engine coolant SUZUKI SWIFT 2000 1.G SF310 Service Service Manual

6-1-82 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
1) 2) 3) 4) 41 – 46 mph
(65 – 75 km / h)
28 – 34 mph
(45 – 55 km / h)
DTC CONFIRMATION PROCEDURE
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 persons, a driver and tester, on a level road.
1) Turn ignition switch OFF.
Clear DTC with ignition switch ON, check vehicle and environmental condition for:
–Altitude (barometric pressure): 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)
–Intake air temp.: between –10C and 80C (14F and 158F)
–Engine coolant temp.: 70C, 230F or higher
2) Start engine and drive vehicle at 41 – 46 mph, 65 – 75 km / h for 8 min. or longer.
While this driving, if “Catalyst Monitoring TEST COMPLETED” is displayed in “READINESS TESTS” mode and
DTC is not displayed in “DTC” mode, confirmation test is completed.
If “TEST NOT COMPLTD” is still being displayed, continue test driving.
3) Decrease vehicle speed at 28 – 34 mph, 45 – 55 km / h, and hold throttle valve at that opening position for 2 min.
and confirm that short term fuel trim vary within –20% –+20% range.
4) Stop vehicle (do not turn ignition switch OFF) and confirm test results according to following “Test Result Con-
firmation Flow Table”.
Test Result Confirmation Flow Table
STEPACTIONYESNO
1Check DTC in “DTC” mode and pending DTC in
“ON BOARD TEST” or “PENDING DTC” mode.
Is DTC or pending DTC displayed?Proceed to applicable
DTC Diag. Flow Table.Go to Step 2.
2Set scan tool to “READINESS TESTS” mode and
check if testing has been completed.
Is test completed?No DTC is detected
(confirmation test is
completed).Repeat DTC
confirmation
procedure.

Radiator cooling fan relay
To
ECM
Main
relay
Relay
box
“RDTR”
(Radiator fan)Radiator cooling
Fan motor
ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-85
DTC P0480 RADIATOR COOLING FAN CONTROL SYSTEM MALFUNCTION
CIRCUIT DESCRIPTION
DTC DETECTING CONDITIONPOSSIBLE CAUSE

Low voltage at terminal C02-18 when engine coolant
temp. is 92C, 197F below.
2 driving cycle detection logic, continuous monitoring.
“B/W” or “P/G” circuit open or short

Radiator cooling fan relay malfunction

ECM (PCM) malfunction
DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF.
2) Clear DTC with ignition switch ON.
3) Warm up engine until radiator cooling fan starts to operate.
4) Check pending DTC in “ON BOARD TEST” or “PENDING DTC” mode and DTC in “DTC” mode.

6-1-86 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
Fig. 1 for Step 2 Fig. 2 for Step 3 Fig. 3 for Step 3
INSPECTION
STEPACTIONYESNO
1Was “ENGINE DIAG. FLOW TABLE” performed?Go to Step 2.Go to “ENGINE DIAG.
FLOW TABLE”.
2Check Radiator Cooling Fan Relay and Its Circuit.
1) Turn ignition switch ON.
2) Check for voltage at terminal C02-18 of ECM
(PCM) connector connected, under following
condition. See Fig. 1.
When engine coolant temp. is lower than
92C, 197F and A / C switch turns OFF:
10 – 14 V
Is voltage as specified?Intermittent trouble or
faulty ECM (PCM).
Check for intermittent
referring to “Intermittent
and Poor Connection”
in Section 0A.Go to Step 3.
3Check Radiator Cooling Fan Control Relay.
1) Turn ignition switch OFF and remove radiator
cooling fan relay.
2) Check for proper connection to the relay at
“B/W” and “P/G” wire terminals.
3) If OK, then measure resistance between
terminals a and b. See Fig. 2 and 3.
Is it 100 – 150 Ω?“B/W” or “P/G” circuit
open or short.
If wires and connections
are OK, substitute a
known-good ECM
(PCM) and recheck.Replace radiator
cooling fan relay.

6-1-106 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
Radiator cooling fan relay
To
ECM
Main
relay
Relay
box
“RDTR”
(Radiator fan)Radiator cooling
Fan motor
TABLE B-7 RADIATOR COOLING FAN CONTROL SYSTEM CHECK
INSPECTION
STEPACTIONYESNO
1Check Fan Control System.
1) Connect scan tool to DLC with ignition switch OFF.
2) Start engine and select “DATA LIST” mode on scan tool.
3) Warm up engine until coolant temp. is 97.5C, 208F or
higher and A / C switch turn OFF. (If engine coolant temp.
does not rise, check engine cooling system or ECT sensor.)
See Fig. 1.
Is radiator cooling fan started when engine coolant temp.
reached above temp.?Radiator cooling
fan control
system is in good
condition.Go to Step 2.
2Check Radiator Cooling Fan Relay and Its Circuit.
1) Check DTC and pending DTC with scan tool.
Is DTC P0480 displayed?Go to DTC
P0480 Diag.
Flow Table.Go to Step 3.
3Check Radiator Cooling Fan Relay.
1) Turn ignition switch OFF and remove radiator cooling fan
relay.
2) Check for proper connection to relay at terminals “c” and “d”.
3) If OK, check that there is continuity between “c” and “d” when
battery is connected to terminals “a” and “b”. See Fig. 2.
Is check result satisfactory?Go to Step 4.Replace radiator
fan relay.
4Check Radiator Cooling Fan.
1) Turn ignition switch OFF.
2) Disconnect cooling fan motor connector.
3) Check for proper connection to motor at “Bl / R” and “B”
terminals.
4) If OK, connect battery to motor and check for operation.
See Fig. 3.
Is it in good condition?“Bl / W”, “Bl / R” or
“B” circuit open.Replace radiator
cooling fan
motor.

1. Throttle body
1. Throttle body
2. ISC actuator
5. Clamp
6A-6 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
4) Remove air cleaner assembly.
5) Disconnect the following electric lead wires:

EGR valve

ISC actuator (2)

Ground wires from intake manifold

Fuel injector (4)

TP sensor (3)

EFE heater (5)

Engine coolant temp. gauge
6) Disconnect fuel return (4) and feed hoses (3) from fuel pipes.
7) Disconnect coolant hoses from intake manifold.
8) Disconnect the following vacuum hoses.

Canister purge hose from intake manifold.

EGR pressure transducer hoses from EGR valve.

EGR valve hose from EGR valve.

Pressure sensor hose from intake manifold.

Brake booster hose from intake manifold.
9) Disconnect breather hose from PCV valve.
10) Disconnect accelerator cable from throttle body.
11) Disconnect other connected to throttle body and intake man-
ifold, if any.
12) Remove intake manifold with throttle body from cylinder head.
13) Remove throttle body from intake manifold.

2. Ground
1. Throttle body
2. ISC actuator
coupler
3. TP sensor
coupler
4. Fuel injector
coupler
5. EFE heater
coupler
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-7
INSTALLATION
1) Install throttle body to intake manifold. (Refer to Section 6E.)
2) Install intake manifold gasket to cylinder head. Use a new gas-
ket.
3) Install intake manifold (1) with throttle body to cylinder head.

Install clamps (3) as shown in figure, and tighten bolts and
nuts to specification.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
4) Connect breather hose to PCV valve.
5) Connect vacuum hoses.
6) Connect coolant hoses.
7) Connect fuel return and feed hoses to throttle body.
8) Connect electric lead wire.
9) Connect accelerator cable to throttle body.
10) Install air cleaner assembly to throttle body.
11) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been reinstalled.
12) Refill cooling system.
13) Connect negative cable at battery.
14) Upon completion of installation, start engine and check for fuel
leaks and engine coolant leaks.
After warming up engine, adjust accelerator cable play to spec-
ification according to description in Section 6E.

1. Rear mounting
2. Rear mounting No.2
bracket
3. Rear mounting No.1
bracket
4. Rear mounting
bracket5. Left mounting
body bracket
6. Left mounting
7. Left mounting bracket
8. Right mounting bracket
9. Right mounting
For M / T model
For A / T model
1. Rear mounting
2. Rear mounting No.2
bracket
3. Rear mounting No.1
bracket
4. Left mounting No.1
bracket
5. Stopper6. Left mounting
7. Left mounting No.2
bracket
8. Right mounting bracket
9. Right mounting
10. Torque rod bracket
11. Stiffener
12. Torque rod
6A-26 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
INSTALLATION
1) Lift engine with transmission into engine compartment, but do
not remove lifting device.
2) Install right side engine mounting to its bracket.
3) Install left side engine mounting and its bracket.
4) Install rear mounting to body.
5) Tighten bolts and nuts of all parts installed in above steps 2),
3) and 4) to specified torque.
Tightening Torque
(a): 55 N
.m (5.5 kg-m, 40.0 lb-ft)
Tightening Torque
(a): 55 N
.m (5.5 kg-m, 40.0 lb-ft)
6) Remove lifting device.
7) Reverse removal procedures for installation of remainder.

Push in each drive shaft joint fully so that snap ring engages
with differential gear or center bearing support.
Use care not to damage oil seal lip when inserting.

Clamp electric wires securely.
8) Adjust clutch pedal free travel referring to Section 7C. (For M / T
model)
Adjust gear select cable and oil pressure control cable referring
to Section 7B. (For A / T model)
9) Adjust gear shift control lever referring to Section 7A. (For M / T
model)
10) Refill transmission with gear oil. (A / T fluid for A / T model) refer-
ring to Section 0B.
11) Refill engine with engine oil referring to Section 0B.
12) Refill cooling system referring to Section 6B.
13) Adjust A / C compressor drive belt referring to Section 0B. (if
equipped)
14) Upon completion of installation, verify that there is no fuel leak-
age, coolant leakage, transmission oil leakage or exhaust gas
leakage at each connection.
15) Adjust accelerator cable play referring to Section 6E.

1. Thickness gauge IN
EX
360
IN
EX
6A1-10 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
6) If valve lash is out of specification, adjust it to specification by
turning adjusting screw after loosening lock nut.
After adjustment, tighten lock nut to specified torque while hold-
ing adjusting screw stationary, and then make sure again that
valve lash is within specification.
Valve
clearance
When cold
(Coolant tempera-
ture is 15 – 25C
or 59 – 77F)When hot
(Coolant tempera-
ture is 60 – 68C
or 140 – 154F)
specifica-
tionIntake0.13 – 0.17 mm
(0.005 – 0.007 in.)0.18 – 0.22 mm
(0.007 – 0.009 in.)
Exhaust0.23 – 0.27 mm
(0.009 – 0.011 in.)0.28 – 0.32 mm
(0.011 – 0.013 in.)
Special Tool
(A): 09917-18211
Tightening Torque
(a): 12 N
.m (1.2 kg-m, 9.0 lb-ft)
7) After checking and adjusting valve lashes at valves (1), (2), (5)
and (7), (or (3), (4), (6) and (8)) rotate crankshaft exactly one full
turn (360) and check the same at valves (3), (4), (6) and (8) (or
(1), (2), (5) and (7)). Adjust them as necessary.
8) After checking and adjusting all valves, reverse removal proce-
dure for installation.

ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE) 6A1-15
7) Disconnect the following electric lead wires and release clamp:

Ground wires (5) from intake manifold

TP sensor (3)

IAC valve (4)

Fuel injectors

EVAP canister purge valve (2)

MAP sensor (6)

EGR valve (1)
8) Disconnect the following hoses:

Brake booster hose (1) from intake manifold

Canister purge hose (3) from EVAP canister purge valve

Engine cooling water (coolant) hose (2) from IAC valve

PCV hose (4)

Breather hose from cylinder head
9) Disconnect fuel feed hose (2) from pipe (1), and disconnect fuel
return hose (3) from fuel pressure regulator.

1. Long bolt
2. Short bolt
6A1-16 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
10) Remove intake manifold rear stiffener (1) and generator adjust
arm reinforcement (2) from intake manifold (3).
11) Remove intake manifold with throttle body from cylinder head,
and then its gasket.
INSTALLATION
Reverse removal procedure for installation noting the followings.

Use new intake manifold gasket.

When installing intake manifold, install clamps securely.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

Adjust accelerator cable play, referring to Section 6E.

Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been reinstalled.

Refill cooling system referring to Section 6B.

Upon completion of installation, turn ignition switch ON but en-
gine OFF and check for fuel leaks.

Finally, start engine and check for engine coolant leaks.