What is the procedure for changing the engine oil?

Use SE, SF, SG, SH or SJ grade engine oil. Before draining engine oil, check for leaks. Drain oil by removing drain plug and reinstall securely with torque of 50 N·m (5.0 kg-m, 36.0 lb-ft). After draining, replace the filter, apply proper torque, fill to full level on dipstick after a three-minute run cycle, and check again until correct level is reached.

What are the warning signs for a failing clutch pedal?

Check free travel of pedal and height ensuring it is within proper range, typically about 5 – 20 mm (0.2-0.8 in). Refer to Section 7C for adjustment if necessary.

What precautions are given for raising the vehicle safely?

Before lifting the car up with hoists or jacks, place safety stands to ensure that body does not slide off and is supported securely. Avoid contact of hoist arm with brake pipes, fuel pipes, brackets etc.

Maruti Suzuki Zen — Manual, FAQ & Troubleshooting

Name: Maruti Suzuki Zen
Brand: Maruti

Page 1

#### IMPORTANT WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.

|WARNING: Indicates a potential hazard that could result in death or injury.| |---|

|CAUTION: Indicates a potential hazard that could result in vehicle damage.| |---|

NOTE: Indicates special information to make maintenance easier or instructions clearer.

|WARNING: This service manual is intended for authorized Maruti dealers and qualified service mechanics only. Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the driver and passengers.| |---|

|![image 1](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile1.png)| |---|

|TABLE OF CONTENTS|SECTION| |---|---| |GENERAL INFORMATION General Information Maintenance and Lubrication|0B

0A| |HEATING AND AIR CONDITIONING

Air Conditioning (If Equipped)|1B|

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CONTENTS HOW TO USE THIS MANUAL 0A- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRECAUTIONS 0A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Precautions 0A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Catalytic Converter 0A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Electrical Circuit Service 0A- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Circuit Inspection Procedure 0A- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermittent and Poor Connection 0A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precaution for Installing Mobile Communication Equipment 0A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IDENTIFICATION INFORMATION 0A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Identification Number 0A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Identification Number 0A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Identification Number 0A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE LIFTING POINTS 0A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ABBREVIATIONS MAY BE USED IN THIS MANUAL 0A-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . METRIC INFORMATION 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metric Fasteners 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fasteners Strength Identification 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Tightening Torque 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

#### HOW TO USE THIS MANUAL

1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a CONTENTS on the first page of EACH SECTION, where the main items in that section are listed.

2) Each section of this manual has its own pagination. It is indicated at the top of each page along with the Section name.

3) The SPECIAL TOOL usage and TORQUE SPECIFICATION are given as shown in figure below.

||![image 2](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile2.png)

1. Flywheel bolts or drive plate bolts for A/T vehicle| |---|

6) Install oil pump. Refer to “Oil pump”.
7) Install flywheel (for M/T vehicle) or drive plate (for A/T vehicle). Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts to specified torque.

Special Tool (A): 09924-17810 Tightening Torque (c): 78 N.m (7.8 kg-m, 56.0 lb-ft)| |---|

4) A number of abbreviations are used in the text. For their full explanations, refer to “ABBREVIATIONS MAY BE USED IN THIS MANUAL” of this section.

5) The SI, metric and foot-pound systems are used as units in this manual.

6) DIAGNOSIS are included in each section as necessary.

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7) At the end of each section, there are descriptions of SPECIAL TOOLS, REQUIRED SERVICE MATERIALS and TIGHTENING TORQUE SPECIFICATIONS that should be used for the servicing work described in that section.

PRECAUTIONS GENERAL PRECAUTIONS

The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply.

|WARNING: Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING POINTS” on SECTION 0A. When it is necessary to do service work with the engine running, make sure that the parking brake is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for automatic transmission vehicles), Keep hands, hair, clothing, tools, etc. away from the fan and belts when the engine is running. When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors. Do not perform service work in areas where combustible materials can come in contact with a hot exhaust system. When working with toxic or flammable materials (such as gasoline and refrigerant), make sure that the area you work in is well-ventilated. To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tailpipe, muffler, etc. New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or used oil. Keep new and used oil and used engine oil filters away from children and pets. Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory animals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing engine oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil, recycle or properly dispose of used oil and filters. Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly during driving, obstructing your view and resulting in an accident.| |---|

|![image 3](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile3.png)| |---|

###### CAUTION:

Before starting any service work, cover fenders, seats and any other parts that are likely to get scratched or stained during servicing. Also, be aware that what you wear (e.g, buttons) may cause damage to the vehicle’s finish.

|![image 4](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile4.png)| |---|

When performing service to electrical parts that does not require use of battery power, disconnect the negative cable of the battery.

|![image 5](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile5.png)|

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0B

#### CONTENTS

PERIODIC MAINTENANCE SCHEDULE 0B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SERVICE 0B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 0B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition System 0B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System 0B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emission Control System 0B-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake 0B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chassis and Body 0B-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Inspection 0B-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RECOMMENDED FLUIDS AND LUBRICANTS 0B-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

#### PERIODIC MAINTENANCE SCHEDULE

|Interval: This interval should be judged by odometer reading or months, whichever comes first.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.| |---|---|---|---|---|---|---|---|---|---|---|---| |Interval: This interval should be judged by odometer reading or months, whichever comes first.|Km (x 1,000)|1|5|10|20|30|40|50|60|70|80| |Interval: This interval should be judged by odometer reading or months, whichever comes first.|Months|1|6|12|24|36|48|60|72|84|96| |ENGINE|ENGINE|ENGINE|ENGINE|ENGINE|ENGINE|ENGINE|ENGINE|ENGINE|ENGINE|ENGINE|ENGINE| |1. Water pump drive belt (tension, wear)|1. Water pump drive belt (tension, wear)|A|I|I|I|I|I|I|R|A|I| |2. Engine coolant (level, leakage)|2. Engine coolant (level, leakage)|I|I|I|R|I|R|I|R|I|R| |3. Engine oil (API GRADE SF, SG, SH) & Oil filter|3. Engine oil (API GRADE SF, SG, SH) & Oil filter|R|I|R|R|R|R|R|R|R|R| |4. Cooling system hoses and connections (leakage, damage)|4. Cooling system hoses and connections (leakage, damage)|I| | | |I|I| |I| |I| |5. Engine bolts (All cylinder head and manifold fixings)|5. Engine bolts (All cylinder head and manifold fixings)|—|—|T|—|T|—|T|—|T|—| |6. Engine mounting (loose, damage)|6. Engine mounting (loose, damage)|—|—|T|—|T|—|T|—|T|—| |7. Valve clearance|7. Valve clearance|—|A|—|A|—|A|—|A|—|A| |8. Camshaft timing belt (damage, wear)|8. Camshaft timing belt (damage, wear)|—|—|—|I|—|I|—|I|—|I| |8. Camshaft timing belt (damage, wear)|8. Camshaft timing belt (damage, wear)|Rep|ace e|ery 1|00,00|km| | | | | |

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|9. Exhaust system (noise, leakage or otherwise defective)|9. Exhaust system (noise, leakage or otherwise defective)|—|I|—|I|—|I|—|I|—|I| |10. Positive crankcase ventilation System (Hoses, connections and valve)|10. Positive crankcase ventilation System (Hoses, connections and valve)|—| | | |—|I| |I| |I| |IGNITION|IGNITION| | | | | | | | | | | |1. Ignition wiring, (damage, deterioration)|1. Ignition wiring, (damage, deterioration)|—|—|—|I|—|I|—|I|—|I| |2. Distributor cap and rotor (wear, deterioration)|2. Distributor cap and rotor (wear, deterioration)|—|—|—|I|—|I|—

|I|—|I| |3. Spark plugs (clean and adjust the gap)|3. Spark plugs (clean and adjust the gap)|—|—|I| |I|R| |R| |R| |FUEL|FUEL| | | | | | | | | | | |1. Air cleaner|Paved-road|Cle|n eve|y 5,0|0 km|Rep|ace e|ery|0,00|km.| | |1. Air cleaner|Dusty condition|Clea km.|ever ore f|2,50 eque|km. t repl|r as r cem|quire nt if|. Rep ust c|ace e nditio|ery 4 is se|,000 ere.| |2. Accelerator cable and Throttle shafts|2. Accelerator cable and Throttle shafts|—|I&L|I&L|I&L|I&L|I&L|I&L|I&L|I&L|I&L| |3. Fuel tank cap, fuel lines & connections (leakage, damage)|3. Fuel tank cap, fuel lines & connections (leakage, damage)|—| | |—|—|I| |—|—|I| |4. Fuel filter (leakage)|4. Fuel filter (leakage)|I|I|I|I|I|R|I|I|I|R| |CLUTCH AND TRANSMISSION|CLUTCH AND TRANSMISSION| | | | | | | | | | | |1. Clutch pedal (play)|1. Clutch pedal (play)|I| | | |I|I| |I| |I| |2. Clutch slipping (dragging or excessive damage)|2. Clutch slipping (dragging or excessive damage)|I| | | |I|I| |I| |I| |3. Manual Transmission/Transfer and Differential oil (level, leakage)|3. Manual Transmission/Transfer and Differential oil (level, leakage)|I| | |R|I|R|I|R|I|R| |4. Automatic Transmission Fluid (Level, Leakage)|4. Automatic Transmission Fluid (Level, Leakage)|I| | | |I|I| |I| |R| |5. Hose Automatic Transmission Fluid|5. Hose Automatic Transmission Fluid|I| | | |I|I| |I| |I|

Notes: "A" : Adjust. "I" : Inspect and correct or replace if necessary "T" : Tighten to specified torque. "C" : Clean. "R" : Replace or change. "O" : Rotate. "L" : Lubricate.

############## MAINTENANCE AND LUBRICATION 0B-3

|Interval: This interval should be judged by odometer reading or months, whichever comes first.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.| |---|---|---|---|---|---|---|---|---|---|---|---|

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Notes: "A" : Adjust. "I" : Inspect and correct or replace if necessary "T" : Tighten to specified torque. "C" : Clean. "R" : Replace or change. "O" : Rotate. "L" : Lubricate.

|Interval: This interval should be judged by odometer reading or months, whichever comes first.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.|This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals respectively.| |---|---|---|---|---|---|---|---|---|---|---|---| |Interval: This interval should be judged by odometer reading or months, whichever comes first.|Km (x 1,000)|1|5|10|20|30|40|50|60|70|80| |Interval: This interval should be judged by odometer reading or months, whichever comes first.|Months|1|6|12|24|36|48|60|72|84|96| |STEERING|STEERING|STEERING|STEERING|STEERING|STEERING|STEERING|STEERING|STEERING|STEERING|STEERING|STEERING| |1. Steering wheel (play, loose)|1. Steering wheel (play, loose)|I|I|I|I|I|I|I|I|I|I| |2. All rods and arms (loose, damage, wear)|2. All rods and arms (loose, damage, wear)|I| | | |I|I| |I| |I| |ELECTRICAL|ELECTRICAL| | | | | | | | | | | |1. Battery electrolyte (level, leakage)|1. Battery electrolyte (level, leakage)|I| | | |I|I| |I| |I| |2. Wiring harness connection (looseness, damage)|2. Wiring harness connection (looseness, damage)|—|I|I|I|I|I|I|I|I|I| |3. Lighting system (operation, stains, damage)|3. Lighting system (operation, stains, damage)|I| | | |I|I| |I| |I| |4. Horn (operation)|4. Horn (operation)|I| | | |I|I| |I| |I| |5. System voltage|5. System voltage|—|I|I|I|I|I|I|I|I|I| |BODY|BODY| | | | | | | | | | | |1. All chassis bolts and nuts (tighten)|1. All chassis bolts and nuts (tighten)|—|I|T|T|T|T|T|T|T|T| |2. All Latches, Hinges & Locks (function)|2. All Latches, Hinges & Locks (function)|I|I&L|I&L|I&L|I&L|I&L|I&L|I&L|I&L|I&L| |ROAD TEST|ROAD TEST| | | | | | | | | | | |1. Operation of Brakes, Gear shifting & speedometer|1. Operation of Brakes, Gear shifting & speedometer|I| | | |I|I| |I| |I| |2. Body and Chassis noise|2. Body and Chassis noise|I| | | |I|I| |I| |I| |AIR CONDITIONER (if equipped)|AIR CONDITIONER (if equipped)| | | | | | | | | | | |1. Check belt tension|1. Check belt tension|I|I|I|I|I|I|I|I|I|I| |2. Check receiver drier bubbles|2. Check receiver drier bubbles|I|I|I|I|I|I|I|I|I|I| |3. Tighten compressor mounting bolts|3. Tighten compressor mounting bolts|—|T|T|T|T|T|T|T|T|T| |4. Check all hose joints, tighten if necessary|4. Check all hose joints, tighten if necessary|I|I|I|I|I|I|I|I|I|I|

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DIAGNOSIS GENERAL DIAGNOSIS TABLE

|Condition|Possible Cause|Correction| |---|---|---| |Cool air won’t come out (A/C system won’t operative)|No refrigerant Fuse blown

A/C switch faulty Blower fan motor switch faulty A/C evaporator thermistor faulty Dual pressure switch faulty Wiring or grounding faulty ECT sensor faulty ECM and its circuit faulty|Recover, evacuation and charging. Check “HEATER” fuse, “A/C” fuse, “Fusible Link” and check short circuit to ground. Check A/C switch. Check blower fan motor switch. Check A/C evaporator thermistor. Check dual pressure switch. Repair as necessary. Check ECT sensor. Check ECM and its circuit.| |Cool air won’t come out (A/C compressor won’t operative (won’t rotative))|Fuse blown

A/C compressor relay faulty ECM faulty Magnet clutch faulty Drive belt loosen or broken A/C compressor faulty|Check “A/C” fuse, “Fusible Link” and check short circuit to ground. Check A/C compressor relay. Check ECM and its circuit. Check magnet clutch. Adjust or replace drive belt. Check A/C compressor.| |Cool air won’t come out A/C condenser cooling fan motor won’t operative)|Fuse blown

A/C condenser cooling fan relay faulty Wiring or grounding faulty A/C condenser cooling fan relay faulty A/C condenser cooling fan motor faulty|Check “A/C” fuse, “Fusible Link” and check short circuit to ground. Check A/C condenser cooling fan relay.

Repair as necessary. Check A/C condenser fan relay.

Check A/C condenser cooling fan motor.| |Cool air won’t come out (Blower motor won’t operative)|Fuse blown

Blower motor resistor faulty Blower fan motor switch faulty Wiring or grounding faulty Blower fan motor faulty|Check “HEATER” fuse and check short circuit to ground. Check blower fan motor resistor. Check blower fan motor switch. Repair as necessary. Check blower fan motor.|

|Condition|Possible Cause|Correction| |---|---|---| |Cool air won’t come out or insufficient cooling (A/C system normal operative)|Insufficient or excessive charge of refrigerant Condenser clogged A/C evaporator clogged or frosted

A/C evaporator thermistor faulty Expansion valve faulty Receiver/dryer clogged Drive belt slipping Magnetic clutch faulty A/C compressor faulty Air in A/C system

Air leaking from cooling unit or air duct Heater and ventilation system faulty

Blower motor faulty Excessive compressor oil existing in A/C system|Check charge of refrigerant. Check system for leaks. Check condenser. Check A/C evaporator and A/C evaporator thermistor. Check A/C evaporator thermistor. Check expansion valve. Check receiver/dryer. Check or replace drive belt. Check magnetic clutch. Check A/C compressor. Replace receiver/dryer, and evacuation and charging. Repair as necessary. Check air inlet box. Check heater control lever assembly. Check heater unit. Check blower motor. Pull out compressor oil in A/C system circuit, and replace compressor.| |Cool air won’t come out only intermittently|Wiring connection faulty Expansion valve faulty Excessive moisture in A/C system

Magnetic clutch faulty Excessive charge of refrigerant|Repair as necessary. Check expansion valve. Replace receiver/dryer, and evacuation and charging. Check magnetic clutch. Check charge of refrigerant.| |Cool air comes out only at high speeds|A/C condenser clogged Insufficient charge of refrigerant Air in A/C system

Drive belt slipping A/C compressor faulty|Check A/C condenser. Check charge of refrigerant. Replace receiver/dryer, and evacuation and charging. Check or replace drive belt. Check A/C compressor.| |Cool air won’t come out only at high speeds|Excessive charge of refrigerant Evaporator frosted|Check charge refrigerant. Check A/C evaporator. Check A/C evaporator thermistor.| |Insufficient velocity of cooled air|Evaporator clogged or frosted

Air leaking from cooling unit or air duct Blower motor faulty Wiring or grounding faulty|Check A/C evaporator. Check A/C evaporator thermistor. Repair as necessary. Check blower motor. Repair as necessary.|

DIAGNOSIS OF ABNORMAL NOISE There are various types of noise, ranging from those produced in the engine compartment to those from the passenger compartment, also from rumbling noises to whistling noises.

ABNORMAL NOISE FROM COMPRESSOR

|Condition|Possible Cause|Correction|

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|Gauges should read as follows when ambient temperature is 30 C.|Gauges should read as follows when ambient temperature is 30 C.| |---|---| |Pressure on high pressure gauge (HI):|1.18 – 1.47 MPa 12.0 – 15.0 kg/cm2| |Pressure on high pressure gauge (LO):|0.2 – 0.3 MPa 2.0 – 3.0 kg/cm2|

|![image 96](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile96.png)

Temp. at Evaporator Air Inlet

Temp. at Center Duct Air Outlet| |---|

10) Check inlet port temperature-to-outlet port temperature relationship using graph at the left. For example, if evaporator inlet port temperature is 25 C and center duct air outlet temperature is 8 C, their crossing point is within acceptable range as shown in graph at the left.

11) If crossing point is out of acceptable range, diagnose trouble referring to following Performance Diagnosis table.

###### PERFORMANCE DIAGNOSIS TABLE

| |TESTING RESULTS|POSSIBLE CAUSE|REMEDY| |---|---|---|---| |SSURE GAUGEHIGH PRE

|Pressure high (“A” area of high side graph)|Refrigerant overcharged Expansion valve frozen or clogged Clogged refrigerant passage of high side Condenser fan malfunction Insufficient

cooling of Dirty or bent condenser fins condenser Compressor malfunction (Insufficient oil etc.) Engine overheat|Recharge Check expansion valve Clean or replace Check condenser fan

Clean or repair Check compressor Check engine cooling system| |SSURE GAUGEHIGH PRE

|Pressure low (“B” area of high side graph)|Insufficient refrigerant (Insufficient charge or leakage) Expansion valve malfunction (valve opens too wide) Compressor malfunction (Insufficient compression)|Check for leakage, repair if necessary and recharge Check expansion valve

Check compressor| |E GAUGELOW PRESSURE

|Pressure high (“A” area of low side graph)|Expansion valve malfunction (valve opens too wide) Compressor malfunction (Insufficient compression)|Check expansion valve

Check compressor| |E GAUGELOW PRESSURE

|Pressure low (“B” area of low side graph)|Insufficient refrigerant (Insufficient charge or leakage) Expansion valve malfunction (valve opens too narrow) Clogged refrigerant passage (crashed pipe)|Check for leakage, repair if necessary and recharge Check expansion valve

Repair or replace| |MOMETER AT

ER DUCT THERM

CENT

|Outlet air temperature at center duct is high (Crossing point is in area “A”)|Insufficient or excessive charge of refrigerant Dirty or bent evaporator fins Air leakage from cooling (heater) unit or air duct Malfunctioning, switchover function of damper in cooling (heater) unit Compressor malfunction|Check refrigerant pressure Clean or repair Repair or replace Repair or replace

Check compressor| |MOMETER AT

ER DUCT THERM

CENT

|Outlet air temperature at center duct is low (Crossing point is in area “B”)|Insufficient air volume from center duct (Heater blower malfunction) Compressor malfunction|Check blower motor and fan Check compressor|

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NOTE: If ambient temperature is within 30 – 35 C, it is possible to do using next page table for detail diagnosis.

###### DETAIL DIAGNOSIS TABLE (AT AMBIENT TEMPERATURE WITHIN 30 – 35 C)

|MPa

MANIFOLD kg/cm2 GAUGE psi|MPa

MANIFOLD kg/cm2 GAUGE psi|CONDITION

|POSSIBLE CAUSE

|CORRECTION

| |---|---|---|---|---| |Lo|Hi|CONDITION

|POSSIBLE CAUSE

|CORRECTION

| |0.2 – 0.3 2.0 – 3.0 28.4 – 42.6|1.18 – 1.47 12.0 – 15.0 170 – 213|Normal condition.| | | |Negative pressure|0.5 – 0.6 5 – 6 71.2 – 85.3|The low pressure side reads a negative pressure, and the high pressure side reads an extremely low pressure. Presence of frost around tubing to and from receiver/ dryer and expansion valve.|Dust particles or water droplets are either stuck or frozen inside expansion valve, preventing the refrigerant from flowing. Gas leak from heat-sensitizing tube is preventing refrigerant flow.|Clean expansion valve. Replace it if it cannot be cleaned. Replace receiver/dryer. Evacuate the A/C system and recharge with fresh refrigerant. If heat-sensitizing tube is defective, replace expansion valve.| |Normal:

0.2 – 0.3 2.0 – 3.0 28.4 – 42.6

Abnormal: Negative pressure|Normal:

1.18 – 1.47 12.0 – 15.0 170 – 213 Abnormal:

0.69 – 0.98 7 – 10 99.4 – 142|During A/C operation, the low pressure side sometimes indicates negative pressure, and sometimes normal pressure. Also high pressure side reading fluctuates between the abnormal and normal pressure.|Expansion valve is frozen due to moisture in the system, and temporarily shuts off the refrigeration cycle.|Replace expansion valve. Replace receiver/dryer. Evacuate A/C system and recharge with fresh refrigerant.| |0.05 – 0.1 0.5 – 1.0 7.1 – 14.2|0.69 – 0.98 7 – 10 100 – 142

|Both low and high pressure sides indicate low readings. Continuous air bubbles are visible through sight glass. Output air is slightly cold.|Insufficient refrigerant in system. (Refrigerant leaking)|Using a gas leak detector, check for leaks and repair as necessary. Recharge refrigerant to a specified amount. If the pressure reading is almost 0 when the manifold gauges are attached, check for any leaks, repair them, and evacuate the system.| |0.4 – 0.6 4 – 6 56.9 – 85.3|0.69 – 0.98 7 – 10 100 – 142

|Pressure on low pressure side is high. Pressure on high pressure side is low. Both pressure becoming equal right after A/C is turned OFF.|Internal leak in compressor.|Inspect compressor and repair or replace as necessary.| |0.25 – 0.3

25 302.5 – 3.0 35.6 – 42.6

|1.96 – 2.45 20 2520 – 25 285 – 355

|High pressure reading on both low and high pressure sides. Air bubbles are not visible even when engine rpm is lowered.|Overcharged A/C system. Faulty condenser cooling operation. Faulty condenser fan operation.|Adjust refrigerant to specified amount. Clean condenser. Inspect and repair condenser fan.| |0.25 – 0.3

25 302.5 – 3.0 35.6 – 42.6

|1.96 – 2.45 20 2520 – 25 285 – 355

|High pressure reading on both low and high pressure sides. Low pressure side tubing is not cold when touched. Air bubbles are visible through sight glass.|Presence of air in A/C system. (Improperly evacuated)|Replace receiver/dryer. Inspect quantity of compressor oil and presence of contaminants in oil. Evacuate system and recharge with fresh refrigerant.| |0.3 – 0.4 3.0 – 4.0 42.7 – 56.8|1.86 – 1.96 19 – 20 271 – 284|High pressure reading on both low and high pressure sides. Large amount of frost or dew on the low pressure side tubing.|Faulty expansion valve or improper attachment of heat-sensitizing tube. Refrigerant flow is not regulated properly.|Inspect if heat-sensitizing tube is properly attached. Replace expansion valve.|

#### WIRING CIRCUIT

|![image 97](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile97.png)

1. Blower fan motor
2. Blower fan motor resistor
3. Blower fan motor switch
4. Dual pressure switch
5. A/C Switch
6. Fuse box
7. A/C condenser cooling fan relay
8. A/C condenser cooling fan motor
9. Compressor

10. Main fuse box
11. Ignition switch
12. A/C evaporator thermistor
13. ECT sensor
14. Compressor relay
15. Alternator
16. Battery
17. A/C fuse holder
18. Fusible link
| |---|

|![image 98](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile98.png)

![image 99](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile99.png)

Fig. A
Fig. B
| |---|

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|---|---|---|---|---|---| |E03-01|B|ECM main ground|Ground to body (Fig A)|–0.4 – 0 volt|Engine running| |E03-02|B/R|Main power supply for ECM|Ground to engine (Fig B)|10 – 14 volts|Ignition switch ON with engine stopped| |E03-13|BI/B|ECM ground for power circuit|Ground to body (Fig A)|–0.4 – 0 volt|Engine running| |E03-15|B/R|Power supply for ECM power circuit|Ground to engine (Fig B)|10 – 14 volts|Ignition switch ON with engine stopped| |E03-19E03-19

|G/R

|Main relay driveMain relay drive

|Ground to engine (Fig B)

|0.5 – 1.2 volt|Ignition switch ON with engine stopped| |E03-19E03-19

|G/R

|Main relay driveMain relay drive

|Ground to engine (Fig B)

|0 volt|Ignition switch OFF| |E03-26|BI/B|ECM ground for power circuit|Ground to body (Fig A)|–0.4 – 0 volt|Engine running| |E01-09E01-09

|P/B|Electric load negative input (blowertive in ut (blower fan load)

|Ground to engine (Fig B)

|0 – 1.5 volt|Blower fan motor switch ON with engine running| |E01-09E01-09

|P/B|Electric load negative input (blowertive in ut (blower fan load)

|Ground to engine (Fig B)

|8 – 14 volts|Blower fan motor switch OFF with engine running| |E01-19E01-19

|G/W

|A/C switch inputA/C switch in ut

|Ground to engine (Fig B)

|0 – 1.5 volts|Blower fan motor switch and A/C switch ON with engine running| |E01-19E01-19

|G/W

|A/C switch inputA/C switch in ut

|Ground to engine (Fig B)

|8 – 14 volts|Blower fan motor switch or A/C switch OFF with engine running| |E02-07|V/W

|Evaporator thermistor temperature (EVAP temp sensor) input

|Ground to engine (Fig B)|2.33 volts (2341 )|Evaporator thermistor temperature at approx. 15 C (59 F) with engine running| |E02-07|V/W

|Evaporator thermistor temperature (EVAP temp sensor) input

|Ground to engine (Fig B)|3.09 volts (4693 )|Evaporator thermistor temperature at approx. 2 C (35.6 F) with engine running

*If the temperature is less than approx. 2 C, in this case compressor and condenser fan should be stop (come back at more than approx. 3.5 C (less than 4064 , 3.00 V))| |E02-08

|Lg/B|Engine coolant temperature sensor input

|Ground to engine (Fig B)|0.74 volts (305 )|Engine coolant temperature at approx. 80 C (176 F) with engine running| |E02-08

|Lg/B|Engine coolant temperature sensor input

|Ground to engine (Fig B)|0.41 volts (142 )|Engine coolant temperature at approx. 110 C (230 F) with engine running

*If the temperature is more than 110 C (142 ), in this case compressor and condenser fan should be stop (come back at less than 108 C (more than 149 , 0.43 V)| |E02-09|B/Or|Sensor common ground|Ground to engine (Fig A)|–0.4 – 0 volt|Engine running| |E02-16

|Br/Y

|Compressor magnet clutch relay and A/C condenser fan relay output

|Ground to engine (Fig B)

|0 – 1 volt|Blower fan motor switch and A/C switch ON with engine running at evaporator thermistor temperature input more than approx. 3.5 C (less than 3.00 V (4064

)) and/or ECT sensor input less than 108 C (more than 0.43 V (149 ))| |E02-16

|Br/Y

|Compressor magnet clutch relay and A/C condenser fan relay output

|Ground to engine (Fig B)

|10 – 14 volts|Except the above-mentioned with engine running|

|![image 102](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile102.png)| |---|

#### A/C COMPRESSOR DRIVE BELT INSPECTION

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(9) (Hi) of manifold gauge set (3). If there is no blockage in the system, there will be an indication on high pressure gauge (10). When this occurs, open the other-side valve (8) (Lo) of the set.

5) Approx. 10 minutes later, low pressure gauge (11) should show a vacuum lower than –760 mmHg providing no leakage exists.

NOTE: If the system does not show a vacuum below –760 mmHg, close both valves, stop vacuum pump and watch movement of low pressure gauge. Increase in the gauge reading suggests existence of leakage. In this case, repair the system before continuing its evacuation. If the gauge shows a stable reading (suggesting no leakage), continue evacuation.

6) Evacuation should be carried out for a total of at least 15 minutes.

7) Continue evacuation until low pressure gauge indicates a vacuum less than –760 mmHg, and then close both valves (8), (9).

8) Stop vacuum pump (7). Disconnect center charging hose (6) from pump inlet. Now, the system is ready for charging refrigerant.

#### CHARGING

|CAUTION: ALWAYS CHARGE THROUGH LOW PRESSURE-SIDE of A/C system at after the initial charging is performed from the high-pressure side with the engine stopped. NEVER CHARGE TO HIGH PRESSURE-SIDE of A/C system with engine running. Do not charge while compressor is hot. When installing tap valve to refrigerant container to make a hole there through, carefully follow directions given by manufacturer. A pressure gauge should always be used before and during charging. The refrigerant container should be emptied of refrigerant when discarding it. The refrigerant container should not be heated up to 40 C or over. Refrigerant container should not be reversed in direction during charging. Reversing in direction causes liquid refrigerant to enter compressor, causing troubles, such as compression of liquid refrigerant and the like.

| |---|

NOTE: The air conditioning system contains CFC-12 (R-12). Described here is a method to charge the air conditioning system with refrigerant from the refrigerant service container. When charging refrigerant recovered by using the refrigerant and recycling equipment (when recycling refrigerant), follow the procedure described in the equipment manufacturer’s instruction manual.

|![image 106](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile106.png)| |---|

CHARGING PROCEDURE The initial charging of the A/C system is performed from the highpressure side with the engine stopped. And next, this method must be followed by charging from the lowpressure side with the engine running.

1) Check to make sure that hoses are routed properly after evacuating the system.

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|CAUTION: None of refrigerant, compressor oil and component parts is interchangeable between two types of A/C: one using CFC-12 (R-12) and the other using HFC-134a (R-134a). (For identification between these two types, refer to page 1B-2). When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced. Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.| |---|

NOTE When servicing air conditioning system, the following rules must be observed. PIPING

|![image 111](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile111.png)

1. Suction hose: Apply compressor oil (refrigerant oil) to O-ring.
2. Discharge hose: Apply compressor oil (refrigerant oil) to O-ring.
3. Receiver/dryer outlet pipe: Apply compressor oil (refrigerant oil) to O-ring.
4. Condenser outlet pipe: Apply compressor oil (refrigerant oil) to O-ring.
5. Expansion valve: Apply compressor oil (refrigerant oil) to O-ring.
6. Dual pressure switch: Apply compressor oil (refrigerant oil) to O-ring.
7. Suction pipe: Apply compressor oil (refrigerant oil) to O-ring.

![image 112](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile112.png)

![image 113](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile113.png)

![image 114](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile114.png)

![image 115](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile115.png)

![image 116](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile116.png)

![image 117](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile117.png)

![image 118](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile118.png)| |---|

Never use heat for bending pipes. When bending a pipe, try to make its bending radius as slight as possible. Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system, install a blind plug or cap to the fitting immediately. When connecting hoses and pipes,apply a few drops of compressor oil (refrigerant oil) to seats of coupling nuts and O-ring. When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.

Tighten flared nuts according to Table of Tightening Torque as shown below:

Tightening Torque (Flared Nut Used for) 8mm pipe: 13 N·m (1.3 kg-m, 9.5 lb-ft) 14.5 mm pipe: 23 N·m (2.3 kg-m, 16.6 Ib-ft) 16 mm pipe: 33 N·m (3.3 kg-m, 23.8 Ib-ft)

Route drain hose so that drained water does not make any contact to vehicle components.

HANDLING REFRIGERANT CFC-12 (R-12) When handling refrigerant, always wear goggles to protect your eyes. Avoid you direct contact to liquid refrigerant. Do not heat refrigerant container higher than 40 C. Do not discharge refrigerant into atmosphere. Do not allow liquid refrigerant to touch bright metals. Refrigerant combined with moisture is corrosive and will tarnish surfaces of bright metals including chrome. After recovering refrigerant from system, the amount of compressor oil removed must be measured and the same amount added to the system.

###### REFRIGERANT RECOVERY

When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment. Discharging refrigerant CFC-12 (R-12) into atmosphere would cause adverse effect to environments

NOTE: When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.

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SECTION 3B1

ELECTRICAL POWER STEERING (EPS) SYSTEM

3B1

#### CONTENTS

GENERAL DESCRIPTION 3B1- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components 3B1- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System circuit 3B1- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGNOSIS 3B1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On-board diagnostic system 3B1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions in diagnosing troubles 3B1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System check flow table 3B1- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC check 3B1- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC clearance 3B1- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC table 3B1- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC 11 Torque sensor main sensor circuit failure 3B1- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC 13 Torque sensor main and sub sensor circuit failure 3B1- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC 15 Torque sensor sub sensor circuit failure 3B1- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC 14 Torque sensor 5V power supply circuit failure 3B1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC 21/23/24 VSS circuit failure 3B1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC 22 Engine speed signal circuit failure 3B1-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC 41/42/43/44/45 Motor circuit failure 3B1-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC 51 Clutch circuit failure 3B1-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC 53 P/S control module power supply circuit failure 3B1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC 52/54/55 P/S control module failure 3B1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection of P/S control module circuit 3B1-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trouble diagnosis (for trouble not indicated by on-board diagnostic system) 3B1-18. . . . . . . . . . . . . . . . . . . . . . . . . . Steering wheel inspection 3B1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering force inspection 3B1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 3B1-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering column assembly 3B1-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking steering column assembly and lower shaft for accident damage 3B1-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . P/S control module 3B1-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque sensor 3B1-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor assembly (with clutch incorporated) 3B1-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL DESCRIPTION

COMPONENTS This electrical power steering (EPS) system consists of a P/S control module, a torque sensor, a motor assembly (with clutch incorporated) installed to the steering column. In this system, the P/S control module determines the level and direction of the assist force for the steering wheel according to the signals from the torque sensor and the vehicle speed, runs the motor so as to assist operation of the steering wheel.

|![image 214](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile214.png)

1. Steering wheel
2. Steering column assembly
3. P/S control module
4. Torque sensor
5. Motor assembly (with clutch incorporated)
6. Steering gear box
7. Battery
| |---|

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PRECAUTIONS IN DIAGNOSING TROUBLES Take a note of DTC indicated first. Be sure to read “PRECAUTIONS FOR ELECTRONIC CIRCUIT SERVICE” in Section 0A before inspection and observe what is written there. When two or more troubles have occurred, their DTCs are indicated three times each starting with the smallest code number and up. DTC 22 (engine speed signal failure) is indicated when ignition switch is ON position and engine is not running but if indication changes to a normal one when engine is started, it means nothing abnormal. As DTC is stored in memory of P/S control module, be sure to clear memory after repair by performing the procedure described in “DTC CLEARANCE”.

#### SYSTEM CHECK FLOW TABLE

|STEP|ACTION|YES|NO| |---|---|---|---| |1|1) Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown below will facilitate collecting information to the point required for proper analysis and diagnosis.
2) Check if what the customer claimed in “CUSTOMER QUESTIONNAIRE” is actually found in the vehicle and if that symptom is found, whether it is identified as a failure. (This step should be shared with the customer if possible.)
3) Check DTC referring to “DTC CHECK” in this section and record the DTC(s).
4) Clear DTC if any malfunction DTC exists referring to “DTC CLEARANCE” in this section, then recheck DTC.

Is any malfunction DTC detected?|Go to Step 2.|Go to Step 3.| |2|1) Inspect and repair referring to applicable diagnostic trouble code table in this section.
2) Clear DTC referring to “DTC CLEARANCE” in this section.

Does the trouble recur?|Go to Step 5.|Go to Step 4.| |3|1) Test drive the vehicle and turn steering wheel fully to the right and left during test driving. See WARNING 1. Check if any trouble symptom exists.
2) Inspect and repair basic parts referring to “DIAGNOSIS CHART” in Section 3.
3) If the trouble cannot be repaired in Step 3-2), inspect and repair referring to “TROUBLE DIAGNOSIS (FOR TROUBLE NOT INDICATED BY ON-BOARD DIAGNOSTIC SYSTEM)” in this section.

Does the trouble recur?|Go to Step 5.|Go to Step 4.| |4|Confirm that the problem symptom has gone and P/S system is free from any abnormal conditions. If what has been repaired is related to the malfunction DTC, clear the DTC once and perform test driving as in Step 3-1) and confirm that no DTC is indicated. Does the trouble recur?|Go to Step 5.|END.| |5|Check DTC referring to “DTC CHECK” in this section Is any malfunction DTC detected?|Go to Step 2.|Go to Step 3.|

|WARNING 1: Carry out test in very little traffic area to prevent an accident.| |---|

NOTE: As execution of DTC CLEARANCE will clear all malfunction DTCs, be sure to record all DTCs before servicing. When 2 or more codes are indicated, the lowest numbered code will appear first. If a code not listed on the table is displayed, then the P/S control module is faulty. DTC 22 is indicated when ignition switch is ON and engine is not running but if DTC 12 is indicated when engine is started, it means nothing abnormal.

###### CUSTOMER QUESTIONNAIRE (EXAMPLE)

|Customer’s name:|Model:|VIN:|VIN:| |---|---|---|---| |Date of issue:|Date Reg:|Date of problem:|Mileage:|

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#### DTC CLEARANCE

1) Turn ignition switch to ON position.

2) Using service wire, short diagnosis output terminal (1) to ground terminal (2) of monitor coupler (3).

3) After keeping them connected for 4 seconds or longer, disconnect one end of service wire (open) and within 2 seconds after that, make the disconnected end of service wire contact where disconnected (short) and repeat these actions (open and short) at least five times within 10 seconds.

4) Perform DTC CHECK and confirm that normal DTC (DTC 12) is displayed and not malfunction DTC.

#### DTC TABLE

|CAUTION: Be sure to perform “SYSTEM CHECK FLOW TABLE” before starting diagnosis according to flow table of each DTC.| |---|

|![image 221](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile221.png)

Voltage between diagnosis switch terminal and ground terminal

Example: When VSS circuit fail (DTC 21) is set

High

Low

TIME (sec.)|![image 221](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile221.png)

Voltage between diagnosis switch terminal and ground terminal

Example: When VSS circuit fail (DTC 21) is set

High

Low

TIME (sec.)|![image 221](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile221.png)

Voltage between diagnosis switch terminal and ground terminal

Example: When VSS circuit fail (DTC 21) is set

High

Low

TIME (sec.)|![image 221](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile221.png)

Voltage between diagnosis switch terminal and ground terminal

Example: When VSS circuit fail (DTC 21) is set

High

Low

TIME (sec.)| |---|---|---|---| |DTC|VOLTMETER DEFLECTION PATTERN|DIAGNOSTIC ITEM|DIAGNOSIS| |12|![image 222](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile222.png)|Normal|This code appears when none of the other codes are identified.| |11|![image 223](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile223.png)|Torque sensorTorque sensor|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

| |13|![image 224](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile224.png)|Torque sensorTorque sensor|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

| |14|![image 225](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile225.png)|Torque sensorTorque sensor|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

| |15|![image 226](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile226.png)|Torque sensorTorque sensor|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

| |21|![image 227](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile227.png)|VSS signal|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

| |23|![image 228](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile228.png)|VSS signal|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

| |24|![image 229](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile229.png)|VSS signal|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

| |22|![image 230](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile230.png)|Engine speed signal|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

|

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|41|![image 231](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile231.png)|Motor|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

| |42|![image 232](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile232.png)|Motor|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

| |43|![image 233](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile233.png)|Motor|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

| |44|![image 234](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile234.png)|Motor|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

| |45|![image 235](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile235.png)|Motor|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

| |51|![image 236](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile236.png)|Clutch|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

| |52|![image 237](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile237.png)|P/S control module|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

| |54|![image 238](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile238.png)|P/S control module|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

| |55|![image 239](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile239.png)|P/S control module|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

| |53|![image 240](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile240.png)|P/S control module power supply|Diagnose trouble according to “DIAGNOSTIC FLOW TABLE”“DIAGNOSTIC FLOW TABLE” corresponding to each code No.

|

#### DTC 11 TORQUE SENSOR MAIN SENSOR CIRCUIT FAILURE

#### DTC 13 TORQUE SENSOR MAIN AND SUB SENSOR CIRCUIT FAILUREDTC 15 TORQUE SENSOR SUB SENSOR CIRCUIT FAILURE

|![image 241](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile241.png)

![image 242](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile242.png)

1. To main fuse
2. Ignition switch
3. “P/S” fuse (30A) in fuse box
4. “IG. COIL METER” fuse (15A) in fuse box

5. P/S control module
6. Torque sensor
7. Connector “E41”
8. Connector “X02”
| |---|

|STEP|ACTION|YES|NO| |---|---|---|---| |1|Was “SYSTEM CHECK FLOW TABLE” performed?|Go to Step 2.|Go to “SYSTEM CHECK FLOW TABLE” in this section.| |2|Is DTC 14 or 16 indicated, too?|Go to flow table corresponding to each DTC No.|Go to Step 3.| |3|1) Remove steering wheel hole cover.
2) Check proper connection to P/S control module.
3) If OK, turn ignition switch to ON position.
4) Hold steering wheel at position for run straight.
5) Check voltage between “X02-5” (“W” wire) terminal and “X02-3” (“G” wire) terminal with “X02” connector connected to P/S control module.

Is it about 2.5V?|Go to Step 4.|Repair high resistance, open or short to power circuit or ground in torque sensor main sensor “X02-5” (“W” wire) circuit and recheck.| |4|1) Check voltage between “X02-4” (“B” wire) terminal and “X02-3” (“G” wire) terminal with “X02” connector connected to P/S control module.

Is it about 2.5V?|Go to Step 5.|Repair high resistance, open or short to power circuit or ground in torque sensor sub sensor “X02-4” (“B” wire) circuit and recheck.|

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ENGINE

#### CONTENTS

GENERAL INFORMATION 6- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE DIAGNOSIS 6- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

On-Board Diagnostic System 6- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precaution in Diagnosing Troubles 6- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Diagnostic Flow Table 6- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Diagnosis Table 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

GENERAL INFORMATION STATEMENT ON CLEANLINESS AND CARE

An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated.

A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surfaces on initial operation. Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal bearings are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts.

|![image 270](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile270.png)

1. No.1 cylinder
2. No.2 cylinder
3. No.3 cylinder
4. No.4 cylinder
| |---|

|![image 271](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile271.png)| |---|

Throughout this manual, the four cylinders of the engine are identified by numbers: No.1, No.2, No.3 and No.4 as counted from crankshaft pulley side to flywheel side.

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#### GENERAL INFORMATION ON ENGINE SERVICE

THE FOLLOWING INFORMATION ON ENGINE SERVICE SHOULD BE NOTED CAREFULLY, AS IT IS IMPORTANT IN PREVENTING DAMAGE, AND IN CONTRIBUTING TO RELIABLE ENGINE PERFORMANCE.

When raising or supporting engine for any reason, do not use a jack under oil pan. Due to small clearance between oil pan and oil pump strainer, jacking against oil pan may cause it to be bent against strainer resulting in damaged oil pick-up unit. It should be kept in mind, while working on engine, that 12-volt electrical system is capable of violent and damaging short circuits. When performing any work where electrical terminals could possibly be grounded, ground cable of the battery should be disconnected at battery. Any time the air cleaner, air intake hose, throttle body or intake manifold is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material which could follow intake passage into cylinder and cause extensive damage when engine is started. When disconnecting couplers, don’t pull wire harness but make sure to hold coupler itself. With lock type coupler, be sure to unlock before disconnection. Attempt to disconnect coupler without unlocking may result in damage to coupler. When connecting lock type coupler, insert it till clicking sound is heard and connect it securely.

|![image 272](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile272.png)| |---|

PRECAUTION ON FUEL SYSTEM SERVICE Work must be done with no smoking, in a well-ventilated area and away from any open flames. As fuel feed line (between fuel pump and fuel pressure regulator) is still under high fuel pressure even after engine was stopped, loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened or disconnected. Before loosening or disconnecting fuel feed line, make sure to release fuel pressure according to FUEL PRESSURE RELIEF PROCEDURE. A small amount of fuel may be released after the fuel line is disconnected. In order to reduce the chance of personal injury, cover the fitting to be disconnected with a shop cloth. Put that cloth in an approved container when disconnection is completed. Never run engine with fuel pump relay disconnected when engine and exhaust system are hot. Fuel or fuel vapor hose connection varies with each type of pipe. When reconnecting fuel or fuel vapor hose, be sure to connect and clamp each hose correctly referring to left figure. After connecting, make sure that the hose has no twist or kink. When installing fuel union bolt gasket, always use new gasket and tighten union bolt to specified torque. See Section 6C for specified torque. When installing injector, fuel feed pipe or fuel pressure regulator, lubricate its O-ring with gasoline. When connecting fuel pipe flare nut, first tighten flare nut by hand and then tighten it to specified torque.

|![image 273](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile273.png)| |---|

###### FUEL PRESSURE RELIEF PROCEDURE

|CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst.| |---|

After making sure that engine is cold, relief fuel pressure as follows.

1) Place transmission gear shift lever in “Neutral” (shift selector lever to “P” range for A/T vehicle), set parking brake, and block drive wheels.

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|3|Visual Inspection

1) Perform visual inspection referring to the “Visual

Inspection” in this section. Is there any faulty condition?|1) Repair or replace malfunction part.
2) Go to Step 11.

|Go to Step 5.| |4|Visual Inspection

1) Perform visual inspection referring to the “Visual

Inspection” in this section. Is there any faulty condition?|1) Repair or replace malfunction part.
2) Go to Step 11.

|Go to Step 8.| |5|Trouble Symptom Confirmation

1) Confirm trouble symptom referring to the “Trouble-

Symptom Confirmation” in this section. Is trouble symptom identified?|Go to Step 6.|Go to Step 7.| |6|Rechecking and Record of DTC

1) Recheck for DTC referring to “DTC Check” in Section 6E1. Is there any DTC(s)?|Go to Step 9.

|Go to Step 8.| |7|Rechecking and Record of DTC

1) Recheck for DTC referring to “DTC Check” in Section 6E1. Is there any malfunction DTC(s)?|Go to Step 9.

|Go to Step 10.| |8|Engine Basic Inspection and Engine Diagnosis Table

1) Check and repair according to “Engine Basic Check”

and “Engine Diagnosis Table” in this section. Are check and repair complete?|Go to Step 11.

|1) Check and repair malfunction part(s).
2) Go to Step 11.

| |9|Trouble shooting for DTC

1) Check and repair according to applicable DTC diag.

flow table in Section 6E1. Are check and repair complete?|Go to Step 11.

|1) Check and repair malfunction part(s).
2) Go to Step 11.

| |10|Check for Intermittent Problems

1) Check for intermittent problems referring to “Check for

Intermittent Problem” in this section. Is there any faulty condition?|1) Repair or replace malfunction part(s).
2) Go to Step 11.
|Go to Step 11.| |11|Final Confirmation Test

1) Clear DTC if any.
2) Perform final confirmation test referring to “Final Confirmation Test” in this section.

Is there any problem symptom, malfunction DTC or abnormal condition?|Go to Step 6.|End.|

1. CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.

###### CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE)

|User name:|Model:|VIN:|VIN:| |---|---|---|---| |Date of issue:|Date of Reg.:|Date of problem:|Mileage:|

|PROBLEM SYMPTOMS| |---| |Difficult Starting No cranking No initial combustion No combustion Poor starting at ( cold warm always) Other

Poor Driveability Hesitation on acceleration Back fire/ After fire Lack of power Surging Abnormal knocking Other

| |Poor idling Poor fast idle Abnormal idling speed ( High Low) ( r/min.) Unstable Hunting ( r/min. to r/min.) Other

Engine Stall when Immediately after start Axal. pedal is depressed Accel. pedal is released Load is applied

A/C Electric load P/S Other

Other

| |OTHERS:|

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|VEHICLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS|VEHICLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS| |---|---| |Environmental Condition|Environmental Condition| |Weather Temperature Frequency Road|Fair Cloudy Rain Snow Always Other Hot Warm Cool Cold ( F/ C) Always Always Sometimes ( times/ day, month) Only once Under certain condition Urban Suburb Highway Mountainous ( Uphill Downhill) Tarmacadam Gravel Other

| |Vehicle Condition|Vehicle Condition| |Engine Condition|Cold Warming up phase Warmed up Always Other at starting Immediately after start Racing without load Engine speed ( r/min)| |Vehicle condition|During driving: Constant speed Accelerating Decelerating Right hand corner left hand corner When shifting (Lever position ) At stop Vehicle speed when problem occurs ( km/h, Mile/h) Other|

|Malfunction indicator lamp condition|Always ON Sometimes ON Always OFF Good condition| |---|---| |Diagnostic troubleg code

|First check: No code Normal code Malfunction code ( )| |Diagnostic troubleg code

|Second check: No code Normal code Malfunction code ( )|

NOTE: The above form is a standard sample. It should be modified according to conditions characteristic of each market.

2. DIAGNOSTIC TROUBLE CODE (DTC) CHECK, RECORD AND CLEARANCE First, check DTC referring to “DTC Check” in Section 6E1. If DTC is indicated, print it or write it down and then clear it by referring to “DTC Clearance” in Section 6E1. DTC indicates malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored now. To check which case applies, check the symptom in question according to Step 5 and recheck DTC according to Step 6 or 7. Attempt to diagnose a trouble based on DTC in this step only or failure to clear the DTC in this step will lead to incorrect diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting.

3. and 4. VISUAL INSPECTION Be sure to perform visual check of the following items that support proper function of the engine.

|INSPECTION ITEM|REFERRING SECTION| |---|---| |Operation

Engine oil – – – – – level, leakage Engine coolant – – – – – level, leakage Fuel – – – – – level, leakage A/T fluid – – – – – level, leakage Air cleaner element – – – – – dirt, clogging Battery – – – – – fluid level, corrosion of terminal Water pump belt and/or cooling fan belt – – – – – tension, damage Throttle cable – – – – – play, installation Vacuum hoses of air intake system – – – – – disconnection, looseness, deterioration, bend Connectors of electric wire harness – – – – – disconnection, friction Fuses – – – – – burning Parts – – – – – installation, bolt – – – – – looseness Parts – – – – – deformation Other parts that can be checked visually

Also check following items at engine start, if possible Malfunction indicator lamp Charge warning lamp Engine oil pressure warning lamp Engine coolant temp. meter Fuel lever meter Abnormal air being inhaled from air intake system Exhaust system – – – – – leakage of exhaust gas, noise Other parts that can be checked visually|Section 0B Section 0B Section 0B Section 0B Section 0B

Section 0B Section 6E1

Section 8

Section 6E1 Section 6H Section 8 Section 8 Section 8|

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5. TROUBLE SYMPTOM CONFIRMATION Based on information obtained in Step 1 customer complaint analysis and Step 2 DTC check, confirm trouble symptoms. Also, reconfirm DTC according to “DTC Confirmation Procedure” in Section 6E1.

6. and 7. RECHECKING AND RECORD OF DTC Refer to “DTC Check” in section 6E1 for checking procedure.

8. ENGINE BASIC INSPECTION AND ENGINE DIAGNOSIS TABLE Perform basic engine check according to the “Engine Basic Inspection Flow Table” first. When the end of the flow table has been reached, check the parts of the system suspected as a possible cause referring to ENGINE DIAGNOSIS TABLE and based on symptoms appearing on the vehicle (symptoms obtained through steps of customer complaint analysis, trouble symptom confirmation and/or basic engine check) and repair or replace faulty parts, if any.

###### ENGINE BASIC INSPECTION FLOW TABLE

|STEP|ACTION|YES|NO| |---|---|---|---| |1|Was “ENGINE DIAG. FLOW TABLE” performed?|Go to Step 2.|Go to “ENGINE DIAG. FLOW TABLE”.| |2|Check battery voltage. Is it 11 V or more?|Go to Step 3.|Charge or replace battery.| |3|Is engine cranked?|Go to Step 4.|Go to “DIAGNOSIS” in section 6G.| |4|Does engine start?|Go to Step 5.|Go to Step 7.| |5|Check engine idle speed/IAC duty referring to “Idle Speed/IAC Duty Inspection” in section 6E1. Is check result as specified?|Go to Step 6.|Go to “ENGINE DIAGNOSIS TABLE” in this section.| |6|Check ignition timing referring to “Ignition Timing Inspection” in section 6F. Is check result as specified?|Go to “ENGINE DIAGNOSIS TABLE” in this section.|Adjust ignition timing.| |7|Check fuel supply as follows:

1) Check to make sure that enough fuel is filled in fuel tank.
2) Turn the ignition switch ON position for 3 seconds and then turn it OFF position. Repeat this a few times.

Is fuel return pressure (returning sounds) felt from fuel return hose when the ignition switch is turned ON position?|Go to Step 9.|Go to Step 8.| |8|Check fuel pump for operating.

1) Was fuel pump operating sound heard from fuel filler for about 3 seconds after turning the ignition switch ON position and stop?|Go to “Diag. Flow Table B-3” in section 6E1.|Go to “Diag. Flow Table B-1” in section 6E1.| |9|Check ignition spark referring to “Ignition Spark Test” in section 6F. Is it in good condition?|Go to Step 10.|Go to “DIAGNOSIS” in section 6F.| |10|Check fuel injector referring to “Fuel Injector Inspection” in section 6E1. Is it in good condition?|Go to “ENGINE DIAGNOSIS TABLE” in this section.|Go to “Diag. Flow Table B-2 in section 6E1.|

9. TROUBLESHOOTING FOR DTC Based on the DTC indicated in Step 6 or 7 and referring to the applicable DTC diag. flow table in Section 6E1, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ECM or other part and repair or replace faulty parts.

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10. CHECK FOR INTERMITTENT PROBLEM Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to “INTERMITTENT AND POOR CONNECTION” in Section 0A and related circuit of DTC recorded in step 2.

11. FINAL CONFIRMATION TEST Confirm that the problem symptom has gone and the engine is free from any abnormal conditions. If what has been repaired is related to the DTC, clear the DTC once, perform DTC confirmation procedure and confirm that no malfunction DTC (a normal code) is indicated.

#### ENGINE DIAGNOSIS TABLE

|Condition|Possible Cause|Reference Item| |---|---|---| |Hard starting (Engine cranks OK)|Engine and emission control system out of order.

Faulty CMP sensing rotor

Faulty idle air control system Faulty ECT sensor or MAP sensor

Faulty ECM

Low compression. Compression leak from valve seat Sticky valve stem Weak or damaged valve springs

Compression leak at cylinder head gasket

Sticking or damaged piston ring Worn piston, ring or cylinder

Others

Malfunctioning PCV valve|CMP sensing rotor inspection in section 6E1. Diag. Flow Table B-4 in Section 6E1. ECT sensor or MAP sensor in Section 6E1. Inspection of ECM and its circuit in Section 6E1. Compression check in Section 6A. Valves inspection in Section 6A. Valves inspection in Section 6A. Valves spring inspection in Section 6A. Cylinder head inspection in Section 6A. Piston ring inspection in Section 6A. Cylinders, pistons and piston rings inspection in Section 6A.

PCV system inspection in Section 6E1.|

|Condition|Possible Cause|Reference Item| |---|---|---| |Engine has no power|Engine overheating. Ignition system out of order.

Defective spark plug Faulty ignition coil

Fuel system out of order.

Fuel pressure out of specification

– Dirty fuel filter
– Dirty or clogged fuel hose or pipe
– Malfunctioning fuel pressure regulator
– Malfunctioning fuel pump

Engine and emission control system out of order.

Faulty injector Faulty TP sensor, ECT sensor or MAP sensor Faulty ECM

Low compression. Others

Dragging brakes Slipping clutch|Refer to “Overheating” Section.

Spark plugs in Section 6F. Ignition coil in Section 6F.

Diag. Flow Table B-3 in Section 6E1.

Fuel injector in Section 6E1. TP sensor, ECT sensor or MAP sensor in Section 6E1. Inspection of ECM and its circuit in Section 6E1.

Previously outlined.

Diagnosis in Section 5. Diagnosis in Section 7C.| |Improper engine idling or engine fails to idle|Ignition system out of order. Faulty spark plug Faulty ignition coil

Fuel system out of order.

Fuel pressure out of specification

– Malfunctioning fuel pressure regulator

Engine overheating. Engine and emission control system out of order.

Faulty idle air control system Faulty evaporative emission control system Faulty injector Faulty ECT sensor, TP sensor or MAP sensor Faulty ECM

Low compression. Others

Malfunctioning PCV valve|Spark plugs in Section 6F. Ignition coil in Section 6F.

Diag. Flow Table B-3 in Section 6E1.

Refer to “Overheating” Section.

Diag. Flow Table B-4 in Section 6E1.
Diag. Flow Table B-5 in Section 6E1. Fuel injector in Section 6E1. ECT sensor, TP sensor or MAP sensor in Section 6E1. Inspection of ECM and its circuit in Section 6E1.

Previously outlined.

PCV system inspection in Section 6E1.|

|Condition|Possible Cause|Reference Item| |---|---|---| |Engine hesitates (Momentary lack of response as the accelerator is depressed. Can occur at all vehicle speeds. Usually most severe when first trying to make the vehicle move, as from a stop sign.)|Ignition system out of order. Spark plug faulty or plug gap as out of adjustment

Fuel system out of order.

Fuel pressure out of specification

– Clogged fuel filter
– Faulty fuel pressure regulator Clogged fuel filter, hose or pipe

Engine overheating Engine and emission control system out of order.

Faulty injector Faulty TP sensor, ECT sensor or MAP sensor Faulty ECM

Low compression|Spark plugs in Section 6F.

Diag. Flow Table B-3 in Section 6E1.

Fuel pressure check in Section 6E1.

Refer to “Overheating” Section.

Fuel injector in Section 6E1. TP sensor, ECT sensor or MAP sensor in Section 6E1. Inspection of ECM and its circuit in Section 6E1. Previously outlined.| |Surges (Engine power variation under steady throttle or cruise. Feels like the vehicle speeds up and down with no change in the accelerator pedal.)|Ignition system out of order. Defective spark plug (excess carbon deposits, improper gap, and burned electrodes, etc.)

Fuel system out of order.

Variable fuel pressure

– Clogged fuel filter
– Kinky or damaged fuel hose and line
– Faulty fuel pressure regulator

Engine and emission control system out of order.

Faulty MAP sensor Faulty injector Faulty ECM|Spark plugs in Section 6F.

Diag. Flow Table B-3 in Section 6E1.

MAP sensor in Section 6E1. Fuel injector in Section 6E1. Inspection of ECM and its circuit in Section 6E1.|

|Condition|Possible Cause|Reference Item| |---|---|---| |Excessive detonation (The engine makes sharp metallic knocks that change with throttle opening. Sounds like pop corn popping.)

|Engine overheating Ignition system out of order.

Faulty spark plug Improper ignition timing

Fuel system out of order.

Clogged fuel filter and fuel lines

Engine and emission control system out of order.

Faulty ECT sensor or MAP sensor

Faulty injector Faulty ECM

Others

Excessive combustion chamber deposits

|Refer to “Overheating” Section.

Spark plugs in Section 6F. Ignition timing in Section 6F.

Fuel pressure check in Section 6E1.

ECT sensor or MAP sensor in Section 6E1. Fuel injector in Section 6E1. Inspection of ECM and its circuit in Section 6E1.

Piston and cylinder head cleaning in Section 6A.

|

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|Overheating|Inoperative thermostat Poor water pump performance Clogged or leaky radiator Improper engine oil grade

Clogged oil filter or oil strainer Poor oil pump performance Dragging brakes Slipping clutch Blown cylinder head gasket|Thermostat in Section 6B. Water pump in Section 6B. Radiator in Section 6B. Engine oil and oil filter change in Section 0B. Oil pressure check in Section 6A. Oil pressure check in Section 6A. Diagnosis in Section 5. Diagnosis in Section 7C. Cylinder head inspection in Section 6A.| |Poor gasoline mileage|Ignition system out of order. Faulty spark plug (improper gap, heavy deposits, and burned electrodes, etc..)

Engine and emission control system out of order.

Fuel pressure out of specification Faulty TP sensor, ECT sensor or MAP sensor Faulty injector Faulty ECM

Low compression Others

Poor valve seating Dragging brakes Slipping clutch Thermostat out of order Improper tire pressure|Spark plugs in Section 6F.

Diag. Flow Table B-3 in Section 6E1. TP sensor, ECT sensor or MAP sensor in Section 6E1. Fuel injector in Section 6E1. Inspection of ECM and its circuit in Section 6E1.

Previously outlined.

Valves inspection in Section 6A. Diagnosis in Section 5. Diagnosis in Section 7C. Thermostat in Section 6B.|

|Condition|Possible Cause|Reference Item| |---|---|---| |Excessive engine oil consumption|Oil entering combustion chamber Sticky piston ring Worn piston and cylinder

Worn piston ring groove and ring

Improper location of piston ring gap Worn or damaged valve stem seal

Worn valve stem|Piston cleaning in Section 6A. Cylinders, pistons and piston rings inspection in Section 6A. Pistons and piston rings inspection in Section 6A. Pistons installation in Section 6A. Valves and cylinder head in Section 6A. Valves inspection in Section 6A.| |Low oil pressure|Improper oil viscosity

Malfunctioning oil pressure switch

Clogged oil strainer

Functional deterioration of oil pump Worn oil pump relief valve Excessive clearance in various sliding parts|Engine oil and oil filter change in Section 0B. Oil pressure switch inspection in Section 8. Oil pan and oil pump strainer cleaning in Section 6A. Oil pump in Section 6A. Oil pump in Section 6A.| |Engine noise Note: Before checking the mechanical noise, make sure that:

Ignition timing is properly adjusted. Specified spark plug is used. Specified fuel is used.|Valve noise Improper valve lash Worn valve stem and guide Weak or broken valve spring

Warped or bent valve Loose camshaft housing bolts

Piston, ring and cylinder noise

Worn piston, ring and cylinder bore

Connecting rod noise

Worn crankpin bearing

Worn crankpin

Loose connecting rod nuts

Low oil pressure

Crankshaft noise Low oil pressure Worn crankshaft journal bearing

Worn crankshaft journal

Loose lower crankcase (bearing cap) bolts Excessive crankshaft thrust play|Valve lash in Section 6A. Valves inspection in Section 6A. Valve springs inspection in Section 6A. Valves inspection in Section 6A. Camshafts in Section 6A.

Pistons and cylinders inspection in Section 6A.

Crankpin and connecting rod bearing inspection in Section 6A. Crankpin and connecting rod bearing inspection in Section 6A. Connecting rod installation in Section 6A. Previously outlined.

Previously outlined. Crankshaft and bearing inspection in Section 6A. Crankshaft and bearing inspection in Section 6A. Crankshaft installation in Section 6A.

Crankshaft inspection in Section 6A.|

|Condition|Possible Cause|Referring Item| |---|---|---| |Excessive hydrocarbon (HC) emission or Excessive carbon monoxide (CO) emission|Ignition system out of order

Defective spark plug

Fuel system out of order

Fuel pressure out of specification

Engine and Emission control system out of order.

Lead contamination of three way catalytic converter (if equipped) Malfunctioning PCV valve Faulty EVAP control system

Closed loop system (A/F feed back compensation) fails

– Faulty TP sensor
– Faulty ECT sensor or MAP sensor
– Faulty O2 sensor Faulty injector Faulty ECM

Low compression|Fuel pressure check in Section 6E1.

Check for absence of filler neck restrictor. PCV valve in Section 6E1. EVAP control system check in Section 6E1. Check oxygen sensor output voltage referring to DTC No.14 Diag. Flow Table in Section 6E1.

Fuel injector in Section 6E1. Inspection of ECM and its circuit in Section 6E1.

Previously outlined.| |Excessive nitrogen oxides (NOx) emission|Fuel system out of order

Fuel pressure out of specification

Engine and emission control system Lead contamination of three way catalytic converter (if equipped) Closed loop system (A/F feed back compensation) fails

– Faulty TP sensor
– Faulty ECT sensor or MAP sensor
– Faulty O2 sensor Faulty injector Faulty ECM
|Fuel pressure check in Section 6E1.

Check for absence of filler neck restrictor. Check oxygen sensor output voltage referring to DTC No.14 Diag. Flow Table in Section 6E1.

Fuel injector Section 6E1. Inspection of ECM and its circuit in Section 6E1.|

SECTION 6A1

ENGINE MECHANICAL

#### CONTENTS

GENERAL DESCRIPTION 6A1- 2. . . . . . . . . . . . . Engine 6A1- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication 6A1- 3. . . . . . . . . . . . . . . . . .

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(a): 55 N.m (5.5 kg-m, 40.0 lb-ft)

(b): 40 N.m (4.0 kg-m, 29.0 lb-ft)

SPECIAL TOOLS

|![image 542](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile542.png)

1. 09915-64510-001 Compression gauge
2. 09915-64510-002 Connector
3. 09915-64530 Hose
4. 09915-67010 Attachment
|![image 543](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile543.png)

09915-67310 Vacuum gauge|![image 544](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile544.png)

09918-08210 Vacuum gauge hose joint|![image 545](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile545.png)

09915-77310 Oil pressure gauge| |---|---|---|---| |![image 546](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile546.png)

09917-18210 Tappet adjuster wrench|![image 547](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile547.png)

09926-18210 Oil seal guide (Vinyl resin)|![image 548](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile548.png)

09917-68221 Camshaft pulley holder|![image 549](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile549.png)

1. 09916-14510 Valve lifter
2. 09916-14910 Valve lifter attachment
| |![image 550](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile550.png)

09916-84511 Forceps|![image 551](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile551.png)

09916-44910 Valve guide remover|![image 552](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile552.png)

09916-34542 Reamer handle|![image 553](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile553.png)

09916-38210 Reamer (11 mm)| |![image 554](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile554.png)

09916-58210 Valve guide installer handle|![image 555](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile555.png)

09916-56011 Valve guide installer attachment|![image 556](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile556.png)

09916-34550 Reamer (5.5 mm)|![image 557](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile557.png)

09917-98221 Valve stem seal installer|

ENGINE MECHANICAL6A1-79

|![image 558](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile558.png)

09916-77310 Piston ring compressor|![image 559](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile559.png)

09924-17810 Flywheel holder| |---|---|

REQUIRED SERVICE MATERIALS

|MATERIALS|RECOMMENDED PRODUCT|USE| |---|---|---| |Sealant|SUZUKI BOND NO. 1207C (99000-31150)|Mating surfaces of cylinder block and oil pan.| |Sealant|SUZUKI BOND NO. 1215 (99000-31110)|Mating surfaces of camshaft housing (No.1 and No.6). Mating surfaces of distributor case and cylinder head. Mating surfaces of cylinder head cover gasket.|

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SECTION 6B

ENGINE COOLING

#### CONTENTS

GENERAL DESCRIPTION 6B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System Circulation 6B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Fan 6B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECT Sensor 6B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGNOSIS 6B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE 6B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant 6B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Level 6B- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System Service 6B- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System Flush and Refill 6B- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Pump Belt Tension 6B- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 6B- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System Draining 6B- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Water Pipes or Hoses 6B- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat 6B- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Pump Belt 6B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator 6B-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Pump 6B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REQUIRED SERVICE MATERIALS 6B-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6B

GENERAL DESCRIPTION

The cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan and thermostat. The radiator is of tube-and-fin type.

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6C

|CAUTION: AMONG THE VEHICLES OF THIS MODEL, THERE ARE THOSE EQUIPPED WITH A CATALYTIC CONVERTER AND THOSE WITHOUT ONE DEPENDING ON STATUTORY REGULATIONS OF EACH COUNTRY. FOR THOSE WITH A CATALYTIC CONVERTER, BE SURE TO USE UNLEADED FUEL ONLY. USE OF LEADED AND/OR LOW LEAD FUEL CAN RESULT IN ENGINE DAMAGE AND REDUCE THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEM.| |---|

GENERAL DESCRIPTION

FUEL SYSTEM The main components of the fuel system are fuel tank, fuel pump, fuel filter and fuel level gauge and it includes three lines; fuel feed line, fuel return line and fuel vapor line.

|![image 587](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile587.png)

1. Fuel tank
2. Fuel pump
3. Fuel level gauge
4. Fuel filter

5. Fuel filler cap
6. Tank pressure control valve
7. Black nozzle
8. Breather hose

9. Fuel feed line
10. Fuel return line
11. Fuel vapor line
12. Liquid-vapor separator
13. Roll over valve
| |---|

|![image 588](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile588.png)

Clamp securely at a position 3 to 7 mm (0.12 – 0.27 in.) from hose end.

With short pipe, fit hose as far as it reaches pipe joint as shown.

Clamp securely at a position 3 to 7 mm (0.12 – 0.27 in.) from hose end.

With following type pipe, fit hose as far as its peripheral projection as shown.

Clamp securely at a position 3 to 7 mm 10.12 – 0.27 in.) from hose end.

With bent pipe, fit hose as far as its bent part as shown or till pipe is about 20 to 30 mm (0.79-1.18 in.) into the hose.

Clamp securely at a position 3 to 7 mm (0.12 – 0.27 in.) from hose end.

With straight pipe, fit hose till pipe is about 20 to 30 mm (0.79-1.18 in.) in the hose.

20 to 30 mm (0.79 – 1.18 in.)

Pipe Hose

Clamp

Hose

Clamp| |---|

|![image 589](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile589.png)| |---|

ON-VEHICLE SERVICE

|WARNING: Before attempting service of any type on fuel system, following cautions should be always observed.

Disconnect negative cable at battery. DO NOT smoke, and place “NO SMOKING” signs near work area. Be sure to have CO2 fire extinguisher handy. Be sure to perform work in a well-ventilated area and away from any open flames (such as gas hot heater). Wear safety glasses. To relieve fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then reinstall it. As fuel feed line is still under high fuel pressure even after engine was stopped, loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened or disconnected. Before loosening or disconnecting fuel feed line, make sure to relieve fuel pressure according to procedure described on p. 6-4. A small amount of fuel may be released after the fuel line is disconnected. In order to reduce the chance of personal injury, cover the fitting to be disconnected with a shop cloth. Be sure to put that cloth in an approved container when disconnection is completed. Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each hose correctly referring to the left figure.| |---|

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B-10 Fuel Cut Operation Check 6E1-40. . . . . . . . Inspection of ECM (PCM) and Its

Circuits 6E1-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Check 6E1-41. . . . . . . . . . . . . . . . . . . . .

Resistance Check 6E1-44. . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 6E1-45. . . . . . . . . . . . . . . . General 6E1-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accelerator Cable Adjustment 6E1-45. . . . . . . . . Idle Speed/Idle Air Control (IAC)

Duty Inspection 6E1-46. . . . . . . . . . . . . . . . . . . . .

AIR INTAKE SYSTEM 6E1-48. . . . . . . . . . . . . . . . . . Throttle Body 6E1-48. . . . . . . . . . . . . . . . . . . . . . . . Idle Air Control Valve (IAC Valve) 6E1-51. . . . . .

FUEL DELIVERY SYSTEM 6E1-52. . . . . . . . . . . . . . Fuel Pressure Inspection 6E1-52. . . . . . . . . . . . . . Fuel Pump 6E1-53. . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pressure Regulator 6E1-54. . . . . . . . . . . . . . Fuel Injector 6E1-55. . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRONIC CONTROL SYSTEM 6E1-58. . . . . . ECM (PCM) 6E1-58. . . . . . . . . . . . . . . . . . . . . . . . . MAP Sensor 6E1-58. . . . . . . . . . . . . . . . . . . . . . . . TP Sensor 6E1-59. . . . . . . . . . . . . . . . . . . . . . . . . . IAT Sensor 6E1-61. . . . . . . . . . . . . . . . . . . . . . . . . . ECT Sensor 6E1-62. . . . . . . . . . . . . . . . . . . . . . . . . Main Relay 6E1-63. . . . . . . . . . . . . . . . . . . . . . . . . . Oxygen Sensor 6E1-64. . . . . . . . . . . . . . . . . . . . . . Fuel Pump Relay 6E1-65. . . . . . . . . . . . . . . . . . . . Fuel Cut Operation 6E1-65. . . . . . . . . . . . . . . . . . . CMP Sensor 6E1-65. . . . . . . . . . . . . . . . . . . . . . . . Radiator Fan Control System 6E1-66. . . . . . . . . . Radiator Fan Motor 6E1-66. . . . . . . . . . . . . . . . . . Radiator Fan Control Relay 6E1-66. . . . . . . . . . . VSS 6E1-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EVAP Emission Control System 6E1-68. . . . . . . . EVAP Canister Purge Valve 6E1-69. . . . . . . . . . . EVAP Canister 6E1-70. . . . . . . . . . . . . . . . . . . . . . . Tank Pressure Control Valve 6E1-71. . . . . . . . . . . PCV System 6E1-72. . . . . . . . . . . . . . . . . . . . . . . . PCV Hose 6E1-72. . . . . . . . . . . . . . . . . . . . . . . . . . PCV Valve 6E1-72. . . . . . . . . . . . . . . . . . . . . . . . . .

########### SPECIAL TOOLS 6E1-73. . . . . . . . . . . . . . . . . . . . . . TIGHTENING TORQUE SPECIFICATIONS 6E1-73

6E1

GENERAL DESCRIPTION

The engine and emission control system has 4 major sub-systems: air intake system, fuel delivery system, electronic control system and emission control system. Air intake system includes air cleaner, MAP sensor, throttle body, IAC valve and intake manifold.

Fuel delivery system includes fuel pump, delivery pipe, fuel pressure regulator, fuel injectors, etc. Electronic control system includes ECM (PCM), various sensors and controlled devices.

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|![image 613](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile613.png)| |---|

DIAGNOSIS The engine and emission control system in this vehicle are controlled by ECM (PCM). ECM (PCM) has an On-Board Diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full understanding of the outline of ON-BOARD DIAGNOSTIC SYSTEM and each item in PRECAUTION IN DIAGNOSING TROUBLE and execute diagnosis according to ENGINE DIAGNOSTIC FLOW TABLE in SECTION 6. ON-BOARD DIAGNOSTIC SYSTEM

ECM (PCM) performs on-board diagnosis (self-diagnosis) on the system and operates malfunction indicator lamp as follows.

Malfunction indicator lamp lights when the ignition switch is turned ON (but the engine at stop) regardless of the condition of engine and emission control system. This is only to check the malfunction indicator lamp bulb and its circuit. If the areas monitored by ECM (PCM) is free from any trouble after the engine start (while engine is running), malfunction indicator lamp turns OFF. When ECM (PCM) detects a trouble which has occurred in the areas,it makes malfunction indicator lamp turn ON while the engine is running to warn the driver of such occurrence of trouble and at the same time it stores the exact trouble area in ECM (PCM) back-up memory.

PRECAUTIONS IN DIAGNOSING TROUBLES Before identifying diagnostic trouble code, don’t disconnect couplers from ECM (PCM), battery cable from battery, ECM (PCM) ground wire harness from engine. Such disconnection will erase memorized trouble in ECM (PCM) memory. Be sure to read PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE in SECTION 0A before inspection and observe what is written there. ECM (PCM) replacement When substituting a known-good ECM (PCM), check for following conditions. Neglecting this check may cause damage to known-good ECM (PCM).

– Resistance value of all relays, actuators is as specified respectively.

– TP sensor and MAP sensor are in good condition and none of power circuits of these sensors is shorted to ground.

|![image 614](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile614.png)| |---|

#### MALFUNCTION INDICATOR LAMP (MIL) CHECK

1) Turn ON ignition switch (but engine at stop) and check that malfunction indicator lamp lights up. If lamp does not light up, go to DIAGNOSTIC FLOW TABLE A-1 in this section. If lamp flashes, go to DIAGNOSTIC FLOW TABLE A-2 in this section.

2) Start engine and check that malfunction indicator lamp turns OFF. If lamp remains ON, go to DTC CHECK NOT USING SUZUKI SCAN TOOL in this section.

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2) Disconnect battery negative cable for specified time below to erase diagnostic trouble code stored in ECM (PCM) memory and reconnect it. Time required to erase DTC:

|Ambient temperature|Time to cut power to ECM (PCM)| |---|---| |Over 0 C (32 F)|30 sec. or longer| |Under 0 C (32 F)|Not specifiable. Select a place with higher than 0 C (32 F) temperature.|

#### DIAGNOSTIC TROUBLE CODE (DTC) TABLE

|DIAGNOSTIC TROUBLE CODE NO.|DIAGNOSTIC TROUBLE CODE NO.|MALFUNCTION INDICATOR LAMP FLASHING PATTERN

|DIAGNOSTIC ITEMDIAGNOSTIC ITEM

|DIAGNOSIS

| |---|---|---|---|---| |SUZUKI SCAN TOOL|MIL

|MALFUNCTION INDICATOR LAMP FLASHING PATTERN

|DIAGNOSTIC ITEMDIAGNOSTIC ITEM

|DIAGNOSIS

| |P0105|11|![image 619](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile619.png)|Manifold absolute pressure sensor|Diagnose trouble according to DIAGNOSTIC FLOW TABLE corresponding to each code No.

| |P0120|13|![image 620](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile620.png)|Throttle position sensor|Diagnose trouble according to DIAGNOSTIC FLOW TABLE corresponding to each code No.

| |P0130|14|![image 621](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile621.png)|Oxygen sensor|Diagnose trouble according to DIAGNOSTIC FLOW TABLE corresponding to each code No.

| |P0340|15|![image 622](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile622.png)|Camshaft position sensor|Diagnose trouble according to DIAGNOSTIC FLOW TABLE corresponding to each code No.

| |P0500|16|![image 623](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile623.png)|Vehicle speed sensor|Diagnose trouble according to DIAGNOSTIC FLOW TABLE corresponding to each code No.

| |P0110|18|![image 624](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile624.png)|Intake air temperature sensor|Diagnose trouble according to DIAGNOSTIC FLOW TABLE corresponding to each code No.

| |P0115|19|![image 625](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile625.png)|Engine coolant temperature sensor|Diagnose trouble according to DIAGNOSTIC FLOW TABLE corresponding to each code No.

| |–––|12|![image 626](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile626.png)|Normal|This code appears when none of the other codes (above codes) are identified.|

#### (A/T ONLY)

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![image 639](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile639.png)

![image 640](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile640.png)

![image 641](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile641.png)

######### NOTE: Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page 6E1-33 to confirm that the trouble has been corrected.

#### CODE NO.13 (P0120) TP SENSOR CIRCUIT(SIGNAL VOLTAGE HIGH OR LOW)

|![image 642](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile642.png)

![image 643](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile643.png)

1. ECM (PCM)
2. ECM (PCM) connector
3. TP sensor
4. TP sensor connector
5. To MAP sensor
6. To other sensors

NOTE:

When Code No.11 (P0105), 13 (P0120), 18 (P0110) and 19 (P0115) are indicated together, it is possible that “B/ Or” wire is open or “E02-9” terminal connection are poor.| |---|

|STEP|ACTION|YES|NO| |---|---|---|---| |1|1) Disconnect TP sensor connector with ignition switch OFF.
2) Check voltage between “a” wire terminal of TP sensor connector and ground with ignition switch ON.

Is voltage about 4 – 5 V?|Go to Step 2.|“Gr/R” wire open or short. Poor “E02-1” connection.

If wire and connection are OK, substitute a known-good ECM (PCM) and recheck.| |2|1) Check voltage between “b” wire terminal of TP sensor connector and ground with ignition switch ON.

Is voltage about 4 – 5 V?|Go to Step 3.|“Gr” wire open or short. Poor “E02-6” connection.

If wire and connection are OK, substitute a known-good ECM (PCM) and recheck.| |3|1) Connect “b” and “c” wire terminal of TP sensor connector using service wire.
2) Check voltage between “b” wire terminal of TP sensor coupler and ground with ignition switch ON.

Is voltage about 0 V?|Go to Step 4.|“B/Or” wire open. Poor “E02-9” connection.

If wire and connection are OK, substitute a known-good ECM (PCM) and recheck.| |4|1) Perform TP SENSOR INSPECTION in this section. Is TP sensor in good condition?|Poor connection of TP sensor connector terminals. If connection is OK, substitute a knowngood ECM (PCM) and recheck.|Faulty TP sensor.|

![image 644](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile644.png)

![image 645](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile645.png)

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![image 646](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile646.png)

######### NOTE: Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page 6E1-33 to confirm that the trouble has been corrected.

#### CODE NO.14 (P0130) OXYGEN SENSOR CIRCUIT(SIGNAL VOLTAGE DOESN’T CHANGE)

|![image 647](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile647.png)

NOTE:

Before diagnosing trouble according to flow table given below, check to make sure that following system and parts other than Electronic Fuel Injection system are in good condition.

– Air cleaner (clogged)
– Vacuum leaks (air inhaling)
– Spark plugs (contamination, gap)
– High-tension cords (crack, deterioration)
– Ignition timing
– Engine compression
– Any other system and parts which might affect A/F mixture or combustion.

If code No.14 (P0130) and another code No. are indicated together, the latter has priority. Therefore, check and correct what is represented by that code No. first and then proceed to the following check. Be sure to use a voltmeter with high impedance (M /V minimum) or digital type voltmeter for accurate measurement.

1. ECM (PCM)
2. Oxygen sensor
3. Connector
| |---|

|STEP|ACTION|YES|NO| |---|---|---|---| |1|1) Warm up engine to normal operating temperature.
2) Connect voltmeter between E02-13 terminal of ECM coupler and body ground.
3) Maintain engine speed at 2000 rpm and after 60 seconds, check voltmeter.

Does the voltage deflect between above and below 0.45 V repeatedly?|Oxygen sensor and its circuit (closed loop system, A/F ratio feed back system) are in good condition. Intermittent trouble or faulty ECM (PCM). Recheck, referring to INTERMITTENT AND POOR CONNECTION in SECTION 0A.|Go to Step 2.| |2|Does the voltage remain unchanged at 0.45 V above?|“Bl” circuit shorted to power circuit or rich A/F mixture. If circuit is OK, check MAP sensor, ECT sensor, fuel pressure, injectors and their circuit. If all above are OK, check ECM (PCM) and its circuit.|Go to Step 3.| |3|1) Maintain engine speed at 2000 rpm for 60 seconds.
2) Check voltmeter while repeating racing engine.
3) Does it indicate 0.45 V or more even once?
|Poor E02-13 connection or lean A/F mixture. If connection is OK, check MAP sensor, ECT sensor, fuel pressure, injectors and their circuit. If all above are OK, check ECM and its circuit.|“Bl” circuit open/short or oxygen sensor malfunction. If wire and connection are OK, replace oxygen sensor and recheck.|

######### Fig. for STEP 1

![image 648](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile648.png)

1. ECM (PCM) connector connected

2. Body ground

######### NOTE: Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page 6E1-33 to confirm that the trouble has been corrected.

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|1|Check each injector for operating sound at engine cranking using sound scope. Do all 4 injector make operating sound?|Fuel injector circuit is in good condition.|Go to Step 2.| |2|Does none of 4 injectors make operating sound at Step 1?|Go to Step 4.|Go to Step 3.| |3|Check fuel injector(s) referring to p. 6E1-57. Is it in good condition?|Check coupler connection and wire harness of injector not making operating sound.|Faulty fuel injector(s).| |4|Check power circuit of injectors for open and short. Is it in normal condition?|Check all 4 injectors for resistance respectively. If resistance is OK, substitute a known-good ECM (PCM) and recheck.|Power circuit open or short.|

|![image 667](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile667.png)

1. Fuel Injector
2. Delivery pipe
3. Fuel regulator
4. Fuel filter
5. Fuel pump Special Tool

(A) Gauge (09912-58441)
(B) Hose (09912-58431)
(C) 3-way joint (09912-58490)
| |---|

|STEP|ACTION|YES|NO| |---|---|---|---| |1|1) Release fuel pressure from fuel feed line.
2) Install fuel pressure gauge.
3) Check fuel pressure by repeating ignition switch ON and OFF.

Is fuel pressure then 270 – 310 kPa (2.7 – 3.1 kg/cm2, 38.4 – 44.0 psi)?|Go to Step 2.|Go to Step 5.| |2|Is 200 kPa (2.0 kg/cm2, 28.4 psi) or higher fuel pressure retained for 1 minute after fuel pump is stopped at step 1?|Go to Step 3.|Go to Step 4.| |3|1) Start engine and warm it up to normal operating temperature.
2) Keep it running at specified idle speed. Is fuel pressure then within 200 – 240 kPa (2.0 – 2.4 kg/cm2, 28.4 – 34.1 psi)?
|Normal fuel pressure.|Clogged vacuum passage for fuel pressure regulator or faulty fuel pressure regulator.| |4|Is there fuel leakage from fuel feed line hose, pipe or their joint?|Fuel leakage from hose, pipe or joint.|Go to Step 10.| |5|Was fuel pressure higher than spec. in step 1?|Go to Step 6.|Go to Step 7.| |6|1) Disconnect fuel return hose from fuel pressure regulator and connect new return hose to it.
2) Put the other end of new return hose into approved gasoline container.
3) Operate fuel pump. Is specified fuel pressure obtained then?
|Restricted fuel return hose or pipe.|Faulty fuel pressure regulator.|

|STEP|ACTION|YES|NO| |---|---|---|---| |7|Was no fuel pressure applied in step 1?|Go to Step 8.|Go to Step 9.| |8|With fuel pump operated and fuel return hose blocked by pinching it, is fuel pressure applied?|Faulty fuel pressure regulator.|Shortage of fuel or fuel pump or its circuit malfunction.| |9|1) Operate fuel pump.
2) With fuel return hose blocked by pinching it, check fuel pressure.

Is it 450 kPa (4.5 kg/cm2, 63.9 psi) or more?|Faulty fuel pressure regulator.|Clogged fuel filter, restricted fuel feed hose or pipe, Faulty fuel pump or fuel leakage from hose connection in fuel tank.| |10|1) Disconnect fuel return hose from pressure regulator and connect new return hose to it.
2) Insert the other end of new return hose into approved gasoline container.
3) Check again if specified pressure is obtained. While doing so, does fuel come out of return hose?
|Faulty fuel pressure regulator.|Fuel leakage from injector, Fuel leakage from between injector and delivery pipe, Faulty fuel pump (faulty check valve in fuel pump) or Fuel leakage from fuel pressure regulator diaphragm.|

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|3|1) Connect SUZUKI scan tool to DLC.
2) With the ignition switch ON position, check “CLOSED THROT POS” in parameter data list. Throttle valve fully close : ON Throttle valve slight open : OFF

Is each check result as specified?|Check for followings: EVAP canister purge valve Accessory engine load PCV system Idle air passage A/C signal|Go to Step 4.| |4|1) With the ignition switch OFF position disconnect negative battery cable for 30 seconds and connect it.
2) Recheck closed throttle position referring to Step 2. Is each check result as specified?
|Recheck engine idle speed.|Go to Step 5.| |5|1) With the ignition switch ON position, check voltage between E02-6 and ground. Throttle valve fully close: 0.78 – 0.83V

Is each check result as specified?|Substitute a known good ECM and recheck.|Check TP sensor referring TP SENSOR INSPECTION in this section.| |6|1) Check “Or”, “B/R” and “Bl/B” wire for open and short. Are they in good condition?|Go to Step 6.|Repair or replace.| |7|1) Substitute a known good IAC valve.
2) Check IAC valve referring to IAC VALVE INSPECTION in this section.

Is check result in good condition?|IAC valve malfunction.|Substitute a known good ECM and recheck.|

#### B-5 EVAPORATIVE EMISSION CONTROL SYSTEM CHECK

|![image 670](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile670.png)

1. To throttle body
2. To fuel tank
3. EVAP canister
4. Air
5. Air and vapor

6. EVAP canister purge valve
7. Main relay
8. Sensed information
9. ECM (PCM)
10. Fuel tank
| |---|

|STEP|ACTION|YES|NO| |---|---|---|---| |1|Check canister purge system for operation referring to p. 6E1-71. Is it in good condition?|Check EVAP canister referring to p. 6E1-74 and fuel filler cap referring to Section 6C. If OK, system is in good condition.|Go to Step 2.| |2|Check vacuum passage, hoses and EVAP canister purge valve referring to p. 6E1-72. Are they in good condition?|“Or” wire open, “Or” wire shorted to ground, Poor EVAP canister purge valve coupler connection, Poor “E03-7” connection, Poor performance of ECT sensor or MAP sensor or TP sensor

If none of the above exists, substitute a known-good ECM (PCM) and recheck.|Vacuum passage clogged, Vacuum leakage or Faulty EVAP canister purge valve|

#### B-6 ENGINE START SIGNAL CHECK

|![image 671](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile671.png)

1. ECM (PCM)
2. ECM (PCM) connector
3. Main switch
4. To starting motor
| |---|

|STEP|ACTION|YES|NO|

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|E01-7E01-7

|Test switch terminalTest switch terminal

|4.5 – 5.5 V|Ignition switch ON| |E01-7E01-7

|Test switch terminalTest switch terminal

|1 V or less|Ignition switch ON, Test switch terminal grounded| |E01-8E01-8

|Diagnosis switch terminalDiagnosis switch terminal

|4.5 – 5.5 V|Ignition switch ON| |E01-8E01-8

|Diagnosis switch terminalDiagnosis switch terminal

|1 V or less|Ignition switch ON, Test switch terminal grounded| |E01-9

|Electric load signal for blower fan motorer fan motor

|2 V or less|Ignition switch ON, Blower fan switch : High, Middle or Low position| |E01-9

|Electric load signal for blower fan motorer fan motor

|4.0 – 14.0 V|Ignition switch ON, Blower fan switch : OFF position| |E01-10E01-10

|Stop light switchg (brake pedal switch)

|1.5V or less|Brake pedal released (switch OFF), Ignition switch ON| |E01-10E01-10

|Stop light switchg (brake pedal switch)

|10 – 14 V|Brake pedal depressed (switch ON), Ignition switch ON| |E01-11|Blank|—|—| |E01-12|Data link connector|10 – 14 V|Ignition switch ON| |E01-13E01-13

|Engine starter switchg (engine starter signal)

|1.5V or less|Ignition switch ON| |E01-13E01-13

|Engine starter switchg (engine starter signal)

|6 – 12 V|While engine cranking| |E01-14E01-14

|Transmission range switchg “L”

|10 – 14 V|Ignition switch ON, selector lever: “L” range| |E01-14E01-14

|Transmission range switchg “L”

|1 V or less|Ignition switch ON, selector lever: Other than “L” range| |E01-15E01-15

|Transmission range switchg “D”

|10 – 14 V|Ignition switch ON, selector lever: “D” range| |E01-15E01-15

|Transmission range switchg “D”

|1 V or less|Ignition switch ON, selector lever: Other than “D” range| |E01-16E01-16

|Transmission range switchg “R”

|10 – 14 V|Ignition switch ON, selector lever: “R” range| |E01-16E01-16

|Transmission range switchg “R”

|1 V or less|Ignition switch ON, selector lever: Other than “R” range| |E01-17|Duty output terminal|1 V or less|Ignition switch ON| |E01-18E01-18

|Electric load signal for small light switch and rear defoglight switch and rear defogger

|1 V or less|Ignition switch ON, Small light turned OFF and Rear defogger turned OFF| |E01-18E01-18

|Electric load signal for small light switch and rear defoglight switch and rear defogger

|10 – 14 V|Ignition switch ON, Small light turned ON or Rear defogger turned ON| |E01-19E01-19

|A/C ON signal from A/Cg switch (if equipped)

|10 – 14 V|Ignition switch ON, A/C switch OFF, Blower fan switch OFF| |E01-19E01-19

|A/C ON signal from A/Cg switch (if equipped)

|2 V or less|Ignition switch ON, A/C switch ON, Blower fan switch ON| |E01-20|Ignition switch signal|10 – 14 V|Ignition switch ON| |E01-21|Blank|—|—| |E01-22|Sensor ground|—|—|

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|![image 760](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile760.png)| |---|

###### PCV VALVE INSPECTION

1) Disconnect PCV valve from cylinder head cover and install plug to head cover hole.

2) Run engine at idle speed.

3) Place your finger over end of PCV valve (1) to check for vacuum. If there is no vacuum, check for clogged valve. Replace as necessary.

|![image 761](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile761.png)| |---|

4) After checking vacuum, stop engine and remove PCV valve (1). Shake valve and listen for the rattle of check needle inside the valve. If valve does not rattle, replace it.

5) After checking, remove plug and install PCV valve.

SPECIAL TOOLS

|![image 762](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile762.png)

1. Pressure gauge 09912-58441
2. Pressure hose 09912-58431
3. 3-way joint & hose 09912-58490
4. Checking tool set 09912-58421

4-1.Tool body & washer
4-2.Body plug
4-3.Body attachment
4-4.Holder
4-5.Return hose & clamp
4-6.Body attachment-2 & washer
4-7.Hose attachment-1
4-8.Hose attachment-2
|![image 762](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile762.png)

1. Pressure gauge 09912-58441
2. Pressure hose 09912-58431
3. 3-way joint & hose 09912-58490
4. Checking tool set 09912-58421

4-1.Tool body & washer
4-2.Body plug
4-3.Body attachment
4-4.Holder
4-5.Return hose & clamp
4-6.Body attachment-2 & washer
4-7.Hose attachment-1
4-8.Hose attachment-2
|![image 762](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile762.png)

1. Pressure gauge 09912-58441
2. Pressure hose 09912-58431
3. 3-way joint & hose 09912-58490
4. Checking tool set 09912-58421

4-1.Tool body & washer
4-2.Body plug
4-3.Body attachment
4-4.Holder
4-5.Return hose & clamp
4-6.Body attachment-2 & washer
4-7.Hose attachment-1
4-8.Hose attachment-2
| |---|---|---| |![image 763](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile763.png)

09917-47010 Vacuum pump gauge

|![image 764](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile764.png)

09930-88530 Injector test lead|![image 765](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile765.png)

09931-76011 SUZUKI scan tool (Tech 1A) kit

1.Storage case
2.Operator’s manual
3.SUZUKI scan tool (Tech 1A)
4.DLC cable
5.Test lead/probe
6.Power source cable
7.DLC cable adapter
8.Self-test adapter
| |![image 766](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile766.png)

Mass storage cartridge|![image 767](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile767.png)

09931-76030 16/14 pin DLC cable| |

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|---|---|---| |Engine cranks, but will not start or hard to start|Blown fuse for ignition coil Loose connection or disconnection of lead wire or high-tension cord(s) Faulty high-tension cord(s) Faulty spark plug(s) Cracked rotor or cap Maladjusted signal rotor air gap Faulty ignition coil Faulty noise suppressor Faulty CMP sensor Faulty igniter Faulty ECM (or PCM) Maladjusted ignition timing|Replace Connect securely

Replace Adjust, clean or replace Replace Adjust Replace Replace Replace Replace Replace Adjust| |Poor fuel economy or engine performance|Incorrect ignition timing Faulty spark plug(s) or high-tension cord(s) Faulty ECM (or PCM)|Adjust Adjust, clean or replace Replace|

DIAGNOSTIC FLOW TABLE

|STEP|ACTION|YES|NO| |---|---|---|---| |1|Was “Engine Diagnostic Flow Table” in SECTION 6 performed?|Go to Step 2.|Go to “Engine Diagnostic Flow Table” in SECTION 6.| |2|Ignition Spark Test

1) Check all spark plug for condition and type, referring to “Spark Plugs” in this section.
2) If OK, perform ignition spark test, referring to “Ignition Spark Check” in this section.

Is spark emitted from all spark plugs?|Go to Step 11 on the next page.|Go to Step 3.| |3|Diagnostic Trouble Code (DTC) Check

1) Check DTC stored in ECM (or PCM), referring to “Diagnostic Trouble Code (DTC) Check” in SECTION 6E1.

Is DTC stored?|Go to applicable flow table corresponding to that code No. in SECTION 6E1.|Go to Step 4.| |4|Electrical Connection and Noise suppressor Check

1) Check ignition coil for electrical connection and

noise suppressor for conductivity. Are they in good condition?|Go to Step 5.|Repair or replace.| |5|High-tension Cord Check

1) Check high-tension cord for resistance, referring to

“High-tension Cords” in this section. Is check result satisfactory?|Go to Step 6.|Replace high-tension cord(s).|

|STEP|ACTION|YES|NO| |---|---|---|---| |6|Ignition Coil Power Supply And Ground Circuit Check

1) Check ignition coil power supply (“B/W” wire) circuit for open and short. Are circuits in good condition?|Go to Step 7.|Repair or replace.| |7|Ignition Coil Check

1) Check ignition coil for resistance, referring to “Ignition Coil” in this section. Is check result satisfactory?|Go to Step 8.|Replace ignition coil assembly.| |8|CMP Sensor Check

1) Check CMP sensor and signal rotor, referring to

“Distributor” in this section. Is check result satisfactory?|Go to Step 9.|Adjust or replace.| |9|Igniter Check

1) Check igniter, referring to “Igniter” in this section. Is check result satisfactory?|Go to Step 10.|Replace igniter.| |10|Ignition Trigger Signal Circuit Check

1) Check ignition trigger signal (“Br/Y” wire) circuit for

open, short and poor connection. Are circuits in good condition?|Go to Step 11.|Repair or replace.| |11|Ignition Timing Check

1) Check initial ignition timing and ignition timing ad-

vance, referring to “Ignition Timing” in this section. Is check result satisfactory?|Substitute a knowngood ECM (or PCM) and then repeat STEP 2.|Go to Step 12.| |12|Ignition Timing Adjustment And Recheck

1) Adjust initial ignition timing, referring to “Ignition Timing” in this section.
2) Recheck initial ignition timing and ignition timing advance, referring to “Ignition Timing” in this section.

Is check result satisfactory?|System is in good condition.|Substitute a knowngood ECM (or PCM) and then repeat STEP 2.|

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DIAGNOSIS 6G-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT REPAIR OVERHAUL 6G-6. . . . . . . . . . . . . . . . . Dismounting and Remounting 6G-6. . . . . . . . . . . . Disassembly 6G-6. . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly 6G-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 6G-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Performance Test 6G-11. . . . . . . . . . . . . . . . . . . . . . Pull-in test 6G-11. . . . . . . . . . . . . . . . . . . . . . . . . . Hold-in test 6G-11. . . . . . . . . . . . . . . . . . . . . . . . . Pinion return test 6G-12. . . . . . . . . . . . . . . . . . . . No-load performance test 6G-12. . . . . . . . . . . . .

SPECIFICATIONS 6G-13. . . . . . . . . . . . . . . . . . . . . . . REQUIRED SERVICE MATERIAL 6G-13. . . . . . . . . SPECIAL TOOL 6G-13. . . . . . . . . . . . . . . . . . . . . . . . .

6G

GENERAL DESCRIPTION

CRANKING CIRCUIT The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These components are connected electrically. Only the starting motor will be covered in this section.

STARTING MOTOR CIRCUIT The magnetic switch coils are magnetized when the starter switch is closed. The resulting plunger and pinion drive lever movement causes the pinion to engage the engine flywheel gear and the magnetic switch main contacts to close, and cranking takes place. When the engine starts, the pinion over-running clutch protects the armature from excessive speed until the switch is opened, at which time the return spring causes the pinion to disengage.

|![image 791](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile791.png)| |---|

STARTING MOTOR Both of them consist of yoke assembly, armature assembly, over-running clutch assembly, magnetic switch assembly, front housing, rear housing, brush holder and drive lever. The magnetic switch assembly and parts in the starting motor are enclosed in the housings so that they will be protected against possible dirt and water splash.

|![image 792](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile792.png)

![image 793](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile793.png)

1. Drive housing assembly
2. Washer
3. Snap ring
4. Pinion stop ring
5. Over-running clutch assembly: Apply grease A 99000-25010 to inside and outside of spline.
6. Armature: Apply grease A 99000-25010 to joint of drive housing bush, over-running clutch and armature shaft bush.
7. Pinion drive lever: Apply grease A 99000-25010 to joint of magnetic switch and over-running clutch.
8. Seal
9. Boot
10. Magnetic switch
11. Rear housing
12. Brush spring
13. Brush holder
14. Insulator
15. Rear housing bush
16. Brush
17. Yoke assembly
18. Housing bolt
19. Front housing bush
20. Nut

: Tightening Torque : Do not reuse

![image 794](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile794.png)

![image 795](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile795.png)

![image 796](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile796.png)

![image 797](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile797.png)

![image 798](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile798.png)| |---|

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DIAGNOSIS

Possible symptoms due to starting system trouble would be as follows:

Starting motor does not run (or runs slowly) Starting motor runs but fails to crank engine Abnormal noise is heard

Proper diagnosis must be made to determine exactly where the cause of each trouble lies ..... in battery, wiring harness, (including starting motor switch), starting motor or engine. Do not remove motor just because starting motor does not run. Check following items and narrow down scope of possible causes.

1) Condition of trouble

2) Tightness of battery terminals (including ground cable connection on engine side) and starting motor terminals

3) Discharge of battery

4) Mounting of starting motor

|Condition|Possible Cause|Correction| |---|---|---| |Motor not running

|No operating sound of magnetic switch Transmission range switch is not in P or N, or not adjusted (A/T) Battery run down Battery voltage too low due to battery deterioration Poor contact in battery terminal connection Loose grounding cable connection Fuse set loose or blown off Poor contacting action of ignition switch and magnetic switch Lead wire coupler loose in place Open-circuit between ignition switch and magnetic switch Open-circuit in pull-in coil Brushes are seating poorly or worn down Poor sliding of plunger and/or pinion|Shift in P or N, or adjust switch.

Recharge battery. Replace battery. Retighten or replace. Retighten. Tighten or replace. Replace.

Retighten. Repair.

Replace magnetic switch. Repair or replace. Repair.| |Motor not running

|Operating sound of magnetic switch heard Battery run down Battery voltage too low due to battery deterioration Loose battery cable connections Burnt main contact point, or poor contacting action of magnetic switch Brushes are seating poorly or worn down Weakened brush spring Burnt commutator Poor grounding of field coil Layer short-circuit of armature Crankshaft rotation obstructed|Recharge battery. Replace battery. Retighten. Replace magnetic switch.

Repair or replace. Replace. Replace armature. Repair. Replace. Repair.|

|Condition|Possible Cause|Correction| |---|---|---| |Starting motor running but too slow (small torque)|If battery and wiring are satisfactory, inspect starting motor

Insufficient contact of magnetic switch main contacts Layer short-circuit of armature Disconnected, burnt or worn commutator

Poor grounding of field coil Worn brushes Weakened brush springs Burnt or abnormally worn end bush|Replace magnetic switch. Replace. Repair commutator or replace armature. Repair. Replace brush. Replace spring Replace bush.| |Starting motor running, but not cranking engine|Worn pinion tip Poor sliding of over-running clutch Over-running clutch slipping Worn teeth of ring gear|Replace over-running clutch. Repair. Replace over-running clutch. Replace flywheel (M/T) or drive plate (A/T).|

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ON-VEHICLE SERVICE 6H-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery 6H-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jump starting in case of emergency with auxiliary (booster) battery 6H-10. . . . . . . . . . . . . . . . . . . . . . . . . . Removal 6H-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling 6H-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 6H-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator 6H-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 6H-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 6H-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator/Water Pump Drive Belt 6H-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt tension inspection 6H-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 6H-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 6H-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT REPAIR OVERHAUL 6H-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator 6H-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly 6H-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 6H-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace Brush 6H-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 6H-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

########## SPECIFICATIONS 6H-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6H

|![image 827](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile827.png)|

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Weekly, start the engine and run it until it reaches normal operating temperature with engine speed of 2000 to 3000 rpm. Make sure all electric switches are off before storing the vehicle. Recharge the battery twice a month to prevent it from discharging excessively. This is especially important when ambient temperature is low. The battery discharges even when it is not used, while vehicles are being stored. Battery electrolyte can freeze and battery case can crack at cold ambient condition if battery is not properly charged.

2) Keep the battery cable connections clean. The cable connections, particularly at the positive (+) terminal post, tend to become corroded. The product of corrosion, or rust, on the mating faces of conductors resists the flow of current. Clean the terminals and fittings periodically to ensure good metal-to-metal contact, and grease the connections after each cleaning to protect them against rusting.

|WARNING: Never expose battery to open flame or electric spark because of battery generate gas which is flammable and explosive. Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive acid. Flush any contacted area with water immediately and thoroughly. Batteries should always be kept out of reach of children.| |---|

3) Be always in the know as to the state of charge of the battery. The simplest way to tell the state of charge is to carry out a hydrometer test. The hydrometer is an instrument for measuring the specific gravity (S.G.) of the battery electrolyte. The S.G. of the electrolyte is indicative of the state of charge. Refer to “BATTERY” of DIAGNOSIS in this section.

GENERATOR The generator is a small and high performance type with an IC regulator incorporated. The internal components are connected electrically as shown below figure.

The generator features are as follows: Solid state regulator is mounted inside the generator. All regulator components are enclosed into a solid mold. This unit along with the brush holder assembly is attached to the rear housing. The IC regulator uses integrated circuits and controls the voltage produced by the generator, and the voltage setting cannot be adjusted. The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication. Two brushes carry current through the two slip rings to the field coil mounted on the rotor, and under normal conditions will provide long period of attention-free service. The stator windings are assembled on the inside of a laminated core that forms part of the generator frame.

|![image 828](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile828.png)

1. Generator with regulator ass’y
2. I.C. regulator
3. Stator coil
4. Diode
5. Field coil (rotor coil)
6. Charge indicator light
7. Main switch
8. Battery

B: Generator output (Battery terminal)

E: Ground
F: Field coil terminal IG: Ignition terminal L: Lamp terminal
| |---|

|![image 829](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile829.png)

![image 830](1665643d1502367344-zen-art-maintaining-maruti-zen-16v-mpfi-service-manual_images/imageFile830.png)

1. Pulley
2. Pulley nut
3. Rotor fan
4. Stator coil
5. Stator core
6. Field coil
7. Regulator
8. Brush
9. Rear end frame
10. Drive end frame

B : Generator output (Battery terminal)

D : Dummy terminal
E : Ground
F : Field coil terminal IG: Ignition terminal L : Lamp terminal
| |---|

DIAGNOSIS BATTERY VISUAL INSPECTION

Check for obvious damage, such as cracked or broken case or cover, that could permit loss of electrolyte. If obvious damage is noted, replace battery. Determine cause of damage and correct as needed.

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