Diagnosis SUZUKI SWIFT 2006 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine FOREWORD
This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service
operations, replacement of components (Service) and for disassembly and reassembly of major components
(Unit Repair-Overhaul).
Applicable Model:
SWIFT (RS416) produced at KOSAI plant in Japan wi th the following vehicle identification numbers
(VINs).

JSAEZC31S############


The contents are classified into sectio ns each of which is given a section number as indicated in the Table of
Contents on following page. And on the first page of ea ch individual section is an index of that section.
This manual should be kept in a handy place for ready reference of the service work.
Strict observance of the so specif ied items will enable one to obtain the full performance of the vehicle.
When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials as specif ied in each description.
All information, illustrations and specif ications contained in this literature are based on the late st product infor-
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specificatio ns among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
JSAEZC31S########

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Vo l u m e 1
Precautions............................................................... 00-iPrecautions ............................................................ 00-1
General Information ................ ................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubricatio n ................................. 0B-1
Engine ......................................................................... 1-i Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1
Aux. Emission Control Devices .............................. 1B-1
Engine Electrical Devices....................................... 1C-1
Engine Mechanical ................................................. 1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System .......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System....................................................... 1H-1
Starting System ....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System ..................................................... 1K-1
Suspension ................................................................. 2-i Precautions .............................................................. 2-1
Suspension General Diagnosis .............................. 2A-1
Front Suspension ................................................... 2B-1
Rear Suspension................ .................................... 2C-1
Wheels and Tires ................................................... 2D-1
Driveline / Axle ........................................................... 3-i Precautions .............................................................. 3-1
Drive Shaft / Axle ................................................... 3A-1
Brakes ......................................................................... 4-i Precautions .............................................................. 4-1
Brake Control System and Diagnosis .................... 4A-1
Front Brakes........................................................... 4B-1
Rear Brakes ........................................................... 4C-1
Parking Brake......................................................... 4D-1
ABS ........................................................................ 4E-1
Electronic Stability Program ................................... 4F-1
Vo l u m e 2
Precautions ............................................................... 00-iPrecautions ............................................................ 00-1
Transmission / Transaxle .... ...................................... 5-i
Precautions .............................................................. 5-1
Automatic Transmission/Transaxle ........................ 5A-1
Manual Transmission/Transaxle ............................ 5B-1
Clutch .....................................................................5C-1
Steering ....................................................................... 6-i Precautions .............................................................. 6-1
Steering General Diagnosis ................................... 6A-1
Steering Wheel and Column .................................. 6B-1
Power Assisted Steering System ...........................6C-1
HVAC ........................................................................... 7-i Precautions .............................................................. 7-1
Heater and Ventilation............................................ 7A-1
Air Conditioning System ......................................... 7B-1
Restraint ...................................................................... 8-i Precautions .............................................................. 8-1
Seat Belts ............................................................... 8A-1
Air Bag System ...................................................... 8B-1
Body, Cab and Accessories .... .................................. 9-i
Precautions .............................................................. 9-1
Wiring Systems ...................................................... 9A-1
Lighting Systems .................................................... 9B-1
Instrumentation / Driver Info. / Horn .......................9C-1
Wipers / Washers ...................................................9D-1
Glass / Windows / Mirrors ...................................... 9E-1
Security and Locks ................................................. 9F-1
Seats ..................................................................... 9G-1
Interior Trim ............................................................9H-1
Hood / Fenders / Doors .......................................... 9J-1
Body Structure ....................................................... 9K-1
Paint / Coatings ...................................................... 9L-1
Exterior Trim .......................................................... 9M-1
Control Systems ....................................................... 10-i Precautions ............................................................ 10-1
Body Electrical Control Sy stem ............................ 10B-1
Immobilizer Control System .................................10C-1
Keyless Start System ........................................... 10E-1
TABLE OF CONTENTS

Downloaded from www.Manualslib.com manuals search engine 00-1 Precautions:
Precautions
Precautions
Precautions
Precautions for Vehicles Equipped with a
Supplemental Restraint (Air Bag) System
S7RS0B0000001
WARNING!
• The configuration of air bag system parts are as shown in the figure. When it is
necessary to service (remove, reinstall and
inspect) these parts, be sure to follow
procedures described in Air Bag System
section. Failure to follow proper
procedures could result in possible air bag
system activation, personal injury, damage
to parts or air bag system being unable to
activate when necessary.
• If the air bag system and another vehicle system both need repair, SUZUKI
recommends that the air bag system be
repaired first, to help avoid unintended air
bag system activation.
• Do not modify the steering wheel, dashboard, or any other air bag system
components. Modifications can adversely
affect air bag system performance and
lead to injury.
• If the vehicle will be exposed to temperatures over 93 °C (200 °F) (for
example, during a paint baking process),
remove the air bag system components
beforehand to avoid component damage
or unintended air bag system activation.

Diagnosis
• When troubleshooting air bag system, be sure to follow “Diagnosis” in Air Bag System section.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacement.
• Never use electrical test equipment other than that specified.
WARNING!
Never attempt to measure the resistance of
the air bag (inflator) modules (driver,
passenger, side and curtain) and seat belt
pretensioners (driver and passenger). It is
very dangerous as the electric current from
the tester may deploy the air bag or activate
the pretensioner.

1. Air bag wire harness (in floor, main and instrument panel harness) 6. Driver air bag (inflator) module
2. Passenger air bag (inflator) module 7. Side air bag (inflator) module (if equipped)
3. SDM 8. Curtain air bag (inflator) module (if equipped)
4. Seat belt pretensioner 9. Forward sensor
5. Contact coil 10. Side sensor (if equipped)
1 2
3
4
4
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6
7 7
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I4RS0B000001-02
I4RS0A000002-02

Downloaded from www.Manualslib.com manuals search engine 00-9 Precautions:
• Be careful not to touch the electrical terminals of parts which use microcomputers (e.g. electronic control unit
like as ECM, PCM, P/S controller, etc.). The static
electricity from your body can damage these parts.
• Never connect any tester (voltmeter, ohmmeter, or whatever) to electronic control unit when its coupler is
disconnected. Attempt to do it may cause damage to
it.
• Never connect an ohmmeter to electronic control unit with its coupler connected to it. Attempt to do it may
cause damage to electronic control unit and sensors.
• Be sure to use a specified voltmeter / ohmmeter. Otherwise, accurate measurements may not be
obtained or personal injury ma y result. If not specified,
use a voltmeter with high impedance (M Ω/V
minimum) or a digital type voltmeter.
• When taking measurements at electrical connectors using a tester probe, be sure to insert the probe (2)
from the wire harness side (backside) of the
connector (1). • When connecting meter probe (2) from terminal side
of coupler (1) because it can’t be connected from
harness side, use extra care not to bend male
terminal of coupler of force its female terminal open
for connection.
In case of such coupler as shown connect probe as
shown to avoid opening female terminal.
Never connect probe where male terminal is
supposed to fit.
• When checking connection of terminals, check its
male half for bend and female half for excessive
opening and both for locking (looseness), corrosion,
dust, etc.
• Before measuring voltage at each terminal, check to make sure that battery voltage is 11 V or higher. Such
terminal voltage check at lo w battery voltage will lead
to erroneous diagnosis.
I3RM0A000004-01
I2RH01010046-01
I2RH01010047-01
I2RH01010048-01

Downloaded from www.Manualslib.com manuals search engine Precautions: 00-10
Air Bag WarningS7RS0B0000009
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 an authorized SUZUKI dealer. Refer
to “Air Bag System Components, Wiring
and Connectors Location in Section 8B” in
order to confirm whether you are
performing service on or near the air bag
system components or wiring. Please
observe all WARNINGS in Air Bag System
section and “Precautions on Service and
Diagnosis of Air Bag System in Section
8B” 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 the
negative cable is disconnected from the
battery. Otherwise, the system may be
activated by reserve energy in the Sensing
and Diagnostic Module (SDM).

Air Bag System Service WarningS7RS0B0000010
WARNING!
• Service on or around the air bag system components or wiring must be performed
only by an authorized SUZUKI dealer.
Please observe all WARNINGS in Air Bag
System section and “Precautions on
Service and Diagnosis of Air Bag System
in Section 8B” before performing service
on or around the air bag system
components or wiring. Failure to follow
WARNINGS could result in unintended
activation of the system or could render
the system inoperative. Either of these two
conditions may result in severe injury.
• The procedures in the air bag system section must be followed in the order
listed to disable the air bag system
temporarily and prevent false DTCs from
setting. Failure to follow procedures could
result in possible activation of the air bag
system, personal injury or otherwise
unneeded air bag system repairs.

Fastener CautionS7RS0B0000011
CAUTION!
When fasteners are removed, always reinstall
them at the same location from which they
were removed. If a fastener needs to be
replaced, use the correct part number
fastener for that application. If the correct
part number fastener is not available, a
fastener of equal size and strength (or
stronger) may be used. Fasteners that are not
reused, and those requiring thread-locking
compound, will be called out. The correct
torque value must be used when installing
fasteners that require it. If the conditions are
not followed, parts or system damage could
result.

Suspension CautionS7RS0B0000012
CAUTION!
• All suspension fasteners are an important attaching part in that it could affect the
performance of vital parts and systems,
and/or could result in major repair
expense. They must be replaced with one
of the same part number or with an
equivalent part if replacement becomes
necessary. Do not use a replacement part
of lesser quality or substitute design.
Torque values must be used as specified
during reassembly to assure proper
retention of this part.
• Never attempt to heat, quench or straighten any suspension part. Replace it
with a new part or damage to the part may
result.

Wheels and Tires CautionS7RS0B0000013
CAUTION!
All wheel fasteners are important attaching
parts in that they could affect the
performance of vital parts and systems, and/
or could result in major repair expense. They
must be replaced with one of the same part
number or with an eq uivalent part if
replacement becomes necessary. Do not use
a replacement part of lesser quality or
substitute design. Torque values must be
used as specified during reassembly to
assure proper retention of all parts.
There is to be no welding as it may result in
extensive damage and weakening of the
metal.

Downloaded from www.Manualslib.com manuals search engine 00-13 Precautions:
Short Circuit Check (Wire Harness to Ground)1) Disconnect negative (–) cable at battery.
2) Disconnect connectors at bot h ends of the circuit to
be checked.
NOTE
If the circuit to be checked is connected to
other parts (1), disconnect all connectors of
those parts.
Otherwise, diagnosis will be misled.

3) Measure resistance between terminal at one end of circuit (“A-1” terminal in the figure) and body ground.
If continuity is indicated, it means that there is a short
to ground between terminals “A-1” and “C-1” of the
circuit. 4) Disconnect the connector included in circuit
(connector-B) and measure resistance between “A-
1” and body ground. If continuity is indicated, it
means that the circuit is shorted to the ground
between terminals “A-1” and “B-1”.
Intermittent and Poor Connection InspectionS7RS0B0006002
Most intermittent are caused by faulty electrical
connections or wiring, although a sticking relay or
solenoid can occasionally be at fault. When checking it
for proper connection, perfor m careful check of suspect
circuits for:
• Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
• Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could
impede proper terminal contact. However, cleaning
the terminal with a sand paper or the like is prohibited.
• Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper
terminal orientation with the component or mating
connector.
I5RH01000006-01
1. To other parts
I2RH01010056-01
I2RH01010057-01

Downloaded from www.Manualslib.com manuals search engine 0A-1 General Information:
General Information
General Information
General Description
AbbreviationsS7RS0B0101001
A:
ABDC: After Bottom Dead Center
ABS: Anti-lock Brake System
AC: Alternating Current
A/C: Air Conditioning
A-ELR: Automatic-Emergency Locking Retractor
A/F: Air Fuel Mixture Ratio
ALR: Automatic Locking Retractor
API: American Petroleum Institute
APP sensor: Accelerator Pedal Position Sensor
A/T: Automatic Transmission , Automatic Transaxle
AT D C : After Top Dead Center
ATF: Automatic Transmission Fluid, Automatic
Transaxle Fluid
B:
B+: Battery Positive Voltage
BBDC: Before Bottom Dead Center
BCM: Body Electrical Control Module
BDC: Bottom Dead Center
BTDC: Before Top Dead Center
C:
CAN: Controller Area Network
CKT: Circuit
CKP Sensor: Crankshaft Position Sensor
CMP Sensor: Camshaft Position Sensor
CO: Carbon Monoxide
CPP Switch: Clutch Pedal Position Switch (Clutch
Switch, Clutch Start Switch)
CPU: Central Processing Unit
CRS: Child Restraint System
D:
DC: Direct Current
DLC: Data Link Connector (Assembly Line Diag. Link,
ALDL, Serial Data Link, SDL)
DOHC: Double Over Head Camshaft
DOJ: Double Offset Joint
DRL: Daytime Running Light
DTC: Diagnostic Trouble Code (Diagnostic Code)
E:
EBCM: Electronic Brake Cont rol Module, ABS Control
Module
EBD: Electronic Brake Force Distribution
ECM: Engine Control Module
ECT Sensor: Engine Coolant Temperature Sensor (Water Temp. Sensor, WTS)
EFE Heater: Early Fuel Evaporation Heater (Positive
Temperature Coefficient, PTC Heater)
EGR: Exhaust Gas Recirculation
EGRT Sensor: EGR Temperature Sensor (Recirculated
Exhaust Gas Temp. Sensor, REGTS)
ELR: Emergency Locking Retractor
ESP ®: Electronic Stability Program
EPS: Electronic Power Steering
EVAP: Evaporative Emission EVAP Canister:
Evaporative Emission Canister
(Charcoal Canister)
F:
4WD: 4 Wheel
Drive
G:
GEN: Generator
GND: Ground
GPS: Global Positioning System
H:
HVAC: Heating, Ventilating and Air Conditioning
HC: Hydrocarbons
HO2S: Heated Oxygen Sensor
I:
IAC Valve: Idle Air Control Valve (Idle Speed Control
Solenoid Valve, ISC Solenoid Valve)
IAT Sensor: Intake Air Temperature Sensor (Air
temperature Sensor, ATS)
ICM: Immobilizer Control Module
IG: Ignition
ISC Actuator: Idle Speed Control Actuator
L:
LH: Left Hand
LHD: Left Hand Drive Vehicle
LSPV: Load Sensing Proportioning Valve
M:
MAF Sensor: Mass Air Flow Sensor (Air Flow Sensor, AFS, Air Flow Meter, AFM)
MAP Sensor: Manifold Absolute Pressure Sensor
(Pressure Sensor, PS)
Max: Maximum
MFI: Multiport Fuel Injection (Mu ltipoint Fuel Injection)
Min: Minimum
MIL: Malfunction Indicator Lamp (“SERVICE ENGINE
SOON” Light)
M/T: Manual Transmission, Manual Transaxle
N:
NOx: Nitrogen Oxides
O:
OBD: On-Board Diagnostic System (Self-Diagnosis
Function)
O/D: Overdrive
OHC: Over Head Camshaft
O2S: Oxygen Sensor
P:
PCM: Powertrain Control Module
PCV: Positive Crankcase Ventilation
PNP: Park / Neutral Position
P/S: Power Steering
PSP Switch: Power Steering Pressure Switch (P/S
Pressure Switch)
R:
RH: Right Hand
RHD: Right Hand Drive Vehicle
S:
SAE: Society of Automotive Engineers

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1
Section 1
CONTENTS
Engine
Precautions ................................................. 1-1
Precautions............................................................. 1-1
Precautions for Engine .......................................... 1-1
Engine General Information and
Diagnosis ............. .................................... 1A-1
Precautions........................................................... 1A-1
Precautions on Engine Service ........................... 1A-1
Precaution on On-Board Diagnostic (OBD) System .............................................................. 1A-1
Precautions in Diagnosing Trouble ..................... 1A-1
Precautions of ECM Circuit Inspection................ 1A-2
Precautions of Electric Throttle Body System
Calibration ......................................................... 1A-2
General Description ............................................. 1A-2 Statement on Cleanliness and Care ................... 1A-2
Engine Diagnosis General Description ............... 1A-3
On-Board Diagnostic System Description ........... 1A-3
Data Link Connector (DLC) ................................. 1A-6
Engine and Emission Control System Description ........................................................ 1A-6
CAN Communication System Description........... 1A-7
Air Intake System Description ............................. 1A-9
Description of Electric Throttle Body System ...... 1A-9
Description of Electric Throttle Body System Calibration ....................................................... 1A-10
Fuel Cut Control Description ............................. 1A-10
Generator Control System Description ............. 1A-11
Electronic Control System Description .............. 1A-12
Engine and Emission Control Input / Output Table ............................................................... 1A-18
Schematic and Routing Diagram ...................... 1A-19 Engine and Emission Control System Diagram .......................................................... 1A-19
Component Locatio n ......................................... 1A-21
Electronic Control System Components Location .......................................................... 1A-21
Diagnostic Information and Procedures .......... 1A-22 Engine and Emission Control System Check.... 1A-22
Malfunction Indicator Lamp (MIL) Check .......... 1A-25
DTC Check ....................................................... 1A-26
DTC Clearance ................................................. 1A-27
DTC Table ......................................................... 1A-27
Fail-Safe Table ................ .................................. 1A-31 Scan Tool Data ................................................. 1A-33
Visual Inspection ............................................... 1A-37
Engine Basic Inspection .................................... 1A-38
Engine Symptom Diagnosis .............................. 1A-41
MIL Does Not Come ON with Ignition Switch
ON and Engine Stop (but Engine Can Be
Started) ........................................................... 1A-47
Malfunction Indicator Lamp Remains ON after Engine Starts................................................... 1A-48
DTC P0010: “A” Camshaft Position Actuator Circuit .............................................................. 1A-49
DTC P0011 / P0012: “A” Camshaft Position - Timing Over-Advanced or System
Performance / -Retarded................................. 1A-52
DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1) .......................... 1A-54
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2) .......................... 1A-56
DTC P0101: Mass or Volume Air Flow Circuit Range / Performance ...................................... 1A-58
DTC P0102: Mass or Volume Air Flow Circuit Low Input......................................................... 1A-61
DTC P0103: Mass or Volume Air Flow Circuit High Input ........................................................ 1A-63
DTC P0106: Manifold Absolute Pressure /
Barometric Pressure Circuit Range /
Performance.................................................... 1A-64
DTC P0107: Manifold Absolute Pressure /
Barometric Pressure Circ uit Low Input............ 1A-66
DTC P0108: Manifold Absolute Pressure /
Barometric Pressure Circ uit High Input ........... 1A-67
DTC P0111: Intake Air Temperature Sensor 1 Circuit Range / Performance ........................... 1A-69
DTC P0112: Intake Air Temperature Sensor 1 Circuit Low ...................................................... 1A-72
DTC P0113: Intake Air Temperature 1 Sensor Circuit High...................................................... 1A-74
DTC P0116: Engine Coolant Temperature Circuit Range / Performance ........................... 1A-76
DTC P0117: Engine Coolant Temperature Circuit Low ...................................................... 1A-79
DTC P0118: Engine Coolant Temperature Circuit High...................................................... 1A-81
DTC P0122: Throttle / Pedal Position Sensor / Switch “A” (Main) Circuit Low ........................ 1A-83

Downloaded from www.Manualslib.com manuals search engine 1-iv Table of Contents
Engine Lubrication System.....................1E-1
General Description ............................................. 1E-1
Engine Lubrication Description ........................... 1E-1
Diagnostic Information and Procedures ............ 1E-2 Oil Pressure Check ............................................. 1E-2
Repair Instructions ........... ................................... 1E-3
Heat Exchanger Components ............................. 1E-3
Heat Exchanger On-Vehicle Inspection .............. 1E-4
Heat Exchanger Removal and Installation .......... 1E-4
Oil Pan and Oil Pump Strainer Components....... 1E-5
Oil Pan and Oil Pump Strainer Removal and
Installation ......................................................... 1E-5
Oil Pan and Oil Pump Stra iner Cleaning ............. 1E-7
Oil Pump Components ........................................ 1E-8
Oil Pump Removal and Installation ..................... 1E-8
Oil Pump Disassembly and Reassembly ............ 1E-8
Oil Pump Inspection ............................................ 1E-9
Specifications .... ................................................. 1E-11
Tightening Torque Specifications ...................... 1E-11
Special Tools and Equipmen t ........................... 1E-11
Recommended Service Material ....................... 1E-11
Special Tool ...................................................... 1E-11
Engine Cooling System ..... ...................... 1F-1
General Description .......... ................................... 1F-1
Cooling System Descriptio n ................................ 1F-1
Coolant Description ............................................. 1F-1
Schematic and Routing Diagram ........................ 1F-2 Coolant Circulation .............................................. 1F-2
Diagnostic Information and Procedures ............ 1F-4 Engine Cooling Symptom Diagnosis ................... 1F-4
Repair Instructions ........... ................................... 1F-5
Cooling System Components.............................. 1F-5
Coolant Level Check ........................................... 1F-6
Engine Cooling System Inspection and Cleaning ............................................................ 1F-6
Cooling System Draining.. ................................... 1F-6
Cooling System Flush and Refill ......................... 1F-7
Cooling Water Pipes or Hoses Removal and Installation ......................................................... 1F-7
Thermostat Removal and In stallation.................. 1F-8
Thermostat Inspection......................................... 1F-8
Radiator Cooling Fan Motor On-Vehicle Inspection .......................................................... 1F-9
Radiator Cooling Fan Rela y Inspection............... 1F-9
Radiator Cooling Fan Removal and Installation ....................................................... 1F-10
Radiator On-Vehicle Inspection and Cleaning .. 1F-10
Radiator Removal and Inst allation .................... 1F-10
Water Pump Removal and In stallation .............. 1F-11
Water Pump Inspection ..................................... 1F-11
Specifications .... ................................................. 1F-12
Tightening Torque Specifications ...................... 1F-12
Special Tools and Equipmen t ........................... 1F-12
Recommended Service Material ....................... 1F-12
Fuel System ................... .......................... 1G-1
Precautions.......................................................... 1G-1 Precautions on Fuel System Service ................. 1G-1
General Description ............................................ 1G-1 Fuel System Description .................................... 1G-1
Fuel Delivery System Description ...................... 1G-1
Fuel Pump Description ....................................... 1G-2
Schematic and Routing Diagram ....................... 1G-2 Fuel Delivery System Diag ram........................... 1G-2
Diagnostic Information and Procedures ........... 1G-2 Fuel Pressure Inspection ................................... 1G-2
Fuel Cut Operation Inspection ........................... 1G-3
Repair Instructions ............ ................................. 1G-4
Fuel System Components .................................. 1G-4
Fuel Hose Disconnecting and Reconnecting ..... 1G-5
Fuel Pressure Relief Procedure ......................... 1G-7
Fuel Leakage Check Procedure......................... 1G-7
Fuel Lines On-Vehicle Inspection ...................... 1G-7
Fuel Pipe Removal and Installation.................... 1G-7
Fuel Injector On-Vehicle Inspection ................... 1G-8
Fuel Injector Removal and Installation ............... 1G-8
Fuel Injector Inspection ...................................... 1G-9
Fuel Filler Cap Inspection . ............................... 1G-10
Fuel Tank Inlet Valve Removal and Installation ...................................................... 1G-11
Fuel Tank Inlet Valve Inspection ...................... 1G-12
Fuel Tank Removal and Installation ................. 1G-12
Fuel Tank Inspection ........................................ 1G-13
Fuel Tank Purging Procedure .......................... 1G-14
Fuel Pump On-Vehicle Inspection.................... 1G-14
Fuel Pump Assembly Removal and Installation ...................................................... 1G-14
Main Fuel Level Sensor Removal and Installation ...................................................... 1G-15
Fuel Pump Inspection ...................................... 1G-16
Specifications ..................... ............................... 1G-16
Tightening Torque Specifications ..................... 1G-16
Special Tools and Equipmen t .......................... 1G-17
Special Tool ..................................................... 1G-17
Ignition System .............. .......................... 1H-1
General Description .............................................1H-1
Ignition System Construction ..............................1H-1
Schematic and Routing Diagram ........................1H-2 Ignition System Wiring Circuit Diagram...............1H-2
Component Location ............ ...............................1H-3
Ignition System Components Location................1H-3
Diagnostic Information and Procedures ............1H-4 Ignition System Symptom Diagnosis...................1H-4
Reference Waveform of Ignition System.............1H-4
Ignition System Check ........................................1H-4
Ignition Spark Test ..............................................1H-6
Repair Instructions ............ ..................................1H-6
High-Tension Cord Removal and Installation......1H-6
High-Tension Cord Inspection.............................1H-7
Spark Plug Removal and Installation ..................1H-7
Spark Plug Inspection .........................................1H-7
Ignition Coil Assembly (Including ignitor)
Removal and Installation ...................................1H-8
Ignition Coil Assembly (Including ignitor)
Inspection ..........................................................1H-8

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Ignition Timing Inspection ................................... 1H-8
Specifications ....................................................... 1H-9
Tightening Torque Specifications ........................ 1H-9
Special Tools and Equipmen t ............................. 1H-9
Special Tool ........................................................ 1H-9
Starting System ................. ........................ 1I-1
Schematic and Routing Diagram ......................... 1I-1
Cranking System Circuit Diagram ........................ 1I-1
Diagnostic Information and Procedures ............. 1I-1
Cranking System Symptom Diagnosis ................. 1I-1
Cranking System Test.......................................... 1I-3
Repair Instructions ............................................... 1I-4 Starting Motor Dismounting and Remounting ...... 1I-4
Starting Motor Components ................................. 1I-5
Starting Motor Inspection ..................................... 1I-6
Specifications ........................................................ 1I-9
Cranking System Specifications........................... 1I-9
Tightening Torque Specifications ......................... 1I-9
Special Tools and Equipment .............................. 1I-9
Recommended Service Material .......................... 1I-9
Charging System ............ .......................... 1J-1
General Description ......... .................................... 1J-1
Battery Description ...............................................1J-1
Generator Descripti on ..........................................1J-2
Diagnostic Information and Procedures ............ 1J-4 Battery Inspection ................................................1J-4
Generator Symptom Diagnosis ............................1J-4 Generator Test (Undercharged Battery
Check) ............................................................... 1J-5
Generator Test (Overcharg ed Battery Check) .... 1J-6
Repair Instructions ........... ................................... 1J-6
Jump Starting in Case of Emergency.................. 1J-6
Battery Dismounting and Remounting ................ 1J-7
Water Pump / Generator Drive Belt Tension Inspection and Adjustment ................................ 1J-7
Water Pump / Generator Drive Belt Removal and Installation .................................................. 1J-8
Generator Unit Co mponents ............................... 1J-9
Generator Dismounting a nd Remounting............ 1J-9
Generator Components........ ............................. 1J-10
Generator Insp ection......................................... 1J-11
Specifications ..................................................... 1J-13 Charging System Specifications ....................... 1J-13
Tightening Torque Specifications ...................... 1J-13
Exhaust System .............. ......................... 1K-1
General Description .............................................1K-1
Exhaust System Description ............................... 1K-1
Diagnostic Information and Procedures ............1K-1 Exhaust System Check ....................................... 1K-1
Repair Instructions ........... ...................................1K-2
Exhaust System Components ............................. 1K-2
Exhaust Manifold Removal and Installation ........ 1K-3
Exhaust Pipe and Muffler Removal and Installation ......................................................... 1K-4
Specifications .................... ...................................1K-5
Tightening Torque Specifications ........................ 1K-5