service SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

6C-6 ENGINE FUEL
FUEL TANK INLET VALVE
REMOVAL
1) Remove fuel filler cap.
2) Insert hose of a hand operated pump into fuel filler hose (1)
and drain fuel in space “A” in the figure.
3) Hoist vehicle and remove clamp (2) and fuel filler hose (1)
from fuel tank.
4) Remove fuel tank inlet valve (1) using flat-bladed screw-
driver.
INSPECTION
Check fuel tank inlet valve for the followings.
Damage
Smooth opening and closing
If any damage or malfunction is found, replace.WARNING:
Refer to the WARNING at the beginning of ON-VEHICLE
SERVICE in this section.
CAUTION:
Do not force pump hose into fuel tank, or pump hose
may damage fuel tank inlet valve (2).
1
2
CAUTION:
Be careful not to damage fuel tank inlet valve (1) with flat-
bladed screwdriver.

ENGINE FUEL 6C-7
INSTALLATION
1) Install fuel tank inlet valve (1) to fuel tank.
2) Install fuel filler hose (1) to fuel tank and secure it with clamp
(2).
For proper installation, refer to “COMPONENTS” under “ON-
VEHICLE SERVICE”.
3) Lower vehicle and install fuel filler cap.
FUEL TANK
REMOVAL
1) Relieve fuel pressure in fuel feed line according to “FUEL
PRESSURE RELIEF PROCEDURE” in Section 6.
2) Disconnect negative cable at battery.
3) Hoist vehicle.
4) Disconnect fuel filler hose (1) and breather hose (2) from
filler neck (3).
5) Due to absence of fuel tank drain plug, drain fuel tank by
pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
1
2
WARNING:
Before starting the following procedure, be sure to
observe “PRECAUTIONS”.
CAUTION:
Never disconnect fuel filler hose (1) from fuel tank inlet. If
half or more of fuel is remaining to fuel tank, fuel over
flows in this case and come out.
CAUTION:
Do not force pump hose into fuel tank, or pump hose
may damage fuel tank inlet valve.
Never drain or store fuel in an open container due to
possibility of fire or explosion.
2
1
3

6C-10 ENGINE FUEL
5) Connect fuel feed hose (1) and vapor hose (2) to each pipe
as shown in figure and clamp them securely.
6) Connect negative cable at battery.
With engine OFF, turn ignition switch to ON position and
check for fuel leaks.
FUEL PUMP ASSEMBLY
REMOVAL
1) Remove fuel tank from vehicle. Refer to “FUEL TANK”.
2) Disconnect fuel breather hose (1), fuel vapor hose (2) and
pipes from fuel pump assembly.
When disconnecting joint of fuel feed line (3) from pipe,
unlock joint by inserting special tool between pipe and joint
lock first.
Special tool
(A) : 09919-47020 CAUTION:
When connecting joint, clean outside surfaces of pipe
where joint is to be inserted, push joint into pipe till
joint lock clicks and check to ensure that pipes are
connected securely, or fuel leak may occur.
Never let the fuel hoses touch the ABS sensor harness
(if equipped).
WARNING:
Refer to the PRECAUTIONS at the beginning of ON-VEHI-
CLE SERVICE.
1
23

ENGINE AND EMISSION CONTROL SYSTEM 6E1-1
6F1
6F2
6G
6H
6E1
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 6E1
ENGINE AND EMISSION CONTROL SYSTEM
CONTENTS
GENERAL DESCRIPTION ............................ 6E1-2
AIR INTAKE SYSTEM ............................... 6E1-5
FUEL DELIVERY SYSTEM ....................... 6E1-6
FUEL PUMP ........................................... 6E1-6
ELECTRONIC CONTROL SYSTEM .......... 6E1-7
ENGINE & EMISSION CONTROL
INPUT/OUTPUT TABLE ........................ 6E1-8
ECM INPUT/OUTPUT CIRCUIT
DIAGRAM............................................... 6E1-9
ECM TERMINAL ARRANGEMENT
TABLE .................................................. 6E1-13
ON-VEHICLE SERVICE .............................. 6E1-15
ACCELERATOR CABLE
ADJUSTMENT ..................................... 6E1-15
IDLE SPEED/IDLE AIR CONTROL
(IAC) DUTY INSPECTION ................... 6E1-15
IDLE MIXTURE INSPECTION /
ADJUSTMENT (VEHICLE WITHOUT
HEATED OXYGEN SENSOR) ............. 6E1-17
AIR INTAKE SYSTEM ............................. 6E1-18
THROTTLE BODY ............................... 6E1-18IDLE AIR CONTROL VALVE (IAC
VALVE) ................................................ 6E1-20
FUEL DELIVERY SYSTEM ..................... 6E1-21
FUEL PRESSURE INSPECTION ........ 6E1-21
FUEL PUMP WITH PRESSURE
REGULATOR ....................................... 6E1-22
FUEL INJECTOR ................................. 6E1-23
ELECTRONIC CONTROL SYSTEM ....... 6E1-27
ENGINE CONTROL MODULE
(ECM) ................................................... 6E1-27
MANIFOLD ABSOLUTE PRESSURE
SENSOR (MAP SENSOR)................... 6E1-27
THROTTLE POSITION SENSOR (TP
SENSOR) ............................................. 6E1-28
INTAKE AIR TEMPERATURE
SENSOR (IAT SENSOR) ..................... 6E1-29
ENGINE COOLANT TEMPERATURE
SENSOR (ECT SENSOR) ................... 6E1-30
HEATED OXYGEN SENSOR (HO2S-1
AND HO2S-2) ...................................... 6E1-31
CAMSHAFT POSITION SENSOR ....... 6E1-32 WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System :
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
Whether the following system (parts) are used in the particular vehicle or not depends on vehicle
specifications. Be sure to bear this in mind when performing service work.
EGR valve
Heated oxygen sensor(s) or CO adjusting resistor
Three way catalytic converter
Immobilizer indicator lamp
Knock sensor

ENGINE AND EMISSION CONTROL SYSTEM 6E1-15
ON-VEHICLE SERVICE
ACCELERATOR CABLE ADJUSTMENT
With accelerator pedal depressed fully (1), check clearance
between throttle lever (2) and lever stopper (3) (throttle body)
which should be within following specification.
If measured value is out of specification, adjust it to specification
with cable adjusting nut (4).
Accelerator cable adjustment clearance (with pedal
depressed fully)
“a” : 0.5 – 2.0 mm (0.02 – 0.07 in.)
IDLE SPEED/IDLE AIR CONTROL (IAC) DUTY
INSPECTION
Before idle speed/IAC duty check, make sure of the following.
Lead wires and hoses of Electronic Fuel Injection and engine
emission control systems are connected securely.
Accelerator cable has some play, that is, it is not tight.
Valve lash is checked and adjusted according to mainte-
nance schedule.
Ignition timing is within specification.
All accessories (wipers, heater, lights, A/C, etc.) are out of
service.
Air cleaner has been properly installed and is in good condi-
tion.
No abnormal air inhaling from air intake system.
After above items are all confirmed, check idle speed and IAC
duty as follows.
NOTE:
Before starting engine, place transmission gear shift
lever in “Neutral” (shift selector lever to “P” range for A/T
vehicle), and set parking brake and block drive wheels.

6E1-16 ENGINE AND EMISSION CONTROL SYSTEM
1) Connect SUZUKI scan tool (1) to DLC with ignition switch
OFF, if it is available.
2) Warm up engine to normal operating temperature.
3) Check engine idle speed and “IAC duty” as follows :
4) When using SUZUKI scan tool :
a) Select “Data List” mode on scan tool to check “IAC duty”.
(A) : 09931-76011 (SUZUKI scan tool)
(B) : Mass storage cartridge
(C) : 09931-76030 (16/14 pin DLC cable)
5) When using duty meter (vehicle without immobilizer indicator
lamp) :
a) Set tachometer.
b) Using service wire (2), ground “Diag. switch terminal” (4) in
monitor connector (3) and connect duty meter between
“Duty output terminal” (5) and “Ground terminal” (6) of mon-
itor connector (3).
6) If duty and/or idle speed is out of specifications, inspect idle
air control system referring to Diagnostic Flow Table B-4 Idle
Air Control System Check in Section 6.
Engine idle speed and IAC duty
7) Remove service wire from monitor connector (1).
8) Check that specified engine idle speed is obtained with A/C
ON if vehicle is equipped with A/C.
If not, check A/C ON signal circuit and idle air control sys-
tem.
[A] : When using SUZUKI scan tool
[B] : When using duty meter (Vehicle without immobilizer indicator lamp)
NOTE:
IAC duty can be checked using monitor connector only
for vehicle not equipped with immobilizer indicator lamp.
A/C OFF A/C ON
M/T vehicle 700 ± 50 r/min (rpm)
5 – 25 %850 ± 50 r/min (rpm)
A/T vehicle
at P/N range750 ± 50 r/min (rpm)
5 – 25 %850 ± 50 r/min (rpm)
NOTE:
Above duty values are ON duty (low voltage rate) meter
indications.
(C)
(A)
(B)
1 2
6
54
3-+
[A]
[B]
1

ENGINE AND EMISSION CONTROL SYSTEM 6E1-25
4) Install suitable vinyl tube onto injector nozzle to prevent fuel
from splashing out when injecting.
5) Put graduated cylinder under injector as shown.
6) Operate fuel pump and apply fuel pressure to injector as fol-
lows:
7) When using SUZUKI scan tool :
a) Connect SUZUKI scan tool to DLC with ignition switch OFF.
b) Turn ignition switch ON, clear DTC and select “MISC TEST”
mode on SUZUKI scan tool.
c) Turn fuel pump ON by using SUZUKI scan tool.
(A) : 09931-76011 (SUZUKI scan tool)
(B) : Mass storage cartridge
(C) : 09931-76030 (16/14 pin DLC cable)
8) Without using SUZUKI scan tool :
a) Remove fuel pump relay from connector.
b) Connect two terminals of relay connector using service wire
(1) as shown in figure.
c) Turn ignition switch ON.
9) Apply battery voltage (3) to injector (2) for 15 seconds and
measure injected fuel volume with graduated cylinder.
Test each injector two or three times.
If not within specification, replace injector.
Injected fuel volume
: 43 – 47 cc/15 sec. (1.45/1.51 – 1.58/ 1.65 US/Imp. oz/15
sec.)
10) Check fuel leakage from injector nozzle. Do not operate
injector for this check (but fuel pump should be at work).
If fuel leaks (1) more than following specifications, replace.
Fuel leakage (1)
: Less than 1 drop/min. CAUTION:
Check to make sure that connection is made between
correct terminals. Wrong connection can cause damage
to ECM, wire harness, etc.
4. Keep as far apart as possible
[A] : When using SUZUKI scan tool
[B] : When not using SUZUKI scan tool
(C)
(A)
(B)
1 [A]
[B]

IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) 6F1-1
6G
6F2
6G
6H
6K
6F1
7A
7A1
7A1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 6F1
IGNITION SYSTEM
(ELECTRONIC IGNITION SYSTEM)
CONTENTS
GENERAL DESCRIPTION ............................. 6F1-2
DIAGNOSIS .................................................... 6F1-3
ON-VEHICLE SERVICE ................................. 6F1-5
IGNITION SPARK TEST ............................. 6F1-5
HIGH-TENSION CORDS ............................ 6F1-5
SPARK PLUGS ........................................... 6F1-6IGNITION COIL ASSEMBLY
(INCLUDING IGNITOR) .............................. 6F1-7
CRANKSHAFT POSITION SENSOR
(CKP SENSOR) .......................................... 6F1-7
IGNITION TIMING ...................................... 6F1-8
SPECIAL TOOL ............................................. 6F1-9

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM 6F1-5
ON-VEHICLE SERVICE
IGNITION SPARK TEST
1) Disconnect all injector couplers (1) from injectors.
2) Remove spark plug and check it for condition and type refer-
ring to “Spark Plugs” in this section.
3) If OK, connect ignition coil coupler to ignition coil assembly
and connect spark plug to ignition coil assembly or high-ten-
sion cord. Ground spark plug.
4) Crank engine and check if each spark plug sparks.
5) If no spark is emitted, inspect the related parts as described
under “Diagnosis” earlier in this section.
HIGH-TENSION CORDS
1) Remove air intake pipe and cylinder head upper cover.
2) Disconnect high-tension cords (2) from ignition coil assem-
blies (1) while gripping each cap.
3) Pull out high-tension cords from spark plugs while gripping
each cap.
4) Measure resistance of high-tension cord (1) by using ohm-
meter.
High-tension cord resistance
: 4 -10 k
Ω/m (1.2 - 3.0 kΩ/ft)
5) If resistance exceeds specification, replace high-tension
cord(s). WARNING:
Without disconnection of injector couplers, combustible
gas may come out from spark plug holes during this test
and may get ignited in engine room.
CAUTION:
Removal of high-tension cords together with clamps
will be recommended so as not to damage their inside
wire (resistive conductor).
For the same reason, pull out each connection by grip-
ping cap portion.

6F1-8 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM)
IGNITION TIMING
INSPECTION
1) When using SUZUKI scan tool, connect SUZUKI scan tool to
DLC with ignition switch OFF.
Special tool
(A) : 09931-76011 (SUZUKI scan tool)
(B) : Mass storage cartridge
(C) : 09931-76030 (16/14 pin DLC cable)
2) Start engine and warm it up to normal operating tempera-
ture.
3) Make sure that all of electrical loads except ignition are
switched off.
4) Check to be sure that idle speed is within specification.
(Refer to Section 6E1)
5) Fix ignition timing to initial one as follows.
Select “MISC” mode on SUZUKI scan tool and fix ignition
timing to initial one.
If scan tool is not available (vehicle without immobilizer indi-
cator lamp), connect D and E terminals of monitor connector
(1) by using service wire so that ignition timing is fixed on ini-
tial one.
6) Using timing light (1), check that ignition timing is within
specification.
Initial ignition timing (test switch terminal grounded or
fixed with SUZUKI scan tool)
: 5
± 3° BTDC at idle speed
Ignition order
: 1-3-4-2 NOTE:
Ignition timing is not adjustable. If ignition timing is
out of specification, check system related parts.
Before starting engine, place transmission gear shift
lever in “Neutral” (shift selector lever to “P” range for
A/T model), and set parking brake.
(C)
(A)
(B)
D
E1