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

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

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