The rear portion is formed as a single body by pressure—insertion of the signal rotor. The oil is drawn up from the oil pump strainer, and passes through the oil filter before flowing into the main channel. Page 55 OIL PUMP The oil pump uses a trochoid system, and is driven directly by engagement with the width across the flat of the crankshaft and the inner rotor. Oil seal 2. Oil pump case 3. Gasket 4. Inner rotor 5. The engine is a water cooled, in—line, 3 cylinder, 4—stroke gasoline unit with its S.
The single overhead camshaft is mounted over the cylinder head; it is driven from the crankshaft through the timing belt.
In another path, oil goes up to cylinder head and lubri- Oil is drawn up through oil pump strainer and passed cates camshaft journals, racker arm, camshaft, etc. NOTE: Observe critically before starting to remove a component or part by loosening bolts, nuts and the like. Page 61 7 Remove camshaft timing belt pulley and key with spe- cial tool attached, as shown, to lock camshaft. Page 62 19 Loosen all valves adjusting screws fully. Leave screws in place. In this way, remove valve spring and valves.
Page 63 25 Remove alternator bracket. NOTE: 27 Remove oil pan. Do not reuse valve guide once disassembled. Be 28 Remove oil pump strainer. Be sure to identify each piston, piston pin, connecting rod and bearing cap by using the cylinder number. Page 65 Wash all disassembled parts clean, removing, grease, carbon and scales, before inspecting them to determine whether repair is necessary or not.
Descale water jackets Used compressed air to clear internal oil holes and passages. Do not disturb set combinations of valves, bear- ings, bearing caps, etc. Page 66 Wear of rocker—arm and adjusting screw: If the tip 1 of adjusting screw is badly worn, replace Measuring Surface of Intake Manifold Seating Face screw. Arm; must be replaced if its cam—riding face 3 is badly worn. Visually examine each rocker—arm wave washer Measuring surface of Exhaust Manifold Seating Face for evidence of breakage or weakening.
Page 67 Valves Stem—to— 0. Remove all carbon from valves. Inspect each valve for wear, burn or distortion at its face and stem and replace as necessary. Measure thickness of valve head.
Valve seat repair: Valve seat not producing uni- Seating contact width: Produce a contact pat- form contact with its valve or showing a width tern on each valve in the usual manner, namely, Page 70 Valve Springs Referring to the criterion—data given below, check to be sure that each spring is in sound 7. Remember, weakened valve springs can be the cause of chatter, not to men- tion the possibility of reducing power output due to gas leakage caused by decreased seating pressure.
Page 71 5 Remove housing, and using scale on gaging plastic envelope, measure gaging plastic width at its widest point. Standard Limit Journal 0. Journal wear: Check camshaft journals and camshaft hous- ings for pitting, scratches, wear or damage. Page 72 Piston Diameter: Piston to cylinder clearance, mentioned above, is equal to the bore diameter minus the piston diameter, which is to be measured by measuring at the level of the piston in the direction trans- verse to piston pin axis, as shown if figure below.
Check the big end of each connecting rod for clearance in clearance in 0. Page 74 Crankpin to bearing clearance: Check this clearance by using gaging plastic Plastigage. Page 75 Crankshaft thrust play: Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing caps installed. Tighten bearing cap bolts to specified torque.
Use a dial gauge to read displacement in axial thrust direction of crankshaft. If the limit is exceeded, replace thrust bearing 4 If the limit, indicated above, is exceeded, re—grind the with new standard one or oversize one to obtain Page 76 CAUTION As in the case of connecting rod bearings, the journal bearings are not meant to be repaired by scraping or sanding with sandpaper or by any other machining.
Journal to bearing clearance: Check this clearance by using gaging plastic Plastigage. Replace them as necessary. Keep away oil and water from the belt. Page 78 Oil Pump 1 Inspect oil seal lip for fault or other damage.
Replace as necessary. Radial clearance: Check radial clearance between outer rotor and case, using thickness gauge. Oil sliding and rubbing surfaces of engine parts with engine oil just before using them in reassembly.
Have liquid packing ready for use. Bond No. Use it wherever its use is specified in order to ensure leak— Page 80 55—60 N—m Tightening torque for bearing 5.
Make sure that the four caps become tight a wash, clean and then dry all disassembled parts. Page 81 To prevent oil lip seal from being damaged or upturned when installing oil pump to crankshaft, fit special tool Oil seal guide to crankshaft, and apply engine oil to special tool. When installing these piston rings to piston, direct marked side of each ring toward top of piston. Page 82 3 Install piston and connecting rod assembly into cylin- After installing piston and connecting rods, der bore.
Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crank pins. Page 83 Oil Pump Strainer remove burrs, making sure that guide hole diameter after reaming comes within specified range. Install oil pump strainer to oil pump. Page 84 tom end small—pitch end. Be sure to position spring in place with painted side up. After apply- ing engine oil to seal and the install seal to valve guide. After installation, check to be sure that seal is properly fixed to valve guide.
Page 85 No. Then tighten to specified torque. So it is not adjusted at this point. Leave rocker arm adjusting screw as loose as possible.
When installing pulley, direct its timing marked side to timing belt outside cover side. Tighten pulley bolt to specified torque with special tool applied as shown in figure below. Page 89 11 Install crankshaft pulley and water pump pulley.
Oil Filter Install oil filter. NOTE: Exhaust Manifold and Cover when replacing belt with a new one, adjust belt ten- 1 Install exhaust manifold gasket to cylinder head. Page 90 0. Page 91 6 Upon completion of check and adjustment, install cyl- 5 Depress accelerator pedal all the way to make throttle inder valve cover and torque bolts to specification.
Oil level in oil pan. If level is low, add oil to Full level line on oil dip stick. Oil quality. If oil is discolored, or deteriorated, change oil. Hg at Sea level specified idling speed. Additionally, by combining integrating the AT controller with the ECM Engine Control Module , space saving is achieved and maintenance qualities are improved. The main characteristics are as follows. A speed density system which determines the fuel injection amount according to the engine rpm and intake manifold pressure is used.
The fuel in the fuel tank is drawn up by the fuel pump, filtered by the fuel filter, transported to the delivery pipe, and injected by the injectors. Page Injectors The injector is a device which injects fuel in the delivery pipe into the intake manifold under control of the ECM, and uses an MPI multi—point injection system, whereby fuel is injected into the manifold of each cylinder. In the injector operation, the injector valve opens when the coil is electri- fied, and closes when power is cut off.
The intake air amount is indirectly measured by measuring the intake air pressure using the pressure sensor. The ISC valve is installed on the throttle body and uses a stepper motor system.
Page Crank Angle Sensor CAS The crank angle sensor is installed on the sensor case and houses an element which converts mag- netic changes into voltage. Information Decal The information decal is located on the vehicle engine cover. The ECM performs optimal actuator control during driving by processing data input from the sensors. The following are the principal control items. The fuel injection method timing and fuel injection amount time are controlled as follows using a start mode that is used when starting the engine and a feedback mode that is used during normal driving.
Injection is performed in the exhaust sequence of each cylinder. The fuel injection amount is calculated by adding following correction to the basic fuel injection time, which is determined according to the engine rpm and air intake amount.
Volume efficiency correction: The fuel injection time is adjusted according to the engine rpm and intake air pressure. Operation shutdown: When the battery voltage is less than 9. When the ignition switch is turned ON, the coil of the relay is ground, and thereby the relay switch circuit is closed. Further, when control is performed based on this abnormal signal, there is a possibility that engine trouble may occur and driving may not be possible, so the failsafe function is provided which secures minimal driving performance using a standard signal in the ECM, ignoring this signal.
See Section 2B for AT system diagnosis codes. NOTE: The jumper will perform diagnostic checks on various electrical components. The engine and transmission are to be removed from the vehicle as an assembly.
Procedure 1. Disconnect negative — and positive cables from battery terminals. Page Disconnect lead wires from alternator terminals. Disconnect lead wires from water temperature sender. Disconnect accelerator cable and speed limiter cable. Remove air cleaner hose. Remove fuel tank cap to release fuel vapor pressure in fuel tank and then reinstall it. Disconnect lead wire from oil pressure gauge.
Disconnect catalytic converter from exhaust man- ifold. Drain radiator of coolant. Disconnect and drain transmission cooling lines. Disconnect heater inlet and outlet hose from Y con- nector. Place wood blocks between trans- mission and jack so that engine with transmission is held horizontally even when motor mount bolts are removed. Remove motor mount bolts. Carefully remove engine with transmission. Both distributor and plug wires are eliminated with this direct ignition system. This vehicle uses a full—transistor type, direct—ignition The ECM has a self—diagnostic mode to detect abnormal system, comprising of 3 ignition coils, 3 spark plugs input signals as a means of component fault detection.
Page Condition Possible Cause Correction Engine cranks, but will No Spark not start or hard to start Blown fuse for ignition coil Replace Connect securely Loose connection or disconnection of lead wires Faulty spark plug s Adjust, clean or replace Poor fuel economy or engine performance Faulty spark plug s Adjust, clean or replace Ignition timing adjustment mode: When diagnositc jumper P. A damaged element must be replaced with a new one, since it allows dust particles to enter the engine if used as it is.
Such dust particles could cause wear to the engine inner parts and this further results in decreased power. Fuel enters the filter through its inlet hole and after pass- Disconnect negative battery cable at bat- ing through the filtering element, comes out of its outlet tery. Page 2 Remove fuel filler can to release fuel vapor pres- sure in the fuel tank. After releasing, reinstall the cap.
Page Installation NOTE: 1 Install filter and clamp, and connect inlet and outlet Before finally removing fuel tank, recheck to ascer- hoses to fuel filter. Installation Reverse removal procedure for installation using care for the following: Refer to general description of this item for piping and 1.
The cap contains a pressure valve and vacuum valve. The pres- sure valve is held against its seat by a spring of pre—de- termined strength which protects the cooling system by relieving the pressure if the pressure in the cooling sys- tem rises above 0. Page Coolant Draining 1 Remove radiator cap. Intake manifold 2. Thermostat cap 3. Thermostat 4. Spacer 5. Page 6 Remove tensioner and timing belt. Should this valve be clogged, engine would tend to overheat.
If any repair is required on pump, replace it as an assembly. Torque each bolt and nut to specification. They may be harmful to proper remove radiator cap while engine and radiator operation of system, and are unnecessary expense.
Starting Motor The starting motor uses a solenoid shift type. These components are connected electrically as shown in the figure. Only the starting motor will be covered in this section. The magnetic switch assembly and parts in the starting motor are enclosed in the housing so that they will be protected against possible dirt and water exposure.
Page Possible symptoms do to starting system trouble would Proper diagnosis must be made To determine exactly be as follows: where the cause of each trouble lies, in battery, wiring harness, including ignition switch , starter motor or Starting motor does not run or runs slowly engine.
Page Condition Possible Cause Correction Starter motor running too If battery and wiring are satisfactory, slow low torque inspect starter motor 1. Insufficient contact of magnetic switch Replace main contacts 2. Layer short—circuit of armature Replace 3. Disconnected, burnt or worn commutator Repair or replace 4. If below the limit, replace armature. Correct with emery Commutator Commutator cloth or lathe, if necessary.
Check commutator for uneven wear. Page Ground Test Check commutator and armature core. If there is conti- nuity, armature is grounded and must be replaced. Install brushes to each brush holder and check for smooth movement. Open Circuit Test Check for continuity between segments, If there is no continuity at any test point, there is an open circuit and armature must be replaced.
Check that plunger returns inward. These tests must be performed within 3—5 seconds to avoid burning out coil. Pull—in Test Connect battery to magnetic switch as shown. The internal components are con- nected electrically as shown in the following schematic diagram battery. The battery has three major functions in the electrical system.
The carrier should be in good condition so it will ken case, that could permit loss of electrolyte. Page 3 Attach end of one jumper cable to positive terminal of booster battery and the other end of the same cable WARNING to positive terminal of discharged battery. Use 12—volt battery only to jump start engine. Departure from these conditions or pro- 4 Attach one end of the remaining negative cable to cedures described below could result in: negative terminal of booster battery, and the other end Page Belt tension spec- 11—14 mm 0.
Repair manuals. Suzuki Carry. Engine: F. The text covers what the Electronic Fuel Injection engine control system does and how it works. Performance and configuration of engine control Engine control system and micro computer This vehicle uses many different electronic control devices which make use of a microcomputer. Ones equipped in vehicles are engine control system and automatic transmission control system.
Use of a microcomputer makes it pos sible to handle a large amount of information in such a short time. Computer allow for highly accurate, multifunction system control. Described in this section is the engine controller utilizing a microcomputer. The controller used in the engine cont Manual download Repair manuals Carry - Repair manuals English suzuki carry ga engine wiring diagram.
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