Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Diagnosis and Testing

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CARBURETED ENGINES



Ignition Spark Test
  1. Remove the spark plug wire from the No. 1 cylinder spark plug.
  2.  
  3. Install a commercially available spark plug/wire tester in the end of the spark plug wire. If this tester is not available, you may also test for spark by grounding the plug wire by holding its end against a metal part of the engine.
  4.  


CAUTION
When performing this test, wearing rubber gloves and using a pair of insulated pliers to hold the spark plug wire against the engine may help avoid receiving an electrical shock.

  1. While watching the spark plug tester or end of the wire, have an assistant inside the vehicle crank the engine with the ignition switch for 3-2 seconds. There should be a visible blue-white spark. If no spark is evident, or if the spark is weak (yellow spark color), inspect the spark plug wire, the ignition coil, the distributor or the spark plug itself for damage.
  2.  
  3. Install the wire to the applicable spark plug.
  4.  
  5. Repeat for each of the spark plugs/wires.
  6.  

Signal Generator

See Figures 1, 2, 3 and 4

  1. Remove the distributor from the vehicle.
  2.  
  3. Remove the igniter and signal generator from the distributor.
  4.  
  5. Remove the dust cover from the igniter.
  6.  
  7. Detach the red and white wires from the igniter.

    Click image to see an enlarged view

    Fig. Fig. 1: Exploded view of the distributor used on carbureted engines. Note the location of the signal generator



    Click image to see an enlarged view

    Fig. Fig. 2: To test the signal generator, remove the generator and the igniter from the distributor, then pull the dust covers off of the two components



    Click image to see an enlarged view

    Fig. Fig. 3: Using an ohmmeter, as indicated, measure the resistance of the signal generator

  8.  
  9. Attach an ohmmeter to the red and white wires, and measure the signal generator resistance. The resistance should be between 130-160 ohms. If the resistance is not within this range, replace the signal generator with a new one.
  10.  
  11. After testing the signal generator, attach the red and white wires to the igniter as shown in the accompanying illustration.***WARNING***Never connect the red and white wires to the wrong terminals; damage to the igniter and/or signal generator can occur.

    Click image to see an enlarged view

    Fig. Fig. 4: When reinstalling the signal generator, be absolutely sure to connect the red and white wires as indicated, otherwise generator or igniter damage will occur

  12.  
  13. Install the signal generator, then the igniter. Inspect the air gap and adjust as necessary.
  14.  
  15. Install the distributor.
  16.  

Centrifugal Advance Mechanism

See Figure 5

Remove the distributor cap. Grasp the distributor rotor with your fingers and turn it clockwise, then release it. The rotor should return to its original position smoothly. If the rotor does not function as described, replace the distributor.



Click image to see an enlarged view

Fig. Fig. 5: To inspect the mechanical advance mechanism, rotate the rotor and turn it clockwise-it should return to its original position smoothly

Vacuum Advance Mechanism

See Figure 6

  1. Remove the distributor cap.
  2.  
  3. Detach the vacuum advance hose from the vacuum hose 3-way connector.
  4.  
  5. Attach a hand-held vacuum pump to vacuum advance hose.
  6.  



Click image to see an enlarged view

Fig. Fig. 6: When applying vacuum to the vacuum advance canister, the generator plate should move smoothly

  1. While observing the signal generator plate in the distributor, apply approximately 13 in. Hg (23 kPa) of vacuum with the hand pump. Check to ensure that the generator plate moves smoothly and that the vacuum does not leak down.
  2.  

If the plate does not move smoothly or if the vacuum leaks down, replace the vacuum advance mechanism.

TFI & MFI ENGINES



Ignition Spark Test

See Figure 7

  1. Label and detach the fuel injector(s), the Throttle Position (TP) sensor (if equipped) and the Idle Air Control (IAC) valve (if equipped) wiring harness at the connector(s).
  2.  


CAUTION
Without properly detaching the aforementioned wiring harness, gasoline vapors may build up and leak out of the air intake, which may lead to an explosive and very dangerous condition.

  1. Remove the spark plug wire from the No. 1 cylinder spark plug.
  2.  
  3. Install a commercially available spark plug/wire tester in the end of the spark plug wire. If this tester is not available, you may also test for spark by grounding the plug wire by holding its end against a metal part of the engine.
  4.  



Click image to see an enlarged view

Fig. Fig. 7: Prior to performing the ignition spark test, label and detach the fuel injector wiring harness connector


CAUTION
When performing this test, wearing rubber gloves and using a pair of insulated pliers to hold the spark plug wire against the engine may help avoid receiving an electrical shock.

  1. While watching the spark plug tester or end of the wire, have an assistant inside the vehicle crank the engine with the ignition switch for 3-2 seconds. There should be a visible blue-white spark. If no spark is evident, or if the spark is weak (yellow spark color), inspect the spark plug wire, the ignition coil, the distributor or the spark plug itself for damage.
  2.  
  3. Install the wire to the applicable spark plug.
  4.  
  5. Repeat for each of the spark plugs/wires.
  6.  
  7. After the testing is complete, reattach the fuel injector(s), TP sensor (if equipped) and IAC valve (if equipped) wiring harness.
  8.  

 
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