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

PRECAUTIONS

GENERAL PRECAUTIONS

The WARNING and CAUTION below describe some general precautions that you should observe when servicing

a vehicle. These general precautions apply to many of the service procedures described in this manual, and they

will not necessarily be repeated with each procedure to which they apply.

WARNING:

D Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING

POINTS” on SECTION 0A.

D When it is necessary to do service work with the engine running, make sure that the parking brake

is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for auto-

matic transmission vehicles), Keep hands, hair, clothing, tools, etc. away from the fan and belts

when the engine is running.

D When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.

D Do not perform service work in areas where combustible materials can come in contact with a hot

exhaust system. When working with toxic or flammable materials (such as gasoline and refriger-

ant), make sure that the area you work in is well-ventilated.

D To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold,

tailpipe, muffler, etc.

D New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new

or used oil. Keep new and used oil and used engine oil filters away from children and pets.

Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory ani-

mals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil,

wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing

engine oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any

clothing or rags if wet with oil, recycle or properly dispose of used oil and filters.

D Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly

during driving, obstructing your view and resulting in an accident.

CAUTION:

D Before starting any service work, cover fenders, seats and

any other parts that are likely to get scratched or stained

during servicing. Also, be aware that what you wear (e.g,

buttons) may cause damage to the vehicle’s finish.

D When performing service to electrical parts that does not

require use of battery power, disconnect the negative cable

of the battery.

GENERAL INFORMATION 0A-3

D When removing the battery, be sure to disconnect the nega-

tive cable first and then the positive cable. When reconnect-

ing the battery, connect the positive cable first and then the

negative cable, and replace the terminal cover.

D When removing parts that are to be reused, be sure to keep

them arranged in an orderly manner so that they may be re-

installed in the proper order and position.

D Whenever you use oil seals, gaskets, packing, O-rings,

locking washers, split pins, self-locking nuts, and certain

other parts as specified, be sure to use new ones. Also, be-

fore installing new gaskets, packing, etc., be sure to remove

any residual material from the mating surfaces.

D Make sure that all parts used in reassembly are perfectly

clean.

D When use of a certain type of lubricant, bond or sealant is

specified, be sure to use the specified type.

“A”: Sealant 99000-31150

D Be sure to use special tools when instructed.

Special Tool

(A): 09917-98221

(B): 09916-58210

0A-4 GENGERAL INFORMATION

D When disconnecting vacuum hoses, attach a tag describ-

ing the correct installation positions so that the hoses can

be reinstalled correctly.

D After servicing fuel, oil, coolant, vacuum, exhaust or brake

systems, check all lines related to the system for leaks.

D For vehicles equipped with fuel injection systems, never

disconnect the fuel line between the fuel pump and injector

without first releasing the fuel pressure, or fuel can be

sprayed out under pressure.

PRECAUTIONS FOR CATALYTIC CONVERT-

For vehicles equipped with a catalytic converter, use only un-

leaded gasoline and be careful not to let a large amount of un-

burned gasoline enter the converter or it can be damaged.

– Conduct a spark jump test only when necessary, make it as

short as possible, and do not open the throttle.

– Conduct engine compression checks within the shortest

possible time.

– Avoid situations which can result in engine misfire (e.g.

starting the engine when the fuel tank is nearly empty.)

GENERAL INFORMATION 0A-5

PRECAUTIONS FOR ELECTRICAL CIRCUIT

SERVICE

D When disconnecting and connecting coupler, make sure to

turn ignition switch OFF, or electronic parts may get dam-

aged.

D Be careful not to touch the electrical terminals of parts

which use microcomputers (e.g. electronic control unit like

as ECM, PCM, P/S controller, etc.). The static electricity

from your body can damage these parts.

D Never connect any tester (voltmeter, ohmmeter, or whatev-

er) to electronic control unit when its coupler is discon-

nected. Attempt to do it may cause damage to it.

D Never connect an ohmmeter to electronic control unit with

its coupler connected to it. Attempt to do it may cause dam-

age to electronic control unit and sensors.

D Be sure to use a specified voltmeter/ohmmeter. Otherwise,

accurate measurements may not be obtained or personal

injury may result. If not specified, use a voltmeter with high-

impedance (MW/V minimum) or a digital type voltmeter.

D When taking measurements at electrical connectors using

a tester probe (2), be sure to insert the probe from the wire

harness side (backside) of the connector (1).

D When connecting meter probe (2) from terminal side of cou-

pler (1) because it can’t be connected from harness side,

use extra care not to bend male terminal of coupler of force

its female terminal open for connection.

In case of such coupler as shown connect probe as shown

to avoid opening female terminal.

Never connect probe where (3) male terminal is supposed

to fit.

0A-6 GENGERAL INFORMATION

D When checking connection of terminals, check its male half

for bend and female half for excessive opening and both for

locking (looseness), corrosion, dust, etc.

D Before measuring voltage to check for electrical system,

check to make sure that battery voltage is 11V or higher.

Such terminal voltage check at low battery voltage will lead

to erroneous diagnosis.

ELECTRICAL CIRCUIT INSPECTION

PROCEDURE

While there are various electrical circuit inspection methods, de-

scribed here is a general method to check its open and short circuit

by using an ohmmeter and a voltmeter.

OPEN CIRCUIT CHECK

Possible causes for the open circuit are as follows. As the cause

is in the connector or terminal in many cases, they need to be

checked particularly carefully.

D Loose connection of connector

D Poor contact of terminal (due to dirt, corrosion or rust on it, poor

contact tension, entry of foreign object etc.)

D Wire harness being open

When checking system circuits including an electronic control unit

such as ECM, TCM, ABS control module, etc., it is important to per-

form careful check, starting with items which are easier to check.

1) Disconnect negative cable from battery.

2) Check each connector at both ends of the circuit being checked

for loose connection. Also check lock condition of connector if

equipped with connector lock.

1. Check for loose connection

Sensor

ECM

GENERAL INFORMATION 0A-7

3) Using a test male terminal, check both terminals of the circuit

being checked for contact tension of its female terminal.

Check each terminal visually for poor contact (possibly caused

by dirt, corrosion, rust, entry of foreign object, etc.).

At the same time, check to make sure that each terminal is

locked in the connector fully.

Check contact tension by

inserting and removing just for

once

4) Using continuity check or voltage check procedure described in

the following page, check the wire harness for open circuit and

poor connection with its terminals. Locate abnormality, if any.

1. Looseness of crimping

2. Open

3. Thin wire (single strand of wire)

Continuity check

1) Measure resistance between connector terminals at both ends

of the circuit being checked (between A-1 and C-1 in the figure).

If no continuity is indicated (infinity or over limit), that means that

the circuit is open between terminals A-1 and C-1.

2) Disconnect the connector included in the circuit (connector-B in

the figure) and measure resistance between terminals A-1 and

B-1.

If no continuity is indicated, that means that the circuit is open

between terminals A-1 and B-1. If continuity is indicated, there

is an open circuit between terminals B-1 and C-1 or an ab-

normality in connector-B.

Voltage check

If voltage is supplied to the circuit being checked, voltage check

can be used as circuit check.

1) With all connectors connected and voltage applied to the circuit

being checked, measure voltage between each terminal and

body ground.

0A-8 GENGERAL INFORMATION

If measurements were taken as shown in the figure at the left and

results were as listed below, it means that the circuit is open be-

tween terminals B-1 and A-1.

Voltage Between:

C-1 and body ground: Approx. 5V

B-1 and body ground: Approx. 5V

A-1 and body ground: 0V

Also, if measured values were as listed below, it means that there

is a resistance (abnormality) of such level that corresponds to the

voltage drop in the circuit between terminals A-1 and B-1.

Voltage Between:

C-1 and body ground: Approx. 5V

B-1 and body ground: Approx. 5V 2V voltage drop

A-1 and body ground: Approx. 3V

SHORT CIRCUIT CHECK (wire harness to ground)

1) Disconnect negative cable from battery.

2) Disconnect connectors at both ends of the circuit to be checked.

NOTE:

If the circuit to be checked is connected to other parts, dis-

connect all connectors of those parts.

Otherwise, diagnosis will be misled.

3) Measure resistance between terminal at one end of circuit (A-1

terminal in figure) and body ground. If continuity is indicated, it

means that there is a short to ground between terminals A-1 and

C-1 of the circuit.

1. Other parts

4) Disconnect the connector included in circuit (connector B) and

measure resistance between A-1 and body ground.

If continuity is indicated, it means that the circuit is shorted to the

ground between terminals A-1 and B-1.

1. To other parts

GENERAL INFORMATION 0A-9

INTERMITTENT AND POOR CONNECTION

Most intermittent are caused by faulty electrical connections or wir-

ing, although a sticking relay or solenoid can occasionally be at

fault. When checking it for proper connection, perform careful

check of suspect circuits for:

D Poor mating of connector halves, or terminals not fully seated in

the connector body (backed out).

D Dirt or corrosion on the terminals. The terminals must be clean

and free of any foreign material which could impede proper ter-

minal contact. However, cleaning the terminal with a sand paper

or the like is prohibited.

D Damaged connector body, exposing the terminals to moisture

and dirt, as well as not maintaining proper terminal orientation

with the component or mating connector.

D Improperly formed or damaged terminals.

Check each connector terminal in problem circuits carefully to

ensure good contact tension by using the corresponding mating

terminal.

If contact tension is not enough, reform it to increase contact ten-

sion or replace.

1. Check contact tension by inserting and removing just once

2. Check each terminal for bend and proper alignment

D Poor terminal-to-wire connection.

Check each wire harness in problem circuits for poor connection

by shaking it by hand lightly. If any abnormal condition is found,

repair or replace.

D Wire insulation which is rubbed through, causing an intermittent

short as the bare area touches other wiring or parts of the ve-

hicle.

D Wiring broken inside the insulation. This condition could cause

continuity check to show a good circuit, but if only 1 or 2 strands

of a multi-strand-type wire are intact, resistance could be far too

high.

If any abnormality is found, repair or replace.

0A-10 GENGERAL INFORMATION

PRECAUTION FOR INSTALLING MOBILE

COMMUNICATION EQUIPMENT

When installing mobile communication equipment such as CB (Cit-

izens-Band)-radio or cellular-telephone, be sure to observe the fol-

lowing precautions.

Failure to follow cautions may adversely affect electronic control

system.

D Keep the antenna as far away as possible from the vehicle’s

electronic control unit.

D Keep the antenna feeder more than 20 cm (7.9 in) away from

electronic control unit and its wire harnesses.

D Do not run the antenna feeder parallel with other wire har-

nesses.

D Confirm that the antenna and feeder are correctly adjusted.

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION NUMBER

The number is punched on the front dash panel in the engine room.

ENGINE IDENTIFICATION NUMBER

The number is punched on the cylinder block.

TRANSMISSION IDENTIFICATION NUMBER

The identification number of the 5 speed transmission is located on

the transmission case.

The identification number of the 4 speed transmission is not avail-

able.

5 speed only

GENERAL INFORMATION 0A-11

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

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