New Model Information -Differences Between '93 & '94 (TS 7-05 08113)
Reference number: TS 7-05 08113
NEW MODEL INFORMATION -DIFFERENCES BETWEEN '93 & '94
TECHNICAL SERVICE BULLETIN
NEW MODEL INFORMATION
Model(s): 1994 Suzuki Sidekick
Section Title: Miscellaneous
Bulletin No.: TS 7-05 08113
Date: August 8, 1993
CONDITION
Changes in vehicles and Service Information.
CAUSE
Factory modifications.
CORRECTION
Note changes for future reference.
This bulletin is to inform you of the main differences between the 1993 and 1994 model Sidekicks.
MAIN DIFFERENCES
VEHICLE SPECIFICATION
| VEHICLE SPECIFICATION | ITEM | 1994 MODEL | 1993 MODEL |
|---|---|---|---|
| CALIFORNIA SPEC. 2-DOOR MODEL | Engine | 1-Cam 16-Valves | 1-Cam 8-valves |
| CALIFORNIA SPEC. 2-DOOR MODEL | E.F.I.System | SFI | TBI |
| CALIFORNIA SPEC. 2-DOOR MODEL | Auto. Transmission | 3 A/T | <----- |
| CALIFORNIA SPEC. 2-DOOR MODEL | 2WD Model | M/T & 3 A/T | <----- |
| CALIFORNIA SPEC. 2-DOOR MODEL | Auto. Cruise System | --- | --- |
| FEDERAL SPEC. (EXCEPT CALIF. SPEC.) | Engine | 1-Cam 8-Valves | <----- <----- |
| FEDERAL SPEC. (EXCEPT CALIF. SPEC.) | E.F.I.System | TBI | <----- |
| FEDERAL SPEC. (EXCEPT CALIF. SPEC.) | Auto. Transmission | 3 A/T | <----- |
| FEDERAL SPEC. (EXCEPT CALIF. SPEC.) | 2WD Model | M/T & 3 A/T | <----- |
| FEDERAL SPEC. (EXCEPT CALIF. SPEC.) | Auto. Cruise System | --- | --- |
| FEDERAL SPEC. (EXCEPT CALIF. SPEC.) | Engine | 1-Cam 16-Valves | <----- <----- |
| CALIFORNIA AND FEDERAL SPEC. 4-DOOR MODEL | E.F.I.System | SFI | <----- |
| CALIFORNIA AND FEDERAL SPEC. 4-DOOR MODEL | Auto. Transmission | 4 A/T | <----- |
| CALIFORNIA AND FEDERAL SPEC. 4-DOOR MODEL | 2WD Model | M/T & 4 A/T | M/T |
| CALIFORNIA AND FEDERAL SPEC. 4-DOOR MODEL | Auto. Cruise System | M/T & 4 A/T | <----- |
AIR CONDITIONING SYSTEM (ACCESSORY)
The refrigerant, compressor oil, and component parts are not interchangeable between the two types of A/C systems: one using CFC-12 (R-12) and the other using HFC-134a (R-134a). The use of inappropriate parts will result in a loss of refrigerant, damage to component parts, or other faulty conditions.
| PARTS NAME | 1994 MODEL | 1993 MODEL |
|---|---|---|
| REFRIGERANT | HFC-134a (R-134a) | CFC-12 (R-12) |
| A/C CAUTIONPLATE | Refer to Fig. Fig 1 . for location | Refer to Fig. Fig 1 . for location |
| A/C SERVICEVALVE | Shaped as shown in Fig. Fig 2 . | Shaped as shown in Fig. Fig 2 . |
| DUAL PRESSURE SWITCH | When system pressure is at the proper specifications, the dual pressure switch will show no continuity. High side pressure: 455 psi (32 kg/cm2 ) or more Low side pressure: 28 psi (2.0 kg/cm2 ) or below | When system pressure is atthe proper specifications,the dual pressure switch will show no continuity. High side pressure: 383 psi (27 kg/cm2 ) or more Low side pressure: 30 psi (2.1 kg/cm2 ) or below |
ENGINE
| PARTS NAME | 1994 MODEL | 1993 MODEL |
|---|---|---|
| CAMSHAFT TIMING PULLEYFOR l-CAM 8-VALVE ENGINE | Shaped as shown in Fig 3 . | Shaped as shown in Fig 3 . |
| CAMSHAFT AND VALVE LASH FOR 1-CAM 16-VALVE ENGINE | Shaped as shown in Fig 4 . | Shaped as shown in Fig 4 . |
| " | Valve Lash Specs. (Intake And Exhaust) | Valve Lash Specs. (Intake And Exhaust) |
| " | COLD Coolant Temp 59°-77° F (15°-25° C) HOT Coolant Temp 140°-154° F (60°-68° C) |
COLD Coolant Temp 59°-77° F (15°-25° C) HOT Coolant Temp 140°-154° F (60°-68° C) |
| " | COLD 0.0051- 0.0067 in. (0.13- 0.17 mm) HOT 0.0067 - 0.0082 in. (0.17- 0.21 mm) |
COLD 0.0031- 0.0047 in. (0.8-0.12 mm) HOT 0.0047 - 0.0063 in. (0.12- 0.16 mm) |
| AIR INTAKE PIPE AND HOSES FOR 1-CAM 16-VALVE ENGINE | Shaped as shown in Fig 5 . | Shaped as shown in Fig 5 . |
ELECTRONIC FUEL INJECTION & EMISSION CONTROL SYSTEM
| PARTS NAME | 1994 MODEL | 1993 MODEL |
|---|---|---|
|
Federal spec. vehicles only. (California vehicles aren't equipped with TBI.) | California spec. vehicles only. |
|
All spec. vehicles. | California spec. vehicles only. |
|
All spec. vehicles. | California spec. vehicles only. |
| SFI: OXYGEN SENSOR | haped as shown in Fig 6 . | Shaped as shown in Fig 6 . |
| SFI: UNDER HOOD MONITOR COUPLER | 6-Terminal type Monitor Coupler shown in Fig 7 . | 4-Terminal type Monitor Coupler shown in Fig 7 . |
| SFI: HEATED OXYGEN SENSOR HEATER CONTROL SYSTEM | Refer to Fig 8 . | Refer to Fig 8 . |
IGNITION SYSTEM
| PARTS NAME | 1994 MODEL | 1993 MODEL |
|---|---|---|
| IGNITION COIL | Resistance of ignition coil is as shown below:Primary: 1.08 - 1.32ohms Secondary: 22.1 - 29.9ohms | Resistance of ignition coil is as shown below: Primary: 0.72 - 0.88ohms Secondary: 10.2 - 14.0ohms |
EXHAUST SYSTEM
| PARTS NAME | 1994 MODEL | 1993 MODEL |
|---|---|---|
| EXHAUST MANIFOLD FOR 1-CAM 16-VALVE ENGINE | Shaped as shown in Fig 9 . | Shaped as shown in Fig 9 . |
| MUFFLER FOR 1-CAM 16-VALVE ENGINE | Shaped as shown in Fig 10 . | Shaped as shown in Fig 10 . |
AUTOMATIC TRANSMISSION
| PARTS NAME | 1994 MODEL | 1993 MODEL |
|---|---|---|
| SFI: 3 A/T KICK DOWN CABLE FOR THROTTLE BODYMODEL | Shaped as shown in Fig 11 . | No 3-speed A/T SFI model is available. |
| SELECTOR ASSEMBLY | Shaped as shown in Fig 12 . Key release system and manual returnare modified. | Shaped as shown in Fig 12 . |
| INTERLOCK SYSTEM | System is as shown in Fig 13 . | System is as shown in Fig 13 . |
TRANSFER CASE
| PARTS NAME | 1994 MODEL | 1993 MODEL |
|---|---|---|
| TRANSFER FOR 2WD 4 SPEED A/T MODELS (* ) | Equipped with Transfer shown in Fig 14 . | No 2WD 4-speed A/T model is available. |
| Note: (* ) This is a transfer extension housing with no front axle output. | ||
BODY ELECTRICAL SYSTEM
| PARTS NAME | 1994 MODEL | 1993 MODEL |
|---|---|---|
| COMBINATIONMETER WIRING | The Combination Meter Wiring is as shown in Fig 15 . | The Combination Meter Wiring is as shown in Fig 16 . |
| COOLANT TEMPERATUREGAUGE UNIT | Temp. Gauge Unit specs. are as shown below: | Temp. Gauge Unit specs. are as shown below: |
| COOLANT GAUGE UNIT TEMPERATURE | Temperature/Resistance 122°F (50°C)/189.4-259.6ohm 239°F (115°C)/24.2 - 28.1ohm |
Temperature/Resistance 122°F (50°C) 133.9-178.9ohm 176°F (80°C) 47.5 - 56.8ohm 212°F (100°C) 26.2 - 29.3ohm |
| CRUISE CONTROL SYSTEM AND ITS CIRCUIT | The Cruise Control System and its circuit is as shown in Fig 17 . | No Cruise available. |
| CRUISE CONTROL ACTUATOR FOR 1-CAM 16-VALVE MODEL | The Cruise Control Actuator is installed as shown in Fig 18 . | No Cruise Control available. |
GENERAL DESCRIPTION
MAINTENANCE SCHEDULE-FEDERAL VEHICLES (FOR NON-CALIFORNIA EMISSION SPEC. VEHICLES ONLY)
Interval: The interval should be judged by odometer reading or months, whichever comes first.
MAINTENANCE SCHEDULE-CALIFORNIA EMISSION SPEC. VEHICLES
Interval: The interval should be judged by odometer reading or months, whichever comes first.
AIR CONDITIONING (OPTIONAL)
Before adding/replacing compressor oil, recharging the system, or replacing component parts, be sure that these parts are applicable to the A/C system that is installed on the vehicle. Using inappropriate parts will result in leakage of refrigerant, damage to component parts, or other faulty condition. Refer to Fig 26 for R134a A/C system.
IDENTIFYING A/C SYSTEM
(refer to Fig 27 )
The type of A/C system can be identified by checking the following three areas:
- A/C CAUTION PLATE located under the hood above the front grille.
- Identification label on the A/C Compressor.
- Shape of the service (charge) valves.
CHECKING REFRIGERANT CHARGE
Dual Pressure Switch (refer to Fig 28 )
- Check the switch for continuity at normal temperature (approx. 77°F, 25°C) when A/C system has a proper charge of refrigerant and when A/C compressor is running under normal operation. In each case, the switch should show proper continuity.
- The switch should show no continuity when the following pressures are indicated:
R134a
High Side Pressure .... 455 psi (32 kg/cm2 ) or more
Low Side Pressure ..... 28 psi (20 kg/cm2 ) or below
R12
High Side Pressure ..... 383 psi (27 kg/cm2 ) or more
Low Side Pressure ...... 30 psi (2.1 kg/cm2 ) or more
PERFORMANCE TEST
After finishing all repairs, perform a performance test of the A/C system as follows:
PROCEDURE
- Connect the high and low side hoses of your manifold gauge set to the appropriate service valve fittings of the A/C Compressor.
- Start the engine and bring engine idle to 2000 rpm.
- Turn on A/C system. Set the blower switch at "HI" and the temperature lever at "COOL".
- Keep all windows and doors open.
- High pressure gauge reading should be within specified pressure range, as stated below:
- R134a: 256 - 313 psi (18.0 - 22.0 kg/cm2 )
- R12: 206 - 213 psi (14.5 - 15.0 kg/cm2 )
- Insert a dry bulb thermometer into the cool air air outlet and a dry and wet bulb thermometer (Psychrometer) close to the inlet of the cooling unit. See Fig 29 . Air inlet temp. should read within 77°-95°F (25°-35°C).
ELECTRONIC FUEL INJECTION SYSTEM (SFI)
For wiring diagram refer to Fig 30 .
| Component | Wire Color |
|---|---|
| 1. No. l Injector | B :Black |
| 2. No. 2 Injector | B/G :Black/Green |
| 3. No. 3 Injector | B/Bl :Black/Blue |
| 4. No. 4 Injector | B/R :Black/Red |
| 5. Idle Air Control Valve (IAC valve) | B/Y :Black/Yellow |
| 6. EVAP Solenoid Purge Valve | Bl :Blue |
| 7. EGR Solenoid Vacuum Valve | Bl/B :Blue/Black |
| 8. TCC Relay (3 A/T model) or Transmission Control Module (4 A/T model) | Bl/G :Blue/Green Bl/O :Blue/Orange Bl/R :Blue/Red |
| 9. Fuel Pump Relay | Bl/W :Blue/White |
| 10. Fuel Pump | Bl/Y :Blue/Yellow |
| 11. Heated Oxygen Sensor Heater | Br :Brown |
| 12 .Igniter | Br/Y :Brown/Yellow |
| 13. Ignition Coil | Gr :Gray |
| 14. Noise Suppressor | Gr/B :Gray/Black |
| 15. "CHECK ENGINE" Light | Gr/R :Gray/Red Gr/Y :Gray/Yellow |
| 16. Cancel Switch - Federal spec. vehicle except California Emission spec. and Canada spec. vehicle | Lg :Light Green Lg/B :Light Green/Black |
| 17. Mileage Sensor - Federal spec. vehicle except California Emission spec. and Canada spec. vehicle | Lg/R :Light Green/Red Lg/Y :Light Green/Yellow Lg/W :Light Green/White |
| 18. Monitor Coupler | O :Orange |
| 19. Data Link Connector | P :Pink |
| 20. Power Steering Pressure Switch (if equipped) | P/B :Pink/Black P/Bl :Pink/Blue |
| 21. VSS | P/G :Pink/Green |
| 22. Heated Oxygen Sensor | R :Red |
| 23. A/C Amplifier (if equipped) | R/B :Red/Black |
| 24. Starter Magnetic Switch | R/Y :Red/Yellow |
| 25. Clutch Pedal Position Switch (M/T) or Shift Switch (A/T) | Y :Yellow Y/B :Yellow/Black |
| 26. IAT Sensor | V :Violet |
| 27. EGRT Sensor (U.S.A. spec. vehicle only) | V/G :Violet/Green V/Y :Violet/Yellow |
| 28. ECI Sensor | --- |
| 29. TP Sensor | --- |
| 30. MAF Sensor | --- |
| 31. Camshaft Position Sensor | --- |
| 32. Main Relay | --- |
| 33. Circuit Fuse | --- |
| 34. Main Switch | --- |
| 35. Main Fuse | --- |
| 36. Battery | --- |
| 37. ECM | --- |
| Connector | Terminal |
|---|---|
| A1 | Power Source |
| A2 | Engine Start Switch |
| A3 | Duty Output Terminal |
| A4 | Igniter (IGt) |
| A5 | Fuel Pump Relay |
| A6 | Test Switch Terminal |
| A7 | VSS |
| A8 | Ignition Coil (IGf) |
| A9 | A/C Amplifier (if equipped) |
| A10 | Main Relay |
| A11 | Blank |
| A12 | Power Source |
| A13 | Power Source |
| A14 | "CHECK ENGINE" Light |
| A15 | EGR SV Valve |
| A16 | T.C.C.Relay (3 A/T model) or Trans. ControlModule (Coolant Temp. Signal, 4 A/T Model) |
| A17 | Diagnostic Switch Terminal |
| A18 | Idle Switch (in TP Sensor) |
| Al9 | P/S Press. Switch (if equipped) |
| A20 | Blank |
| A21 | Blank |
| A22 | Shift Switch (A/T model) |
| Connector | Terminal |
|---|---|
| B1 | Ground |
| B2 | Ground |
| B3 | Camshaft Position Sensor |
| B4 | Blank |
| B5 | Blank |
| B6 | Sensor Power Source |
| B7 | TP Sensor |
| B8 | MAF Sensor |
| B9 | ECT Sensor |
| B10 (4A/T model) | Transmission Control Module (Throttle Valve Opening Signal) |
| B11 | Injector No. 1 |
| B12 | Idle Air Control Valve |
| B13 | Injector No. 3 |
| B14 | Ground |
| Bl5 | Sensor Ground |
| B16 | Data Link Connector |
| B17 | EGRT Sensor (U.S.A. spec. only) |
| B18 | Blank |
| B19 | Blank |
| B20 | Heated Oxygen Sensor |
| B21 | IAT Sensor |
| B22 | Blank |
| B23 | Heated Oxygen Sensor Heater |
| B24 | Injector No. 2 |
| B25 | EVAP SP Valve |
| B26 | Injector No. 4 |
TORQUE CONVERTER CLUTCH (TCC) RELAY CONTROL SYSTEM (3 A/T MODEL)
This system controls the TCC relay, which is one of the components that controls the A/T Torque Converter Clutch. An example of the circuit is shown in Fig 31 .
The TCC Solenoid Valve, under the control of the Brake Pedal Switch (Stop Light Switch), A/T Oil Pressure Switch, and TCC Relay opens and closes the A/T oil passage to lock and unlock the Torque Converter Clutch.
The factors that the ECM uses to control the relay are signals from:
- Throttle Position Sensor
- CMP Sensor (Camshaft Position)
- ECI Sensor (Coolant Temp. Sensor)
The ECM turns ON the relay only when the Throttle Valve opening is in the shaded zone shown in Fig 32 , provided that the engine is at normal operating temperature of 140°F (60°C) or higher.
The battery voltage is applied to the TCC Solenoid valve only when
- The relay is on
- The Brake Pedal is released (Brake Pedal Switch is ON)
- Oil Pressure Switch is ON
If the Brake Pedal is depressed, or the A/T oil pressure is too low, even when the relay is ON, the TCC Solenoid Valve circuit opens and no voltage is applied.
AUTOMATIC TRANSMISSION BRAKE INTERLOCK SYSTEM
GENERAL DESCRIPTION
This system consists of a Shift Lock Solenoid Control System and an Interlock Cable Control System.
The Shift Lock Solenoid Control System is designed to keep the Selector Lever from being shifted out of the "P" position until the Ignition Switch is turned ON and the Brake Pedal is depressed.
The Interlock Cable Control System is designed to keep the Selector Lever shown in Fig 34 , from shifting out of the "P" position until the Ignition Switch is turned to the "ACC" or "ON" position. It also keeps the Ignition Key from being pulled out of the key slot until the Selector Lever is in the "P" position.
Operations
SHIFT LOCK SOLENOID CONTROL
(refer to Fig 35 )
When the Selector Lever is in the "P" position, the Ignition Key is in the "ON" position, and the Brake Pedal is depressed, electrical current is allowed to flow to the Solenoid. As the Lock Plate is drawn toward the solenoid under these conditions, it frees the Detent Pin, allowing the Selector Lever to be shifted from the "P" position to any other position that is desired.
If the Ignition Key is in either the "LOCK" or "ACC" positions and the brake pedal is not depressed, electrical current will not flow to the solenoid. even when the selector lever is in the "P" position. In this state, the Lock Plate is pushed away from the solenoid by spring force, obstructing the Detent Pin's movement. Thus, the Selector Lever Button will not operate and the Selector Lever cannot be taken out of the "P" position.
SHIFT LOCK SOLENOID MANUAL RELEASE
As an auxiliary device, a Shift Lock Release is installed on the Shift Selector Column. This will allow you to shift out of the "P" position without having to depress the brake pedal.
INTERLOCK CABLE OPERATION
- Locking the Ignition Key When the Selector Lever is shifted to any position other than "P" (such as R, N, D, 2, or L), the Key Release Cam turns in the "a" direction, as shown in Fig 36 . This causes the cable connecting the Key Release Cam and the Key Interlock Lever to remain stationary, causing the Key Interlock Lever to be pushed into the Key Cylinder by cable locking the Ignition Key. Once the Ignition Key is in the "ON" position. it s impossible to turn it toward the "LOCK" position.
- Releasing the Ignition Key When the Selector Lever is shifted into the "P" position and the Shift Knob Button is released, the Key Release Cam turned by the Select Lever (Detent Pin) pushes the cable, which then pushes the Key Interlock Lever out of the Key Cylinder. This allows the Key Cylinder to rotate freely. See Fig 37 .
AUTOMATIC TRANSMISSION (4 A/T)
ELECTRONIC SHIFT CONTROL SYSTEM (refer to Fig 39 for wiring diagram)
TRANSMISSION CONTROL MODULE (TCM)
The TCM is an electronic circuit component that controls gear shift and idle-up, according to the signal from each sensor. It is a microcomputer, consisting of an IC, Transistor, Diode, etc. It is installed at the right side of the Steering Column.
TRANSFER CASE (2WD 4 A/T MODEL)
GENERAL DESCRIPTION (refer to Fig 40 and Fig 41 )
The aluminum Transfer Case mounted to the back of the 4-speed Automatic Transmission contains the Input Gear, Countershaft and gear, Output Rear Shaft, and Output Low Gear.
This transfer, which is different from the 4WD model, is not equipped with a selective mechanism for 4H, 4L 2H, or N.
The power coming through the input gear is transferred as it is through the Reduction Shift Sleeve, which keeps the Input Gear and the Output Rear Shaft in constant engagement; both to the Output Rear Shaft and then to the Propeller Shaft.
When reassembling the Transfer Case after servicing, be sure to 1) use sealant to seal the case, and 2) tighten the bolts exactly to the specified torque with a torque wrench. Also note that the case has an oil gutter to provide proper lubrication, even under harsh conditions.
BODY ELECTRICAL SYSTEM
CRUISE CONTROL SYSTEM FOR l-CAM 16-VALVE ENGINE MODEL WITH M/T (if equipped)
The Cruise Control Actuator is installed in the vehicle as shown in Fig 42 .
CRUISE CONTROL SYSTEM FOR 4 A/T MODEL (if equipped)
GENERAL DESCRIPTION
The Cruise Control System is a device which maintains a preset vehicle speed while driving at highway speeds. It allows the driver to operate the vehicle at constant speeds between 25 - 75 mph (40 - 120 km/h) without having to depress the accelerator pedal (constant cruising). The system also has functions that will allow you to change the vehicle's speed without touching the Accelerator Pedal ("SET COAST" and "ACCEL/RESUME" Switches, Cancel Cruise Control ) "CANCEL" Switch, and resume the speed in memory automatically after the Cruise Control is cancelled ("ACCEL/RESUME" Switch).
The system mainly consists of a Vehicle Speed Sensor, a Control Unit, an Actuator, and "SET COAST/ACCEL RESUME/CANCEL" Switch. See Fig 43 . Refer to Fig 44 for Cruise Control System Wiring Diagram.
| Component | Function |
|---|---|
| Vehicle Speed Sensor (In Combination Meter) | Converts vehicle's speed into an electrical pulse to be sent to the Cruise Control Unit. |
| Cruise Control Unit | Executes centralized control by means of a microcomputer over all functions, including setting a constant speed, resuming it, setting coast, limiting maximum/minimum speed, and canceling Cruise Control. |
| Cruise Control Actuator | Actuates link lever of accelerator pedal, according to a signal from the Cruise Control Unit to control vehicle's speed. |
| SET COAST Switch | When this switch is depressed and released while cruising within 25-75 mph (40-120 km/h), the vehicles speed at this moment is stored into memory and is maintained. If the switch is continually held down, the vehicle will coast until the switch is released. When released, the vehicle's speedat this moment is again stored into memory and maintained. |
| ACCEL RESUME Switch | When this switch is depressed while cruisingwithin 25-75 mph (40-120 km/h), the vehicle's speed will continue to increase until the switch is released. When released,the vehicle's speed at this moment is storedinto memory and is maintained. |
| CANCEL Switch | When this switch is depressed, the Cruise Control is cancelled. |
CANCEL CONDITIONS
Constant cruising is cancelled under the following conditions:
- Ignition Switch is turned OFF
- Cruise Main Switch is turned OFF.
- Vehicle Speed has slowed down to lower than the minimum operating speed of 25 mph (40 kg/h).
- Vehicle speed varied beyond canceled speed range of +/- 9 mph (+/- 15 km/h) from preset speed.
- When vehicle speed exceeds the maximum operating speed of 80 mph (130 hm/h).
- Brake Pedal is depressed (Brake Light Switch is turned OFF).
- Shift Switch is turned ON, usually when Shift Lever is shifted into Neural.
- CANCEL Switch is turned ON.