Suzuki DF200 - Engine Control System

3
6
ENGINE CONTROL SYSTEM 3-1
CONTENTS
ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM STRUCTURE ..................................................... 3- 2
SYSTEM STRUCTURE 1 .......................................................................... 3- 2
SYSTEM STRUCTURE 2 .......................................................................... 3- 3
COMPONENTS FOR SYSTEM CONTROL ....................................................... 3- 5
ENGINE CONTROL MODULE (ECM) ...................................................... 3- 5
ECM CONNECTOR/TERMINALS LAYOUT .............................................3- 6
ECM INTERNAL STRUCTURE ................................................................ 3- 7
LOCATION OF SENSOR AND SWITCH ..................................................3- 8
SENSOR AND SWITCH ............................................................................3-10
IGNITION SYSTEM ............................................................................................ 3-17
IGNITION CONTROL SYSTEM ................................................................ 3-18
ELECTRONIC FUEL INJECTION SYSTEM ....................................................... 3-20
FUEL INJECTION CONTROL SYSTEM ...................................................3-20
FUEL DELIVERY SYSTEM COMPONENTS ............................................ 3-22
HIGH PRESSURE FUEL PUMP CONTROL SYSTEM ............................. 3-25
LOW PRESSURE FUEL PUMP CONTROL SYSTEM .............................3-26
EVAPORATION PURGE SYSTEM ........................................................... 3-26
AIR INTAKE COMPONENTS ................................................................... 3-27
IDLE AIR CONTROL SYSTEM ................................................................. 3-28
MULTI-STAGE INDUCTION ............................................................................... 3-31
OUTLINE ...................................................................................................3-31
SYSTEM COMPOSITION ......................................................................... 3-31
SYSTEM OPERATION .............................................................................. 3-32
VVT (Variable Valve Timing) SYSTEM ............................................................. 3-33
CAUTION SYSTEM ............................................................................................ 3-35
OVER-REVOLUTION CAUTION SYSTEM ............................................... 3-35
LOW OIL PRESSURE CAUTION SYSTEM ............................................. 3-36
OVERHEAT CAUTION ............................................................................. 3-37
LOW BATTERY VOLTAGE CAUTION SYSTEM ..................................... 3-38
SELF-DIAGNOSTIC SYSTEM ............................................................................ 3-39
PRIORITY/CODE/PATTERN FOR SELF-DIAGNOSTIC
SYSTEM OPERATION .............................................................................. 3-39
CONDITION FOR SELF-DIAGNOSTIC SYSTEM OPERATION .............. 3-41
FAIL-SAFE SYSTEM .......................................................................................... 3-43
PRE-PROGRAMMED VALUE FOR FAIL-SAFE SYSTEM ...................... 3-43
OPERATING HOUR INDICATION SYSTEM ...................................................... 3-44
OIL CHANGE REMINDER SYSTEM .................................................................. 3-45
START-IN-GEAR PROTECTION SYSTEM ........................................................ 3-46
O2 FEEDBACK SYSTEM ................................................................................... 3-47
INSPECTION ...................................................................................................... 3-48
PRECAUTION ON SYSTEM INSPECTION ..............................................3-48
26-PIN & 34-PIN TEST CORD .................................................................. 3-48
INSPECTION FOR ECM CIRCUIT VOLTAGE .........................................3-49
INSPECTION FOR RESISTANCE ............................................................3-52
COMPONENT INSPECTIONS .................................................................. 3-53
MULTI-STAGE INDUCTION ..................................................................... 3-63
REMOVAL/INSTALLATION ............................................................................... 3-66
FLYWHEEL ............................................................................................... 3-66
CKP SENSOR ...........................................................................................3-68
CMP SENSOR ........................................................................................... 3-69
IAC VALVE ................................................................................................ 3-69
OIL PRESSURE SWITCH ......................................................................... 3-69
OCV (Oil control valve) ............................................................................3-70
THROTTLE CONTROL ......................................................................................3-71
SYNCHRONIZING THROTTLE BODIES ..................................................3-71
THROTTLE CONTROL CABLE ...............................................................3-72