charging SUZUKI SWIFT 2000 1.G RG413 Service User Guide

1B-26 AIR CONDITIONING (OPTIONAL)
REMOVING MANIFOLD GAUGE SET
When A/C system has been charged with a specified amount of refrigerant, remove manifold gauge set as fol-
lows :
1) Close low pressure side valve of manifold gauge set. (The high pressure side valve is closed continuously
during the process of charging.)
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service valves. This operation must be performed rapidly.
5) Put caps on service valves.
LEAK TEST
Whenever a refrigerant leak is suspected in the system or any
service operation has been performed which may result in dis-
turbing lines or connections, it is advisable to test for leaks.
Common sense should be used in performing any refrigerant leak
test, since the need and extent of any such test will, in general,
depend upon the nature of a complaint and the type of a service
performed on the system.
LIQUID LEAK DETECTORS
There are a number of fittings and places throughout the air con-
ditioning system where a liquid leak detector solution may be
used to pinpoint refrigerant leaks.
By merely applying the solution to the area in question with a
swab, such as attached to the cap of a vial, bubbles will form
within seconds if there is a leak.
For confined areas, such as sections of the evaporator and con-
denser, an electronic (refrigerant) leak detector is more practical
for determining leaks.
Special tool
(A) : 09990 - 86011 WARNING:
High pressure side is naturally under high pressure. So, care must be used to protect your eyes and
skin.
WARNING:
 To prevent explosions or fires, make sure that there
are no flammables in the vicinity.
 When exposed to fire, the refrigerant turns into a poi-
sonous gas (phosgene). Do not inhale this gas.

1B-28 AIR CONDITIONING (OPTIONAL)
Route drain hose so that drained water does not make any contact to vehicle components.
If pipes or hoses are replaced, replenish specified amount of compressor oil to compressor suction side by
referring to “REPLENISHING COMPRESSOR OIL” in this section.
HANDLING REFRIGERANT HFC-134a (R-134a)
Always wear goggles to protect your eyes.
Avoid you direct contact to liquid refrigerant.
Do not heat refrigerant container higher than 40°C (104°F).
Do not discharge refrigerant into atmosphere.
Do not allow liquid refrigerant to touch bright metals. Refrigerant combined with moisture is corrosive and
will tarnish surfaces of bright metals including chrome.
REFRIGERANT RECOVERY
When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling
equipment. Discharging refrigerant HFC-134a (R-134a) into atmosphere would cause adverse effect to environ-
ments.
REFRIGERANT CHARGE
After perform replenishing compressor oil and evacuating, charge a proper amount of refrigerant to A/C system
referring to “CHARGING” in this section.
CONDENSER ASSEMBLY
INSPECTION
Check the following.
Clog of condenser fins.
If, any clogs are found, condenser fins should be washed
with water, and should be dried with compressed air.
Condenser fins for leakage and breakage.
If any defects are found, repair or replace condenser.
Condenser fittings for leakage.
If any defects are found, repair or replace condenser. CAUTION:
Do not perform an additional refrigerant charging to A/C system. This cause it to overcharge.
CAUTION:
Be careful not to damage condenser fins. If condenser fin
is bent, straighten it by using flat head screwdriver or
pair of pliers.

AIR CONDITIONING (OPTIONAL) 1B-29
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant from A/C system by referring to
“RECOVERY” in this section.
3) Remove front bumper referring to “FRONT BUMPER” in
Section 8.
4) Remove front cross member cover (1) and engine food
cover (2) from vehicle body.
5) Disconnect discharge hose (1) and condenser outlet pipe (2)
from condenser (3).
6) Remove condenser mounting bolts (4).
7) Remove condenser (3).
INSTALLATION
Reverse removal procedure to install condenser noting the follow-
ing instructions.
Replenish specified amount of compressor oil to compressor
suction side by referring to “REPLENISHING COMPRES-
SOR OIL” in this section.
Evacuate and charge refrigerant by referring to “EVACUAT-
ING” and “CHARGING” in this section. NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.

AIR CONDITIONING (OPTIONAL) 1B-33
4) Remove fresh air control cable (1) and A/C evaporator tem-
perature sensor coupler.
5) Disconnect suction hose (1) and condenser outlet hose (2)
by removing attaching bolt (3).
6) Remove cooling unit mounting nuts (4) and screws (5).
7) Remove cooling unit (6).
INSPECTION
Check the following.
Clog of A/C evaporator fins.
If any clogs are found, A/C evaporator fins should be
washed with water, and should be dried with compressed
air.
A/C evaporator fins for leakage and breakage.
If any defects are found, repair or replace A/C evaporator.
A/C evaporator fittings for leakage.
If any defects are found, repair or replace A/C evaporator.
INSTALLATION
Reverse removal procedure to install cooling unit noting the fol-
lowing instructions.
If A/C evaporator temperature sensor removed, its should be
reinstalled in original position.
Replenish specified amount of compressor oil to compressor
suction side by referring to “REPLENISHING COMPRES-
SOR OIL” in this section.
Install uniformly the packing (1) to installation hole.
Evacuate and charge refrigerant by referring to “EVACUAT-
ING” and “CHARGING” in this section.
Adjust fresh air control cable, refer to “HEATER LEVER
ASSEMBLY” in Section 1A.

1B-34 AIR CONDITIONING (OPTIONAL)
A/C EVAPORATOR TEMPERATURE SENSOR
Check resistance between terminals for A/C evaporator tempera-
ture sensor (1).
If check results are as not specified, replace A/C evaporator tem-
perature sensor.
A/C evaporator temperature sensor resistance
EXPANSION VALVE
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant from A/C system by referring to
“RECOVERY” in this section.
3) Remove attaching bolt (1).
4) Remove suction hose (2) and receiver/dryer outlet pipe (3)
from expansion valve (4).
5) Remove expansion valve (4).
INSTALLATION
Reverse removal procedure to install expansion valve noting the
following instructions.
Replenish specified amount of compressor oil to compressor
suction side by referring to “REPLENISHING COMPRES-
SOR OIL” in this section.
Evacuate and charge refrigerant by referring to “EVACUAT-
ING” and “CHARGING” in this section.
INSPECTION
Refer to “PERFORMANCE DIAGNOSIS” in this section. Sensor Temperature Resistance
0°C (32°F) 6.4 – 6.9 k
Ω
ΩΩ Ω
25°C (77°F) 1.8 – 2.2 k
Ω
ΩΩ Ω
NOTE:
When A/C evaporator temperature sensor removed, its
should be reinstalled in original position.
NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.

ANTILOCK BRAKE SYSTEM (ABS) 5E-27
DTC C1057 (DTC 57) – POWER SOURCE CIRCUIT
DESCRIPTION
The ABS control module monitors the power source voltage at terminal “E19-18”. When the power source volt-
age becomes extremely high or low, this DTC will be set. As soon as the voltage rises or lowers to the specified
level, the set DTC will be cleared.
INSPECTION
1. Ignition switch 3. ABS hydraulic unit/control module assembly
2. Main fuse 4. ABS hydraulic unit/control module connector
Step Action Yes No
1 1) Connect a voltmeter between battery posi-
tive (+) terminal and body ground.
2) Start the engine and measure the maximum
voltage when racing the engine.
Is it over 18V?Check charging system
referring to “CHARGING
SYSTEM” section.Go to Step 2.
2 1) Disconnect ABS hydraulic unit/control mod-
ule connector.
2) Keep the engine idling, measure the voltage
between terminal “E19-18” of ABS control
module and body ground.
Is it always under 9V?Check charging system
referring to “CHARGING
SYSTEM” section.
Imperfect short between
wire “GRN/ORN” and
ground.Poor connection of termi-
nal “E19-18” or “E19-24”
of the ABS control mod-
ule.
If the above are in good
condition, substitute a
known-good ABS hydrau-
lic unit/control module and
recheck.

ANTILOCK BRAKE SYSTEM (ABS) 5E-29
DTC C1063 (DTC 63) – ABS FAIL-SAFE RELAY CIRCUIT
DESCRIPTION
ABS control module monitors the voltage at the terminal of solenoid circuit constantly with ignition switch turned
ON. Also, immediately after ignition switch is turned ON, perform initial check as follows.
Switch fail-safe relay in the order of OFF → ON and check if voltage changes to Low → High. If anything faulty
is found in the initial check and when the voltage is low with ignition switch turned ON, this DTC will be set.
INSPECTION
1. Ignition switch 3. ABS hydraulic unit/control module connector 5. To pump motor relay
2. ABS hydraulic unit/control module assembly 4. To solenoid valves 6. Fail-safe relay
Step Action Yes No
1 Check battery voltage. Is it about 11 V or
higher?Go to Step 2. Check charging system
referring to “CHARGING
SYSTEM” section.
2 Check ABS main fuse and connection.
Is it in good condition?Go to Step 3. Repair and/or replace
fuse.
3 1) Ignition switch OFF.
2) Disconnect ABS hydraulic unit/control mod-
ule connector.
3) Check proper connection to ABS hydraulic
unit/control module at terminal “E19-25”.
4) If OK, then measure voltage between con-
nector terminal “E19-25” and body ground.
Is it 10 – 14 V?Substitute a known-good
ABS hydraulic unit/con-
trol module assembly and
recheck.“WHT/BLU” circuit open
or short to ground.

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-1
6
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10A
10B
SECTION 6
ENGINE GENERAL INFORMATION AND
DIAGNOSIS
ENGINE GENERAL INFORMATION AND ENGINE DIAGNOSIS................................................. Section 6
ENGINE MECHANICAL ................................................................................................................. Section 6A1
ENGINE COOLING......................................................................................................................... Section 6B
ENGINE FUEL ................................................................................................................................ Section 6C
ENGINE AND EMISSION CONTROL SYSTEM ............................................................................ Section 6E1
IGNITION SYSTEM ........................................................................................................................ Section 6F1
CRANKING SYSTEM ..................................................................................................................... Section 6G
CHARGING SYSTEM ..................................................................................................................... Section 6H
EXHAUST SYSTEM ....................................................................................................................... Secton 6K
CONTENTS
GENERAL INFORMATION ................................ 6-4
STATEMENT ON CLEANLINESS AND
CARE .............................................................. 6-4
GENERAL INFORMATION ON ENGINE
SERVICE ........................................................ 6-4PRECAUTION ON FUEL SYSTEM
SERVICE .................................................... 6-5
FUEL PRESSURE RELIEF
PROCEDURE ............................................. 6-6
FUEL LEAKAGE CHECK PROCEDURE.... 6-6 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).
NOTE:
Whether the following systems (parts) are used in the particular vehicle or not depends on vehicle
specifications. Be sure to bear this in mind when performing service work.
EGR valve
Heated oxygen sensor(s) or CO adjusting resistor
Three way catalytic converter
Immobilizer indicator lamp (vehicle with immobilizer indicator lamp can be identified also by HO2S-
2)
Knock sensor

CHARGING SYSTEM 6H-1
6F1
6F2
6G
6K
7A
6H
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 6H
CHARGING SYSTEM
CONTENTS
GENERAL DESCRIPTION .............................. 6H-2
BATTERY ..................................................... 6H-2
CARRIER AND HOLD-DOWN ................. 6H-2
ELECTROLYTE FREEZING .................... 6H-2
SULFATION ............................................. 6H-2
BUILT-IN INDICATOR (IF EQUIPPED) ... 6H-2
CARE OF BATTERY ................................ 6H-3
GENERATOR .............................................. 6H-4
DIAGNOSIS ..................................................... 6H-5
BATTERY ..................................................... 6H-5
VISUAL INSPECTION.............................. 6H-5
HYDROMETER TEST.............................. 6H-5
GENERATOR .............................................. 6H-6
CHARGING INDICATOR LAMP
OPERATION ............................................ 6H-6
UNDERCHARGED BATTERY ................. 6H-7
OVERCHARGED BATTERY.................... 6H-8ON-VEHICLE SERVICE .................................. 6H-9
BATTERY .................................................... 6H-9
JUMP STARTING IN CASE OF
EMERGENCY .......................................... 6H-9
DISMOUNTING...................................... 6H-10
HANDLING............................................. 6H-10
REMOUNTING....................................... 6H-10
GENERATOR ............................................ 6H-10
GENERATOR BELT .............................. 6H-10
DISMOUNTING AND REMOUNTING ... 6H-11
DISASSEMBLY AND REASSEMBLY .... 6H-11
INSPECTION ......................................... 6H-12
SPECIFICATION ........................................... 6H-14
BATTERY .................................................. 6H-14
GENERATOR ............................................ 6H-14
TIGHTENING TORQUE SPECIFICATION.... 6H-14

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).

6H-2 CHARGING SYSTEM
GENERAL DESCRIPTION
BATTERY
The battery has three major functions in the electrical system.
It is a source of electrical energy for cranking the engine.
It acts as a voltage stabilizer for the electrical system.
It can, for a limited time, provide energy when the electrical load exceeds the output of the generator.
CARRIER AND HOLD-DOWN
The battery carrier should be in good condition so that it will support the battery securely and keep it level.
Before installing the battery, the battery carrier and hold-down clamp should be clean and free from corrosion
and make certain there are no parts in carrier.
To prevent the battery from shaking in its carrier, the hold-down bolts should be tight enough but not over-tight-
ened.
ELECTROLYTE FREEZING
The freezing point of electrolyte depends on its specific gravity. Since freezing may ruin a battery, it should be
protected against freezing by keeping it in a fully charged condition. If a battery is frozen accidentally, it should
not be charged until it is warmed.
SULFATION
If the battery is allowed to stand for a long period in discharged condition, the lead sulfate becomes converted
into a hard, crystalline substance, which will not easily turn back to the active material again during the subse-
quent recharging. “Sulfation” means the result as well as the process of that reaction. Such a battery can be
revived by very slow charging and may be restored to usable condition but its capacity is lower than before.
BUILT-IN INDICATOR (IF EQUIPPED)
The battery has a built-in temperature compensated indicator in the top of the battery. This indicator is to be
used with the following diagnostic procedure. When checking the indicator, make sure that the battery has a
clean top. A light may be needed in some poorly-lit areas.
Three types of indication available under normal operation are as
follows.
Green Dot
Battery is sufficiently charged for testing.
Dark
Battery must be charged before testing.
If there is a cranking complaint, battery should be tested as
described in Diagnosis section. Charging and electrical sys-
tems should also be checked at this time.
Clear or Light Yellow
This means that fluid level is below the bottom of hydrome-
ter. Its possible cause is excessive or prolonged charging, a
broken case, excessive tipping or normal battery deteriora-
tion. When the battery is found in such condition, it is possi-
ble that high charging voltage is caused by the faulty
charging system and therefore, charging and electrical sys-
tems need to be checked. If there is a trouble in cranking
and its cause lies in the battery, it should be replaced.