battery replacement SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

MAINTENANCE AND LUBRICATION 0B-5
MAINTENANCE SERVICE
ENGINE
DRIVE BELT
WATER PUMP AND GENERATOR DRIVE BELT INSPEC-
TION
1) Disconnect negative (–) cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanli-
ness. If any defect exists, replace.
Check belt for tension.
Water pump and generator belt tension
“a” : 4.5 - 5.5 mm (0.18 - 0.22 in.) deflection under 100 N
(10 kg, 22 lb) pressure
3) If belt is too tight or too loose, adjust it to specification by
adjusting alternator position.
4) Tighten alternator adjusting bolts and pivot bolt.
5) Connect negative (–) cable to battery.
WATER PUMP AND GENERATOR DRIVE BELT REPLACE-
MENT
Replace belt with new one referring to “WATER PUMP BELT” in
Section 6B.WARNING:
All inspection and replacement are to be performed with
ENGINE NOT RUNNING.
NOTE:
When replacing belt with a new one, adjust belt tension
to 3 - 4 mm (0.12 - 0.16 in.)

0B-6 MAINTENANCE AND LUBRICATION
A/C COMPRESSOR DRIVE BELT (IF EQUIPPED) INSPEC-
TION
1) Disconnect negative (–) cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanli-
ness. If any defect exists, replace.
Check belt for tension.
If belt tension is out of specification, adjust it referring to
“COMPRESSOR DRIVE BELT” in Section 1B.
A/C compressor drive belt tension
“a” : 3 - 5 mm (0.12 - 0.20 in.) deflection under 100 N
(10 kg, 22 lb) pressure
3) Connect negative (–) cable to battery.
REPLACEMENT
Replace belt with new one referring to “COMPRESSOR DRIVE
BELT” in Section 1B.
VALVE LASH (CLEARANCE)
INSPECTION
1) Inspect intake and exhaust valve lash and adjust as neces-
sary.
Refer to “VALVE LASH” in Section 6A1 for valve lash
inspection and adjustment procedure.
ENGINE OIL AND OIL FILTER
REPLACEMENT
Before draining engine oil, check engine for oil leakage. If any evi-
dence of leakage is found, make sure to correct defective part
before proceeding to the following work.
1. Camshaft
2. Thickness gauge
WARNING:
 New and used engine oil can be hazardous.
Be sure to read “WARNING” in General Precaution in
Section 0A and observe what in written there.
 Step 1) - 7) outlined below must be performed with
ENGINE NOT RUNNING. For step 8), be sure to have
adequate ventilation while engine is running.

MANUAL RACK AND PINION 3B-1
6F1
6F2
6G
6H
7A
3B
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3B
MANUAL RACK AND PINION
CONTENTS
GENERAL DESCRIPTION .............................. 3B-2
DIAGNOSIS ..................................................... 3B-3
ON-VEHICLE SERVICE .................................. 3B-4
LUBRICATION ............................................. 3B-4
TIE ROD END .............................................. 3B-6
MANUAL RACK AND PINION ASSEMBLY
(STEERING GEAR CASE) .......................... 3B-7
RACK BOOT/TIE ROD .............................. 3B-10STEERING RACK PLUNGER ................... 3B-12
STEERING PINION ................................... 3B-14
STEERING RACK...................................... 3B-15
PINION BEARING ..................................... 3B-17
RACK BUSHING ........................................ 3B-18
REQUIRED SERVICE MATERIAL................ 3B-19
SPECIAL TOOL ............................................ 3B-20

WARNING:
For vehicles equipped with a Air Bag System
Service on or around air bag system components or wiring must be performed only by an autho-
rized suzuki dealer. Please observe all WARNINGS and CAUTIONS in SECTION 10B and Precau-
tions, Air Bag System Components and Wiring Location view in Section 10B before performing
service on or around air bag system components or wiring. Failure to follow WARNINGS could
result in unintended 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 deployed by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
All steering gear 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 the same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified dur-
ing reassembly to assure proper retention of these parts.

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.

ANTILOCK BRAKE SYSTEM (ABS) 5E-39
Reference
When using oscilloscope for this check, check if peak-to-peak
voltage (1) meets specification and waveform is complete.
Peak-to-peak voltage at 1/2 to 1 rotation per second
2WD vehicle : 120 mV or more at 20 Hz
4WD vehicle : 150 mV or more at 20 Hz
REMOVAL
1) Disconnect negative cable at battery.
2) Remove rear seat referring to Section 9.
3) Turn over floor carpet.
4) Hoist vehicle.
5) Disconnect rear wheel speed sensor coupler (1).
6) Detach ABS wheel sensor wire harness (2) from suspension
frame (3).
7) Remove rear wheel speed sensor (4) from rear axle housing.
SENSOR INSPECTION
Check sensor for damage.
Check sensor for resistance and continuity.
Between both terminals of sensor
2WD vehicle : 0.9 – 1.3 k
Ω
ΩΩ Ω at 20°C (68°F)
4WD vehicle : 1.2 – 1.6 k
Ω
ΩΩ Ω at 20°C (68°F)
Between sensor terminal and sensor body
: No continuity
If the check result is not as specified and any malcondition is
found, replace.
NOTE:
Do not detach crip of rear wheel speed sensor connector
from vehicle body unless replacement is necessary.
CAUTION:
Do not pull wire harness when removing rear wheel
speed sensor.
Do not cause damage to surface of rear wheel speed
sensor and do not allow dust, etc. to enter its installa-
tion hole.
4
231

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) 6A1-9
VALVE LASH (CLEARANCE)
INSPECTION
1) Remove negative cable at battery.
2) Remove cylinder head cover referring to “CYLINDER HEAD
COVER”.
3) Remove right side engine cover if necessary.
4) Using 17 mm wrench, turn crankshaft pulley (1) clockwise
until cam lobes (2) become perpendicular to shim faces (3)
at valves “1” and “7” as shown in figure.
5) Check valve lashes with thickness gauge (4) according to
the following procedure.
a) Check valve lashes at valves “1” and “7”.
b) Turn camshafts by 90° (by turning crankshaft with wrench).
c) Make sure that cam lobes are perpendicular to shim faces
at valves to be checked (in this case, “3” and “8”), if not,
adjust it by turning crankshaft. Check valve lashes.
d) In the same manner as b) – c), check valve lashes at valves
“4” and “6”.
e) In the same manner as b) – c) again, check valve lashes at
valves “2” and “5”.
Valve clearance specification
If valve lash is out of specification, record valve lash and adjust it
to specification by replacing shim.
REPLACEMENT OF SHIM
1) Close the valve whose shim (2) is to be replaced by turning
crankshaft, then turn tappet (3) till its cut section (1) faces
inside as shown in figure.
2) Lift down the it valve by turning crankshaft to 180°.
3) Hold tappet at that position using special tool as follows.
a) Remove its housing bolts.When cold
(Coolant temperature
is 15 – 25°C
(59 – 77°F))When hot
(Coolant temperature
is 60 – 68°C
(140 – 154°F))
Intake 0.18 – 0.22 mm
(0.007 – 0.009 in.)0.21 – 0.27 mm
(0.008 – 0.011 in.)
Exhaust 0.28 – 0.32 mm
(0.011 – 0.013 in.)0.30 – 0.36 mm
(0.012 – 0.014 in.)