fuel SUZUKI SWIFT 2000 1.G RG413 Service Owner's Manual

6-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS
FUEL PRESSURE RELIEF PROCEDURE
After making sure that engine is cold, release fuel pressure as fol-
lows.
1) Place transmission gear shift lever in “Neutral” (Shift selector
lever to “P” range for A/T model), set parking brake, and
block drive wheels.
2) Remove relay box cover.
3) Disconnect fuel pump relay (1) from relay box.
4) Remove fuel filler cap to release fuel vapor pressure in fuel
tank and then reinstall it.
5) Start engine and run it till it stops for lack of fuel. Repeat
cranking engine 2-3 times for about 3 seconds each time to
dissipate fuel pressure in lines. Fuel connections are now
safe for servicing.
6) Upon completion of servicing, connect fuel pump relay (1) to
relay box and install relay box cover.
FUEL LEAKAGE CHECK PROCEDURE
After performing any service on fuel system, check to make sure
that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump)
and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply fuel pres-
sure to fuel line. (till fuel pressure is felt by hand placed on
fuel feed hose.)
2) In this state, check to see that there are no fuel leakages
from any part of fuel system.
ENGINE DIAGNOSIS
GENERAL DESCRIPTION
This vehicle is equipped with an engine and emission control system which are under control of ECM.
The engine and emission control system in this vehicle are controlled by ECM. ECM has an On-Board Diagnos-
tic system which detects a malfunction in this system and abnormality of those parts that influence the engine
exhaust emission. When diagnosing engine troubles, be sure to have full understanding of the outline of “On-
Board Diagnostic System” and each item in “Precaution in Diagnosing Trouble” and execute diagnosis accord-
ing to “ENGINE DIAGNOSTIC FLOW TABLE”.
There is a close relationship between the engine mechanical, engine cooling system, ignition system, exhaust
system, etc. and the engine and emission control system in their structure and operation. In case of an engine
trouble, even when the malfunction indicator lamp (MIL) doesn’t turn ON, it should be diagnosed according to
this flow table.CAUTION:
This work must not be done when engine is hot. If done
so, it may cause adverse effect to catalyst.
1

6-8 ENGINE GENERAL INFORMATION AND DIAGNOSIS
FREEZE FRAME DATA
ECM stores the engine and driving conditions (in the from of data
as shown in the figure) at the moment of the detection of a mal-
function in its memory. This data is called “Freeze frame data”.
Therefore, it is possible to know engine and driving conditions
(e.g., whether the engine was warm or not, whether the vehicle
was running or stopped, whether air/fuel mixture was lean or rich)
when a malfunction was detected by checking the freeze frame
data. Also, ECM has a function to store each freeze frame data
for three different malfunctions in the order as the malfunction is
detected. Utilizing this function, it is possible to know the order of
malfunctions that have been detected. Its use is helpful when
rechecking or diagnosing a trouble.
Priority of freeze frame data :
ECM has 4 frames where the freeze frame data can be stored.
The first frame stores the freeze frame data of the malfunction
which was detected first. However, the freeze frame data stored
in this frame is updated according to the priority described below.
(If malfunction as described in the upper square “1” below is
detected while the freeze frame data in the lower square “2” has
been stored, the freeze frame data “2” will be updated by the
freeze frame data “1”.)
In the 2nd through the 4th frames, the freeze frame data of each
malfunction is stored in the order as the malfunction is detected.
These data are not updated.
Shown in the table below are examples of how freeze frame data
are stored when two or more malfunctions are detected.
[A] : An Example of Freeze Frame Data
[B] : 1st, 2nd or 3rd in parentheses here represents which position in the order
the malfunction is detected.
PRIORITY FREEZE FRAME DATA IN FRAME 1
1 Freeze frame data at initial detection of mal-
function among misfire detected (P0300-
P0304), fuel system too lean (P0171) and fuel
system too rich (P0172)
2 Freeze frame data when a malfunction other
than those in “1” above is detected

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-9
Freeze Frame Data Clearance :
The freeze frame data is cleared at the same time as clearance of
diagnostic trouble code (DTC).
DATA LINK CONNECTOR (DLC)
DLC (1) is in compliance with SAEJ1962 in its installation posi-
tion, the shape of connector and pin assignment.
Serial data line (K line of ISO 9141) is used for SUZUKI scan tool
(Tech-1) or generic scan tool to communicate with ECM, TCM,
ABS control module and Air bag SDM.
SUZUKI serial data line is used for SUZUKI scan tool (Tech -1) to
communicate with immobilizer control module.FRAME
FRAME 1 FRAME 2 FRAME 3 FRAME4
FREEZE FRAME
DATA to be updated1st FREEZE
FRAME DATA2nd FREEZE
FRAME DATA3rd FREEZE
FRAME DATA
MALFUNCTION
DETECTED
ORDERNo malfunction No freeze frame data
1 P0400 (EGR)
detectedData at P0400
detectionData at P0400
detection––
2 P0171 (Fuel sys-
tem) detectedData at P0171
detectionData at P0400
detectionData at P0171
detection–
3 P0300 (Misfire)
detectedData at P0171
detectionData at P0400
detectionData at P0171
detectionData at P0300
detection
4 P0301 (Misfire)
detectedData at P0171
detectionData at P0400
detectionData at P0171
detectionData at P0300
detection
2. B+
3. Serial data line (K line of ISO 9141)
4. ECM ground
5. Body ground
6. SUZUKI serial data line
2
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ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-11
DATA LINK CONNECTOR (DLC)
ELC (1) is in compliance with SAEJ1962 in its installation posi-
tion, the shape of connector and pin assignment.
Serial data line (K line of ISO 9141) is used for SUZUKI scan tool
(Tech-1) to communicate with ECM, TCM, ABS control module
and Air bag SDM.
SUZUKI serial data line is used for SUZUKI scan tool (Tech -1) to
communicate with immobilizer control module.
PRECAUTION IN DIAGNOSING TROUBLE
Do not disconnect couplers from ECM, battery cable from battery, ECM ground wire harness from engine or
main fuse before confirming diagnostic information (DTC, freeze frame data, etc.) stored in ECM memory.
Such disconnection will erase memorized information in ECM memory.
Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan
tool (Tech-1) or generic scan tool (Vehicle with immobilizer indicator lamp). Before using scan tool, read its
Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and
how to use it.
Priorities for diagnosing troubles (Vehicle with immobilizer indicator lamp).
If two or more DTCs are stored, proceed to the flow table of the DTC which has detected earliest in the order
(it can be identified by referring to freeze frame data) and follow the instruction in that table.
If no instructions are given, troubleshoot diagnostic trouble codes according to the following priorities.
–Diagnostic trouble codes (DTCs) other than DTC P0171/P0172 (Fuel system too lean/too rich), DTC
P0300/P0301/P0302/P0303/P0304 (Misfire detected) and DTC P0400 (EGR flow malfunction)
–DTC P0171/P0172 (Fuel system too lean/too rich) and DTC P0400 (EGR flow malfunction)
–DTC P0300/P0301/P0302/P0303/P0304 (Misfire detected)
Be sure to read “Precautions for Electrical Circuit Service” in Section 0A before inspection and observe what
is written there.
ECM Replacement
When substituting a known-good ECM, check for following conditions. Neglecting this check may cause
damage to a known-good ECM.
–Resistance value of all relays, actuators is as specified respectively.
–MAP sensor and TP sensor are in good condition and none of power circuits of these sensors is shorted
to ground.AMBIENT
TEMPERATURETIME TO CUT POWER TO ECM
Over 0°C (32°F) 60 sec. or longer
Under 0°C (32°F) Not specifiable. Select a place with
temperature higher than 0°C (32°F).
2. B+
3. Serial data line (K line of ISO 9141)
4. ECM ground
5. Body ground
6. SUZUKI serial data line
2
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6-18 ENGINE GENERAL INFORMATION AND DIAGNOSIS
P0141 HO2S heater circuit mal-
function (Sensor-2)Terminal voltage is lower than specifica-
tion at heater OFF or it is higher at heater
ON. (or heater circuit or short)2 driving
cyclesNot
applicable
P0171 Fuel system too lean Short term fuel trim or total fuel trim (short
and long terms added) is larger than spec-
ification for specified time or longer.
(fuel trim toward rich side is large.)2 driving
cyclesNot
applicable
P0172 Fuel system too rich Short term fuel trim or total fuel trim (short
and long term added) is smaller than spec-
ification for specified time or longer.
(fuel trim toward lean side is large.)2 driving
cyclesNot
applicable
P0300
P0301
P0302
P0303
P0304Random misfire detected
Cylinder 1 misfire detected
Cylinder 2 misfire detected
Cylinder 3 misfire detected
Cylinder 4 misfire detectedMisfire of such level as to cause damage
to three way catalystMIL
flashing
during
misfire
detectionNot
applicable
Misfire of such level as to deteriorate emis-
sion but not to cause damage to three way
catalyst2 driving
cyclesNot
applicable
P0325
(No.17)Knock sensor circuit mal-
functionKnock sensor circuit low input
Knock sensor circuit high input1 driving
cycle1 driving
cycle
P0335
(No.23)Crankshaft position sensor
circuit malfunctionNo signal for 2 sec. during engine cranking 1 driving
cycle1 driving
cycle
P0340
(No.15)Camshaft position sensor
circuit malfunctionNo signal during engine running 1 driving
cycle1 driving
cycle
P0400 Exhaust gas recirculation
flow malfunction detectedExcessive or insufficient EGR flow 2 driving
cyclesNot
applicable
P0420 Catalyst system efficiency
below thresholdOutput waveforms of HO2S-1 and HO2S-2
are similar.
(Time from output voltage change of
HO2S-1 to that of HO2S-2 is shorter than
specification.)2 driving
cyclesNot
applicable
P0443 Purge control valve circuit
malfunctionPurge control valve circuit is open or
shorted to ground2 driving
cyclesNot
applicable
P0480 Radiator fan control circuit
malfunctionRadiator cooling fan relay terminal voltage
is low when cooling temp. is lower than
specification2 driving
cyclesNot
applicable
P0500
(No.16)Vehicle speed sensor mal-
functionNo signal while running in “D” range or
during fuel cut at decelerating2 driving
cycles1 driving
cycle
P0505 Idle control system malfunc-
tionNo closed signal to IAC valve is detected 2 driving
cyclesNot
applicable
P0601
(No.71)Internal control module
memory check sum errorData write error (or check sum error) when
written into ECM2 driving
cycles1 driving
cycle
P1450
(No.29)Barometric pressure sen-
sor circuit malfunctionBarometric pressure is lower or higher
than specification. (or sensor malfunction)1 driving
cycle1 driving
cycle DTC
NO.DETECTING ITEM DETECTING CONDITION
(DTC will set when detecting :)MIL
(vehicle
with immo-
bilizer indi-
cator lamp)MIL
(vehicle
without
immobi-
lizer indica-
tor lamp)

6-20 ENGINE GENERAL INFORMATION AND DIAGNOSIS
FAIL-SAFE TABLE
When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction continues to
exist but that mode is canceled when ECM detects normal condition after that.P1620
(No.84)ECU code not registered
Refer to Section 8G P1621
(No.83)No ECU code transmitted from Immobilizer
Control Module
P1622
(No.82)Fault in ECM
P1623
(No.81)ECU code not matched DTC NO. DETECTING ITEM DETECTING CONDITION
(DTC will set when detecting :)MIL
NOTE:
For (
) marked No. in DTC column, it is used for vehicle without immobilizer indication lamp.
DTC No.12 appears when none of the other codes is identified.
For vehicle with immobilizer indication lamp, star (
✱) marked DTCs can be read with SUZUKI scan
tool ECM application.
DTC NO. TROUBLE AREA FAIL-SAFE OPERATION SYMPTOM
P0105
(No.11)MAP SENSOR ECM uses value determined by throt-
tle opening and engine speed.
ECM stops EGR, EVAP purge and
idle air control.Hard starting/ rough or incorrect
idle/ excessive fuel consumption/
hesitation/ poor acceleration/
surge/ detonation or spark knock
P0110
(No.18)IAT SENSOR ECM controls actuators assuming
that intake air temperature is 20°C.Hard starting/ rough or incorrect
idle/ excessive fuel consumption/
hesitation poor acceleration/ deto-
nation or spark knock
P0115
(No.19)ECT SENSOR ECM controls actuators assuming
that engine coolant temperature is
80°C.
Radiator fan motor ON.Hard starting/ rough or incorrect
idle/ excessive fuel consumption/
hesitation poor acceleration/ deto-
nation or spark knock
P0120
(No.13)TP SENSOR ECM controls actuators assuming
that throttle opening is 20°.Rough or incorrect idle/ excessive
fuel consumption/ hesitation/ poor
acceleration
P0130,
P0134
(No.14)HEATED OXYGEN
SENOR-1–Hard starting/rough or incorrect
idle/ excessive fuel consumption/
hesitation/ poor acceleration
P0325
(No.17)KNOCK SENSOR–Detonation/ spark knock
P0335
(No.23)CKP SENSORFix ignition timing.
ECM changes injection control sys-
tem from sequential injection to
simultaneous one.Hard staring/ engine stall

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-21
P0340
(No.15)CMP SENSOR ECM changes injection control sys-
tem from sequential injection to simul-
taneous one.Hard starting
P0400 EGR VALVE–Hard starting/rough or incorrect
idle/ excessive fuel consumption/
hesitation/ poor acceleration/
surge/ detonation or spark knock/
engine stall
P0420 CATALYST––
P0443 PURGE CONTROL
VALVE–Rough or incorrect idle/ surge/
hard starting/ engine stall
P0480 RADIATOR FAN
CONTROL SYSTEM–Engine overheating
P0500
(No.16)VEHICLE SPEED
SENSORECM stops idle air control. Rough or incorrect idle
P0505 IDLE CONTROL
SYSTEM–Engine stall/ rough or incorrect idle
P0601
(No.71)ECM INTERNAL–Hard starting/ rough or incorrect
idle/ excessive fuel consumption/
detonation or spark knock/ hesita-
tion poor acceleration/
P1450
(No.29)BAROMETRIC
PRESSURE SEN-
SORECM controls actuators assuming
that barometric pressure is
100 kPa (760 mmHg).Hard starting/ rough or incorrect
idle DTC NO. TROUBLE AREA FAIL-SAFE OPERATION SYMPTOM

6-22 ENGINE GENERAL INFORMATION AND DIAGNOSIS
VISUAL INSPECTION
Visually check following parts and systems.
INSPECTION ITEM REFERRING SECTION
Engine oil – level, leakage Section 0B
Engine coolant – level, leakage Section 0B
Fuel – level, leakage Section 0B
A/T fluid – level, leakage Section 0B
Air cleaner element – dirt, clogging Section 0B
Battery – fluid level, corrosion of terminal
Water pump belt – tension, damage Section 0B
Throttle cable – play, installation
Section 6E1 Vacuum hoses of air intake system – disconnection, looseness,
deterioration, bend
Connectors of electric wire harness – disconnection, friction
Fuses – burning Section 8
Parts – installation, bolt – looseness
Parts – deformation
Other parts that can be checked visually
Check following items at engine start, if possible
–Malfunction indicator lamp – Operation Section 6
–Charge warning lamp – Operation Section 6H
–Engine oil pressure warning lamp – Operation Section 8 (Section 6 for pressure check)
–Engine coolant temp. meter – Operation Section 8
–Fuel level meter – Operation Section 8
–Tachometer, if equipped – Operation
–Abnormal air being inhaled from air intake system
–Exhaust system – leakage of exhaust gas, noise

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-23
ENGINE BASIC INSPECTION
This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been
found in visual inspection.
Follow the flow table carefully.
Step Action Yes No
1Was “ENGINE DIAG. FLOW TABLE” per-
formed?Go to Step 2. Go to “ENGINE DIAG.
FLOW TABLE”.
2 Check battery voltage.
Is it 11 V or more?Go to Step 3. Charge or replace battery.
3 Is engine cranked? Go to Step 4. Go to “DIAGNOSIS” in
Section 6G.
4 Does engine start? Go to Step 5. Go to Step 7.
5 Check idle speed as follows :
1) Warm up engine to normal operating temp.
2) Shift transmission to neutral position for M/T
(“P” position for A/T).
3) All of electrical loads are switched off.
4) Check engine idle speed with scan tool.
See Fig. 1.
Is it 650 – 750 r/min (700 – 800 r/min. for A/T
vehicle)?Go to Step 6. Go to “ENGINE DIAGNO-
SIS TABLE”.
6 Check ignition timing as follows :
1) When SUZUKI scan tool is not available,
disconnect scan tool from DLC and connect
test switch terminal of monitor connector to
ground. See Fig. 2.
When using SUZUKI scan tool, select
“MISC” mode on SUZUKI scan tool and fix
ignition timing to initial one. See Fig. 3.
2) Using timing light (1), check initial ignition
timing. See Fig. 4.
Is it 5° ± 3° BTDC at specified idle speed?Go to “ENGINE DIAGNO-
SIS TABLE”.Check ignition control
related parts referring to
Section 6F1.
7 Is immobilizer control system equipped? Go to Step 8. Go to Step 9.
8 Check immobilizer system malfunction as fol-
lows.
1) Check immobilizer indicator lamp or MIL
(malfunction indicator lamp) for flashing.
Is it flashing when ignition switch is turned to
ON position?Go to “DIAGNOSIS” in
Section 8G.Go to Step 9.
9 Check fuel supply as follows :
1) Check to make sure that enough fuel is
filled in fuel tank.
2) Turn ON ignition switch for 2 seconds and
then OFF. See Fig. 5.
Is fuel pressure felt from fuel feed hose (1)
when ignition switch is turned ON?Go to Step 11. Go to Step 10.
10 Check fuel pump for operating.
Was fuel pump operating sound heard from fuel
filler for about 10 seconds after ignition switch
ON and stop?Go to “DIAG. FLOW
TABLE B-3”.Go to “DIAG. FLOW
TABLE B-2”.

6-24 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Fig. 1 for Step 5
Fig. 2 for Step 611 Check ignition spark as follows :
1) Disconnect injector couplers.
2) Remove spark plugs and connect them to
high tension cords.
3) Ground spark plugs.
4) Crank engine and check if each spark plug
sparks.
Is it in good condition?Go to Step 12. Go to “DIAGNOSIS” in
Section 6F1.
12 Check fuel injector for operation as follows :
1) Install spark plugs and connect injector con-
nectors.
2) Using sound scope (1), check operating
sound of each injector (2) when cranking
engine. See Fig. 6.
Was injector operating sound heard from all
injectors?Go to “ENGINE DIAGNO-
SIS TABLE”.Go to “DIAG. FLOW
TABLE B-1”. Step Action Yes No
[A] : When not using SUZUKI scan tool:[A]