Intake Manifold SUZUKI SWIFT 2000 1.G RG413 Service User Guide

6-40 ENGINE GENERAL INFORMATION AND DIAGNOSIS
For TYPE B (For applicable mode, refer to NOTE in “ECM VOLTAGE VALUES TABLE”) G02 17 Power source for back-up 10 – 14 V Anytime
TERMINAL NO. CIRCUIT NORMAL VOLT-
AGECONDITION
C421Ground––
2Ground––
3Ground––
4 EVAP canister purge valve 10 – 14 V Ignition switch ON
5–– –
6 Idle air control valve 0 – 13 V At specified idle speed after engine warmed up
7 Heater of HO2S-1 (if equipped) 10 – 14 V Ignition switch ON
8 Fuel injector NO.4 10 – 14 V Ignition switch ON
9 Fuel injector NO.1 10 – 14 V Ignition switch ON
10 Sensor ground––
11 Camshaft position sensor 0 – 0.8 V and
4 – 6 VIgnition switch ON
12 Shield ground––
13 Heated oxygen sensor-1 (if equipped) Refer to DTC P0130 diag. flow table
CO adjusting resistor (if equipped)––
14 Engine coolant temp. sensor 0.55 - 0.95 V Ignition switch ON
Engine coolant temp. : 80°C (176°F)
15 Intake air temp. sensor 2.0 – 2.7 V Ignition switch ON
Intake air temp. : 20°C (68°F)
16 Throttle position sensor 0.2 – 1.0 V Ignition switch ON
Throttle valve at idle position
2.8 – 4.8 V Ignition switch ON
Throttle valve at full open position
17 EGR valve (stepper motor coil 3)
(if equipped)10 – 14 V Ignition switch ON
18 EGR valve (stepper motor coil 1)
(if equipped)10 – 14 V Ignition switch ON
19 Ignition coil #2––
20 Ignition coil #1––
21 Fuel injector NO.2 10 – 14 V Ignition switch ON
22 Power source for sensor 4.75 – 5.25 V Ignition switch ON
23 Crankshaft position sensor––
24–– –
25 knock sensor (if equipped) 2.1 – 2.9 V Ignition switch ON
26 Manifold absolute pressure sensor 3.3 – 4.0 V Ignition switch ON
Barometric pressure : 100 kPa (760 mmHg)
27–– –
28 EGR valve (stepper motor coil 4)
(if equipped)10 – 14 V Ignition switch ON
29 EGR valve (stepper motor coil 2)
(if equipped)10 – 14 V Ignition switch ON
30 A/C triple pressure switch 10 – 14 V A/C not operated
31 Fuel injector NO.3 10 – 14 V Ignition switch ON
TERMINAL
NO.CIRCUIT NORMAL
VOLTAGECONDITION

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-53
MAP SENSOR INDIVIDUAL CHECK
1) Disconnect connector from MAP sensor (1).
2) Remove MAP sensor (1).
3) Arrange 3 new 1.5 V batteries (2) in series (check that total
voltage is 4.5 – 5.0 V) and connect its positive terminal to
“Vin” terminal of sensor and negative terminal to “Ground”
terminal. Then check voltage between “Vout” and “Ground”.
Also, check if voltage reduces when vacuum is applied up to
400 mmHg by using vacuum pump (3).
Output voltage (When input voltage is 4.5 – 5.5 V, ambient
temp. 20 – 30°C, 68 – 86°F)
If check result is not satisfactory, replace MAP sensor (1).
4) Install MAP sensor (1) securely.
5) Connect MAP sensor (1) connector securely.
INSPECTION
ALTITUDE
(Reference)BAROMETRIC
PRESSUREOUTPUT
VOLTAGE
(ft) (m) (mmHg) (kPa) (V)
0
|
2 0000
|
610760
|
707100
|
943.3 – 4.3
2 001
|
5 000611
|
1 524Under 707
over 63494
|
853.0 – 4.1
5 001
|
8 0001 525
|
2 438Under 634
over 56785
|
762.7 – 3.7
8 001
|
10 0002 439
|
3 048Under 567
over 52676
|
702.5 – 3.3
Step Action Yes No
1Was “ENGINE DIAG. FLOW TABLE” per-
formed?Go to Step 2. Go to “ENGINE DIAG.
FLOW TABLE”.
2 Check MAP Sensor and Its Circuit.
1) Connect scan tool to DLC with ignition
switch OFF.
2) Turn ignition switch ON.
3) Check intake manifold pressure.
See Fig. 1.
Is it 114 kPa or more or 43 kPa or less?Go to Step 3. Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection” in
Section 0A.

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-63
DTC P0121 THROTTLE POSITION CIRCUIT RANGE/PERFORMANCE PROB-
LEM
WIRING DIAGRAM / CIRCUIT DESCRIPTION
DTC CONFIRMATION PROCEDURE
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)
–Ambient temp. : –10°C, 14°F or higher
–Intake air temp. : 70°C, 158°F or lower
–Engine coolant temp. : 70 – 110°C, 158 – 230°F
2) Warm up engine to normal operating temperature.
3) Increase vehicle speed to 30 – 40 mph, 50 – 60 km/h in 3rd gear or “D” range and hold throttle valve at that
opening position for 1 min.
4) Stop vehicle.
5) Check DTC in “DTC” mode and pending DTC in “ON BOARD TEST” or “PENDING DTC” mode.
[A] : Case of TYPE A is shown (See NOTE) [B] : Case of TYPE B is shown (See NOTE)
C42-10
C42-22
5V5V
ECM
GRY/RED
GRY/BLU
ORN
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
C42-16 [B]C41-3 [A]
NOTE:
For TYPE A and TYPE B, refer to NOTE in “ECM VOLTAGE VALUES TABLE” for applicable model.
DTC DETECTING CONDITION POSSIBLE CAUSE
DTC will set when the following conditions are detected.
After engine warmed up.
While vehicle running at specified engine speed.
No change in intake manifold pressure (constant throttle opening)
Difference between actual throttle opening (detected from TP sensor)
and opening calculated by ECM (Obtained on the basis of engine
speed and intake manifold pressure) in larger than specified value.
✱2 driving cycle detection logic, continuous monitoringTP sensor malfunction
High resistance in the circuit
ECM malfunction
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic acci-
dent and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.

6-78 ENGINE GENERAL INFORMATION AND DIAGNOSIS
5 Check Fuel Injectors and Circuit.
1) Using sound scope (1) or such, check oper-
ating sound of each injector (2) when
engine is running. Cycle of operating sound
should vary according to engine speed. See
Fig. 3. If no sound or an unusual sound is
heard, check injector circuit (wire or cou-
pler) or injector.
2) Turn ignition switch OFF and disconnect a
fuel injector connector.
3) Check for proper connection to fuel injector
at each terminal. See Fig. 4.
4) If OK, then check injector resistance.
Injector Resistance : 11.3 – 13.8 ohm at
20°C (68°F)
5) Carry out steps 1) and 3) on each injector.
6) Check each injector for injected fuel volume
(1) referring to Section 6E1. See Fig. 5.
Injected Fuel Volume : 43 – 47 cc/15 sec
1.45/1.51 – 1.58/1.65 US/Imp.oz/15 sec)
7) Check each injector for fuel leakage after
injector closed. Fuel Leakage : Less than 1
drop/min.
Is check result in step 1) and 3) to 7) satisfac-
tory?Go to Step 6. Check injector circuit or
replace fuel injector(s).
6 Check EVAP Canister Purge Valve.
1) Disconnect purge hose from EVAP canister
purge valve.
2) Place finger against the end of EVAP canis-
ter purge valve.
3) Check that vacuum is not felt there when
engine is cool and running at idle. See Fig.
6.
Is vacuum felt?Check EVAP control sys-
tem (See Section 6E1).Go to Step 7.
7 Check Intake manifold absolute pressure sen-
sor for performance (See DTC P0105 (No.11)
Diag. Flow Table).
Is it in good condition?Go to Step 8. Repair or replace.
8 Check Engine Coolant Temp. Sensor for perfor-
mance (See Section 6E1).
Is it in good condition?Go to Step 9. Replace engine coolant
temp. sensor.
9 Check Intake Air Temp. Sensor for perfor-
mance (See Section 6E1).
Is it in good condition?Go to Step 10. Replace intake air temp.
sensor.
10 Check Throttle Position Sensor for performance
(See Step 4 of DTC P0121 Diag. Flow Table).
Is it in good condition?Go to Step 11. Replace throttle position
sensor.
11 Check PCV Valve for valve clogging (See Sec-
tion 6E1).
Is it good condition?Substitute a known-good
ECM and recheck.Replace PCV valve. Step Action Yes No

6-82 ENGINE GENERAL INFORMATION AND DIAGNOSIS
DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF.
2) Clear DTC with ignition switch ON.
3) Check vehicle and environmental condition for :
–Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)
–Ambient temp. : –10°C, 14°F or higher
–Intake air temp. : 70°C, 158°F or lower
–Engine coolant temp. : – 10 – 110°C, 14 – 230°F
4) Start engine and keep it at idle for 2 min. or more.
5) Check DTC in “DTC” mode and pending DTC in “ON BOARD TEST” or “PENDING DTC” mode.
6) If DTC is not detected at idle, consult usual driving based on information obtained in “Customer complaint
analysis” and “Freeze frame data check”.
INSPECTION
DTC DETECTING CONDITION POSSIBLE CAUSE
Engine under other than high revolution condition
Not on rough road
Engine speed changing rate (Below specified value)
Manifold absolute pressure changing rate (Below
specified value)
Throttle opening changing rate (Below specified
value)
Misfire rate per 200 or 1000 engine revolutions (how
much and how often crankshaft revolution speed
changes) is higher than specified valueEngine overheating
Vacuum leaks (air inhaling) from air intake system
Ignition system malfunction (spark plug(s), high-
tension cord(s), ignition coil assembly)
Fuel pressure out of specification
Fuel injector malfunction (clogged or leakage)
Engine compression out of specification
Valve lash (clearance) out of specification
Manifold absolute pressure sensor malfunction
Engine coolant temp. sensor malfunction
PCV valve malfunction
EVAP control system malfunction
EGR system malfunction
NOTE:
Among different types of random misfire, if misfire occurs at cylinders 1 and 4 or cylinders 3 and 2
simultaneously, it may not possible to reconfirm DTC by using the following DTC confirmation proce-
dure. When diagnosing the trouble of DTC P0300 (Random misfire detected) of the engine which is
apparently misfiring, even if DTC P0300 cannot be reconfirmed by using the following DTC confirma-
tion procedure, proceed to the following Diag. Flow Table.
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic acci-
dent and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester.
CAUTION:
For iridium spark plugs, do not adjust air gap or clean.
Step Action Yes No
1Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE
DIAG. FLOW
TABLE”.

6-94 ENGINE GENERAL INFORMATION AND DIAGNOSIS
DTC P0400 EXHAUST GAS RECIRCULATION FLOW MALFUNCTION
WIRING DIAGRAM / CIRCUIT DESCRIPTION
DTC CONFIRMATION PROCEDURE
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)
–Ambient temp. : –10°C, 14°F or higher
–Intake air temp. : 70°C, 122°F or lower
2) Start engine and warm it up to normal operating temperature (70 – 110°C, 158 – 230°F) and run it at idle for
5 min.
3) Increase vehicle speed to 50 – 55 mph, 80 – 88 km/h in 5th gear or in “D” range.
4) Hold throttle valve at that opening position for 2 min. or longer.
5) Increase engine speed to 4000 r/min. in 3rd gear or in “2” range.
6) Release accelerator pedal and with engine brake applied, keep vehicle coasting (fuel cut condition) till
engine speed reaches 1500 r/min.
1. EGR valve [A] : Case of TYPE A is shown (See NOTE) [B] : Case of TYPE B is shown (See NOTE)
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
+BECM
C42-18
C42-29
C42-28 C42-17
C42-1
GRY
GRN/ORN
WHT/RED
C42-3 BRN/YEL
BLK/ORN
BLK/ORN BLK/RED1
3
1 2
4
6 5
+BECM
C41-2
C41-9
C41-17 C41-8
C42-1
GRN
GRN/ORN
WHT/RED
C42-3 BRN/YEL
BLK/ORN
BLK/ORN BLK/RED1
3
1 2
4
6 5
[A][B]
NOTE:
For TYPE A and TYPE B, refer to NOTE in “ECM VOLTAGE VALUES TABLE” for applicable model.
DTC DETECTING CONDITION POSSIBLE CAUSE
While running at specified vehicle speed after engine warm-up
During deceleration (engine speed high with closed throttle position
ON) in which fuel cut is involved, difference in intake manifold abso-
lute pressure between when EGR valve is opened at specified value
and when it is closed is larger or smaller than specified value.
✱2 driving cycle detection logic, monitoring once/1 drivingEGR valve or its circuit
EGR passage
ECM
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic acci-
dent and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.

6-108 ENGINE GENERAL INFORMATION AND DIAGNOSIS
DTC P1450 BAROMETRIC PRESSURE SENSOR LOW/HIGH INPUT
DTC P1451 BAROMETRIC PRESSURE SENSOR PERFORMANCE PROBLEM
WIRING DIAGRAM / CIRCUIT DESCRIPTION
Barometric pressure sensor is installed in ECM.
DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF.
2) Clear DTC with ignition switch ON.
3) Turn ignition switch ON for 2 sec., crank engine for 2 sec. and run it at idle for 1 min.
4) Check pending DTC in “ON BOARD TEST” or “PENDING DTC” mode and DTC in “DTC” mode.
INSPECTION
DTC P1450 :
Substitute a known-good ECM and recheck.
DTC P1451 :
DTC DETECTING CONDITION POSSIBLE CAUSE
DTC P1450 :
Barometric pressure : Sensor voltage is 4.7 V or higher, or
1.6 V or lowerECM (barometric pressure sensor) malfunc-
tion
DTC P1451 :
Vehicle stopped
Engine cranking
Difference between barometric pressure and intake mani-
fold absolute pressure is 26 kPa, 200 mmHg or more
Difference between intake manifold absolute pressure at
engine start and the pressure after engine start is 1.3 kPa,
10 mmHg or less.
✱2 driving cycle detection logic, monitoring once/1 driving.Manifold absolute pressure sensor and its
circuit malfunction
ECM (barometric pressure sensor) malfunc-
tion
NOTE:
Note that atmospheric pressure varies depending on weather conditions as well as altitude.
Take that into consideration when performing these check.
Step Action Yes No
1 Check Barometric Pressure Valve.
1) Connect scan tool to DLC with ignition
switch OFF.
2) Turn ignition switch ON and select “DATA
LIST” mode on scan tool.
3) Check manifold absolute pressure. See Fig.
1.
Is it barometric pressure (approx. 100 kPa, 760
mmHg) at sea level?Substitute a known-good
ECM and recheck.Go to Step 2.

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-109
Table 1
Fig. 1 for Step 1
Fig. 2 for Step 22 Check MAP Sensor.
1) Remove MAP sensor from intake manifold
and connect vacuum pump gauge to MAP
sensor. See Fig. 2.
2) Connect scan tool to DLC and turn ignition
switch ON.
3) Check intake manifold absolute pressure
displayed on scan tool for specified valve.
See Table 1.
Is check result satisfactory?Check air intake system
for air being drawn in and
engine compression.
If OK, then substitute a
known-good ECM and
recheck.Replace MAP sensor. Step Action Yes No
Applying Vacuum Displayed Value on Scan Tool
0 Barometric pressure
(Approx. 100 kPa, 760 mmHg)
27 kPa
200 mmHgBarometric pressure – 27 kPa
(Approx. 73 kPa, 560 mmHg)
67 kPa
500 mmHgBarometric pressure – 67 kPa
(Approx. 33 kPa, 260 mmHg)

ENGINE MECHANICAL (M13 ENGINE) 6A1-1
6F1
6A1
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10B
SECTION 6A1
ENGINE MECHANICAL (M13 ENGINE)
CONTENTS
GENERAL DESCRIPTION .............................6A1-2
ENGINE ...................................................... 6A1-2
ENGINE LUBRICATION ............................. 6A1-3
DIAGNOSIS ....................................................6A1-4
DIAGNOSIS TABLE .................................... 6A1-4
COMPRESSION CHECK ............................ 6A1-4
ENGINE VACUUM CHECK ........................ 6A1-6
OIL PRESSURE CHECK ............................ 6A1-7
VALVE LASH (CLEARANCE) ..................... 6A1-9
ON-VEHICLE SERVICE ...............................6A1-12
AIR CLEANER ELEMENT ........................ 6A1-12
AIR CLEANER ASSEMBLY AND
RESONATOR ........................................... 6A1-13
KNOCK SENSOR ..................................... 6A1-13
CYLINDER HEAD COVER ....................... 6A1-13
THROTTLE BODY AND INTAKE
MANIFOLD ................................................ 6A1-16
EXHAUST MANIFOLD .............................. 6A1-19OIL PAN AND OIL PUMP STRAINER ...... 6A1-21
TIMING CHAIN COVER ........................... 6A1-25
OIL PUMP ................................................. 6A1-30
TIMING CHAIN AND CHAIN
TENSIONER ............................................. 6A1-34
CAMSHAFT, TAPPET AND SHIM............ 6A1-39
VALVES AND CYLINDER HEAD ............. 6A1-44
PISTONS, PISTON RINGS,
CONNECTING RODS AND
CYLINDERS ............................................. 6A1-57
ENGINE MOUNTINGS ............................. 6A1-67
UNIT REPAIR OVERHAUL .......................... 6A1-68
ENGINE ASSEMBLY ................................ 6A1-68
MAIN BEARINGS, CRANKSHAFT AND
CYLINDER BLOCK................................... 6A1-73
REQUIRED SERVICE MATERIAL............... 6A1-85
TIGHTENING TORQUE SPECIFICATION... 6A1-86
SPECIAL TOOL ........................................... 6A1-87

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
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” 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).

6A1-6 ENGINE MECHANICAL (M13 ENGINE)
13) After checking, install spark plugs and ignition coil assem-
blies (1) with high-tension cord (2).
14) Connect ignition coil couplers (3).
15) Connect fuel injector wires(4) at the coupler.
16) Check cylinder head upper cover gasket for deterioration
and then install it into groove of cylinder head upper cover
(1) securely.
17) Install cylinder head upper cover with gasket on to cylinder
head cover.
18) Install air cleaner assembly, resonator and hoses referring to
“AIR CLEANER ASSEMBLY AND RESONATOR”.
ENGINE VACUUM CHECK
The engine vacuum that develops in the intake line is a good indi-
cator of the condition of the engine. The vacuum checking proce-
dure is as follows :
1) Warm up engine to normal operating temperature.
2) Stop engine and turn off the all electric switches.
3) Remove cap (1) from intake manifold.
NOTE:
After warming up engine, be sure to place transmission
gear shift lever in “Neutral” (shift selector lever to “P”
range for A/T model), and set parking brake and block
drive wheels.