Torque SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

ENGINE FUEL 6C-13
INSTALLATION
1) Clean mating surfaces of fuel pump assembly (1) and fuel
tank.
2) Put plate (2) on fuel pump assembly (1) by matching the pro-
trusion of fuel pump assembly (3) to plate hole (4) as shown.
3) Install new gasket (2) and fuel pump assembly (1) with plate
(3) to fuel tank.
Tightening torque
Fuel pump assembly bolts (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
4) Connect fuel breather hose (1), fuel vapor hose (2) and fuel
feed line (3) (pipe joint) to fuel pump assembly.
5) Install fuel tank (1) to vehicle. Refer to “FUEL TANK” in this
section.
3 2
4 43
1
3
1
2
(a)
CAUTION:
When connecting joint, clean outside surface of pipe
where joint is to be inserted, push joint into pipe till joint
lock clicks and check to ensure that pipes are connected
securely, or fuel leak may occur.1
23

6C-14 ENGINE FUEL
SPECIAL TOOL
TIGHTENING TORQUE SPECIFICATION
09917-47010 09919-47020
Vacuum pump gauge Quick joint remover
Fastening partTightening torque
Nm kg-m lb-ft
Fuel tank bolts 23 2.3 17
Fuel filler hose clamps 1.5 0.15 1
Fuel pump assembly bolts 10 1 7.5

6E1-2 ENGINE AND EMISSION CONTROL SYSTEM
CRANKSHAFT POSITION SENSOR .. 6E1-32
VEHICLE SPEED SENSOR (VSS) ...... 6E1-33
FUEL LEVEL SENSOR (GAUGE) ....... 6E1-33
KNOCK SENSOR (IF EQUIPPED) ...... 6E1-33
MAIN RELAY, FUEL PUMP RELAY
AND RADIATOR FAN RELAY NO.1.... 6E1-33
FUEL CUT OPERATION ..................... 6E1-34
RADIATOR FAN CONTROL
SYSTEM .............................................. 6E1-34
RADIATOR FAN RELAY NO. 2 AND
NO.3 ..................................................... 6E1-34OUTPUT SIGNALS OF THROTTLE
VALVE OPENING AND ENGINE
COOLANT TEMP. (VEHICLE WITH
A/T ONLY) ........................................... 6E1-36
EMISSION CONTROL SYSTEM ............. 6E1-36
EGR SYSTEM ..................................... 6E1-36
EVAPORATIVE EMISSION CONTROL
SYSTEM .............................................. 6E1-37
PCV SYSTEM ...................................... 6E1-39
SPECIAL TOOL .......................................... 6E1-40
TIGHTENING TORQUE SPECIFICATION . 6E1-41
GENERAL DESCRIPTION
The engine and emission control system is divided into 4 major sub-systems : air intake system, fuel delivery
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, various sensors and controlled devices.
Emission control system includes EGR, EVAP and PCV system.

6E1-18 ENGINE AND EMISSION CONTROL SYSTEM
AIR INTAKE SYSTEM
THROTTLE BODY
ON-VEHICLE INSPECTION
Check that throttle valve lever (1) moves smoothly.
REMOVAL
1) Disconnect negative cable at battery.
2) Drain cooling system.
3) Disconnect accelerator cable (1) from throttle valve lever.
4) Disconnect IAT sensor connector and remove air cleaner
assembly with air cleaner outlet hose.
1. Throttle body 4. Gasket 7. TP sensor screws
2. Throttle stop screw 5. Idle air control valve Tightening torque
3. TP sensor 6. IAC valve screws Do not reuse.

6E1-20 ENGINE AND EMISSION CONTROL SYSTEM
3) Install throttle body (1) to intake manifold.
4) Connect connector to TP sensor (2) and IAC valve (3)
securely.
5) Connect accelerator cable and adjust cable play to specifica-
tion.
6) Install air cleaner assembly with air cleaner outlet hose and
connect IAT sensor connector.
7) Refill cooling system.
8) Connect negative cable at battery.
IDLE AIR CONTROL VALVE (IAC VALVE)
REMOVAL
1) Remove throttle body from intake manifold referring to
“Throttle Body Removal” section.
2) Remove IAC valve from throttle body.
INSPECTION
1) Connect each connector to IAC valve (1), TP sensor and IAT
sensor.
2) Check that rotary valve (2) of lAC valve opens and closes
once and then stops in about 60 ms as soon as ignition
switch is turned ON.
INSTALLATION
1) Install new gasket (2) to IAC valve (1).
2) Install IAC valve (1) to throttle body (3).
Tighten IAC valve screws to specified torque.
Tightening torque
IAC valve screw (a) : 3.5 N·m (0.35 kg-m, 2.5 lb-ft)
3) Install throttle body to intake manifold referring to “Throttle
Body Installation” section.
NOTE:
This check should be performed by two people, one
person turns on ignition switch while the other checks
valve operation.
As valve operation is momentary, it may be over-
looked. To prevent this, perform this operation check 3
times or more continuously.
If rotary valve of lAC valve does not operate at all,
check wire harness for open and short. If wire harness
is in good condition, replace lAC valve and recheck.

6E1-26 ENGINE AND EMISSION CONTROL SYSTEM
INSTALLATION
For installation, reverse removal procedure and note following
precautions.
Replace injector O-ring (1) with new one using care not to
damage 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, proba-
ble 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) rotate smoothly (6).
Tightening torque
Delivery pipe bolts (a) : 28 N·m (2.8 kg-m, 20.5 lb-ft)
After installation, with engine “OFF” and ignition switch “ON”,
check for fuel leaks around fuel line connection.5, (a)
4
1
3 2

6E1-28 ENGINE AND EMISSION CONTROL SYSTEM
THROTTLE POSITION SENSOR (TP SENSOR)
INSPECTION
1) Disconnect negative cable at battery and connector from IAT
sensor.
2) Remove air cleaner assembly with air cleaner outlet hose
and disconnect TP sensor connector.
3) Using ohmmeter, check resistance between terminals under
each condition given in table below.
If check result is not satisfactory, replace TP sensor.
TP sensor resistance
4) Connect TP sensor connector securely.
5) Connect negative cable to battery.
REMOVAL
1) Disconnect battery negative cable at battery.
2) Remove throttle body from intake manifold referring to
“Throttle Body Removal” in this section.
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 figure and turn TP sensor clockwise so that those holes
align (4).
Tightening torque
TP sensor screw (a) : 2.5 N·m (0.25 kg-m, 1.8 lb-ft)
2) Connect connector to TP sensor securely.
3) Connect battery negative cable to battery.TERMINALS RESISTANCE
Between 1 and
3 terminals4.0 – 6.0 k
Ω
Between 2 and
3 terminals20
Ω – 6.0 k
Ω, varying according to throt-
tle valve opening.
NOTE:
There should be more than 2 k
Ω resistance difference
between when throttle valve is at idle position and when
it is fully open.
1. Reference voltage terminal
2. Output voltage terminal
3. Ground terminal

6E1-30 ENGINE AND EMISSION CONTROL SYSTEM
ENGINE COOLANT TEMPERATURE SENSOR (ECT
SENSOR)
REMOVAL
1) Disconnect battery negative cable at battery.
2) Drain coolant referring to Section 6B.
3) Remove air intake pipe.
4) Disconnect connector from ECT sensor.
5) 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 does not 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
ECT sensor (a) : 15 N·m (1.5 kg-m, 11.5 lb-ft)
Connect connector to ECT sensor (1) securely.
Refill coolant referring to Section 6B. WARNING:
To help avoid danger of being burned, do not remove
radiator 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.
1
1, (a)

ENGINE AND EMISSION CONTROL SYSTEM 6E1-31
HEATED OXYGEN SENSOR (HO2S-1 AND HO2S-2)
OXYGEN SENSOR HEATER INSPECTION
1) Disconnect sensor connector.
2) Using ohmmeter, measure resistance between terminals
“V
B” and “GND” of sensor connector.
If found faulty, replace oxygen sensor.
Resistance of oxygen sensor heater
HO2S-1 : 5.0 – 6.4
Ω at 20°C (68°F)
HO2S-2 : 11.7 – 14.3
Ω at 20°C (68°F)
3) Connect sensor connector securely.
REMOVAL
1) Disconnect negative cable at battery.
2) For HO2S-1, disconnect connector of heated oxygen sensor
and release its wire harness from clamps, then remove front
bumper and heat insulator panel.
3) For HO2S-2, disconnect connector of heated oxygen sensor
and release its wire harness from clamp and hoist vehicle.
4) Remove heated oxygen sensor (1) from exhaust manifold or
exhaust pipe.
INSTALLATION
Reverse removal procedure noting the following.
Tighten heated oxygen sensor (1) to specified torque.
Tightening torque
Heated oxygen sensor (a) : 45 N·m (4.5 kg-m, 32.5 lb-ft)
Connect connector of heated oxygen sensor (1) and clamp
wire harness securely.
After installing heated oxygen sensor (1), start engine and
check that no exhaust gas leakage exists. NOTE:
Temperature of sensor affects resistance value largely.
Make sure that sensor heater is at correct temperature.
1. Viewed from terminal side
WARNING:
To avoid danger of being burned, do not touch exhaust
system when system is hot. Oxygen sensor removal
should be performed when system is cool.
[A] : HO2S-1
[B] : HO2S-2

6E1-32 ENGINE AND EMISSION CONTROL SYSTEM
CAMSHAFT POSITION SENSOR
INSPECTION
Check camshaft position sensor referring to DTC P0340 (No.15)
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 cylinder head.
INSTALLATION
1) Check that O-ring is free from damage.
2) Check that camshaft position sensor and signal rotor teeth
are free from any metal particles and damage.
3) Install camshaft position sensor to cylinder head.
Tightening torque
Camshaft position sensor bolt
(a) : 10 N·m (1.0 kg-m, 7.5 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 (No.23) Flow Table. If malfunction is found, replace.
REMOVAL
1) Disconnect negative cable at battery.
2) Remove generator drive belt, loosen pivot bolt and move
generator outward.
3) Disconnect connector from crankshaft position sensor.
4) Remove crankshaft position sensor (1) from cylinder block.
INSTALLATION
1) Check to make sure that crankshaft position sensor and pul-
ley teeth are free from any metal particles and damage.
2) Install crankshaft position sensor to cylinder block.
3) Connect connector to it securely.
4) Adjust generator belt tension, refer to Section 6B.
5) Connect negative cable to battery.