check engine SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

ENGINE COOLING 6B-17
5) Remove water pump assembly (1).
INSPECTION
Rotate water pump by hand to check for smooth operation.
If pump does not rotate smoothly or makes abnormal noise,
replace it.
INSTALLATION
1) Apply sealant to mating surface of water pump as shown in
figure.
“A” : Sealant 99000-31150
Sealant quantity (to mating surface of water pump)
Width “a” : 3mm (0.12 in.)
Height “b” : 2mm (0.08 in.)
2) Install water pump assembly (1) to cylinder block and tighten
bolts and nut to specified torque.
Tightening torque
Water pump bolts and nut (a) : 22 N·m (2.2 kg-m, 16.0 lb-ft)
3) Install water pump pulley.
4) Install water pump/generator drive belt. Refer to “WATER
PUMP/GENERATOR DRIVE BELT” in this Section.
5) Install A/C compressor belt (if equipped). Refer to “COM-
PRESSOR DRIVE BELT” in Section 1B.
6) Fill coolant. Refer to “COOLING SYSTEM REFILL”.
7) Connect negative cable at battery.
8) Check each part for leakage.
CAUTION:
Do not disassemble water pump.
If any repair is required on pump, replace it as assembly.
“a”
“b”

ENGINE FUEL 6C-5
4) Mark the location of clamps (1) on fuel pipes (2), so that the
clamps can be reinstalled to where they were.
5) Remove pipes (2) with clamp (1) from vehicle.
6) Remove clamp (1) from pipes (2).
INSTALLATION
1) Install clamps to marked location on pipes. If clamp is
deformed or its claw is bent or broken, replace it with new
one.
2) Install pipes with pipe clamps to vehicle.
3) Connect fuel hoses and pipes to each pipe.
4) With engine OFF, turn ignition switch to ON position and
check for fuel leaks.
FUEL FILLER CAP
INSPECTION
Remove cap (1), and check gasket for even filler neck imprint,
and deterioration or any damage. If gasket (2) is in malcondition,
replace cap.
2
1
CAUTION:
When connecting joint, clean outside surfaces 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.
NOTE:
If cap requires replacement, only a cap with the same fea-
tures should be used. Failure to use correct cap can
result in critical malfunction of system.

6C-6 ENGINE FUEL
FUEL TANK INLET VALVE
REMOVAL
1) Remove fuel filler cap.
2) Insert hose of a hand operated pump into fuel filler hose (1)
and drain fuel in space “A” in the figure.
3) Hoist vehicle and remove clamp (2) and fuel filler hose (1)
from fuel tank.
4) Remove fuel tank inlet valve (1) using flat-bladed screw-
driver.
INSPECTION
Check fuel tank inlet valve for the followings.
Damage
Smooth opening and closing
If any damage or malfunction is found, replace.WARNING:
Refer to the WARNING at the beginning of ON-VEHICLE
SERVICE in this section.
CAUTION:
Do not force pump hose into fuel tank, or pump hose
may damage fuel tank inlet valve (2).
1
2
CAUTION:
Be careful not to damage fuel tank inlet valve (1) with flat-
bladed screwdriver.

6C-8 ENGINE FUEL
6) Disconnect fuel pipe joint and fuel hoses from pipes.
For quick joint, disconnect it as follows :
a) Remove mud, dust and/or foreign material between pipe
and joint by blowing compressed air.
b) Unlock joint (1) lock by inserting special tool between pipe
(2) and joint (1).
Special tool
(A) : 09919-47020
c) Disconnect joint from pipe.
7) Support fuel tank (1) with jack (2) and remove its mounting
bolts.
8) Lower fuel tank a little as to disconnect wire harness at con-
nector (1), then remove fuel tank.
INSPECTION
After removing fuel tank, check hoses and pipes connected to
fuel tank for leaks, loose connections, deterioration or damage.
Also check fuel pump assembly gaskets for leaks, visually inspect
fuel tank for leaks and damage.
Replace any damaged or malconditioned parts.WARNING:
A small amount of fuel may be released after the fuel
hose is disconnected. In order to reduce the chance of
personal injury, cover the hose and pipe to be discon-
nected with a shop cloth. Be sure to put that cloth in an
approved container when disconnection is completed.
1

6C-10 ENGINE FUEL
5) Connect fuel feed hose (1) and vapor hose (2) to each pipe
as shown in figure and clamp them securely.
6) Connect negative cable at battery.
With engine OFF, turn ignition switch to ON position and
check for fuel leaks.
FUEL PUMP ASSEMBLY
REMOVAL
1) Remove fuel tank from vehicle. Refer to “FUEL TANK”.
2) Disconnect fuel breather hose (1), fuel vapor hose (2) and
pipes from fuel pump assembly.
When disconnecting joint of fuel feed line (3) from pipe,
unlock joint by inserting special tool between pipe and joint
lock first.
Special tool
(A) : 09919-47020 CAUTION:
When connecting joint, clean outside surfaces 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.
Never let the fuel hoses touch the ABS sensor harness
(if equipped).
WARNING:
Refer to the PRECAUTIONS at the beginning of ON-VEHI-
CLE SERVICE.
1
23

ENGINE FUEL 6C-11
3) Remove fuel pump assembly (1) from fuel tank (2).
INSPECTION
Check fuel pump assembly for damage.
Check fuel suction filter (1) for evidence of dirt and contami-
nation.
If present, replace or clean and check for presence of dirt in
fuel tank.
For operation or electrical circuit inspection by referring to
Section 6E1.
For inspection of fuel level gauge (2) by referring to Section
8.
Check tank pressure control valve referring to the following
procedures.
a) Air should pass through valve (2) smoothly from fuel vapor
line hose (3) “A” to “B” when blown hard.
b) Also, when vacuum pump (4) is connected to fuel vapor
hose and pump air through valve, air should pass from “B”
to “A”.
Special tool
(A) : 09917-47910
If air doesn’t pass through valve in Step a) or vacuum is main-
tained in Step b), replace fuel filter assembly (1).
1
2
WARNING:
Do not such air through fuel vapor line hose. Fuel vapor
inside valve is harmful.12

6C-12 ENGINE FUEL
DISASSEMBLY AND REASSEMBLY
Disassemble and reassemble fuel pump assembly, noting the fol-
lowings.
When removing fuel level sensor (3), press snap-fit part (4)
and slide it in the arrow direction as shown in figure.
When installing fuel level sensor to housing, fit fuel level sen-
sor securely.
“A” : Apply oil 5. O-ring 10. Fuel pressure regulator
1. Fuel filter assembly (including check valve) 6. Fuel level sensor (Fuel sender gauge) 11. Gasket
2. Grommet 7. Fuel pump 12. Fuel pump plate
3. Tube 8. Cushion Do not reuse.
4. Housing 9. Bracket
CAUTION:
While removing fuel level gauge, do not contact resis-
tor plate (1) or deform arm (2). It may cause fuel level
gauge to fail.
When removing grommet from fuel tube or bracket sub
assembly, be very careful not to cause damage to
grommet installed section (sealed section in bore).
Should it be damaged, replace it with new one, or fuel
will leak from that part.

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

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.

6E1-16 ENGINE AND EMISSION CONTROL SYSTEM
1) Connect SUZUKI scan tool (1) to DLC with ignition switch
OFF, if it is available.
2) Warm up engine to normal operating temperature.
3) Check engine idle speed and “IAC duty” as follows :
4) When using SUZUKI scan tool :
a) Select “Data List” mode on scan tool to check “IAC duty”.
(A) : 09931-76011 (SUZUKI scan tool)
(B) : Mass storage cartridge
(C) : 09931-76030 (16/14 pin DLC cable)
5) When using duty meter (vehicle without immobilizer indicator
lamp) :
a) Set tachometer.
b) Using service wire (2), ground “Diag. switch terminal” (4) in
monitor connector (3) and connect duty meter between
“Duty output terminal” (5) and “Ground terminal” (6) of mon-
itor connector (3).
6) If duty and/or idle speed is out of specifications, inspect idle
air control system referring to Diagnostic Flow Table B-4 Idle
Air Control System Check in Section 6.
Engine idle speed and IAC duty
7) Remove service wire from monitor connector (1).
8) Check that specified engine idle speed is obtained with A/C
ON if vehicle is equipped with A/C.
If not, check A/C ON signal circuit and idle air control sys-
tem.
[A] : When using SUZUKI scan tool
[B] : When using duty meter (Vehicle without immobilizer indicator lamp)
NOTE:
IAC duty can be checked using monitor connector only
for vehicle not equipped with immobilizer indicator lamp.
A/C OFF A/C ON
M/T vehicle 700 ± 50 r/min (rpm)
5 – 25 %850 ± 50 r/min (rpm)
A/T vehicle
at P/N range750 ± 50 r/min (rpm)
5 – 25 %850 ± 50 r/min (rpm)
NOTE:
Above duty values are ON duty (low voltage rate) meter
indications.
(C)
(A)
(B)
1 2
6
54
3-+
[A]
[B]
1