radiator SUZUKI SWIFT 2000 1.G RG413 Service Repair Manual

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.

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

6E1-2 ENGINE AND EMISSION CONTROL SYSTEM
CRANKSHAFT POSITION SENSOR .. 6E1-32
VEHICLE SPEED SENSOR (VSS) ...... 6E1-33
FUEL LEVEL SENSOR (GAUGE) ....... 6E1-33
KNOCK SENSOR (IF EQUIPPED) ...... 6E1-33
MAIN RELAY, FUEL PUMP RELAY
AND RADIATOR FAN RELAY NO.1.... 6E1-33
FUEL CUT OPERATION ..................... 6E1-34
RADIATOR FAN CONTROL
SYSTEM .............................................. 6E1-34
RADIATOR FAN RELAY NO. 2 AND
NO.3 ..................................................... 6E1-34OUTPUT SIGNALS OF THROTTLE
VALVE OPENING AND ENGINE
COOLANT TEMP. (VEHICLE WITH
A/T ONLY) ........................................... 6E1-36
EMISSION CONTROL SYSTEM ............. 6E1-36
EGR SYSTEM ..................................... 6E1-36
EVAPORATIVE EMISSION CONTROL
SYSTEM .............................................. 6E1-37
PCV SYSTEM ...................................... 6E1-39
SPECIAL TOOL .......................................... 6E1-40
TIGHTENING TORQUE SPECIFICATION . 6E1-41
GENERAL DESCRIPTION
The engine and emission control system is divided into 4 major sub-systems : air intake system, fuel delivery
system, electronic control system and emission control system.
Air intake system includes air cleaner, throttle body, IAC valve and intake manifold.
Fuel delivery system includes fuel pump, delivery pipe, fuel pressure regulator, etc. Electronic control system
includes ECM, various sensors and controlled devices.
Emission control system includes EGR, EVAP and PCV system.

ENGINE AND EMISSION CONTROL SYSTEM 6E1-7
ELECTRONIC CONTROL SYSTEM
The electronic control system consists of 1) various sensors which detect the state of engine and driving condi-
tions, 2) ECM which controls various devices according to the signals from the sensors and 3) various controlled
devices.
Functionally, it is divided into nine sub systems :
Fuel injection control system
Idle speed control system
Fuel pump control system
A/C control system (if equipped)
Radiator fan control system
EGR system (if equipped)
Evaporative emission control system
Oxygen sensor heater control system (if equipped)
Ignition control system
Also, with A/T model, ECM sends throttle valve opening signal and coolant temp. signal to transmission control
module to control A/T.
INFORMATION SENSORS CONTROL DEVICES OTHERS
1. MAP sensor a : Fuel injector A : ECM
2. TP sensor b : EVAP canister purge valve B : Main relay
3. IAT sensor c : Fuel pump relay C : EVAP canister
4. ECT sensor d : EGR valve (step motor) (if equipped) D : Monitor connector
5. Heated oxygen sensor-1 (if equipped) e : Malfunction indicator lamp E : Data link connector
5-1. Heated oxygen sensor-2 (if equipped) f : Ignition coil assembly F : A/C EVAP thermistor (if equipped)
6. VSS g : Radiator fan control relay G : TCM (A/T)
7. Transmission range switch (A/T) h : IAC valve
8. Battery i : Immobilizer indicator lamp
9. CMP sensor
10. CKP sensor
11. Fuel level sensor (gauge) (in fuel tank)
12. Stop lamp switch
13. Knock sensor (if equipped)

6E1-8 ENGINE AND EMISSION CONTROL SYSTEM
ENGINE & EMISSION CONTROL INPUT/OUTPUT TABLE
INPUTOUTPUT
ELECTRIC CONTROL DEVICE
FUEL LEVEL SENSOR (VEHICLE WITH IMMOBILIZER INDICATOR LAMP) For detecting fuel level DIAGNOSIS SWITCH (VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP)
BAROMETRIC PRESSURE SENSOR (VEHICLE WITH EGR VALVE)
STOP LAMP SWITCH
START SWITCH
IGNITION SWITCH
LIGHTING SWITCH
REAR DEFOGGER SWITCH
BLOWER SWITCH
A/C SWITCH
A/C EVAP TEMP. SENSOR
VSS
HEATED OXYGEN SENSOR-1
(VEHICLE WITH EGR VALVE)
HEATED OXYGEN SENSOR-2
(VEHICLE WITH IMMOBILIZER INDICATOR LAMP)For detecting deterioration of
three way catalytic convertor
IAT SENSOR
ECT SENSOR
TP SENSOR
MAP SENSOR
CMP SENSOR
CKP SENSOR
TEST SWITCH TERMINAL
(VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP)
KNOCK SENSOR (VEHICLE WITH EGR VALVE)
FUEL PUMP RELAY
FUEL INJECTOR
HO2S HEATER
IAC VALVE
IGNITION COIL WITH IGNITER
EGR VALVE (IF EQUIPPED)
EVAP CANISTER PURGE VALVE
A/C COMPRESSOR CLUTCH
RADIATOR FAN RELAY
MIL
MAIN RELAY
TRANSMISSION CONTROL MODULE SIGNAL FROM SENSOR, SWITCH AND CONTROL MODULE

6E1-10 ENGINE AND EMISSION CONTROL SYSTEM
1. CKP sensor 20. Blank 39. Ignition coil assembly (for No.1 and No.4 spark plugs)
2. CMP sensor 21. A/C switch 40. Ignition coil assembly (for No.2 and No.3 spark plugs)
3. VSS 22. A/C pressure switch 41. Stop lamp switch
4. MAP sensor 23. Immobilizer control module 42. Stop lamp
5. Knock sensor (if equipped) 24. Data link connector 43. Lighting switch
6. TP sensor 25. Injector No.1 44. Position lamp
7. ECT sensor 26. Injector No.2 45. Rear defogger switch
8. IAT sensor 27. Injector No.3 46. Rear defogger
9. Heated oxygen sensor-1 (if equipped) 28. Injector No.4 47. A/C compressor clutch (if equipped)
10. Heated oxygen sensor-2 (if equipped) 29. IAC valve 48. Ignition switch
11. A/C evaporator temp. sensor 30. EVAP canister purge valve 49. Main relay
12. Combination meter 31. Fuel pump relay 50. Transmission range switch (A/T)
13. Fuel level sensor (vehicle with immobilizer
indicator lamp)32. Fuel pump 51. Starting motor
14. TCM 33. Radiator fan relay 52. Shield wire
15. Transmission range switch 34. Radiator fan motor 53. Main fuse
16. ABS control module 35. EGR valve (if equipped) 54. Barometric pressure sensor
17. CO adjusting resistor (if equipped) 36. Malfunction indicator lamp 55. Immobilizer indicator lamp (if equipped)
18. Heater fan motor 37. Tachometer 56. Engine ground
19. Heater fan switch 38. Monitor connector (vehicle without immo-
bilizer indicator lamp)57. Body ground

6E1-12 ENGINE AND EMISSION CONTROL SYSTEM
1. CKP sensor 20. Blank 39. Ignition coil assembly (for No.1 and No.4 spark plugs)
2. CMP sensor 21. A/C switch 40. Ignition coil assembly (for No.2 and No.3 spark plugs)
3. VSS 22. A/C pressure switch 41. Stop lamp switch
4. MAP sensor 23. Immobilizer control module 42. Stop lamp
5. Knock sensor (if equipped) 24. Data link connector 43. Lighting switch
6. TP sensor 25. Injector No.1 44. Position lamp
7. ECT sensor 26. Injector No.2 45. Rear defogger switch
8. IAT sensor 27. Injector No.3 46. Rear defogger
9. Heated oxygen sensor-1 (if equipped) 28. Injector No.4 47. A/C compressor clutch (if equipped)
10. Blank 29. IAC valve 48. Ignition switch
11. A/C evaporator temp. sensor 30. EVAP canister purge valve 49. Main relay
12. Combination meter 31. Fuel pump relay 50. Transmission range switch (A/T)
13. Fuel level sensor (vehicle with immobilizer
indicator lamp)32. Fuel pump 51. Starting motor
14. TCM 33. Radiator fan relay 52. Shield wire
15. Transmission range switch 34. Radiator fan motor 53. Main fuse
16. ABS control module 35. EGR valve (if equipped) 54. Barometric pressure sensor
17. CO adjusting resistor (if equipped) 36. Malfunction indicator lamp 55. Immobilizer indicator lamp (if equipped)
18. Heater fan motor 37. Tachometer 56. Engine ground
19. Heater fan switch 38. Monitor connector (vehicle without immo-
bilizer indicator lamp)57. Body ground

ENGINE AND EMISSION CONTROL SYSTEM 6E1-13
ECM TERMINAL ARRANGEMENT TABLE
For TYPE A (Refer to NOTE in page “ECM INPUT/OUTPUT CIRCUIT DIAGRAM” for applicable model.)
CONNEC-
TORTERMINAL WIRE COLOR CIRCUITCONNEC-
TORTERMINAL WIRE COLOR CIRCUIT
C421 BLK/ORN Ground for ECM
C4112––
2 BLK Ground for drive circuit 13–Heated oxygen sensor-2
3 BLK/ORN Ground for drive circuit 14 LT BLU“D”, “2”, “L”-range ID-UP signal
4 BLU/BLK Canister purge valve 15 RED“R”-range signal
5 WHT/BLK Coolant temp. signal output 16 YEL/GRN A/C SW signal
6 GRN/RED IAC valve 17 BRN/YEL EGR valve (stepper motor coil 4)
7 RED/BLU Heater of HO2S-1 18 BLU Radiator fan relay 1
8 BLU/ORN No.4 fuel injector 19 PNK Fuel pump relay
9 BLU/YEL No.1 fuel injector 20––
10 ORN Ground for sensor circuit 21 PPL Throttle opening signal output for A/T
11 RED/YEL CMP sensor 22 YEL/RED Fuel level gauge
12 RED Knock sensor (if equipped) 23 BLK/WHT TCM serial data line
13 WHTHeated oxygen sensor-1
(if equipped)
24––
CO adjusting resistor
(if equipped)
14 LT GRN Coolant temp. sensor
15 LT GRN/BLK Intake air temp. sensor
G021 PPL/WHT Malfunction indicator lamp
16 WHT/GRN Test switch terminal (if equipped) 2 PPL Vehicle speed sensor
17 RED/BLK Electric load (+) 3 PPL/YEL Radiator fan relay 2
18 PNK/GRN A/C switch 4––
19 GRN/WHTIG coil assembly for No.2 and 3 spark
plugs5 BLU Data link connector
20 GRN/YELIG coil assembly for No.1 and 4 spark
plugs6 BLK/WHT Ignition switch signal
21 BLU/WHT No.2 fuel injector 7 YEL Data link connector
22 GRY/RED Power supply for sensor 8––
23 YEL/BLK CKP sensor (+) 9 GRN/WHTStop lamp switch (Brake pedal
switch)
24––10 ORN GND for sensor
25–Ground for sensor shield wire 11––
26 RED/WHT MAP sensor 12 PNKImmobilizer indicator lamp
(if equipped)
27 PPL/WHTDiagnosis switch terminal
(if equipped)13 PNK/BLU Electrical load (-)
28 PNK/BLU Duty output terminal (if equipped) 14 WHT/BLK A/C evaporator temp. sensor
29 BRN Heater of HO2S-2 15––
30 GRN/BLK Heated oxygen sensor-2 16 BRN Tachometer signal
31 BLU/RED No.3 fuel injector 17 WHT/RED Backup power source
C411 PNK/BLK A/C compressor clutch
2 GRN EGR valve (stepper motor coil 1)
3 GRY/BLU Throttle position (TP) sensor
4–Heater of HO2S-2
5 BLK/RED Power source
6 BLK/RED Power source
7 BLK/YEL Engine start signal
8 WHT/RED EGR valve (stepper motor coil 3)
9 GRN/ORN EGR valve (stepper motor coil 2)
10 BRN/WHT Ground for main relay
11––
C42 (31P) C41 (24P) G02 (17P)1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 28 27 29 30 315 6
1 2 3 4 5 6 7
11 12
9 10 11 13 12 14 15 16
16 171 2
7 8
13 14 3 4
9 10
15 17 188
19 20 21 22 23 24
NOTE:
For abbreviation of wire color, refer to Section 0A.

6E1-14 ENGINE AND EMISSION CONTROL SYSTEM
For TYPE B (Refer to NOTE in page “ECM INPUT/OUTPUT CIRCUIT DIAGRAM” for applicable model.)
CONNEC-
TORTERMINAL WIRE COLOR CIRCUITCONNEC-
TORTERMINAL WIRE COLOR CIRCUIT
C421 BLK/ORN Ground for ECM
C4112––
2 BLK Ground for drive circuit 13––
3 BLK/ORN Ground for drive circuit 14 PPL/WHT Diagnosis switch terminal
4 BLU/BLK Canister purge valve 15 WHT/GRN Test switch terminal
5––16 YEL/GRN A/C SW signal
6 GRN/RED IAC valve 17 RED/YEL
Electric load (+)
7 RED/BLU Heater of HO2S-1 18 BLU Radiator fan relay 1
8 BLU/ORN No.4 fuel injector 19 PNK Fuel pump relay
9 BLU/YEL No.1 fuel injector 20 BLK/YEL
Cranking signal
10 ORN Ground for sensor circuit 21 GRN/WHTStop lamp switch (Brake pedal
switch)
11 RED/YEL CMP sensor 22 PPL Vehicle speed sensor
12 Or Grand for shield wire 23––
13 WHTHeated oxygen sensor-1
(if equipped)
24––
CO adjusting resistor
(if equipped)
14 LT GRN Coolant temp. sensor
15 LT GRN/BLK Intake air temp. sensor
G021 WHT/BLK A/C evaporator temp. sensor
16 GRY/BLU Throttle position (TP) sensor 2 RED“R” range signal
17 WHT/RED EGR valve (stepper motor coil 3) 3––
18 GRY EGR valve (stepper motor coil 1) 4––
19 GRN/WHTIG coil assembly for No.2 and 3 spark
plugs5 WHT/BLK Engine coolant temp. signals output
20 GRN/YELIG coil assembly for No.1 and 4 spark
plugs6 GRN/RED“D”, “2”, “L” range ID-UP signal
21 BLU/WHT No.2 fuel injector 7 YEL Data link connector
22 GRY/RED Power supply for sensor 8––
23 YEL/BLK CKP sensor (+) 9 PPL/WHT Malfunction indicator lamp
24––10––
25 RED Knock sensor (if equipped) 11 BLU
Data link connector
26 RED/WHT MAP sensor 12––
27––13 PNK/BLU Electrical load (-)
28 BRN/YEL EGR valve (stepper motor coil 4) 14 ORN Ground for sensor
29 GRN/ORNEGR valve (stepper motor coil 2)
15 PPL
Throttle opening signal output for
A/T
30 PNK/GRN A/C switch 16 BRN Tachometer signal
31 BLU/RED No.3 fuel injector 17––
C411 PNK/BLK A/C compressor clutch
2––
3––
4––
5 BLK/RED Power source for drive circuit
6 BLK/RED Power source for main circuit
7 WHT/RED Power source for memory circuit
8 PNK/BLU Duty signal output terminal
9 GRN/RED Radiator fan drive relay No.2
10 BRN/WHT Ground for main relay
11 BLK/WHT
Ignition switch signal
C42 (31P) C41 (24P) G02 (17P)1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 28 27 29 30 315 6
1 2 3 4 5 6 7
11 12
9 10 11 13 12 14 15 16
16 171 2
7 8
13 14 3 4
9 10
15 17 188
19 20 21 22 23 24
NOTE:
For abbreviation of wire color, refer to Section 0A.