Section 6-2

6A-66 ENGINE MECHANICAL
Flywheel
If ring gear is damaged, cracked or worn, replace flywheel.
If the surface contacting clutch disc is damaged, or excessively
worn, replace flywheel.
Check flywheel for face runout with dial gauge.
If runout exceeds its limit, replace flywheel.
Limit on runout: 0.2 mm (0.0078 in.)
Cylinder Block
Distortion of gasketed surface
Using straightedge and thickness gauge, check gasketed surface
for distortion and, if flatness exceeds its limit, correct it.
Item Limit
0.03 mm
Flatness
(0.0012 in.)
Honing or reboring cylinders

1) When any cylinder needs reboring, all other cylinders must also
be rebored at the same time.
2) Select oversized piston according to amount of cylinder wear.
Size Piston diameter
68.720 – 68.740 mm
O/S 0.25
(2.7055 – 2.7062 in.)
68.970 – 68.990 mm
O/S 0.50
(2.7154 – 2.7161 in.)
3) Using micrometer, measure piston diameter.
1. 20 mm (0.79 in.)
4) Calculate cylinder bore diameter to be rebored.

D = A+B–C
D:Cylinder bore diameter to be rebored.
A: Piston diameter as measured.
B: Piston clearance = 0.025 – 0.045 mm
(0.0009 – 0.0017 in.)
C:Allowance for honing = 0.02 mm (0.0008 in.)
ENGINE MECHANICAL 6A-67
5) Rebore and hone cylinder to calculated dimension.

NOTE:
Before reboring, install all main bearing caps in place and
tighten to specification to avoid distortion of bearing
bores.
6) Measure piston clearance after honing.
INSTALLATION
NOTE:
All parts to be installed must be perfectly clean.
Be sure to oil crankshaft journals, journal bearings, thrust
bearings, crankpins, connecting rod bearings, pistons, pis-
ton rings and cylinder bores.
Journal bearings, bearing caps, connecting rods, rod bear-
ings, rod bearing caps, pistons and piston rings are in com-
bination sets. Do not disturb such combination and make
sure that each part goes back to where it came from, when
installing.
1) Install main bearings to cylinder block (1).

One of two halves of main bearing (2), has an oil groove (3).
Install it to cylinder block, and the other half without oil groove
to bearing cap.
Make sure that two halves are painted in the same color.
2) Install thrust bearings (1) to cylinder block between No.2 and

No.3 cylinders. Face oil groove (2) sides to crank webs.
3) Install crankshaft to cylinder block.

4) Install bearing cap to cylinder block, making sure to point arrow
mark (on each cap) to crankshaft pulley side. Fit them sequen-
tially in ascending order, 1, 2, 3, 4 and 5, starting from pulley
side.
After installing bearing cap stiffeners, tighten bearing cap bolts
in such order as shown in figure a little at a time and repeat it till
they are tightened to specified torque.
Tightening Torque
(a): 47 N.m (4.7 kg-m, 34.0 lb-ft)
NOTE:
After tightening cap bolts, check to be sure that crankshaft
rotates smoothly when turning it by 8.0 N.m (0.8 kg-m, 5.8
lb-ft) torque or below.
5) Install new gasket and oil seal housing.

Do not reuse gasket removed in disassembly. Apply engine oil
to oil seal lip before installation. Tighten housing bolts to specifi-
cation.
Tightening Torque
(a): 11 N.m (1.1 kg-m, 8.0 lb-ft)
NOTE:
As there are 2 types (long bolts (1) and short bolts (2)) of
housing bolts, refer to figure for their correct use.
After installing oil seal housing, gasket edges might bulge out;
if so, cut them off to make them flush with cylinder block and oil
seal housing.
6) Install oil pump.
Refer to item OIL PUMP for installation of oil pump.
7) Install flywheel (M/T model).

Using special tool, lock flywheel or drive plate, and torque its
bolts (1) to specification.
Special Tool
(A): 09924-17810
Tightening Torque
(a): 42 N.m (4.2 kg-m, 30.5 lb-ft)
8) Install pistons and connecting rods as previously outlined.

9) Install oil pump strainer and oil pan as previously outlined.
10) Install cylinder head assembly to cylinder block as previously

outlined.
NOTE:
Tighten cylinder head bolts to specified torque as pre-
viously outlined and loosen them once till tightening
torque becomes “zero”. And then torque them to specifi-
cation again.
11) Install camshaft, crankshaft timing belt pulley, timing belt,
crankshaft pulley, water pump pulley, etc., as previously out-
lined.
12) Install clutch to flywheel (for M/T vehicle). For clutch installa-
tion, refer to CLUTCH section.
13) Install engine mountings brackets.

14) Install engine assembly to vehicle as previously outlined.
REQUIRED SERVICE MATERIALS
RECOMMENDED
MATERIALS USE
SUZUKI PRODUCT
Mating surfaces of cylinder block and oil pan.

SUZUKI BOND NO. 1207C
Sealant Mating surface of camshaft housing No.1 and
(99000-31150)
housing end
SPECIAL TOOLS
1. 09915-64510-001
Compression gauge
2. 09915-64510-002
Connector
3. 09915-64530
09913-75520 Hose 09915-67310
4. 09915-64550 09915-77310
Bearing installer Attachment Vacuum gauge Oil pressure gauge
09916-14510 09916-14910 09916-34542 09916-34550

Valve lifter Valve lifter attachment Reamer handle Reamer (5.5 mm)
09916-57340 09916-58210
09916-37320 09916-44910 Valve guide installer Valve guide installer
Reamer (10.5 mm) Valve guide remover attachment handle
09916-77310 09917-18210 09917-68221 09917-98221

Piston ring compressor Tappet adjuster wrench Camshaft pulley holder Valve stem seal installer
09926-18210
09918-08210 09924-17810 Oil seal guide
Vacuum gauge hose joint Flywheel holder (Vinyl resin)
ENGINE COOLING 6B-1
SECTION 6B
ENGINE COOLING 6B
CONTENTS
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B- 2

Cooling System Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B- 2
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B- 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B- 4
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B- 4
Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B- 5
Cooling System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B- 5
Cooling System Flush and Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B- 6
Water Pump Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B- 7
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B- 8
Cooling System Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B- 8
Cooling Water Pipes or Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B- 8
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B- 9
Water Pump Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-11
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-12
REQUIRED SERVICE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13
6B-2 ENGINE COOLING
GENERAL DESCRIPTION
The cooling system mainly consists of the radiator cap, radiator, coolant reservoir tank, hoses, water pump, cooling
fan and thermostat. The radiator is of tube-and-fin type.
COOLING SYSTEM CIRCULATION

1) While the engine is warmed up (thermostat closed), coolant circulates as follows.
Throttle body
Water pump Cylinder block Cylinder head Water intake pipe
Heater unit ( A/T oil cooler)
Thermostat closed
2) When coolant is warmed up to normal temperature and the thermostat opens, coolant passes through the radia-
tor core to be cooled as well as the above flow circuit.
16
1. Radiator inlet hose 6. Throttle body 11. Radiator 16. Heater unit
2. Radiator outlet hose 7. Cylinder block 12. Reservoir tank
3. Water intake pipe 8. Cylinder head 13. Radiator cap : A/T vehicle
4. Thermostat 9. Heater inlet hose (if equipped) 14. Cooling fan
5. Water pump 10. Heater outlet hose (if equipped) 15. A/T oil cooler
ENGINE COOLING 6B-3
DIAGNOSIS
Symptom Possible Cause Remedy

Engine overheats D Loose or broken water pump belt Adjust or replace.
D Not enough coolant Check coolant level and add as necessary.
D Faulty thermostat Replace.
D Faulty water pump Replace.
D Dirty or bent radiator fins Clean or remedy.
D Coolant leakage on cooling system Repair.
D Defective cooling fan motor Check and replace as necessary.
D Faulty fan motor control circuit Refer to SECTION 6E.
D Plugged radiator Check and replace radiator as necessary.
D Faulty radiator cap Replace.
D Improper ignition timing Adjust.
D Dragging brakes Adjust brake.
D Slipping clutch Adjust or replace.
6B-4 ENGINE COOLING
MAINTENANCE
COOLANT done even if freezing temperatures are not ex-
pected.
The coolant recovery system is standard. The coolant D Add ethylene glycol base coolant when coolant has
in the radiator expands with heat, and the overflow is to be added because of coolant loss or to provide
collected in the reservoir tank. added protection against freezing at temperature
When the system cools down, the coolant is drawn lower than –36C (–33F).
back into the radiator.
NOTE:
The cooling system has been filled at the factory with D Alcohol or methanol base coolant or plain
a quality coolant that is a 50/50 mixture of water and water alone should not be used in cooling
ethylene glycol antifreeze (70/30; in a market where system at any time as damage to cooling sys-
no freezing temperature is anticipated). tem could occur.
D Even in a market where no freezing tempera-
This 50/50 mixture coolant solution provides freezing ture is anticipated, mixture of 70% water and
protection to –36C (–33F). 30% ethylene glycol antifreeze (Antifreeze/
D Maintain cooling system freeze protection at Anticorrosion coolant) should be used for
–36C (–33F) to ensure protection against corro- the purpose of corrosion protection and lu-
sion and loss of coolant from boiling. This should be brication.
ANTI-FREEZE PROPORTIONING CHART
C –16 –36
R-
OPOR
Freezing temperature
F 3 –33
EZE PRO
NG CHART
Anti-freeze/Anti-corrosion
% 30 50
coolant concentration
FREE
C
ltr. 1.05/2.45 1.75/1.75

ONIN
NTI-F
Ratio of compound to cooling water US pt. 2.22/5.18 3.70/3.70

TIO
AN
lmp pt. 1.85/4.31 3.08/3.08
3.1 liters
Engine radiator and heater
(6.55/5.46 US/Imp. pt.)
TY
COOLANNT
CAPACIT
0.40 liters
Reservoir tank
(0.85/0.70 US/lmp. pt.)
C
C
3.5 liters
Total
(7.40/6.16 US/Imp. pt.)
ENGINE COOLING 6B-5
COOLANT LEVEL
Coolant Level
To check level, lift hood and look at “see-through” coolant reservoir
tank.
It is not necessary to remove radiator cap to check coolant level.
WARNING:
To help avoid danger of being burned:
D do not remove reservoir tank cap while coolant is boil-
ing, and
D do not remove radiator cap while engine and radiator
are still hot.
Scalding fluid and steam can be blown out under pres-
sure if either cap is taken off too soon.
When engine is cool, check coolant level in reservoir tank (1).

A normal coolant level should be between FULL and LOW marks
on reservoir tank.
If coolant level is below LOW mark (2), remove reservoir tank cap
and add proper coolant to tank to bring coolant level up to FULL
mark (3). Then, reinstall cap (4) and align match marks on tank and
cap.
NOTE:
D If proper quality antifreeze is used, there is no need to add
extra inhibitors or additives that claim to improve system.
They may be harmful to proper operation of system, and are
unnecessary expense.
D When installing reservoir cap, align arrow marks on reser-
voir and cap.
COOLING SYSTEM SERVICE

WARNING:
To help avoid danger of being burned, do not remove ra-
diator cap while engine and radiator are still hot.
Scalding fluid and steam can be blown out under pres-
sure if cap is taken off too soon.
Cooling system should be serviced as follows.

1) Check cooling system for leakage or damage.
2) Wash radiator cap and filler neck with clean water by removing
radiator cap when engine is cold.
3) Check coolant for proper level and freeze protection.
6B-6 ENGINE COOLING
4) Using a pressure tester (1), check system and radiator cap (2)
for proper pressure holding capacity about 110 kPa (1.1 kg/cm2,
15.6 psi). If replacement of cap is required, use a proper cap for
this vehicle.
NOTE:
After installing radiator cap to radiator, make sure that the
ear of cap lines is parallel to radiator.
5) Tighten hose clamps and inspect all hoses. Replace hoses
whenever cracked, swollen or otherwise deteriorated.
6) Clean frontal area of radiator core.
COOLING SYSTEM FLUSH AND REFILL

1) Remove radiator cap when engine is cool:
Turn cap counterclockwise slowly until it reaches a “stop”.
(Do not press down while turning it.)
Wait until pressure is relieved (indicated by a hissing sound)
then press down on cap and continue to turn it counterclock-
wise.
WARNING:
To help avoid danger of being burned, do not remove
radiator cap while engine and radiator are still hot.
Scalding fluid and steam can be blown out under
pressure if cap is taken off too soon.
2) With radiator cap removed, run engine until upper radiator

hose is hot (this shows that thermostat is open and coolant is
flowing through system).
3) Stop engine and drain coolant.

4) Close drain plug. Add water until system is filled and run en-
gine until upper radiator hose is hot again.
5) Repeat steps 3) and 4) several times until drained liquid is
nearly colorless.
6) Drain system and then close radiator drain plug (1) tightly.
ENGINE COOLING 6B-7
7) Remove reservoir tank (1) and remove cap (2) from reservoir
tank and pour out any fluid, scrub and clean inside of tank with
soap and water.
Flush it well with clean water and drain. Reinstall tank.
8) Add 50/50 mixture of good quality ethylene glycol antifreeze
and water to radiator and tank.
Fill radiator to the base of radiator filler neck and reservoir tank
to FULL level mark (3). Reinstall reservoir tank cap and align
match marks (4) on tank and cap.
9) Run engine, with radiator cap removed, until radiator upper
hose is hot.
10) With engine idling, add coolant to radiator until level reaches
the bottom of filler neck. Install radiator cap, making sure that
the ear of cap lines is parallel to radiator.
WATER PUMP BELT TENSION

WARNING:
D Disconnect negative cable at battery before checking
and adjusting belt tension.
D See WARNING described in COOLING SYSTEM SER-
VICE.
1) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
If it is necessary to replace belt, refer to page 6B-10 for proce-
dure.
2) Check belt (4) for tension. Belt is in proper tension when it de-
flects 12 – 15 mm (0.47 – 0.59 in.) under thumb pressure (1)
(about 10 kg or 22 Ib.).
Belt tension “a”: 3 – 4 mm (0.12 – 0.16 in.) as deflection
NOTE:
When replacing belt with a new one, adjust belt tension to
6 – 7 mm (0.24 – 0.28 in.).
3) If belt is too tight or too loose, adjust it to proper tension by dis-
placing generator position.
4) Tighten belt adjusting bolt (2) and generator pivot bolts (3).
5) Connect negative cable at battery terminal.
6B-8 ENGINE COOLING
ON-VEHICLE SERVICE
WARNING:
D Check to make sure that engine coolant temperature
is cold before removing any part of cooling system.
D Also be sure to disconnect negative cord from battery
terminal before removing any part.
COOLING SYSTEM DRAINING

1) Remove radiator cap.
2) Loosen drain plug (1) on radiator to drain coolant.
3) After draining coolant, be sure to tighten drain plug securely.
4) Fill cooling system. (Refer to Item COOLANT of MAINTE-
NANCE.)
COOLING WATER PIPES OR HOSES

REMOVAL
1) Drain cooling system.
2) To remove these pipes or hoses, loosen clamp on each hose
and pull hose end off.
INSTALLATION
Install removed parts in reverse order of removal procedure, noting
the following.
D Tighten each clamp securely.
D Refill cooling system with proper coolant, referring to description
on COOLANT of MAINTENANCE.
ENGINE COOLING 6B-9
THERMOSTAT
REMOVAL
1) Drain coolant and tighten drain plug.
2) Remove air cleaner case together with air inlet hose.
3) Remove thermostat cap (1) with air cleaner case bracket.
4) Remove thermostat (2) and gasket.
INSPECTION
1) Make sure that air bleed valve (1) of thermostat is clean.
Should this valve be clogged, engine would tend to overheat.
2) Check to make sure that valve seat is free from foreign matters
which would prevent valve from seating tight.
4) Check thermostatic movement of wax pellet as follows:

(1) Immerse thermostat in water, and heat water gradually.
(2) Check that valve starts to open at specific temperature.
(3) If valve starts to open at a temperature substantially below
or above specific temperature, thermostat unit should be re-
placed with a new one. Such a unit, if reused, will bring about
overcooling or overheating tendency.
Thermostat functional spec. "1.5C (2.7F)
Temp. at which valve begins

82C (179F)
to open
Temp. at which valve be-
95C (203F)
come fully open
Valve lift More than 8 mm at 95C
1. Thermostat
2. Thermometer
3. Heater
6B-10 ENGINE COOLING
INSTALLATION
1) When positioning thermostat (1) on thermostat case (2), be
sure to position it so that air bleed valve (3) comes at position
as shown in figure.
2) Install gasket.
NOTE:
Use new gasket.
3) Install thermostat cap to thermostat case.

4) Connect cooling water hose.
5) Fill cooling system (refer to page 6B-6, 6B-7).
6) Install air cleaner case.
7) Connect negative cable at battery.
8) After installation, check each part for leakage.
WATER PUMP BELT

REMOVAL
1) Disconnect negative cable at battery.
2) Loosen drive belt adjusting bolt (2) and generator pivot bolts (3).
When servicing car equipped with A/C, remove compressor
drive belt before removing water pump belt (1).
3) Slacken belt by displacing generator and then remove it.
INSTALLATION
1) Install belt to water pump pulley, crankshaft pulley and genera-
tor pulley.
When servicing car equipped with A/C, install compressor drive
belt, too.
2) Adjust A/C compressor drive belt tension.
For Adjustment of compressor drive belt tension, refer to SEC-
TION 0B of this manual.
3) Tighten water pump belt adjusting bolt and pivot bolts.
4) Connect negative cable at battery.
WATER PUMP BELT TENSION INSPECTION AND AD-

JUSTMENT
For this inspection or adjustment, refer to WATER PUMP BELT
TENSION.
ENGINE COOLING 6B-11
RADIATOR
REMOVAL
2) Drain cooling system by loosening drain plug (1) of radiator.
3) Disconnect coupler of cooling fan motor.
4) Remove air cleaner case and air intake hose (see SECTION
6A).
5) Remove A/C condenser mounting bolts (3) (if equipped) and

radiator bolts (1).
6) Disconnect radiator inlet and outlet hoses and reservoir tank
hose from radiator.
2. A/C condenser (if equipped)
7) Remove A/C receiver/dryer mounting bolts (1) from cooling

fan.
8) Remove 3 cooling fan mounting bolts and take out cooling fan
unit.
9) Pull out A/C condenser a little and make its bottom off from ra-
diator.
10) Remove radiator from vehicle.
INSPECTION
Check radiator for leakage or damage. Straighten bent fins, if any.
CLEANING
Clean frontal area of radiator cores.
INSTALLATION
Reverse removal procedures.
NOTE:
D Refill cooling system with proper coolant referring to
COOLANT item of MAINTENANCE.
D Refer to the figure at REMOVAL for tightening torque.
D After installation, check each joint for leakage.
6B-12 ENGINE COOLING
WATER PUMP
2) Drain cooling system.
3) Remove oil level gauge guide with oil level gauge.
4) Remove timing belt and tensioner according to procedure de-
scribed in item “TIMING BELT AND TENSIONER” of SECTION
6A.
5) Remove water pump (1), gasket (2) and rubber seal.
INSPECTION
NOTE:
Do not disassemble water pump.
If any repair is required on pump, replace it as assembly.
Rotate water pump by hand to check for smooth operation.
If pump does not rotate smoothly or makes abnormal noise, re-
place it.
INSTALLATION
1) Install new pump gasket (1) to cylinder block.
2) Install water pump (1) to cylinder block.

Tightening Torque
(a): 11 N·m (1.1 kg-m, 8.0 lb-ft)
3) After installing water pump, install rubber seal (2).
4) Install belt tensioner, timing belt and timing belt outside cover
according to procedure described in item “TIMING BELT AND
TENSIONER” of SECTION 6A.
ENGINE COOLING 6B-13
5) With engine oil applied to O-ring, install oil level gauge guide.
6) Adjust drive belt tension.
7) Fill cooling system.
8) After installation, check each part for leakage.
REQUIRED SERVICE MATERIAL
MATERIALS USE
Ethylene glycol base coolant Additive to engine cooling system for improving cooling effi-
(Anti-freeze/Anti-corrosion coolant) ciency and for protection against rusting.
ENGINE FUEL 6C-1
SECTION 6C
ENGINE FUEL
6C
CONTENTS
GENERAL DESCRIPTION . . . . . . . . . . . . . . 6C- 1 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C- 4
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 6C- 1 Fuel Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C- 4
DIAGNOSIS Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . 6C- 5
Diagnosis Chart . . . . . . . . . . Refer to SECTION 6 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C- 6
Fuel Pump Assembly (With Fuel Level
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 6C- 2
Gauge and Fuel Cut Valve) . . . . . . . . . . 6C-11
Precautions . . . . . . . Refer to SECTION 0A and 6
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . 6C-13
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C- 3
GENERAL DESCRIPTION
FUEL SYSTEM
The main components of the fuel system are fuel tank, fuel pump (with fuel level gauge) and fuel filter. And there
are three lines, fuel feed line, fuel return line and fuel vapor line.
For the details of fuel flow and fuel vapor flow, refer to SECTION 6E.
1. Fuel tank
2. Fuel pump (with fuel level gauge)
3. Fuel filter
4. Fuel filler cap
5. Breather hose
6. Fuel feed line (to delivery pipe)
7. Fuel return line (from delivery pipe)
8. Fuel vapor line (to EVAP canister)
9 Fuel tank bolt
’99
YM1 (E)
6C-2 ENGINE FUEL
DIAGNOSIS
DIAGNOSIS CHART
Refer to SECTION 6.
With short pipe, fit hose as far as it reaches pipe joint

ON-VEHICLE SERVICE
as shown.
Hose
PRECAUTIONS
WARNING:
Pipe Before attempting service of any type on fuel system, fol-
lowing cautions should be always observed.
Clamp Clamp securely at a position
Disconnect negative cable at battery.
3 to 7 mm (0.12 – 0.27 in.) DO NOT smoke, and place “NO SMOKING” signs near
from hose end.
work area.
Be sure to have CO2 fire extinguisher handy.
With following type pipe, fit hose as far as its peripheral
projection as shown.
Be sure to perform work in a well-ventilated area and away
from any open flames (such as gas hot heater).
Wear safety glasses.
To release fuel vapor pressure in fuel tank, remove fuel fill-
er cap from fuel filler neck and then reinstall it.
As fuel feed line is still under high fuel pressure even after
Clamp securely at a position
3 to 7 mm (0.12 – 0.27 in.) engine was stopped, loosening or disconnecting fuel feed
from hose end. line directly may cause dangerous spout of fuel to occur
where loosened or disconnected. Before loosening or dis-
With bent pipe, fit hose as far its bent part as shown connecting fuel feed line, make sure to release fuel pres-
or till pipe is about 25 to 30 mm (0.98 – 1.18 in.) into
the hose. sure according to procedure described in SECTION 6.
A small amount of fuel may be released after the fuel line
is disconnected.
In order to reduce the chance of personal injury, cover the
fitting to be disconnected with a shop cloth. Put that cloth
in an approved container when disconnection is com-
Clamp securely at a position pleted.
3 to 7 mm (0.12 – 0.27 in.)
from hose end. Note that fuel hose connection varies with each type of
pipe. Be sure to connect and clamp each hose correctly
referring to the following.
With straight pipe, fit hose till pipe is about 25 to 30 mm
When performing any work that requires to lift up vehicle,
(0.98 – 1.18 in.) in the hose.
Hose check fuel hose clamp for rust.
For other information, refer to Precautions in SECTION 0A
and SECTION 6 of this manual.
25 to 30 mm
(0.98 – 1.18 in.)
Clamp
Clamp securely at a position 3 to 7 mm

(0.12 – 0.27 in.) from hose end.
’99
YM1 (E)
ENGINE FUEL 6C-3
FUEL FILTER
REMOVAL
1) Relieve fuel pressure in fuel feed line referring to SECTION 6.
CAUTION:
This work must not be done when engine is hot. If done
so, it may cause adverse effect to catalyst.

3) Hoist vehicle.
4) Disconnect inlet (1) and outlet (2) hoses from fuel filter.
WARNING:
A small amount of fuel may be released after fuel line is
disconnected. In order to reduce the chance of personal
injury, cover the fitting to be disconnected with a shop
cloth. Be sure to put that cloth in an approved container
when disconnection is completed.
5) Remove 2 nuts (3) and then fuel filter (4) with bracket from fuel
tank.
INSTALLATION
Reverse removal procedure noting the following.
Tighten fuel filter nuts (1) to specified torque.
Upon completion of installation, verify that there is no fuel leakage
at each connection referring to SECTION 6.
Tightening Torque
(a): 23 N.m (2.3 kg-m, 16.5 lb-ft)
’99
YM1 (E)
6C-4 ENGINE FUEL
FUEL LINES
Due to the fact that fuel feed line is under high pressure, use special
care when servicing it.
INSPECTION
Visually inspect fuel lines for evidence of fuel leakage, hose crack
and deterioration, or damage.
Make sure all clamps are secure.
Replace parts as needed.
FUEL PIPE
REMOVAL
1) Relieve fuel pressure in fuel feed line according to procedure on
SECTION 6.
3) Remove steering gear box ass’y. Refer to SECTION 3B of this
manual for details.
4) Remove pipe cover (1) from vehicle.
5) Disconnect fuel hoses from fuel pipe at the front and rear of each
fuel pipe.
WARNING:
A small amount of fuel may be released after fuel hose is
disconnected. In order to reduce the chance of personal
injury, cover hose and pipe to be disconnected with a
shop cloth.
Be sure to put that cloth in an approved container when
disconnection is completed.
’99
YM1 (E)
ENGINE FUEL 6C-5
3 6) Mark the location (1) of clamps (2) on fuel pipes, so that the
clamps can be reinstalled to where they were.
1 7) Remove pipes (3) with clamp from vehicle.
1
8) Remove clamp from pipes.
INSTALLATION
1) Install clamps to marked location on pipes. If clamp is deformed
or its claw is bent or broken, replace it with new one.
2) Install pipes with pipe clamps to vehicle.
3) Connect fuel hoses to each pipe.

4) Install pipe cover (2) to vehicle.
5) Install steering gear box. Refer to Section 3B of this manual for
details.
6) With engine “OFF” and ignition switch “ON”, check for fuel leaks.
1. Clamp
FUEL FILLER CAP

Remove cap, and check gasket for even filler neck imprint, and de-
terioration or any damage. If gasket is in malcondition, replace cap.
NOTE:
If cap requires replacement, only a cap with the same features
should be used. Failure to use correct cap can result in critical
malfunction of system.
1. Fuel filler cap
2. Gasket
’99
YM1 (E)
6C-6 ENGINE FUEL
FUEL TANK
REMOVAL
1) Relieve fuel pressure in fuel feed line referring to SECTION 6.
CAUTION:
This work must not be done when engine is hot. If done
so, it may cause adverse effect to catalyst.
3) Insert hose of a hand operated pump into fuel filler hose (1) and
drain fuel in space “A” in the figure (drain fuel through it till fuel
stops).
CAUTION:
Do not force hose of a hand operated pump into fuel tank.
Doing so can damage inlet valve (2).
4) Disconnect filler hose (1) from fuel tank (2) and breather hose
from fuel filler neck.
5) Remove fuel tank inlet valve (3).
Use care not to damage inlet valve when removing.
6) Drain fuel tank by pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
CAUTION:
Never drain or store fuel in an open container due to pos-
sibility of fire or explosion.
’99
YM1 (E)
ENGINE FUEL 6C-7
7) Remove fuel filter (1) referring to “Fuel Filter” previously de-

scribed in this section.
8) Disconnect fuel vapor hose (1) and return hose (2) from pipes.
9) Lower fuel tank gradually while holding it horizontally and pull

out coupler (1) at fuel pump.
INSPECTION
After removing fuel tank, check hoses and pipes connected to fuel
tank for leaks, loose connections, deterioration or damage. Also
check fuel pump and level gauge gaskets for leaks, visually inspect
fuel tank for leaks and damage.
Replace any damaged or malconditioned parts.
’99
YM1 (E)
6C-8 ENGINE FUEL
Fuel Tank Purging Procedure
WARNING:
This purging procedure will NOT remove all fuel vapor.
Do not attempt any repair on tank using heat of flame as an
explosion resulting in personal injury could occur.
Following procedure is used purging fuel tank.

1) After removing fuel tank, disconnect fuel feed hose (1), fuel va-
por hose (2) and fuel return hose (3) from fuel pump assembly.
When disconnecting joint (4) of fuel feed line or return line from
pipe, unlock joint (4) by inserting special tool between pipe and
joint lock first.
Special Tool
(A): 09919-47020
1. Joint
2. Fuel return hose Disconnect joint from pipe.
3. Fuel feed hose
4. Fuel vapor hose
1: Before disconnecting, blow off dust, etc. of this WARNING:
portion with compressed air.
A small amount of fuel may be released after the fuel
hose is disconnected. In order to reduce the chance of
personal injury, cover the hose and pipe to be discon-
nected with a shop cloth. Be sure to put that cloth in an
approved container when disconnection is completed.
2) Remove fuel pump assembly from fuel tank.

3) Drain all remaining fuel from tank.
4) Move tank to flushing area.
5) Fill tank with warm water or tap water, and agitate vigorously and
drain. Repeat this washing until inside of tank is clean.
Replace tank if its inside is rusty.
6) Completely flush out remaining water after washing.
CAUTION:
Never remain water in fuel tank after washing, or fuel tank
inside will get corrosion.
’99
YM1 (E)
ENGINE FUEL 6C-9
INSTALLATION
1) If parts have been removed from fuel tank, install them before
installing fuel tank to vehicle.
2) Connect fuel vapor hose (1) (refer to 6C-2 for connection) and
pipe joints (2) to fuel pump assembly, and clamp hoses securely.
CAUTION:
When connecting joint, clean outside surfaces of pipe
where joint is to be inserted, push joint into pipe till joint
lock clicks and check to ensure that pipes are connected
securely, or fuel leak may occur.
3) With fuel tank supported on jack, connect coupler to fuel pump
assembly.
4) Install fuel tank to vehicle.
Tightening Torque for fuel tank bolts

(a): 23 N·m (2.3 kg-m, 17.0 lb-ft)
3. Fuel feed hose
5) Connect fuel filler hose (1) to fuel tank (4) and breather hose (2)
to fuel filler neck (3) and clamp hoses securely.
Tightening Torque
(a): 1.5 N·m (0.15 kg-m, 1.0 lb-ft)
’99
YM1 (E)
6C-10 ENGINE FUEL
6) Connect fuel vapor hose (1) and return hose (2) to fuel pipe.
Clamp them securely.
7) Install fuel filter (3) and tighten 2 nuts. Connect fuel filter inlet
and outlet hoses to fuel filter.
Tightening Torque
(a): 23 N·m (2.3 kg-m, 16.5 lb-ft)
8) Connect negative cable to battery.

9) Upon completion of installation, check fuel system for leakage.
’99
YM1 (E)
ENGINE FUEL 6C-11
FUEL PUMP ASSEMBLY (WITH FUEL LEVEL

GAUGE AND FUEL CUT VALVE)
WARNING:
Refer to the WARNING at the beginning of ON-VEHICLE
SERVICE in this section.
REMOVAL
1) Remove fuel tank from vehicle. Refer to “Fuel Tank” in this sec-
tion.
2) Disconnect fuel breather hose (1) and, fuel vapor hose (2) from
fuel pump assembly.
When disconnecting joint (3) of fuel feed line and return line from
pipe, unlock joint by inserting special tool between pipe and joint
lock first.
Special Tool
(A): 09919-47020
3) Remove fuel pump assembly (1) from fuel tank.
’99
YM1 (E)
6C-12 ENGINE FUEL
INSPECTION
Check fuel pump assembly for damage.
Check fuel suction filter (1) for evidence of dirt and contamination.
If present, replace or clean and check for presence of dirt in fuel
tank.
For inspection of fuel pump itself, refer to Section 6E of this manual.
For inspection of fuel level gauge, refer to Section 8 of this manual.
2. Bracket assembly
3. Fuel pump motor &
level gauge assembly
DISASSEMBLY/REASSEMBLY
“A”: Apply oil

1. Bracket sub assembly
2. Grommet
3. Return outlet
4. Lead wire
5. Fuel level gauge
(Fuel sender gauge)
6. Fuel pump
7. Cushion
8. Bracket
9. Spacer
10. O-ring
CAUTION:
While removing fuel level gauge, do not contact resis-
tor plate or deform arm. It may cause fuel level gauge
to fail.
When removing grommet from bracket sub assembly,
be very careful not to cause damage to grommet
installed section (sealed section in bore). Should it be
damaged, replace it with new one, or fuel will leak from
that part.
NOTE
When removing fuel level gauge, unhook snap-fit part and
slide it out.
When installing fuel level gauge to housing, make sure that
both sides of snap fit part are hooked on bracket subassem-
bly.
’99
YM1 (E)
ENGINE FUEL 6C-13
INSTALLATION
(a)
1) Clean mating surfaces of fuel pump assembly (1) and fuel tank.
2) Install new gasket (2) and plate (3) to fuel pump assembly (1)
then install fuel pump assembly to fuel tank.
TIghtening Torque
(a): 10 N.m (1.0 kg-m, 7.5 lb-ft)
3) Connect fuel feed hose (1), return hose (2) and fuel vapor hose
(3) to fuel pump assembly.
CAUTION:
When connecting joint, clean outside surfaces of pipe
where joint is to be inserted, push joint into pipe till joint
lock clicks and check to ensure that pipes are connected
securely, or fuel leak may occur.
4) Install fuel tank to vehicle. Refer to “Fuel Tank” in this section.
SPECIAL TOOL
09919-47020
Quick joint remover
’99
YM1 (E)
ENGINE AND EMISSION CONTROL SYSTEM 6E1-1
SECTION 6E1
ENGINE AND EMISSION CONTROL SYSTEM

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by 6E1
an authorized MARUTI dealer. Refer to AIR BAG SYSTEM COMPONENTS AND WIRING
LOCATION VIEW of GENERAL DESCRIPTION in air bag system section in order to confirm
whether you are performing service on or near the air bag system components or wiring.
Please observe all WARNINGS and SERVICE PRECAUTIONS of ON-VEHICLE SERVICE in air
bag system section before performing service on or around the air bag system components
or wiring. Failure to follow WARNINGS could result in unintentional activation of the system
or could render the system inoperative. Either of these two conditions may result in severe
injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned
to the LOCK position and negative cable is disconnected from the battery. Otherwise, the
system may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CONTENTS
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . 6E1- 2 B-3 Fuel Pressure Check . . . . . . . . . . . . . . . 6E1-36
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . 6E1- 5 B-4 Idle Air Control System Check . . . . . . . 6E1-38
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . 6E1- 6 B-5 Evaporative Emission Control
ELECTRONIC CONTROL SYSTEM . . . . . . 6E1- 7 System Check . . . . . . . . . . . . . . . . . . . . . . . . 6E1-40
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1-12 B-6 Engine Start Signal Check . . . . . . . . . . . 6E1-41
On-Board Diagnostic System . . . . . . . . . . . . 6E1-12 B-7 Radiator Fan Control System Check . . 6E1-42
Precautions in Diagnosing Troubles . . . . . . 6E1-12 B-8 A / C Control Signal Check
MIL Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1-13 (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . 6E1-43
DTC Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1-13 B-9 Electric Load Signal Circuits Check . . . 6E1-44
DTC Clearance . . . . . . . . . . . . . . . . . . . . . . . . 6E1-15 B-10 Transmission Range Signal
DTC Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1-16 Circuits Check (A / T Vehicle Only) . . . . . . . 6E1-45
A-1 MIL Circuit Check . . . . . . . . . . . . . . . . . . 6E1-17 Inspection of ECM (PCM) and Its
A-2 MIL Circuit Check . . . . . . . . . . . . . . . . . . 6E1-18 Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1-46
A-3 MIL Circuit Check . . . . . . . . . . . . . . . . . . 6E1-19 Voltage Check . . . . . . . . . . . . . . . . . . . . . . . 6E1-46
A-4 ECM (PCM) Power and Ground Resistance Check . . . . . . . . . . . . . . . . . . . 6E1-49
Circuit Check . . . . . . . . . . . . . . . . . . . . . . . . . 6E1-20 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 6E1-50
Code No.11 (P0105) MAP Sensor Circuit . 6E1-22 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1-51
Code No.13 (P0120) TP Sensor Circuit . . . 6E1-24 Accelerator Cable Adjustment . . . . . . . . . . . 6E1-51
Code No.14 (P0130) O2 Sensor Circuit . . . 6E1-26 Idle Speed/Idle Air Control (IAC)
Code No.15 (P0340) CMP Sensor Circuit . 6E1-28 Duty Inspection . . . . . . . . . . . . . . . . . . . . . . . 6E1-52
Code No.16 (P0500) VSS Circuit . . . . . . . . . 6E1-29 AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . 6E1-54
Code No.18 (P0110) IAT Sensor Circuit . . . 6E1-31 Throttle Body (On-vehicle Inspection,
Code No.19 (P0115) ECT Sensor Circuit . . 6E1-32 Removal, Disassembly, Cleaning
DTC Confirmation Procedure . . . . . . . . . . . . 6E1-33 and Installation) . . . . . . . . . . . . . . . . . . . . . . 6E1-54
B-1 Fuel Pump and Its Circuit Check . . . . . 6E1-34 Idle Air Control Valve (IAC Valve)
B-2 Fuel Injector and Its Circuit Check . . . . 6E1-35 (Removal, Inspection and Installation) . . . 6E1-57
6E1-2 ENGINE AND EMISSION CONTROL SYSTEM
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . 6E1-58 Fuel Pump Relay (Inspection) . . . . . . . . . . . 6E1-73

Fuel Pressure Inspection . . . . . . . . . . . . . . . . 6E1-58 Fuel Cut Operation (Inspection) . . . . . . . . . . 6E1-73
Fuel Pump (On-vehicle Inspection, A/C Compressor Control Relay
Removal, Inspection and Installation) . . . . 6E1-59 (Inspection) (If equipped) . . . . . . . . . . . . . . 6E1-73
Fuel Pressure Regulator (On-vehicle CMP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1-73
Inspection, Removal and Installation) . . . . 6E1-60 Radiator Fan Control System . . . . . . . . . . . . 6E1-74
Fuel Injector (On-vehicle Inspection, System Inspection . . . . . . . . . . . . . . . . . . . 6E1-74
Removal, Inspection and Installation) . . . . 6E1-61 Radiator Fan Control Relay (Inspection) 6E1-74
ELECTRONIC CONTROL SYSTEM . . . . . . . . 6E1-64 VSS (On-vehicle Inspection) . . . . . . . . . . . . . 6E1-75
ECM (PCM) (Removal and Installation) . . . 6E1-64 EVAP Emission Control System . . . . . . . . . . 6E1-76
MAP Sensor (Inspection, Removal EVAP Canister Purge Inspection . . . . . . . 6E1-76
and Installation) . . . . . . . . . . . . . . . . . . . . . . 6E1-64 Vacuum Passage Inspection . . . . . . . . . . 6E1-76
TP Sensor (Inspection, Adjustment, Vacuum Hose Inspection . . . . . . . . . . . . . 6E1-76
Removal and Installation) . . . . . . . . . . . . . . 6E1-67 EVAP Canister Purge Valve Inspection . 6E1-77
IAT Sensor (Removal, Inspection EVAP Canister Inspection . . . . . . . . . . . . . 6E1-78
and Installation) . . . . . . . . . . . . . . . . . . . . . . 6E1-69 Tank Pressure Control Valve (Inspection) 6E1-79
ECT Sensor (Removal, Inspection PCV System . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1-80
and Installation) . . . . . . . . . . . . . . . . . . . . . . 6E1-70 PCV Hose (Inspection) . . . . . . . . . . . . . . . 6E1-80
Main Relay (Inspection) . . . . . . . . . . . . . . . . . 6E1-71 PCV Valve (Inspection) . . . . . . . . . . . . . . . 6E1-80
Oxygen Sensor (Inspection, Removal SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 6E1-81
and Installation) . . . . . . . . . . . . . . . . . . . . . . 6E1-72 TIGHTENING TORQUE SPECIFICATIONS . 6E1-81
GENERAL DESCRIPTION
The engine and emission control system has 4 major Fuel delivery system includes fuel pump, delivery
sub-systems: air intake system, fuel delivery system, pipe, fuel pressure regulator, fuel injectors, etc.
electronic control system and emission control sys- Electronic control system includes ECM (PCM), vari-
tem. ous sensors and controlled devices.
Air intake system includes air cleaner, MAP sensor,
throttle body, IAC valve and intake manifold. Emission control system includes EVAP and PCV
systems.
1. Air Cleaner 23. ECM (PCM)

2. EVAP canister purge valve 24. Radiator fan
3. IAT sensor 25. Radiator fan control relay
4. TP sensor 26. Speedometer in combination meter
5. IAC valve 27. A/C compressor control relay
6. MAP sensor 28. Malfunction indicator lamp in combination meter
7. A/C evaporator temp. sensor (if equipped) 29. Transmission range switch (A / T)
8. EVAP canister 30. Ignition switch
9. Tank pressure control valve
31. Starter magnetic switch
10. Fuel pressure regulator
32. Main fuse
11. A/C dual pressure switch (if equipped)
33. Battery
12. PCV valve
34. Shift solenoid A (A/T)
13. Fuel injector
35. Shift solenoid B (A/T)
14. Oxygen sensor
36. Monitor connector
15. Fuel pump
36-1. Diagnosis switch terminal
16. Stop light switch
17. ECT sensor 36-2. Test switch terminal
18. Three way catalytic convertor 36-3. Duty output terminal
19. CMP sensor 37. VSS
20. Main relay 38. Heater blower fan
21. Ignition coil assembly 39. Electric load (blower fan and small light)
(For No.1 and No.4 spark plugs) 40. Data link connector (DLC)
22. Ignition coil assembly 41. Fuel pump relay
(For No.2 and No.3 spark plugs) 42. Fuel filter
AIR INTAKE SYSTEM

The main components of the air intake system are air uted by the intake manifold and finally drawn into each
cleaner, air cleaner outlet hose, throttle body, IAC combustion chamber.
valve and intake manifold. When the IAC valve is opened according to the signal
The air (by the amount corresponding to the throttle from ECM (PCM), the air bypasses the throttle valve
valve opening and engine speed) is filtered by the air through bypass passage and is finally drawn into the
cleaner, passes through the throttle body, is distrib- intake manifold.
1. Air cleaner 5. Throttle valve 9. Exhaust manifold

2. IAT sensor 6. IAC valve 10. Air flow
3. Air cleaner outlet hose 7. Intake manifold 11. MAP sensor
4. Throttle body 8. Cylinder head 12. Engine coolant
FUEL DELIVERY SYSTEM

The fuel delivery system consists of the fuel tank, fuel the fuel feed line) is always kept a certain amount
pump, fuel filter, fuel pressure regulator, delivery pipe higher than the pressure in the intake manifold by the
and fuel injectors. fuel pressure regulator, the fuel is injected into the in-
take port of the cylinder head when the injector opens
The fuel in the fuel tank is pumped up by the fuel according to the injection signal from ECM (PCM).
pump, filtered by the fuel filter and fed under pressure
to each injector through the delivery pipe. As the fuel The fuel relieved by the fuel pressure regulator re-
pressure applied to the injector (the fuel pressure in turns through the fuel return line to the fuel tank.
1. Fuel injector 5. EVAP canister 9. Fuel vapor line

2. Delivery pipe 6. EVAP canister purge valve 10. Fuel filter
3. Fuel pressure regulator 7. Fuel feed line 11. Fuel tank
4. Intake manifold 8. Fuel return line 12. Fuel pump
ELECTRONIC CONTROL SYSTEM

The electronic control system consists of 1) various Idle speed control system
sensors which detect the state of engine and driving Fuel pump control system
conditions, 2) ECM (PCM) which controls various de- Ignition control system
vices according to the signals from the sensors and 3) Radiator fan control system
various controlled devices. Evaporative emission control system
Functionally, it is divided into the following sub sys- A/C control system (if equipped)
tems: Also, with 3 A/T model, ECM (PCM) controls auto-
Fuel injection control system matic transmission.
INFORMATION SENSORS CONTROL DEVICES OTHERS

1. MAP sensor a : Fuel injectors A : ECM (PCM)
2. TP sensor b : EVAP canister purge valve B : PCV valve
3. IAT sensor c : Fuel pump relay C : EVAP canister
4. ECT sensor d : Ignition coil assembly D : Monitor connector
5. Oxygen sensor (No.1 & No.4 spark plugs) E : DLC
6. VSS e : Ignition coil assembly
7. Battery (No.2 & No.3 spark plugs)
8. CMP sensor f : Malfunction indicator lamp
9. Transmission range switch (3 A/T) g : Radiator fan control relay
10. A/C evaporator temp. sensor (if equipped) h : IAC valve
11. A/C dual pressure switch (if equipped) i : A/C compressor control relay
(if equipped)
j : Main relay
TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE)
1. Fuel injector No.1

TERMINAL CIRCUIT TERMINAL CIRCUIT
2. Fuel injector No.2
3. Fuel injector No.3 C51-1 Blank C50-1 Ground
4. Fuel injector No.4 C51-2 IAC valve C50-2 Power source
5. Idle air control (IAC) valve
6. EVAP canister purge valve C51-3 Transmission range switch “2” C50-3 Blank
7. Fuel pump relay C51-4 Transmission range switch “N” C50-4 Blank
8. Fuel pump
C51-5 Transmission range switch “P” C50-5 Shift solenoid B
9. Radiator fan control relay
10. Radiator fan motor C51-6 Tachometer C50-6 Shift solenoid A
11. Malfunction indicator light C51-7 C50-7
Test switch terminal EVAP canister purge valve
13. Ignition coil assembly for No.1 and 4 C51-8 Diagnosis switch terminal C50-8 Blank
spark plugs Electric load signal for blower C50-9 Blank
14. Ignition coil assembly for No.2 and 3 C51-9
fan motor
spark plugs Ignition coil assembly for No.1
C50-10
15. Capacitor (noise suppressor) Stop light switch and 4 spark plugs
C51-10
16. Shift solenoid A (brake pedal switch) C50-11 Fuel injector No. 3
17. Shift solenoid B C51-11 Blank C50-12 Fuel injector No. 1
18. A/C compressor control relay
C51-12 Data link connector
(if equipped) C50-13 Ground
19. Blank Engine starter switch C50-14
C51-13 Power source for backup
20. Main relay (engine starter signal)
21. Starter magnetic switch C50-15 Power source
C51-14 Transmission range switch “L”
22. Camshaft position (CMP) sensor C50-16 Blank
23. Speedometer C51-15 Transmission range switch “D”
24. Vehicle speed sensor (VSS) C50-17 Malfunction indicator light
C51-16 Transmission range switch “R”
25. Manifold absolute pressure (MAP) C50-18 Fuel pump relay
sensor C51-17 Duty output terminal
C50-19 Main relay
26. Throttle position (TP) sensor Electric load signal for small
C51-18 C50-20
27. Engine coolant temp. (ECT) sensor light switch Radiator fan control relay
with gauge C50-21
A/C ON signal from A/C switch Blank
27-1.ECT sensor C51-19
(if equipped) C50-22 Blank
27-2.ECT gauge
28. Intake air temp.(IAT) sensor C51-20 Blank Ignition coil assembly for No.2
29. A/C evaporator temp. sensor C50-23
C51-21 Blank and 3 spark plugs
(if equipped)
30. Oxygen sensor C51-22 Sensor ground C50-24 Fuel injector No. 4
31. Tachometer C52-1 Power supply for sensor C50-25 Fuel injector No. 2
32. Stop light switch
C52-2 Blank C50-26 Ground
33. Small light switch
34. Heater blower motor switch C52-3 CMP sensor (+)
35. Heater blower motor
C52-4 VSS
36. A/C dual pressure switch (if equipped)
37. A/C switch (if equipped) C52-5 MAP sensor
38. Transmission range switch (sensor) C52-6 TP sensor
39. Data link connector
A/C evaporator temp. sensor
C52-7
(with A/C)
C52-8 ECT sensor
C52-9 Sensor ground
C52-10 Blank
C52-11 CMP sensor (–)
C52-12 Blank
C52-13 Oxygen sensor
C52-14 IAT sensor
C52-15 Blank
A/C compressor magnet clutch
C52-16
(with A/C)
Air
IAC
Fuel
valve
ÎÎ
ÎÎ
Exhaust gas
MAP sensor
AIR
EXHAUST 3 WAY
AIR CLEANER THROTTLE INTAKE
ENGINE CATALYTIC
MANIFOLD
ÏÏ
ÏÏ
ÏÏ
CLEANER OUTLET BODY MANIFOLD
CONVERTER
HOSE
IAT
TP sensor ECT CMP
sensor Oxygen sensor
sensor sensor
FUEL
INJECTOR
Camshaft and
each piston
position
Pressure in
Intake air Throttle valve
throttle Battery voltage
temp. opening
body Engine coolant Exhaust oxygen Vehicle speed
temp. concentration Engine start signal
A / C signal (if equipped)
Diagnosis signal
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎ ÎÎÎÎÎÎÎ
Fuel pump Test signal
Electric load signal
Transmission range
signals (3 A / T)
ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏ
Fuel pump
ECM (PCM)
relay
Fuel injection control Ignition coil assemblies

EVAP A / C compressor
Malfunction (for No.1 and No.4
canister control relay
indicator lamp piston and No.2 and
Idle air control purge valve (if equipped)
No.3 piston)
Radiator fan
Automatic transmission (3 A / T)
control relay
(shift solenoid A and B)
SIGNAL FROM SENSOR, SWITCH AND CONTROL MODULE
CMP SENSOR
MAP SENSOR
TP SENSOR
ECT SENSOR
IAT SENSOR
O2S
VSS
BLOWER FAN SWITCH
LIGHTING SWITCH
IGNITION SWITCH
START SWITCH
STOP LAMP SWITCH
TRANSMISSION RANGE SWITCH
A/C SWITCH (IF EQUIPPED)
DIAGNOSIS SWITCH
TEST SWITCH
INPUT
OUTPUT
FUEL PUMP RELAY f f f

ELECTRIC CONTROL DEVICE
FUEL INJECTOR f f f f f f f f f
A/C COMPRESSOR CONTROL RELAY f f
IAC VALVE f f f f f f f f f f f
IGNITION COIL WITH IGNITER f f f f f f f f
EVAP CANISTER PURGE VALVE f f f f
RADIATOR FAN CONTROL RELAY f f
MIL f f f f f f f f f
MAIN RELAY f
DIAGNOSIS
The engine and emission control system in this vehicle are con-
trolled by ECM (PCM). ECM (PCM) has an On-Board Diagnostic
system which detects a malfunction in this system.
When diagnosing troubles, be sure to have full understanding of
the outline of ON-BOARD DIAGNOSTIC SYSTEM and each item
in PRECAUTION IN DIAGNOSING TROUBLE and execute diag-
nosis according to ENGINE DIAGNOSTIC FLOW TABLE in SEC-
TION 6.
ON-BOARD DIAGNOSTIC SYSTEM

ECM (PCM) performs on-board diagnosis (self-diagnosis) on the
system and operates malfunction indicator lamp as follows.
Malfunction indicator lamp lights when the ignition switch is
turned ON (but the engine at stop) regardless of the condition of
engine and emission control system. This is only to check the
malfunction indicator lamp bulb and its circuit.
If the areas monitored by ECM (PCM) is free from any trouble
after the engine start (while engine is running), malfunction indi-
cator lamp turns OFF.
When ECM (PCM) detects a trouble which has occurred in the
areas,it makes malfunction indicator lamp turn ON while the en-
gine is running to warn the driver of such occurrence of trouble
and at the same time it stores the exact trouble area in ECM
(PCM) back-up memory.
PRECAUTIONS IN DIAGNOSING TROUBLES

Before identifying diagnostic trouble code, don’t disconnect cou-
plers from ECM (PCM), battery cable from battery, ECM (PCM)
ground wire harness from engine. Such disconnection will erase
memorized trouble in ECM (PCM) memory.
Be sure to read PRECAUTIONS FOR ELECTRICAL CIRCUIT
SERVICE in SECTION 0A before inspection and observe what
is written there.
ECM (PCM) replacement
When substituting a known-good ECM (PCM), check for follow-
ing conditions. Neglecting this check may cause damage to
known-good ECM (PCM).
– Resistance value of all relays, actuators is as specified re-
spectively.
– TP sensor and MAP sensor are in good condition and none
of power circuits of these sensors is shorted to ground.
MALFUNCTION INDICATOR LAMP (MIL)

CHECK
1) Turn ON ignition switch (but engine at stop) and check that mal-
function indicator lamp lights up.
If lamp does not light up, go to DIAGNOSTIC FLOW TABLE A-1
in this section.
If lamp flashes, go to DIAGNOSTIC FLOW TABLE A-2 in this
section.
2) Start engine and check that malfunction indicator lamp turns
OFF.
If lamp remains ON, go to DTC CHECK NOT USING SUZUKI
SCAN TOOL in this section.
DIAGNOSTIC TROUBLE CODE (DTC) CHECK

[Using SUZUKI scan tool]
1) Check malfunction indicator lamp referring to MALFUNCTION
INDICATOR LAMP (MIL) CHECK in this section.
2) Turn ignition switch OFF.

3) After setting cartridge to SUZUKI scan tool, connect it to data
link connector (DLC) (1) located on underside of instrument
panel at driver’s seat side.
Special Tool
(A): 09931-76011 (SUZUKI scan tool)
(B): Mass storage cartridge
(C): 09931-76030 (16/14-pin DLC adapter)
4) Turn ignition switch ON.
5) Read DTC according to instructions displayed on SUZUKI scan
tool and print it or write it down. Refer to SUZUKI scan tool oper-
ator’s manual for further details.
If communication between SUZUKI scan tool and ECM (PCM)
is not possible, check if SUZUKI scan tool is communicable by
connecting it to ECM (PCM) in another vehicle. If communica-
tion is possible in this case, SUZUKI scan tool is in good condi-
tion. Then check data link connector and serial data line (circuit)
in the vehicle with which communication was not possible.
6) After completing the check, turn ignition switch OFF and discon-
1. Data link connector
nect SUZUKI scan tool from data link connector (DLC).
[Not using SUZUKI scan tool]

1) Check malfunction indicator lamp referring to MALFUNCTION
INDICATOR LAMP (MIL) CHECK in this section.
2) Using service wire, ground diagnosis switch terminal in monitor
coupler.
3) Read DTC from flashing pattern of malfunction indicator lamp.
Refer to DTC TABLE.
If lamp remains ON, go to Table A-3 in this section.
NOTE:
If abnormality or malfunction lies in two or more areas,
malfunction indicator lamp indicates applicable codes
three times each.
And flashing of these codes is repeated as long as diag-
nosis terminal is grounded and ignition switch is held at
ON position.
Take a note of diagnostic trouble code indicated first.
4) After completing the check, turn ignition switch OFF and discon-
nect service wire from monitor connector.
1. Malfunction indicator lamp

2. Diagnostic switch terminal
3. Ground terminal
4. Monitor coupler
EXAMPLE: When throttle position sensor is defective (Code No. 13)

DIAGNOSTIC TROUBLE CODE (DTC)

CLEARANCE
[Using SUZUKI scan tool]
2) Connect SUZUKI scan tool to data link connector (DLC) in the
same manner as when making this connection for DTC check.
4) Erase DTC according to instructions displayed on SUZUKI
scan tool.
Refer to SUZUKI scan tool operator’s manual for further details.
5) After completing the clearance, turn ignition switch OFF and
disconnect SUZUKI scan tool from data link connector (DLC).
[Not using SUZUKI scan tool]
1) Turn OFF ignition switch.
2) Disconnect battery negative cable for specified time below to
erase diagnostic trouble code stored in ECM (PCM) memory
and reconnect it.
Time required to erase DTC:
Ambient temperature Time to cut power to ECM (PCM)
Over 0_C (32_F) 30 sec. or longer
Not specifiable.
Under 0_C (32_F) Select a place with higher than
0_C (32_F) temperature.
DIAGNOSTIC TROUBLE CODE (DTC) TABLE

DIAGNOSTIC
TROUBLE
CODE NO. MALFUNCTION INDICATOR
DIAGNOSTIC ITEM DIAGNOSIS
SUZUKI LAMP FLASHING PATTERN
SCAN MIL
TOOL
Manifold absolute pressure

P0105 11
sensor
P0120 13 Throttle position sensor
P0130 14 Oxygen sensor
Diagnose trouble according to DIAG-

P0340 15 Camshaft position sensor NOSTIC FLOW TABLE corresponding to
each code No.
P0500 16 Vehicle speed sensor
P0110 18 Intake air temperature sensor
Engine coolant temperature

P0115 19
sensor
This code appears when none of the oth-

––– 12 Normal
er codes (above codes) are identified.
(A/T ONLY)
DIAGNOSTIC
TROUBLE
CODE NO. MALFUNCTION INDICATOR
DIAGNOSTIC ITEM DIAGNOSIS
SUZUKI LAMP FLASHING PATTERN
SCAN MIL
TOOL
4 1
P0753 41 Shift solenoid A
4 2
Refer to SECTION 7B AUTOMATIC
P0758 42 Shift solenoid B
TRANSMISSION.
4 6
P0705 46 Transmission range switch
A-1 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK

(MALFUNCTION INDICATOR LAMP DOES NOT LIGHT AT IGNITION SWITCH ON.)
1. Battery positive voltage

2. Main fuse
3. Ignition switch
4. “IG” fuse
6. Combination meter
7. ECM (PCM)
STEP ACTION YES NO

1 MIL Power Supply Check Go to Step 2. “IG” fuse blown, main fuse
1) Turn ignition switch ON. blown, ignition switch malfunc-
Do other indicator/warning lights in combination, “B/W” circuit between “IG”
tion meter come ON? fuse and combination meter or
poor coupler connection at com-
bination meter.
2 ECM (PCM) Power and Ground Circuit Check Go to Step 3. Go to TABLE A-4 ECM (PCM)
Does engine start? POWER AND GROUND CIR-
CUIT CHECK.
If engine is not cranked, go to
DIAGNOSIS in SECTION 6G.
3 MIL Circuit Check Substitute a known- Bulb burned out or “V/Y” wire
1) Turn ignition switch OFF and disconnect good ECM (PCM) circuit open.
connectors from ECM (PCM). and recheck.
2) Check for proper connection to ECM (PCM)
at terminal C50-17.
3) If OK, then using service wire, ground ter-
minal C50-17 in connector disconnected.
Does MIL turn on at ignition switch ON?
Fig. for STEP 1 Fig. for STEP 3
1. ECM (PCM) coupler disconnected

2. Body ground
1. “IG” fuse 3. Service wire

(MALFUNCTION INDICATOR LAMP FLASHES AT IGNITION SWITCH ON.)
V/Y
2. Main fuse
3. Ignition switch
4. “IG” fuse
7. ECM (PCM)
8. Diagnosis switch terminal
10. Relay / fuse box
STEP ACTION YES NO

1 MIL Flashing Pattern Check Go to Step 2. Substitute a known-good
1) Turn ignition switch ON. ECM (PCM) and recheck.
Does lamp flashing pattern indicate diagnostic trouble
code?
2 Diag. Switch Circuit Check System is in good “V/W” circuit shorted to
Is diag. switch terminal connected to ground via ser- condition. ground. If circuit is OK,
vice wire? substitute a known-good
ECM (PCM) and recheck.

(MALFUNCTION INDICATOR LAMP DOES NOT FLASH OR JUST REMAINS ON EVEN WITH GROUND-
ING DIAGNOSIS SWITCH TERMINAL.)
V/Y
2. Main fuse
3. Ignition switch
4. “IG” fuse
7. ECM (PCM)
8. Diagnosis switch terminal
10. Relay / fuse box
STEP ACTION YES NO

1 MIL Circuit Check “V/Y” circuit shorted Go to Step 2.
1) Turn ignition switch OFF and disconnect connec- to ground.
tors from ECM (PCM).
Does MIL turn ON at ignition switch ON?
2 ECM (PCM) Connection Check Go to Step 3. Poor connector connection.
Is connector (C51-8 connection) connected to ECM
(PCM) properly?
3 Diag. Switch Terminal Circuit Check “V/W” or “B” circuit Substitute a known-good
1) Connect connectors to ECM (PCM). open. ECM (PCM) and recheck.
2) Using service wire, ground C51-8 terminal with
connectors connected to ECM (PCM).
Does MIL flash?
Fig. for STEP 3
1. ECM (PCM) coupler connected

2. Body ground
3. Service wire
A-4 ECM (PCM) POWER AND GROUND CIRCUIT CHECK (Page 1 of 2)

(MALFUNCTION INDICATOR LAMP DOES NOT LIGHT AT IGNITION SWITCH ON AND ENGINE DOES
NOT START THOUGH IT IS CRANKED UP.)

2. Main fuse box
3. Ignition switch
4. “IG” fuse in J / B
5. “FI” fuse in relay / fuse box
6. Main relay
7. ECM (PCM)
STEP ACTION YES NO

1 Main Relay Opening Sound Check Go to Step 5. Go to Step 2.
Is operating sound of main relay heard at ignition switch ON?
2 Fuse Check Go to Step 3. Check for short in
Is main “FI” fuse in good condition? circuits connected
to this fuse.
3 Main Relay Check Go to Step 4. Replace main relay.
1) Turn OFF ignition switch and remove main relay.
2) Check for proper connection to main relay at terminal “A” and
“B”.
3) If OK, check main relay for resistance and operation referring
to MAIN RELAY INSPECTION in this section.
Is check result satisfactory?
4 ECM (PCM) Power Circuit Check Go to Step 5. “Br / W” or “B/W”
1) Turn OFF ignition switch, disconnect connectors from ECM circuit open.
(PCM) and install main relay.
2) Check for proper connection to ECM (PCM) at terminals
C50-2, C50-15 and C50-19.
3) If OK, then measure voltage between terminal C50-19 and
ground with ignition switch ON.
Is each voltage 10 – 14 V?
A-4 ECM (PCM) POWER AND GROUND CIRCUIT CHECK (Page 2 of 2)

STEP ACTION YES NO
5 ECM (PCM) Power Circuit Check Check ground circuits Go to Step 6.
1) Using service wire, ground terminal C50-19 and “B/O” and “B” for open.
measure voltage between terminal C50-2 If OK, then substitute a
(C50-15) and ground at ignition switch ON. known-good ECM (PCM)
Is it 10 – 14 V? and recheck.
6 Is operating sound of main relay heard in Step 1? Go to Step 7. “B/Y” or “B/R” wire
open.
7 Main Relay Check “B/Y” or “B/R” wire open. Replace main relay.
1) Check main relay according to procedure in Step
3.
Is main relay in good condition?
Fig. for STEP 2 and 3 Fig. for STEP 4
1. ECM (PCM) coupler
1. Main relay
2. “FI” fuse
CODE NO.11 (P0105) MAP SENSOR CIRCUIT

(SIGNAL VOLTAGE LOW, HIGH OR PERFORMANCE PROBLEM)
NOTE:
When Code No.11 (P0105), 13 (P0120), 18 (P0110) and
19 (P0115) are indicated together, it is possible that “O”
wire is open or “C52-9” terminal connections are poor.
1. ECM (PCM)
3. MAP sensor
4. MAP sensor coupler
5. To TP sensor
6. To other sensors
STEP ACTION YES NO

1 1) Disconnect MAP sensor coupler with igni- Go to Step 2. “Gr/R” wire open or short.
tion switch OFF. Poor “C52-1” connection.
2) Check voltage between “Gr/R” wire termi- If wire and connection are OK,
nal of MAP sensor coupler and ground substitute a known-good ECM
with ignition switch ON. (PCM) and recheck.
Is voltage about 4 – 5 V?
2 1) Check voltage between “Lg/R” wire termi- Go to Step 3. “Lg/R” wire open or short.
nal of MAP sensor coupler and ground Poor “C52-5” connection.
with ignition switch ON. If wire and connection are OK,
Is voltage about 4 – 5 V? substitute a known-good ECM
(PCM) and recheck.
3 1) Connect “Lg/R” and “O” wire terminals of Go to Step 4. “O” wire open.
MAP sensor coupler using service wire. Poor “C52-9” connection.
2) Check voltage between “Lg/R” wire termi- If wire and connection are OK,
nal of MAP sensor coupler and ground. substitute a known-good ECM
Is voltage about 0 V? (PCM) and recheck.
4 1) Remove MAP sensor. Clean air passage or Go to Step 5.
2) Visually inspect air pressure inlet passage replace as necessary.
of MAP sensor for clogging.
Is there any blockage?
5 1) Perform “MAP sensor inspection” in this Poor connection of Faulty MAP sensor.
section. MAP sensor coupler
Is MAP sensor in good condition? terminals.
If connection is OK,
substitute a known-
good ECM (PCM) and
recheck.
Fig. for STEP 1 Fig. for STEP 2 Fig. for STEP 3
NOTE:
Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page
6E1-33 to confirm that the trouble has been corrected.
CODE NO.13 (P0120) TP SENSOR CIRCUIT

(SIGNAL VOLTAGE HIGH OR LOW)
NOTE:
wire is open or “C52-9” terminal connection are poor.
1. ECM (PCM)
3. TP sensor
4. TP sensor coupler
5. To MAP sensor
6. To other sensors
STEP ACTION YES NO

1 1) Disconnect TP sensor coupler with ignition Go to Step 2. “Gr/R” wire open or short.
switch OFF. Poor “C52-1” connection.
2) Check voltage between “Gr/R” wire terminal If wire and connection are OK,
of TP sensor coupler and ground with igni- substitute a known-good ECM
tion switch ON. (PCM) and recheck.
2 1) Check voltage between “Gr/Bl” wire termi- Go to Step 3. “Gr/Bl” wire open or short.
nal of TP sensor coupler and ground with Poor “C52-6” connection.
ignition switch ON. If wire and connection are OK,
Is voltage about 4 – 5 V? substitute a known-good ECM
(PCM) and recheck.
3 1) Connect “Gr/Bl” and “O” wire terminal of TP Go to Step 4. “O” wire open.
sensor coupler using service wire. Poor “C52-9” connection.
2) Check voltage between “Gr/Bl” wire termi- If wire and connection are OK,
nal of TP sensor coupler and ground with substitute a known-good ECM
ignition switch ON. (PCM) and recheck.
Is voltage about 0 V?
4 1) Perform “TP sensor inspection” in this sec- Poor connection of TP Faulty TP sensor.
tion. sensor coupler termi-
Is TP sensor in good condition? nals.
substitute a known-
good ECM (PCM) and
recheck.
Fig. for STEP 1 Fig. for STEP 2 Fig. for STEP 3
NOTE:
CODE NO.14 (P0130) OXYGEN SENSOR CIRCUIT

(SIGNAL VOLTAGE DOESN’T CHANGE)
NOTE:
Before diagnosing trouble according to flow table
given below, check to make sure that following sys-
tem and parts other than Electronic Fuel Injection
system are in good condition.
– Air cleaner (clogged)
– Vacuum leaks (air inhaling)
– Spark plugs (contamination, gap)
– High-tension cords (crack, deterioration)
– Ignition timing
– Engine compression
– Any other system and parts which might affect A / F
mixture or combustion.
If code No.14 (P0130) and another code No. are indi-
cated together, the latter has priority. Therefore,
check and correct what is represented by that code
No. first and then proceed to the following check.
Be sure to use a voltmeter with high impedance
1. ECM (PCM) (M / V minimum) or digital type voltmeter for accu-
2. Oxygen sensor rate measurement.
3. Coupler
STEP ACTION YES NO

1 1) Remove ECM (PCM) and connect Wire between sensor and ECM (PCM) Go to Step 2.
couplers to ECM (PCM). open.
2) Warm up engine to normal operat- Poor connection of oxygen sensor coupler
ing temperature. terminal.
3) Connect voltmeter between C52-13 If wire and connection are OK,
terminal of ECM (PCM) coupler and replace oxygen sensor and recheck.
body ground.
4) Maintain engine speed at 2000
r / min.
After 60 seconds, check voltmeter.
Is voltage 0 V?
2 Does voltmeter indicate deflection be- Oxygen sensor and its circuit (Air / fuel ratio Go to Step 3.
tween above and below 0.45 V repeat- feedback system) are in good condition.
edly? Intermittent trouble or faulty ECM (PCM).
Recheck, referring to “Intermittent Trouble” on
SECTION 0A.
3 Does voltmeter indicator remain un- “R” wire shorted to power circuit or rich A / F Go to Step 4.
changed at above 0.45 V? mixture.
If wire is OK, check TP sensor, clogged MAP
sensor air passage, MAP sensor, IAT sensor,
ECT sensor, fuel pressure and injector.
If all above are OK, check ECM (PCM) and its
circuit referring to p.6E1-46.
4 1) Maintain engine speed at 2000 Poor C52-13 connection or lean A / F mixture. Faulty oxygen
r / min for 60 seconds. If connection is OK, check MAP sensor, ECT sensor.
2) Check voltmeter while repeating sensor, IAT sensor, fuel pressure and injector.
racing engine. If all above are OK, check ECM (PCM) and its
3) Does it indicate 0.45 V or more circuit referring to p. 6E1-46.
even once?
Fig. for STEP 1

2. Body ground
NOTE:
CODE NO.15 (P0340) CMP SENSOR CIRCUIT

(SENSOR SIGNAL NOT INPUTTED FOR 2 SECONDS AT ENGINE CRANKING)
1. ECM (PCM)
2. CMP sensor
3. Rotor
4. CMP sensor coupler
NOTE:
If starter circuit is open (i.e., start signal circuit is OK but starter fails to run), this DTC is stored in memory
at starter switch ON, even through CMP sensor is in good condition.
When starter motor fails to run and this DTC appears, check starter circuit first.
STEP ACTION YES NO

1 1) Disconnect couplers from ECM (PCM). Go to Step 2. “Y” wire open or short.
2) Measure resistance between “C52-3” and “Br” wire open or short.
“C52-11” terminals of ECM (PCM) coupler. Poor terminal connec-
CMP sensor resistance: 205 – 255 W tion of CMP sensor cou-
at 20 C (68 F) pler.
3) Measure resistance between “C52-3” termi- If wire and connection are
nal of ECM (PCM) coupler and ground. OK, replace CMP sensor.
Insulation resistance: 1 MW or more
Were measured resistance values in above 2)
and 3) as specified?
2 1) Check CMP sensor referring to Section Poor “C52-3” or “C52-11” Faulty CMP sensor.
6F1. terminal connection of
Is it in good condition? ECM (PCM) coupler.
substitute a known-good
ECM (PCM) and recheck.
Fig. for STEP 1
NOTE:
CODE NO.16 (P0500) VSS CIRCUIT

(VSS SIGNAL NOT INPUTTED ALTHOUGH FUEL IS KEPT CUT AT LOWER THAN
4000 R/MIN. FOR LONGER THAN 4 SECONDS)
1. ECM (PCM)
2. VSS signal rotor (installed on differential case)
3. Speedometer
4. VSS (installed on transmission case)
5. VSS coupler
6. Power supply from main relay
STEP ACTION YES NO

1 Does speedometer indicate vehicle “V” wire open. Go to Step 2.
speed? Poor “C52-4” connection.
If OK, substitute a known-
good ECM (PCM) and re-
check.
2 1) Disconnect VSS coupler with ignition Go to Step 3. “B/R” or “B/O” wire open or
switch OFF. “B/R” wire shorted to ground.
2) Turn ignition switch ON, leaving engine
OFF.
3) Measure voltage between “B/R” and
“B/O” wire terminals of disconnected
VSS coupler.
3 1) Measure voltage between “V” and Go to Step 4. Go to Step 5.
VSS coupler.
Is voltage more than 4 V?
4 1) Remove VSS. Faulty VSS signal rotor. Poor connection of VSS cou-
2) Visually inspect VSS signal rotor for pler terminal.
damage. If OK, substitute a known-
Was any damage found? good VSS and recheck.
5 1) Turn ignition switch OFF. Faulty speedometer. “V” wire open or short.
2) Disconnect combination meter cou- If OK, substitute a known-
plers. Refer to Section 8. good ECM (PCM) and re-
3) Turn ignition switch ON, leaving engine check.
OFF.
4) Measure voltage between “V” and
VSS coupler.
Fig. for STEP 2 Fig. for STEP 3 and 5
1. VSS coupler disconnected 1. VSS coupler disconnected
NOTE:
CODE NO.18 (P0110) IAT SENSOR CIRCUIT

NOTE:
wire is open or “C52-9” terminal connections are poor.
1. ECM (PCM)
2. IAT sensor
3. IAT sensor coupler
4. To other sensors
STEP ACTION YES NO

1 1) Disconnect IAT sensor coupler with ignition Go to Step 2. “Lg/B” wire open or short.
2) Check voltage between “Lg/B” wire terminal
of IAT sensor coupler and ground with igni-
tion switch ON.
2 1) Connect IAT sensor coupler terminals using Go to Step 3. “O” wire open or poor “C52-9”
service wire. connection.
2) Check voltage between “Lg/B” wire terminal If wire and connection are OK,
of IAT sensor coupler and ground with igni- substitute a known-good ECM
tion switch ON. (PCM) and recheck.
Is voltage 0.15 V or less?
3 1) Perform “IAT sensor inspection” in this sec- Poor connection of IAT Faulty IAT sensor.
tion. sensor coupler termi-
Is IAT sensor in good condition? nals.
substitute a known-
good ECM (PCM) and
recheck.
1. IAT sensor coupler disconnected

1. IAT sensor coupler disconnected 2. Service wire
2. Engine ground 3. Engine ground
NOTE:
CODE NO.19 (P0115) ECT SENSOR CIRCUIT

NOTE:
wire is open or “C52-9” terminal connection is poor.
1. ECM (PCM)
2. ECT sensor
3. ECT sensor coupler
4. To other sensors
5. To combination meter
STEP ACTION YES NO

1 1) Disconnect ECT sensor coupler with ignition Go to Step 2. “Lg” wire open or short.
2) Check voltage between “Lg” wire terminal of
ECT sensor coupler and ground with ignition
switch ON.
2 1) Connect ECT sensor couple terminals using Go to Step 3. “O” wire open or poor “C52-9”
service wire. connection.
2) Check voltage between “Lg” wire terminal of If wire and connection are OK,
ECT sensor coupler and ground with ignition substitute a known-good ECM
switch ON. (PCM) and recheck.
Is voltage 0.15 V or less?
3 1) Perform “ECT sensor inspection” in this sec- Poor connection of Faulty ECT sensor.
tion. ECT sensor coupler
Is ECT sensor in good condition? terminals.
substitute a known-
good ECM (PCM)
and recheck.
1. ECT sensor coupler disconnected

1. ECT sensor coupler disconnected 2. Service wire
2. Engine ground 3. Engine ground
NOTE:
DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE
WARNING:
When performing a road test, select a safe place where there is not traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.
1) Clear DTC stored in ECM memory referring to DTC CLEARANCE in this section.
2) Perform DTC confirmation test under the following conditions.
3) Check DTC referring to DTC CHECK in this section.
Test Condition for Code No. 13 (P0120), 18 (P0110), 19 (P0115)

Turn ignition switch ON.
Test Condition for Code No. 15 (P0340)

Crank engine for 3 sec.
Driving Test Condition for Code No. 16 (P0500)
1) Start engine and warm up engine to normal operating

temperature.
2) Increase engine speed to 4,000 r/min. in 3rd gear in case
of M/T model and “2” range in case of A/T model.
3) Release accelerator pedal and with engine brake applied,
keep vehicle coasting for 5 to 8 seconds till engine speed
reaches 2,000 r/min.
4) Repeat above steps 2) and 3) 3 times or more.
5) Stop vehicle.
Driving Test Condition for Code No. 14 (P0130)

1) Start engine and warm up engine to normal operating
temperature.
2) Increase vehicle speed to 31 to 37 mile/h (50 – 60
km/h) in 5th gear of M/T or in 4th of “D” range of A/T.
3) Keep driving at above vehicle speed for 25 to 30 se-
conds.
4) Release accelerator pedal and with engine brake ap-
plied, decrease vehicle speed to about 18 mile/h (30
km/h).
5) Repeat above steps 2) to 4) 3 times or more.
NOTE: 6) Stop vehicle.
If the above driving test can not be performed, check oxygen sensor for voltage referring to Step 1 and
2 of Code No. 14 (P0130) Diag. Flow Table and confirm that oxygen sensor and its circuit (Closed Loop
System) are in good condition.
Test Condition for Code No. 11 (P0105)

1) Clear DTC referring to DTC CLEARANCE in this section.
2) Start engine.
3) Maintain engine speed at 2000RPM for 5 seconds.
4) Check DTC referring to DTC CHECK in this section.
B-1 FUEL PUMP AND ITS CIRCUIT CHECK
1. ECM (PCM)
2. Fuel pump relay
3. Fuel pump
4. Main relay
STEP ACTION YES NO

1 Is fuel pump heard to operate 2 se- Fuel pump and its circuit are in good Go to Step 2.
conds after ignition switch ON? condition.
2 1) Remove fuel pump relay from relay Go to Step 3. “B/R” or “P” wire open,
box with ignition switch OFF. poor fuel pump relay-
2) Connect two terminals of relay to-coupler connection
connector as shown in figure using or faulty fuel pump.
service wire.
Is fuel pump heard to operate with
ignition switch ON?
3 1) Check fuel pump relay, referring to Poor fuel pump relay-to-coupler con- Faulty fuel pump relay.
p.6E1-59. nection, “P” wire open or poor C50-18
Is it in good condition? connection.
If wire and connection are OK, substi-
tute a known-good ECM (PCM) and
recheck.
Fig. for STEP 2
1. Fuel pump relay coupler

2. Service wire
B-2 FUEL INJECTOR AND ITS CIRCUIT CHECK

2. Main fuse box
3. “FI” fuse in fuse/relay box
4. Main relay
5. ECM (PCM)
6. No.1 injector
7. No.3 injector
8. No.4 injector
9. No.2 injector
STEP ACTION YES NO

1 Check each injector for operating sound at engine Fuel injector circuit is in Go to Step 2.
cranking using sound scope. good condition.
Do all 4 injector make operating sound?
2 Does none of 4 injectors make operating sound at Go to Step 4. Go to Step 3.
Step 1?
3 Check fuel injector(s) referring to p. 6E1-61. Check coupler connection Faulty fuel injector(s).
Is it in good condition? and wire harness
of injector not making
operating sound.
4 Check power circuit of injectors for open and short. Check all 4 injectors for Power circuit open or
Is it in normal condition? resistance respectively. short.
If resistance is OK,
ECM (PCM) and
recheck.
B-3 FUEL PRESSURE CHECK (Page 1 of 2)
1. Fuel Injector
2. Delivery pipe
3. Fuel regulator
4. Fuel filter
5. Fuel pump
Special Tool
(A) Gauge (09912-58441)
(B) Hose (09912-58431)
(C) 3-way joint (09912-58490)
STEP ACTION YES NO

1 1) Release fuel pressure from fuel feed line. Go to Step 2. Go to Step 5.
2) Install fuel pressure gauge.
3) Check fuel pressure by repeating ignition switch ON
and OFF.
Is fuel pressure then 270 – 310 kPa
(2.7 – 3.1 kg / cm2, 38.4 – 44.0 psi)?
2 Is 200 kPa (2.0 kg / cm2, 28.4 psi) or higher fuel pres- Go to Step 3. Go to Step 4.
sure retained for 1 minute after fuel pump is stopped at
step 1?
3 1) Start engine and warm it up to normal operating Normal fuel pressure. Clogged vacuum
temperature. passage for fuel
2) Keep it running at specified idle speed. pressure regulator or
Is fuel pressure then within 200 – 240 kPa faulty fuel pressure
(2.0 – 2.4 kg / cm2, 28.4 – 34.1 psi)? regulator.
4 Is there fuel leakage from fuel feed line hose, pipe or Fuel leakage from Go to Step 10.
their joint? hose, pipe or joint.
5 Was fuel pressure higher than spec. in step 1? Go to Step 6. Go to Step 7.
6 1) Disconnect fuel return hose from fuel pressure Restricted fuel return Faulty fuel pressure
regulator and connect new return hose to it. hose or pipe. regulator.
2) Put the other end of new return hose into approved
gasoline container.
3) Operate fuel pump.
Is specified fuel pressure obtained then?
B-3 FUEL PRESSURE CHECK (Page 2 of 2)

STEP ACTION YES NO
7 Was no fuel pressure applied in step 1? Go to Step 8. Go to Step 9.
8 With fuel pump operated and fuel return hose blocked Faulty fuel pressure Shortage of fuel or fuel
by pinching it, is fuel pressure applied? regulator. pump or its circuit
malfunction.
9 1) Operate fuel pump. Faulty fuel pressure Clogged fuel filter,
2) With fuel return hose blocked by pinching it, check regulator. restricted fuel feed
fuel pressure. hose or pipe, Faulty
Is it 450 kPa (4.5 kg / cm2, 63.9 psi) or more? fuel pump or fuel
leakage from hose
connection in fuel
tank.
10 1) Disconnect fuel return hose from pressure Faulty fuel pressure Fuel leakage from
regulator and connect new return hose to it. regulator. injector, Fuel leakage
2) Insert the other end of new return hose into from between injector
approved gasoline container. and delivery pipe,
3) Check again if specified pressure is obtained. Faulty fuel pump
While doing so, does fuel come out of return hose? (faulty check valve in
fuel pump) or Fuel
leakage from fuel
pressure regulator
diaphragm.
Fig. for STEP 1
1. Fuel feed hose

2. Fuel delivery pipe
3. Fuel return hose
Special Tool
(A) Gauge
(B) Hose
(C) 3-way joint
B-4 IDLE AIR CONTROL SYSTEM CHECK (Page 1 of 2)

2. Main fuse box
3. “FI” fuse in fuse/relay box
4. Main relay
5. ECM (PCM)
6. IAC valve
7. Throttle body
8. Engine coolant
9. Bypass air
STEP ACTION YES NO

1 Check engine idle speed and IAC duty referring to Go to Step 2. Go to Step 4.
“Idle Speed/IAC Duty Inspection” on p. 6E1-52.
Is idle speed within specification?
2 Is IAC duty within specification in step 1? Go to Step 3. Check for followings:
– Vacuum leak
– EVAP canister purge
control system
– Clog of IAC air passage
– Accessory engine load
– Stuck of PCV valve
3 Is engine idle speed kept specified speed even System is in good Go to Step 11.
with headlight ON? condition.
4 Was idle speed higher than specification in step 1? Go to Step 5. Go to Step 8.
5 Check A/C (input) signal circuit referring to “B-8 Go to Step 6. Repair or replace A/C
A/C Signal Circuits Check”, if equipped. signal circuit or A/C
Is it in good condition? system.
6 Check IAC system referring to step 11 of this table. Go to Step 7. Go to Step 12.
7 Was IAC duty less than about 3% (or more than Check abnormal air Check TP sensor
about 97% for OFF duty meter) in step 1 of this inhaling from air intake (closed throttle position)
table? system, PCV valve and and ECT sensor for
EVAP canister purge performance.
control system. If sensors are OK,
ECM (PCM).
B-4 IDLE AIR CONTROL SYSTEM CHECK (Page 2 of 2)

STEP ACTION YES NO
8 Check transmission range signal referring to “B-10 Go to Step 9. Repair or replace.
Transmission Range Signal Check (3 A / T Vehicle
Only)”.
Is it in good condition?
9 Check IAC system referring to step 11 of this table. Go to Step 10. Go to Step 12.
10 Was IAC duty more than about 30% or :40% (or Check parts or system Substitute a known-good
less than 70% or :60% for OFF duty meter) in which can cause ECM (PCM) and recheck.
step 1 of this table? engine low idle.
– Accessory engine
NOTE:
load
Duty value with (:) are applicable to vehicle
– Clog of air passage
used at high altitude (higher than 2000 m or
– Etc.
6560 ft).
11 1) Remove IAC valve from throttle body referring Intermittent trouble or Go to Step 12.
to “IAC Valve” on p. 6E1-57. faulty ECM (PCM).
2) Check IAC valve for operation referring to “IAC Recheck for referring to
Valve” on p. 6E1-57. “Intermittent Trouble”
Is check result satisfactory? on SECTION 0A.
12 1) Turn ignition switch OFF. Replace IAC valve and Repair or replace.
2) Disconnect IAC valve coupler. recheck.
3) Check for proper connection to IAC valve at
each terminals.
4) If OK, disconnect ECM (PCM) couplers.
5) Check for proper connection to ECM (PCM) at
C51-2 terminal.
6) If OK, check “B /R”, “R/B” and “B/O” circuits for
open and short.
Are they in good condition?
Fig. for STEP 6, 9 and 11

B-5 EVAPORATIVE EMISSION CONTROL SYSTEM CHECK
1. To throttle body 6. EVAP canister purge valve

2. To fuel tank 7. Main relay
3. EVAP canister 8. Sensed information
4. Air 9. ECM (PCM)
5. Air and vapor 10. Fuel tank
STEP ACTION YES NO

1 Check canister purge system for opera- Check EVAP canister referring to p. Go to Step 2.
tion referring to p. 6E1-76. 6E1-78 and fuel filler cap referring
Is it in good condition? to Section 6C.
If OK, system is in good condition.
2 Check vacuum passage, hoses and “Bl/B” wire open, Vacuum passage
EVAP canister purge valve referring to p. “Bl/B” wire shorted to ground, clogged,
6E1-76. Poor EVAP canister purge valve Vacuum leakage or
Are they in good condition? coupler connection, Faulty EVAP canister
Poor “C50-7” connection, purge valve
Poor performance of ECT sensor
or MAP sensor or TP sensor
If none of the above exists, substi-
tute a known-good ECM (PCM) and
recheck.
B-6 ENGINE START SIGNAL CHECK
1. ECM (PCM)
3. Main switch
4. To starting motor
STEP ACTION YES NO

1 1) With ignition switch OFF, disconnect couplers from ECM Engine starter “B/Y” wire open or
(PCM). signal circuit is Poor “C51-13”
2) Is 6 – 12 V voltage applied to C51-13 terminal of coupler in good condition. connection
only when cranking engine.
Fig. for STEP 1

2. Body ground
B-7 RADIATOR FAN CONTROL SYSTEM CHECK
1. Radiator fan motor

2. Radiator fan control (RFC) relay
3. ECM (PCM)
4. Main relay
5. Engine coolant temp. (ECT) sensor
6. Vehicle speed sensor
7. A/C signal
STEP ACTION YES NO

1 Check radiator fan control system referring to p. RFC system is in good Go to Step 2.
6E1-74. condition.
2 Check RFC relay referring to p. 6E1-74. Go to Step 3. Faulty RFC relay.
3 Check wire harnesses and connections for open Poor performance of ECT Wire open or short
or short. sensor. If ECT sensor is OK, Poor connection or
Are they in good condition? substitute a known-good Faulty radiator fan
ECM (PCM) and recheck. motor
B-8 A/C CONTROL SIGNAL CHECK (IF EQUIPPED)
1. Battery
2. Main fuse box
3. Ignition switch
4. Circuit fuse
5. Blower fan motor
6. Blower fan switch
7. A/C switch
8. Dual pressure switch
9. A/C evaporator thermistor
10. A/C compressor
11. ECM (PCM)
12. A/C compressor control relay
13. Heater relay
14. High relay
STEP ACTION YES NO

1 1) Check voltage at “C51-19” terminal under each A/C control signal is “Bl/R” wire open or short
condition given in table below. in good condition. Poor “C51-19” terminal
Ignition switch ON connection
A/C switch OFF If wire and connection are
10 – 14 V
Blower fan switch OFF OK, check dual pressure
switch and A/C switch re-
Ignition switch ON
ferring to Section 1B.
A/C switch ON 2 V or less
Blower fan switch ON
2) Is check result satisfactory?
Fig. for STEP 1

2. Body ground
B-9 ELECTRIC LOAD SIGNAL CIRCUITS CHECK
1. ECM (PCM)
3. From lighting switch (small)
4. From heater blower switch
STEP ACTION YES NO

1 Check voltage at C51-18 terminal under each condition given Go to Step 2. “R/Y” wire open or
below. short
Poor “C51-18” ter-
Small light turned OFF 1 V or less
minal connection
Small light turned ON 10 – 14 V
2 Check voltage at C51-9 terminal under each condition given Electric load “P/Bl” wire open or
below. signal circuit short
are in good Poor “C51-9” termi-
Ignition switch ON
condition. nal connection
Heater blower fan switch : OFF or Low position 4 – 14 V
Ignition switch ON
Heater blower fan switch : High or Middle position 2 V or less
Fig. for STEP 1 and 2

2. Body ground
B-10 TRANSMISSION RANGE SIGNAL CIRCUITS CHECK

(A/T VEHICLE ONLY)

2. Main fuse box
3. Ignition switch
4. “IG” fuse
5. Transmission range switch
6. PCM
STEP ACTION YES NO

1 Ignition switch ON and check voltage at each terminal in Transmission range Wire open or short
PCM coupler under each condition given below. signal circuits are in Poor each terminal
Selector lever good condition. connection
in “P” range position: 10 – 14 V at “P” range terminal If wire and connec-
About 0 V at other range terminal tion are OK, check
Selector lever transmission range
in “R” range position: 10 – 14 V at “R” range terminal switch, referring to
About 0 V at other range terminal SECTION 7B.
Selector lever
in “N” range position: 10 – 14 V at “N” range terminal
About 0 V at other range terminal
Selector lever
in “D” range position: 10 – 14 V at “D” range terminal
Selector lever
in “2” range position: 10 – 14 V at “2” range terminal
Selector lever
in “L” range position: 10 – 14 V at “L” range terminal
INSPECTION OF ECM (PCM) AND ITS

CIRCUITS
ECM (PCM) and its circuits can be checked at ECM (PCM) wiring
couplers by measuring voltage and resistance.
CAUTION:
ECM (PCM) cannot be checked by itself. It is strictly pro-
hibited to connect voltmeter or ohmmeter to ECM (PCM)
with couplers disconnected from it.
Voltage Check
1) Remove ECM (PCM) from body with ignition switch OFF refer-
ring to ECM (PCM) REMOVAL.
2) Connect ECM (PCM) couplers to ECM (PCM).
3) Check voltage at each terminal of couplers connected.
NOTE:
As each terminal voltage is affected by the battery voltage,
confirm that it is 11V or more when ignition switch is ON.
1. ECM (PCM)
2. Couplers
3. Body ground
TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE)

TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION

C51-1 Blank — —
C51-2 IAC valve — —
Transmission range
g switch 10 – 14 V Ignition switch ON, selector lever: “2” range
C51-3
“2” 1 V or less Ignition switch ON, selector lever: Other than “2” range
Transmission range
g switch 10 – 14 V Ignition switch ON, selector lever: “N” range
C51-4
“N” 1 V or less Ignition switch ON, selector lever: Other than “N” range
Transmission range
g switch 10 – 14 V Ignition switch ON, selector lever: “P” range
C51-5
“P” 1 V or less Ignition switch ON, selector lever: Other than “P” range
C51-6 Tachometer 1 V or less Ignition switch ON
4.5 – 5.5 V Ignition switch ON
C51-7 Test switch terminal
1 V or less Ignition switch ON, Test switch terminal grounded
4.5 – 5.5 V Ignition switch ON
C51-8 Diagnosis switch terminal
1 V or less Ignition switch ON, Test switch terminal grounded
Ignition switch ON, Blower fan switch : High or Middle
2 V or less
g for blow- position
C51-9
er fan motor Ignition switch ON, Blower fan switch : OFF or Low posi-
4.0 – 14.0 V
tion
Stop lamp switch 1.5V or less Brake pedal released (switch OFF), Ignition switch ON
C51-10
(brake pedal switch) 10 – 14 V Brake pedal depressed (switch ON), Ignition switch ON
C51-11 Blank — —
C51-12 Data link connector 10 – 14 V Ignition switch ON
Engine
g starter switch 1.5V or less Ignition switch ON
C51-13
(engine starter signal) 6 – 12 V While engine cranking
Transmission range
g switch 10 – 14 V Ignition switch ON, selector lever: “L” range
C51-14
“L” 1 V or less Ignition switch ON, selector lever: Other than “L” range
Transmission range
g switch 10 – 14 V Ignition switch ON, selector lever: “D” range
C51-15
“D” 1 V or less Ignition switch ON, selector lever: Other than “D” range
Transmission range
g switch 10 – 14 V Ignition switch ON, selector lever: “R” range
C51-16
“R” 1 V or less Ignition switch ON, selector lever: Other than “R” range
C51-17 Duty output terminal 1 V or less Ignition switch ON
g for small 1 V or less Ignition switch ON, Small light turned OFF
C51-18
light switch 10 – 14 V Ignition switch ON, Small light turned ON
Ignition switch ON, A/C switch OFF, Blower fan switch
10 – 14 V
A/C ON signal
g from A/C OFF
C51-19
switch (if equipped) Ignition switch ON, A/C switch ON, Blower fan switch
2 V or less
ON
C51-20 Blank — —
C51-21 Blank — —
C51-22 Sensor ground — —

C52-1 Power supply for sensor 4.5 – 5.5 V Ignition switch ON
C52-2 Blank — —
C52-3 CMP sensor (+) 1 V or less Ignition switch ON
Indicator deflection
Ignition switch ON, Front left tire turned quickly with front
C52-4 VSS repeated between
right tire locked
0 – 1 V and 4 – 14 V
About 3.6 V Ignition switch ON, engine stop
C52-5 MAP sensor
About 1 – 3 V Engine running at idle speed, A/C OFF
0.78 – 0.83 V Throttle valve at idle position
C52-6 TP sensor
3.7 – 4.7 V Throttle valve at full open position

A/C evaporator temp. sen-
C52-7 2.0 – 2.5 V A/C ventilator outlet temp.: at 20C
sor (with A/C)
2.5 – 3.0 V Engine coolant temp.: at 20C
C52-8 ECT sensor
0.6 – 0.9 V Engine coolant temp.: at 80C
C52-9 Sensor ground — —
C52-10 Blank — —
C52-11 CMP sensor (–) About 0 V —
C52-12 Blank — —
Deflect between 0
C52-13 Oxygen sensor After engine warmed up
and 1 V
2.0 – 2.5 V IAT sensor ambient temp.: at 20C
C52-14 IAT sensor
0.4 – 0.6 V IAT sensor ambient temp.: at 80C
C52-15 Blank — —
A/C compressor magnetg 1 V or less Engine running, A/C compressor: ON
C52-16
clutch (with A/C) relay 10 – 14 V Engine running, A/C compressor: OFF

C50-1 Ground — —
C50-2 Power source 10 – 14 V Ignition switch ON
C50-3 Blank — —
C50-4 Blank — —
C50-5 Shift solenoid B 1 V or less Ignition switch ON, “P” range
C50-6 Shift solenoid A 1 V or less Ignition switch ON, “P” range
C50-7 EVAP canister purge valve 10 – 14 V Ignition switch ON
C50-8 Blank — —
C50-9 Blank — —
Ignition coil assembly for
C50-10 1 V or less Ignition switch ON
No.1 and 4 spark plugs
C50-11 Fuel injector No.3 10 – 14 V Ignition switch ON
C50-14 Power source for backup 10 – 14 V —
C50-15 Power source 10 – 14 V Ignition switch ON
C50-16 Blank — —
Malfunction indicator light
g About 0.5 V or less Ignition switch ON, engine stops
C50-17
(“CHECK ENGINE” light) 10 – 14 V Engine running
For 3 seconds after ignition switch ON or while engine
1 V or less
running
C50-18 Fuel pump
um relay
After 3 seconds from ignition switch ON with engine
10 – 14 V
stopped
C50-19 Main relay 1 V or less Ignition switch ON
10 – 14 V Ignition switch ON
C50-20 Radiator fan control relay
1 V or less Engine cooling fan ON
C50-21 Blank — —
C50-22 Blank — —
Ignition coil assembly for
C50-23 1 V or less Ignition switch ON
No.2 and 3 spark plugs

Section 6-2

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Section 6-2

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6A-66 ENGINE MECHANICAL

Honing or reboring cylinders

3) Using micrometer, measure piston diameter.

4) Calculate cylinder bore diameter to be rebored.

5) Rebore and hone cylinder to calculated dimension.

1) Install main bearings to cylinder block (1).

2) Install thrust bearings (1) to cylinder block between No.2 and

3) Install crankshaft to cylinder block.

5) Install new gasket and oil seal housing.

7) Install flywheel (M/T model).

8) Install pistons and connecting rods as previously outlined.

10) Install cylinder head assembly to cylinder block as previously

13) Install engine mountings brackets.

REQUIRED SERVICE MATERIALS

Mating surfaces of cylinder block and oil pan.

09916-14510 09916-14910 09916-34542 09916-34550

09916-77310 09917-18210 09917-68221 09917-98221

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B- 2

COOLING SYSTEM CIRCULATION

Symptom Possible Cause Remedy

ANTI-FREEZE PROPORTIONING CHART

ltr. 1.05/2.45 1.75/1.75

Ratio of compound to cooling water US pt. 2.22/5.18 3.70/3.70

lmp pt. 1.85/4.31 3.08/3.08

When engine is cool, check coolant level in reservoir tank (1).

COOLING SYSTEM SERVICE

Cooling system should be serviced as follows.

COOLING SYSTEM FLUSH AND REFILL

2) With radiator cap removed, run engine until upper radiator

3) Stop engine and drain coolant.

WATER PUMP BELT TENSION

COOLING SYSTEM DRAINING

COOLING WATER PIPES OR HOSES

4) Check thermostatic movement of wax pellet as follows:

Thermostat functional spec. "1.5C (2.7F)

Temp. at which valve begins

3) Install thermostat cap to thermostat case.

WATER PUMP BELT

WATER PUMP BELT TENSION INSPECTION AND AD-

5) Remove A/C condenser mounting bolts (3) (if equipped) and

2. A/C condenser (if equipped)

7) Remove A/C receiver/dryer mounting bolts (1) from cooling

5) Remove water pump (1), gasket (2) and rubber seal.

2) Install water pump (1) to cylinder block.

REQUIRED SERVICE MATERIAL

With short pipe, fit hose as far as it reaches pipe joint

Clamp securely at a position 3 to 7 mm

2) Disconnect negative cable at battery.

3) Connect fuel hoses to each pipe.

FUEL FILLER CAP

2) Disconnect negative cable at battery.

7) Remove fuel filter (1) referring to “Fuel Filter” previously de-

9) Lower fuel tank gradually while holding it horizontally and pull

Fuel Tank Purging Procedure

Following procedure is used purging fuel tank.

2) Remove fuel pump assembly from fuel tank.

Tightening Torque for fuel tank bolts

3. Fuel feed hose

8) Connect negative cable to battery.

FUEL PUMP ASSEMBLY (WITH FUEL LEVEL

3) Remove fuel pump assembly (1) from fuel tank.

“A”: Apply oil

4) Install fuel tank to vehicle. Refer to “Fuel Tank” in this section.