92 samurai..new ecu, no spark or fuel - Suzuki Forums: Suzuki Forum Site
Suzuki Forum Suzuki Forums

» Auto Insurance
» Featured Product
Wheel & Tire Center

Go Back   Suzuki Forums: Suzuki Forum Site > Suzuki Models > Suzuki Jimny, Sierra & Samurai Forum
Register Home Forum Active Topics Photo Gallery Garage Search Today's Posts Mark Forums Read Auto EscrowAuto LoansInsurance Advertise

Suzuki-Forums.com is the premier Suzuki All Forum on the internet. Registered Users do not see the above ads.
Reply
 
LinkBack Thread Tools Display Modes
Old 07-27-2012, 01:14 AM   #1 (permalink)
Newbie
 
Join Date: Jul 2012
Location: Southeast South Dakota
Posts: 8
Gallery: 0
Jason in SD is on a distinguished road
Default 92 samurai..new ecu, no spark or fuel

I recently purchased a 92 Samurai that wasn't running. Previous owner bought it the same way. Upon trying to start it, I found it has no spark. After reading some troubleshooting on this and other forums, I sent the ecu in for repair. I installed rebuilt ecu and still have no spark. I also realized the fuel pump does not run although the relay near ecu was clicking. I swapped relays with each other and repeated clicking stopped but still have no fuel or spark. All fuses are good and tight. I have been searching locally for a running Samurai to swap test parts but the only ones I find are carb models. Any help greatly appreciated.

(side note) I have read dozens of threads where similar problems are discussed and links to troubleshooting or schematics are now dead or the original poster never reported what the problem ended up being. Very frustrating!
Jason in SD is offline   Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Old 07-27-2012, 08:45 AM   #2 (permalink)
Senior
 
Join Date: Nov 2009
Location: Mt Juliet, TN
Posts: 293
Gallery: 0
Haptown is on a distinguished road
Default

Here are some resource links for the FSM that might be helpful. The first link has a pretty good troubleshooting guide.

Suzuki Samurai TBI Supplement

1988 Samurai Factory Service Manual
Haptown is offline   Reply With Quote Quick reply to this message
Old 07-27-2012, 01:40 PM   #3 (permalink)
Senior
 
Join Date: Nov 2009
Location: Mt Juliet, TN
Posts: 293
Gallery: 0
Haptown is on a distinguished road
Default

Here is the wiring diagram for the EFI models that I forgot that I had.



wiring_diagram_efi.jpg
Haptown is offline   Reply With Quote Quick reply to this message
 
Old 07-27-2012, 03:30 PM   #4 (permalink)
Moderator
 
Join Date: Mar 2009
Location: Georgetown, Guyana
Posts: 11,954
Gallery: 0
fordem will become famous soon enough
Default

Do you have any more information about the history of the "no start" problem - or should we just start troubleshooting from scratch?

Was it a running vehicle that just failed or is it a project that was never completed?

Can we assume that the mechanicals are intact? A broken timing belt will cuase the symptoms you describe - as will many other things - we just have to find a place to start - and we can eliminate some of the simple stuff very simply.

Remove the distributor cap and watch the rotor whilst you crank the engine over - does the rotor turn? There's a sensor in the distributor that's the "key" to both fuel & spark - if the ECU never sees that signal you'll get neither fuel nor spark.
__________________
98 - 1.8 Mitsubishi Pajero iO
98 - 2.0 Suzuki Grand Vitara - SQ420
05 - 2.0 Suzuki Grand Vitara - JB420
15 - 2.4 Kia Sportage
fordem is offline   Reply With Quote Quick reply to this message
Old 07-27-2012, 04:01 PM   #5 (permalink)
Newbie
 
Join Date: Jul 2012
Location: Southeast South Dakota
Posts: 8
Gallery: 0
Jason in SD is on a distinguished road
Default

Thank you for the assistance..

Previous owner couldn't tell me anything other than it had no spark when he bought it. I am operating under the assumption that whatever keeps it from running now is what took it out of service (apart from a sloppy front axle, but that's another story)

The distributor is turning when cranked and engine seems to be in proper cam timing. I replaced both relays near the ECU with no improvements. I also attached a plug wire directly to the coil to bypass distributor to no avail. Another symptom that reared it's head today was that the battery drained overnight.

As it sits now:

No Spark
Fuel pump does not run
Rebuilt ECU (Speedometer Repair Guy) He said it had a bad trace in fuel inj circuit)
Two new relays
Fuses all good

I will spend a few hours with test light this evening and report
Jason in SD is offline   Reply With Quote Quick reply to this message
Old 07-27-2012, 06:09 PM   #6 (permalink)
Newbie
 
Join Date: Jul 2012
Location: Southeast South Dakota
Posts: 8
Gallery: 0
Jason in SD is on a distinguished road
Default We have fuel.

Tracked fuel pump to backwoods toggle wiring. Seems they didn't want to spent $20 for a new fuel relay but spent $5 for a switch and sacrificed a nice extension cord for wire. Repaired and properly running off keyswitch/relay. Removed all other added wiring and accounted for any added toggles.

Still no spark (not that I expected any for that repair) I have 12v at coil with key on. 12v at efi fuse and all others except I read about 2.5 v at fuse for dome light which is long gone with wires capped. ??

White wire that attaches to positive post of battery has current draw with key off. No clock, radio or lights on to account for this.
Jason in SD is offline   Reply With Quote Quick reply to this message
Old 07-29-2012, 12:35 AM   #7 (permalink)
Senior
 
Join Date: Apr 2008
Location: Trinidad And Tobago
Posts: 193
Gallery: 0
ebattleon is on a distinguished road
Default

Start by pulling fuses from the Fuse Box one at a time until your mysterious current drain disappears...then trace that circuit for the fault. After that you should look at the ignition circuit, and test the dizzy based on FSM testing procedures.
Good luck.
__________________
[B]Common Sense[/B] is not that common.
ebattleon is offline   Reply With Quote Quick reply to this message
Old 07-29-2012, 11:38 AM   #8 (permalink)
Newbie
 
Join Date: Jul 2012
Location: Southeast South Dakota
Posts: 8
Gallery: 0
Jason in SD is on a distinguished road
Default

The current drain is still there with all fuses removed. I'm afraid I will be unwrapping the harness this afternoon to look for a short.

FSM= Factory service manual? Looking for one now.
Jason in SD is offline   Reply With Quote Quick reply to this message
Old 07-29-2012, 12:38 PM   #9 (permalink)
Guest
 
Join Date: Jun 2008
Location: The Kingdom of England
Posts: 5,299
Gallery: 5
Rhinoman is on a distinguished road
Default

Did the guy that repaired the ECU test it? it seems that many people that claim to do repairs don't have a tester. I would try and get the power restored to the white wire, its best to have that back up power supply, it pretty much guarantees that the ECU will power up correctly if therev are no major faults.
Do the relays click on when you turn on the ignition? does the Check Engine Light come on?

Last edited by Rhinoman; 07-29-2012 at 12:58 PM.
Rhinoman is offline   Reply With Quote Quick reply to this message
Old 07-29-2012, 02:42 PM   #10 (permalink)
Newbie
 
Join Date: Jul 2012
Location: Southeast South Dakota
Posts: 8
Gallery: 0
Jason in SD is on a distinguished road
Default

There is always a power draw on the white wire (short) although it is a small one.

The guy that repaired the ECU says he has done thousands of Samurai/Tracker ecu repairs and put a lifetime warranty on it. I'm still trying to find a running efi samurai locally to test it.

Relay clicks and fuel pump does run not that it is wired correctly. Check engine lights, (Code 12) and engine cranks. I am seeing 12v at coil with key on.
Jason in SD is offline   Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Reply

  Suzuki Forums: Suzuki Forum Site > Suzuki Models > Suzuki Jimny, Sierra & Samurai Forum

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Suzuki Forums: Suzuki Forum Site forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:
Insurance
Please select your insurance company (Optional)

Log-in



Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Powered by vBadvanced CMPS v3.2.3

All times are GMT -5. The time now is 08:00 PM.



Powered by vBulletin® Copyright ©2000 - 2019, Jelsoft Enterprises Ltd.
Search Engine Optimization by vBSEO 3.6.1
Garage Plus vBulletin Plugins by Drive Thru Online, Inc.
vBulletin Security provided by vBSecurity v2.2.2 (Pro) - vBulletin Mods & Addons Copyright © 2019 DragonByte Technologies Ltd.