Engine Controls - System/component Tests: Other Suzuki Sidekick I

ELECTRONIC CONTROL MODULE (ECM)

Note. For identification of ECM connectors and terminals, see WIRING DIAGRAMS or PIN VOLTAGE CHART S article.

ECM LOCATION

ECM Power Circuits

Turn ignition on. Check for battery voltage between ground and indicated ECM connector terminal. See ECM POWER & GROUND CIRCUITS table. If battery voltage is not indicated, check EFI main relay or control relay (Samurai and Sidekick) operation. See RELAYS & SOLENOIDS .

ECM Ground Circuits

Disconnect ECM connector. Check continuity between ground and indicated ECM connector terminal. See ECM POWER & GROUND CIRCUITS table. If continuity does not exist, repair appropriate wire between ECM connector and ground.

ECM POWER & GROUND CIRCUITS

ECM Circuit Resistance

Make circuit resistance tests with ECM connector disconnected. See CIRCUIT RESISTANCE CHARTS .

CRANK ANGLE SENSOR

For testing, see CODE 42 in appropriate TESTS W/CODES article.

EGR TEMPERATURE (EGRT) SENSOR (SAMURAI, SIDEKICK & SWIFT DOHC CALIF.)

See EXHAUST GAS RECIRCULATION (EGR) under EMISSION SYSTEMS & SUB-SYSTEMS.

ENGINE COOLANT TEMPERATURE (ECT) SENSOR

Remove sensor from intake manifold and place in water with a thermometer. Heat water to specified temperature and check resistance. See ENGINE COOLANT TEMPERATURE (ECT) SENSOR RESISTANCE table. Replace sensor if resistance is not within specification.

ENGINE COOLANT TEMPERATURE (ECT) SENSOR RESISTANCE

INTAKE AIR TEMPERATURE (IAT) SENSOR (SAMURAI, SIDEKICK TBI & SWIFT SOHC)

1. Disconnect IAT sensor connector. Turn ignition on. Check voltage between Red/Black wire (Samurai and Sidekick TBI) or Gray wire (Swift SOHC) terminals and ground. If voltage is not 4-5 volts, check wiring harness for open or short. If voltage is present, go to next step.
2. Remove IAT sensor and place it in water with a thermometer. Heat water to specified temperature and check resistance. See «INTAKE AIR TEMPERATURE (IAT) SENSOR RESISTANCE»(ref-25813-S20277577772001010500000) table. Replace IAT sensor if resistance is not within specification.

INTAKE AIR TEMPERATURE (IAT) SENSOR RESISTANCE

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR (SAMURAI, SIDEKICK TBI & SWIFT SOHC)

1. Sensor is mounted to right center of firewall. To test pressure sensor on vehicle, turn ignition on. Connect voltmeter between ground and indicated ECM connector terminal (backprobe ECM terminal). See «MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR OUTPUT VOLTAGE (ON-VEHICLE)»(ref-25813-S39699226312001010500000) table.
2. If voltage is not within specification, see CODE 31 or CODE 32 in appropriate TESTS W/CODES article. To bench test pressure sensor, see «MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR OUTPUT VOLTAGE (OFF-VEHICLE)»(ref-25813-S14683056282001010500000) table. If voltage is not within specification, replace MAP sensor.

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR OUTPUT VOLTAGE (ON-VEHICLE)

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR OUTPUT VOLTAGE (OFF-VEHICLE)

MASS AIRFLOW (MAF) SENSOR (SIDEKICK MPI & SWIFT DOHC)

1. Turn ignition switch to ON position. Without disconnecting MAF sensor connector, move connector seal for access to terminals. Turn ignition on. Using a DVOM with a minimum 10-megohm input impedance, backprobe between White and Red wire terminals of connector.
2. If battery voltage is present, go to next step. If battery voltage is not present, check continuity of White and Red wire circuits between ECM and MAF sensor connector.
3. Measure voltage between Black and Red wire terminals of MAF sensor connector. If voltage is not 0.2-0.8 volt, check continuity of Black and Red wire circuits between ECM and MAF sensor connector.
4. Start engine. MAF sensor voltage signal should increase as engine RPM increases. If MAF sensor does not test as described, check MAF sensor connections. If connections are okay, replace MAF sensor.

OXYGEN (O2) SENSOR

1. Start and warm engine to operating temperature. Pull back seal at oxygen sensor connector. Using a DVOM with at least a 10-megohm input impedance, backprobe oxygen sensor connector.
2. Increase engine speed to 2000 RPM and hold for about one minute while watching voltmeter. Reading should fluctuate between zero and one volt, without being constantly high or low. If voltage is not as specified, see CODE 13 in appropriate TESTS W/CODES article.

PARK/NEUTRAL POSITION (PNP) SWITCH (SIDEKICK A/T)

Disconnect negative battery cable. Disconnect connector at PNP switch on right side of transmission. Connect ohmmeter between appropriate terminals of switch connector. See PARK/NEUTRAL POSITION (PNP) SWITCH CONTINUITY (SIDEKICK) table. Replace PNP switch if it does not test as described.

PARK/NEUTRAL POSITION (PNP) SWITCH CONTINUITY (SIDEKICK)

PARK/NEUTRAL POSITION (PNP) SWITCH (SWIFT A/T)

1. Engine ECM receives park/neutral gear selection information from automatic transmission ECM. Disconnect connector at PNP switch on right side of transmission.
2. With ignition on and transmission in Drive, check voltage on appropriate shift lever switch terminals. See «PARK/NEUTRAL POSITION (PNP) SWITCH VOLTAGE (SWIFT)»(ref-25813-S40525333952001010500000) table.

PARK/NEUTRAL POSITION (PNP) SWITCH VOLTAGE (SWIFT)

POWER STEERING PRESSURE (PSP) SWITCH (SIDEKICK & SWIFT SOHC)

1. Disconnect wire connector from PSP switch on power steering pump. Start engine. Connect ohmmeter between ground and switch terminal. With steering wheel in straight-ahead position, there should be no continuity.
2. Turn steering wheel. As steering pressure increases, continuity should exist. If there is no continuity when steering wheel is turned or if there is continuity with steering wheel in straight-ahead position, replace PSP switch.

POWER STEERING VACUUM SWITCHING VALVE (VSV)

1. Turn ignition off. Disconnect power steering VSV connector. Check resistance of VSV at connector terminals. Resistance should be 33-39 ohms. Replace VSV if resistance is not correct. If resistance is okay, remove vacuum hoses from VSV.
2. Blow air into one VSV vacuum fitting. Air should not pass through VSV. If air passes through VSV, replace VSV. Apply battery voltage and ground to VSV connector terminals. Air should pass through VSV. If air does not pass through VSV, replace VSV.

THROTTLE POSITION (TP) SENSOR

1. Disconnect negative battery cable and TP sensor connector. (Scheme 102), (Scheme 103) or (Scheme 104). Using ohmmeter, check resistance between indicated terminals. See «THROTTLE POSITION (TP) SENSOR RESISTANCE»(ref-25813-S20813088672001010500000) table. If resistance is not as specified, adjust TP sensor.
2. See ADJUSTMENTS article. If resistance is not as specified after adjustment, replace TP sensor. For further diagnostic procedures, see appropriate TESTS W/CODES article.

THROTTLE POSITION (TP) SENSOR RESISTANCE

Scheme 102

Scheme 103

Scheme 104

VEHICLE SPEED SENSOR (VSS)

1. Disconnect negative battery cable. Remove instrument cluster. Connect ohmmeter between RSW and GND terminals on back of instrument cluster. Insert screwdriver into speedometer cable connector. Rotate screwdriver. (Scheme 105), (Scheme 106) or (Scheme 107).
2. Ohmmeter reading should alternate between zero and infinity 4 times for each revolution of speedometer cable. Replace speedometer if VSS does not test as described.

Scheme 105

Scheme 106

Scheme 107

5TH GEAR SWITCH (SAMURAI M/T)

Disconnect 2-wire connector near ignition coil. Connect ohmmeter between Light Blue and Black/Green wire terminals of connector. With shift lever in 5th gear position, continuity should exist. With shift lever in any other position, continuity should not exist.

EFI Main Relay (Samurai)

1. Relay is mounted on top of ECM, located under glove compartment. Turn ignition off. Check for battery voltage on White wire terminal of relay. If battery voltage is present, go to next step. If battery voltage is not present, check White wire circuit between relay and battery, including fuse No. 7.
2. Turn ignition on. Check for battery voltage on Black/White wire terminal of relay. If battery voltage is present, go to next step. If battery voltage is not present, check Black/White wire circuit between relay and battery, including fuse No. 8.
3. Turn ignition off. Disconnect negative battery cable. Remove relay from main fuse box. Check for continuity between terminals "A" and "B". (Scheme 109) Continuity should not be present. If continuity exists, replace relay.
4. Measure resistance between terminals "C" and "D". Resistance should be 56-84 ohms. If resistance is not correct, replace relay. Apply battery voltage and ground to terminals "C" and "D". Continuity should now be present across terminals "A" and "B". If continuity is not present, replace relay.

EFI Main Relay (Sidekick)

1. Relay is mounted under left side of instrument panel. Turn ignition off. Check for battery voltage on Black/Red wire terminal of relay. If battery voltage is present, go to next step. If battery voltage is not present, check Black/Red wire circuit between relay and battery, including fuse No. 14.
2. Turn ignition on. Check for battery voltage on Black/White wire terminal of relay. If battery voltage is present, go to next step. If battery voltage is not present, check Black/White wire circuit between relay and battery, including fuse No. 8.
3. Turn ignition off. Disconnect negative battery cable. Remove relay from main fuse box. Check for continuity between terminals "A" and "B". (Scheme 109) Continuity should not be present. If continuity exists, replace relay.
4. Measure resistance between terminals "C" and "D". Resistance should be 63-77 ohms. If resistance is not correct, replace relay. Apply battery voltage and ground to terminals "C" and "D". Continuity should now be present across terminals "A" and "B". If continuity is not present, replace relay.

EFI Main Relay (Swift)

1. Remove relay from main fuse box in engine compartment, located between battery and left fenderwell. (Scheme 108) Turn ignition on. Check for battery voltage on White/Red wire terminal and Black/White wire terminal of relay connector. Battery voltage should be present.
2. If battery voltage is not present, check White/Red wire and Black/White wire circuits between fuse and relay. Repair as necessary. Turn ignition off. Disconnect negative battery cable. Remove relay from main fuse box. Check for continuity between terminals "A" and "B". (Scheme 109)
3. Continuity should not be present. If continuity exists, replace relay. Measure resistance between terminals "C" and "D". Resistance should be 56-84 ohms. If resistance is not correct, replace relay. Apply battery voltage and ground to terminals "C" and "D". Continuity should now be present across terminals "A" and "B". If continuity is not present, replace relay.

Fuel Pump Relay

1. Fuel pump relay is constructed the same as EFI main relay and should be checked in same manner. See appropriate EFI MAIN RELAY heading above. Turn ignition off. Disconnect negative battery cable. Disconnect relay connector and remove relay. Using an ohmmeter, check continuity between terminals "A" and "B". (Scheme 109) If continuity is not present, go to next step. If continuity is present, replace relay.
2. Check resistance between terminals "C" and "D". If resistance is 56-84 ohms, go to next step. If resistance is not 56-84 ohms, replace relay.
3. Energize relay by applying battery voltage and ground to terminals "C" and "D". Check continuity between terminals "A" and "B". If continuity is present, relay is okay. If continuity is not present, replace relay.

FUEL PUMP RELAY LOCATION

Scheme 108

Scheme 109

EGR Vacuum Switching Valve (VSV)

See EXHAUST GAS RECIRCULATION (EGR) under EMISSION SYSTEMS & SUB-SYSTEMS.

Canister Purge Vacuum Switching Valve (VSV)

See FUEL EVAPORATION under EMISSION SYSTEMS & SUB-SYSTEMS.

Fuel Injector(s)

See FUEL CONTROL under FUEL SYSTEM.

Idle Air Control (IAC) Solenoid

See IDLE AIR CONTROL (IAC) SOLENOID under IDLE CONTROL SYSTEM.

Throttle Opener Vacuum Switching Valve (Samurai & Sidekick TBI)

See THROTTLE OPENER SYSTEM (SAMURAI & SIDEKICK TBI) under IDLE CONTROL SYSTEM.

See RELAYS under RELAYS & SOLENOIDS.

Fuel Pressure Regulator (Except Swift SOHC)

1. Regulator is mounted to throttle body, above TPS (Samurai and Sidekick) or at end of fuel rail closest to distributor (Swift DOHC).
2. Start and idle engine. Disconnect vacuum hose from regulator. If vacuum is present, go to next step. If no vacuum is present, check for blocked hose between regulator and intake manifold.
3. Check fuel pressure with engine running and vacuum hose connected to regulator. Disconnect vacuum hose from fuel pressure regulator. If fuel pressure does not increase, replace fuel pressure regulator.

Note. For fuel system pressure testing and specifications, see the BASIC TESTING article.

Fuel Pressure Regulator (Swift SOHC)

Regulator is mounted on top of throttle body. If fuel pressure is not within specification, check fuel pump unregulated pressure. If unregulated pressure is within specification, check for clogged vacuum passage between intake manifold and fuel pressure regulator. If passage is clear, replace regulator.

1. If engine does not run, go to step 3). If engine runs, listen for operational noise from fuel injector(s). Cycling of injectors should increase and decrease with engine speed.
2. On TBI models, if fuel is not injected in a conical-shaped pattern while engine is cranking or running, replace injector. Turn ignition off. If fuel leaks from injector at a rate of more than one drop per minute with ignition off, replace injector.
3. On all models, turn ignition off. Disconnect injector connector. Measure resistance across injector terminals. At 68°F (20°C), resistance should be as specified in «FUEL INJECTOR RESISTANCE»(ref-25813-S29542233122001010500000) table.

FUEL INJECTOR RESISTANCE

Fuel Injector Resistor (Swift SOHC)

Disconnect 2-wire connector from resistor, mounted on left end of firewall. Check resistance between terminals. If resistance is not 1.9-2.1 ohms, replace resistor.

Note. For fuel system pressure testing and specifications, see BASIC TESTING article.

FAST IDLE AIR (FIA) VALVE

Samurai & Sidekick TBI

1. For exploded view of throttle body showing fast idle air valve, see appropriate THROTTLE BODY under FUEL SYSTEM in N - REMOVE/INSTALL/OHAUL article. To check fast idle air valve, turn engine off. Remove valve cap.
2. When coolant temperature is less than 140°F (60°C), valve should be open. When coolant temperature is greater than 158°F (70°C), valve should be closed. Install NEW valve cap gasket when installing valve cap.

Sidekick MPI

Fast idle air valve is bolted to throttle body. To check valve, turn engine off. Remove valve from throttle body. Immerse valve in water. When water temperature is less than 140°F (60°C), valve should be open. When water temperature is greater than 158°F (70°C), valve should be closed. Install NEW valve gasket when installing valve.

Swift DOHC

Fast idle air valve is bolted to intake manifold. To check valve on vehicle, turn engine off. Remove valve cap at end of valve. With coolant temperature less than 176°F (80°C), valve should be open. With temperature greater than 176°F (80°C), valve should be closed. Install NEW valve cap gasket when installing valve cap.

Swift SOHC

Remove throttle body. See appropriate THROTTLE BODY under FUEL SYSTEM in N - REMOVE/INSTALL/OHAUL article. Immerse fast idle air valve portion of throttle body in water. Ensure valve closes gradually as water temperature rises. Valve should be fully closed at approximately 176°F (80°C).

Samurai

1. Before idle speed/IAC duty is checked or adjusted, check the following: all wires and vacuum hoses are connected securely, accelerator cable has some play, valve clearance and timing are set to specification, and all accessories are turned off.
2. Warm engine to normal operating temperature. Connect spare fuse to diagnostic switch terminal. Enter self-diagnostics and check if Code 12 is present. See appropriate TESTS W/CODES article. If Code 12 is present, proceed to step 3). If Code 12 is not present, see appropriate INITIAL DIAGNOSTIC PROCEDURE chart in appropriate TESTS W/CODES article.
3. Ensure idle speed and IAC duty are within specification. See ADJUSTMENTS article. If idle speed and IAC duty are correct, system is operating correctly. If idle speed is correct, but IAC duty is not correct, go to step 4). If idle speed is high, go to step 5). If idle speed is low, go to step 8).
4. If idle speed is correct, but IAC duty is incorrect, adjust IAC duty. See ADJUSTMENTS article. NOTE: When IAC is almost closed, check air intake system for vacuum leaks. If no vacuum leaks are present, adjust IAC duty. If IAC duty remains unchanged when adjusting screw is rotated, check wiring circuit of duty check terminal. For information on duty check terminal, see appropriate SELF- DIAGNOSTICS article.
5. If idle speed is high, pinch upper hose on IAC solenoid closed. (Scheme 110) The IAC solenoid is located on right side of engine, near valve cover. Note if engine speed decreases. If engine speed did not decrease, go to step 7). If engine speed decreased, go to next step.
6. Turn ignition off. Disconnect electrical connector from IAC solenoid. Using ohmmeter, check resistance between IAC solenoid terminals. Resistance should be 30-33 ohms. Replace IAC solenoid if defective. If resistance is okay, check for short in Light Green/Black wire. (Scheme 110) If wiring is okay, substitute a known good ECM and recheck.
7. Ensure no vacuum leaks are present in air intake system or A/C Vacuum Switching Valve (VSV). Adjust idle speed and IAC duty. See ADJUSTMENTS article. If idle speed cannot be adjusted, check air valve. See «FAST IDLE AIR (FIA) VALVE»(ref-25813-S40606102822001010500000) under IDLE CONTROL SYSTEM.
8. If idle speed is low, disconnect IAC solenoid hose from air cleaner. Note if air is being drawn into hose. If no air is being drawn in, go to next step. If air is being drawn in, adjust idle speed and IAC duty. See ADJUSTMENTS article.
9. Turn ignition off. Disconnect electrical connector from IAC solenoid. Using ohmmeter, check resistance between IAC solenoid terminals. Resistance should be 30-33 ohms. Replace IAC solenoid if defective. If resistance is okay, go to next step.
10. Check for open in Light Green/Black wire, defective wiring connections or clogged hoses to IAC solenoid. (Scheme 110) If all are okay, substitute a known good ECM and recheck operation.

Scheme 110

1. Before idle speed/IAC duty is checked or adjusted, check the following: all wires and vacuum hoses are connected securely, accelerator cable has some play, valve clearance and timing are set to specification, and all accessories are turned off.
2. Warm engine to normal operating temperature. Connect a jumper wire between terminals "C" (ground) and "B" (diagnostic terminal) of test connector. Test terminal is located next to battery. (Scheme 110) Observe CHECK ENGINE light. If Code 12 flashes, go to next step. If Code 12 does not flash, see appropriate INITIAL DIAGNOSTIC PROCEDURE chart in appropriate TESTS W/CODES article.
3. Stop engine, and connect duty meter between terminals "A" (output) and "C" (ground). Check IAC duty and idle speed. If IAC duty and idle speed are correct, even with headlights on, system is functioning properly. If idle speed and/or IAC duty are correct, adjust by turning idle speed screw. See IDLE SPEED under IGNITION TIMING in ADJUSTMENTS article. After adjustments, remove jumper wire and replace protective caps (if equipped). Recheck idle speed with A/C on. See ADJUSTMENTS article.
4. If idle speed is too high, check IAC solenoid valve resistance. If reading is not 11-14 ohms at 68 °F (20 °C), replace solenoid valve. If resistance is 11-14 ohms, observe duty meter. Duty values are relative to battery voltage. Off-duty indication percentage at zero voltage would be 100 percent and zero percent at highest battery voltage. Off-duty value should be more than 72 percent. If off-duty value is as specified, substitute ECM with a known good unit and recheck. Adjust duty to specification by turning idle adjusting screw. If not adjustable, check Fast Idle Air (FIA) valve for leakage. Repair or replace as necessary. If FIA valve is okay, check for shorted Light Green/Black wire.
5. If idle speed is too low, check IAC solenoid valve resistance. If reading is not 11-14 ohms at 68 °F (20 °C), replace solenoid valve. If resistance is 11-14 ohms, observe duty meter. Duty values are relative to battery voltage. Off-duty indication percentage at zero voltage would be 100 percent and zero percent at highest battery voltage. Off-duty value should be 0-10 percent. On-duty reading would be 90-100 percent. If reading is as specified, substitute ECM with a known good unit and recheck.
6. If idle is still too low, turn ignition off. Disconnect ECM connectors and check resistance between terminals B12 (Light Green/Black wire) and A12 (Blue/Black wire). If resistance is 11-14 ohms at 68 °F (20 °C), check for poor connector contacts at IAC solenoid and ECM. If contacts are okay, substitute ECM with a known good unit and recheck. If connection and wire are okay, replace IAC solenoid.
7. If reading is okay, disconnect IAC air hose from air intake case. Attempt to blow air into hose. Resistance should be felt. If resistance is felt, connect battery voltage to IAC solenoid valve terminals. If it is still difficult to blow air through valve, replace IAC solenoid valve.

Sidekick TBI

1. Before idle speed/IAC duty is checked or adjusted, check the following: all wires and vacuum hoses are connected securely, accelerator cable has some play, valve clearance and timing are set to specification, and all accessories are turned off.
2. Warm engine to normal operating temperature. Connect a jumper wire between terminals "C" (ground) and "B" (diagnostic terminal) of test connector. Test terminal is located next to battery. (Scheme 110) Observe CHECK ENGINE light. If Code 12 flashes, go to next step. If Code 12 does not flash, see appropriate INITIAL DIAGNOSTIC PROCEDURE chart in appropriate TESTS W/CODES article.
3. Stop engine and connect duty meter between terminals "A" (output) and "C" (ground). Check IAC duty and idle speed. If IAC duty and idle speed are correct, system is functioning properly. If idle speed is too high, go to next step. If idle speed is too low, go to step 6).
4. If idle speed is too high, check IAC solenoid valve resistance. If reading is not 11-14 ohms at 68 °F (20 °C), replace solenoid valve. If resistance is 11-14 ohms, observe duty meter. Duty values are relative to battery voltage. Off-duty indication percentage at zero voltage would be 100 percent and zero percent at highest battery voltage. Off-duty value should be more than 72 percent. If off-duty value is not as specified, check Light Green/Black wire for short to ground. If Light Green/Black wire is okay, substitute ECM with a known good unit and recheck.
5. If off-duty value is as specified, ensure intake system is free of vacuum leaks. Repair or replace as necessary. Adjust duty and idle to specification by turning idle adjusting screw. If not adjustable, check Fast Idle Air (FIA) valve for leakage. Repair or replace as necessary.
6. If idle speed is too low, check IAC solenoid valve resistance. If reading is not 11-14 ohms at 68 °F (20 °C), replace solenoid valve. If resistance is 11-14 ohms, observe duty meter. Duty values are relative to battery voltage. Off-duty indication percentage at zero voltage would be 100 percent and zero percent at highest battery voltage. Off-duty value should be approximately zero percent. On-duty reading would be approximately 100 percent.
7. If reading is as specified, adjust by turning idle speed screw. See IDLE SPEED under IGNITION TIMING in ADJUSTMENTS article. After making adjustments, remove jumper wire and replace protective caps (if equipped). Recheck idle speed with A/C on. See ADJUSTMENTS article. If reading is as specified, check for clogged IAC hose, open in Light Green/Black wire or poor connector connections. Repair or replace as necessary. If all are okay, substitute ECM with a known good unit and recheck.

1. Before idle speed/IAC duty is checked or adjusted, ensure all wires and vacuum hoses are connected securely, accelerator cable has some play, valve clearance and timing are set to specification, and all accessories are turned off.
2. Warm engine to normal operating temperature. Connect tachometer. Using a service wire, connect terminal "D" (ground) to terminal "B" (diagnostic switch). Ensure CHECK ENGINE light indicates a Code 12. Connect duty meter between terminal "D" (ground) and terminal "F" (duty output). If idle speed and IAC duty are not within specification, remove adjusting screw protective cap and adjust idle speed by turning adjusting screw. See ADJUSTMENTS article. Replace IAC solenoid if defective. If IAC solenoid is okay, go to next step.
3. If vehicle is equipped with A/C, go to next step. If vehicle is not equipped with A/C, replace adjusting screw protective cap and remove service wire.
4. Turn A/C on, and set heater blower switch to high (maximum) speed. With A/C working properly, ensure idle speed and IAC duty are within specification. If idle speed and/or IAC duty are not within specification, adjust at A/C Vacuum Switching Valve (VSV). See ADJUSTMENTS article. Replace IAC solenoid and/or A/C VSV if defective. Remove service wire. Replace adjusting screw protective cap if removed.

1. Before idle speed/IAC duty is checked or adjusted, ensure all wires and vacuum hoses are connected securely, accelerator cable has some play, valve clearance and timing are set to specification, and all accessories are turned off.
2. Warm engine to normal operating temperature. Connect tachometer. Using a service wire, connect terminal "D" (ground) to terminal "B" (diagnostic switch). Ensure CHECK ENGINE light indicates a Code 12. Connect duty meter between terminal "D" (ground) and terminal "F" (duty output). If idle speed and/or IAC duty are not within specification, adjust by turning idle speed adjusting screw. See ADJUSTMENTS article. If idle is too high, go to next step. If idle is too low, go to step 5). If idle is unchanged (even with headlights on), go to step 7).
3. If idle is too high and cannot be lowered, pinch IAC solenoid valve hose shut. If engine speed reduces, check IAC solenoid resistance. If IAC solenoid resistance is not 30-33 ohms, replace IAC solenoid. Ensure idle switch and circuit are okay. If Red/White wire from ECM (terminal A4) to IAC is not grounded, replace ECM with a known good unit and recheck system.
4. If engine speed does not reduce, ensure air intake system is free from vacuum leaks. If there are no vacuum leaks, adjust duty and idle speed by turning idle speed adjusting screw. See ADJUSTMENTS article. If engine speed is still not adjustable, check air valve for proper operation.
5. If idle is too low and cannot be increased, ensure air is being drawn into IAC hose to air cleaner case. If engine speed increases, adjust duty and idle speed. If idle remains unchanged, check IAC solenoid resistance. If IAC solenoid resistance is not 30-33 ohms, replace IAC solenoid.
6. Check for clogged IAC hose, open circuit in Red/White wire or poor connection at IAC solenoid. If okay, replace ECM with a known good unit and recheck system.
7. If idle speed remains unchanged, turn ignition off. Disconnect ECM connector. If resistance between terminals A4 and A13 is 30-33 ohms, check connector terminal. If connection is okay, replace ECM with a known good unit and recheck. If resistance reading is not 30-33 ohms, check for poor terminal connection or an open wire in harness. If ECM terminal connection and wire harnesses are okay, replace IAC solenoid.

1. Turn ignition off. Disconnect electrical connector from IAC solenoid. Check resistance between IAC solenoid terminals. On Samurai and Swift, resistance should be 30-33 ohms at 68 °F (20 °C). On Sidekick, resistance should be 11-14 ohms at 68 °F (20 °C). Replace IAC solenoid if defective.
2. If reading is okay, disconnect IAC solenoid air hose from air intake case. It should be difficult to blow air into hose. If resistance is felt, connect battery voltage to IAC solenoid valve terminals. If it is still difficult to blow air through valve, replace IAC solenoid valve. Reinstall hose and connector securely.

THROTTLE OPENER SYSTEM (SAMURAI & SIDEKICK TBI)

Note. For throttle opener system vacuum and wiring schematic see scheme 10

Throttle Opener Diaphragm

Disconnect vacuum hose from throttle opener diaphragm. Using a hand-held vacuum pump and gauge, apply 20 in. Hg to diaphragm. Ensure throttle opener rod moves freely and remains in position. Replace throttle opener if defective.

Throttle Opener Vacuum Switching Valve

1. Vacuum Switching Valve (VSV) is Brown and located on right side of valve cover, near front of engine. Turn ignition off. Disconnect electrical connector from VSV.
2. Using ohmmeter, check resistance between VSV terminals. Replace VSV if resistance is not 33-39 ohms. If resistance is okay, go to next step.
3. Disconnect vacuum hoses from VSV. Blow air through upper port. Air should exit from lower port, not from the filter. Replace VSV if air exits from filter. If air exits from lower port, go to next step.
4. Energize VSV by applying battery voltage to Blue/Black wire terminal and ground to other terminal. (Scheme 111) Blow air through upper port. Air should exit from filter, not from lower port. Replace VSV if defective. Reconnect vacuum hoses and electrical connector.

Scheme 111

TIMING CONTROL SYSTEMS

Note. Ensure increasing engine speed advances ignition timing.

Samurai & Sidekick

1. Ensure transmission is in Neutral or Park and parking brake is set. Inspect crankshaft pulley timing mark and timing mark indicator on timing belt cover. Clean marks as required. Start engine, and warm it to normal operating temperature. Turn engine off with ignition on for 5 seconds. Restart engine, run it at 2000 RPM for 5 minutes and then return it to idle. Ensure all accessories are off. Attach timing light to No. 1 spark plug wire. Ensure idle speed is correct. See IDLE SPEED SPECIFICATIONS table in SPECIFICATIONS article. CAUTION: Driving with jumper wire installed in monitor connector will damage catalytic converter.
2. Remove protective cap from monitor connector located beside battery. Connect jumper wire between ground terminal "C" and test switch terminal "D". Aim timing light at crankshaft pulley and timing cover timing marks. If ignition timing is not within specification, loosen distributor hold-down flange bolts and rotate distributor to obtain correct ignition timing. Tighten distributor hold-down flange bolts, and recheck ignition timing. See IGNITION TIMING table in SPECIFICATIONS article. NOTE: With jumper wire installed, timing should be fixed. If timing varies, terminal "D" is not properly grounded.
3. Remove jumper wire from monitor connector. Ensure ignition timing advances with engine speed (RPM). If ignition timing does not advance, check TPS, monitor connector wiring circuit, engine start signal circuit and ECM.

Swift

1. Ensure transmission is in Neutral or Park and parking brake is set. Inspect crankshaft pulley timing mark and timing mark indicator on timing belt cover. Clean marks as required. Start engine, and warm it to normal operating temperature. Turn all accessories off. Attach timing light to No. 1 spark plug wire. Ensure idle speed is correct. See IDLE SPEED SPECIFICATIONS table in SPECIFICATIONS article. CAUTION: Driving with jumper wire installed in monitor connector will damage catalytic converter.
2. Connect ground terminal "D" and test switch terminal "E" of monitor connector. Aim timing light at crankshaft pulley and timing cover timing marks. If ignition timing is not within specification, loosen distributor hold-down bolt and rotate distributor to obtain correct ignition timing. See IGNITION TIMING table in SPECIFICATIONS article. Tighten distributor hold-down bolt, and recheck ignition timing.

Note. With jumper wire installed, timing should be fixed. If timing varies, terminal "D" is not properly grounded.

Exhaust Gas Recirculation Temperature (EGRT) Sensor Calif.

1. Sensor is threaded into EGR valve. Disconnect negative battery cable. Disconnect 2-wire connector from sensor and remove sensor. Position sensor threads in container of water with thermometer. Connect ohmmeter leads to sensor terminals.
2. Apply heat to container until water reaches specified temperature. See «EGRT SENSOR RESISTANCE»(ref-25813-S33277696862001010500000) table. Replace sensor if resistance is not within specification.

EGRT SENSOR RESISTANCE

EGR Valve

1. Disconnect EGR vacuum hose and attach a hand-held vacuum pump to vacuum hose port. Apply approximately 8 in. Hg to EGR valve while checking for smooth operation of diaphragm. Ensure diaphragm maintains position without losing vacuum.
2. With engine at idle, apply vacuum to EGR diaphragm. Engine should idle rough and/or stall. If diaphragm retracts and engine RPM does not change, remove EGR valve and check for clogged passages.

EGR Modulator

1. For EGR modulator location, see appropriate vacuum diagram in VACUUM DIAGRAMS article. Remove upper cap from modulator. Remove filter and clean with compressed air. Reinstall filter and upper cap. Remove EGR modulator.
2. Using low air pressure, apply air to one upper vacuum hose port and plug opposite vacuum hose port. Air should flow freely through filter housing.
3. Connect hand-held vacuum pump to one upper vacuum hose port. Connect vacuum gauge to opposite vacuum hose port. Using low air pressure, apply air to bottom port while applying vacuum with vacuum pump. Vacuum should be indicated on gauge. When low air pressure application stops at bottom port, vacuum gauge indicator should return to zero. Replace EGR modulator if operation is not as specified.

1. Turn ignition off. Disconnect connector from VSV. On Samurai and Sidekick, VSV is mounted near right side of valve cover, at front of engine. On Swift DOHC, VSV is mounted behind engine, near center of firewall. On Swift SOHC, VSV is located between distributor and EGR modulator.
2. On all models, turn ignition on and then off. Check resistance between VSV terminals. If resistance is not 30-39 ohms at 68°F (20°C), replace VSV.
3. Disconnect upper and lower hoses from VSV. Connect short section of hose to lower horizontal port of VSV. Blow air through hose connected to VSV. Air should exit through other port, not filter.
4. If air exits through filter, replace solenoid. If air does not exit through filter, energize solenoid by applying battery voltage to appropriate wire terminal and ground to other terminal. Refer to the «EGR VACUUM SWITCHING VALVE TERMINAL IDENTIFICATION»(ref-25813-S26458221222001010500000) table. Solenoid should click. Blow air through hose connected to solenoid. Air should now exit through filter and not through other port. If test is not as specified, replace solenoid.

EGR VACUUM SWITCHING VALVE TERMINAL IDENTIFICATION

Bimetallic Vacuum Switching Valve (Samurai)

Disconnect both vacuum hoses from valve, located under intake manifold. Connect a hose to either port on valve. Blow through hose. With engine coolant temperature less than 131°F (55°C), air should not pass through valve. With engine coolant temperature greater than 149°F (65°C), air should flow through valve. If valve does not operate as described, replace valve.

Bimetallic Vacuum Switching Valve (Swift)

Disconnect vacuum hose from valve, located under intake manifold. Connect a hose to port on valve. Blow through hose. With engine coolant temperature less than 113°F (45°C), air should exit through filter on valve. With engine coolant temperature greater than 140°F (60°C), air should not exit through filter.

Canister Purge Valve (Sidekick)

1. With engine at normal operating temperature, disconnect purge hose from top of canister. With engine idling, vacuum should not be present. As engine speed increases to more than 1500 RPM, vacuum should be present. If vacuum is not as specified, check vacuum passage, hoses, solenoid valve, wiring harness or ECM for defects. Repair or replace as necessary.
2. Place finger over nozzle to check for vacuum. If necessary, clean blocked nozzle with compressed air. Check hoses for proper connection, leaks, clogging and/or deterioration. Replace as necessary.

Canister Purge Solenoid Valve (Sidekick)

1. With ignition off, disconnect connector from solenoid valve and check resistance between both terminals. If resistance is not 28-36 ohms at 68°F (20°C), replace canister purge solenoid valve.
2. Disconnect vacuum hose from intake manifold and canister. With connector disconnected, air blown into one hose should not exit other hose.
3. With 12 volts and ground connected to solenoid valve terminals, air blown into one hose should come out of other hose. If air does not exit as specified, replace canister purge solenoid valve.
4. To check charcoal canister, blow air into tank pipe at top of canister. Air should flow freely from both purge pipe (next to tank pipe) and air pipe (at bottom of canister). When air is blown into purge pipe, air should not pass through either tank pipe or air pipe. Replace charcoal canister if operation is not as specified.

Canister Purge Valve (Swift)

1. Disconnect hoses at purge valve on top of canister. (Scheme 112) Using low air pressure, blow through fuel tank port. Air should exit through air vent. Blow air through purge port. No air should exit and pressure should hold.
2. While applying more than 3.1 in. Hg to throttle body port, blow air through purge port. Air should exit through fuel tank port and air vent. If canister purge valve does not test as specified, replace canister.

Scheme 112

Canister Purge Vacuum Switching Valve (Swift DOHC)

1. Turn ignition off. Using ohmmeter, check resistance between terminals of Vacuum Switching Valve (VSV) connector. If resistance is not 33-39 ohms, replace VSV. Disconnect vacuum hoses from VSV. Connect short section of hose to either port of VSV. Blow through hose. Air should not pass through VSV.
2. Apply battery voltage to White/Blue wire terminal and ground to other wire terminal. Blow through hose. Air should pass through VSV. If VSV does not test as specified, replace VSV.

PCV Valve

Valve is located in intake manifold. Start engine. Remove valve from intake manifold. Place finger over valve. Vacuum should be present. Remove finger from PCV valve. Valve should snap back.

TRANSMISSION

Note. Although lock-up relay system is not technically an engine performance system, it can affect driveability if it malfunctions.

Lock-Up Relay System (Sidekick TBI)

1. Lock-up relay system is used on A/T models only. Disconnect negative battery terminal. Remove ECM from holder. Disconnect ECM harness connector. Install harness connector between ECM and ECM harness connector. Connect negative battery terminal.
2. Start and warm engine to normal operating temperature. Connect DVOM between ECM connector terminal A6 and ground. With engine running, shift transaxle to Drive and release brake pedal. DVOM should read zero volts.
3. On a flat road, drive vehicle with transaxle in Drive at speed greater than 42 MPH. Maintain speed for at least 4 seconds, with throttle valve open less than 70 percent. Voltage at ECM terminal A6 should indicate battery voltage when lock-up relay transmits an engine signal to solenoid.
4. If battery voltage is not indicated, check wiring harness, lock-up relay, solenoid, brake pedal switch or oil pressure switch. To check lock-up relay, see TORQUE CONVERTER CLUTCH (TCC) RELAY (SIDEKICK TBI A/T) under «RELAYS»(ref-25813-S34652804772001010500000) under RELAYS & SOLENOIDS. If system components and circuits test okay, replace faulty ECM.

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117