Get Ignition System Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

IGNITION SYSTEM 6F-1

SECTION 6F

IGNITION SYSTEM

CONTENTS

GENERAL DESCRIPTION 6F- 2. . . . . . . . . . . . . . .

Components 6F- 2. . . . . . . . . . . . . . . . . . . . . . . . .

System Wiring 6F- 3. . . . . . . . . . . . . . . . . . . . . . . .

DIAGNOSIS 6F- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Flow Table 6F- 4. . . . . . . . . . . . . . . . .

Ignition Spark Test 6F- 6. . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 6F- 6. . . . . . . . . . . . . . . . .

High-Tension Cords 6F- 6. . . . . . . . . . . . . . . . . . .

Spark Plugs 6F- 7. . . . . . . . . . . . . . . . . . . . . . . . . .

Noise suppressor 6F- 8. . . . . . . . . . . . . . . . . . . . .

Igniter 6F- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition Coil 6F- 9. . . . . . . . . . . . . . . . . . . . . . . . . .

Distributor 6F- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition Timing 6F-11. . . . . . . . . . . . . . . . . . . . . . . .

DISTRIBUTOR UNIT 6F-13. . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 6F-15. . . . . . . . . . . . . . . . . . . . . . .

6F-2 IGNITION SYSTEM

GENERAL DESCRIPTION

The ignition system used for this vehicle has an electronic ignition control system and consists of the following

parts.

D ECM

It detects the engine condition through the signals from the sensors, determines the most suitable ignition timing

and time for electricity to flow to the primary coil and sends a signal to the igniter.

D Igniter

It turns ON and OFF the primary current of the ignition coil according to the signal from ECM.

D Ignition coil

When the ignition coil primary current is turned OFF, a high voltage is induced in the secondary winding.

D Distributor

It distributes a high voltage current to each plug.

D High-tension cords, spark plugs and noise suppressor.

D CMP sensor (Camshaft position Sensor)

Located in the distributor, it converts the crank angle into voltage variation and sends it to ECM. For its details,

refer to SECTION 6E.

D TP sensor, ECT sensor and MAP sensor

For their details, refer to SECTION 6E.

COMPONENTS

1. CMP sensor

2. Noise suppressor

3. Monitor coupler

4. Spark plug

5. Distributor

6. High-tension cord

7. Ignition coil

8. Igniter

IGNITION SYSTEM 6F-3

SYSTEM WIRING

1. Battery

2. Main fuse box

3. Ignition switch

4. Main relay

5. Ignition coil

6. Igniter

7. Noise suppressor

8. Distributor

9. Distributor rotor

10. Signal rotor

11. CMP sensor

12. Spark plug

6F-4 IGNITION SYSTEM

DIAGNOSIS

Condition

Possible Cause Correction

Engine cranks, but will

not start or hard to start

D Blown fuse for ignition coil

D Loose connection or disconnection of lead wire or

high-tension cord(s)

D Faulty high-tension cord(s)

D Faulty spark plug(s)

D Cracked rotor or cap

D Maladjusted signal rotor air gap

D Faulty ignition coil

D Faulty noise suppressor

D Faulty CMP sensor

D Faulty igniter

D Faulty ECM

D Maladjusted ignition timing

Replace

Connect securely

Replace

Adjust, clean or replace

Replace

Adjust

Replace

Adjust

Poor fuel economy or

engine performance

D Incorrect ignition timing

D Faulty spark plug(s) or high-tension cord(s)

D Faulty ECM

Adjust

Adjust, clean or replace

Replace

DIAGNOSTIC FLOW TABLE

STEP

ACTION YES NO

1 Was ENGINE DIAGNOSTIC FLOW TABLE in SEC-

TION 6 performed?

Go to Step 2. Go to ENGINE DIAG-

NOSTIC FLOW

TABLE in SECTION 6.

2 Ignition Spark Test

1) Check all spark plug for condition and type, refer-

ring to SPARK PLUG in this section.

2) If OK, perform ignition spark test, referring to IGNI-

TION SPARK TEST in this section.

Is spark emitted from all spark plugs?

Go to Step 11 on the

next page.

Go to Step 3.

3 Diagnostic Trouble Code (DTC) Check

1) Check DTC stored in ECM, referring to DIAGNOS-

TIC TROUBLE CODE (DTC) CHECK in SECTION

6E1.

Is DTC stored?

Go to applicable flow

table corresponding to

that code No. in SEC-

TION 6E1.

Go to Step 4.

4 Electrical Connection Check/Noise Suppressor Check

1) Check ignition coil for electrical connection.

2) Check noise suppressor referring to NOISE SUP-

PRESSOR.

Are they in good condition?

Go to Step 5. Connect securely.

Replace noise sup-

pressor.

5 High-tension Cord Check

1) Check high-tension cord for resistance, referring to

HIGH-TENSION CORDS in this section.

Is check result satisfactory?

Go to Step 6. Replace high-tension

cord(s).

6 Igniter Check

1) Check igniter, referring to IGNITER in this section.

Is check result satisfactory?

Go to Step 7. Replace igniter.

IGNITION SYSTEM 6F-5

STEP ACTION YES NO

7 Ignition Coil Power Supply And Ground Circuit Check

1) Check ignition coil power supply (“B/W” wire) circuit

for open and short.

Are circuits in good condition?

Go to Step 8. Repair or replace.

8 Ignition Coil Check

1) Check ignition coil for resistance, referring to IGNI-

TION COIL in this section.

Is check result satisfactory?

Go to Step 9. Replace ignition coil

assembly.

9 CMP Sensor Check

1) Check CMP sensor and signal rotor, referring to

DISTRIBUTOR in this section.

Is check result satisfactory?

Go to Step 10 on the

next page.

Adjust or replace.

10 Ignition Trigger Signal Circuit Check

1) Check ignition trigger signal (“Br/W” wire) circuit for

open, short and poor connection.

Are circuits in good condition?

Go to Step 11. Repair or replace.

11 Ignition Timing Check

1) Check initial ignition timing and ignition timing ad-

vance, referring to IGNITION TIMING in this sec-

tion.

Is check result satisfactory?

Substitute a known-

good ECM and then

repeat STEP 2.

Go to Step 12.

12 Ignition Timing Adjustment And Recheck

1) Adjust initial ignition timing, referring to IGNITION

TIMING in this section.

2) Recheck initial ignition timing and ignition timing

advance, referring to IGNITION TIMING in this sec-

tion.

Is check result satisfactory?

System is in good

condition.

Substitute a known-

good ECM and then

repeat STEP 2.

IGNITION SPARK TEST

1) Disconnect injector couplers (1) from injectors.

WARNING:

Without disconnection of injector coupler, combus-

tible gas may come out from spark plug holes during

this test and may get ignited in engine room.

2) Remove spark plugs and connect them to high-tension cords,

and then ground spark plugs.

3) Crank engine and check if each spark plug sparks.

4) If no spark is emitted, inspect high-tension cords, spark plugs,

ignition coil, distributor, etc.

ON-VEHICLE SERVICE

HIGH-TENSION CORDS

REMOVAL

1) Remove high-tension cord at ignition coil while gripping its cap.

2) Remove distributor cap (1) installed with high-tension cords.

3) Remove high-tension cord clamp from cylinder head cover.

4) Pull out high-tension cords from spark plugs while gripping each

cap.

CAUTION:

D Removal of high-tension cords together with

clamps will be recommended so as not to damage

their inside wire (resistive conductor).

D For the same reason, pull out each connection by

gripping cap portion.

5) Measure resistance of high-tension cord by using ohmmeter.

High-tension cord resistance:

10 – 22 kW/m (3.0 – 6.7 kW/ft) Z–16 marked. . .

4 – 10 kW/m (1.3 – 3.3 kW/ft) Z– 7 marked. . .

1. Marking on cord (Z–7E or Z–16)

6F-6 IGNITION SYSTEM

6) If resistance exceeds specification, inspect distributor terminal

and replace high-tension cord(s) and/or distributor cap as re-

quired.

CAUTION:

D Never attempt to use metal conductor high-tension

cords as replacing parts.

D Insert each cap portion fully when installing high-

tension cords.

INSTALLATION

1) Reverse removal procedure for installation.

CAUTION:

D Never attempt to use metal conductor high-tension

cords as replacing parts.

D Insert each cap portion fully when installing high-

tension cords.

SPARK PLUGS

REMOVAL

1) Remove high-tension cords, referring to HIGH-TENSION

CORDS under ON-VEHICLE SERVICE earlier in this section.

2) Remove spark plugs.

INSPECTION

1) Inspect them for:

D Electrode wear

D Carbon deposits

D Insulator damage

2) If any abnormality is found, adjust air gap, clean with spark plug

cleaner or replace them with specified new plugs.

F8D engine

Spark plug air gap “a”: 0.8 – 0.9 mm (0.031 – 0.035 in.)

Spark plug type: NGK DCPR7E

F8B engine

Spark plug air gap “a”: 0.7 – 0.8 mm (0.028 – 0.031 in.)

Spark plug type: NGK BPR5ES

: DENSO W16EXR-U

IGNITION SYSTEM 6F-7

INSTALLATION

1) Install spark plugs and torque them to specification.

Tightening Torque for spark plug

15 N·m (1.5 kg-m, 10.5 lb-ft) F8D engine. . . .

25 N·m (2.5 kg-m, 18.0 lb-ft) F8B engine. . . .

2) Install high-tension cords, referring to HIGH-TENSION CORDS

under ON-VEHICLE SERVICE earlier in this section.

NOISE SUPPRESSOR

REMOVAL

1) Unwrap tape from nose suppressor.

2) Disconnect coupler of noise suppressor (1).

3) Remove noise suppressor.

INSPECTION

Using ohmmeter (1), check to be sure that capacitor (Condenser)

in noise suppressor (2) is not conductive.

If check result is not satisfactory, replace noise suppressor (2).

INSTALLATION

Reverse removal procedure for installation.

IGNITER

Before this inspection, prepare 5V power supply (3 new 1.5V bat-

teries), one 12V 3.4W light bulb and one 12V battery (fully

charged).

1) Remove ignition coil/igniter unit assembly from vehicle.

2) Remove igniter from bracket.

6F-8 IGNITION SYSTEM

3) Arrange 3 new batteries in series (1) (check total voltage is

above 4.7V)

4) Connect light bulb (2) between “c” terminal of igniter (3) and bat-

tery (4) positive (+) terminal, then connect battery negative (–)

terminal to igniter body.

Also connect battery positive (+) terminal, and “b” terminal/ of

igniter.

Check that the light bulb does not illuminate.

5) Connect negative (–) terminal of batteries and igniter body.

Check that the light bulb illuminate when positive (+) terminal of

batteries is connected to “a” terminal of igniter.

If inspection result is not satisfactory, replace igniter.

6) Install igniter.

IGNITION COIL

1) Pull out high-tension cord by gripping its cap.

2) Disconnect ignition coil coupler.

3) Measure primary and secondary coil resistances.

Ignition coil resistance (at 20_C/68_F)

Primary : 1.33 – 1.63 W (A). .

Secondary: 10.7 – 14.5 kW (B).

(A)

(B)

DISTRIBUTOR

INSPECTION

Distributor Cap and Rotor

Check cap and rotor for crack and their terminals for corrosion and

wear. Replace as necessary.

IGNITION SYSTEM 6F-9

Signal Rotor Air Gap

1) Remove distributor cap and rotor.

2) Using thickness gauge, measure air gap, between signal rotor

tooth (2) and CMP sensor (generator) (1).

Signal rotor air gap “a”: 0.2 – 0.4 mm (0.008 – 0.016 in.)

3) If gap is out of specification, loosen CMP sensor (signal genera-

tor) securing screws (3). Move CMP sensor (generator) and ad-

just gap to specification. After adjustment, tighten securing

screws and recheck gap.

NOTE:

Check to make sure that CMP sensor (signal generator)

tooth is free from any metal particles.

4) Install distributor cap and rotor.

CMP Sensor Resistance

1) Disconnect distributor lead wire coupler (1).

2) Measure resistance of CMP sensor by using ohmmeter.

CMP sensor resistance:

185 – 275 W (at -10–505C/ 14–1225F)

240 – 325 W (at 50–1005C/122–2125F)

3) If resistance is out of specification, replace CMP sensor as fol-

lows.

4) Remove distributor cap and rotor.

5) Remove CMP sensor securing screws.

6) Replace CMP sensor.

7) Adjust signal rotor air gap to specifications as previously out-

lined.

8) Install rotor, distributor cap seal and cap.

6F-10 IGNITION SYSTEM

IGNITION TIMING

NOTE:

Before starting engine, place transmission gear shift lever in

“Neutral” and set parking brake.

INSPECTION AND ADJUSTMENT

1) When using SUZUKI scan tool, connect SUZUKI scan tool to

DLC with ignition switch OFF.

Special Tool (when using SUZUKI scan tool)

(A): 09931-76011 (SUZUKI scan tool)

(B): Mass storage cartridge

(C): 09931-76030 (16/14 pin DLC adapter)

2) Start engine and warm it up to normal operating temperature.

3) Make sure that all of electrical loads except ignition are

switched off.

4) Check to be sure that idle speed is within specification. (Refer

to SECTION 6E1).

5) Set timing light to No.1 high-tension cord.

6) Fix ignition timing to initial one as follows:

When using SUZUKI scan tool:

a) Select “MISC” mode on SUZUKI scan tool and fix ignition

timing to initial one.

When not using SUZUKI scan tool:

a) Disconnect scan tool from DLC if connected and connect

A and B terminals of monitor coupler by using service wire

so that ignition timing is fixed on initial one.

IGNITION SYSTEM 6F-11

7) Using timing light (1), check that timing is within specification.

Initial ignition timing (Test switch terminal grounded or

fixed by scan tool):

5 " 15 BTDC (at idle speed)

Ignition order 1-3-2

F8B engine

F8D engine

8) If ignition timing is out of specification, remove air cleaner as-

sembly then loosen flange bolts (1), adjust timing by turning

distributor assembly (2) while engine is running, and then

tighten bolts (1).

Tightening Torque

(a): 23 N·m (2.3 kg-m, 14.0 lb-ft)

9) After tightening distributor flange bolts, recheck that ignition

timing is within specification.

10) After checking and/or adjusting initial ignition timing, release

ignition timing fixation by SUZUKI scan tool or disconnect ser-

vice wire from monitor coupler.

11) With engine idling (test switch terminal ungrounded, vehicle

stopped), check that ignition timing is about 85 BTDC

(Constant variation within a few degrees from 85 indicates no

abnormality but proves operation of electronic timing control

system). Also, check that increasing engine speed advances

ignition timing.

If above check results are not satisfactory, check test switch

terminal circuit and ECM.

6F-12 IGNITION SYSTEM

REMOVAL

1) Disconnect negative cable at battery.

2) Disconnect distributor connector.

3) Disconnect high tension cords from distributor cap.

4) Remove distributor cap. Then to facilitate re-installation, turn

crankshaft in normal direction (clockwise as viewed from crank-

shaft pulley side) so that distributor rotor is positioned at No.1

terminal of distributor cap.

5) Remove distributor flange bolt.

6) Pull out distributor housing assembly.

IGNITION SYSTEM 6F-13

DISTRIBUTOR UNIT

1. Cap

2. Cap seal

3. Cap screw

4. Rotor

5. CMP sensor (Signal generator)

6. Housing

7. O-ring

INSTALLATION

1) If distributor rotor has not been positioned at No.1 terminal of

distributor cap in distributor removal, perform following step.

a) Turn over crankshaft in normal direction (clockwise as

viewed from crankshaft pulley side) until Timing notch (2)

on pulley aligns with timing mark “0” (1) on timing tab or “T”

mark on flywheel (1).

b) After aligning two marks, remove cylinder head cover to

visually confirm that rocker arms are not riding on camshaft

cams at No.1 cylinder. If the arms are found to be riding on

the cams, turn over crankshaft 360_ to align two marks

anew.

2) Check O-ring for damage and deterioration.

Replace if necessary.

NOTE:

If O-ring is installed, apply engine oil to it.

3) Align punch mark on gear with dent mark on housing.

4) Insert distributor into gear case in such a way that the center

of distributor flange bolt (1) will coincide with distributor flange

bolt hole (2) provided in distributor gear case. When inserting

the distributor completely, position of distributor rotor becomes

as shown in figure. Secure distributor in place tentatively by

making flange bolt finger-tight.

5) Check to make sure that rotor is in good condition.

6) Inspect distributor cap and clean or replace as required.

7) Make sure that distributor cap seal is placed properly and

install cap, and then fasten it with screws.

8) Connect distributor coupler.

9) Connect negative cable at battery.

10) Check and adjust ignition timing as previously outlined, refer

to IGNITION TIMING in this section.

6F-14 IGNITION SYSTEM

IGNITION SYSTEM 6F-15

SPECIAL TOOLS

09900-27301

Timing light (DC 12 V)

09930-76420

Timing light (Dry cell type)

09900-25002

Pocket tester

Ignition System for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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