check engine SUZUKI GRAND VITARA 1987 Service User Guide

1. Mixture adjusting screw pin
2. Rod
Mixture adjusting screw pin
10) With engine running at idle speed, adjust idle
mixture adjusting screw slowly in small incre-
ment allowing time for duty to stabilize after
turning screw to obtain duty of 10 - 50.
If duty is too low, back screw out; if too
high, screw it in. After obtaining duty of
10- 50, recheck idle speed, and adjust if
necessary.
NOTE:
If adjustment can’t be made because duty meter
indicator does not deflect, check feed baCk
system according to the checking procedure of
system described in section of Emission Control
System.
3) Reinstall carburetor following normal service
procedures.
Connect emission control system hoses and
lead wires. Make specified play on accelerator
cable and refill cooling system.
11) After adjustment, install seal rubber to duty
check coupler and drive in idle mixture
adjusting screw pin.
4) Place transaxle gear shift lever in “Neutral”,
set parking brake and block drive wheels.
5) Start engine, and warm it up to normal
operating temperature, stop engine.
6) Be sure to check the following before idle
mixutre adjustment.
l Fuel level is within round mark at the
center of level gauge.
l Valve lash is checked and adjusted accord-
ing to the maintenance schedule.
l Air cleaner has been properly installed
and is in good condition.
l All accessories (wipers, heater, lights etc)
are out of service.
29. CARBURETOR INSPECTION
Check each carburetor mounting nut for tight-
ness.
If it is found loose, tighten it securely.
Also, check where the carburetor and intake
manifold are mated and other parts of the
carburetor body for leakage. Be sure to correct
the cause for leakage, if any.
l Ignition timing is within specification.
l Choke valve opens fully.
l Idle-up actuator does not operate.
7) Check and adjust idle speed to specification
if necessary.
8) Remove seal rubber of duty check coupler
and connect positive terminal of duty
meter to“Blue/Red” wire and negative
terminal to “Black/Green” wire.
9) Run engine at 1,500 - 2,000 r/min for 30
seconds and bring it to idle speed.
1-16

FINAL INSPECTION
Carry out road test in safe place.
WARNING:
When carrying out the following road
tests, select a safe place where no man or
no running car is seen so as to prevent any
accident.
1) Engine start
Check engine start for readiness.
2) Clutch
Check the following:
l that clutch is completely released when
depressing clutch pedal,
l that no slipping clutch occurs when releas-
ing pedal and accelerating,
l and that clutch itself is free from any
abnormal condition.
3) Gearshift Lever (Transmission and Transfer)
Check gearshift lever for smooth shifting
to all positions and for good performance of
transmission and transfer in any position.
4) Brake
[Foot brake]
Check the following when depressing brake
pedal while driving;
l that brake works properly,
l that it is free from noise,
l and that braking force applies equally on
all wheels.
[Parking brake]
Check to ensure that parking brake is fully
effective when the car is stopped on the slop
and brake lever is pulled all the way.
5) Steering
Check to ensure that steering wheel is free
from instability, or abnormally heavy feeling
while driving.
1-22

2-1. ENGINE
Cond it ion
Poor starting
(Hard starting)
Possible cause
Starter will not run
1. Main fuse blown off
2. Contact not closing in main switch, or this
switch open-circuited
3. Run-down battery
4. Defective magnetic switch of starter
5. Loose battery terminal connection
6. Defective brushes in starter
7. Loose battery cord connection
8. Open in field or armature circuit of starter.
Correction
Replace
Repair or replace
Recharge
Replace
Clean and retighten
Replace
Retighten
Repair or replace
No sparking
1. Defective spark plugAdjust gap, or replace
2. High tension cord short-circuited (grounded)Repair or replace
3. Cracked rotor or cap in distributorReplace
4. Defective signal generator or ignitorReplace
5. Maladjusted signal rotor air gap.Adjust
6. Contact not closing positively in main switch,Replace
or this switch open-circuited
7. Loose or blown fuseSet right or replace
8. Improper ignition timingAdjust
9. Defective ignition coil.Replace
Faulty intake and exhaust systems
1. Carburetor out of adjustment
2. Fuel pump not discharging adequately
3. Clogged fuel filter
4. Defective choke mechanism
5. Loose intake manifold
6. Dirty and clogged carburetor
7. Float level out of adjustment
8. Clogged fuel hose or pipe
9. Not enough fuel in the tank
10. Malfunctioning fuel cut solenoid valve
Adjust
Replace
Clean, or replace
Repair or replace
Retighten
Disassemble and clean
Adjust
Clean or replace
Refill
Check solenoid valve for
proper operation and
replace if necessary
Abnormal engine internal condition
1. Ruptured cylinder head gasket
2. Improper valve clearance
3. Weakened or broken valve spring
4. Loose manifold, permitting air to be
drawn in
5. Worn pistons, rings or cylinders
Replace
Adjust
Replace
Retighten and, as neces-
sary, replace gasket
Replace worn rings and
pistons and rebore as
necessary
2-2

ConditionPossible causeCorrection
Not enough powerEmission control
1. Malfunctioning EGR valve
Check and replace as
necessary.
Check and replace as
2. Malfunctioning bowl vent solenoid valve.necessary.
Check and replace as
3. Malfunctioning high altitude switch.necessary
Check nad replace as
4. Malfunctioning throttle position switch
(wide open switch)
necessary
Others
1. Dragging brakes
2. Slipping clutch
.Repair or replace
Adjust or replace
Engine hesitatesAbnormal condition in electrical systems
(Momentary lack of1. Defective spark plug or plug gap out ofReplace or adjust gap
response as the acceler-
ator
adjustment
is depressed. Can2. Cracked rotor or cap in distributor,Replace
occur at all car speeds.resulting in leakage
Usually most severe3. Deteriorated ignition coil, or crackReplace
when first trying toresulting in leakage
make the car move, as4. Leaky high-tension cordsReplace
from a stop sign.)5. Ignition timing out of adjustmentAdjust as prescribed
Abnormal condition in fuel system
1. Improper adjustment of float level
2. Clogged carburetor jets
3. Malfunctioning accelerator pump
Adjust
Clean
Check and replace as
necessary
4. Inadequately discharging fuel pumpReplace
Abnormal condition in engine
1. Loss of compression pressure due to leaky
cylinder head gasket
Replace
2. Compression pressure too low because ofReplace and rebore as
worn pistons, rings, cylinders or burnt valvesnecessary
Emission control
1. Malfunctioning bowl vent solenoid valveCheck and replace as
necessary
2. Malfunctioning throttle position switch
(wide open switch)
3. Malfunctionnig high altitude switch
4. Malfunctioning EGR valve
Check and replace as
necessary
Check and replace as
necessary
Check and replace as
necessary
5. Malfunctioning thermostatically controlled
air cleaner
Check and replace as
necessary
2-4

ConditionPossible causeCorrection
SurgesFuel system out of order
(Engine power varia- 1. Clogged fuel filterReplace
tion under steady2. Kinky, leaky or damaged fuel hoses and linesCheck and replace as
throttle or cruise.necessary
Feels like the car3. Malfunctioning fuel pumpCheck and replace as
speeds up and downnecessary
with no change in the4. Leaky manifold and carburetor gasketsReplace
accelerator pedal.)5. Improper float levelAdjust
Ignition system out of order
1. Improper ignition timing
2. Malfunctioning ignition timing advancers
(mechanical and vacuum)
Adjust
Check or replace
3. Leaky or loosely connected high tension cordCheck and repair or
replace
4. Defective spark plug (excess carbon deposits,Check and clean, adjust
improper gap, burned electrodes, etc..)or replace
5. Cracked rotor or cap in distributorReplace
Emission control
1. Malfunctioning bowl vent solenoid valve
2. Malfunctioning throttle position switch
(wide open switch)
3. Malfunctioning high altitude switch
4. Malfunctioning EGR valve
5. Malfunctioning thermostatically controlled
air cleaner
Check and replace as
necessary
Check and replace as
necessary
Check and replace as
necessary
Check and replace as
necessary
Check and replace as
necessary.
Dieseling
(Engine continues to
run after ignition
switch is turned off.
it runs unevenly and
may make knocking
noise. )
Malfunctioning fuel cut solenoid valve in
carburetor
Check solenoid valve for
proper operation and
replace as necessary
Erratic idling
(Improper engine
idling)
Abnormal condition in ignition system
1. Defective spark plug
2. Leaky or disconnected high tension cord
3. Worn distributor terminals
4. Improper ignition timing
5. Cracked cap in distributor, leakage inside
Adjust or replace
Connect or replace
Replace
Adjust
Replace
2-5

ConditionPossible causeCorrection
Erratic idling
(Improper engine
idling)
Abnormal condition in fuel system
1. Clogged carburetor jets
2. Incorrect idle adjustment
3. Clogged air cleaner element
4. Leaky manifold, carburetor or cylinder
head gaskets
5. Improper float level
6. Malfunctioning choke system
7. Malfunctioning fuel cut solenoid valve
Clean
Adjust
Clean or replace
Replace
Adjust
Adjust or replace
Replace
Others
1. Loose connection or disconnection. of
vacuum hoses
Connect
2. Malfunctioning PCV valve
3. Low compression
4. Loose carburetor and intake manifold bolts
and nuts
Check and replace as
necessary
Previously outlined
Tighten bolts and nuts
5. Leaky carburetor and intake manifold
gaskets
Replace
Abnormal detonationAbnormal condition in ignition system
1. Spark plugs tending to overheatChange plug heat value
2. Improper ignition timingAdjust
3. Loose connection in high-tension or low-Retighten
tension circuit.
Abnormal condition in fuel system
1. Clogged fuel filter and fuel lines
2. Clogged carburetor jets
3. Improper adjustment of float level
4. Malfunctioning fuel pump
5. Air inhaling from intake manifold and
carburetor gaskets
Replace or clean
Clean
Adjust
Replace
Replace
Abnormal condition in engine
1. Excessive carbon deposit on piston crowns
or cylinder head
Clean
2. Blown cylinder head gasket, resulting in
low compression pressure
3. Improper valve clearance
4. Valves tending to seize
5. Weakened valve springs
Replace
Adjust
Replace
Replace
Others
Malfunctioning EGR valveReplace
2-6

9
Cond it ionPossible causeCorrection
OverheatingAbnormal condition in ignition system
1. Improper ignition timingAdjust
2. Wrong heat value of spark plugsChange heat value
Abnormal condition in fuel systems
1. Float level set too lowAdjust
2. Clogged jets in carburetorClean
3. Loose inlet manifoldRetighten
Abnormal condition in cooling system,,
1. Not enough coolantRefill
2. Loose or broken fan beltAdjust or replace
3. Erratically working thermostatReplace
4. Poor water pump performanceReplace
5. Leaky radiator coresRepair or replace
Abnormal condition in lubrication system
1. Clogged oil filterReplace
2. Clogged oil strainerClean
3. Deteriorated oil pump performanceReplace
4. Oil leakage from oil pan or pumpRepair
5. Improper engine oil gradeReplace with proper grade
oil
6. Not enough oil in oil panReplenish
Others
1. Dragging brakesRepair or replace
2. Slipping clutchAdjust or replace
3. Blown cylinder head gasketReplace
Engine noiseCrankshaft noise
Note: Before check- 1. Worn-down bearings, resulting in excessivelyReplace
ing the mechanicallarge running clearances
noise, make sure that:2. Worn connecting-rod bearingsReplace
0 Ignition timing is3. Distorted connecting rodsRepair or replace
properly adjusted.4. Worn crankshaft journalsRepair by grinding, or re-
l Specified spark plugplace crankshaft
is used.5. Worn crankpins.Repair by grinding, or re-
l Specified fuel is used.place crankshaft
Noise due to pistons, rings, pins or cylinders
1. Abnormally worn cylinder boresRebore to next oversize
or replace
2. Worn pistons, rings or pinsReplace
3. Pistons tending to seizeReplace
4. Broken piston ringsReplace
, Others
1’. Excessively large camshaft thrust playReplace
2. Excessively large crankshaft thrust clearanceAdjust as prescribed
3. Valve clearance too largeAdjust as prescribed
4. Not enough engine oilReplenish
2-7

ConditionPossible causeCorrection
High fuel consumptionAbnormal condition ignition system
1. Improper ignition timingAdjust
2. Leak or loose connection of high tension cordRepair or replace
3. Defective spark plug (improper gap, heavyClean, adjust or replace
deposits, and burned electrodes, etc..)
4. Cracked distributor cap or rotorReplace
5. Malfunctioning mechanical and vacuumCheck and repair or
advancers in distributorreplace
Abnormal condition in fuel system
1. Improper float levelAdjust
2. Fuel leakage from tank, pipe or carburetorRepair or replace
3. Malfunctioning carburetor choke systemRepair or replace
4. Dirty or clogged carburetor jetsClean
5. Clogged air cleaner elementClean or replace
6. Malfunctioning thermostatically controlledCheck and repair or
air cleanerreplace
Abnormal condition in engine
1. Low compressionPreviously outlined
2. Poor valve seatingRepair or replace
3. Improper valve clearanceAdjust
Emission control
1. Air leaks at exhaust manifoldTighten manifold bolts
and nuts.
Replace gasket.
2. Oxygen sensor out of orderReplace.
3. Water temperature switch out of orderReplace.
4. Malfunctioning throttle position switchReplace
5. Malfunctioning MCS (mixture controlReplace
solenoid) valve in carburetor
6. Malfunctioning EGR valveReplace
Others
1. Dragging brakesRepair or replace
2. Slipping clutchAdjust or replace
3. Improper tire pressureAdjust
Excessive engine oilOil leakage
consumption1. Loose oil drain plugTighten
2. Loose oil pan securing boltsTighten
3. Deteriorated or broken oil pan sealantReplace sealant
4. Leaky oil sealsReplace
5. Blown cylinder head gasketReplace
6. Improper tightening of oil filterTighten
7. Loose oil pressure switchTighten
2-8

Condition
Starter will not run
at all, or runs but
runs too slow to
crank with full
force
Starter does not
stop running.
2-11. ALTERNATOR
Condition
Battery quickly
becomes over-
discharged.
Charge light does not
light with ignition ON
and engine off
Alternator noise
Possible cause
Magnet switch trouble
1. Lead wire socket loose in place
2. Burnt contact plate, or poor contacting
action
3. Open-circuit in pull-in coil
4. Open-circuit in holding coil
Starter proper trouble
1. Brushes seating poorly or worn down
2. Burnt commutator
3. Open-circuit in armature winding
4. Worn-down starter.
1. Fused contact points of magnet-switch
contact plate
2. Short-circuit between turns of magnet-
switch coil (layer short-circuit)
3. Failure of returning action in ignition
switch
Possible cause
1. Loose or broken “V” belt
2. Battery cables loose, corroded or worn
3. Low level of battery electrolyte
4. Defective battery cell plates
5. Insufficient contact in battery terminal
connection.
6. Excessive electrical load
7. IC regulator or alternator faulty
8. Defective idle up system
1. Fuse blown
2. Light burned out
3. Loose wiring connection
4. IC regulator faulty
1. Worn, loose or otherwise defective bearings
Correction
Retighten
Replace, or repair
Replace
Replace
Repair or replace
Repair or replace
Replace
Replace
Repair or replace
Replace
Replace
Correction
Adjust or replace
Repair or replcae
Replace
Replace the battery
Clean and retighten
Check charging system
Replace
Repair or replace
Check fuse
Replace light
Tighten loose connection!
Replace
i
Replace
2-17

32) Lower vehicle and remove 4 bolts securing
right and left engine mounting brackets(body side).
Fig. 3-3-10
Fig. 3-3-8
CAUTION:Before lifting engine and transmission,
recheck to ascertain all hoses, electric wires
and cables are disconnected from engine
and transmission.
34) Remove clutch lower plate.
35) Separate transmission from engine.
Throughout this MANUAL, 4 cylinders ofengine are identified by numbers: No. 1, No. 2, No. 3 and No. 4 as counted from front end.
33) Take down engine by operating a hoisting
means.
Fig. 3-3-11
Fig. 3-3-9
3-8