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    Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

    Camshaft Position (CMP) Sensor or Crank Angle Sensor (CAS)

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    OPERATION



    Carbureted engines and 1989-90 1.6L TFI engines covered by this guide do not use a Camshaft Position (CMP) sensor or a Crank Angle Sensor (CAS).

    1.3L TFI and 1991-98 1.6L Engines

    See Figure 1

    The CMP sensor used on all 1.3L TFI and 1991 1.6L TFI engines is referred to as the Crank Angle Sensor (CAS).

    The Camshaft Position (CMP) sensor is located inside the distributor assembly. The CMP sensor consists of a signal rotor, a stationary magnet, and a stationary Hall-effect switch, which is supplied ignition voltage, and is equipped with its own ground. As the signal rotor spins, magnetic flux from the magnet is applies to the Hall element intermittently. The Hall element generates AC current in proportion with the magnetic flux. The sensor pulse signal is received by the ECM, by which it used to determine crank angle input. The CMP sensor sends four pulses, per complete revolution, to the ECM. The ECM uses the crank angle input to determine when to ground the igniter, thus controlling the ignition coil and ignition timing. If the ECM does not receive the proper signal, it should set a Diagnostic Trouble Code (DTC).

    The CMP is located inside the distributor, which is mounted on the rear of the cylinder head.



    Click image to see an enlarged view

    Fig. Fig. 1: The Camshaft Position (CMP) sensor, or the Crank Angle Sensor (CAS), produces four voltage pulses for each camshaft revolution

    1.8L Engine

    The Camshaft Position (CMP) sensor is mounted on the rear of the cylinder head and is comprised of the signal generator (photo transistors) and the signal rotor (slot plate).

    The signal generator produces reference signal pulses through two types of slots in the signal rotor, both of which are turned by the camshaft.

    The CMP sensor generates 4 pulse signals, each of which has a different wave form, for each camshaft rotation. The ECM uses these signals for piston position at 10 Before Top Dead Center (BTDC). The sensor also generates a second set of 360 pulse signals for each camshaft generation, which is used by the ECM for engine speed and precise piston positioning.

    TESTING



    1.3L TFI Engine

    For all Engine Control Module (ECM) terminal identification, refer to the illustrations earlier in this section.

    1. Remove all necessary components for access to the ECM. Remove the ECM with the wiring harness connected, then set it on the floor of the vehicle for access during the test procedure. Ensure that the wiring harness connectors are fully engaged with the ECM.
    2.  
    3. Disengage the yellow connector from the ECM.
    4.  
    5. Using a Digital Volt-Ohmmeter (DVOM) set on the voltmeter function, connect the positive lead to terminal B1 on the green ECM connector, and the negative lead to terminal A13 on the detached yellow ECM connector. Refer to the ECM terminal identification illustrations earlier in this section.
    6.  
    7. Turn the ignition ON .
    8.  
    9. While observing the DVOM, have an assistant rotate the crankshaft with a large socket and ratchet on the center crankshaft pulley bolt. Turn the crankshaft so that it travels through 3 or 4 full revolutions.
    10.  
    11. The voltage observed on the DVOM should fluctuate from 0-1 volt to battery voltage four times for each crankshaft revolution.
      1. If the voltage did not fluctuate four times for each revolution, or does not oscillate from 0-1 volt to battery voltage, inspect the wiring harness for an open or short circuit, or, if available, substitute a known good distributor and recheck the system. If the circuit checks out okay, replace the distributor assembly.
      2.  
      3. If the voltage functioned as described, inspect the ECM, the wiring harness and related components.
      4.  

    12.  

    1.6L Engine

    For all Engine Control Module (ECM) terminal identification, refer to the illustrations earlier in this section.

    1991 MODELS
    1. Turn the ignition switch OFF .
    2.  
    3. Remove all necessary components for access to the ECM. Remove the ECM with the wiring harness connected, then set it on the floor of the vehicle for access during the test procedure. Ensure that the wiring harness connectors are fully engaged with the ECM.
    4.  
    5. Disengage the yellow connector from the ECM.
    6.  
    7. Using a Digital Volt-Ohmmeter (DVOM) set on the voltmeter function, connect the positive lead to terminal B1 on the green ECM connector (which should still be attached to the ECM), and the negative lead to terminal A13 on the detached yellow ECM connector.
    8.  
    9. Turn the ignition ON .
    10.  
    11. While observing the DVOM, have an assistant rotate the crankshaft with a large socket and ratchet on the center crankshaft pulley bolt. Turn the crankshaft so that it travels through 3 or 4 full revolutions.
    12.  
    13. The voltage observed on the DVOM should fluctuate from 0-1 volt to battery voltage four times for each crankshaft revolution.
      1. If the voltage did not fluctuate four times for each revolution, or does not oscillate from 0-1 volt to battery voltage, inspect the wiring harness for an open or short circuit, or, if available, substitute a known good distributor and recheck the system. If the circuit checks out okay, replace the distributor assembly.
      2.  
      3. If the voltage functioned as described, inspect the ECM, the wiring harness and related components.
      4.  

    14.  

    1992-98 MODELS
    1. Turn the ignition switch OFF .
    2.  
    3. Remove all necessary components for access to the ECM. Remove the ECM with the wiring harness connected, then set it on the floor of the vehicle for access during the test procedure. Ensure that the wiring harness connectors are fully engaged with the ECM.
    4.  
    5. Using a Digital Volt-Ohmmeter (DVOM) set on the voltmeter function, attach the positive lead to ECM connector terminal B3 (1992-95 models) or terminal E33-3 (1996-98 models), and the negative lead to a good chassis ground.
    6.  
    7. Turn the ignition ON .
    8.  
    9. While observing the DVOM, have an assistant rotate the crankshaft clockwise (viewing the crankshaft from the front of the engine) with a large socket and ratchet on the center crankshaft pulley bolt. Turn the crankshaft so that it travels through 3 or 4 full revolutions.
    10.  
    11. The voltage observed on the DVOM should fluctuate from 0-1 volt to 3-5 volts (1992-95 models) or 3-5.25 volts (1996-98 models) four times for each crankshaft revolution. The voltage presented on the DVOM should read 0-1 volt whenever the signal rotor is not between the Hall-effect switch and the magnet, whereas the voltage should be 3-5 (1992-95 models) or 3-5.25 volts (1996-98 models) when the rotor is positioned between the two components.
      1. If the voltage did not fluctuate four times for each revolution, or does not oscillate from 0-1 volt to battery voltage, inspect the wiring harness for an open or short circuit, or, if available, substitute a known good distributor and recheck the system. If the circuit checks out okay, replace the distributor assembly.
      2.  
      3. If the voltage functioned as described, inspect the ECM, the wiring harness and related components.
      4.  

    12.  

    1.8L Engine

    See Figure 2

    For all Engine Control Module (ECM) terminal identification, refer to the illustrations earlier in this section.

    1. Turn the ignition switch OFF .
    2.  
    3. Detach the wiring harness connector from the CMP sensor.
    4.  
    5. Using a Digital Volt-Ohmmeter (DVOM) set on the voltmeter function, attach the positive lead to CMP sensor wiring harness connector terminal 2, and the negative lead to terminal 3.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 2: Attach the positive lead of a voltmeter to terminal 2 of the CMP sensor wiring harness connector, and the negative lead to terminal 3 of the connector

    1. Turn the ignition switch ON , and measure the voltage on the DVOM. Voltage should be the same as battery voltage; if the voltage is not battery voltage, inspect the wiring harness for open or short circuits.
    2.  
    3. Turn the ignition switch OFF .
    4.  
    5. Reattach the wiring harness connector to the CMP sensor.
    6.  
    7. Remove all necessary components for access to the ECM. Remove the ECM with the wiring harness connected, then set it on the floor of the vehicle for access during the test procedure. Ensure that the wiring harness connectors are fully engaged with the ECM.
    8.  
    9. For 1996-97 vehicles, perform the following:
      1. Using a Digital Volt-Ohmmeter (DVOM) set on the voltmeter function, attach the positive lead to ECM connector terminal E33-5 or E33-6, and the negative lead to a good chassis ground.
      2.  
      3. Turn the ignition ON .
      4.  
      5. While observing the DVOM, have an assistant rotate the crankshaft clockwise (viewing the crankshaft from the front of the engine) with a large socket and ratchet on the center crankshaft pulley bolt. Turn the crankshaft so that it travels through 3 or 4 full revolutions.
      6.  
      7. The voltage observed on the DVOM should fluctuate from 0-1 volt to 4-6 volts four times for each crankshaft revolution.
      8.  
      9. Turn the ignition OFF .
      10.  
      11. Now attach the positive lead to ECM connector terminal E33-3 or E33-4, and the negative lead to a good chassis ground.
      12.  
      13. Turn the ignition ON .
      14.  
      15. While observing the DVOM, have an assistant rotate the crankshaft clockwise (viewing the crankshaft from the front of the engine) with a large socket and ratchet on the center crankshaft pulley bolt. Turn the crankshaft so that it travels through 3 or 4 full revolutions.
      16.  
      17. The voltage observed on the DVOM should fluctuate from 0-1 volt to 4-6 volts four times for each crankshaft revolution.
      18.  

    10.  
    11. For 1998 vehicles equipped with automatic transmissions or the EVAP II system, perform the following:
      1. Using a Digital Volt-Ohmmeter (DVOM) set on the voltmeter function, attach the positive lead to ECM connector terminal E11-10, and the negative lead to a good chassis ground.
      2.  
      3. Turn the ignition ON .
      4.  
      5. While observing the DVOM, have an assistant rotate the crankshaft clockwise (viewing the crankshaft from the front of the engine) with a large socket and ratchet on the center crankshaft pulley bolt. Turn the crankshaft so that it travels through 3 or 4 full revolutions.
      6.  
      7. The voltage observed on the DVOM should fluctuate from 0-1 volt to 4-6 volts four times for each crankshaft revolution.
      8.  
      9. Turn the ignition OFF .
      10.  
      11. Now attach the positive lead to ECM connector terminal E11-22, and the negative lead to a good chassis ground.
      12.  
      13. Turn the ignition ON .
      14.  
      15. While observing the DVOM, have an assistant rotate the crankshaft clockwise (viewing the crankshaft from the front of the engine) with a large socket and ratchet on the center crankshaft pulley bolt. Turn the crankshaft so that it travels through 3 or 4 full revolutions.
      16.  
      17. The voltage observed on the DVOM should fluctuate from 0-1 volt to 4-6 volts four times for each crankshaft revolution.
      18.  

    12.  
    13. For 1998 vehicles, other than those equipped with automatic transmissions or the EVAP II system, perform the following:
      1. Using a Digital Volt-Ohmmeter (DVOM) set on the voltmeter function, attach the positive lead to ECM connector terminal E33-5, and the negative lead to a good chassis ground.
      2.  
      3. Turn the ignition ON .
      4.  
      5. While observing the DVOM, have an assistant rotate the crankshaft clockwise (viewing the crankshaft from the front of the engine) with a large socket and ratchet on the center crankshaft pulley bolt. Turn the crankshaft so that it travels through 3 or 4 full revolutions.
      6.  
      7. The voltage observed on the DVOM should fluctuate from 0-1 volt to 4-6 volts four times for each crankshaft revolution.
      8.  
      9. Turn the ignition OFF .
      10.  
      11. Now attach the positive lead to ECM connector terminal E33-3, and the negative lead to a good chassis ground.
      12.  
      13. Turn the ignition ON .
      14.  
      15. While observing the DVOM, have an assistant rotate the crankshaft clockwise (viewing the crankshaft from the front of the engine) with a large socket and ratchet on the center crankshaft pulley bolt. Turn the crankshaft so that it travels through 3 or 4 full revolutions.
      16.  
      17. The voltage observed on the DVOM should fluctuate from 0-1 volt to 4-6 volts four times for each crankshaft revolution.
      18.  

    14.  
    15. If the voltage did not function as described, inspect the wiring harness for an open or short circuit, or, if available, substitute a known good CMP sensor and recheck the system. If the circuit checks out okay, replace the CMP sensor.
    16.  
    17. If the voltage functioned as described, inspect the ECM, the wiring harness and related components.
    18.  

    REMOVAL & INSTALLATION



    1.3L and 1.6L Engines

    The CMP sensor/CAS cannot be individually replaced; the entire distributor assembly must be replaced if the sensor is found to be defective. Distributor removal and installation is described in Engine Electrical of this repair guide.

    1.8L Engine

    See Figures 3 and 4


    WARNING
    Do not attempt to disassemble the CMP sensor; the sensor must be replaced as a unit if found defective.

    1. Disconnect the negative battery cable.
    2.  
    3. Detach the wiring harness connector from the CMP sensor.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 3: Loosen the CMP sensor mounting screws, then remove the sensor from the camshaft

    1. Loosen the two CMP sensor retaining bolts, then pull the sensor off of the rear side of the cylinder head.
    2.  
    3. Remove and discard the old O-ring from the CMP sensor.
    4.  

    To install:
    1. Install a new O-ring, lubricated with clean engine oil, onto the CMP sensor.
    2.  
    3. Install the sensor by fitting the tangs of the sensor coupling in the camshaft end slots. The tangs of the sensor coupling are slightly offset. Therefore, if the tangs are difficult to mate with the camshaft slots, rotate the sensor shaft 180 degrees and reinsert it.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 4: When installing the CMP sensor on the camshaft, ensure that the coupling slots of the camshaft are properly engaged by the tangs on the sensor

    1. Install and tighten the sensor mounting bolts to 133 inch lbs. (15 Nm).
    2.  
    3. Reattach the wiring harness connector to the CMP sensor.
    4.  
    5. Connect the negative battery cable.
    6.  
    7. Adjust the ignition timing.
    8.  

     
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