Get Engine Diagnosis -> General Information Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

ENGINE DIAGNOSIS 6-1

SECTION 6

ENGINE DIAGNOSIS

CONTENTS

GENERAL INFORMATION 6- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE DIAGNOSIS 6- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

On-Board Diagnostic System 6- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precaution in Diagnosing Troubles 6- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Diagnostic Flow Table 6- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Diagnosis Table 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION

STATEMENT ON CLEANLINESS AND CARE

An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances

that are measured in the thousands of an millimeter (ten thousands of inch). Accordingly, when any internal engine

parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that proper

cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered

standard shop practice even if not specifically stated.

D A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the

surfaces on initial operation.

D Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal

bearings are removed for service, they should be retained in order. At the time of installation, they should be

installed in the same locations and with the same mating surfaces as when removed.

D Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect

cables may result in damage to wire harness or other electrical parts.

PRECAUTION ON FUEL SYSTEM SERVICE

D Work must be done with no smoking, in a well-ventilated area

and away from any open flames.

D As fuel feed line (between fuel pump and fuel pressure regula-

tor) is still under high fuel pressure even after engine was

stopped, loosening or disconnecting fuel feed line directly may

cause dangerous spout of fuel to occur where loosened or dis-

connected.

Before loosening or disconnecting fuel feed line, make sure to

release fuel pressure according to FUEL PRESSURE RELIEF

PROCEDURE.

A small amount of fuel may be released after the fuel line is dis-

connected.

In order to reduce the chance of personal injury, cover the fitting

to be disconnected with a shop cloth. Put that cloth in an ap-

proved container when disconnection is completed.

D Never run engine with fuel pump relay disconnected when en-

gine and exhaust system are hot.

D Fuel or fuel vapor hose connection varies with each type of pipe.

When reconnecting fuel or fuel vapor hose, be sure to connect

and clamp each hose correctly referring to left figure.

After connecting, make sure that the hose has no twist or kink.

D When installing fuel union bolt gasket, always use new gasket

and tighten union bolt to specified torque. See Section 6C for

specified torque.

D When installing injector, fuel feed pipe or fuel pressure regulator,

lubricate its O-ring with gasoline.

D When connecting fuel pipe flare nut, first tighten flare nut by

hand and then tighten it to specified torque.

ENGINE DIAGNOSIS 6-3

FUEL PRESSURE RELIEF PROCEDURE

After making sure that engine is cold, relief fuel pressure as follows.

1) Place transmission gear shift lever in “Neutral”, set parking

brake, and block drive wheels.

2) Remove fuel pump relay (1) from connector.

3) Remove fuel filler cap to release fuel vapor pressure in fuel tank

and then reinstall it.

4) Start engine and run it till it stops for lack of fuel. Repeat crank-

ing engine 2 – 3 times of about 3 seconds each time to dissipate

fuel pressure in lines. Fuel connections are now safe for servic-

ing.

5) Upon completion of servicing, install fuel pump relay to relay

box.

CAUTION:

This work must not be done when engine is hot. If done

so, it may cause adverse effect to catalyst.

FUEL LEAKAGE CHECK PROCEDURE

After performing any service on fuel system, check to make sure

that there are no fuel leakages as follows.

1) Turn the ignition switch ON position for 3 seconds (to operate

fuel pump) and then turn it OFF position.

Repeat this (ON and OFF) 3 or 4 times and apply fuel pressure

to fuel line (till fuel pressure is felt by hand placed on fuel return

hose).

2) In this state, check to see that there are no fuel leakages from

any part of fuel system.

6-4 ENGINE DIAGNOSIS

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

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