- •Generalinformation
- •Informationlabels
- •Periodicmaintenance
- •Valveclearance...................................................................2-8
- •Valveclearance
- •Inspectevery24000km(15000miles,24months).
- •IrWtl09900-20803:Thicknessgauge
- •09913-10750:Adaptor
- •Ventitsshortoropencircuit.
- •Iacautioni
- •09900-22302:Plastigauge
- •09900-22403:Smallboregauge{18-35mm)
- •09916-34542:Reamerhandle
- •09916-43220:Attachment(2)
- •Initialseatcut
- •15Mm(0.6in)fromthepistonskirtend.
- •Installation
- •1Root109913-70210:Bearinginstallerset
- •Inspectionandcleaning
- •09900-20701:Magneticstand
- •09900-21304:V-block(100mm)
- •09900-22401:Smallboregauge(1o-18mm)
- •Inspection
- •Iacautioni
- •Initial:18n·m(1.8kgf·m,13.0lb-ft)Final:32n·m(3.2kgf·m,23.0lb-ft)
- •Becareful!nottodamagethecylinderwallbytheconrod.
- •1L1molybdenumoilsolution
- •Iacautioni
- •Initial:15n·m(1.5kgf·m,11.0lb-ft)Final:90°(1/.Iturn)
- •Inglightly.
- •Initial:18n·m(1.8kgf·m,13.0lb-ft)Final:32n·m(3.2kgf·m,23.0lb-ft)
- •Usethenewgaskettopreventoilleakage.
- •FlSystemandintakeairsystem
- •Voltagecheck
- •VoltageBetween:
- •VoltageBetween:
- •Injectiontime(injectionvolume)
- •Various
- •ISensors
- •IUltimate
- •Injectionstopcontrol
- •Injectiontiming
- •Intakeairsystem
- •Injection"yes""'yes"
- •Inspection
- •1Root109900-25008:Multicircuittester
- •1Rq109900-25008:Multicircuittester
- •Inspection
- •Irk!09900-25008:Multicircuittester
- •1Rkib09900-25008:Multicircutitester
- •Construction
- •Inspection
- •1Root109930-11960:Torxwrench
- •Inspection
- •Iapsensorinspection
- •Iapsensorremoval/installation
- •28ForTPsensorsettingprocedure.
- •Iatsensorinspection
- •Iatsensorremoval/installation
- •Inspection
- •Installation
- •Inspection
- •..Takespecialcarewhenhandlingthetemperature-sen• sor.Itmaycausedamageifitgetsasharpimpact.
- •Installation
- •Inspection
- •Installation
- •Inspection
- •Usethenew0-ringstopreventenginecoolantleakage.
- •Icamdrivechaini
- •Istarterclutchi
- •Chassis
- •Installation
- •Installation
- •Inspectionanddisassembly
- •09900-20701:Magneticstand
- •Inspection
- •Itemn·mkgf·mlb-ft
- •Inspection
- •09940-14960:Steeringstemnutwrenchsocket
- •Inspectionanddisassembly
- •09940-14960:Steeringstemnutwrenchsocket
- •09940-14960:Steeringstemnutwrenchsocket
- •Itemn·mkgf-mlb-ft
- •Inspectionanddisassembly
- •09900-20701:Magneticstand
- •Inspection
- •Inspectionanddisassembly
- •Ingsolventsuchasgasoline,kerosineortheothers.
- •Iw)lllllu.D
- •Inspection
- •Valveinspection
- •Valveinstallation
- •Electricalsystem
- •IIncorrectt
- •Ignitioncoil
- •Ignitionsystem
- •0 Sensor
- •ICorrectIncorrect
- •Inspection
- •Ventanelectricshockwhiletesting.
- •Ignitioncoiuplugcapresistance
- •1Riot109900-25008:Multicircuittesterset
- •Inspection
- •09930-11940:Bitholder
- •Initialcharging
- •Iacautioni
- •Iacautioni
- •Insideofthebodycowling
- •Itemstd/spec.Limit
- •Itemstd/spec.Limit
- •Itemstd/spec.Limit
- •Itemstd/spec.Note
- •Itemstd/spec.Note
- •11IiiIu
- •Iatsensor
- •Suzukimotorcorporation
FlSystemandintakeairsystem
PRECAUTIONSINSERVICING |
. |
4- |
2 |
||
FlSYSTEMTECHNICALFEATURES |
. |
4- |
8 |
||
INJECTIONTIME |
. |
4- |
8 |
||
COMPENSATIONOFINJECTIONTIME |
. |
4- |
9 |
||
INJECTIONSTOPCONTROL |
. |
4- |
9 |
||
FUELDELIVERYSYSTEM |
. |
4-10 |
|||
FUELPUMP |
. |
4-11 |
|||
FUELPRESSUREREGULATOR |
. |
4-12 |
|||
FUELINJECTOR |
. |
4-12 |
|||
FUELPUMPCONTROLSYSTEM |
. |
4-13 |
|||
ECM(FlCONTROLUNIT) |
. |
4-14 |
|||
INJECTIONTIMING |
. |
4-15 |
|||
SENSORS |
. |
4-16 |
|||
INTAKEAIRSYSTEM.4-20 |
|||||
SECONDARYTHROTTLECONTROLSYSTEM |
. |
4-20 |
|||
OPERATION |
. |
4-21 |
|||
FlSYSTEMPARTSLOCATION |
. |
4-22 |
|||
FlSYSTEMDIAGRAM |
. |
4-24 |
|||
FlSYSTEMWIRINGDIAGRAM |
. |
4-25 |
|||
SELF-DIAGNOSISFUNCTION |
. |
4-26 |
|||
USERMODE |
. |
4-26 |
|||
DEALERMODE |
. |
4-27 |
|||
FAIL-SAFEFUNCTION |
. |
4-29 |
|||
FlSYSTEMTROUBLESHOOTING |
. |
4-30 |
|||
CUSTOMERCOMPLAINTANALYSIS |
. |
4-30 |
|||
SELF-DIAGNOSTICPROCEDURES |
. |
4-31 |
|||
SELF-DIAGNOSISRESETPROCEDURE |
. |
4-31 |
|||
MALFUNCTIONCODEANDDEFECTIVECONDITION |
. |
4-32 |
|||
"C11"CMPSENSORCIRCUITMALFUNCTION |
. |
4-34 |
|||
"C12"CKPSENSORCIRCUITMALFUNCTION |
. |
4-35 |
|||
"C13"/APSENSORCIRCUITMALFUNCTION |
. |
4-36 |
|||
"C14"TPSENSORCIRCUITMALFUNCTION |
. |
4-38 |
|||
"Ct5"ECTSENSORCIRCUITMALFUNCTION |
. |
4-40 |
|||
"C21"/ATSENSORCIRCUITMALFUNCTION |
. |
4-41 |
|||
"C22"APSENSORCIRCUITMALFUNCTION |
. |
4-42 |
|||
"C23"TOSENSORCIRCUITMALFUNCTION |
. |
4-44 |
|||
"C24","C25","C26"or"C27"IGNITIONSYSTEMMALFUNCTION |
. |
4-45 |
|||
"C28"STVACTUATORCIRCUITMALFUNCTION |
. |
4-45 |
|||
"C29"STPSENSORCIRCUITMALFUNCTION |
. |
4-46 |
|||
"C30"STCUNITCIRCUINMALFUNCTION |
. |
4-48 |
|||
''C31"GEARPOSITIONSWITCHCIRCUITMALFUNCTION |
. |
4-49 |
|||
"C32","C33","C34"or"C35"FUELINJECTIONMALFUNCTION |
. |
4-50 |
|||
"C41"FPRELAYCIRCUITMALFUNCTION |
. |
4-51 |
|||
"C42"JGSWITCHCIRCUITMALFUNCTION |
. |
4-51 |
|||
CONTENTS
_,.
FUEL |
TANK |
LIFT-UP..................................................................... |
4-52 |
||
FUEL |
TANK |
REMOVAL |
4-52 |
||
FUEL |
TANK |
INSTALLATION........................................................ |
4-52 |
||
FUELPRESSUREINSPECTION.................................................4-53 |
|||||
FUEL |
PUMP |
INSPECTION........................................................... |
4-54 |
||
FUEL |
PUMP |
RELAYINSPECTION.............................................. |
4-56 |
||
FUEL |
PUMP |
ANDFUELFILTERREMOVAL.............................. |
4-56 |
||
FUEL |
MESH |
FILTERINSPECTIONANDCLEANING................ |
4-58 |
||
FUEL |
PUMP |
ANDFUELMESHFILTERINSTALLATION.......... |
4-58 |
||
THROTTLEBODYANDSTVACTUATOR...................................... |
4-61 |
||||
CONSTRUCTION.......................................................................... |
4-61 |
||||
AIRCLEANERBOXANDTHROTTLEBODYREMOVAL |
4-62 |
||||
THROTTLEBODYDISASSEMBLY.............................................. |
4-64 |
||||
THROTTLEBODYCLEANING..................................................... |
4-66 |
||||
INSPECTION................................................................................. |
4-66 |
||||
THROTTLEBODYREASSEMBLY.............................................. |
4-67 |
||||
THROTTLEBODYINSTALLATION............................................. |
4-70 |
||||
STPSENSORADJUSTMENT...................................................... |
4-71 |
||||
FUELINJECTORINSPECTION |
4-72 |
||||
FUELINJECTORREMOVAL........................................................ |
4-72 |
||||
FUELINJECTORINSTALLATION............................................... |
4-72 |
||||
FASTIDLEADJUSTMENT...........................................................4-72 |
|||||
THROTTLE |
VALVESYNCHRONIZATION................................... |
4-73 |
|||
THROTTLE |
POSITIONSENSOR(TPS)SETTING...................... |
4-76 |
|||
THROTTLE |
CABLEADJUSTMENT............................................ |
4-76 |
|||
SENSORS......................................................................................... /APSENSORINSPECTION.......................................................... /APSENSORREMOVAUINSTALLATION...................................TPSENSORINSPECTION...........................................................TPSENSORREMOVAUINSTALLATION CKPSENSORINSPECTION........................................................CKPSENSORREMOVAUINSTALLATION CMPSENSORINSPECTION........................................................ CMPSENSORREMOVAUINSTALLATION................................. /ATSENSORINSPECTION.......................................................... /ATSENSORREMOVAUINSTALLATIONECTSENSORINSPECTION ECTSENSORREMOVAUINSTALLAT/ON APSENSORINSPECTION........................................................... APSENSORREMOVAUINSTALLATION....................................TOSENSORINSPECTION........................................................... TOSENSORREMOVAU/NSTALLATIONSTPSENSORINSPECTION.. STPSENSORREMOVAUINSTALLATION.................................. |
4-77 |
||||
4-77 |
|||||
4-77 |
|||||
4-77 |
|||||
4-77 |
|||||
4-77 |
|||||
4-77 |
|||||
4-77 |
|||||
4-77 |
|||||
4-77 |
|||||
4-77 |
|||||
4-78 |
|||||
4-78 |
|||||
4-78 |
|||||
4-78 |
|||||
4-78 |
|||||
4-78 |
|||||
4-78 |
|||||
4-78 |
|||||
FUELSYSTEM4-52
PRECAUTIONSINSERVICING
WhenhandlingtheFlcomponentpartsorservicingtheFlsys•
tem,observethefollowingpointsforthesafetyofthesystem.
CONNECTOR/COUPLER
•Whenconnectingaconnector,besuretopushitinuntilaclickisfelt.
•Withalocktypecoupler,besuretoreleasethelockwhendis•connecting,andpushitinfullytillthelockworkswhencon•nectingit.
•Whendisconnectingthecoupler,besuretoholdthecoupler
bodyanddonotpulltheleadwires.
-
•Inspecteachterminalontheconnector/couplerforloosenessorbending.•Inspecteachterminalforcorrosionandcontamination.
Theterminalsmustbecleanandfreeofanyforeignmaterialwhichcouldimpedeproperterminalcontact.
•Inspecteachleadwirecircuitforpoorconnectionbyshakingitbyhandlightly.Ifanyabnormalconditionisfound,repairorreplace.
•Whentakingmeasurementsatelectricalconnectorsusingatesterprobe,besuretoinserttheprobefromthewireharness
side(backside)oftheconnector/coupler.
G)Coupler
~Probe
•Whenconnectingmeterprobefromtheterminalsideofthecoupler(connectionfromharnesssidenotbeingpossible),useextracarenottoforceandcausethemaleterminaltobendorthefemaleterminaltoopen.
Connecttheprobeasshowntoavoidopeningoffemaletermi•
nal.
Neverpushintheprobewheremaleterminalissupposedtofit.
•Checkthemaleconnectorforbendandfemaleconnectorfor
excessiveopening.Alsocheckthecouplerforlocking(loose•
ness),corrosion,dust,etc.
G)Coupler
CZ)Probe
Q)Wheremale
terminalfits
FUSE
•Whenafuseblows,alwaysinvestigatethecause,correctitandthenreplacethefuse.
•Donotuseafuseofadifferentcapacity.
•Donotusewireoranyothersubstituteforthefuse.
ECMNARIOUSSENSORS
•Sinceeachcomponentisahigh-precisionpart,greatcareshouldbetakennottoapplyanysharpimpactsduringremovalandinstallation.
•BecarefulnottotouchtheelectricalterminalsoftheECM.Thestaticelectricityfromyourbodymaydamagethispart.
•WhendisconnectingandconnectingtheECMcouplers,makesuretoturnOFFtheignitionswitch,orelectronicpartsmaygetdamaged.
•Batteryconnectioninreversepolarityisstrictlyprohibited.SuchawrongconnectionwilldamagethecomponentsoftheFlsys•teminstantlywhenreversepowerisapplied.
IgnitionS/W
•Removinganybatteryterminalofarunningengineisstrictlyprohibited.
Themomentsuchremovalismade,damagingcounterelectro•motiveforcewillbeappliedtotheECMwhichmayresultinseriousdamage.
•Beforemeasuringvoltageateachterminal,checktomakesurethatbatteryvoltageis11Vorhigher.Terminalvoltagecheckatlowbatteryvoltagewillleadtoerroneousdiagnosis.
•Neverconnectanytester(voltmeter,ohmmeter,orwhatever)totheECMwhenitscouplerisdisconnected.Otherwise,dam•agetoECMmayresult.
•NeverconnectanohmmetertotheECMwithitscouplercon•
nected.Ifattempted,damagetoECMorsensorsmayresult.
•Besuretouseaspecifiedvoltmeter/ohmmeter.Otherwise,ac•curatemeasurementsmaynotbeobtainedandpersonalinjurymayresult.
ELECTRICALCIRCUITINSPECTIONPROCEDURE
Whiletherearevariousmethodsforelectricalcircuitinspection,describedhereisageneralmethodtocheckforopenandshortcircuitusinganohmmeterandavoltmeter.
OPENCIRCUITCHECK
-
Possiblecausesfortheopencircuitareasfollows.Asthecausecanexistintheconnector/couplerorterminal,theyneedtobecheckedcarefully.•Looseconnectionofconnector/coupler
•Poorcontactofterminal(duetodirt,corrosionorrust,poorcontacttension,entryofforeignobjectetc.)
•Wireharnessbeingopen
•Poorterminal-to-wireconnection
•Disconnectthenegativecablefromthebattery.
•Checkeachconnector/coupleratbothendsofthecircuitbeingcheckedforlooseconnection.Alsocheckforconditionofthe
couplerlockifequipped.
•Usingatestmaleterminal,checkthefemaleterminalsofthecircuitbeingcheckedforcontacttension.
Checkeachterminalvisuallyforpoorcontact(possiblycaused
bydirt,corrosion,rust,entryofforeignobject,etc.).Atthesametime,checktomakesurethateachterminalisfullyinsertedinthecouplerandlocked.
Ifcontacttensionisnotenough,rectifythecontacttoincrease
tensionorreplace.
Theterminalsmustbecleanandfreeofanyforeignmaterialwhichcouldimpedeproperterminalcontact.
•Usingcontinuityinspectorvoltagecheckprocedureasde•scribedbelow,inspectthewireharnessterminalsforopencir•cuitandpoorconnection.Locateabnormality,ifany.
Checkcontacttensionbyinsertingandremoving.
~A~!1b}
t.~®
(2)
G)Loosenessofcrimping
(2)Open
@Thinwire(afewstrandsleft)
Continuitycheck
•Measureresistanceacrosscoupler~·(between®and©inthefigure).
Ifnocontinuityisindicated(infinityoroverlimit),thecircuitis
openbetweenterminals15,,and©.
~
©
•Disconnectthecoupler@andmeasureresistancebetweencouplers®and@.
Ifnocontinuityisindicated,thecircuitisopenbetweencou•plers®and@.Ifcontinuityisindicated,thereisanopencir•cuitbetweencouplers@'and©oranabnormalityincoupler
®'orcoupler©.
