egr SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

0A-22 GENERAL INFORMATION
ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL
ABBREVIATIONS
AABS Anti-lock Brake System
EEFE Heater Early Fuel Evaporation Heater
(Positive Temperature Coefficient,
PTC Heater) ATDC After Top Dead Center
API American Petroleum Institute
ATF Automatic Transmission Fluid EPS Electronic Power Steering
ALR Automatic Locking Retractor EVAP Evaporative Emission
AC Alternating Current EVAP Canister Evaporative Emission Canister
(Charcoal Canister)
A/T Automatic TransmissionF
4WD 4 Wheel Drive
A/C Air Conditioning
GGEN Generator
ABDC After Bottom Dead Center GND Ground
A/F Air Fuel Mixture Ratio
HHC Hydrocarbons
A-ELR Automatic-Emergency Locking
RetractorHO2S Heated Oxygen Sensor
IIAC Valve Idle Air Control Valve (Idle Speed
Control Solenoid Valve ISC Sole-
noid Valve)
BB+ Battery Positive Voltage
BTDC Before Top Dead Center
BBDC Before Bottom Dead Center IAT Sensor Intake Air Temperature Sensor
(Air temperature Sensor, ATS)
CCKT Circuit
CKP sensor Crankshaft Position Sensor ICM Immobilizer Control Module
CMP sensor Camshaft Position Sensor IG Ignition
CO Carbon Monoxide ISC Actuator Idle Speed Control Actuator
CPP switch Clutch Pedal Position Switch
(Clutch Switch, Clutch Start
Switch)LLH Left Hand
LSPV Load Sensing Proportioning Valve
CPU Central Processing Unit
MMAF Sensor Mass Air Flow Sensor (Air Flow
Sensor, AFS, Air Flow Meter,
AFM) CRS Child Restraint System
DDC Direct Current
DLC Data Link Connector (Assembly
Line Diag. Link, ALDL, Serial Data
Link, SDL)MAP Sensor Manifold Absolute Pressure Sen-
sor (Pressure Sensor, PS)
Max Maximum
DOHC Double Over Head Camshaft MFI Multiport Fuel Injection
(Multipoint Fuel Injection)
DOJ Double Offset Joint
DRL Daytime Running Light MIN Minimum
DTC Diagnostic Trouble Code (Diag-
nostic Code)MIL Malfunction Indicator Lamp
(“SERVICE ENGINE SOON”
Light)
EEBCM Electronic Brake Control Module,
ABS Control Module M/T Manual Transmission
EBD Electronic Brake Force Distribu-
tionNNOx Nitrogen Oxides
ECM Engine Control Module
OOBD On-Board Diagnostic System
(Self-Diagnosis Function)
ECT sensor Engine Coolant Temperature Sen-
sor (Water Temp. Sensor, WTS)
O/D Overdrive
EGR Exhaust Gas Recirculation OHC Over Head Camshaft
EGRT sensor EGR Temperature Sensor (Recir-
culated Exhaust Gas Temp. Sen-
sor, REGTS)O2S Oxygen Sensor
PPNP Park/Neutral Position
P/S Power Steering

3A-2 FRONT END ALIGNMENT
GENERAL DESCRIPTION
Front alignment refers to the angular relationship between the
front wheels, the front suspension attaching parts and the ground.
Generally, the only adjustment required for front alignment is toe
setting.
Camber and caster can’t be adjusted. Therefore, should camber
or caster be out of specification due to the damage caused by
hazardous road conditions or collision, whether the damage is in
body or in suspension should be determined. If the body is dam-
aged, it should be repaired and if suspension is damaged, it
should be replaced.
TOE SETTING
Toe is the turning in or out of the front wheels. The purpose of a
toe specification is to ensure parallel rolling of the front wheels
(Excessive toe-in or toe-out may increase tire wear).
Toe-in
“B”-“A” : 0 ± 1 mm (0 ± 0.039 in.)
For adjusting toe setting, refer to “TOE ADJUSTMENT” in this
section.
CAMBER
Camber is the tilting of the front wheels from the vertical, as
viewed from the front of the vehicle. When the wheels tilt outward
at the top, the camber is positive. When the wheels tilt inward at
the top, the camber is negative. The amount of tilt is measured in
degrees.
Camber “C”
2WD vehicle : –0° 20’ ± 1°
4WD vehicle : 0° ± 1°
ALIGNMENT SERVICE DATA (REFERENCE)
Caster
2WD vehicle : 3° 25’ ± 2°
4WD vehicle : 3° 35’ ± 2°
Kingpin inclination
2WD vehicle : 12° 40’ ± 2°
4WD vehicle : 12° 15’ ± 2° NOTE:
Toe-in value was measured by using a toe-in gauge.
[A]: Wheel top view
1. Forward
“A”
“B”1 [A]
1. Body center [A]: Front view
2. Center line of wheel
2
1
90
o
C [A]

3F-4 WHEELS AND TIRES
Dynamic balance, as shown in left figure, is the equal distribution
of weight on each side of the wheel centerline so that when the
tire spins there is no tendency for the assembly to move from side
to side. Wheels that are dynamically unbalanced may cause
shimmy.
GENERAL BALANCE PROCEDURES
Deposits of mud, etc. must be cleaned from inside of rim.
Each tire should be inspected for any damage, then balanced according to equipment manufacturer’s recom-
mendation.
OFF-VEHICLE BALANCING
Most electronic off-vehicle balancers are more accurate than the on-vehicle spin balancers. They are easy to
use and give a dynamic (two plane) balance. Although they do not correct for drum or disc unbalance as does
on-vehicle spin balancing, this is overcome by their accuracy, usually to within 1/8 ounce.
ON-VEHICLE BALANCING
On-vehicle balancing methods vary with equipment and tool manufacturers. Be sure to follow each manufac-
turer’s instructions during balancing operation.
1. Heavy spot wheel shimmy [C] : Before correction
2. Balance weights addition point [D] : Corrective weights
3. C/L of spindle
WARNING:
Stones should be removed from the tread in order to avoid operator injury during spin balancing and
to obtain good balance.
WARNING:
Wheel spin should be limited to 35 mph (55 km/h) as indicated on speedometer.
This limit is necessary because speedometer only indicates one-half of actual wheel speed when one
drive wheel is spinning and the other drive wheel is stopped.
Unless care is taken in limiting drive wheel spin, spinning wheel can reach excessive speeds. This
can result in possible tire disintegration or differential failure, which could cause serious personal
injury or extensive vehicle damage.
CAUTION:
For vehicle equipped with ABS, using on-vehicle balancing method with ignition switch ON may set
malfunction diagnostic trouble code (DTC) of ABS even when system is in good condition.
Never turn ignition switch ON while spinning wheel.

FRONT DRIVE SHAFT 4A-5
10) Remove drive shaft assembly.
11) For vehicle with center shaft
Remove center bearing support bolts (3) and remove center
bearing support (2) with center shaft (1) from differential side
gear.
DISASSEMBLY
For Tripod Joint Type Drive Shaft
1) Remove differential side boot band, then take out tripod joint
housing (1).
2) Remove grease from shaft and take off snap ring (1) by
using special tool, then pull out spider (2) from shaft.
Special tool
(A) : 09900-06107 CAUTION:
To prevent breakage of boots, be careful not to bring
them into contact with other parts, when removing drive
shaft assembly.
3
2
1
CAUTION:
To prevent needle bearing of joint from being degreased,
do not wash it if it is to be reused.

4A-8 FRONT DRIVE SHAFT
5) Remove circlip (1) by using flat end rod or the like.
6) Remove center bearing (2) from center bearing support.
ASSEMBLY
For Tripod Joint Type Drive Shaft
Judging from abnormality noted before disassembly and what is
found through visual check of component parts after disassembly,
prepare replacing parts and proceed to reassembly.
Make sure that wheel side joint assembly (1) and tripod joint
housing (2) are washed thoroughly and air dried, and boots (3)
are cleaned with cloth if they are to be reused.
“A” : Black grease (about 60 - 80 g/2.1 - 2.8 oz)
“B” : Orange grease (about 85 - 105 g/3.0 - 3.7 oz)
1) Wash disassembled parts (except boots). After washing, dry
parts completely by blowing air.
2) Clean boots with cloth. DO NOT wash boots in degreaser,
such as gasoline or kerosene, etc. Washing in degreaser
causes deterioration of boot.
3) Apply grease to wheel side joint. Use specified grease in
tube in wheel side boot set.
4) Install wheel side boot on shaft.
CAUTION:
To ensure full performance of joint as designed, be sure
to distinguish between two types of grease in repair set
and apply specified volume to respective joint. Refer to
the followings for identification of the grease.
[A] : Wheel side
[B] : Differential side

4A-10 FRONT DRIVE SHAFT
10) When fixing boot (1) to outer race (2) with differential side big
band (3), adjust so that measured dimensions become as
indicated below.
Drive shaft boot fixing position
“a” : 155.5 mm (6.12 in.) for M/T vehicle
“b” : 189.3 mm (7.45 in.) for A/T vehicle
CAUTION:
To prevent any problem caused by washing solution, do
not wash joint boots and tripod joint except its housing.
Degreasing of those parts with cloth is allowed.
[A] : Wheel side
[B] : Differential side
CAUTION:
Bend each boot band against forward rotation.
Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its
durability.

FRONT DRIVE SHAFT 4A-11
For DOJ Type Drive Shaft
Judging from abnormality noted before disassembly and what is
found though visual check of component parts after disassembly,
prepare replacing parts and proceed to reassembly.
Make sure that wheel side joint assembly (1) and DOJ housing
(2) are washed thoroughly and air dried, and boots (3) are
cleaned with cloth if they are to be reused.
“A” : Black grease (about 60 - 80 g/2.1 - 2.8 oz)
“B” : Black grease (rather light than “A”)
(about 70 - 90 g/2.5 - 3.2 oz)
1) Wash disassembled parts (except boots). After washing. dry
parts completely by blowing air.
2) Clean boots with cloth. Do not wash boots in degreaser,
such as gasoline or kerosene, etc.
Washing in degreaser causes deterioration of boot.
3) Apply grease to wheel side joint. Use specified grease in
tube included in wheel side boot set.
4) Install wheel side boot on shaft, fill up boot inside with
grease and then fasten boot with bands (1).
5) Install dynamic damper (1) on left side drive shaft according
to dimension specified below. (For A/T model of 2WD vehi-
cle)
Dynamic damper installing position
“a” : 151 - 157 mm (5.9 - 6.2 in.)
6) Set new differential side small bend and differential side boot
on shaft temporarily. CAUTION:
To ensure full performance of joint as designed, be sure
to distinguish between two types of grease in repair set
and apply specified volume to respective joint.
[A] : Wheel side
[B] : Differential side
CAUTION:
Bend each boot band against forward rotation (A).
Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its
durability.

FRONT DRIVE SHAFT 4A-13
12) When fixing boot (1) to outer race (2) with differential side big
band (3), adjust so that measurements become as indicated
below.
Drive shaft boot fixing position
“d” : 157.8 mm (6.21 in.) for left side
“e” : 192.9 mm (7.59 in.) foe right side
For Center Shaft and Center Bearing Support
Install center shaft by reversing removal procedure and noting fol-
lowing points
When installing bearing support circlip (1), make sure that if
fits in circlip groove in center bearing support (2) securely as
shown.
When installing left oil seal (1), use care so that oil seal in
proper direction as shown figure.
Be sure to apply grease to oil seal lip and bearing side space
indicated in figure.
“A” : Grease 99000-25010
After press-fit center shaft (2) from left oil seal side, install
circlip to groove of center shaft securely. CAUTION:
To prevent any problem caused by washing solution, do
not wash joint boots. Degreasing of those parts with
cloth is allowed.
CAUTION:
Bend each boot band against forward rotation (A).
Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its
durability.
[A] : Differential side

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-1
6
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10A
10B
SECTION 6
ENGINE GENERAL INFORMATION AND
DIAGNOSIS
ENGINE GENERAL INFORMATION AND ENGINE DIAGNOSIS................................................. Section 6
ENGINE MECHANICAL ................................................................................................................. Section 6A1
ENGINE COOLING......................................................................................................................... Section 6B
ENGINE FUEL ................................................................................................................................ Section 6C
ENGINE AND EMISSION CONTROL SYSTEM ............................................................................ Section 6E1
IGNITION SYSTEM ........................................................................................................................ Section 6F1
CRANKING SYSTEM ..................................................................................................................... Section 6G
CHARGING SYSTEM ..................................................................................................................... Section 6H
EXHAUST SYSTEM ....................................................................................................................... Secton 6K
CONTENTS
GENERAL INFORMATION ................................ 6-4
STATEMENT ON CLEANLINESS AND
CARE .............................................................. 6-4
GENERAL INFORMATION ON ENGINE
SERVICE ........................................................ 6-4PRECAUTION ON FUEL SYSTEM
SERVICE .................................................... 6-5
FUEL PRESSURE RELIEF
PROCEDURE ............................................. 6-6
FUEL LEAKAGE CHECK PROCEDURE.... 6-6 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 systems (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 (vehicle with immobilizer indicator lamp can be identified also by HO2S-
2)
Knock sensor

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
3456
1