ECM SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-7
CON-
NECTOR
C02TERMI-
NAL
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
26ECM ground
Power source (from main relay)
Blank
Blank
Blank
Blank
EVAP canister purge valve
Shift solenoid-B (A / T)
Shift solenoid-A (A / T)
Igniter
Idle speed control actuator
Fuel injector
Injector ground
Power source (from battery)
Power source (from main relay)
Idle speed control actuator relay
Malfunction indicator lamp
Immobilizer indicator lamp
Heater of HO2S-2
Radiator fan relay
Fuel pump relay
Main relay
Blank
Idle speed control actuator
EFE heater relay
Injector groundC031
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22Data link connector
Vehicle speed sensor (+) (A / T)
Vehicle speed sensor (M / T)
Transmission range sensor (switch)“2”
Transmission range sensor (switch)“N”
Transmission range sensor (switch)“P”
Blank
Blank
Heated oxygen sensor-2
Blank
Fuel level sensor (gauge)
Blank
Data link connector
Vehicle speed sensor (–) (A / T)
Transmission range sensor (switch)“L”
Transmission range sensor (switch)“D”
Transmission range sensor (switch)“R”
A / C ON (output) signal for A / C control module
(if equipped)
Electric load signal
A / C (input) signal from A / C control module
(if equipped)
Ignition switch
Blank
Blank CIRCUITCON-
NECTORTERMI-
NALCIRCUIT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16Power source for sensors
Camshaft position sensor (+)
Crankshaft position sensor (+)
Closed throttle position switch
Manifold absolute pressure sensor
Throttle position sensor
Engine coolant temp. sensor
Heater of HO2S-1
Sensor ground
Camshaft position sensor (–)
Crankshaft position sensor (–)
EFE heater (monitor)
Heated oxygen sensor-1
Intake air temp sensor
Power steering pressure switch (if equipped)
Engine start signal circuit
C01
1. CMP sensor (in Distributor)
2. CKP sensor
3. TP sensor
4. MAP sensor
5. ECT sensor
6. IAT sensor
7. HO2S-1
8. HO2S-2
9. Transmission range switch (A / T)
10. VSS (A / T)
11. A / C control module (if equipped)
12. Heater blower switch
13. Fuel level sensor
14. Speedometer
15. P.SP switch
16. Rear defogger switch
17. Light switch
18. DLC
19. Fuel injector20. Injector resistor
21. Conister purge valve
22. Fuel pump relay
23. Rediator fan relay
24. EFE heater relay
25. ISC actuator relay
26. ISC actuator
27. Ignition coil
28. Igniter
29. Immobilizer indicator lamp
30. MIL
31. Main relay
32. Shift solenoid A (A / T)
33. Shift solenoid B (A / T)
34. Starter motor
35. Ignition switch

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-17
1. ECM
2. Instrument panel
3. Steering wheel
1. Injector wire
2. Screws
1. Stay
3) Make sure that injector wire O-ring is free from any damage and
deterioration, and apply thin coat of spindle oil or gasoline to O-
ring.
Install injector wire and tighten new wire screw to specified
torque.
Tightening Torque
(a): 3.5 N
.m (0.35 kg-m, 2.5 lb-ft)
4) Connect battery negative cable at battery.
5) With engine “OFF” and ignition switch “ON”, check for fuel leaks.
6) Install air cleaner mounting stay as shown left.
7) Install air cleaner assembly referring to Section 6A.
ELECTRONIC CONTROL SYSTEM
ENGINE CONTROL MODULE (ECM)
CAUTION:
As ECM consists of precision parts, be careful not to ex-
pose it to excessive shock.
REMOVAL
1) Disconnect battery negative cable at battery.
2) Lower fuse box after removing bolt.
3) Disconnect couplers from ECM while releasing coupler lock.
4) Remove ECM from body.
INSTALLATION
1) Install ECM to body.
2) Connect couplers to ECM securely.
3) Install fuse box and tighten its bolt.
4) Connect battery negative cable at battery.

6E1-20 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10)
1. Plunger
2. Throttle lever screw
2) Check to make sure that plunger of ISC actuator and throttle le-
ver screw are not in contact with each other. If they are, warm
up engine.
3) Loosen TP sensor screws.
a) Connect SUZUKI scan tool to DLC with ignition switch OFF.
b) Select “Data List” mode on SUZUKI scan tool.
c) Observe TP sensor voltage.
4) Turn TP sensor clockwise or counterclockwise and tighten TP
sensor screw at a position where voltage as specified below is
obtained.
TP sensor voltage when lever-to-stop
screw clearance is 3.5 mm (0.14 in.) : 0.98 – 1.02 V
Tightening Torque
(a): 2.0 N
.m (0.20 kg-m, 1.5 lb-ft)
5) Install ECM and connect couplers securely.
INTAKE AIR TEMPERATURE SENSOR (IAT SENSOR)
REMOVAL
1) Disconnect battery negative cable at battery.
2) Disconnect coupler from IAT sensor.
3) Remove IAT sensor and gasket from air cleaner case.

6E1-30 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10)
1. Insulator
2. Lower gasket
3. Heater
1. Intake manifold
2. EFE heater
1. EFE heater relay
2. Relay box
1. Radiator fan motor
INSPECTION

Check lower gasket for damage and deterioration. Replace as
necessary.

Check heater and insulator for crack, corrosion or any other dam-
age. Replace as necessary.
INSTALLATION
1) Clean mating surfaces of throttle body and intake manifold that
mate with EFE heater.
2) Install EFE heater to intake manifold.
Use new upper gasket.
3) Install throttle body according to procedure described previous-
ly.
4) Connect EFE heater coupler.
EFE HEATER RELAY
INSPECTION
1) Disconnect negative cable at battery.
2) Remove EFE heater relay from relay box.
3) Structure of EFE heater relay is the same as that of main relay.
Check its resistance and operation using the same procedure as
that for main relay.
If found defective, replace.
RADIATOR FAN CONTROL SYSTEM
SYSTEM INSPECTION
WARNING:
Keep hands, tools, and clothing away from engine cooling
fan to help prevent personal injury. This fan is electric and
can come on whether or not the engine is running. The fan
can start automatically in response to the ECT sensor with
the ignition switch in the “ON” position.
Connect SUZUKI scan tool (2) to DLC (3).
Start engine and keep it running to warm it up.
Now check to ensure that radiator fan is started when the coolant
temperature displayed on SUZUKI scan tool reaches 96C
(205F).
If check result is not satisfactory, check RFC relay, wire harness,
ECT sensor, ECM, coolant temp. meter and sender gauge unit.
Refer to “DTC P0480 FLOW TABLE” of Section 6 and “COOLANT
TEMP. METER AND GAUGE UNIT” of Section 8.

6E1-32 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10)
RH
LH
EMISSION CONTROL SYSTEM
EVAPORATIVE EMISSION CONTROL SYSTEM
EVAP CANISTER PURGE INSPECTION
NOTE:
Before inspection, check to make sure that gear shift lever is
in neutral position (with A / T model, selector lever in “P” range)
and that parking brake lever is pulled all the way up.
1) Disconnect purge hose from EVAP canister.
2) Place finger against the end of disconnected hose and check
that vacuum is not felt there when engine is cool and running at
idle speed.
3) Connect purge hose to EVAP canister and warm up engine to
normal operating temperature.
4) Disconnect purge hose from EVAP canister.
5) Also check that vacuum is felt when engine is running at idle
speed.
NOTE:
The EVAP canister purge system does not perform purging
(vacuum is not detected at the purge hose) unless the en-
gine is sufficiently warmed up and the heated oxygen sen-
sor is activated fully. Also, when the purge hose is discon-
nected in Step 4), the air is drawn into the purge line. As a
result, ECM detects a change in the purge gas concentra-
tion and sometimes stops purging but this indicates noth-
ing abnormal.
If check result is not satisfactory, check vacuum passage, hoses,
EVAP canister purge valve, wire harness and ECM.
VACUUM PASSAGE INSPECTION
Start engine end run it at idle speed. Disconnect vacuum hose from
EVAP canister purge valve. With finger placed against hose discon-
nected, check that vacuum is applied.
If it is not applied, clean vacuum passage by blowing compressed
air.
VACUUM HOSE INSPECTION
Check hoses for connection, leakage, clog and deterioration. Re-
place as necessary.

6E2
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-1
GENERAL DESCRIPTION6E2- 2 . . . . . . . . . . . . . .
AIR INTAKE SYSTEM 6E2- 6. . . . . . . . . . . . . . . . . .
FUEL DELIVERY SYSTEM 6E2- 7. . . . . . . . . . . . . .
ELECTRONIC CONTROL SYSTEM 6E2- 8. . . . . .
Engine and Emission Control Input /
Output Table 6E2- 9. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSISSee Section 6. . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE6E2-13 . . . . . . . . . . . . . . . .
Accelerator Cable Adjustment 6E2-13. . . . . . . . . .
Idle Speed/Idle Air Control (IAC)
Duty Inspection 6E2-14. . . . . . . . . . . . . . . . . . . . .
AIR INTAKE SYSTEM 6E2-15. . . . . . . . . . . . . . . . . .
Throttle Body 6E2-15. . . . . . . . . . . . . . . . . . . . . . . .
Idle Air Control Valve 6E2-17. . . . . . . . . . . . . . . . .
FUEL DELIVERY SYSTEM 6E2-18. . . . . . . . . . . . . .
Fuel Pressure Inspection 6E2-18. . . . . . . . . . . . . .
Fuel Pump 6E2-21. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pressure Regulator 6E2-22. . . . . . . . . . . . . . .
Fuel Injector 6E2-23. . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRONIC CONTROL SYSTEM 6E2-27. . . . . .
ECM / PCM 6E2-27. . . . . . . . . . . . . . . . . . . . . . . . . .
MAP Sensor 6E2-27. . . . . . . . . . . . . . . . . . . . . . . . .
TP Sensor 6E2-28. . . . . . . . . . . . . . . . . . . . . . . . . . .
IAT Sensor 6E2-29. . . . . . . . . . . . . . . . . . . . . . . . . .
ECT Sensor 6E2-30. . . . . . . . . . . . . . . . . . . . . . . . . Heated Oxygen Sensor -1 and -2 6E2-31. . . . . . .
Camshaft Position Sensor 6E2-32. . . . . . . . . . . . .
Crankshaft Position Sensor 6E2-32. . . . . . . . . . . .
Vehicle Speed Sensor 6E2-33. . . . . . . . . . . . . . . . .
Fuel Level Sensor (gauge) 6E2-33. . . . . . . . . . . . .
Main Relay, Fuel Pump Relay and
Radiator Fan Control Relay 6E2-33. . . . . . . . . . .
Fuel Cut Operation (Inspection) 6E2-34. . . . . . . .
Radiator Fan Control System 6E2-34. . . . . . . . . .
System Inspection 6E2-34. . . . . . . . . . . . . . . . . .
Radiator Fan 6E2-34. . . . . . . . . . . . . . . . . . . . . . .
EMISSION CONTROL SYSTEM 6E2-35. . . . . . . . .
EGR System 6E2-35. . . . . . . . . . . . . . . . . . . . . . . . .
EVAP Control System 6E2-36. . . . . . . . . . . . . . . . .
EVAP Canister Purge Inspection 6E2-36. . . . . .
Vacuum Passage Inspection 6E2-37. . . . . . . . .
Vacuum Hose Inspection 6E2-37. . . . . . . . . . . .
EVAP Canister Purge Valve
Inspection 6E2-37. . . . . . . . . . . . . . . . . . . . . . . .
EVAP Canister Inspection 6E2-38. . . . . . . . . . .
PCV System 6E2-38. . . . . . . . . . . . . . . . . . . . . . . . .
PCV Hose Inspection 6E2-38. . . . . . . . . . . . . . .
PCV Valve Inspection 6E2-38. . . . . . . . . . . . . . .
SPECIAL TOOLS6E2-39 . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS6E2-39 . . . . . . . . . . . . . . . . . . . . .
SECTION 6E2
ENGINE AND EMISSION CONTROL SYSTEM
(SFI FOR G13)
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 autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” 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).
CONTENTS

6E2-2 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
The engine and emission control system is divided
into 4 major sub-systems: air intake system, fuel de-
livery 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 (PCM), various sensors and
controlled devices.
Emission control system includes EGR, EVAP and
PCV system.
GENERAL DESCRIPTION

6E2-6 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
The main components of the air intake system are air
cleaner (1), air cleaner outlet hose (2), throttle body
(3), idle air control valve (4) and intake manifold (5).
The air (by the amount corresponding to the throttle
valve (6) opening and engine speed) is filtered by the
air cleaner (1), passes through the throttle body (3),is distributed by the intake manifold (5) and finally
drawn into each combustion chamber.
When the idle air control valve (4) is opened accord-
ing to the signal from ECM (PCM), the air (7) by-
passes the throttle valve (6) through bypass passage
and is finally drawn into the intake manifold (5).
AIR INTAKE SYSTEM

6. EVAP canister purge valve
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-7
The fuel delivery system consists of the fuel tank (11),
fuel pump (12), fuel filter (10), fuel pressure regulator
(3), delivery pipe (2) and fuel injectors (1).
The fuel in the fuel tank (11) is pumped up by the fuel
pump (12), filtered by the fuel filter (10) and fed under
pressure to each injector through the delivery pipe
(2). As the fuel pressure applied to the injector (the
fuel pressure in the fuel feed line (7)) is always kept
a certain amount higher than the pressure in the in-take manifold (4) by the fuel pressure regulator (3),
the fuel is injected into the intake port of the cylinder
head when the injector opens according to the injec-
tion signal from ECM (PCM).
The fuel relieved by the fuel pressure regulator re-
turns through the fuel return line (8) to the fuel tank
(11).
Also, fuel vapor generated in fuel tank is led through
the fuel vapor line (9) into the EVAP canister (5).
FUEL DELIVERY SYSTEM

6E2-8 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
INFORMATION SENSORS
-1. MAP sensor
-2. TP sensor
-3. IAT sensor
-4. ECT sensor
-5. Heated oxygen sensor-1
5-1. Heated oxygen sensor-2
-6. VSS (A / T)
-7. Transmission range switch (A / T)
-8. Battery
-9. CMP sensor
-10. CKP sensor
-11. Fuel level sensor (gauge) (in fuel tank)
-12. PSP switch
-13. A / C control module (if equipped)
-14. VSS (speedometer) (M / T)OTHERS
A: ECM (PCM)
B: Main relay
C: EVAP canister
D: Data link connector CONTROL DEVICES
a: Fuel injector
b: EVAP canister purge valve
c: Fuel pump relay
d: EGR valve (step motor)
e: Malfunction indicator lamp
f: Ignition coil assembly
g: Radiator fan control relay
h: IAC valve
The electronic control system consists of 1) various
sensors which detect the state of engine and driving
conditions, 2) ECM (PCM) which controls various de-
vices 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

Evaporative emission control system

Oxygen sensor heater control system

Ignition control system
Also, with A / T model, PCM controls A / T.
ELECTRONIC CONTROL SYSTEM