Engine Controls - Basic Testing: Other Suzuki Sidekick I

Compression

Check engine mechanical condition using a compression gauge, vacuum gauge or an engine analyzer. See engine analyzer manual for specific instructions.

COMPRESSION SPECIFICATIONS

Exhaust System Backpressure

The exhaust system can be checked with a vacuum or pressure gauge. If using a pressure gauge, remove O2 sensor or air injection check valve (if equipped). (Scheme 7)and (Scheme 8). Connect a 0-5 psi pressure gauge and run engine at 2500 RPM. If exhaust system backpressure is greater than 1 3/4 - 2 psi, exhaust system or catalytic converter is plugged.

If using a vacuum gauge, connect vacuum gauge hose to intake manifold vacuum port and start engine. Observe vacuum gauge. Open throttle part way and hold steady. If vacuum gauge reading slowly drops after stabilizing, exhaust system should be checked for a restriction.

Scheme 7

Scheme 8

FUEL SYSTEM

Samurai

1. Place transmission in Neutral or Park, and set parking brake. Loosen fuel tank filler cap to relieve tank vapor pressure. Remove harness connector from fuel pump relay which is located under extreme right side of dash, mounted at top front of ECM.
2. Start engine, and let it idle until it dies. Crank engine 2-3 times to ensure fuel pressure is dissipated from system. Turn ignition off, and remove key. Fuel system may now be opened safely. When loosening fuel line, hose or fitting, cover with shop towel to absorb leaking fuel. When repair is completed, reconnect relay.

Sidekick

1. Place transmission in Neutral or Park, and set parking brake. Disconnect 4-wire connector from fuel pump relay, located under left side of dash, left of ECM. (Scheme 9)
2. Loosen fuel tank filler cap to release tank vapor pressure. Start engine, and let it idle until it dies. Crank engine 2-3 more times to ensure fuel pressure is dissipated from system. Turn ignition off, and remove key. Fuel system may now be opened safely. When loosening fuel line, hose or fitting, cover using shop towel to absorb leaking fuel. When repair is completed, reconnect relay.

Scheme 9

Swift

1. Place transmission in Neutral or Park, and set parking brake. Remove fuse/relay box cover located in engine compartment, behind battery. Remove coolant reservoir from bracket.
2. Disengage harness connector from fuel pump relay from underneath fuse/relay box. see scheme 6and see scheme 7. Loosen fuel tank filler cap to release tank vapor pressure. Start engine, and let it idle until it dies. Crank engine 2-3 more times to ensure fuel pressure is dissipated from system. Fuel system may now be opened safely. Cover fuel line, hose or fitting using shop towel to absorb leaking fuel when loosening. When repair is completed, reconnect relay.

Fuel Pump Circuit

Turn ignition on. Leave engine off. Fuel pump should operate for 2 seconds. If fuel pump does not operate, check fuses, fuel pump relay, fuel pump, all electrical connections and ECM. See I - SYS/COMP TESTS article.

IGNITION CHECKS

Note. To diagnose a no-spark condition, perform all procedures listed under IGNITION CHECKS.

Sidekick & Swift DOHC

1. To ensure power supply to power unit, disconnect primary wires connector at ignition coil. Turn ignition on. Using voltmeter, check for battery voltage between coil positive terminal (Black/White wire) and ground. (Scheme 10) If battery voltage does not exist, check ignition fuse circuit.
2. To check power unit resistance, turn ignition off. Remove power unit from under ignition coil. Tape together two 1.5-volt batteries in series to create a 3-volt power source. Install leads to 3-volt power source. Apply negative lead to "G" terminal and positive lead to terminal IB of power unit. (Scheme 11)
3. Using ohmmeter, connect positive lead to terminal "G" and negative lead to terminal OC of power unit. (Scheme 11) Check for continuity with 3-volt power source applied to terminal IB. Check for no continuity with 3-volt power source disconnected from terminal IB. Replace power unit if test results are not within specification.

Scheme 10

Scheme 11

Disconnect secondary cable/wire from coil. Remove primary wire connector from ignition coil. Using ohmmeter, check coil primary and secondary resistances. See the IGNITION COIL RESISTANCE table. (Scheme 12) Replace coil if resistance is not within specification.

Scheme 12

IGNITION COIL RESISTANCE- Ohms @ 68°F (20°C)

Remove secondary coil wire and primary wire connector from coil. Using ohmmeter, check coil primary and secondary resistances. (Scheme 13) Replace coil if resistance is not within specification. See IGNITION COIL RESISTANCE table.

Swift SOHC

Disconnect secondary cable/wire from coil. Remove primary leads from ignition coil. Using ohmmeter, check resistance between primary terminals of coil. See IGNITION COIL RESISTANCE table. Check secondary resistance between coil secondary terminal and primary positive terminal. Replace coil if resistance is not within specification.

Scheme 13

PICK-UP COIL

Note. An integral crank angle sensor is incorporated in pick-up coil.

Samurai & Sidekick

1. With ignition off, disconnect ECM connector. ECM is under lower left side of dash. Connect voltmeter between ground and terminal A13 (Samurai) or terminal B3 (Sidekick). (Scheme 14)or (Scheme 15).
2. Remove distributor cap, rotor and shield cover. Turn ignition on. Check voltmeter reading when signal rotor is between magnet and Hall Effect pick-up coil. Voltmeter reading should be 3-5 volts.
3. Turn signal rotor so that it is not between magnet and Hall Effect pick-up coil, thus breaking magnetic field. Voltage should be 0-1 volt. If results are not as indicated, inspect wiring and connections and repair as required. If wiring is okay, replace Hall Effect pick-up coil (crank angle sensor).

Scheme 14

Scheme 15

1. Disconnect pick-up coil connector at distributor. Using ohmmeter, measure resistance between 2 upper terminals (connector on SOHC model has only 2 terminals). See «PICK-UP COIL RESISTANCE»(ref-25802-S12743838542001010500000) table. (Scheme 16) Replace pick-up coil if resistance is not within specification. If resistance is within specification, go to next step.
2. If ignition coil and pick-up coil test okay, use feeler gauge to check air gap. See «PICK-UP COIL AIR GAP»(ref-25802-S09751342012001010500000) table. If gap is not correct, loosen signal generator mount screws and move generator to adjust air gap. Recheck for spark. If spark is still not available, go to TESTS W/CODES article to retrieve stored codes.

Scheme 16

PICK-UP COIL RESISTANCE - Ohms @ 68°F (20°C)

PICK-UP COIL AIR GAP

IDLE SPEED & IGNITION TIMING

Ensure idle speed and base ignition timing are set to specification. Refer to the IDLE SPEED SPECIFICATIONS table and the IGNITION TIMING table. If necessary, see ADJUSTMENTS article.

IDLE SPEED SPECIFICATIONS (1)

IGNITION TIMING (Degrees BTDC @ RPM)

SUMMARY

If no faults were found while performing BASIC DIAGNOSTIC PROCEDURES, proceed to TESTS W/CODES article. If no hard codes are found in self-diagnostics, proceed to TESTS W/O CODES article for diagnosis by symptom (i.e., ROUGH IDLE, NO START, etc.) or intermittent diagnostic procedures.