1998-2003 Suzuki Alto 4 Door Engine Diagnosis -> Engine Diagnosis User Manual
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Engine Diagnosis -> Engine Diagnosis for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

ON-BOARD DIAGNOSTIC SYSTEM
Refer to “On-Board Diagnostic System” in Section 6E1.
PRECAUTION IN DIAGNOSING TROUBLES
Be sure to read “Precaution in Diagnosing Troubles” in Section 6E1
and observe what is written there.
ENGINE DIAGNOSIS 6-5
ENGINE DIAGNOSIS
This vehicle is equipped with an engine and emission control system, which controls the A/F mixture, ignition tim-
ing, emission, etc. suitably to engine conditions by ECM. ECM has an On-Board Diagnostic system which detects
a malfunction in this system.
When diagnosing a trouble in the engine including this system, be sure to have understanding of the outline of “On-
Board Diagnostic system” and each item in “Precaution in Diagnosing Trouble” and follow “ENGINE DIAGNOSTIC
FLOW TABLE” given below to obtain correct result smoothly.
6-6 ENGINE DIAGNOSIS
ENGINE DIAGNOSTIC FLOW TABLE
Refer to the following pages for the details of each step.
STEP
ACTION YES NO
1 Customer Complaint Analysis
1) Perform customer complaint analysis.
Was customer complaint analysis performed?
Go to Step 2. Perform customer
complaint analysis.
2 Diagnostic Trouble Code (DTC) Check, Record and
Clearance
1) Check for DTC referring to “DTC Check” in
Section 6E1.
Is there any malfunction DTC(s)?
1) Print DTC or
write it down and
clear it by refer-
ring to “DTC
Clearance” in
section 6E1.
2) Go to Step 3.
Go to Step 4.
3 Visual Inspection
1) Perform visual inspection referring to the “Visual
Inspection” in this section.
Is there any faulty condition?
1) Repair or replace
malfunction part.
2) Go to Step 11.
Go to Step 5.
4 Visual Inspection
1) Perform visual inspection referring to the “Visual
Inspection” in this section.
Is there any faulty condition?
Go to Step 8.
5 Trouble Symptom Confirmation
1) Confirm trouble symptom referring to the “Trouble-
Symptom Confirmation” in this section.
Is trouble symptom identified?
Go to Step 6. Go to Step 7.
6 Rechecking and Record of DTC
1) Recheck for DTC referring to “DTC Check” in
Section 6E1.
Is there any DTC(s)?
Go to Step 9.
Go to Step 8.
7 Rechecking and Record of DTC
1) Recheck for DTC referring to “DTC Check” in
Section 6E1.
Is there any malfunction DTC(s)?
Go to Step 10.
8 Engine Basic Inspection and Engine Diagnosis Table
1) Check and repair according to “Engine Basic Check”
and “Engine Diagnosis Table” in this section.
Are check and repair complete?
Go to Step 11. 1) Check and repair
malfunction
part(s).
2) Go to Step 11.
9 Trouble shooting for DTC
1) Check and repair according to applicable DTC diag.
flow table in Section 6E1.
Are check and repair complete?
10 Check for Intermittent Problems
1) Check for intermittent problems referring to “Check for
Intermittent Problem” in this section.
Is there any faulty condition?
1) Repair or replace
malfunction
part(s).
2) Go to Step 11.
Go to Step 11.
11 Final Confirmation Test
1) Clear DTC if any.
2) Perform final confirmation test referring to “Final
Confirmation Test” in this section.
Is there any problem symptom, malfunction DTC or abnor-
mal condition?
Go to Step 6. End.
ENGINE DIAGNOSIS 6-7
1. CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this
purpose, use of such an inspection form will facilitate collecting information to the point required for proper anal-
ysis and diagnosis.
CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE)
User name: Model: VIN:
Date of issue: Date of Reg.: Date of problem: Mileage:
PROBLEM SYMPTOMS
j Difficult Starting
j No cranking
j No initial combustion
j No combustion
j Poor starting at
(j cold j warm j always)
j Other
j Poor Driveability
j Hesitation on acceleration
j Back fire/j After fire
j Lack of power
j Surging
j Abnormal knocking
j Other
j Poor idling
j Poor fast idle
j Abnormal idling speed
(j High j Low) ( r / min.)
j Unstable
j Hunting ( r/min. to r/min.)
j Other
j Engine Stall when
j Immediately after start
j Axal. pedal is depressed
j Accel. pedal is released
j Load is applied
j A/C j Electric load j P/S
j Other
j Other
j OTHERS:
VEHICLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS
Environmental Condition
Weather
Temperature
Frequency
Road
j Fair j Cloudy j Rain j Snow j Always j Other
j Hot j Warm j Cool j Cold ( _F/ _C) j Always
j Always j Sometimes ( times/ day, month) j Only once j Under certain condition
j Urban j Suburb j Highway j Mountainous (j Uphill j Downhill) j Tarmacadam
j Gravel j Other
Vehicle Condition
Engine
Condition
j Cold j Warming up phase j Warmed up j Always j Other at starting
j Immediately after start j Racing without load j Engine speed ( r / min)
Vehicle
condition
j During driving: j Constant speed j Accelerating j Decelerating
j Right hand corner j left hand corner j When shifting (Lever position ) j At stop
j Vehicle speed when problem occurs ( km/h, Mile/h) j Other
Malfunction indicator
lamp condition
j Always ON j Sometimes ON j Always OFF j Good condition
Diagnostic trouble
First check: j No code j Normal code j Malfunction code ( )
g
code
Second check: j No code j Normal code j Malfunction code ( )
NOTE:
The above form is a standard sample. It should be modified according to conditions characteristic of each
market.
Operation
6-8 ENGINE DIAGNOSIS
2. DIAGNOSTIC TROUBLE CODE (DTC) CHECK, RECORD AND CLEARANCE
First, check DTC referring to “DTC Check” in Section 6E1. If DTC is indicated, print it or write it down and then
clear it by referring to “DTC Clearance” in Section 6E1. DTC indicates malfunction that occurred in the system
but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored
now. To check which case applies, check the symptom in question according to Step 5 and recheck DTC accord-
ing to Step 6 or 7.
Attempt to diagnose a trouble based on DTC in this step only or failure to clear the DTC in this step will lead
to incorrect diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting.
3. and 4. VISUAL INSPECTION
Be sure to perform visual check of the following items that support proper function of the engine.
INSPECTION ITEM
REFERRING SECTION
D Engine oil – – – – – level, leakage
D Engine coolant – – – – – level, leakage
D Fuel – – – – – level, leakage
D Air cleaner element – – – – – dirt, clogging
D Battery – – – – – fluid level, corrosion of terminal
D Water pump belt and/or cooling fan belt – – – – – tension, damage
D Throttle cable – – – – – play, installation
D Vacuum hoses of air intake system – – – – – disconnection, looseness,
deterioration, bend
D Connectors of electric wire harness – – – – – disconnection, friction
D Fuses – – – – – burning
D Parts – – – – – installation, bolt – – – – – looseness
D Parts – – – – – deformation
D Other parts that can be checked visually
Also check following items at engine start, if possible
D Malfunction indicator lamp
D Charge warning lamp
D Engine oil pressure warning lamp
D Engine coolant temp. meter
D Fuel lever meter
D Abnormal air being inhaled from air intake system
D Exhaust system – – – – – leakage of exhaust gas, noise
D Other parts that can be checked visually
Section 0B
Section 0B
Section 0B
Section 0B
Section 0B
Section 6E1
Section 8
Section 6E1
Section 6H
Section 8
Section 8
Section 8
ENGINE DIAGNOSIS 6-9
5. TROUBLE SYMPTOM CONFIRMATION
Based on information obtained in Step 1 customer complaint analysis and Step 2 DTC check, confirm trouble
symptoms. Also, reconfirm DTC according to “DTC Confirmation Procedure” in Section 6E1.
6. and 7. RECHECKING AND RECORD OF DTC
Refer to “DTC Check” in section 6E1 for checking procedure.
8. ENGINE BASIC INSPECTION AND ENGINE DIAGNOSIS TABLE
Perform basic engine check according to the “Engine Basic Inspection Flow Table” first. When the end of the
flow table has been reached, check the parts of the system suspected as a possible cause referring to ENGINE
DIAGNOSIS TABLE and based on symptoms appearing on the vehicle (symptoms obtained through steps of
customer complaint analysis, trouble symptom confirmation and/or basic engine check) and repair or replace
faulty parts, if any.
ENGINE BASIC INSPECTION FLOW TABLE
STEP
ACTION YES NO
1 Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE
DIAG. FLOW
TABLE”.
2 Check battery voltage.
Is it 11 V or more?
Go to Step 3. Charge or replace
battery.
3 Is engine cranked? Go to Step 4. Go to “DIAGNOSIS”
in section 6G.
4 Does engine start? Go to Step 5. Go to Step 7.
5 Check engine idle speed/IAC duty referring to “Idle
Speed/IAC Duty Inspection” in section 6E1.
Is check result as specified?
Go to Step 6. Go to “ENGINE
DIAGNOSIS TABLE”
in this section.
6 Check ignition timing referring to “Ignition Timing Inspec-
tion” in section 6F.
Is check result as specified?
Go to “ENGINE
DIAGNOSIS TABLE”
in this section.
Adjust ignition
timing.
7 Check fuel supply as follows:
1) Check to make sure that enough fuel is filled in fuel
tank.
2) Turn the ignition switch ON position for 3 seconds and
then turn it OFF position.
Repeat this a few times.
Is fuel return pressure (returning sounds) felt from fuel
return hose when the ignition switch is turned ON posi-
tion?
Go to Step 9. Go to Step 8.
8 Check fuel pump for operating.
1) Was fuel pump operating sound heard from fuel filler
for about 3 seconds after turning the ignition switch ON
position and stop?
Go to “Diag. Flow
Table B-3” in section
6E1.
Go to “Diag. Flow
Table B-1” in section
6E1.
9 Check ignition spark referring to “Ignition Spark Test”
in section 6F.
Is it in good condition?
Go to Step 10. Go to “DIAGNOSIS”
in section 6F.
10 Check fuel injector referring to “Fuel Injector Inspection” in
section 6E1.
Is it in good condition?
Go to “ENGINE
DIAGNOSIS TABLE”
in this section.
Go to “Diag. Flow
Table B-2 in section
6E1.
6-10 ENGINE DIAGNOSIS
9. TROUBLESHOOTING FOR DTC
Based on the DTC indicated in Step 6 or 7 and referring to the applicable DTC diag. flow table in Section 6E1,
locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ECM or other
part and repair or replace faulty parts.
10. CHECK FOR INTERMITTENT PROBLEM
Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to
“INTERMITTENT AND POOR CONNECTION” in Section 0A and related circuit of DTC recorded in step 2.
11. FINAL CONFIRMATION TEST
Confirm that the problem symptom has gone and the engine is free from any abnormal conditions. If what has
been repaired is related to the DTC, clear the DTC once, perform DTC confirmation procedure and confirm
that no malfunction DTC (a normal code) is indicated.
ENGINE DIAGNOSIS TABLE
Condition
Possible Cause Reference Item
Hard starting
(Engine cranks OK)
Engine and emission control system
out of order.
D Faulty CMP sensing rotor
D Faulty idle air control system
D Faulty ECT sensor or MAP sensor
D Faulty ECM
Low compression.
D Compression leak from valve seat
D Sticky valve stem
D Weak or damaged valve springs
D Compression leak at cylinder head gasket
D Sticking or damaged piston ring
D Worn piston, ring or cylinder
Others
D Malfunctioning PCV valve
CMP sensing rotor inspection in section
6E1.
Diag. Flow Table B-4 in Section 6E1.
ECT sensor or MAP sensor in Section
6E1.
Inspection of ECM and its circuit in Sec-
tion 6E1.
Compression check in Section 6A or 6A1.
Valves inspection in Section 6A or 6A1.
Valves inspection in Section 6A or 6A1.
Valves spring inspection in Section 6A or
6A1.
Cylinder head inspection in Section 6A or
6A1.
Piston ring inspection in Section 6A or
6A1.
Cylinders, pistons and piston rings
inspection in Section 6A or 6A1.
PCV system inspection in Section 6E1.
ENGINE DIAGNOSIS 6-11
Condition Possible Cause Reference Item
Engine has no power Engine overheating.
Ignition system out of order.
D Defective spark plug
D Faulty ignition coil
Fuel system out of order.
D Fuel pressure out of specification
– Dirty fuel filter
– Dirty or clogged fuel hose or pipe
– Malfunctioning fuel pressure regulator
– Malfunctioning fuel pump
Engine and emission control system
out of order.
D Faulty injector
D Faulty TP sensor, ECT sensor or
MAP sensor
D Faulty ECM
Low compression.
Others
D Dragging brakes
D Slipping clutch
Refer to “Overheating” Section.
Spark plugs in Section 6F.
Ignition coil in Section 6F.
Diag. Flow Table B-3 in Section 6E1.
Fuel injector in Section 6E1.
TP sensor, ECT sensor or MAP
sensor in Section 6E1.
Inspection of ECM and its circuit in
Section 6E1.
Previously outlined.
Diagnosis in Section 5.
Diagnosis in Section 7C.
Improper engine
idling or engine fails
to idle
Ignition system out of order.
D Faulty spark plug
D Faulty ignition coil
Fuel system out of order.
D Fuel pressure out of specification
– Malfunctioning fuel pressure regulator
Engine overheating.
Engine and emission control system
out of order.
D Faulty idle air control system
D Faulty evaporative emission control system
D Faulty injector
D Faulty ECT sensor, TP sensor or
MAP sensor
D Faulty ECM
Low compression.
Others
D Malfunctioning PCV valve
Spark plugs in Section 6F.
Ignition coil in Section 6F.
Diag. Flow Table B-3 in Section 6E1.
Refer to “Overheating” Section.
Diag. Flow Table B-4 in Section 6E1.
Diag. Flow Table B-5 in Section 6E1.
Fuel injector in Section 6E1.
ECT sensor, TP sensor or MAP
sensor in Section 6E1.
Inspection of ECM and its circuit in
Section 6E1.
Previously outlined.
PCV system inspection in Section
6E1.
6-12 ENGINE DIAGNOSIS
Condition Possible Cause Reference Item
Engine hesitates
(Momentary lack of
response as the
accelerator is
depressed.
Can occur at all
vehicle speeds.
Usually most severe
when first trying to
make the vehicle
move, as from a
stop sign.)
Ignition system out of order.
D Spark plug faulty or plug gap as out
of adjustment
Fuel system out of order.
D Fuel pressure out of specification
– Clogged fuel filter
– Faulty fuel pressure regulator
D Clogged fuel filter, hose or pipe
Engine overheating
Engine and emission control system out
of order.
D Faulty injector
D Faulty TP sensor, ECT sensor or MAP
sensor
D Faulty ECM .
Low compression
Spark plugs in Section 6F.
Diag. Flow Table B-3 in Section 6E1.
Fuel pressure check in Section 6E1.
Refer to “Overheating” Section.
Fuel injector in Section 6E1.
TP sensor, ECT sensor or MAP
sensor in Section 6E1.
Inspection of ECM and its circuit in
Section 6E1.
Previously outlined.
Surges
(Engine power variation
under steady
throttle or cruise.
Feels like the vehicle
speeds up and down
with no change in
the accelerator
pedal.)
Ignition system out of order.
D Defective spark plug (excess carbon
deposits, improper gap, and burned
electrodes, etc.)
Fuel system out of order.
D Variable fuel pressure
– Clogged fuel filter
– Kinky or damaged fuel hose and line
– Faulty fuel pressure regulator
Engine and emission control system out
of order.
D Faulty MAP sensor
D Faulty injector
D Faulty ECM
Spark plugs in Section 6F.
Diag. Flow Table B-3 in Section 6E1.
MAP sensor in Section 6E1.
Fuel injector in Section 6E1.
Inspection of ECM and its circuit in
Section 6E1.
ENGINE DIAGNOSIS 6-13
Condition Possible Cause Reference Item
Excessive detonation
(The engine makes
sharp metallic knocks
that change with
throttle opening.
Sounds like pop corn
popping.)
Engine overheating
Ignition system out of order.
D Faulty spark plug
D Improper ignition timing
Fuel system out of order.
D Clogged fuel filter and fuel lines
Engine and emission control system
Refer to “Overheating” Section.
Spark plugs in Section 6F.
Ignition timing in Section 6F.
Fuel pressure check in Section 6E1.
out of order.
D Faulty ECT sensor or MAP sensor
D Faulty injector
D Faulty ECM
Others
D Excessive combustion chamber deposits
ECT sensor or MAP sensor in Section
6E1.
Fuel injector in Section 6E1.
Inspection of ECM and its circuit in Sec-
tion 6E1.
Piston and cylinder head cleaning in
Section 6A or 6A1.
Overheating D Inoperative thermostat
D Poor water pump performance
D Clogged or leaky radiator
D Improper engine oil grade
D Clogged oil filter or oil strainer
D Poor oil pump performance
D Dragging brakes
D Slipping clutch
D Blown cylinder head gasket
Thermostat in Section 6B.
Water pump in Section 6B.
Radiator in Section 6B.
Engine oil and oil filter change in
Section 0B.
Oil pressure check in Section 6A or 6A1.
Oil pressure check in Section 6A or 6A1.
Diagnosis in Section 5.
Diagnosis in Section 7C.
Cylinder head inspection in Section 6A
or 6A1.
Poor gasoline
mileage
Ignition system out of order.
D Faulty spark plug (improper gap, heavy
deposits, and burned electrodes, etc.)
Engine and emission control system
out of order.
D Fuel pressure out of specification
D Faulty TP sensor, ECT sensor or MAP
sensor
D Faulty injector
D Faulty ECM
Low compression
Others
D Poor valve seating
D Dragging brakes
D Slipping clutch
D Thermostat out of order
D Improper tire pressure
Spark plugs in Section 6F.
Diag. Flow Table B-3 in Section 6E1.
TP sensor, ECT sensor or MAP
sensor in Section 6E1.
Fuel injector in Section 6E1.
Inspection of ECM and its circuit in Sec-
tion 6E1.
Previously outlined.
Valves inspection in Section 6A or 6A1.
Diagnosis in Section 5.
Diagnosis in Section 7C.
Thermostat in Section 6B.
6-14 ENGINE DIAGNOSIS
Condition Possible Cause Reference Item
Excessive engine oil
consumption
Oil entering combustion chamber
D Sticky piston ring
D Worn piston and cylinder
D Worn piston ring groove and ring
D Improper location of piston ring gap
D Worn or damaged valve stem seal
D Worn valve stem
Piston cleaning in Section 6A or 6A1.
Cylinders, pistons and piston rings
inspection in Section 6A or 6A1.
Pistons and piston rings inspection in Sec-
tion 6A or 6A1.
Pistons installation in Section 6A or 6A1.
Valves and cylinder head in Section 6A
or 6A1.
Valves inspection in Section 6A or 6A1.
Low oil pressure D Improper oil viscosity
D Malfunctioning oil pressure switch
D Clogged oil strainer
D Functional deterioration of oil pump
D Worn oil pump relief valve
D Excessive clearance in various sliding
parts
Engine oil and oil filter change in
Section 0B.
Oil pressure switch inspection in
Section 8.
Oil pan and oil pump strainer
cleaning in Section 6A or 6A1.
Oil pump in Section 6A or 6A1.
Oil pump in Section 6A or 6A1.
Engine noise
Note: Before check-
ing the mechanical
noise, make sure
that:
D Ignition timing is
properly adjusted.
D Specified spark
plug is used.
D Specified fuel is
used.
Valve noise
D Improper valve lash
D Worn valve stem and guide
D Weak or broken valve spring
D Warped or bent valve
D Loose camshaft housing bolts
Piston, ring and cylinder noise
D Worn piston, ring and cylinder bore
Connecting rod noise
D Worn crankpin bearing
D Worn crankpin
D Loose connecting rod nuts
D Low oil pressure
Crankshaft noise
D Low oil pressure
D Worn crankshaft journal bearing
D Worn crankshaft journal
D Loose lower crankcase
(bearing cap) bolts
D Excessive crankshaft thrust play
Valve lash in Section 6A or 6A1.
Valves inspection in Section 6A or 6A1.
Valve springs inspection in Section 6A or
6A1.
Valves inspection in Section 6A or 6A1.
Camshafts in Section 6A or 6A1.
Pistons and cylinders inspection in Sec-
tion 6A or 6A1.
Crankpin and connecting rod bearing in-
spection in Section 6A or 6A1.
Crankpin and connecting rod bearing in-
spection in Section 6A or 6A1.
Connecting rod installation in Section 6A
or 6A1.
Previously outlined.
Previously outlined.
Crankshaft and bearing inspection in
Section 6A or 6A1.
Crankshaft and bearing inspection in
Section 6A or 6A1.
Crankshaft installation in Section 6A or
6A1.
Crankshaft inspection in Section 6A or
6A1.
ENGINE DIAGNOSIS 6-15
Condition Possible Cause Referring Item
Excessive
hydrocarbon (HC)
emission or
Excessive carbon
monoxide (CO)
emission
Ignition system out of order
D Defective spark plug
Fuel system out of order
D Fuel pressure out of specification
Engine and Emission control system
out of order.
D Lead contamination of three way catalytic
converter (if equipped)
D Malfunctioning PCV valve
D Faulty EVAP control system
D Closed loop system (A/F feed back
compensation) fails
– Faulty TP sensor
– Faulty ECT sensor or MAP sensor
– Faulty O
2
sensor
D Faulty injector
D Faulty ECM
Low compression
Fuel pressure check in Section 6E1.
Check for absence of filler neck
restrictor.
PCV valve in Section 6E1.
EVAP control system check in
Section 6E1.
Check oxygen sensor output voltage
referring to DTC No.14 Diag. Flow
Table in Section 6E1.
Fuel injector in Section 6E1.
Inspection of ECM and its circuit in
Section 6E1.
Previously outlined.
Excessive nitrogen
oxides (NOx)
emission
Fuel system out of order
D Fuel pressure out of specification
Engine and emission control system
D Lead contamination of three way catalytic
converter (if equipped)
D Closed loop system (A/F feed back
compensation) fails (vehicle with O
2
sensor)
– Faulty TP sensor
– Faulty ECT sensor or MAP sensor
– Faulty O
2
sensor
D Faulty injector
D Faulty ECM
Fuel pressure check in Section 6E1.
Check for absence of filler neck
restrictor.
Check oxygen sensor output voltage
referring to DTC No.14 Diag. Flow
Table in Section 6E1.
Fuel injector Section 6E1.
Inspection of ECM and its circuit in
Section 6E1.

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