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Old 04-15-2015, 12:29 AM   #1 (permalink)
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Default Time to put 'er down... send her off to the farm

On my 2007 Reno with manual transmission:
TLDR: Coolant overflow bottle venting, head gasket blown, possible transmission slave cylinder failure imminent, new O2 sensor not responding.

For quite a while now, I've had issues with coolant boiling over and venting from the overflow bottle. I suspect this was from an inexperienced technician who overtightened the cap, expecting it to "click" like a gas cap. I think this caused the system to lose pressure.

It what may or may not be related, the head gasket blew. Mechanic in a bottle (Blue Devil Head Gasket sealer) seems to have stemmed the flow, since there is no more blue smoke, and a recent oil change reported no indications of coolant in the oil. This was after a significant amount of coolant venting from the overflow bottle (enough to see from under the hood and condense on the window).

I've replaced various manual transmission components (slave cylinder under warranty), and a second time for $1300, rather than be stranded 1700 miles from home. I'm now losing brake fluid (not visibly, but the reservoir runs low, and the brake warning light comes on if not properly monitored). This happens every 4 months or so.

I've replaced the O2 sensor after getting an intermittent MIL code for a low voltage on the sensor that sits in the exhaust manifold. The issue did not resolve, and now I also see errors indicating that there is no response at all from the sensor. I've tried chasing the wiring harness to check for a burned or shorted wire, but didn't see anything.
Errors - P0134 - O2 Sensor Circuit No Activity Detected and
P0131 - O2 Sensor Circuit Low Voltage

Is there anything practical that can be done to save it, or is it best to cut my losses and find a mechanic who's looking for a project car?

Also, at some point an oil change tech forgot to replace my spark plug/valve cover cover (the part that displays the engine displacement and looks like this: http://i.ebayimg.com/00/s/MTIwMFgxNjAw/z/9PMAAOSw8cNUT8QL/$_12.JPG

Would anyone have a spare or be able to suggest a used spot beyond eBay or a scrap yard in a state that doesn't have much in the of Suzuki parts?
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:cool: [COLOR="Silver"][B][I]Service Manuals[/I][/B]:
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Last edited by kc-guy; 04-15-2015 at 12:40 AM.
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Old 04-17-2015, 04:19 PM   #2 (permalink)
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Sucks to hear about all the issues..

If you've been around the forums enough, head gasket issues seem to be pretty common with the stock head gasket. I'd bet it was your headgasket that is going bad, and allowing exhaust gases into the coolant which over-pressurize the system and cause it to overflow... that's what happened to me and several others at least. Sometimes it only shows symptoms under certain conditions.

I hate the slave cylinder design on this car where its one piece concentric unit integrated with the release bearing. Have to remove the transmission just to change something simple like that! I've had 3 of them fail on me, although I'm using a heavier clutch as well.

Strange about the O2 code... you would have to do some further troubleshooting to figure out where the issue is. It could be a corroded connection on the O2 sensor harness or a broken wire. Could also be a bad connection on the pins at the ECU itself... You can perform continuity and resistance checks with a multimeter.
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Old 04-18-2015, 02:05 PM   #3 (permalink)
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Thanks. I've been around the forums quite a bit, although not as much in the last few months. I was a good little forum-reader and checked thru a couple dozen pages to see if there were any easy ways out, but didn't find what I was looking for.

I've actually had the head gasket, water pump, and timing belt replaced previously as well. I wasn't sure about a resistance check, since I'd be pushing T-pins thru the insulation to check, and wasn't sure how reliable that would be.

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Old 07-16-2015, 02:01 PM   #4 (permalink)
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Hi! Sorry about your problems that's rough. Two things about the 02 sensor if you haven't gotten rid of the car already lol. There could be a break in the harness behind the engine. I've heard of this happening before. Also it could be as simple as it burned out from the engine overheating or from burning coolant. Yes you can perform a resistance check to see what the problem is and yes, OEM head gaskets aren't the best. Was the head ever checked to see if it was warped. Or did you have it machined flat before it was out back together? The break fluid, it's possible one of the brake lines has a small leak in it. There rubber molded to metal and can fail over time. I believe the parts are fairly cheap and not such a big deal to replace. Hope you get everything worked out.
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Old 07-18-2015, 10:21 PM   #5 (permalink)
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Thanks, 7.
I'm sure you're right about the engine overheating causing the wiring shorts.
The head gasket has blown twice. The first time, it was replaced by the dealership and the block was brought to a machine shop to ensure it was still within spec.

I've decided to bypass the wiring harness and run wires straight to the ECM, but I'm having trouble with the wiring harness. I went into a bit more detail in a new post (with and OBDII dump and pictures): https://www.suzuki-forums.com/general...cm-wiring.html
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Old 07-23-2015, 01:21 AM   #6 (permalink)
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Update:

O2 sensor: Splicing in a new wiring harness at the first junction where it combines into the rest of the harness didn't help. I'll have to run new wires the entire way.

Coolant venting issue: Caused by an oil change tech who over-tightened the cap a long time ago. I never put the two things together until now. A $10 trip to the junkyard later, I have a new overflow tank and seems to hold pressure.

If only I had made that trip before the coolant got too low and the head gasket blew. :/
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Old 08-26-2015, 12:40 PM   #7 (permalink)
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Lessons learned lol. Cars are finicky and unfortunate they can't always tell us what's wrong.
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