engine SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

6
6
6-1
6A
6A1
6B
6C
6E1
6E1
6E2
6F
6F
6F1
6G
6H
6K
GENERAL INFORMATION
General Information
Maintenance and Lubrication
1A
1B
TABLE OF CONTENTS SECTION
0A
0B
7B
8
8A
8G HEATING AND AIR CONDITIONING
Heater and Ventilation
Air Conditioning (Oprional)
ENGINE
General Information and Diagnosis
(TBI for G10)
General Information and Diagnosis
(TBI for G13)
General lnformation and Diagnosis
(SFI for G13)
Engine Mechanical (G10 Engine)
Engine Mechanical
(G13 1-cam 16-valves Engine)
Engine Cooling
Engine Fuel
Engine and Emission Control System
(TBI for G10)
Engine and Emission Control System
(TBI for G13)
Engine and Emission Control System
(SFI for G13)
Ignition System (TBI for G10)
Ignition System (TBI for G13)
Ignition System (SFI for G13)
Cranking System
Charging System
Exhaust System
TRANSMISSION, CLUTCH AND
DIFFERENTIAL
Automatic Transmission
BODY ELECTRICAL SYSTEM
Wiring Diagram
IMMOBILIZER CONTROL SYSTEM
1B
0B
0A
1A
6
6B
6C
6E1
6A1
6F
6G
6H
6K
7B
8
8A
8G
6-1
6A
6E2
6F1
6
6E1
6F
NOTE:
The screen toned Section 8A is contained in WIRING DIAGRAM MANUAL mentioned in
RELATED MANUALS.

GENERAL INFORMATION 0A-1
0ASECTION 0A
GENERAL INFORMATION
CONTENTS
HOW TO USE THIS MANUAL0A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS0A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System 0A- 3. . . . . . . . . . . . . . . .
General Precautions0A- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Catalytic Converter 0A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Electrical Circuit Service 0A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Circuit Inspection Procedure 0A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermittent and Poor Connection 0A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precaution for Installing Mobile Communication Equipment 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precaution in Servicing Full-Time 4WD Vehicle 0A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDENTIFICATION INFORMATION0A-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Identification Number0A-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Whether Vehicle Equipped with WU-TWC or Not 0A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Identification Number0A-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Identification Number 0A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING, CAUTION AND INFORMATION LABELS0A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE LIFTING POINTS0A-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL0A-22 . . . . . . . . . . . . . . . . . . . . . . . . . . .
FASTENER INFORMATION0A-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric Fasteners0A-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fasteners Strength Identification 0A-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tightening Torque0A-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0A-6 GENERAL INFORMATION
GENERAL PRECAUTIONS
The WARNING and CAUTION below describe some general precautions that you should observe when servicing
a vehicle. These general precautions apply to many of the service procedures described in this manual, and they
will not necessarily be repeated with each procedure to which they apply.
WARNING:

Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING
POINTS” on SECTION 0A.

When it is necessary to do service work with the engine running, make sure that the parking brake
is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for automatic
transmission vehicles). Keep hands, hair, clothing, tools, etc. away from the fan and belts when the
engine is running.

When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.

Do not perform service work in areas where combustible materials can come in contact with a hot
exhaust system. When working with toxic or flammable materials (such as gasoline and refrigerant),
make sure that the area you work in is well-ventilated.

To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail-
pipe, muffler, etc.

New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or
used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory animals.
Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a
long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing engine
oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or
rags if wet with oil, recycle or properly dispose of used oil and filters.

Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly
during driving, obstructing your view and resulting in an accident.
CAUTION:

Before staring any service work, cover fenders, seats and
any other parts that are likely to get scratched or stained dur-
ing servicing. Also, be aware that what you wear (e.g. but-
tons) may cause damage to the vehicle’s finish.

When performing service to electrical parts that does not re-
quire use of battery power, disconnect the negative cable of
the battery.

GENERAL INFORMATION 0A-9

Always be careful not to handle electrical parts (computer,
relay, etc.) in a rough manner or drop them.
PRECAUTIONS FOR CATALYTIC CONVERTER
For vehicles equipped with a catalytic converter, use only un-
leaded gasoline and be careful not to let a large amount of un-
burned gasoline enter the converter or it can be damaged.
–Conduct a spark jump test only when necessary, make it as
short as possible, and do not open the throttle.
–Conduct engine compression checks within the shortest
possible time.
–Avoid situations which can result in engine misfire (e.g.
starting the engine when the fuel tank is nearly empty.).
PRECAUTIONS FOR ELECTRICAL CIRCUIT
SERVICE

When replacing a fuse, make sure to use a fuse of the speci-
fied capacity. Use of a fuse with a larger capacity will cause
a damage to the electrical parts and a fire.

When disconnecting and connecting coupler, make sure to
turn ignition switch OFF, or electronic parts may get dam-
aged.

M/T A/T
G10 G13
[A] [A]
[B] [B]
0A-18 GENERAL INFORMATION
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER
The number is punched on the front dash panel in the engine room.
IDENTIFICATION WHETHER VEHICLE
EQUIPPED WITH WU-TWC OR NOT
It can be identified by the shape of exhaust manifold (1) and ex-
haust pipe (2).
[A]: Vehicle equipped with WU-TWC (3)
[B]: Vehicle not equipped with WU-TWC
ENGINE IDENTIFICATION NUMBER
The number is punched on the cylinder block.
TRANSMISSION IDENTIFICATION NUMBER
The number is punched on the transmission case.

NOTE:
Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only.
Air bag
caution
labelTire information
placard
Child lock caution label
Fuel limitation
Emission control
information label
(if equipped)
A / C warning label
(if equipped with A / C)
Engine cooling fan
warning label
Air bag warning label on driver air bag
(inflator) module
Air bag warning label on combination
switch / contact coil assembly
Air bag caution label
on steering columnAir bag warning
label on passenger
air bag (inflator)
module
Air bag warning
label on SDMRadiator cap
warning label
GENERAL INFORMATION 0A-19
WARNING, CAUTION AND INFORMATION LABELS
The figure below shows main labels among others that are attached to vehicle component parts.
When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels.
If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.

0A-22 GENERAL INFORMATION
A
ABS : Anti-Lock Brake System
ATDC : After Top Dead Center
API : American Petroleum Institute
ATF : Automatic Transmission Fluid
ALR : Automatic Locking Retractor
AC : Alternating Current
A / T : Automatic Transmission
A / C : Air Conditioning
ABDC : After Bottom Dead Center
A / F : Air Fuel Mixture Ratio
A-ELR : Automatic-Emergency Locking
Retractor
B
B+ : Battery Positive Voltage
BTDC : Before Top Dead Center
BBDC : Before Bottom Dead Center
C
CKT : Circuit
CMP Sensor : Camshaft Position Sensor
(Crank Angle Sensor, CAS)
CO : Carbon Monoxide
CPP Switch : Clutch Pedal Position Switch
(Clutch Switch, Clutch Start
Switch)
CPU : Central Processing Unit
CRS : Child Restraint System
D
DC : Direct Current
DLC : Data Link Connector (Assembly
Line Diag. Link, ALDL, Serial
Data Link, SDL)
DOHC : Double Over Head Camshaft
DOJ : Double Offset Joint
DRL : Daytime Running Light
DTC : Diagnostic Trouble Code
(Diagnostic Code)
E
EBCM : Electronic Brake Control
Module, ABS Control Module
ECM : Engine Control Module
ECT Sensor : Engine Coolant Temperature
Sensor (Water Temp. Sensor,
WTS)
EGR : Exhaust Gas Recirculation
EGRT Sensor : EGR Temperature Sensor
(Recirculated Exhaust
Gas Temp. Sensor, REGTS)
EFE Heater : Early Fuel Evaporation Heater
(Positive Temperature
Coefficient, PTC Heater)
ELR : Emergency Locking Retractor
EPS : Electronic Power Steering
EVAP : Evaporative Emission
EVAP Canister : Evaporative Emission Canister
(Charcoal Canister)
F
4WD : 4 Wheel Drive
G
GEN : Generator
GND : Ground
H
HC : Hydrocarbons
HO2S : Heated Oxygen Sensor
I
IAC Valve : Idle Air Control Valve (Idle
Speed Control Solenoid Valve,
ISC Solenoid Valve)
IAT Sensor : Intake Air Temperature Sensor
(Air temperature Sensor, ATS)
ICM : Immobilizer Control Module
IG : Ignition
ISC Actuator : Idle Speed Control Actuator
(Motor)
ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL
ABBREVIATIONS

GENERAL INFORMATION 0A-23
L
LH : Left Hand
LSPV : Load Sensing Proportioning
Valve
M
MAF Sensor : Mass Air Flow Sensor (Air Flow
Sensor, AFS, Air Flow Meter,
AFM)
MAP Sensor : Manifold Absolute Pressure
Sensor (Pressure Sensor, PS)
Max : Maximum
MFI : Multiport Fuel Injection
(Multipoint Fuel Injection)
Min : Minimum
MIL : Malfunction Indicator Lamp
M / T : Manual Transmission
N
NOx : Nitrogen Oxides
O
OBD : On-Board Diagnostic System
(Self-Diagnosis Function)
O / D : Overdrive
OHC : Over Head Camshaft
P
PNP : Park / Neutral Position
P / S : Power Steering
PSP Switch : Power Steering Pressure Switch
(P / S Pressure Switch)
PCM : Powertrain Control Module
PCV : Positive Crankcase Ventilation
R
RH : Right Hand
S
SAE : Society of Automotive
Engineers
SDM : Sensing and Diagnostic Module
(Air Bag Controller, Air Bag
Control Module)
SFI : Sequential Multiport Fuel
Injection
SOHC : Single Over Head Camshaft
T
TBI : Throttle Body Fuel Injection
(Single-Point Fuel Injection,
SPI)
TCC : Torque Converter Clutch
TCM : Transmission Control Module
(A / T Controller, A / T Control
Module)
TP Sensor : Throttle Position Sensor
TVV : Thermal Vacuum Valve
(Thermal Vacuum Switching
Valve, TVSV, Bimetal Vacuum
Switching Valve, BVSV)
TWC : Three-Way Catalytic Converter
(Three-Way Catalyst)
2WD : 2 Wheel Drive
V
VIN : Vehicle Identification Number
VSS : Vehicle Speed Sensor
W
WU-OC : Warm Up Oxidation Catalytic
Converter
WU-TWC : Warm Up Three-Way Catalytic
Converter

G (Base Color)
G (Base Color)
Y (Stripe Color)
0A-24 GENERAL INFORMATION
SYMBOLS
SYMBOLDEFINITIONSYMBOLDEFINITION
Tightening torqueApply SUZUKI BOND NO. 1216
99000-31160
Apply oil (Engine, transmission,
transfer, differential)Apply SILICONE SEALANT
99000-31120
Apply fluid (Brake, power steering or
automatic transmission fluid)Apply SEALING COMPOUND 366E
99000-31090
Apply SUZUKI SUPER GREASE A
99000-25010
Apply SUZUKI SUPER GREASE C
99000-25030Apply THREAD LOCK 1322
99000-32110
Apply SUZUKI SUPER GREASE E
99000-25050Apply THREAD LOCK 1333B
99000-32020
Apply SUZUKI SUPER GREASE H
99000-25120Apply THREAD LOCK 1342
99000-32050
Apply SUZUKI SUPER GREASE I
99000-25210
Apply SUZUKI BOND NO. 1215
99000-31110Do not reuse
Apply SUZUKI BOND NO. 1207C
99000-31150Note on reassembly
WIRE COLOR SYMBOLS
SymbolWire ColorSymbolWire Color
BBLKBlackO, OrORNOrange
BlBLUBlueRREDRed
BrBRNBrownWWHTWhite
GGRNGreenYYELYellow
GrGRYGrayPPNKPink
LblLT BLULight blueVPPLViolet
LgLT GRNLight green
There are two kinds of colored wire used in this vehicle. One is
single-colored wire and the other is dual-colored (striped) wire.
The single-colored wire uses only one color symbol (i.e. “G”).
The dual-colored wire uses two color symbols (i.e. “G/Y”). The first
symbol represents the base color of the wire (“G” in the figure) and
the second symbol represents the color of the stripe (“Y” in the fig-
ure).

0B
MAINTENANCE AND LUBRICATION 0B-1
SECTION 0B
MAINTENANCE AND LUBRICATION
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
MAINTENANCE SCHEDULE0B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Condition Schedule0B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Recommended Under Severe Driving Conditions 0B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SERVICE0B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine0B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System0B-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System0B-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emission Control System0B-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake0B-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis and Body0B-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Inspection0B-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECOMMENDED FLUIDS AND LUBRICANTS0B-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .