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

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

Ignition System -> On-Vehicle Service for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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