Suzuki g13 Engine Adjustment

D - ADJUSTMENTS Article Text1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company, LLC Thursday, April 08, 1999 09:26AM ARTICLE BEGINNING 1993 ENGINE PERFORMANCE Suzuki of America Corp. On-Vehicle Adjustments Suzuki; Samurai, Sidekick, Swift ENGINE MECHANICAL Before performing any on-vehicle adjustments to fuel or ignition system, ensure engine mechanical condition is okay. VALVE CLEARANCE NOTE: Swift DOHC uses hydraulic lifters. No adjustments are required. Samurai & Sidekick 1) Remove valve cover. Rotate engine until zero degree (TDC) timing mark of timing belt cover is in line with timing mark on crankshaft pulley. See Fig. 1. 2) Ensure cylinder No. 1 is at TDC on compression stroke. Remove distributor cap. On Samurai and Sidekick (TBI), ensure rotor is pointed upward at distributor hold-down bolt and to No. 1 terminal of distributor cap. On Sidekick (MPI), ensure rotor is at about 1 o’clock position and pointed to No. 1 terminal of distributor cap. If rotor is not as described, rotate crankshaft 360 degrees. 3) Measure valve clearance between adjustment screw and valve stem using shim thickness gauge. Check intake valve clearance of cylinders No. 1 and 2 and exhaust valve clearance of cylinders No. 1and 3. See VALVE CLEARANCE SPECIFICATIONS table. 4) Turn crankshaft one complete revolution (360 degrees). Check intake valve clearance of cylinders No. 3 and 4 and exhaust valve clearance of cylinders No. 2 and 4. 5) Adjust valves by loosening lock nut and turning adjusting screw until clearance is as specified. After adjusting clearance, tighten adjusting screw lock nut to 11.0-13.5 ft. lbs. (15-18 N.m) for Samurai or 90-108 INCH lbs. (10-13 N.m) on Sidekick. On all models, recheck clearance. VALVE CLEARANCE SPECIFICATIONS TABLE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Samurai, Sidekick (TBI) & Swift SOHC Engine Cold Intake ........................................ Exhaust ....................................... Engine Hot Intake ........................................ Exhaust ....................................... In. (mm) .005-.007 (.13-.18) .006-.008 (.15-.20) .009-.011 (.23-.28) .010-.012 (.25-.30) . If ignition timing is not within .. See Fig.. Start engine. See IDLE SPEED SPECIFICATIONS table under IDLE SPEED & MIXTURE.08-.... Ensure rotor is pointing upward toward distributor hold-down bolt and to No..... 2.. Turn all accessories off... (1) (1) ..D . Turn engine off with ignition on for 5 seconds. and then return it to idle..... Restart engine....... 4) Adjust valves by loosening lock nut and turning adjusting screw until clearance is as specified. Samurai & Sidekick 1) Ensure transmission is in Neutral or Park and parking brake is set. rotate crankshaft 360 degrees.. Ensure idle speed is correct. CAUTION: Driving with jumper wire installed in monitor coupler will damage catalytic converter.......16) Swift DOHC .. LLC Thursday.. Turn crankshaft one complete revolution (360 degrees).005 (........005-. 2) Remove protective cap from monitor coupler located next to battery... lbs. 2) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company....... Clean marks as required.. Inspect crankshaft pulley timing mark and timing mark indicator on timing belt cover. See VALVE CLEARANCE SPECIFICATIONS table..0-13. Attach timing light to No. 1 and 2 and exhaust valve clearance of cylinders No.m).. 1and 3.12) Engine Hot Intake & Exhaust .. See Fig.ADJUSTMENTS Article Text (p. Check intake valve clearance of cylinders No.. Check intake valve clearance of cylinders No..Hydraulic valve lash adjusters are used and no adjustment is required... 1... ....... 1...006 (..12-. Align crankshaft pulley timing mark with TDC mark on timing belt cover..... April 08. Remove right inner fender apron extension to enable timing marks to be seen.. IGNITION TIMING NOTE: Verify that increasing engine speed advances ignition timing... 1999 09:26AM Sidekick (MPI) Engine Cold Intake & Exhaust . and warm it to normal operating temperature.. 3) Measure valve clearance between adjustment screw and valve stem using shim thickness gauge.... 2 and 4..... . Run engine at 2000 RPM for 5 minutes.. 1 spark plug wire. Aim timing light at crankshaft pulley and timing cover timing marks...003-. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Swift SOHC 1) Remove valve cover. 1 terminal of distributor cap. If rotor is not as described.......5 ft....... Connect jumper wire between terminals "C" (ground) and "D" (test switch)... 2) Remove distributor cap. Hold adjusting screw while tightening lock nut to 11... (15-18 N. See Fig... 3 and 4 and exhaust valve clearance of cylinders No..... Recheck clearance.... ..... NOTE: With jumper wire installed. If ignition timing does not advance........ check TPS.. Ensure ignition timing advances as engine speed increases. timing should be fixed. Swift Man... 1999 09:26AM specification. 1: Locating Ignition Timing Mark Courtesy of Suzuki of America Corp... .... (2) 7-9 @ 800 (2) 4-6 @ 800 (2) 7-9 @ 800 Auto. Tighten distributor hold-down flange bolts.... April 08. Fig...... loosen distributor hold-down flange bolts..... 3) Remove jumper wire from monitor coupler. Fig....... and rotate distributor to obtain correct ignition timing. Not Used (2) 4-6 @ 800 (2) 7-9 @ 800 ................ See IGNITION TIMING table. engine start signal circuit and ECM. 3) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company.....ADJUSTMENTS Article Text (p. LLC Thursday........ If timing varies.... Sidekick MPI . monitor coupler wiring circuit.. and recheck ignition timing... terminal "D" is not properly grounded. Trans.. TBI ... 2: Identifying Monitor Coupler Terminals (Samurai & Sidekick) Courtesy of Suzuki of America Corp....... .. ........ Trans.D .... IGNITION TIMING TABLE (Degrees BTDC @ RPM) (1) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Samurai ... . ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Swift 1) Ensure transmission is in Neutral or Park.... 3.... (3) 4-6 @ 850 location. between "D" and "E" terminals of located near ignition coil.. Aim timing light at crankshaft pulley and timing cover timing marks.. See Fig.. Turn all accessories off... Inspect crankshaft pulley timing mark and timing mark indicator on timing belt cover. 3: Identifying Monitor Coupler Terminals (Swift) Courtesy of Suzuki of America Corp.. 1 for timing mark (2) .. 2) Connect terminals "D" (ground) and "E" (test switch) of monitor coupler. See Fig.. and warm it to normal operating temperature. (3) ..With jumper wire installed monitor coupler connector.D . Clean marks as required.See Fig.. 1 spark plug wire. CAUTION: Driving with jumper wire installed in monitor coupler will damage catalytic converter.... If ignition timing is not within specification... April 08... 4) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company. Tighten distributor hold-down bolt.. See IDLE SPEED SPECIFICATIONS table under IDLE SPEED & MIXTURE.. (3) 5-7 @ 800-900 .... and recheck ignition timing.... Attach timing light to No.. (3) 5-7 @ 800-900 . 1999 09:26AM DOHC SOHC . See IGNITION TIMING table. LLC Thursday... Set parking brake.ADJUSTMENTS Article Text (p. See Fig.. (1) . .. 3... 2. loosen distributor hold-down bolt and rotate distributor to obtain correct ignition timing..... between "C" and "D" terminals of located near battery... Start engine. (3) 4-6 @ 750 . Fig..With jumper wire installed monitor coupler connector.. Ensure idle speed is correct.. 1. See Fig.. ..... 3) Start engine. Using duty meter... 5) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company..... See PICK-UP COIL AIR GAP table..........Not adjustable..... 2) Turn engine off... IDLE SPEED NOTE: DO NOT adjust idle speed in areas above 8200 ft.......... 2) Using blade screwdriver......20-...Also referred to as crank angle sensor air gap..D .. See IDLE SPEED SPECIFICATIONS and IAC DUTY AT SPECIFIED IDLE SPEED tables.30) SOHC .... Install spare fuse into diagnosis terminal of fuse box. Mixture is controlled by ECM from various sensor inputs.. loosen pick-up coil plate hold-down screws. See PICK-UP COIL AIR GAP table. .. measure air gap between reluctor tooth and pick-up coil.. (1) Sidekick ..... and wait 5 seconds.... ensure idle speed and IAC duty percentage are within specification....... (2) .... Connect Duty Meter (99963-00006) to monitor coupler duty check terminal "A" and ground terminal "C".012 (. (1) Swift DOHC (2) .. PICK-UP COIL AIR GAP TABLE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application In.... Ensure no metal particles are on pick-up coil tooth........ Tighten screws. and warm it to normal operating temperature..... (mm) Samurai .. run it at 2000 RPM for 5 minutes and then return it to idle... remove idle speed adjusting screw ...... ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ IDLE SPEED & MIXTURE NOTE: Mixture is not adjustable.... See Fig.. Test connector is located near battery...... April 08....008-.... Turn ignition on...ADJUSTMENTS Article Text (p......... COLD (FAST) IDLE NOTE: Cold start or fast idle speed is not adjustable...008 (.... Air valve operation supplies by-pass air for cold starting. move pick-up coil plate to adjust air gap to specification. 2. See Fig...... Samurai 1) Start engine. 1999 09:26AM PICK-UP COIL AIR GAP 1) Remove distributor cap and rotor............. LLC Thursday. Using non-magnetic shim thickness gauge. elevation. If adjustment is required...... If idle speed and/or IAC duty percentage require adjustment...............20) (1) ....................... 4.. .............. and recheck air gap.. and ensure Malfunction Indicator Light (MIL) indicates Code 12..... D . 1999 09:26AM protective cap on throttle body. turn A/C VSV adjusting screw to adjust idle. See Fig. See Fig. and set fan switch to LOW position. go to step 5). Remove spare fuse from diagnosis terminal of fuse box. .ADJUSTMENTS Article Text (p. 4) When idle speed and IAC duty percentage are within specification and vehicle is equipped with A/C. If vehicle is not equipped with A/C. Remove duty meter from monitor coupler. Check idle speed and IAC duty percentage. If idle speed and/or IAC duty percentage is not within specification. 5. Fig. 5) Turn A/C on. reinstall idle speed adjusting screw protective cap to throttle body. 6) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company. Fig. To adjust idle speed. LLC Thursday. 5: Locating Idle Speed Adjusting Screw (Typical) Courtesy of Suzuki of America Corp. 6. and rein-stall cap. April 08. 4: Installing Diagnosis Terminal Fuse (Samurai) Courtesy of Suzuki of America Corp. turn adjusting screw. ........ 750-850 With A/C On ...... 700-800 With A/C On Auto.... ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ IAC DUTY AT SPECIFIED IDLE SPEED TABLE (1) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Percent .................. Transaxle ...... 850-950 (1) ....................... (4) .......A/C idle speed is adjusted by rotating adjusting screw on A/C Vacuum Switching Valve (VSV)....... (2) 950-1050 Sidekick With A/C Off .......................................................... Transaxle (4) ..................With auto........................... 800-900 Man.............. (2) ......Transaxle or transmission in Neutral or Park...........D ......When ECM part number ends with "0".......ADJUSTMENTS Article Text (p......... 1999 09:26AM Fig............................................. 7) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company............................................ (5) .... LLC Thursday..... IDLE SPEED SPECIFICATIONS TABLE (1) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Idle RPM Samurai With A/C Off ..... Transaxles (5) ............ 6: Locating A/C VSV Adjusting Screw (Samurai & Sidekick) Courtesy of Suzuki of America Corp... April 08.... (2) 800-900 Man..... (3) 950-1050 Swift DOHC With A/C Off ...... 750-850 With A/C On ........ 800-900 With A/C On ......... idle RPM is 750-850.When ECM part number ends with number other than "0"......... Transaxle ................... transmission in gear.............. Transaxle (4) .... (2)700-800 Auto.... (2) 850-950 SOHC With A/C Off Auto....................... (3) ............... & Man.. ...... air cleaner and ducts are properly installed and air filter element is in good condition....... See IGNITION TIMING table under IGNITION TIMING. Turn engine off........ Turn idle speed adjusting screw to adjust idle to specification..... See Fig... 2... 5) Turn A/C on..... Ensure all fuel and emission control system wire connectors and hoses are properly connected.... Remove duty meter from monitor coupler. Swift SOHC 1) Idle speed is controlled by ECM using IAC valve and requires no adjustments under normal conditions..... (2) .. Ensure ignition timing is correct. 30-40 SOHC (2) ......See IDLE SPEED SPECIFICATIONS table. and set fan switch to LOW position. Ensure MIL (CHECK ENGINE light) indicates Code 12.......... LLC Thursday. See Fig.. turn A/C VSV adjusting screw to adjust idle to specification....D .. See Fig.. If conditions require idle speed to be adjusted... If vehicle is not equipped with A/C... 8) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company.With A/C turned off (if equipped)....... Ensure air cleaner and ducts are properly installed and air filter element is in good condition... 6.............. start engine and warm it to operating temperature.... specified values used for this inspection and adjustment vary depending on type of ECM... 50 Swift DOHC .... Type of ECM can be identified by last digit of ECM part number... Turn all accessories off.... Ensure idle speed and IAC duty percentage are within specification. See IDLE SPEED SPECIFICATIONS and IAC DUTY AT SPECIFIED IDLE SPEED tables.. Last digit will be "0" or a number other than "0".. NOTE: On Swift.... Test connector is located near battery......... April 08........ If idle speed and/or IAC duty percentage require adjustment. Check idle speed and IAC duty percentage with A/C on.... Turn all accessories off...ADJUSTMENTS Article Text (p.. and reinstall cap... reinstall idle speed adjusting screw protective cap to throttle body and remove service jumper wire.. and warm it to operating temperature.. and warm it to operating temperature. ... 3) Start engine. Ensure all fuel and emission control system wire connectors and hoses are properly connected.. 25-35 (1) . 5. 1999 09:26AM Samurai & Sidekick . If idle speed and IAC duty percentage are not as specified... go to next step.. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Sidekick 1) Start engine.. remove idle speed adjusting screw protective cap on throttle body...... 2) Connect service wire between terminals "B" (diagnosis switch) and "C" (ground) of monitor coupler.. and connect Duty Meter (99963-00006) to monitor coupler duty terminals "A" (output) and "C" (ground).. Ensure accelerator cable has free play at throttle body.. Connect tachometer... 4) When idle speed and IAC duty percentage are as specified and vehicle is equipped with A/C........ Ensure accelerator cable has free-play. Turn all accessories off. reinstall protective cap to throttle body and recheck idle speed.D . Ensure all fuel and emission control system wire connectors and hoses are properly connected. On vehicles without A/C. 3. Ensure air cleaner and ducts are properly installed and air filter element is in good condition. Attach duty meter to duty output terminal "F" and ground terminal "D". Swift DOHC 1) Idle speed is controlled by IAC valve and should not require adjustment. MIL (CHECK ENGINE light) should indicate Code 12. turn A/C Vacuum Switching Valve (VSV) adjusting screw as necessary. LLC Thursday. See IDLE SPEED SPECIFICATIONS table. Remove service wire. Connect terminal "B" (diagnosis switch) to terminal "D" (ground) using a service wire. 1999 09:26AM 2) Ensure ignition timing is correct. If adjustment is required. Fig. April 08. verify idle speed is 850-950 RPM. 2) Ensure ignition timing is correct. If idle speed needs to be changed. 7: Identifying Typical Idle Adjustment System (Swift) Courtesy of Suzuki of America Corp.ADJUSTMENTS Article Text (p. reinstall protective cap to throttle body and recheck idle speed. 9) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company. See Fig. remove service wire. Ensure accelerator cable has free play. See Fig. 3) On vehicles equipped with A/C. turn A/C switch to ON position and set fan switch to HIGH position. See IGNITION TIMING table under IGNITION TIMING. start engine and warm it to operating temperature. With A/C operating correctly. See IDLE SPEED SPECIFICATIONS and IAC DUTY AT SPECIFIED IDLE SPEED tables. See IGNITION TIMING . Remove idle speed adjusting screw cap from side of throttle body. 7. just above throttle lever. Turn idle speed adjusting screw to obtain correct idle speed. Use lock nut and adjusting nut on cable bracket to adjust free play.4-0.6" (10-15 mm) free play.07" (0. 2) If throttle opener rod is pushed back by hand (i. See Fig. Attach duty meter to duty output terminal "F" and ground terminal "D".0 mm). throttle valve is at idle position). Remove idle speed adjusting screw protective cap from top of throttle body.ADJUSTMENTS Article Text (p. See Fig. 1999 09:26AM table under IGNITION TIMING. turn A/C Vacuum Switching Valve (VSV) adjusting screw to obtain correct idle. adjust transmission kickdown cable. Use lock nut and adjusting nut on cable bracket to adjust free play. Fig. check clearance between throttle lever and lever stopper at throttle body. 3. See Fig. cable free play should be 0. 8: Adj. reinstall protective cap to throttle body and recheck idle speed.0 mm). April 08. turn A/C switch to ON position and set fan switch to HIGH position.27" (2. accelerator pedal play should be 0. use lock nut and adjusting nut on cable .e. 9. See Fig. Sidekick (MPI) 1) With throttle valve closed.0 mm). verify idle is 850-950 RPM and IAC duty is 30-40 percent.12-0. 8. Sidekick TBI & Swift) Courtesy of Suzuki of America Corp. 3) On vehicles equipped with A/C. correct by changing height of pedal stopper bolt located under accelerator pedal. Typical Acc. MIL (CHECK ENGINE light) should indicate Code 12.0-7. Remove service wire. LLC Thursday. With A/C operating correctly. 10) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company. 20" (3.08-0.8-1. THROTTLE CABLE Samurai 1) Ensure throttle cable has 0. If clearance is not 0. Turn idle speed adjusting screw to obtain correct idle RPM. Cable Play (Samurai. After throttle cable adjustment is complete.02-0. 3) Check A/T cable free play. If adjustment is required.D .. See IDLE SPEED SPECIFICATIONS table. 2) With accelerator pedal depressed fully. Connect terminal "B" (diagnosis switch) to terminal "D" (ground) using a service wire. If clearance is not 0. 9. 7.06" (0. See Fig.0-5. See IDLE SPEED SPECIFICATIONS and IAC DUTY AT SPECIFIED IDLE SPEED tables.03-0. Use lock nut and adjusting nut on cable bracket to adjust free play.5 mm). Hold exposed portion of cable at center and move cable up and down to measure play.5-2. 3) Holding upper lock nut position on kickdown cable.0 mm) free play. See Fig.039" (1. 2) After throttle cable adjustment is complete.6" (10-15 mm) free play. 8. With free play removed. Sidekick (TBI) 1) Ensure cable has 0. Hold exposed portion of cable at center and move cable up and down to adjust free play. Swift Ensure cable has .00 mm).12-. LLC Thursday. release accelerator pedal. Loosen and back off kickdown lock nut and adjusting nut considerably. pull on kickdown cable housing to remove cable free play.0-5.D . 9: Adjusting Cable Play (Sidekick MPI) Courtesy of Suzuki of America Corp. With accelerator pedal fully depressed. Hold exposed portion of cable at center and move cable up and down to measure free play. adjust transmission kickdown cable.4-0. DASHPOT . 1999 09:26AM bracket to adjust free play. 11) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company. See Fig. Fig. Adjust upper lock nut as necessary.ADJUSTMENTS Article Text (p.20" (3. April 08. 8. While holding upper lock nut position. ensure clearance between kickdown cable bracket and upper lock nut is 0. Use lock nut and adjusting nut on cable bracket to adjust free play. securely tighten lower adjusting nut to bracket. . 8 and 13..... (1) RPM 3000-3400 (1) . See IDLE SPEED SPECIFICATIONS table under IDLE SPEED. DASHPOT ADJUSTMENT TABLE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Swift DOHC ...... 12) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company. See Figs. (1) RPM 2150-2250 2100-2300 .Engine speed when throttle lever contacts dashpot rod after deceleration.... See Fig... See DASHPOT ADJUSTMENT table. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ THROTTLE OPENER Samurai 1) Ensure transmission is in Neutral or Park.ADJUSTMENTS Article Text (p.. Disconnect and plug vacuum hose from throttle opener on throttle body... If engine speed is not within specification........ Warm engine to operating temperature. 10...D . Turn all accessories off.. adjust by turning throttle opener adjusting screw.............. Turn all accessories off........ Reconnect vacuum hose when adjustment is within specification. Turn ignition on for 5 seconds..... LLC Thursday.. Set parking brake....... Return engine to idle speed.............. Adjust dashpot adjusting screw to specified RPM at which dashpot rod should contact throttle lever... April 08.. Turn all accessories off... and then start engine.. 1999 09:26AM Swift DOHC 1) Ensure transmission is in Park or Neutral and parking brake is set... If engine speed is not within specification.. See Fig...... Disconnect and plug vacuum hose from throttle opener on throttle body....... and set parking brake.... See THROTTLE OPENER SPECIFICATIONS table... 10... Reconnect vacuum hose when adjustment is within specification.... THROTTLE OPENER SPECIFICATIONS TABLE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Samurai . adjust by turning throttle opener adjusting screw. 2) Engine speed should increase to 2100-2300 RPM when vacuum hose is removed from throttle opener.. Ensure idle speed is within specification. Sidekick TBI ........... Run engine at 2000 RPM for 5 minutes to warm it to operating temperature. 2) Engine speed should increase to 2150-2250 RPM when vacuum hose is removed from throttle opener.. See THROTTLE OPENER SPECIFICATIONS table... Sidekick (TBI) 1) Ensure transmission is in Neutral or Park...... 2) Operate throttle lever to increase and decrease engine RPM while noting RPM at which dashpot rod contacts throttle lever. and warm it to operating temperature...... Start engine.............. . ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Fig.5 mm) Clearance At Stop Screw ....... 0-500 With ..........80 mm) Clearance At Stop Screw ................ 0-500 With ................ 10: Adjusting Throttle Opener (Samurai & Sidekick TBI) Courtesy of Suzuki of America Corp.. THROTTLE POSITION SENSOR (TPS) THROTTLE POSITION SENSOR (TPS) RESISTANCE TABLE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Ohms Samurai Between Terminals "C" & "D" With .020" (.................. Infinity Between Terminals "A" & "D" ................ 3500-6500 .........D ..... 3500-6500 Between Terminals "B" & "D" At Idle (1) .... 3500-6500 Between Terminals "A" & "C" At Idle ........................... 300-2000 At Wide Open Throttle ..3 mm) Clearance At Stop Screw ......50 mm) Clearance At Stop Screw ...................Transaxle or transmission in Neutral or Park with vacuum hose disconnected and plugged at throttle opener.......................20 mm) Clearance At Stop Screw ..008" (........012" (..................... April 08............... 0-550 With .. (2) 2000-6500 Sidekick (MPI) Between Terminals "A" & "B" With ... 13) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company.....41 mm) Clearance At Stop Screw ...........016" (. 1999 09:26AM (1) ...................... LLC Thursday...031" (.......... (3) 2000-6500 Sidekick (TBI) Between Terminals "C" & "D" With .............................020" (.. 0-2000 At Wide Open Throttle ...............................ADJUSTMENTS Article Text (p... Infinity Between Terminals "A" & "D" ....... Infinity Between Terminals "A" & "D" ...... ........89 mm) Clearance At Stop Screw ......035" (.. and turn TPS fully clockwise. 2) If TPS inspection results are not within specification.. Insert ... Using hand vacuum pump.... Using ohmmeter... 10...... (1) 300-2000 At Wide Open Throttle ................ 3500-6500 Swift (SOHC) Between Terminals "A" & "B" With ......30 mm) shim thickness gauge between throttle lever and throttle stop screw.. See THROTTLE POSITION SENSOR (TPS) RESISTANCE table....ADJUSTMENTS Article Text (p...........30 mm) Clearance At Stop Screw ........... Hg vacuum to throttle opener to move throttle lever to idle position.......89 mm) Clearance At Stop Screw ..................... ........ and is used as zero reference point for all other adjustments.... See Fig............................ LLC Thursday.... Using hand vacuum pump........ Replace TPS if it cannot be adjusted to specification........ check resistance between upper and lower terminals of TPS connector with proper shim thickness gauge inserted between throttle valve lever and stop screw.. 0-500 With ..... Less Than 5000 With .. Infinity Between Terminals "A" & "D" ... 3500-6500 Between Terminals "C" & "B" At Idle ......................... 240-1140 At Wide Open Throttle .... April 08..... 0-2000 At Wide Open Throttle ........There should be more than 2000 ohms difference between idle and wide open throttle resistance... apply 19 in........ TPS Adjustment (Samurai) 1) Disconnect TPS harness connector and throttle opener vacuum hose....... Hg vacuum to throttle opener to move throttle lever to idle position. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ CAUTION: DO NOT rotate Samurai throttle stop screw to adjust idle...... 10.... 2) Connect ohmmeter between terminals "C" and "D" of TPS connector........ 11..................... 14) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company..... 3170-6600 (1) .. Loosen TPS mounting bolts....... Turn TPS counterclockwise slowly to find position ohmmeter reading changes from infinity to zero ohms..To obtain idle position... See Fig. Hg vacuum to throttle opener. Infinity Between Terminals "C" & "A" .............. 4370-8130 Between Terminals "A" & "C" At Idle .....012" (............ (2) 2000-6500 Swift (DOHC) Between Terminals "C" & "D" With .035" (.. apply 20 in..... apply 20 in......... 1999 09:26AM Between Terminals "B" & "D" At Idle ........ adjust TPS...30 mm) Clearance At Stop Screw .012" (...D ....012" (........ (2) ........ See Fig............ Throttle stop screw is factory-set.. TPS Inspection (Samurai) 1) Disconnect TPS connector... Tighten TPS mounting bolts at that position..... 14 and 15. Tighten TPS mounting screws to 22. If results are the same after readjusting. Unplug TPS connector. tighten TPS mounting screws snug.5 mm) shim thickness gauge is inserted between throttle lever and throttle stop screw. Start adjustment sequence again. 5) If continuity is not as specified in steps 3) and 4). See Fig. 4) Ensure continuity exists between terminals "A" and "B" when 0. Holding TPS at that position. replace TPS. See THROTTLE POSITION SENSOR (TPS) RESISTANCE table. . 15.8 mm) shim thickness gauge is inserted between throttle lever and throttle stop screw. 4) Ensure continuity exists between terminals "C" and "D" when .5-4. Loosen TPS mounting screws. TPS zero adjustment is incorrect.037" (0. Connect ohmmeter between TPS terminals "A" and "B". 3) Ensure continuity does not exist between terminals "A" and "B" when 0. (2. After final adjustment is completed. Sensor (TPS) Term. See Figs. Unplug TPS connector. See THROTTLE POSITION SENSOR (TPS) RESISTANCE table.026" (0. adjust TPS installation angle. April 08.40 mm) shim thickness gauge is inserted between throttle lever and throttle stop screw.8-38.016" (0.008" (0. 11: Throttle Pos.m). check resistance between terminals of TPS connector. TPS Inspection (Sidekick MPI) Disconnect negative battery cable. Using ohmmeter. 3) Ensure continuity does not exist between terminals "C" and "D" when . TPS Adjustment (Sidekick MPI) 1) Disconnect negative battery cable. and check resistance.20 mm) shim thickness gauge is inserted between throttle lever and throttle stop screw. LLC Thursday.020" (0. and then turn it clockwise slowly to locate point where ohmmeter reading changes from zero to infinity.D . 15) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company.65 mm) shim thickness gauge between throttle lever and throttle stop screw. ID (Samurai & Sidekick TBI) Courtesy of Suzuki of America Corp. reconnect TPS connector and vacuum hose to throttle opener. and insert . 4 INCH lbs. Replace TPS if it cannot be adjusted to specification. 2) Turn TPS fully counterclockwise. 1999 09:26AM Fig.ADJUSTMENTS Article Text (p.5 N. If idle switch check is not within specification. 3) After verifying adjustment. adjust TPS. check resistance with selected shim thickness gauges between throttle stop screw and throttle lever. (3. See Fig. Record number of turns. 11.016" (. reconnect TPS connector. Using ohmmeter. tighten mounting screws to 30 INCH lbs. Throttle stop screw is factory-set. apply 19 in. Using hand vacuum pump. If TPS cannot be adjusted to obtain correct values at terminals "C" and "D". Using ohmmeter. 12 and 13. replace TPS. Turn idle speed adjusting screw inward number of turns previously recorded. See IDLE SPEED. Recheck resistance between each pair of terminals. replace TPS. Connect ohmmeter between terminals "C" and "D". TPS Adjustment (Sidekick TBI) 1) Disconnect TPS harness connector and throttle opener vacuum hose. CAUTION: DO NOT adjust Swift DOHC throttle stop screw to adjust idle. If results are the same after readjusting. Turn TPS fully clockwise.m. Holding TPS at this position. April 08. Slowly rotate TPS counterclockwise to locate position where ohmmeter readings changes from infinity to zero ohms. 2) Insert . TPS zero adjustment is incorrect. 11.ADJUSTMENTS Article Text (p.4 N. and is used as zero reference point for all other adjustments. replace TPS. After final adjustment is completed. Hg vacuum to throttle opener to move throttle lever to idle position. TPS Inspection (Sidekick TBI) Disconnect negative battery cable. reconnect TPS harness connector and throttle opener vacuum hose. If necessary. See Fig. loosen idle speed adjusting screw until clearance is obtained between throttle lever and adjusting screw. Counting number of turns. Repeat TPS INSPECTION (SIDEKICK TBI) to verify correct adjustment and operation. LLC Thursday. . 1999 09:26AM 5) If continuity is not as specified in steps 3) and 4). If resistances are not as specified. Disconnect TPS harness connector. check resistance between each pair of terminals. See THROTTLE POSITION SENSOR (TPS) RESISTANCE table. readjust idle speed. See Figs. See THROTTLE POSITION SENSOR (TPS) RESISTANCE table.40 mm) thickness gauge between idle speed adjusting screw and throttle lever. Loosen TPS mounting screws. If TPS cannot be adjusted to obtain correct values.D . TPS Inspection (Swift DOHC) Unplug TPS connector. Start adjustment sequence again. 16) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company.). 1999 09:26AM Fig. Fig. and then slowly rotate TPS counterclockwise to locate position at which ohmmeter reading changes from zero to infinity.025" (. Holding TPS at that position. See Fig. Tighten TPS mounting screws to . 2) Connect ohmmeter between terminals "C" and "D". 13: Inserting Shim Thickness Gauge (Swift DOHC) Courtesy of Suzuki of America Corp. 13. tighten mounting screws snug. 12. LLC Thursday. 17) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company.30 mm) shim thickness gauge is inserted between throttle lever and throttle stop screw. April 08. Place a .035" (0. 4) Ensure continuity exists between terminals "C" and "D" when 0.012" (0. See Fig. TPS Adjustment (Swift DOHC) 1) Unplug TPS connector. Turn TPS fully clockwise.63 mm) shim thickness gauge between throttle lever and throttle stop screw.ADJUSTMENTS Article Text (p.90 mm) shim thickness gauge is inserted between throttle lever and throttle stop screw. 3) Ensure continuity does not exist between terminals "C" and "D" when 0. 12: Throttle Position Sensor (TPS) Terminal ID (Swift DOHC) Courtesy of Suzuki of America Corp.D . and loosen TPS mounting screws. replace TPS. reconnect TPS connector. After final adjustment is completed. Throttle stop screw is factory-set.m).4 N. See Figs. ID (Swift SOHC Shown.ADJUSTMENTS Article Text (p. CAUTION: DO NOT adjust Swift SOHC throttle stop screw to adjust idle. check resistance between terminals of TPS connector with proper shim thickness gauge inserted between throttle lever and throttle stop screw. Fig. 15: Throttle Position Sensor (TPS) Term. 14: Inserting Shim Thickness Gauge (Sidekick MPI & Swift SOHC) Courtesy of Suzuki of America Corp. LLC Thursday. If results are the same after readjusting. April 08. Sidekick MPI Is Similar) Courtesy of Suzuki of America Corp. 14 and 15. 1999 09:26AM 30 INCH lbs. and is used as zero reference point for all other adjustments. . TPS zero adjustment is incorrect. TPS Inspection (Swift SOHC) Unplug TPS connector. 18) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company. Fig. Using ohmmeter. Start adjustment sequence again.(3. 5) If continuity is not as specified in steps 3) and 4).D . See THROTTLE POSITION SENSOR (TPS) RESISTANCE table. If results are the same after readjusting.(2. If resistance is not 33-39 ohms.60 mm) shim thickness gauge between throttle lever and throttle stop screw. blow into top hose. 2) Turn TPS fully counterclockwise. 4) Ensure continuity exists between terminals "A" and "B" when 0. Insert . 3) Ensure continuity does not exist between terminals "A" and "B" when 0. and loosen TPS mounting screws. disconnect vacuum hoses from 3-way joints.012" (0. April 08. Air should pass through hoses. POWER STEERING VSV Disconnect VSV connector. Tighten TPS mounting screws to 18 INCH lbs. Turn TPS clockwise to locate position ohmmeter reading changes from zero to infinity.ADJUSTMENTS Article Text (p. replace VSV. 19) 1993 Suzuki Swift For 111 Copyright © 1998 Mitchell Repair Information Company.D . Start adjustment sequence again. replace VSV. and check resistance between terminals. END OF ARTICLE . Air should not come out of other hose. See Fig. Holding TPS at that position.m). 15.30 mm) shim thickness gauge is inserted between throttle lever and throttle stop screw. LLC Thursday. tighten TPS mounting screws snug. TPS zero adjustment is incorrect. If resistance is 33-39 ohms. reconnect TPS connector.90 mm) shim thickness gauge is inserted between throttle lever and throttle stop screw. 5) If continuity is not as specified in steps 3) and 4).024" (. replace TPS. With 12 volts and ground applied to terminals. Blow into top hose.035" (0.0 N. If results are not as described. Connect ohmmeter between TPS terminals "A" and "B". 1999 09:26AM TPS Adjustment (Swift SOHC) 1) Unplug TPS connector. After final adjustment is completed.