fuel SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

6E1-10 ENGINE AND EMISSION CONTROL SYSTEM
1. CKP sensor 20. Blank 39. Ignition coil assembly (for No.1 and No.4 spark plugs)
2. CMP sensor 21. A/C switch 40. Ignition coil assembly (for No.2 and No.3 spark plugs)
3. VSS 22. A/C pressure switch 41. Stop lamp switch
4. MAP sensor 23. Immobilizer control module 42. Stop lamp
5. Knock sensor (if equipped) 24. Data link connector 43. Lighting switch
6. TP sensor 25. Injector No.1 44. Position lamp
7. ECT sensor 26. Injector No.2 45. Rear defogger switch
8. IAT sensor 27. Injector No.3 46. Rear defogger
9. Heated oxygen sensor-1 (if equipped) 28. Injector No.4 47. A/C compressor clutch (if equipped)
10. Heated oxygen sensor-2 (if equipped) 29. IAC valve 48. Ignition switch
11. A/C evaporator temp. sensor 30. EVAP canister purge valve 49. Main relay
12. Combination meter 31. Fuel pump relay 50. Transmission range switch (A/T)
13. Fuel level sensor (vehicle with immobilizer
indicator lamp)32. Fuel pump 51. Starting motor
14. TCM 33. Radiator fan relay 52. Shield wire
15. Transmission range switch 34. Radiator fan motor 53. Main fuse
16. ABS control module 35. EGR valve (if equipped) 54. Barometric pressure sensor
17. CO adjusting resistor (if equipped) 36. Malfunction indicator lamp 55. Immobilizer indicator lamp (if equipped)
18. Heater fan motor 37. Tachometer 56. Engine ground
19. Heater fan switch 38. Monitor connector (vehicle without immo-
bilizer indicator lamp)57. Body ground

6E1-12 ENGINE AND EMISSION CONTROL SYSTEM
1. CKP sensor 20. Blank 39. Ignition coil assembly (for No.1 and No.4 spark plugs)
2. CMP sensor 21. A/C switch 40. Ignition coil assembly (for No.2 and No.3 spark plugs)
3. VSS 22. A/C pressure switch 41. Stop lamp switch
4. MAP sensor 23. Immobilizer control module 42. Stop lamp
5. Knock sensor (if equipped) 24. Data link connector 43. Lighting switch
6. TP sensor 25. Injector No.1 44. Position lamp
7. ECT sensor 26. Injector No.2 45. Rear defogger switch
8. IAT sensor 27. Injector No.3 46. Rear defogger
9. Heated oxygen sensor-1 (if equipped) 28. Injector No.4 47. A/C compressor clutch (if equipped)
10. Blank 29. IAC valve 48. Ignition switch
11. A/C evaporator temp. sensor 30. EVAP canister purge valve 49. Main relay
12. Combination meter 31. Fuel pump relay 50. Transmission range switch (A/T)
13. Fuel level sensor (vehicle with immobilizer
indicator lamp)32. Fuel pump 51. Starting motor
14. TCM 33. Radiator fan relay 52. Shield wire
15. Transmission range switch 34. Radiator fan motor 53. Main fuse
16. ABS control module 35. EGR valve (if equipped) 54. Barometric pressure sensor
17. CO adjusting resistor (if equipped) 36. Malfunction indicator lamp 55. Immobilizer indicator lamp (if equipped)
18. Heater fan motor 37. Tachometer 56. Engine ground
19. Heater fan switch 38. Monitor connector (vehicle without immo-
bilizer indicator lamp)57. Body ground

ENGINE AND EMISSION CONTROL SYSTEM 6E1-13
ECM TERMINAL ARRANGEMENT TABLE
For TYPE A (Refer to NOTE in page “ECM INPUT/OUTPUT CIRCUIT DIAGRAM” for applicable model.)
CONNEC-
TORTERMINAL WIRE COLOR CIRCUITCONNEC-
TORTERMINAL WIRE COLOR CIRCUIT
C421 BLK/ORN Ground for ECM
C4112––
2 BLK Ground for drive circuit 13–Heated oxygen sensor-2
3 BLK/ORN Ground for drive circuit 14 LT BLU“D”, “2”, “L”-range ID-UP signal
4 BLU/BLK Canister purge valve 15 RED“R”-range signal
5 WHT/BLK Coolant temp. signal output 16 YEL/GRN A/C SW signal
6 GRN/RED IAC valve 17 BRN/YEL EGR valve (stepper motor coil 4)
7 RED/BLU Heater of HO2S-1 18 BLU Radiator fan relay 1
8 BLU/ORN No.4 fuel injector 19 PNK Fuel pump relay
9 BLU/YEL No.1 fuel injector 20––
10 ORN Ground for sensor circuit 21 PPL Throttle opening signal output for A/T
11 RED/YEL CMP sensor 22 YEL/RED Fuel level gauge
12 RED Knock sensor (if equipped) 23 BLK/WHT TCM serial data line
13 WHTHeated oxygen sensor-1
(if equipped)
24––
CO adjusting resistor
(if equipped)
14 LT GRN Coolant temp. sensor
15 LT GRN/BLK Intake air temp. sensor
G021 PPL/WHT Malfunction indicator lamp
16 WHT/GRN Test switch terminal (if equipped) 2 PPL Vehicle speed sensor
17 RED/BLK Electric load (+) 3 PPL/YEL Radiator fan relay 2
18 PNK/GRN A/C switch 4––
19 GRN/WHTIG coil assembly for No.2 and 3 spark
plugs5 BLU Data link connector
20 GRN/YELIG coil assembly for No.1 and 4 spark
plugs6 BLK/WHT Ignition switch signal
21 BLU/WHT No.2 fuel injector 7 YEL Data link connector
22 GRY/RED Power supply for sensor 8––
23 YEL/BLK CKP sensor (+) 9 GRN/WHTStop lamp switch (Brake pedal
switch)
24––10 ORN GND for sensor
25–Ground for sensor shield wire 11––
26 RED/WHT MAP sensor 12 PNKImmobilizer indicator lamp
(if equipped)
27 PPL/WHTDiagnosis switch terminal
(if equipped)13 PNK/BLU Electrical load (-)
28 PNK/BLU Duty output terminal (if equipped) 14 WHT/BLK A/C evaporator temp. sensor
29 BRN Heater of HO2S-2 15––
30 GRN/BLK Heated oxygen sensor-2 16 BRN Tachometer signal
31 BLU/RED No.3 fuel injector 17 WHT/RED Backup power source
C411 PNK/BLK A/C compressor clutch
2 GRN EGR valve (stepper motor coil 1)
3 GRY/BLU Throttle position (TP) sensor
4–Heater of HO2S-2
5 BLK/RED Power source
6 BLK/RED Power source
7 BLK/YEL Engine start signal
8 WHT/RED EGR valve (stepper motor coil 3)
9 GRN/ORN EGR valve (stepper motor coil 2)
10 BRN/WHT Ground for main relay
11––
C42 (31P) C41 (24P) G02 (17P)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 26 28 27 29 30 315 6
1 2 3 4 5 6 7
11 12
9 10 11 13 12 14 15 16
16 171 2
7 8
13 14 3 4
9 10
15 17 188
19 20 21 22 23 24
NOTE:
For abbreviation of wire color, refer to Section 0A.

6E1-14 ENGINE AND EMISSION CONTROL SYSTEM
For TYPE B (Refer to NOTE in page “ECM INPUT/OUTPUT CIRCUIT DIAGRAM” for applicable model.)
CONNEC-
TORTERMINAL WIRE COLOR CIRCUITCONNEC-
TORTERMINAL WIRE COLOR CIRCUIT
C421 BLK/ORN Ground for ECM
C4112––
2 BLK Ground for drive circuit 13––
3 BLK/ORN Ground for drive circuit 14 PPL/WHT Diagnosis switch terminal
4 BLU/BLK Canister purge valve 15 WHT/GRN Test switch terminal
5––16 YEL/GRN A/C SW signal
6 GRN/RED IAC valve 17 RED/YEL
Electric load (+)
7 RED/BLU Heater of HO2S-1 18 BLU Radiator fan relay 1
8 BLU/ORN No.4 fuel injector 19 PNK Fuel pump relay
9 BLU/YEL No.1 fuel injector 20 BLK/YEL
Cranking signal
10 ORN Ground for sensor circuit 21 GRN/WHTStop lamp switch (Brake pedal
switch)
11 RED/YEL CMP sensor 22 PPL Vehicle speed sensor
12 Or Grand for shield wire 23––
13 WHTHeated oxygen sensor-1
(if equipped)
24––
CO adjusting resistor
(if equipped)
14 LT GRN Coolant temp. sensor
15 LT GRN/BLK Intake air temp. sensor
G021 WHT/BLK A/C evaporator temp. sensor
16 GRY/BLU Throttle position (TP) sensor 2 RED“R” range signal
17 WHT/RED EGR valve (stepper motor coil 3) 3––
18 GRY EGR valve (stepper motor coil 1) 4––
19 GRN/WHTIG coil assembly for No.2 and 3 spark
plugs5 WHT/BLK Engine coolant temp. signals output
20 GRN/YELIG coil assembly for No.1 and 4 spark
plugs6 GRN/RED“D”, “2”, “L” range ID-UP signal
21 BLU/WHT No.2 fuel injector 7 YEL Data link connector
22 GRY/RED Power supply for sensor 8––
23 YEL/BLK CKP sensor (+) 9 PPL/WHT Malfunction indicator lamp
24––10––
25 RED Knock sensor (if equipped) 11 BLU
Data link connector
26 RED/WHT MAP sensor 12––
27––13 PNK/BLU Electrical load (-)
28 BRN/YEL EGR valve (stepper motor coil 4) 14 ORN Ground for sensor
29 GRN/ORNEGR valve (stepper motor coil 2)
15 PPL
Throttle opening signal output for
A/T
30 PNK/GRN A/C switch 16 BRN Tachometer signal
31 BLU/RED No.3 fuel injector 17––
C411 PNK/BLK A/C compressor clutch
2––
3––
4––
5 BLK/RED Power source for drive circuit
6 BLK/RED Power source for main circuit
7 WHT/RED Power source for memory circuit
8 PNK/BLU Duty signal output terminal
9 GRN/RED Radiator fan drive relay No.2
10 BRN/WHT Ground for main relay
11 BLK/WHT
Ignition switch signal
C42 (31P) C41 (24P) G02 (17P)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 26 28 27 29 30 315 6
1 2 3 4 5 6 7
11 12
9 10 11 13 12 14 15 16
16 171 2
7 8
13 14 3 4
9 10
15 17 188
19 20 21 22 23 24
NOTE:
For abbreviation of wire color, refer to Section 0A.

ENGINE AND EMISSION CONTROL SYSTEM 6E1-15
ON-VEHICLE SERVICE
ACCELERATOR CABLE ADJUSTMENT
With accelerator pedal depressed fully (1), check clearance
between throttle lever (2) and lever stopper (3) (throttle body)
which should be within following specification.
If measured value is out of specification, adjust it to specification
with cable adjusting nut (4).
Accelerator cable adjustment clearance (with pedal
depressed fully)
“a” : 0.5 – 2.0 mm (0.02 – 0.07 in.)
IDLE SPEED/IDLE AIR CONTROL (IAC) DUTY
INSPECTION
Before idle speed/IAC duty check, make sure of the following.
Lead wires and hoses of Electronic Fuel Injection and engine
emission control systems are connected securely.
Accelerator cable has some play, that is, it is not tight.
Valve lash is checked and adjusted according to mainte-
nance schedule.
Ignition timing is within specification.
All accessories (wipers, heater, lights, A/C, etc.) are out of
service.
Air cleaner has been properly installed and is in good condi-
tion.
No abnormal air inhaling from air intake system.
After above items are all confirmed, check idle speed and IAC
duty as follows.
NOTE:
Before starting engine, place transmission gear shift
lever in “Neutral” (shift selector lever to “P” range for A/T
vehicle), and set parking brake and block drive wheels.

ENGINE AND EMISSION CONTROL SYSTEM 6E1-21
FUEL DELIVERY SYSTEM
FUEL PRESSURE INSPECTION
1) Relieve fuel pressure in fuel feed line referring to “Fuel Pres-
sure Relief Procedure” in Section 6.
2) Disconnect fuel feed hose from fuel delivery pipe.
3) Connect special tools and hose between fuel delivery pipe
and fuel feed hose (1) as shown in figure, and clamp hoses
securely to ensure no leaks occur during checking.
Special tool
(A) : 09912-58441
(B) : 09912-58431
(C) : 09912-58490
4) Check that battery voltage is above 11 V.
5) Turn ignition switch ON to operate fuel pump and after 2 sec-
onds turn it OFF. Repeat this 3 or 4 times and then check
fuel pressure.
Fuel pressure specification WARNING:
Be sure to perform work in a well-ventilated area and
away from any open flames, or there is a risk of a fire
breaking out.
CAUTION:
A small amount of fuel may be released when fuel hose is
disconnected. Place container under the joint with a
shop cloth so that released fuel is caught in container or
absorbed in cloth. Place that cloth in an approved con-
tainer.
(A)
(B)
(C)1
CONDITION FUEL PRESSURE
With fuel pump operating and
engine stopped270 – 310 kPa
(2.7 – 3.1 kg/cm
2,
38.4 – 44.0 psi) At specified idle speed
With 1 min. after engine (fuel
pump) stop (Pressure
reduces as time passes)over 250 kPa
(2.5 kg/cm
2, 35.6 psi)

6E1-22 ENGINE AND EMISSION CONTROL SYSTEM
6) Start engine and warm it up to normal operating tempera-
ture.
7) Measure fuel pressure at idling.
If measured pressure does not satisfy specification, refer to
“Diagnostic Flow Table B-3” in “Engine Diagnosis” section
and check each possibly defective part. Replace if found
defective.
8) After checking fuel pressure, remove fuel pressure gauge.
9) Remove special tools from fuel delivery pipe.
10) Connect fuel feed hose to fuel delivery pipe and clamp it
securely.
11) With engine “OFF” and ignition switch “ON”, check for fuel
leaks.
FUEL PUMP WITH PRESSURE REGULATOR
ON-VEHICLE INSPECTION
1) Remove filler cap and turn ON ignition switch. Then fuel
pump operating sound should be heard from fuel filler for
about 2 seconds and stop. Be sure to reinstall fuel filler cap
after checking.
If above check result is not satisfactory, advance to “Diag-
nostic Flow Table B-2”. CAUTION:
As fuel feed line is still under high fuel pressure, make
sure to release fuel pressure according to following pro-
cedures.
Place fuel container under joint.
Cover joint with rag and loosen joint nut slowly to
release fuel pressure gradually.
CAUTION:
When fuel filler cap is removed in any procedure, work
must be done in a well-ventilated area, keep away from
any open flames and without smoking.
NOTE:
The fuel pressure regulator is the one body with the fuel
pump assembly so individual inspection of it is impossi-
ble.
1. Fuel filler
2. Ignition switch

ENGINE AND EMISSION CONTROL SYSTEM 6E1-23
2) Turn OFF ignition switch and leave over 10 minutes as it is.
3) Fuel pressure should be felt at fuel feed hose (1) for about 2
seconds after ignition switch ON.
If fuel pressure is not felt, advance to “Diagnostic Flow Table
B-3”.
REMOVAL
Remove fuel tank from body according to procedure described in
Section 6C and remove fuel pump from fuel tank.
INSPECTION
Check fuel pump filter for evidence of dirt and contamination. If
present, clean and check for presence of dirt in fuel tank.
INSTALLATION
1) Install fuel pump to its bracket.
2) Install fuel pump to fuel tank and then install fuel tank to
body according to procedure described in Section 6C.
FUEL INJECTOR
ON-VEHICLE INSPECTION
1) Using sound scope (1) or such, check operating sound of
injector (2) when engine is running or cranking.
Cycle of operating sound should vary according to engine
speed.
If no sound or an unusual sound is heard, check injector cir-
cuit (wire or connector) or injector (2).
2) Disconnect connector (1) from injector, connect ohmmeter
between terminals of injector and check resistance.
If resistance is out of specification, replace.
Resistance of fuel injector
: 11.3 – 13.8
Ω at 20°C (68°F)
3) Connect connector (1) to injector securely.

6E1-24 ENGINE AND EMISSION CONTROL SYSTEM
REMOVAL
1) Relieve fuel pressure according to procedure described in
Section 6.
2) Disconnect battery negative cable at battery.
3) Disconnect IAT sensor connector and remove air cleaner
assembly with air cleaner outlet hose.
4) Disconnect fuel injector couplers.
5) Disconnect fuel feed hose from fuel delivery pipe (1).
6) Remove fuel delivery pipe bolts (2).
7) Remove fuel injector(s) (3).
INSPECTION
1) Install injector to special tool (injector checking tool).
Special tool
(A) : 09912-58421
(B) : 09912-57610
2) Connect special tools (hose and attachment) to fuel feed
pipe (1) of vehicle.
3) Connect special tool (test lead) to injector.
Special tool
(C) : 09930-88530 CAUTION:
A small amount of fuel may come out after removal of
fuel injectors, cover them with shop cloth.
2
1
3
3
WARNING:
As fuel is injected in this inspection, perform in a well
ventilated area and away from open flames.
Use special care to prevent sparking when connecting
and disconnecting test lead to and from battery.

ENGINE AND EMISSION CONTROL SYSTEM 6E1-25
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 fol-
lows:
7) 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.
(A) : 09931-76011 (SUZUKI scan tool)
(B) : Mass storage cartridge
(C) : 09931-76030 (16/14 pin DLC cable)
8) Without 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.
c) Turn ignition switch ON.
9) Apply battery voltage (3) to injector (2) for 15 seconds and
measure injected fuel volume with graduated cylinder.
Test each injector two or three times.
If not within specification, replace injector.
Injected fuel volume
: 43 – 47 cc/15 sec. (1.45/1.51 – 1.58/ 1.65 US/Imp. oz/15
sec.)
10) 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. CAUTION:
Check to make sure that connection is made between
correct terminals. Wrong connection can cause damage
to ECM, wire harness, etc.
4. Keep as far apart as possible
[A] : When using SUZUKI scan tool
[B] : When not using SUZUKI scan tool
(C)
(A)
(B)
1 [A]
[B]