Suzuki Canvas SQ416 User manual

WARNING:
For vehicles equipped with a Supplemental
Restraint (Air Bag) System:
DService 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 and
Wiring Location View” under “General De-
scription” in air bag system section in order
to confirm whether you are performing ser-
vice on or near the air bag system compo-
nents or wiring. Please observe all WARN-
INGS and “Service Precautions” under “On-
Vehicle Service” in air bag system section
before performing service on or around the
air bag system components or wiring. Fail-
ure 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.
DIf the air bag system and another vehicle
system both need repair, SUZUKI recom-
mends that the air bag system be repaired
first, to help avoid unintended air bag sys-
tem activation.
DDo not modify the steering wheel, instru-
ment panel or any other air bag system com-
ponent (on or around air bag system compo-
nents or wiring). Modifications can adverse-
ly affect air bag system performance and
lead to injury.
DIf the vehicle will be exposed to tempera-
tures over 93_C (200_F) (for example, during
a paint baking process), remove the air bag
system components (air bag (inflator) mod-
ule, sensing and diagnostic module (SDM),
seat belt pretensioner (if equipped) before-
hand to avoid component damage or unin-
tended activation.
IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions
carefully. To emphasize special information, the
words WARNING, CAUTION and NOTE have spe-
cial meanings. Pay special attention to the messages
highlighted by these signal words.
NOTE:
Indicates special information to make mainte-
nance easier or instructions clearer.
WARNING:
Indicates a potential hazard that could result
in death or injury.
CAUTION:
Indicates a potential hazard that could result
in vehicle damage.
WARNING:
This service manual is intended for authorized
SUZUKI dealers and qualified service me-
chanics only. Inexperienced mechanics or
mechanics without the proper tools and
equipment may not be able to properly per-
form the services described in this manual.
Improper repair may result in injury to the me-
chanic and may render the vehicle unsafe for
the driver and passengers.

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FOREWORD
This SUPPLEMENTARY SERVICE MANUAL is a supplement to SQ416/SQ420/SQ625 SER-
VICE MANUAL. It has been prepared exclusively for the following applicable model.
Applicable model: SQ416/SQ420/SQ625 of and after the vehicle identification number
below.
JSAFTA03V00170001 2S2GTA03C00490001
JSAFTL52V00170001 2S2GTA03C20490001
JSAFTD62V00170001 2S2GTA03C26490001
JSAFTB52V00170001 2S3TA03C 26100001
2S3TA52C 26100001
2S2GTA52C00490001
2S2GTA52C20490001
2S3TD52V 26100001
It describes only different service information of the above applicable model as compared with
SQ416/SQ420/SQ625 SERVICE MANUAL.
Therefore, whenever servicing the above applicable model, consult this supplement first.
And for any section, item or description not found in this supplement, refer to the related manuals
mentioned in the next page.
When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine
parts, tools and service materials (lubricant, sealants, etc.) as specified in each description.
All information, illustrations and specifications contained in this literature are based on the latest
product information available at the time of publication approval. And used as the main subject
of description is the vehicle of standard specifications 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.
NOTE:
Refer to the next page for RELATED MANUALS.
OVERSEAS SERVICE DEPARTMENT
COPYRIGHT SUZUKI MOTOR CORPORATION 2001

RELATED MANUAL
MANUAL NAME MANUAL NO. APPLICABILITY
SQ416/SQ420/SQ625
Unit Repair Manual
99501-65D01-xxx This manual is the base manual for Transmission,
Transfer and Differentials (Front and Rear) of this
supplementary service manual.
SQ416/SQ420/SQ625
Wiring Diagram Manual
99512-65D11-015 Applicable model mentioned in FOREWORD
of this supplementary service manual.
SQ416/SQ420/SQ625
Service Manual
99500-65D10-xxx This manual is the base manual for this
supplementary service manual.

0A
0B
1A
1B
3
3A
3B1
3C
3C1
3D
3E
3F
4A2
4B
5
6
7A5A
5B
5C
5E1
6A1
6A2
6A4
6B
6C
6E1
6E2
6F1
6F2
6G
6G1
6H
6K
7A1
7B1
7C1
7D
7E
7F
8
8B
8C
8D
8E
8A
6-1
8G
9
10
10A
10B
10A
GENERAL INFORMATION
General Information
Maintenance and Lubrication
TABLE OF CONTENTS TABLE OF CONTENTS SECTIONSECTION
0B
HEATING AND AIR
CONDITIONING
Heater and Ventilation
Air Conditioning
STEERING, SUSPENSION,
WHEELS AND TIRES
Front End Alignment
Power Steering (P/S) System
Steering Wheel and Column
(Not Equipped with Air Bag)
Air Bag Steering Wheel
and Column
Front Suspension
Rear Suspension
Wheel and Tires
1A
3A
0A
1B
3B1
3C
3C1
3D
3E
3F
3
6A1
6
6A2
6A4
6B
6C
6E1
6E2
6F1
DRIVE SHAFT/ PROP. SHAFT
Front Drive Shaft/Shaft
Bearing, Oil Seal
Propeller Shaft
BRAKES
Brake Pipe/Hose /Master
Cylinder
Front Brakes
Parking and Rear Brakes
Antilock Brake System
4A2
4B
5
5A
5B
5C
5E1
6F2
6G
6G1
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8
8A
8B
8C
8D
8E
9
10
10B
6-1
8G
ENGINE
General Information and
Diagnosis (G16/J20)
General Information and
Diagnosis (H25)
Engine Mechanical (G16)
Engine Mechanical (H25)
Engine Mechanical (J20)
Engine Cooling
Engine Fuel
Engine and Emission Control
System (SFI for G16/J20)
Engine and Emission Control
System (SFI for H25)
Ignition System (G16)
Ignition System (J20/H25)
Cranking System
(Reduction Type)
Cranking System
(No-Reduction Type)
Charging System
Exhaust System
TRANSMISSION, CLUTCH
AND DIFFERENTIAL
Manual Transmission (Type 1)
Manual Transmission (Type 2)
Automatic Transmission
Clutch (Hydraulic Type)
Transfer
Differential (Front)
Differential (Rear)
BODY ELECTRICAL SYSTEM
Wiring Diagram
Lighting System
Instrumentation/Driver
Information
Windows, Mirrors, Security
and Lock
Cruise Control System
Immobilizer Control System
BODY SERVICE
RESTRAINT SYSTEM
Seat Belt
Air Bag System
NOTE:
For the screen toned sections in the above table, refer to the same sections of Service
Manual mentioned in FOREWORD of this manual.

0A
GENERAL INFORMATION 0A-1
SECTION 0A
GENERAL INFORMATION
NOTE
For the descriptions (items) not found in this section, refer to the same section of the Service Manual men-
tioned in FOREWORD of this manual.
CONTENTS
Abbreviations and Symbols May Be Used in This Manual 0A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations 0A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols 0A-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Color Symbols 0A-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0A-2 GENERAL INFORMATION
Abbreviations and Symbols May Be Used in This Manual
ABBREVIATIONS
ABS Anti-lock Brake System EFE Heater Early Fuel Evaporation Heater
ATDC After Top Dead Center (Positive Temperature Coefficient,
API American Petroleum Institute PTC Heater)
ATF Automatic Transmission Fluid EEPS Electronic Power Steering
ALR Automatic Locking Retractor EVAP Evaporative Emission
AC Alternating Current EVAP Evaporative Emission Canister
A
Canister (Charcoal Canister)
A/T Automatic Transmission F4WD 4 Wheel Drive
A/C Air Conditioning
G
GEN Generator
ABDC After Bottom Dead Center
G
GND Ground
A/F Air Fuel Mixture Ratio
H
HC Hydrocarbons
A-ELR Automatic-Emergency Locking
H
HO2S Heated Oxygen Sensor
Retractor IAC Valve Idle Air Control Valve (Idle Speed
B+ Battery Positive Voltage Control Solenoid Valve ISC
BBTDC Before Top Dead Center Solenoid Valve)
BBDC Before Bottom Dead Center
I
IAT Sensor Intake Air Temperature Sensor
CKT Circuit
I
(Air temperature Sensor, ATS)
CKP sensor Crankshaft Position Sensor ICM Immobilizer Control Module
CMP sensor Camshaft Position Sensor IG Ignition
CO Carbon Monoxide ISC Actuator Idle Speed Control Actuator
CCPP switch Clutch Pedal Position Switch LH Left Hand
(Clutch Switch, Clutch Start LLSPV Load Sensing Proportioning Valve
Switch)
CPU Central Processing Unit MAF Sensor Mass Air Flow Sensor (Air Flow
CRS Child Restraint System Sensor, AFS, Air Flow Meter,
DC Direct Current AFM)
DLC Data Link Connector (Assembly MAP Sensor Manifold Absolute Pressure
Line Diag. Link, ALDL, Sensor (Pressure Sensor, PS)
Serial Data Link, SDL) Max Maximum
DDOHC Double Over Head Camshaft
M
MFI Multiport Fuel Injection
DOJ Double Offset Joint (Multipoint Fuel Injection)
DRL Daytime Running Light MIN Minimum
DTC Diagnostic Trouble Code MIL Malfunction Indicator Lamp
(Diagnostic Code) (“SERVICE ENGINE SOON”
EBCM Electronic Brake Control Module, Light)
ABS Control Module M/T Manual Transmission
EBD Electronic Brake Force
N
NOx Nitrogen Oxides
Distribution
N
ECM Engine Control Module OBD On-Board Diagnostic System
E
ECT sensor Engine Coolant Temperature Sensor (Self-Diagnosis Function)
E
(Water Temp. Sensor, WTS)
O
O
O/D Overdrive
EGR Exhaust Gas Recirculation OHC Over Head Camshaft
EGRT sensor EGR Temperature Sensor O2S Oxygen Sensor
(Recirculated Exhaust Gas Temp.
Sensor, REGTS)

GENERAL INFORMATION 0A-3
PNP Park/Neutral Position
P/S Power Steering
P
PSP Switch Power Steering Pressure Switch
P
(P/S Pressure Switch)
PCM Powertrain Control Module
PCV Positive Crankcase Ventilation
RRH Right Hand
SAE Society of Automotive Engineers
SDM Sensing and Diagnostic Module
(Air bag controller, Air bag
Scontrol module)
SFI Sequential Multiport Fuel
Injection
SOHC Single over Head Camshaft
TBI Throttle Body Fuel Injection
(Single-Point Fuel Injection, SPI)
TCC Torque Converter Clutch
TCM Transmission Control Module
(A/T Controller, A/T Control
Module)
T
TP Sensor Throttle Position Sensor
T
TVV Thermal Vacuum Valve
(Thermal Vacuum Switching
Valve, TVSV, Bimetal Vacuum
Switching Valve, BVSV)
TWC Three Way Catalytic Converter
(Three Way Catalyst)
2WD 2 Wheel Drive
V
VIN Vehicle Identification Number
V
VSS Vehicle Speed Sensor
WU-OC Warm Up Oxidation Catalytic
W
Converter
W
WU-TWC Warm Up Three Way Catalytic
Converter

0A-4 GENERAL INFORMATION
GRN (Base Color)
GRN
(Base Color)
YEL
(Stripe Color)
GRN /
YEL
SYMBOLS
SYMBOL DEFINITION SYMBOL DEFINITION
Tightening torque Apply SUZUKI BOND NO. 1216
99000-31160
Apply oil (engine, transmission,
transfer, differential)
Apply SILICONE SEALANT
99000-31120
Apply fluid (brake, power steering or
automatic transmission fluid)
Apply SEALING COMPOUND
366E 99000-31090
Apply SUZUKI SUPER GREASE A
99000-25010
Apply SUZUKI SUPER GREASE C
99000-25030
Apply THREAD LOCK 1322
99000-32110
Apply SUZUKI SUPER GREASE E
99000-25050
Apply THREAD LOCK 1333B
99000-32020
Apply SUZUKI SUPER GREASE H
99000-25120
Apply THREAD LOCK 1342
99000-32050
Apply SUZUKI SUPER GREASE I
99000-25210
Apply SUZUKI BOND NO. 1215
99000-31110
Do not reuse
Apply SUZUKI BOND NO. 1207C
99000-31150
Note on reassembly
WIRE COLOR SYMBOLS
Symbol Wire Color Symbol Wire Color
B BLK Black O, Or ORN Orange
Bl BLU Blue R RED Red
Br BRN Brown W WHT White
GGRN Green Y YEL Yellow
Gr GRY Gray P PNK Pink
Lbl LT BLU Light blue V PPL Violet
Lg LT GRN Light green
There are two kinds of colored wire used in this vehicle. One is
single-colored wire and the other is dual-colored (striped) wire.
The single-colored wire uses only one color symbol (i.e. “GRN”).
The dual-colored wire uses two color symbols (i.e. “GRN/YEL”).
The first symbol represents the base color of the wire (“GRN”in the
figure) and the second symbol represents the color of the stripe
(“YEL”in the figure).

3E
REAR SUSPENSION 3E-1
SECTION 3E
REAR SUSPENSION
NOTE:
DFor the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in FOREWORD of this manual.
DAll 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 replace-
ment part of lesser quality or substitute design. Torque values must be used as specified during reas-
sembly to assure proper retention of this part.
DNever attempt to heat, quench or straighten any suspension part. Replace it with a new part, or damage
to the part may result.
CONTENTS
ON-VEHICLE SERVICE 3E-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shock Absorber 3E-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Rod 3E-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lateral Rod 3E-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Housing 3E-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS 3E-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3E-2 REAR SUSPENSION
1. Rear axle housing
2. Floor jack
1. Lock nut (if equipped)
2. Absorber nut
3. Upper support
4. Rubber bush
5. Lower support
6. Shock absorber
7. Bolt
Upper side
Lower side
1. Lock nut (if equipped)
2. Absorber nut
3. Body outside
ON-VEHICLE SERVICE
SHOCK ABSORBER
The shock absorber is non-adjustable, non-refillable, and cannot
be disassembled. The only service the shock absorber requires is
replacement when it has lost its resistance, is damaged, or leaking
fluid.
REMOVAL
1) Hoist vehicle and remove rear wheel.
2) Support rear axle housing by using floor jack to prevent it from
lowering.
3) Remove lock nut (if equipped) and absorber nut.
4) Remove lower mounting bolt.
5) Remove shock absorber.
INSTALLATION
1) Install shock absorber. Refer to figure for proper installing direc-
tion of lower mounting bolt.
2) Remove floor jack.
3) Lower hoist.
4) Tighten nuts to specified torque.
NOTE:
DTighten lower nut with vehicle off hoist and in non-loaded
condition.
Tightening Torque
(a): 29 N.m (2.9 kg-m, 21.0 lb-ft)
(b): 100 N.m (10.0 kg-m. 72.5 lb-ft)

REAR SUSPENSION 3E-3
1. Axle housing
2. Floor jack
1. Lower rod
2. Rear mount nut
1. Lower rod
2. Front mount bolt
1. Lower rod
2. Front bolt
3. Rear bolt
4. Vehicle body
5. Axle housing
6. Body center
7. Body out side
[A]: Body side
[B]: Axle side
LOWER ROD
REMOVAL
1) Hoist vehicle and remove rear wheel.
2) Support rear axle housing by using floor jack.
3) Remove lower rod front mount bolt.
4) Remove lower rod rear mount bolt.
INSTALLATION
1) Install lower rod to chassis frame and axle housing, referring to
figure for proper installing direction of bolts.
Nuts should not be tightened.
2) Remove floor jack from rear axle housing.
3) Install wheel and tighten wheel nuts to specified torque.
Tightening Torque for wheel nuts
100 N.m (10.0 kg-m, 72.5 lb-ft)
4) Lower hoist and with vehicle in non loaded condition, tighten
front bolt and rear nut of lower rod to specified torque.
Tightening Torque
(a): 90 N.m (9.0 kg-m, 65.0 lb-ft)
(b): 100 N.m (10.0 kg-m, 72.5 lb-ft)

3E-4 REAR SUSPENSION
1. Body center
1
1. Rear axle housing
2. Spring seat
3. Coil spring
4. Stepped part
(a)
(a)
1. Bolt
2. Washer
3. Lateral rod
1. Lower rod
2. Body center
1
2
LATERAL ROD
REMOVAL
1) Hoist vehicle.
2) Remove lateral rod mounting bolts.
3) Remove lateral rod.
INSTALLATION
1) Install lateral rod to rear axle, and vehicle body.
2) Lower hoist.
3) Tighten lateral rod mounting bolts to specified torque.
Tightening Torque
(a): 100 N.m (10.0 kg-m, 72.5 lb-ft)
REAR AXLE HOUSING
INSTALLATION
Install removed parts in reverse order of removal, noting the follow-
ing.
1) Place rear axle housing on floor jack. Then install upper/lower
rod rear mounting bolts (right & left) in proper direction as shown
(refer to UPPER ROD INSTALLATION for upper rod bolts). At
this time, mount nuts but don’t tighten them.
2) Install coil spring (right & left) on spring seat of axle housing and
raise axle housing.
NOTE:
When seating coil spring, mate spring end with stepped
part of rear axle spring seat as shown.
3) Install lateral rod to rear axle housing.
4) Install lower part of shock absorber to right and left sides of axle
housing and install bolts in proper direction as shown in figure.
At this time, mount nuts but don’t tighten them.

(c)
“A”1. Axle housing
REAR SUSPENSION 3E-5
5) Clean mating surfaces of axle housing and differential carrier
and apply sealant to housing side.
“A”: Sealant 99000-31110
6) Install differential carrier assembly to axle housing and tighten
carrier nuts to specified torque.
Tightening Torque
(a): 55 N.m (5.5 kg-m, 40.0 lb-ft)
7) For vehicle with ABS, connect wheel speed sensor coupler and
install harness.
8) Install propeller shaft and torque nuts to specification.
Tightening Torque
(b): 50 N.m (5.0 kg-m, 36.5 lb-ft)
9) Remove floor jack from axle housing and connect breather
hose onto axle housing and clamp it securely.
10) Connect brake pipes onto axle housing and clamp them se-
curely.
For clamping positions, refer to SECTION 5A of this manual.
11) Connect brake flexible hose to bracket on axle housing and se-
cure it with E-ring.
12) Install LSPV stay to axle housing, tighten LSPV stay bolt to
specified torque.
And adjust LSPV referring to “LSPV ASSEMBLY INSPEC-
TION AND ADJUSTMENT”in SECTION 5A.
Tightening Torque
(c): 23 N.m (2.3 kg-m, 17.0 lb-ft)
13) Connect brake pipe to brake flexible hose and tighten brake
pipe flare nut to specified torque.
Tightening Torque
(d): 16 N.m (1.6 kg-m, 11.5 lb-ft)

(f)
(e)
1. Bearing retainer
“A”
1. Axle housing
1. Axle housing
3E-6 REAR SUSPENSION
14) Clean mating surface of axle housing (right & left) and brake
back plate, then apply sealant as shown.
“A”: Sealant 99000-31110
15) Apply grease to axle shaft inner oil seal lip as shown.
“A”: Grease 99000-25010
16) Apply sealant to mating surface of bearing retainer with brake
back plate.
NOTE:
Make sure to remove old sealant before applying it anew.
“B”: Sealant 99000-31110
17) Install rear axle shaft to rear axle housing and tighten bearing
retainer nuts to specified torque.
NOTE:
When installing rear axle shaft, be careful not to cause
damage to oil seal lip in axle housing.
Tightening Torque
(e): 23 N.m (2.3 kg-m, 17.0 lb-ft)
18) For vehicle with ABS, tighten wheel speed sensor bolt to speci-
fied torque.
Tightening Torque
(f): 21 N.m (2.1 kg-m, 15.5 lb-ft)

3. Container1. Plug cap
2. Vinyl tube
(g)
REAR SUSPENSION 3E-7
19) Connect brake pipes to wheel cylinders (right & left) and tighten
brake pipe flare nuts to specified torque.
Tightening Torque
(g): 16 N.m (1.6 kg-m, 11.5 lb-ft)
20) Install brake drum (right & left). For details, refer to SECTION
5C “BRAKE DRUM INSTALLATION”.
21) Refill differential gear housing with new specified gear oil. Re-
fer to “ON-VEHICLE SERVICE”in SECTION 7F for refill.
22) Fill reservoir with brake fluid and bleed brake system.(For
bleeding operation, see SECTION 5.)
23) Install wheel and tighten wheel nuts to specified torque.
Tightening Torque
(h): 100 N.m (10.0 kg-m, 72.5 lb-ft)
24) Upon completion of all jobs, depress brake pedal with about 30
kg (66 lbs) load three to ten times so as to obtain proper drum-
to-shoe clearance.
Adjust parking brake cable (for adjustment, see SECTION 5C
of this manual.)
25) Tighten parking brake lever cover screws.
26) Lower hoist.

3E-8 REAR SUSPENSION
27) Tighten right and left lower/upper rod nuts lateral rod mount
bolt and shock absorber nuts to specified torque.
NOTE:
When tightening these nuts, be sure that vehicle is off
hoist and in non loaded condition.
Tightening Torque
(i): 100 N.m (10.0 kg-m, 72.0 lb-ft)
(m): 85 N.m (8.5 kg-m, 61.5 lb-ft)
(k): 90 N.m (9.50 kg-m, 65.0 lb-ft)
28) Check to ensure that brake drum is free from dragging and
proper braking is obtained.
29) Perform brake test (foot brake and parking brake).
30) Check each installed part for oil leakage.
TIGHTENING TORQUE SPECIFICATIONS
Fastening
p
arts
Tightening torque
Fastening
arts
N.m Kg-m lb-ft
Shock absorber lock nut 29 2.9 21.0
Shock absorber nut 29 2.9 21.0
Shock absorber lower nut 100 10.0 72.5
Lower rod bolt 100 10.0 72.5
Lower rod nut
90
90
65 0
Upper rod bolt and nut
90
9
.
0
65
.
0
Lateral rod bolt 100 10.0 72.5
Differential carrier nut 55 5.5 40.0
Propeller shaft nut 50 5.0 36.5
Brake pipe flare nut 16 1.6 11.5
Bearing retainer nut 23 2.3 17.0
Differentiation
g
ear oil Filler plug 50 5.0 36.5
g
filler & drain plug Drain plug 27 2.7 16.0
Wheel nut 100 10.0 72.5

6
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16 / J20 ENGINES) 6-1
SECTION 6
ENGINE GENERAL INFORMATION AND
DIAGNOSIS
(G16/J20 ENGINES)
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
DService on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al 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 Precau-
tions” under “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.
DTechnical 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).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual men-
tioned in FOREWORD of this manual.
CONTENTS
ENGINE DIAGNOSIS 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Diagnostic Flow Table 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of PCM (ECM) and its circuits 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Check 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistance Check 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-1 fuel pump circuit inspection 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. PCM (ECM)
2. PCM (ECM) connector
(Viewed from harness side)
6-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16 / J20 ENGINES)
ENGINE DIAGNOSIS
Engine Diagnostic Flow Table
INSPECTION OF PCM (ECM) AND ITS CIRCUITS
PCM (ECM) and its circuits can be checked at PCM (ECM) wiring
couplers by measuring voltage and resistance.
CAUTION:
PCM/ECM cannot be checked by itself. It is strictly prohib-
ited to connect voltmeter or ohmmeter to PCM (ECM) with
couplers disconnected from it.
Voltage Check
1) Remove PCM (ECM) cover from bracket referring to PCM
(ECM) REMOVAL.
2) Check voltage at each terminal of couplers connected.
NOTE:
As each terminal voltage is affected by the battery voltage,
confirm that it is 11 V or more when ignition switch is ON.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16 / J20 ENGINES) 6-3
E61
TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION
1Power source for CO adjusting
resistor (if equipped) 4.75 – 5.25 V Ignition switch ON
2Power source for back up 10 – 14 V Ignition switch ON and OFF
3
Heater of HO2S 2 (if equi
pp
ed)
10 – 14 V Ignition switch ON
3
Heater
of
HO2S
-
2
(if
eq
u
ipped)
0 – 2 V At specified condition
4 ——— —— ———
Immobilizer indicator lamp (without 0 – 1 V Ignition switch ON, engine stops
5
(
monitor connector) 10 – 14 V Engine running
5
Duty output terminal (with monitor
connector) 0 – 1 V Ignition switch ON
6 Tachometer 0 – 1 V Ignition switch ON
7
Malfunction indicator lam
p0 – 2.5 V Ignition switch ON, engine stops
7
Malf
u
nction
indicator
lamp
10 – 14 V Engine running
8
A/C cut signal (if equi
pp
ed)
0 – 1.5 V A/C is not operating
8
A/C
c
u
t
signal
(if
eq
u
ipped)
10 – 14 V A/C is operating
10 – 14 V Ignition switch OFF
9Main relay 0 – 2 V Ignition switch ON or for 4 seconds after
ignition switch OFF
10 CO adjusting resistor (if equipped) —— ———
11 ——— —— ———
12 Data link connector (5 V)
(if equipped) 4 – 6 V Ignition switch ON
13 Data link connector (12 V) 10 – 14 V Ignition switch ON
14 Test switch terminal (if equipped) 10 – 14 V Ignition switch ON
15
Rear defogger switch 0 – 1.5 V Ignition switch ON, rear defogger switch OFF and
lighting switch OFF
15
gg
(if equipped) 10 – 14 V Ignition switch ON, rear defogger switch or lighting
switch ON
16
Heater blower switch
10 – 14 V Ignition switch ON, heater blower switch OFF
16
Heater
blo
w
er
s
w
itch
0 – 1.5 V Ignition switch ON, heater blower switch ON
17
A/C signal (if equi
pp
ed)
10 – 14 V Ignition switch ON, A/ C switch or heater
blower switch OFF
17
A/C
signal
(if
eq
u
ipped)
0 – 1 V Ignition switch ON, A/ C switch ON and heater
blower switch ON
18 ——— —— ———
19
“
4WD
”
lam
p
(if equi
pp
ed)
0 – 1 V Ignition switch ON, Transfer lever: H4 or 4L range
19
“4WD”
lamp
(if
eq
u
ipped)
10 – 14 V Ignition switch ON, Transfer lever: 2H range
20
“
O/D OFF
”
lam
p
(if equi
pp
ed)
0 – 1 V For 4 sec. after ignition switch ON or overdrive cut
switch ON
20
“O/D
OFF”
lamp
(if
eq
u
ipped)
10 – 14 V After 4 sec. from ignition switch ON and overdrive cut
switch OFF
21
“
POWER
”
lam
p
(if equi
pp
ed)
0 – 1 V Ignition switch ON, P/ N change switch: POWER
mode
21
“POWER”
lamp
(if
eq
u
ipped)
10 – 14 V Ignition switch ON, P/ N change switch: NORMAL
mode
22 A/C condenser fan motor relay
(if equipped) 10 – 14 V Ignition switch ON, Engine coolant temp.: less than 113_C, 235_F
23
Fuel pump relay 0 – 2.5 V For 3 sec. after ignition switch ON or while engine
running
23
y
(Type B only: See NOTE.) 10 – 14 V After 3 sec. from ignition switch ON with engine
stopped
24 Ground for HO2S-2 or CO
adjusting resistor —— ———

6-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (G16 / J20 ENGINES)
C51-3 E61
TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION
25 ——— —— ———
26 Heated oxygen sensor-2
(if equipped) 0.01 –0.95 V While engine running at 2000 r/ min. for 3 min. or longer after warming up.
27 ——— —— ———
28 Fuel level sensor 0 –6 V Ignition switch ON
Voltage depends on fuel level
29 Diagnosis switch terminal
(if equipped) 10 –14 V Ignition switch ON
30 ABS control module (if equipped) 10 –14 V Ignition switch ON
31
Power/Normal change switch 0 –1 V Ignition switch ON, P /N change switch: POWER
mode
31
g
(if equipped) 10 –14 V Ignition switch ON, P/N change switch: NORMAL
mode
32
Lighting switch (if equi
pp
ed)
0 –1 V Ignition switch ON, Lighting switch OFF
32
Lighting
s
w
itch
(if
eq
u
ipped)
10 –14 V Ignition switch ON, Lighting switch ON
33
Overdrive cut switch
10 –14 V Ignition switch ON, Overdrive cut switch OFF
33
O
v
erdri
v
e
c
u
t
s
w
itch
0 –1 V Ignition switch ON, Overdrive cut switch ON
34
Sto
p
lam
p
switch
0 –1 V Brake pedal released (switch OFF),
Ignition switch ON
34
Stop
lamp
s
w
itch
10 –14 V Brake pedal depressed (switch ON),
Ignition switch ON
35 ——— ——— ———
1Intake air temp. sensor 2.2 –3.0 V Ignition switch ON, Sensor ambient temp.:
20_C, 68_F
2Engine coolant temp. sensor 0.5 –0.9 V Ignition switch ON, Engine coolant temp.:
80_C, 176_F
Knock sensor (J20) About 2.5 V Ignition switch ON
3Ignition timing adjusting resistor
(G16) (if equipped) —— ———
4Power source 10 –14 V Ignition switch ON
5Ground for MAF sensor —— ———
6 Ground —— ———
10 –14 V Ignition switch ON
7Power steering pressure switch 0 –1 V With engine running at idle speed, turning
steering wheel to the right or left as far as it stops.
8Manifold absolute pressure
sensor 3.3 –4.3 V Ignition switch ON
9
Throttle
p
osition sensor
0.5 –1.2 V Ignition switch ON, Throttle valve at idle position
9
Throttle
position
sensor
3.4 –4.7 V Ignition switch ON, Throttle valve at full open position
10
Mass air flow sensor
1.0 –1.6 V Ignition switch ON and engine stops
10
Mass
air
flo
w
sensor
1.7 –2.0 V With engine running at idle speed
11 Heated oxygen sensor-1 Deflects between
over and under 0.45 V
While engine running at 2,000 r/ min.
for 1 min. or longer after warmed up.