G13 SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

When not using
SUZUKI scan tool : When using
SUZUKI scan tool :
4. Keep as far apart
as possible
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-25
4) Install suitable vinyl tube onto injector nozzle to prevent fuel from
splashing out when injecting.
5) Put graduated cylinder under injector as shown.
6) Operate fuel pump and apply fuel pressure to injector as follows:
When using SUZUKI scan tool :
a) Connect SUZUKI scan tool to DLC with ignition switch OFF.
b) Turn ignition switch ON, clear DTC and select “MISC TEST”
mode on SUZUKI scan tool.
c) Turn fuel pump ON by using SUZUKI scan tool.
Special Tool
(A): 09931-76011 (SUZUKI scan tool)
(B): Mass storage cartridge
(C): 09931-76030 (16 / 14 pin DLC cable)
When not using SUZUKI scan tool :
a) Remove fuel pump relay from connector.
b) Connect two terminals of relay connector using service wire
(1) as shown in figure.
CAUTION:
Check to make sure that connection is made between
correct terminals. Wrong connection can cause dam-
age to ECM, wire harness, etc.
c) Turn ignition switch ON.
7) Apply battery voltage (3) to injector (2) for 15 seconds and mea-
sure injected fuel volume with graduated cylinder.
Test each injector two or three times.
If not within specification, replace injector.
Injected fuel volume:
38 – 48 cc / 15 sec. (1.28 / 1.34 – 1.62 / 1.69 US / Imp. oz / 15 sec.)
8) Check fuel leakage from injector nozzle. Do not operate injector
for this check (but fuel pump should be at work).
If fuel leaks (1) more than following specifications, replace.
Fuel leakage (1): Less than 1 drop / min.

6E2-26 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
Installation
For installation, reverse removal procedure and note following pre-
cautions.

Replace injector O-ring (1) with new one using care not to dam-
age it.

Check if cushion (2) is scored or damaged. If it is, replace with
new one.

Apply thin coat of fuel to O-rings (1) and then install injectors (3)
into delivery pipe (4) and intake manifold.
Make sure that injectors (3) rotate smoothly (6). If not, probable
cause is incorrect installation of O-ring (1). Replace O-ring (1)
with new one.

Tighten delivery pipe bolts (5) and make sure that injectors (3) ro-
tate smoothly (6).
Tightening Torque
(a): 25 N
.m (2.5 kg-m, 18.0 lb-ft)

After installation, with engine OFF and ignition switch ON, check
for fuel leaks around fuel line connection.

ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-27
ELECTRONIC CONTROL SYSTEM
ENGINE CONTROL MODULE (POWERTRAIN
CONTROL MODULE) [ECM (PCM)]
CAUTION:
As ECM (PCM) consists of precision parts, be careful not to
expose it to excessive shock.
Removal
1) Disconnect battery negative cable at battery.
2) Disable air bag system, refer to “DISABLING THE AIR BAG
SYSTEM” in Section 9J if equipped.
3) Lower fuse box after removing screws and remove fuse box
bracket.
4) Remove ECM (PCM) (1) from body.
5) Disconnect couplers from ECM (PCM).
Installation
Reverse removal procedure noting the following:

Connect couplers to ECM (PCM) securely.
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP
SENSOR)
Inspection
Check MAP sensor referring to “MAP Sensor Individual Check” in
DTC P0105 Flow Table. If malfunction is found, replace.

1
2
3
1. Ground terminal
2. Reference voltage terminal
3. Output voltage terminal
(a)
1
23
4
6E2-28 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
THROTTLE POSITION SENSOR (TP SENSOR)
Inspection
1) Disconnect negative cable at battery and coupler from TP sen-
sor.
2) Using ohmmeter, check resistance between terminals under
each condition given in table below.
TERMINALS
RESISTANCE
Between 1 and
2 terminals2.5 – 6.0 kΩ
Between 1 and
Throttle valve is
at idle position0.17 – 11.4 kΩ
3 terminalsThrottle valve is
fully opened1.72 – 15.50 kΩ
NOTE:
There should be more than 1.5 kΩ resistance difference
between when throttle valve is at idle position and when
it is fully open.
If check result is not satisfactory, replace TP sensor.
3) Connect TP sensor coupler securely.
4) Connect negative cable to battery.
Removal
1) Disconnect battery negative cable at battery.
2) Disconnect coupler from TP sensor.
3) Remove TP sensor from throttle body.
Installation
1) Install TP sensor (1) to throttle body.
Fit TP sensor to throttle body in such way that its holes (3) are
a little away from TP sensor screw holes (2) as shown in left fig-
ure and turn TP sensor clockwise so that those holes align (4).
Tightening Torque
(a): 2.0 N
.m (0.20 kg-m, 1.5 lb-ft)
2) Connect coupler to TP sensor securely.
3) Connect battery negative cable to battery.

ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-29
INTAKE AIR TEMPERATURE SENSOR (IAT SENSOR)
Removal
1) Disconnect battery negative cable at battery.
2) Disconnect coupler from IAT sensor (1).
3) Remove IAT sensor (1) from air cleaner outlet hose (2).
Inspection
Immerse temperature sensing part of IAT sensor in water (or ice)
and measure resistance between sensor terminals while heating
water gradually.
If measured resistance doesn’t show such characteristic as shown
in left figure, replace IAT sensor.
Installation
Reverse removal procedure noting the following.

Clean mating surfaces of IAT sensor and air cleaner outlet hose.

Connect IAT sensor coupler (1) securely.

2.297 – 2.595
0.298 – 0.320
6E2-30 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
ENGINE COOLANT TEMPERATURE SENSOR
(ECT SENSOR)
Removal
1) Disconnect battery negative cable at battery.
2) Drain coolant referring to Section 6B.
WARNING:
To help avoid danger of being burned, do not remove ra-
diator 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.
3) Disconnect coupler from ECT sensor.
4) Remove ECT sensor (1) from thermostat case.
Inspection
Immerse temperature sensing part of ECT sensor (1) in water (or
ice) and measure resistance between terminal “A” and “B” while
heating water gradually.
If measured resistance doesn’t show such characteristic as shown
in left figure, replace ECT sensor (1).
Installation
Reverse removal procedure noting the following:

Clean mating surfaces of ECT sensor (1) and thermostat case.

Check O-ring for damage and replace if necessary.

Tighten ECT sensor (1) to specified torque.
Tightening Torque
(a): 12 N
.m (1.2 kg-m, 9.0 lb-ft)

Connect coupler to ECT sensor (1) securely.

Refill coolant referring to Section 6B.

ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-31
1. Viewed from terminal side
Sensor-1
Sensor-2
“VB”
“GND”
HEATED OXYGEN SENSOR (Sensor-1 and Sensor-2)
Oxygen Sensor Heater Inspection
1) Disconnect sensor coupler.
2) Using ohmmeter, measure resistance between terminals “V
B”
and “GND” of sensor coupler.
NOTE :
Temperature of sensor affects resistance value largely.
Make sure that sensor heater is at correct temperature.
Resistance of oxygen sensor heater :
11.7 – 14.3 Ω at 20C, 68F
If found faulty, replace oxygen sensor.
3) Connect sensor coupler securely.
Removal
WARNING:
To avoid danger of being burned, do not touch exhaust sys-
tem when system is hot. Oxygen sensor removal should be
performed when system is cool.
1) Disconnect negative cable at battery.
2) For sensor-1, disconnect coupler of heated oxygen sensor and
release its wire harness from clamps and remove exhaust man-
ifold cover (1).
3) For sensor-2, disconnect coupler of heated oxygen sensor and
release its wire harness from clamp and hoist vehicle.
4) Remove heated oxygen sensor (2) from exhaust manifold or ex-
haust pipe.
Installation
Reverse removal procedure noting the following.

Tighten heated oxygen sensor (2) to specified torque.
Tightening Torque for heated oxygen sensor
(a): 45 N·m (4.5 kg-m, 32.5 lb-ft)

Connect coupler of heated oxygen sensor (2) and clamp wire har-
ness securely.

After installing heated oxygen sensor (2), start engine and check
that no exhaust gas leakage exists.

(a)
6E2-32 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
CAMSHAFT POSITION SENSOR
Inspection
Check camshaft position sensor referring to DTC P0340 Diag. Flow
Table in Section 6. If malfunction is found, replace.
Removal
1) Disconnect negative cable at battery.
2) Disconnect connector from camshaft position sensor.
3) Remove camshaft position sensor from sensor case
(distributorless ignition case).
Installation
1) Check that O-ring is free from damage.
2) Check that camshaft position sensor and signal rotor tooth are
free from any metal particles and damage.
3) Install camshaft position sensor to sensor case.
Tightening Torque
(a): 9 N
.m (0.9 kg-m, 6.5 lb-ft)
4) Connect connector to it securely.
5) Connect negative cable to battery.
CRANKSHAFT POSITION SENSOR
Inspection
Check crankshaft position sensor referring to step 1 and 2 of DTC
P0335 Flow Table. If malfunction is found, replace.
Removal
1) Hoist vehicle.
2) Disconnect connector from crankshaft position sensor.
3) Remove crankshaft position sensor from oil pan.
Installation
1) Check to make sure that crankshaft position sensor and pulley
tooth is free from any metal particles and damage.
2) Install crankshaft position sensor to oil pan.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
CAUTION:
Be sure to tighten to specified torque. CKP sensor will be
deformed if overtightened and correct CKP sensor signal
will not be fed if loosened.
3) Connect connector to it securely.

ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-33
VEHICLE SPEED SENSOR (VSS)
Inspection
Check vehicle speed sensor referring to step 3 of DTC P0500 Flow
Table. If malfunction is found, replace.
Removal / Installation
Refer to Section 7A.
FUEL LEVEL SENSOR (GAUGE)
Inspection
Refer to Section 8.
Removal / Installation
Refer to Section 6C.
MAIN RELAY, FUEL PUMP RELAY AND RADIATOR
FAN CONTROL RELAY
Inspection
1) Disconnect negative cable at battery.
2) Remove main relay (1), fuel pump relay (2) and radiator fan con-
trol relay (3) from relay box.
3) Check that there is no continuity between terminal “c” and “d”.
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 battery,
replace relay.

6E2-34 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
FUEL CUT OPERATION
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), A / C is OFF and that parking brake lever is pulled all the
way up.
1) Warm up engine to normal operating temperature.
2) While listening to sound of injector (1) by using sound scope (2)
or such, increase engine speed to higher than 3,000 r / min.
3) Check to make sure that sound to indicate operation of injector
stops when throttle valve is closed instantly and it is heard again
when engine speed is reduced to less than about 2,000 r / min.
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.
Check system for operation referring to Flow Table B-8 in Section
6.
If radiator fan fails to operate properly, check relay, radiator fan and
electrical circuit.
Radiator Fan
Inspection
1) Check continuity between each two terminals.
If there is no continuity, replace radiator fan motor.