check engine SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

6B-4 ENGINE COOLING
DIAGNOSIS
DIAGNOSIS TABLE
Condition Possible Cause Correction
Engine overheats
(It is in case that radia-
tor fan operates)Loose or broken water pump belt Adjust or replace.
Not enough coolant Check coolant level and add as
necessary.
Faulty thermostat Replace.
Faulty water pump Replace.
Dirty or bent radiator fins Clean or remedy.
Coolant leakage on cooling system Repair.
Clogged radiator Check and replace radiator as nec-
essary.
Faulty radiator cap Replace.
Improper ignition timing Adjust.
Dragging brakes Adjust brake.
Slipping clutch Adjust or replace.
Poor charge battery Check and replace as necessary.
Poor generation generator Check and repair.
ECT sensor faulty Check and replace as necessary.
Radiator cooling fan relay No.2 and/or No.3
faultyCheck and replace as necessary.
ECM faulty Check and replace as necessary.
Wiring or grounding faulty Repair and necessary.
Equipped with too much electric load part Dismount.
Radiator cooling fan motor faulty Check and replace as necessary.
Engine overheats
(It is in case that radia-
tor fan won’t operates)Fuse blown Check “RADTR fan” fuse and
check for short circuit to ground.
Radiator cooling fan relay No.1 Check and replace as necessary.
ECT sensor faulty Check and replace as necessary.
Radiator cooling fan motor faulty Check and replace as necessary.
Wiring or grounding faulty Repair as necessary
ECM faulty Check and replace as necessary.

ENGINE COOLING 6B-5
SYSTEM CIRCUIT
SYSTEM CIRCUIT INSPECTION
Refer to “RADIATOR COOLINGFAN CONTROL SYSTEM CHECK” in Section 6
1. Main fuse box 6. ECM main fuse 11. Radiator and condenser cooling fan motor
2. Generator 7. ECM main relay 12. Refrigerant pressure triple switch (if equipped with A/C)
3. Battery 8. Radiator and condenser cooling fan relay No.1 13. ECT sensor
4. Battery fuse 9. Radiator and condenser cooling fan relay No.2 14. ECM
5. RADTR fuse 10. Radiator and condenser cooling fan relay No.3 15. TO A/C switch
ACG
15A 30A
BLU/WHT
BLK/YEL
BLK
BLU
ORN
BLK
BLK
BLUH–
H+
L– L+
GRN/BLK
BLU/BLK
BRN/WHT
YEL/GRN
PNK/GRN
PPL/YEL
LT GRN/BLK
BLK/RED
BLK/RED 80A
145
6
2
3
7
8
9
11
10
13 15
12
14

6B-6 ENGINE COOLING
MAINTENANCE
COOLANT LEVEL CHECK
To check level, lift hood and look at “see-through” coolant reser-
voir tank.
It is not necessary to remove radiator cap to check coolant level.
When engine is cool, check coolant level in reservoir tank (1).
A normal coolant level should be between FULL mark (2) and
LOW mark (3) on reservoir tank (1).
If coolant level is below LOW mark (3), remove reservoir tank cap
(4) and add proper coolant to tank to bring coolant level up to
FULL mark (2). Then, reinstall cap (4) and align match marks (5)
on tank and cap (4). WARNING:
Do not remove radiator cap to check engine coolant level; check coolant visually at the see-through
coolant reservoir.
Coolant should be added only to reservoir as necessary.
As long as there is pressure in the cooling system, the temperature can be considerably higher
than the boiling temperature of the solution in the radiator without causing the solution to boil.
Removal of the radiator cap while engine is hot and pressure is high will cause the solution to boil
instantaneously and possibly with explosive force, spewing the solution over engine, fenders and
person removing cap. If the solution contains flammable anti-freeze such as alcohol (not recom-
mended for use at any time), there is also the possibility of causing a serious fire.
WARNING:
To help avoid danger of being burned :
do not remove reservoir tank cap while coolant is boil-
ing, and
do not remove radiator cap while engine and radiator
are still hot.
Scalding fluid and steam can be blown out under pres-
sure if either cap is taken off too soon.
NOTE:
If proper quality antifreeze is used, there is no need to
add extra inhibitors or additives that claim to improve
system.
They may be harmful to proper operation of system,
and are unnecessary expense.
When installing reservoir cap, align arrow marks on
reservoir and cap.
LOW FULL
5 41
1 32 1

ENGINE COOLING 6B-7
ENGINE COOLING SYSTEM INSPECTION
AND SERVICE
1) Check cooling system for leakage or damage.
2) Wash radiator cap and filler neck with clean water by remov-
ing radiator cap when engine is cold.
3) Check coolant for proper level and freeze protection.
4) Using a pressure tester (1), check system and radiator cap
(2) for proper pressure holding capacity.
If replacement of cap is required, use a proper cap for this
vehicle.
Cooling system and radiator cap holding pressure (for
inspection)
: 110 kPa (1.1 kg/cm
2, 15.6 psi)
5) Tighten hose clamps and inspect all hoses. Replace hoses
whenever cracked, swollen or otherwise deteriorated.
6) Clean frontal area of radiator core.
COOLING SYSTEM FLUSH AND REFILL
1) Remove radiator cap when engine is cool.
a) Turn cap counterclockwise slowly until it reaches a “stop”.
(Do not press down while turning it).
b) Wait until pressure is relieved (indicated by a hissing
sound) then press down on cap and continue to turn it
counterclockwise.
2) With radiator cap removed, run engine until upper radiator
hose is hot (this shows that thermostat is open and coolant is
flowing through system). WARNING:
To help avoid danger of being burned, do not remove
radiator cap while engine and radiator are still hot.
Scalding fluid and steam can be blown out under pres-
sure if cap is taken off too soon.
NOTE:
After installing radiator cap to radiator, make sure that
the ear of cap lines is parallel to radiator.
WARNING:
To help avoid danger of being burned, do not remove
radiator cap while engine and radiator are still hot.
Scalding fluid and steam can be blown out under pres-
sure if cap is taken off too soon.

ENGINE COOLING 6B-9
WATER PUMP/GENERATOR DRIVE BELT TENSION INSPECTION AND
ADJUSTMENT
1) Inspect belt for cracks, cuts, deformation, wear and cleanli-
ness. If it is necessary to replace belt, refer to “WATER
PUMP/GENERATOR DRIVE BELT” in this section.
2) Check belt for tension. Belt is in proper tension when it
deflects 4.5 to 5.5 mm (0.18 – 0.22 in.) under thumb pres-
sure (about 10 kg or 22 lb.).
Water pump / generator drive belt tension “a”
4.5 – 5.5 mm (0.18 – 0.22 in.) as deflection/10 kg (22 lbs)
3) If belt is too tight or too loose, adjust it to proper tension by
displacing generator position.
4) Tighten generator adjusting bolt and pivot bolts as specified
torque.
Tightening torque
Generator adjusting bolt (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Generator pivot bolt (b) : 50 N·m (5.0 kg-m, 36.0 lb-ft)
5) Connect negative cable at battery. WARNING:
Disconnect negative cable at battery before checking and adjusting belt tension.
To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still
hot. Scalding fluid and steam can be blown out under pressure if cap is taken off too soon.
NOTE:
When replacing belt with a new one, adjust belt tension
to 3 – 4 mm (0.12 – 0.16 in.).
“a”

6B-10 ENGINE COOLING
ON-VEHICLE SERVICE
SYSTEM COMPONENTS
WARNING:
Check to make sure that engine coolant temperature is cold before removing any part of cooling
system.
Also be sure to disconnect negative cord from battery terminal before removing any part.
1. Radiator 11. To throttle body 21. To timing chain cover
2. Reservoir tank 12. To heater unit 22. O-Ring
3. Radiator cap 13. To water pump 23. Gasket
4. Drain plug 14. Radiator and condenser cooling fan assembly 24. Water outlet cap O-ring No.1
5. Radiator outlet hose 15. Water inlet pipe No.1 25. Water outlet cap O-ring No.2
6. Radiator inlet hose 16. Water inlet pipe No.2 26. Thermostat cap bolts
7. Thermostat 17. Thermostat cap 27. Thermostat case bolts
8. ECT sensor 18. Water outlet cap Tightening torque
9. Thermostat case 19. Heater inlet hose Do not reuse.
10. To cylinder head 20. Heater outlet hose

6B-12 ENGINE COOLING
COOLING WATER PIPES OR HOSES
REMOVAL
1) Drain cooling system.
2) To remove these pipes or hoses, loosen clamp on each
hose and pull hose end off.
INSTALLATION
Install removed parts in reverse order of removal procedure, not-
ing the following.
Tighten each clamp securely.
Refill cooling system with proper coolant referring to “COOL-
ING SYSTEM REFILL”.
THERMOSTAT
REMOVAL
1) Drain cooling system by loosening drain plug of radiator
referring to “COOLING SYSTEM DRAINING”.
2) Remove air cleaner assembly and resonator referring to sec-
tion 6A1
3) Remove intake manifold referring to Section 6A1.
4) Remove generator referring to Section 6H.
5) Disconnect water hose (1) and heater hose (2) from each
pipe.
6) Remove thermostat case (3) with thermostat cap (4) and
water inlet pipe (5).
7) Remove water inlet pipe with thermostat cap from thermo-
stat case.
8) Remove thermostat.
INSPECTION
Make sure that air bleed valve (1) of thermostat is clean.
Should this valve be clogged, engine would tend to overheat.
Check to make sure that valve seat is free from foreign mat-
ters which would prevent valve from seating tight.
Check thermostat seal (2) for breakage, deterioration or any
other damage.

ENGINE COOLING 6B-13
Check thermostatic movement of wax pellet as follows :
a) Immerse thermostat (1) in water, and heat water gradually.
b) Check that valve starts to open at specific temperature.
Temperature at which valve begins to open
: 80 – 84°C (176 – 183°F)
Temperature at which valve become fully open
: 95 – 97°C (203°F)
Valve lift
: More than 8 mm at 95°C (203°F)
If valve starts to open at a temperature substantially below or
above specific temperature, thermostat unit should be replaced
with a new one. Such a unit, if reused, will bring about overcool-
ing or overheating tendency.
INSTALLATION
Reverse removal procedure for installation noting the following
points.
When positioning thermostat (1) on thermostat case (2), be
sure to position it so that air bleed valve (3) comes at posi-
tion as shown in figure.
Use new O-rings when installing.
Adjust water pump belt tension referring to WATER PUMP/
GENERATOR DRIVE BELT TENSION INSPECTION AND
ADJUSTMENT in this section.
Adjust A/C compressor belt tension (if equipped) referring to
Section 1B.
Refill cooling system with proper coolant referring to “COOL-
ING SYSTEM REFILL”.
Verify that there is no coolant leakage at each connection.
2. Thermometer
3. Heater

6B-14 ENGINE COOLING
RADIATOR
REMOVAL
1) Disconnect negative cable at battery.
2) Drain cooling system by loosening drain plug of radiator.
Refer to “COOLING SYSTEM DRAINING”.
3) Disconnect connector of cooling fan motor.
4) Remove air cleaner inlet hose (1) and suction pipe (2).
5) Remove reservoir tank (1) and then its bracket (2).
6) Disconnect radiator inlet and outlet hoses from radiator.
7) Remove cooling fan assembly (3).
8) Remove radiator.
INSPECTION
Check radiator for leakage or damage. Straighten bent fins, if
any.
CLEANING
Clean frontal area of radiator cores.
INSTALLATION
Reverse removal procedures, noting the followings.
Refill cooling system with proper coolant referring to “COOL-
ING SYSTEM REFILL”.
After installation, check each joint for leakage.

ENGINE COOLING 6B-15
RADIATOR AND CONDENSER COOLING FAN
Refer to “RADIATOR AND CONDENSER COOLING FAN” in
Section 1B for removal, inspection and installation.
RADIATOR AND CONDENSER COOLING FAN
RELAY
INSPECTION
1) Disconnect negative (–) cable at battery.
2) Remove radiator and condenser cooling fan relay No.1 (1),
No.2 (2) and No.3 (3) from vehicle.
3) Check that there is no continuity between terminal “c” and
“b”. If there is continuity, replace relay.
4) Connect battery positive (+) terminal to terminal “b” of relay.
Connect battery negative (–) terminal “a” of relay.
Check continuity between terminal “c” and “d”.
If there is no continuity when relay is connected to the bat-
tery, replace relay.
WATER PUMP/GENERATOR DRIVE BELT
REMOVAL
1) Disconnect negative cable at battery.
2) Loosen drive belt adjusting bolt (2) and generator pivot bolt
(3).
When servicing car equipped with A/C, remove compressor
drive belt (4) before removing water pump belt (1).
Refer to “COMPRESSOR DRIVE BELT” in Section 1B.
3) Slacken belt by displacing generator and then remove it.
ba
1
c
dc
ad
b
2
3
1
c
d
2, 3b a
ac
d
b
2
3
1
4