air bag SUZUKI SWIFT 2000 1.G RG413 Service Owner's Guide

ANTILOCK BRAKE SYSTEM (ABS) 5E-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
5E
9
10
10A
10B
SECTION 5E
ANTILOCK BRAKE SYSTEM (ABS)
CONTENTS
GENERAL DESCRIPTION .............................. 5E-2
COMPONENTS/PARTS LOCATION AND
BRAKE HOSE/PIPE ROUTING ................... 5E-2
SYSTEM SCHEMATIC ................................ 5E-4
ABS HYDRAULIC UNIT/CONTROL
MODULE ASSEMBLY ................................. 5E-5
SELF-DIAGNOSIS FUNCTION................ 5E-5
FAIL-SAFE FUNCTION............................ 5E-5
SYSTEM CIRCUIT ....................................... 5E-6
DIAGNOSIS ..................................................... 5E-8
PRECAUTION IN DIAGNOSING
TROUBLES .................................................. 5E-8
ABS DIAGNOSTIC FLOW TABLE ............... 5E-9
ABS WARNING LAMP CHECK ................. 5E-12
EBD WARNING LAMP (BRAKE
WARNING LAMP) CHECK ........................ 5E-12
TABLE – A ABS WARNING LAMP
CIRCUIT CHECK – LAMP DOES NOT
COME “ON” AT IGNITION SWITCH ON.... 5E-13
TABLE – B ABS WARNING LAMP
CIRCUIT CHECK – LAMP COMES
“ON” STEADY ............................................ 5E-14TABLE – C ABS WARNING LAMP
CIRCUIT CHECK – THE LAMP FLASHES
CONTINUOUSLY WHILE IGNITION
SWITCH IS ON .......................................... 5E-15
TABLE – D CODE (DTC) IS NOT
OUTPUTTED EVEN WITH DIAGNOSIS
SWITCH TERMINAL CONNECTED TO
GROUND ................................................... 5E-16
TABLE – E EBD WARNING LAMP
(BRAKE WARNING LAMP) CHECK
– LAMP COMES “ON” STEADY ................ 5E-17
DIAGNOSTIC TROUBLE CODE
(DTC) CHECK (USING ABS WARNING
LAMP) ........................................................ 5E-18
DIAGNOSTIC TROUBLE CODE (DTC)
CHECK (USING SUZUKI SCAN TOOL).... 5E-19
DIAGNOSTIC TROUBLE CODE
(DTC) CLEARANCE .................................. 5E-19
DIAGNOSTIC TROUBLE CODE (DTC)
TABLE........................................................ 5E-20
DTC C1013 (DTC 13) – SYSTEM
SPECIFICATIONS DIFFERENT FROM ABS
CONTROL MODULE SPECIFICATIONS .. 5E-22 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:
All brake fasteners are important attaching parts in that they could affect the performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of
same part number or with an equivalent part if replacement becomes necessary. Do not use a replace-
ment part of lesser quality or substitute design. Torque values must be used as specified during reas-
sembly to assure proper retention of all parts. There is to be no welding as it may result in extensive
damage and weakening of the metal.

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

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-9
Freeze Frame Data Clearance :
The freeze frame data is cleared at the same time as clearance of
diagnostic trouble code (DTC).
DATA LINK CONNECTOR (DLC)
DLC (1) is in compliance with SAEJ1962 in its installation posi-
tion, the shape of connector and pin assignment.
Serial data line (K line of ISO 9141) is used for SUZUKI scan tool
(Tech-1) or generic scan tool to communicate with ECM, TCM,
ABS control module and Air bag SDM.
SUZUKI serial data line is used for SUZUKI scan tool (Tech -1) to
communicate with immobilizer control module.FRAME
FRAME 1 FRAME 2 FRAME 3 FRAME4
FREEZE FRAME
DATA to be updated1st FREEZE
FRAME DATA2nd FREEZE
FRAME DATA3rd FREEZE
FRAME DATA
MALFUNCTION
DETECTED
ORDERNo malfunction No freeze frame data
1 P0400 (EGR)
detectedData at P0400
detectionData at P0400
detection––
2 P0171 (Fuel sys-
tem) detectedData at P0171
detectionData at P0400
detectionData at P0171
detection–
3 P0300 (Misfire)
detectedData at P0171
detectionData at P0400
detectionData at P0171
detectionData at P0300
detection
4 P0301 (Misfire)
detectedData at P0171
detectionData at P0400
detectionData at P0171
detectionData at P0300
detection
2. B+
3. Serial data line (K line of ISO 9141)
4. ECM ground
5. Body ground
6. SUZUKI serial data line
2
3456
1

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-11
DATA LINK CONNECTOR (DLC)
ELC (1) is in compliance with SAEJ1962 in its installation posi-
tion, the shape of connector and pin assignment.
Serial data line (K line of ISO 9141) is used for SUZUKI scan tool
(Tech-1) to communicate with ECM, TCM, ABS control module
and Air bag SDM.
SUZUKI serial data line is used for SUZUKI scan tool (Tech -1) to
communicate with immobilizer control module.
PRECAUTION IN DIAGNOSING TROUBLE
Do not disconnect couplers from ECM, battery cable from battery, ECM ground wire harness from engine or
main fuse before confirming diagnostic information (DTC, freeze frame data, etc.) stored in ECM memory.
Such disconnection will erase memorized information in ECM memory.
Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan
tool (Tech-1) or generic scan tool (Vehicle with immobilizer indicator lamp). Before using scan tool, read its
Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and
how to use it.
Priorities for diagnosing troubles (Vehicle with immobilizer indicator lamp).
If two or more DTCs are stored, proceed to the flow table of the DTC which has detected earliest in the order
(it can be identified by referring to freeze frame data) and follow the instruction in that table.
If no instructions are given, troubleshoot diagnostic trouble codes according to the following priorities.
–Diagnostic trouble codes (DTCs) other than DTC P0171/P0172 (Fuel system too lean/too rich), DTC
P0300/P0301/P0302/P0303/P0304 (Misfire detected) and DTC P0400 (EGR flow malfunction)
–DTC P0171/P0172 (Fuel system too lean/too rich) and DTC P0400 (EGR flow malfunction)
–DTC P0300/P0301/P0302/P0303/P0304 (Misfire detected)
Be sure to read “Precautions for Electrical Circuit Service” in Section 0A before inspection and observe what
is written there.
ECM Replacement
When substituting a known-good ECM, check for following conditions. Neglecting this check may cause
damage to a known-good ECM.
–Resistance value of all relays, actuators is as specified respectively.
–MAP sensor and TP sensor are in good condition and none of power circuits of these sensors is shorted
to ground.AMBIENT
TEMPERATURETIME TO CUT POWER TO ECM
Over 0°C (32°F) 60 sec. or longer
Under 0°C (32°F) Not specifiable. Select a place with
temperature higher than 0°C (32°F).
2. B+
3. Serial data line (K line of ISO 9141)
4. ECM ground
5. Body ground
6. SUZUKI serial data line
2
3456
1

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).

ENGINE FUEL 6C-1
6F1
6F2
6G
6C
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 6C
ENGINE FUEL
CONTENTS
GENERAL DESCRIPTION .............................. 6C-1
ON-VEHICLE SERVICE .................................. 6C-2
COMPONENTS ........................................... 6C-2
PRECAUTIONS ........................................... 6C-3
FUEL LINES ................................................. 6C-4
FUEL PIPE ................................................... 6C-4
FUEL FILLER CAP ...................................... 6C-5FUEL TANK INLET VALVE ......................... 6C-6
FUEL TANK ................................................. 6C-7
FUEL PUMP ASSEMBLY .......................... 6C-10
DISASSEMBLY AND REASSEMBLY .... 6C-12
SPECIAL TOOL ............................................ 6C-14
TIGHTENING TORQUE SPECIFICATION.... 6C-14

GENERAL DESCRIPTION
The main components of the fuel system are fuel tank, fuel pump assembly (with fuel filter, fuel level gauge, fuel
pressure regulator and tank pressure control valve), fuel/vapor separator fuel feed line and fuel vapor line.
For the details of fuel flow and fuel vapor flow, refer to “GENERAL DESCRIPTION” in Section 6E. 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).
CAUTION:
The engine of this vehicle requires the use of unleaded fuel only. Use of leaded and/or low lead fuel
can result in engine damage and reduce the effectiveness of the emission control system.

ENGINE AND EMISSION CONTROL SYSTEM 6E1-1
6F1
6F2
6G
6H
6E1
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 6E1
ENGINE AND EMISSION CONTROL SYSTEM
CONTENTS
GENERAL DESCRIPTION ............................ 6E1-2
AIR INTAKE SYSTEM ............................... 6E1-5
FUEL DELIVERY SYSTEM ....................... 6E1-6
FUEL PUMP ........................................... 6E1-6
ELECTRONIC CONTROL SYSTEM .......... 6E1-7
ENGINE & EMISSION CONTROL
INPUT/OUTPUT TABLE ........................ 6E1-8
ECM INPUT/OUTPUT CIRCUIT
DIAGRAM............................................... 6E1-9
ECM TERMINAL ARRANGEMENT
TABLE .................................................. 6E1-13
ON-VEHICLE SERVICE .............................. 6E1-15
ACCELERATOR CABLE
ADJUSTMENT ..................................... 6E1-15
IDLE SPEED/IDLE AIR CONTROL
(IAC) DUTY INSPECTION ................... 6E1-15
IDLE MIXTURE INSPECTION /
ADJUSTMENT (VEHICLE WITHOUT
HEATED OXYGEN SENSOR) ............. 6E1-17
AIR INTAKE SYSTEM ............................. 6E1-18
THROTTLE BODY ............................... 6E1-18IDLE AIR CONTROL VALVE (IAC
VALVE) ................................................ 6E1-20
FUEL DELIVERY SYSTEM ..................... 6E1-21
FUEL PRESSURE INSPECTION ........ 6E1-21
FUEL PUMP WITH PRESSURE
REGULATOR ....................................... 6E1-22
FUEL INJECTOR ................................. 6E1-23
ELECTRONIC CONTROL SYSTEM ....... 6E1-27
ENGINE CONTROL MODULE
(ECM) ................................................... 6E1-27
MANIFOLD ABSOLUTE PRESSURE
SENSOR (MAP SENSOR)................... 6E1-27
THROTTLE POSITION SENSOR (TP
SENSOR) ............................................. 6E1-28
INTAKE AIR TEMPERATURE
SENSOR (IAT SENSOR) ..................... 6E1-29
ENGINE COOLANT TEMPERATURE
SENSOR (ECT SENSOR) ................... 6E1-30
HEATED OXYGEN SENSOR (HO2S-1
AND HO2S-2) ...................................... 6E1-31
CAMSHAFT POSITION SENSOR ....... 6E1-32 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 system (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
Knock sensor

ENGINE AND EMISSION CONTROL SYSTEM 6E1-27
ELECTRONIC CONTROL SYSTEM
ENGINE CONTROL MODULE (ECM)
REMOVAL
1) Disconnect battery negative cable at battery.
2) Disable air bag system, referring to “Disabling The Air Bag
System” in Section 10B if equipped.
3) Disconnect ECM (1) and TCM (2) (if equipped) connectors.
4) Remove bolt and nuts, remove ECM and TCM (if equipped).
INSTALLATION
Reverse removal procedure noting the following:
Connect connectors to ECM and TCM (if equipped) securely.
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP
SENSOR)
INSPECTION
Check MAP sensor referring to “MAP Sensor Individual Check” in
DTC P0105 (No.11) Flow Table. If malfunction is found, replace.CAUTION:
As ECM consists of precision parts, be careful not to
expose it to excessive shock.
2
1

IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) 6F1-1
6G
6F2
6G
6H
6K
6F1
7A
7A1
7A1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 6F1
IGNITION SYSTEM
(ELECTRONIC IGNITION SYSTEM)
CONTENTS
GENERAL DESCRIPTION ............................. 6F1-2
DIAGNOSIS .................................................... 6F1-3
ON-VEHICLE SERVICE ................................. 6F1-5
IGNITION SPARK TEST ............................. 6F1-5
HIGH-TENSION CORDS ............................ 6F1-5
SPARK PLUGS ........................................... 6F1-6IGNITION COIL ASSEMBLY
(INCLUDING IGNITOR) .............................. 6F1-7
CRANKSHAFT POSITION SENSOR
(CKP SENSOR) .......................................... 6F1-7
IGNITION TIMING ...................................... 6F1-8
SPECIAL TOOL ............................................. 6F1-9

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).

CRANKING SYSTEM 6G-1
6F1
6F2
6H
6K
6G
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 6G
CRANKING SYSTEM
CONTENTS
GENERAL DESCRIPTION .............................. 6G-2
CRANKING CIRCUIT ................................... 6G-2
DIAGNOSIS ..................................................... 6G-2
DIAGNOSIS TABLE ..................................... 6G-2
PERFORMANCE TEST ............................... 6G-4
PULL-IN TEST ......................................... 6G-4
HOLD-IN TEST ........................................ 6G-4
PLUNGER AND PINION RETURN TEST 6G-4
NO-LOAD PERFORMANCE TEST .......... 6G-5ON-VEHICLE SERVICE ...................................6G-5
STARTING MOTOR .....................................6G-5
DISMOUNTING.........................................6G-5
REMOUNTING..........................................6G-5
DISASSEMBLY AND REASSEMBLY .......6G-6
SPECIFICATION ..............................................6G-8
1.0 kW TYPE.............................................6G-8
1.2 kW TYPE.............................................6G-8
REQUIRED SERVICE MATERIAL...................6G-8

WARNING:
For vehicles equipped with Supplement 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 DIAGNOSIS in air bag system section in order to confirm whether you are performing service
on or near the air bag system components or wiring. Please observe all WARNINGS and SERVICE
PRECAUTIONS under PRECAUTIONS 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 unin-
tentional activation of the system or could render the system inoperative. Either of these two condi-
tions 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:
Starting motor varies depending on specifications, etc. Therefore, be sure to check model and speci-
fication of the vehicle being serviced before replacing parts.