelerator cable has some play, that is, it is not tight.
D Valve lash is checked and adjusted according to maintenance
schedule.
D Ignition timing is within specification.
D All accessories (wipers, heater, lights, A/C, etc.) are out of service.
D Air cleaner has been properly installed and is in good condition.
D No abnormal air inhaling from air intake system.
D 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.
[Using SUZUKI scan tool]
1) Connect SUZUKI scan tool to DLC (1) with ignition switch OFF.
Special Tool
(A): 09931-76011 (SUZUKI scan tool)
(B): Mass storage cartridge
(C): 09931-76030 (16/14 pin DLC cable)
2) Start engine and warm it up to normal operating temperature.
3) Check idle speed and IAC duty by using “DATA LIST” mode of
SUZUKI scan tool.
NOTE:
D Check to ensure that radiator fan is not running and then
measure IAC-duty.
D Duty values with (*) are applicable to vehicle used at high
place (higher than 2000 in or 6560 ft.)
When using SUZUKI scan tool:
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-49
ENGINE IDLE SPEED AND IAC DUTY
A/C OFF A/C ON
900 " 50 r/min.
3 – 30 or *40%
1000 " 50 r/min.
[Not using SUZUKI scan tool]
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.
4) Start engine and warm it up to normal operating temperature.
5) Confirm that all accessories (light, A/C, blower fan, etc.) are out
of service.
6) Check idle speed and IAC duty.
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
control system referring to “B-4 Idle Air Control System Check”
in this section.
1. Monitor connector
2. Service wire
3. Duty meter
A: Blank
B: Diagnosis switch terminal
C: Blank
D: Ground terminal
E: Test switch terminal
F: Duty output terminal
NOTE:
D Duty values with (*) are applicable to vehicle used at high
place (higher than 2000 m or 6560 ft.)
D Above duty values are on duty meter indications (high
voltage rate).
D IAC duty can be checked roughly by using voltmeter. IAC
duty to voltage relation is as follows.
– “OFF DUTY METER” is such duty meter that indicates
approx. 100% when terminal voltage is approx. “0V”.
–“V
B” represents battery voltage while engine of vehicle
being checked is running.
6E1-50 ENGIINE AND EMISSION CONTROL SYSTEM
ENGINE IDLE SPEED AND IAC DUTY
A/C OFF A/C ON
900 " 50 r/min.
3 – 30 or *40%
1000 " 50 r/min.
ON DUTY
METER INDICATION
(%)
OFF DUTY
METER INDICATION
(%)
VOLTMETER
INDICATION
(V)
0
50
100
100
50
0
0
0.5 y V
B
VB
ON-VEHICLE INSPECTION
Check that throttle valve lever moves smoothly.
REMOVAL
1) Disconnect negative cable at battery.
2) Drain cooling system referring to Section 6B.
3) Disconnect accelerator cable from throttle body.
4) Remove air cleaner outlet hose (1).
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-51
AIR INTAKE SYSTEM
THROTTLE BODY
1. Throttle body
2. Throttle stop screw
3. TP sensor
4. O-ring
5. IAC valve
6. MAP sensor
CAUTION:
Do not remove or adjust
throttle stop screw as it is
factory adjusted precisely
CAUTION:
Do not disassemble IAC
valve. Disassembly spoils
its original performance
: Tightening torque
: Do not reuse
5) Disconnect couplers from TP sensor, MAP sensor and IAC
valve.
6) Remove throttle body from intake manifold.
7) Disconnect engine coolant hoses and EVAP canister purge
valve hose from throttle body.
1. Engine coolant hose
2. TP sensor
3. IAC valve
4. MAP sensor
5. EVAP canister purge valve hose
6. 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:
D 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.
D Do not blow compressed air through bypass air pas-
sage with IAC valve installed to throttle body. This will
cause IAC valve to malfunction.
1. Throttle body bore
2. Idle bypass passage
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.
6E1-52 ENGIINE AND EMISSION CONTROL SYSTEM
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 engine coolant hoses and EVAP canister purge valve
hose.
4) Connect couplers to TP sensor, MAP sensor and IAC valve se-
curely.
1. Engine coolant hose
2. TP sensor
3. IAC valve
4. MAP sensor
5. EVAP canister purge valve hose
6. 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.
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-53
IAC VALVE
REMOVAL
1) Remove throttle body from intake manifold referring to “Throttle
Body Removal” section.
2) Remove IAC valve from throttle body.
INSPECTION
1) Remove IAC valve (1) from throttle body.
2) Connect each connector to IAC valve, MAP sensor, TP sensor
and IAT sensor.
3) Check that rotary valve (2) of lAC valve opens and closes once
and then stops in about 60 ms as soon as ignition switch is
turned ON.
NOTE:
D This check should be performed by two people, one per-
son turns on ignition switch while the other checks valve
operation.
D As valve operation is momentary, it may be overlooked.
To prevent this, perform this operation check 3 times or
more continuously.
If rotary valve of lAC valve does not operate at all, check
wire harnesses for open and short. If wire harnesses are
in good condition, replace lAC valve and recheck.
INSTALLATION
1) Install new O-ring (2) to IAC valve (1).
2) Install IAC valve to throttle body (3).
Tighten IAC valve screws to specified torque.
Tightening Torque
(a): 3.5 N·m (0.35 kg-m, 2.5 lb-ft)
3) Install throttle body to intake manifold referring to THROTTLE
BODY INSTALLATION section.
6E1-54 ENGIINE AND EMISSION CONTROL SYSTEM
FUEL DELIVERY SYSTEM
FUEL PRESSURE INSPECTION
1) Relieve fuel pressure in fuel feed line referring to FUEL PRES-
SURE RELIEF PROCEDURE in SECTION 6.
2) Disconnect fuel feed hose from fuel delivery pipe.
3) Connect special tools and hose between fuel delivery pipe and
fuel feed hose (1) as shown in figure, and clamp hoses securely
to ensure no leaks occur during checking.
Special Tool
(A): 09912-58441
(B): 09912-58431
(C): 09912-58490
4) Check that battery voltage is above 11V.
WARNING:
Be sure to perform work in a well-ventilated area and
away from any open flames, or there is a risk of a fire
breaking out.
CAUTION:
A small amount of fuel may be released when fuel
hose is disconnected. Place container under the joint
with a shop cloth so that released fuel is caught in
container or absorbed in cloth. Place that cloth in an
approved container.
5) Turn ignition switch ON to operate fuel pump and after 2 se-
conds turn it OFF. Repeat this 3 or 4 times and then check fuel
pressure.
6) Start engine and warm it up to normal operating temperature.
7) Measure fuel pressure at idling.
If measured pressure doesn’t satisfy specification, refer to B-3
FUEL PRESSURE CHECK in this section and check each
possibly defective part. Replace if found defective.
At specified
idle speed
200 – 240 kPa
2.0 – 2.4 kg/cm
2
28.4 – 34.1 psi
With 1 min. after
engine (fuel pump) stop
(Pressure reduces as
time passes)
over 200 kPa
2.0 kg/cm
2
28.4 psi
CONDITION FUEL PRESSURE
With fuel pump
operating and
engine stopped
270 – 310 kPa
2.7 – 3.1 kg/cm
2
38.4 – 44.0 psi
8) After checking fuel pressure, remove fuel pressure gauge.
CAUTION:
As fuel feed line is still under high fuel pressure, make
sure to release fuel pressure according to following
procedures.
D Place fuel container under joint.
D Cover joint with rag and loosen joint nut slowly to
release fuel pressure gradually.
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-55
9) Remove special tools from fuel delivery pipe.
10) Connect fuel feed hose to fuel delivery pipe and clamp it se-
curely.
11) With engine “OFF” and ignition switch “ON”, check for fuel
leaks.
FUEL PUMP
ON-VEHICLE INSPECTION
CAUTION:
When fuel filler cap is removed in any procedure, work
must be done in a well-ventilated area, keep away from
any open flames and without smoking.
1) Remove filler cap and turn ON ignition switch. Then fuel pump
operating sound should be heard from fuel filler for about 2 se-
conds and stop. Be sure to reinstall fuel filler cap after checking.
If above check result is not satisfactory, advance to DIAGNOS-
TIC FLOW TABLE B-1.
1. Fuel filler
2. Ignition switch
2) Fuel pressure should be felt at fuel return hose for 2 seconds
after ignition switch ON.
If fuel pressure is not felt, advance to DIAGNOSTIC FLOW
TABLE B-3.
REMOVAL
1) Remove fuel tank from body according to procedure described
in Section 6C and remove fuel pump from fuel tank.
INSPECTION
Check fuel pump filter for evidence of dirt and contamination. If
present, clean and check for presence of dirt in fuel tank.
INSTALLATION
Install fuel pump to fuel tank and then install fuel tank to body ac-
cording procedure described in Section 6C.
6E1-56 ENGIINE AND EMISSION CONTROL SYSTEM
FUEL PRESSURE REGULATOR
ON-VEHICLE INSPECTION
Perform fuel pressure inspection according to procedure de-
scribed in FUEL PRESSURE INSPECTION in this section.
REMOVAL
1) Relieve fuel pressure according to procedure described in Sec-
tion 6.
2) Disconnect battery negative cable at battery.
3) Remove air cleaner outlet hose referring to Section 6A.
4) Remove air cleaner case by removing its fastening bolts.
5) Disconnect vacuum hose (1) from fuel pressure regulator (2).
6) Disconnect fuel return hose (3) from fuel pressure regulator.
7) Remove fuel pressure regulator from fuel delivery pipe (4).
CAUTION:
A small amount of fuel may be released when hose is
disconnected. Cover hose to be disconnected with a
shop cloth.
CAUTION:
A small amount of fuel may be released when it is
from delivery pipe.
Place a shop cloth under delivery pipe so that re-
leased fuel is absorbed in it.
INSTALLATION
For installation, reverse removal procedure and note following pre-
cautions.
D Use new O-ring.
D Apply thin coat of spindle oil or gasoline to O-ring to facilitate
installation.
D With engine “OFF” and ignition switch “ON”, check for fuel leaks
around fuel line connection.
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-57
FUEL INJECTOR
ON-VEHICLE INSPECTION
1) Using sound scope or such, check operating sound of injector
when engine is running or cranking.
Cycle of operating sound should vary according to engine
speed.
If no sound or an unusual sound is heard, preform B-2 FUEL IN-
JECTOR AND ITS CIRCUIT CHECK in this section.
1. Sound scope
2. Injector
2) Disconnect coupler from injector, connect ohmmeter between
terminals of injector and check resistance.
Resistance of injector : 10 – 15 W
If resistance is out of specification, replace.
3) Connect coupler to injector securely.
REMOVAL
1) Relieve fuel pressure according to procedure described in Sec-
tion 6.
2) Disconnect battery negative cable at battery.
3) Remove air cleaner outlet hose referring to Section 6A.
4) Remove intake manifold stiffener.
5) Disconnect fuel injector couplers.
6) Remove fuel delivery pipe bolts.
7) Remove fuel injector(s).
CAUTION:
A small amount of fuel may come out after removal of
fuel injectors, cover them with shop cloth.
1. Fuel delivery pipe
2. Fuel injector
3. Grommet
4. O-ring
5. Cushion
INSPECTION
WARNING:
As fuel is injected in this inspection, perform in a well
ventilated area and away from open flames.
Use special care to prevent sparking when connecting
and disconnecting test lead to and from battery.
6E1-58 ENGIINE AND EMISSION CONTROL SYSTEM
1) Install injector (1) and fuel pressure regulator (2) to special tool
(injector checking tool).
Special Tool
(A): 09912-58421
2) Connect special tools (hoses and attachment) to pipes of ve-
hicle.
Special Tool
(B): 09912-58431
3) Connect special tool (test lead) to injector.
Special Tool
(C): 09930-88530
4) Install suitable vinyl tube onto injector nozzle to prevent fuel
from splashing out when injecting.
5) Put graduated cylinder under injector as shown.
6) Remove fuel pump relay.
7) To operate fuel pump and apply fuel pressure to injector, con-
nect two terminals of disconnected connecter (1) by using ser-
vice wire (2) as shown in figure.
CAUTION:
Check to make sure that connections made between
correct terminals. Wrong connection can cause dam-
age to ECM, wire harness, etc.
8) Apply battery voltage to injector for 15 seconds and measure in-
jected fuel volume with graduated cylinder.
Test each injector two or three times.
If not within specification, replace injector.
Injected fuel volume:
35 – 37 cc/15 sec. (1.18/1.23 – 1.25/1.30 US/Imp.
oz/15 sec.) ... F8B
38.3 – 40.7 cc/15 sec. (1.29/1.35 – 1.37/1.43 US/Imp.
oz/15 sec.) ... F8D
1. Injector
2. Battery
3. Keep as far apart as possible
4. Fuel pump relay coupler
5. Service wire
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-59
9) Check fuel leakage from injector nozzle. Do not operate injector
for this check (but fuel pump should be at work). If fuel leaks
more than following specification, replace.
Fuel leakage: Less than 1 drop/min.
1. Injector
2. Vinyl tube
3. Less than one fuel
drop/min.
4. Graduated cylinder
INSTALLATION
For installation, reverse removal procedure and note following pre-
cautions.
D Replace injector O-ring with new one using care not to damage
it.
D Check if cushion is scored or damaged. If it is, replace with new
one.
D Apply thin coat of fuel to O-rings and then install injectors into de-
livery pipe and intake manifold.
Make sure that injectors rotate smoothly. If not, probable cause
is incorrect installation of O-ring. Replace O-ring with new one.
D Tighten delivery pipe bolts and make sure that injectors rotate
smoothly.
D With engine “OFF” and ignition switch “ON”, check for fuel leaks
around fuel line connection.
1. Grommet
2. O-ring
3. Cushion
1. O-ring
2. Grommet
6E1-60 ENGIINE AND EMISSION CONTROL SYSTEM
ELECTRONIC CONTROL SYSTEM
ECM
REMOVAL
1) Disconnect battery negative cable at battery.
2) Remove ECM from body.
3) Disconnect couplers from ECM.
CAUTION:
As ECM consists of precision parts, be careful not to ex-
pose it to excessive shock.
INSTALLATION
1) Install ECM to body.
2) Connect couplers to ECM securely.
3) Connect battery negative cable at battery.
MAP SENSOR
OUTPUT VOLTAGE CHECK
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 E33-201.
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-61
4) Check output voltage at coupler terminal E33-205.
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 – 405C, 50 – 1045F)
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 (P0105).
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 (205C,
685F) for a while and recheck.
5) Upon completion of checking, install ECM and connect ECM
couplers securely.
MAP SENSOR INDIVIDUAL CHECK
1) Remove MAP sensor referring MAP sensor removal.
6E1-62 ENGIINE AND EMISSION CONTROL SYSTEM
ALTITUDE
(Reference)
BAROMETRIC
PRESSURE
OUTPUT
VOLTAGE
(ft) (m) (kPa(mmHg)) (V)
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
0
305
610
914
1219
1524
1829
2133
2438
2743
3048
101.3 (760)
97.7 (733)
94.3 (707)
90.9 (682)
87.7 (658)
84.5 (634)
81.5 (611)
78.5 (589)
75.6 (567)
72.8 (546)
70.1 (526)
3.3 – 3.9
3.2 – 3.8
3.1 – 3.7
3.0 – 3.6
3.0 – 3.5
2.9 – 3.4
2.8 – 3.3
2.7 – 3.2
2.6 – 3.1
2.5 – 3.0
2.5 – 3.0
2) Arrange 3 new 1.5 V batteries in series (2) (check that total volt-
age is 4.5 – 5.0 V) and connect its positive terminal to “Vcc” ter-
minal of MAP sensor (1) and negative terminal to “Ground”
terminal. Then check voltage between “Vout” and “Ground”.
Also, check if voltage reduces when vacuum is applied up to 40
cmHg by using vacuum pump (3) and volt meter (4).
Output voltage (Vin voltage 4.5 – 5.0 V, ambient temp.
20 – 305C, 68 – 865F)
If check result is not satisfactory, replace MAP sensor.
3) Install MAP sensor referring to MAP SENSOR INSTALLATION.
REMOVAL
1) Disconnect battery negative cable at battery.
2) Disconnect coupler from MAP sensor.
3) Remove MAP sensor from throttle body.
INSTALLATION
1) Before installation check vacuum passage hole for clogged
install MAP sensor (1) to throttle body.
Tightening Torque
(a): 2.0 N·m (0.2 kg-m, 1.5 Ib-ft)
2) Connect coupler to MAP sensor.
3) Connect battery negative cable to battery.
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-63
ALTITUDE
(Reference)
BAROMETRIC
PRESSURE
OUTPUT
VOLTAGE
(ft) (m) (kPa(mmHg)) (V)
0
J
2000
0
J
610
760
J
707
3.1 – 3.6
2001
J
5000
611
J
1524
Under 707
over 634
2.8 – 3.4
5001
J
8000
1525
J
2438
Under 634
over 567
2.6 – 3.1
8001
J
10000
2439
J
3048
Under 567
over 526
2.4 – 2.9
TP SENSOR
INSPECTION
1) Disconnect negative cable at battery and coupler from TP sen-
sor.
2) Using ohmmeter, check resistance between terminals under
each condition given in table below.
NOTE:
There should be more than 1.5 kW resistance difference be-
tween when throttle valve is at idle position and when it is
fully open.
If check result is not satisfactory, replace TP sensor.
3) Connect TP sensor coupler securely.
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.
3) Remove TP sensor from throttle body.
INSPECTION
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
(a): 2.5 N·m (0.25 kg-m, 2.0 lb-ft)
2) Connect coupler to TP sensor securely.
3) Connect battery negative cable to battery.
6E1-64 ENGIINE AND EMISSION CONTROL SYSTEM
TERMINAL RESISTANCE
Between “Vcc” and
“GND” terminals
4 – 6 kW
Between “Vout” and
Throttle valve is
at idle position
0.6 – 1.2 kW
“GND” terminals
Throttle valve is
fully opened
3.2 – 5.4 kW
ADJUSTMENT
1) Warm up engine to normal operating temperature.
1) Loosen TP sensor screws.
3) [Using SUZUKI scan tool]
Connect SUZUKI scan tool to DLC with ignition switch OFF and
check “TP SENSOR VOLT” value displayed on scan tool by us-
ing “DATA LIST” mode.
[Not using SUZUKI scan tool]
Remove ECM as previously outlined and with couplers con-
nected to ECM, connect digital type voltmeter between
“E33-206” and “E34-22” terminal.
TERMINAL ARRANGEMENT OF ECM
COUPLER (VIEWED FROM HARNESS SIDE)
[Not using SUZUKI scan tool]
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.
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-65
IAT SENSOR
REMOVAL
1) Disconnect battery negative cable at battery.
2) Disconnect coupler from IAT sensor (1).
3) Remove IAT sensor from air cleaner outlet hose.
INSPECTION
Immerse temperature sensing part of IAT sensor in water (or ice)
and measure resistance between sensor terminals while heating
water gradually.
If measured resistance doesn’t show such characteristic as shown
in left figure, replace IAT sensor.
( ) for reference
INSTALLATION
Reverse removal procedure noting the following.
D Clean mating surfaces of IAT sensor (1) and air cleaner outlet
hose.
D Connect IAT sensor coupler securely.
6E1-66 ENGIINE AND EMISSION CONTROL SYSTEM
ECT SENSOR
REMOVAL
1) Disconnect battery negative cable at battery.
2) Drain coolant referring to Section 6B.
3) Disconnect coupler from ECT sensor.
4) Remove ECT (1) sensor from water outlet pipe.
WARNING:
To help avoid danger of being burned, do not remove
radiator cap while engine and radiator are still hot.
Scalding fluid and steam can be blown out under pres-
sure it cap is taken off too soon.
INSPECTION
Immerse temperature sensing part of ECT sensor in water (or ice)
and measure resistance between sensor terminals while heating
water gradually.
If measured resistance doesn’t show such characteristic as shown
in left figure, replace ECT sensor.
( ) for reference
INSTALLATION
Reverse removal procedure noting the following.
D Clean mating surfaces of ECT sensor and water outlet pipe.
D Check O-ring for damage and replace if necessary.
D Tighten ECT sensor to specified torque.
Tightening Torque
(a): 12 N·m (1.2 kg-m, 9.0 lb-ft)
D Connect coupler to ECT sensor securely.
D Refill coolant referring to Section 6B.
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-67
MAIN RELAY/FUEL PUMP RELAY
INSPECTION
1) Disconnect negative cable at battery.
2) Remove ECM main/fuel pump relay from main fuse box after
disconnecting its coupler.
3) Check resistance between each two terminals as in table below.
If check results are as specified, proceed to next operation
check. If not, replace.
4) Check that there is continuity between terminals “A” and “B”
when battery is connected to terminals “C” and “D”.
If found defective, replace.
5) Install the relay and connect its coupler securely.
6E1-68 ENGIINE AND EMISSION CONTROL SYSTEM
TERMINALS RESISTANCE
Between A and B R (infinity)
Between C and D 80 – 100 W at 205C (685F)
OXYGEN SENSOR
INSPECTION
Inspect oxygen sensor referring to flow table of diagnostic trouble
code No. 14 (P0130).
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.
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect coupler of oxygen sensor and release its wire har-
ness from clamps.
3) Remove oxygen sensor (1) from exhaust manifold.
INSTALLATION
Reverse removal procedure noting the followings.
D Tighten oxygen sensor (1) to specified torque.
Tightening Torque
(a): 45 N·m (4.5 kg-m, 32.5 lb-ft)
D Connect coupler of oxygen sensor and clamp wire harness se-
curely.
D After installing oxygen sensor, start engine and check that no ex-
haust gas leakage exists.
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-69
FUEL CUT OPERATION
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) Warm up engine to normal operating temperature.
2) While listening to sound of injector (2) by using sound scope (1)
or such, increase engine speed to higher than 3,000 r/min.
3) Check to make sure that sound to indicate operation of injector
stops when throttle valve is closed instantly and it is heard again
when engine speed is reduced to less than about 2,000 r/min.
A/C COMPRESSOR CONTROL RELAY
(IF EQUIPPED)
INSPECTION
1) Disconnect negative cable at battery.
2) Remove A/C compressor control relay from its connecter.
3) Structure of A/C compressor control relay (1) is the same as that
of main relay. Check its resistance and operation using the
same procedure as that for main relay.
If found defective, replace.
CMP SENSOR
Refer to Section 6F for removal, installation, inspection and adjust-
ment of CMP sensor.
6E1-70 ENGIINE AND EMISSION CONTROL SYSTEM
RADIATOR FAN CONTROL SYSTEM
SYSTEM INSPECTION
Start engine and keep it running to warm it up.
Now check to ensure that radiator fan is started under either follow-
ing condition:
D A/C compressor magnet clutch operates (if equipped A/C).
D Engine coolant temperature value on scan tool is over 98 5C
(208 5F).
If check result is not satisfactory, check RFC relay, wire harness,
ECT sensor, ECM.
WARNING:
Keep hands, tools and clothing away from engine cool-
ing fan to help prevent personal injury. This fan is electric
and can come on whether or not the engine is running.
The fan can start automatically in response to the ECT
sensor with the ignition switch in the “ON” position.
RADIATOR FAN CONTROL RELAY (RFC RELAY)
INSPECTION
1) Disconnect negative cable at battery.
2) Remove RFC relay (1) from its connecter.
3) Check resistance between each two terminals as in table below.
If check results are as specified, proceed to next operation
check. If not, replace.
4) Check that there is continuity between terminals “A” and “B”
when battery is connected to terminals “C” and “D”.
If found defective, replace.
5) Install relay and connect its coupler securely.
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-71
TERMINALS RESISTANCE
Between “A” and “B” R (infinity)
Between
“
C
”
and
“
D
”
90 – 110 W at 205C (685F) omron. .
made
Between
“C”
and
“D”
60 – 88 W at 205C (685F) inter-. . .
face made
VEHICLE SPEED SENSOR (VSS)
INSPECTION
1) Remove combination meter from instrument panel.
2) Connect ohmmeter between vehicle speed sensor terminal and
ground terminal of combination meter and turn cable joint of
speedometer with a screwdriver.
Ohmmeter indicator should move back and forth between conti-
nuity and infinity 4 times while cable joint is turned one full revo-
lution.
Replace speedometer, if check result is not satisfactory.
6E1-72 ENGIINE AND EMISSION CONTROL SYSTEM
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.
F8D engine
1. EVAP canister purge valve
2. EVAP canister
3. Tank pressure control valve
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.
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.
F8D engine
F8B engine
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-73
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
[Using SUZUKI scan tool]
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 – 36 W at 20_C (68_F) F8B engine
37 – 44 W at 20_C (68_F) F8D engine
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): 09931-76011 (SUZUKI scan tool)
(B): Mass Storage Cartridge
(C): 09931-76030 (16/14-pin DLC cable)
5) Disconnect vacuum hoses from intake manifold.
Blow into hose (1). Air should not come out of nozzle (2).
6E1-74 ENGIINE AND EMISSION CONTROL SYSTEM
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.
[Not using SUZUKI scan tool]
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 W at 20_C (68_F) F8B engine
37 – 44 W at 20_C (68_F) F8D 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.
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-75
6) Connect vacuum hoses.
7) Connect EVAP canister purge valve coupler securely.
EVAP CANISTER/1-WAY VALVE INSPECTION
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 (F8B engine).
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).
F8D engine
F8B engine
6E1-76 ENGIINE AND EMISSION CONTROL SYSTEM
TANK PRESSURE CONTROL VALVE INSPECTION
1) Remove tank pressure control valve installed on the side of
EVAP canister.
2) Air should pass through valve smoothly from fuel tank side (3)
(black side (2) of check valve) to orange side (1) when blown
hard.
3) From orange side, even when blown softly, air should come out
of black side.
4) If air doesn’t pass through valve in step 2) or hard blow is re-
quired in step 3), replace tank pressure control valve.
WARNING:
DO NOT SUCK air through tank pressure control
valve. Fuel vapor inside the valve is harmful.
5) Install tank pressure control valve.
NOTE:
When connecting tank pressure control valve between
hoses, refer to left figure for installing direction.
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-77
PCV SYSTEM
NOTE:
Be sure to check that there is no obstruction in PCV valve or
its hoses before checking engine idle speed/IAC duty, for ob-
structed PCV valve or hose hampers its accurate checking.
PCV HOSE INSPECTION
Check hoses for connection, leakage, clog and deterioration. Re-
place as necessary.
PCV VALVE INSPECTION
1) Disconnect PCV valve from cylinder head cover and install plug
to head cover hole.
2) Run engine at idle speed.
3) Place your finger over end of PCV valve to check for vacuum.
If there is no vacuum, check for clogged valve. Replace as nec-
essary.
4) After checking vacuum, stop engine and remove PCV valve.
Shake valve and listen for the rattle of check needle inside the
valve.
If valve does not rattle, replace it.
5) After checking, remove plug and install PCV valve.
6E1-78 ENGIINE AND EMISSION CONTROL SYSTEM
ENGIINE AND EMISSION CONTROL SYSTEM 6E1-79
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
09917-47910
Vacuum pump gauge
09930-88530
Injector test lead
09931-76011
SUZUKI scan tool (Tech 1A) kit
1.Storage case
2.Operator’s manual
3.SUZUKI scan tool
(Tech 1A)
4.DLC cable
5.Test lead/probe
6.Power source cable
7.DLC cable adapter
8.Self-test adapter
Mass storage cartridge
09931-76030
16/14 pin DLC cable

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