ESP SUZUKI SWIFT 2000 1.G RG413 Service Owner's Manual

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-17
Without Using Scan Tool
1) Turn the ignition switch OFF position.
2) Disconnect battery negative cable for specified time below to
erase diagnostic trouble code stored in ECM memory and
reconnect it.
Time required to erase DTC :
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
Ambient
temperatureTime to cut power to ECM
Over 0°C (32°F) 30 sec. or longer
Under 0°C
(32°F)Not specifiable.
Select a place with higher than 0°C
(32°F) temperature.
DTC
NO.DETECTING ITEM DETECTING CONDITION
(DTC will set when detecting :)MIL
(vehicle
with immo-
bilizer indi-
cator lamp)MIL
(vehicle
without
immobi-
lizer indica-
tor lamp)
P0105
(No.11)Manifold absolute pressure
circuit malfunctionLow pressure-high vacuum-low voltage
(or MAP sensor circuit shorted to ground)
High pressure-low vacuum-high voltage
(or MAP sensor circuit open)1 driving
cycle1 driving
cycle
P0110
(No.18)Intake air temp. circuit mal-
functionIntake air temp. circuit low input
Intake air temp. circuit high input1 driving
cycle1 driving
cycle
P0115
(No.19)Engine coolant temp. cir-
cuit malfunctionEngine coolant temp. circuit low input
Engine coolant temp. circuit high input1 driving
cycle1 driving
cycle
P0120
(No.13)Throttle position circuit mal-
functionThrottle position circuit low input
Throttle position circuit high input1 driving
cycle1 driving
cycle
P0121 Throttle position circuit per-
formance problemPoor performance of TP sensor 2 driving
cyclesNot
applicable
P0130
(No.14)HO2S circuit malfunction
(Sensor-1)Min. output voltage of HO2S-higher than
specification
Max. output voltage of HO2S-lower than
specification2 driving
cycle1 driving
cycle
P0133 HO2S circuit slow response
(Sensor-1)Response time of HO2S-1 output voltage
between rich and lean is longer than spec-
ification.2 driving
cyclesNot
applicable
P0134 HO2S circuit no activity
detected (Sensor-1)Output voltage of HO2S-1 fails to go above
specification (or HO2S-1 circuit shorted to
ground).2 driving
cycles1 driving
cycle
P0135
(No.14)HO2S heater circuit mal-
function (Sensor-1)Terminal voltage is lower than specifica-
tion at heater OFF or it is higher at heater
ON.2 driving
cycles1 driving
cycle
P0136 HO2S circuit malfunction
(Sensor-2)Max. voltage of HO2S-2 is lower than
specification or its min. voltage is higher
than specification2 driving
cyclesNot
applicable

6-28 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Poor gasoline mile-
age Leaks or loose connection of high-tension
cordHigh-tension cords in Section 6F1.
Faulty spark plug (improper gap, heavy
deposits and burned electrodes, etc.)Spark plugs in Section 6F1.
Malfunctioning EGR valve (if equipped) EGR system in Section 6E1.
High idle speed Refer to item “Improper engine idle
speed” previously outlined.
Poor performance of TP sensor, ECT sensor
or MAP sensorTP sensor, ECT sensor or MAP sensor
in Section 6E1.
Faulty EGR valve (if equipped) EGR system in Section 6E1.
Faulty fuel injector(s) Diagnostic Flow Table B-1.
Faulty ECM
Poor valve seating Valves inspection in Section 6A1.
Dragging brakes Trouble diagnosis in Section 5.
Slipping clutch Trouble diagnosis in Section 7C.
Thermostat out of order Thermostat in Section 6B.
Improper tire pressure Refer to Section 3F.
Low Compression Previously outlined
Excessive engine
oil consumption Blown cylinder head gasket Cylinder head in Section 6A1.
Leaky camshaft oil seals Camshaft in Section 6A1.
Sticky piston ring Piston cleaning in Section 6A1.
Worn piston and cylinder Pistons and cylinders inspection in Sec-
tion 6A1.
Worn piston ring groove and ring Pistons inspection in Section 6A1.
Improper location of piston ring gap Pistons assembly in Section 6A1.
Worn or damaged valve stem seal Valves removal and installation in Sec-
tion 6A1.
Worn valve stem Valves inspection in Section 6A1.
Engine hesitates
(Momentary lack of
response as accel-
erator is depressed.
Can occur at all
vehicle speeds.
Usually most severe
when first trying to
make vehicle move,
as from a stop sign.)Spark plug faulty or plug gap out of adjust-
mentSpark plugs in Section 6F1.
Leaky high-tension cord High-tension cords in Section 6F1.
Fuel pressure out of specification Diagnostic Flow Table B-3.
Malfunctioning EGR valve (if equipped) EGR system in section 6E1.
Poor performance of TP sensor, ECT sensor
or MAP sensorTP sensor, ECT sensor or MAP sensor
in Section 6E1.
Faulty fuel injector Diagnostic Flow Table B-1.
Faulty ECM
Engine overheating Refer to “Overheating” section.
Low compression Previously outlined.
Surge
(Engine power vari-
ation under steady
throttle or cruise.
Feels like vehicle
speeds up and
down with no
change in accelera-
tor pedal.)Leaky or loosely connected high-tension cord High-tension cords in Section 6F1.
Faulty spark plug (excess carbon deposits,
improper gap, and burned electrodes, etc.)Spark plugs in Section 6F1.
Variable fuel pressure Diagnostic Flow Table B-3.
Kinky or damaged fuel hose and lines
Faulty fuel pump (clogged fuel filter)
Malfunctioning EGR valve EGR system in Section 6E1.
Poor performance of MAP sensor MAP sensor in Section 6E1.
Faulty fuel injector Diagnostic Flow Table B-1.
Faulty ECM Condition Possible Cause Correction

6-68 ENGINE GENERAL INFORMATION AND DIAGNOSIS
DTC P0133 HEATED OXYGEN SENSOR (HO2S) CIRCUIT SLOW RESPONSE
(SENSOR-1)
WIRING DIAGRAM / CIRCUIT DESCRIPTION
Refer to DTC P0130 section.
Fig. 1
DTC CONFIRMATION PROCEDURE
Refer to DTC P0130 section.
INSPECTION
DTC DETECTING CONDITION POSSIBLE CAUSE
When running at specified idle speed after engine warmed up and
running at specified vehicle speed, response time (time to change
from lean to rich or from rich to lean) of HO2S-1 output voltage is
about 1 sec. at minimum or average time of 1 cycle is 5 sec. at
minimum. See. Fig. 1
✱2 driving cycle detection logic, Monitoring once/1 driving.Heated oxygen sensor-1 malfunction
Step Action Yes No
1Was “ENGINE DIAG. FLOW TABLE” per-
formed?Go to Step 2. Go to “ENGINE DIAG.
FLOW TABLE”.
2 Is there DTC(s) other than HO2S-1 (DTC
P0133)?Go to applicable DTC
Diag. Flow Table.Replace HO2S-1.

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-89
INSPECTION
Step Action Yes No
1Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG.
FLOW TABLE”.
2 Check CKP Sensor and Connector for proper
installation.
Is CKP sensor installed properly and connector
connected securely?Go to Step 3. Correct.
3 Check Wire Harness and Connection.
1) Disconnect connector from CKP sensor.
2) Check for proper connection to CKP sensor at
each terminal.
3) If OK, turn ignition switch ON and check for
voltage at each terminal of sensor connector
disconnected. See Fig. 1.
Terminal “B+” : 10 – 14 V
Terminal “Vout” : 4 – 5 V
Terminal “GND” : – 0 V
Is check result satisfactory?Go to Step 5. Go to Step 4.
4 Was terminal “Vout” voltage out of specification in
Step 3 check?“YEL/BLK” wire open,
short or poor connection.
If wire and connection are
OK, substitute a known-
good ECM and recheck.“BLK/RED” or “BLK/
ORN” wire open, short
or poor connection.
5 Check Ground Circuit for open.
1) Turn ignition switch OFF.
2) Check for continuity between “GND” terminal
of CKP sensor connector and engine ground.
Is continuity indicated?Go to Step 6.“BLK/ORN” wire open
or poor ground con-
nection.
6 Check CKP Sensor for operation.
1) Remove CKP sensor from sensor case.
2) Remove metal particles on end face of CKP
sensor, if any.
3) Connect each connector to ECM and CKP
sensor.
4) Turn ignition switch ON.
5) Check for voltage at terminal C42-23 of con-
nector connected to ECM by passing magnetic
substance (iron) while keeping approximately
1 mm (0.03 in.) gap with respect to end face of
CKP sensor. See Fig. 2 and 3.
Does voltage vary from low (0 –1 V) to high (4 – 5
V) or from high to low?Go to Step 7. Replace CKP sensor.
7 Check Signal Rotor for the following. See Fig. 4.
Damage
No foreign material attached
Is it in good condition?Intermittent trouble or
faulty ECM.
Check for intermittent
referring to “Intermittent
and Poor Connection” in
Section 0A.Clean rotor teeth or
replace CMP sensor.

6-92 ENGINE GENERAL INFORMATION AND DIAGNOSIS
INSPECTION
Step Action Yes No
1Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE
DIAG.
FLOW TABLE”.
2 Check CMP Sensor and connector for proper installa-
tion.
Is CMP sensor installed properly and connector con-
nected securely?Go to Step 3. Correct.
3 Check Wire Harness and Connection.
1) Disconnect connector from CMP sensor.
2) Check for proper connection to CMP sensor at
each terminal.
3) If OK, turn ignition switch ON and check for volt-
age at each terminal of sensor connector discon-
nected. See Fig. 1.
Terminal “B+” : 10 – 14 V
Terminal “Vout” : 4 – 5 V
Terminal “GND” : 0 V
Is check result satisfactory?Go to Step 5. Go to Step 4.
4Was terminal “Vout” voltage out of specification in
Step 3 check?“RED/YEL” wire open,
short or poor connection.
If wire and connection
are OK, substitute a
known-good ECM and
recheck.“BLK/RED” or “BLK/
ORN” wire open,
short or poor con-
nection.
5 Check Ground Circuit for open.
1) Turn ignition switch OFF.
2) Check for continuity between “GND” terminal of
CMP sensor connector and engine ground.
Is continuity indicated?Go to Step 6.“BLK/ORN” wire
open or poor ground
connection.
6 Check CMP Sensor for operation.
1) Remove CMP sensor from sensor case.
2) Remove metal particles on end face of CMP sen-
sor, if any.
3) Connect each connector to ECM and CMP sensor.
4) Turn ignition switch ON.
5) Check for voltage at terminal C42-11 of connector
connected to ECM by passing magnetic sub-
stance (iron) while keeping approximately 1 mm
(0.03 in.) gap with respect to end face of CMP
sensor. See Fig. 2 and 3.
Does voltage vary from low (0 – 1 V) to high (4 – 5 V)
or from high to low?Go to Step 7. Replace CMP sen-
sor.
7 Check Signal Rotor for the following.
See Fig. 4.
Damage
No foreign material attached
Is it in good condition?Intermittent trouble or
faulty ECM.
Check for intermittent
referring to “Intermittent
and Poor Connection” in
Section 0A.Clean rotor teeth or
replace CMP sensor.

6-112 ENGINE GENERAL INFORMATION AND DIAGNOSIS
DTC P1600 SERIAL COMMUNICATION PROBLEM BETWEEN ECM AND TCM
WIRING DIAGRAM
CIRCUIT DESCRIPTION
The serial data line is pulled up to about 12 V by ECM and TCM transmits information to ECM through it by con-
trolling its grounding.
TCM constantly sends information while ignition switch is ON as to whether judgement was made or not with
respect to all detectable DTCs as well as whether or not abnormality exists after judgement.
DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF.
2) Clear DTC with ignition switch ON.
3) Start engine and run it at idle for 1 min.
4) Select “DTC” mode on scan tool and check DTC.
INSPECTION
ECM
TCMIG1
BLK/WHT
12V
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
C44-20
C41-23
DTC DETECTING CONDITION POSSIBLE CAUSE
No signal inputted from TCM to ECM or check sum
error while engine running“BLK/WHT” circuit open or short
TCM power or ground circuit open
TCM malfunction
ECM malfunction
Step Action Yes No
1Was “ENGINE DIAG. FLOW TABLE” per-
formed?Go to Step 2. Go to “ENGINE DIAG.
FLOW TABLE”.
2 Check Signal Voltage.
Check voltage between terminal C41-23 and
body ground with ignition switch ON.
Does it change between 0 – 12 V? See Fig. 1.Intermittent trouble or
faulty ECM or TCM.
Check for intermittent
trouble referring to “Inter-
mittent and poor connec-
tion” in Section 0A.Go to Step 3.

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-117
TABLE B-1 FUEL INJECTOR CIRCUIT CHECK
WIRING DIAGRAM
INSPECTION
1. No.1 injector 3. No.3 injector
2. No.2 injector 4. No.4 injector
ECM
1
2
3
4
+B
C42-9
C42-21
C42-8 C42-31 BLU/YEL
BLU/WHT
BLU/RED
BLU/ORN
BLK/RED
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
Step Action Yes No
1Was “ENGINE DIAG. FLOW TABLE” per-
formed?Go to Step 2. Go to “ENGINE DIAG.
FLOW TABLE”.
2 Check Injector for operating sound.
Using sound scope, check each injector for
operating sound at engine cranking.
Do all 4 injector make operating sound?Fuel injector circuit is in
good condition.Go to Step 3.
3 Dose none of 4 injectors make operating sound
at Step 2?Go to Step 4. Check coupler connec-
tion and wire harness of
injector not making oper-
ating sound and injector
itself (Refer to Section
6E1).
4 Check power circuit of injectors for open and
short.
Is it normal?Check all 4 injectors for
resistance respectively.
If resistance is OK, substi-
tute a known-good ECM
and recheck.Power circuit open or
short.

6A1-10 ENGINE MECHANICAL (M13 ENGINE)
b) Check housing No. and select special tool corresponding to
housing No., referring to “special tool selection table”.
Special tool selection table
c) Hold down the tappet so as not to hang to the shim with
special tool by installing it on camshaft housing with hous-
ing bolt (1) to specified torque.
Special tool
(A) : 09916-67020
Tightening torque
Camshaft housing bolts (for tightening of special tool )
(a) : 8 N·m (0.8 kg-m, 6.0 lb-ft)
4) Turn camshaft by approximately 90° clockwise and remove
shim (3).
5) Using a micrometer (2), measure the thickness of the
removed shim (1), and determine replacement shim by cal-
culating the thickness of new shim with the following formula
and table.
Intake side:
A = B + (C – 0.20 mm (0.008 in.))
Exhaust side:
A = B + (C – 0.30 mm (0.012 in.))
A : Thickness of new shim
B : Thickness of removed shim
C : Measured valve clearance No. on camshaft
housingEmbossed mark
on special tool
I2 IN2
I3, I4, I5 IN345
E2 EX2
E3, E4, E5 EX345
A: I : Intake side or E : Exhaust side
B: Position from timing chain side
C: Pointing to timing chain side
WARNING:
Never put in the hand between cam shaft and tappet.
1. Special tool
2. Magnet

6A1-34 ENGINE MECHANICAL (M13 ENGINE)
TIMING CHAIN AND CHAIN TENSIONER
REMOVAL
1) Disconnect negative cable at battery.
2) Drain engine oil.
3) Remove oil pan referring to “OIL PAN AND OIL PUMP
STRAINER”.
4) Remove cylinder head cover referring to “CYLINDER HEAD
COVER”.
5) Remove timing chain cover referring to “TIMING CHAIN
COVER”.
6) Align both intake and exhaust camshaft timing sprocket
marks (1) with notches (2) of cylinder head respectively by
turning crankshaft.
7) Remove timing chain tensioner adjuster assembly (3).
8) Remove timing chain tensioner (4).
9) Remove timing chain No.1 guide (5).
10) Remove timing chain (6) with crankshaft timing sprocket (7).
1. Crankshaft timing sprocket 4. Timing chain tensioner
: Apply engine oil to sliding surface.7. Chain tensioner mounting bolt
2. Timing chain
: Apply engine oil.5. Timing chain tensioner adjuster assembly 8. Chain guide mounting bolt
3. Timing chain No.1 guide
: Apply engine oil to sliding surface.6. Chain tensioner adjuster mounting bolt Tightening torque
CAUTION:
After timing chain is removed, never turn crankshaft and
camshafts independently more than its allowable turning
range described in “INSTALLATION” section.
If turned, interference may occur between piston and
valves and valves themselves, and parts related to piston
and valves may be damaged.

6A1-64 ENGINE MECHANICAL (M13 ENGINE)
6) If clearance can not be brought to within its limit even by
using a new standard size bearing, regrind crankpin to
undersize and use 0.25 mm undersize bearing.
ASSEMBLY
1) Install piston pin to piston (1) and connecting rod (2) :
a) After applying engine oil to piston pin and piston pin holes
in piston and connecting rod.
b) Fit connecting rod as shown in figure.
c) Insert piston pin to piston and connecting rod.
d) Install piston pin circlips (3).
2) Install piston rings to piston :
a) As indicated in figure, 1st and 2nd rings have “T” mark
respectively. When installing these piston rings to piston,
direct marked side of each ring toward top of piston.
b) 1st ring (1) differs from 2nd ring (2) in thickness, shape and
color of surface contacting cylinder wall.
Distinguish 1st ring from 2nd ring by referring to figure.
c) When installing oil ring (3) install spacer first and then two
rails.
3) After installing three rings (1st, 2nd and oil rings), distribute
their end gaps as shown in figure. NOTE:
After checking the rod bearing clearance, make sure that
checking for Connecting rod bolt deformation.
Refer to “INSPECTION” of “CONNECTING ROD”.
NOTE:
Circlip should be installed with its cut part facing as
shown in figure. Install so that circlip end gap comes
within such range as indicated by arrow.
1. 1st ring
2. 2nd ring
3. Oil ring
1. Arrow mark
2. 1st ring end gap
3. 2nd ring end gap and oil ring spacer gap
4. Oil ring upper rail gap
5. Oil ring lower rail gap