engine SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

TABLE OF CONTENTS
GENERAL INFORMATION ENGINE0A6
General Information0A
General Information and Diagnosis6
0B6A1
Maintenance and Lubrication0B
Engine Mechanical6A1
6B
HEATING AND AIR CONDITIONING
Engine Cooling6B
1A6C
Heater and Ventilation1A
Engine Fuel6C
1B6E1
Air Conditioning1B
Engine and Emission Control System6E1
6F1
STEERING, SUSPENSION, WHEELS
AND TIRESIgnition System6F1
36G
Cranking System6G
3A6H
Steering, Suspension, Wheels and Tires3
Charging System6H
3B6K
Front End Alignment3A
Exhaust System6K
3B1 6B
Manual Rack and Pinion3B TRANSMISSION, CLUTCH AND
DIFFERENTIAL
3C7A
Power Steering System3B1
3D7B
Steering Wheel and Column3C
Manual Transmission7A
3E7C
Front Suspension3D
Automatic Transmission7B
3F7D
Rear Suspension3E
Clutch7C
7F
Wheels and Tires3F
Transfer7D
4A
DRIVE SHAFT AND PROPELLER SHAFT
Differential (Rear)(4WD)7F
4B8
Front Drive Shaft 4A ELECTRICAL SYSTEM
8A
Propeller Shaft4B
Body Electrical System8
58G
BRAKE SYSTEM
Wiring Diagram8A5E
Brakes5
Immobilizer Control System (if equipped)8G
9
Antilock Brake System5E BODY SERVICE 9
RESTRAINT SYSTEM
10
Restraint System10
10B
Air Bag System (if equipped)10B
NOTE:
The screen toned Section 8A is in Wiring Diagram Manual mentioned in FOREWORD of this manual.

GENERAL INFORMATION 0A-1
0A
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 0A
GENERAL INFORMATION
CONTENTS
HOW TO USE THIS MANUAL .........................0A-2
PRECAUTIONS ................................................0A-3
PRECAUTION FOR VEHICLES EQUIPPED
WITH A SUPPLEMENTAL RESTRAINT
(AIR BAG) SYSTEM ..................................... 0A-3
DIAGNOSIS .............................................. 0A-3
SERVICING AND HANDLING .................. 0A-4
GENERAL PRECAUTIONS .......................... 0A-6
PRECAUTIONS FOR CATALYTIC
CONVERTER ................................................ 0A-9
PRECAUTION FOR INSTALLING MOBILE
COMMUNICATION EQUIPMENT ................. 0A-9
PRECAUTION IN SERVICING FULL-TIME
4WD VEHICLE ............................................ 0A-10
PRECAUTIONS FOR ELECTRICAL
CIRCUIT SERVICE ..................................... 0A-11
ELECTRICAL CIRCUIT INSPECTION
PROCEDURE ............................................. 0A-13
OPEN CIRCUIT CHECK ......................... 0A-13
CONTINUITY CHECK ............................. 0A-14
VOLTAGE CHECK .................................. 0A-15SHORT CIRCUIT CHECK (WIRE
HARNESS TO GROUND)....................... 0A-16
INTERMITTENT AND POOR
CONNECTION ............................................ 0A-16
IDENTIFICATION INFORMATION ................. 0A-18
VEHICLE IDENTIFICATION NUMBER ...... 0A-18
ENGINE IDENTIFICATION NUMBER ........ 0A-18
TRANSMISSION IDENTIFICATION
NUMBER .................................................... 0A-18
WARNING, CAUTION AND INFORMATION
LABELS.......................................................... 0A-19
VEHICLE LIFTING POINTS ........................... 0A-20
ABBREVIATIONS AND SYMBOLS MAY
BE USED IN THIS MANUAL.......................... 0A-22
FASTENER INFORMATION .......................... 0A-25
METRIC FASTENERS................................ 0A-25
FASTENER STRENGTH
IDENTIFICATION ....................................... 0A-25
STANDARD TIGHTENING TORQUE......... 0A-25

0A-6 GENERAL INFORMATION
 Air bag wire harness can be identified easily as it is covered with a yellow protection tube. Be very
careful when handling it.
 When an open in air bag wire harness, damaged wire harness, connector or terminal is found,
replace wire harness, connectors and terminals as an assembly.
 Do not apply power to the air bag system unless all components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble code.
 Never use air bag system component parts from another vehicle.
 When using electric welding, be sure to temporarily disable air bag system referring to “DISABLING
AIR BAG SYSTEM” in Section 10B.
 Never expose air bag system component parts directly to hot air (drying or baking the vehicle after
painting) or flames.
 WARNING/CAUTION labels are attached on each part of air bag system components. Be sure to fol-
low the instructions.
 After vehicle is completely repaired, perform “AIR BAG DIAGNOSTIC SYSTEM CHECK” in SECTION
10B.
GENERAL PRECAUTIONS
The WARNING and CAUTION below describe some general precautions that you should observe when servic-
ing a vehicle. These general precautions apply to many of the service procedures described in this manual, and
they will not necessarily be repeated with each procedure to which they apply.
WARNING:
 Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING
POINTS” in this section.
 When it is necessary to do service work with the engine running, make sure that the parking brake
is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for auto-
matic transmission vehicles), Keep hands, hair, clothing, tools, etc. away from the fan and belts
when the engine is running.
 When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.
 Do not perform service work in areas where combustible materials can come in contact with a hot
exhaust system. When working with toxic or flammable materials (such as gasoline and refriger-
ant), make sure that the area you work in is well-ventilated.
 To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail
pipe, muffler, etc.
 New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or
used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory ani-
mals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil,
wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing
engine oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any
clothing or rags if wet with oil, recycle or properly dispose of used oil and filters.
 Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpect-
edly during driving, obstructing your view and resulting in an accident.

GENERAL INFORMATION 0A-9
 Use care not to expose connectors and electrical parts
to water which will be a cause of a trouble.
 Always be careful not to handle electrical parts (com-
puter, relay, etc.) in a rough manner or drop them.
PRECAUTIONS FOR CATALYTIC CONVERTER
For vehicles equipped with a catalytic converter, use only unleaded gasoline and be careful not to let a
large amount of unburned gasoline enter the converter or it can be damaged.
 Conduct a spark jump test only when necessary, make it as short as possible, and do not open the
throttle.
 Conduct engine compression checks within the shortest possible time.
 Avoid situations which can result in engine misfire (e.g. starting the engine when the fuel tank is
nearly empty.)
PRECAUTION FOR INSTALLING MOBILE COMMUNICATION EQUIPMENT
When installing mobile communication equipment such as CB (Citizens-Band)-radio or cellular-tele-
phone, be sure to observe the following precautions.
Failure to follow cautions may adversely affect electronic control system.
 Keep the antenna as far away as possible from the vehicle’s electronic control unit.
 Keep the antenna feeder more than 20 cm (7.9 in) away from electronic control unit and its wire har-
nesses.
 Do not run the antenna feeder parallel with other wire harnesses.
 Confirm that the antenna and feeder are correctly adjusted.

0A-18 GENERAL INFORMATION
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER
The number is punched on front dash panel in engine room.
ENGINE IDENTIFICATION NUMBER
The number is punched on cylinder block.
TRANSMISSION IDENTIFICATION NUMBER
The automatic transmission identification number is located on
transmission case.

GENERAL INFORMATION 0A-19
WARNING, CAUTION AND INFORMATION LABELS
The figure below shows main labels among others that are attached to vehicle component parts.
When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels.
If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary.
1. Air bag label on back side of engine hood (if equipped)
2. Air bag label on sun visor (if equipped)
3. Radiator cap label
4. Engine cooling fan label
1. Air bag label on driver air bag (inflator) module 4. Air bag label on SDM
2. Air bag label on combination switch and contact coil assembly 5. Pretensioner label on seat belt retractor
3. Air bag label on passenger air bag (inflator) module [A] : These labels are attached on vehicle equipped with air bag system only.
5

0A-22 GENERAL INFORMATION
ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL
ABBREVIATIONS
AABS Anti-lock Brake System
EEFE Heater Early Fuel Evaporation Heater
(Positive Temperature Coefficient,
PTC Heater) ATDC After Top Dead Center
API American Petroleum Institute
ATF Automatic Transmission Fluid EPS Electronic Power Steering
ALR Automatic Locking Retractor EVAP Evaporative Emission
AC Alternating Current EVAP Canister Evaporative Emission Canister
(Charcoal Canister)
A/T Automatic TransmissionF
4WD 4 Wheel Drive
A/C Air Conditioning
GGEN Generator
ABDC After Bottom Dead Center GND Ground
A/F Air Fuel Mixture Ratio
HHC Hydrocarbons
A-ELR Automatic-Emergency Locking
RetractorHO2S Heated Oxygen Sensor
IIAC Valve Idle Air Control Valve (Idle Speed
Control Solenoid Valve ISC Sole-
noid Valve)
BB+ Battery Positive Voltage
BTDC Before Top Dead Center
BBDC Before Bottom Dead Center IAT Sensor Intake Air Temperature Sensor
(Air temperature Sensor, ATS)
CCKT Circuit
CKP sensor Crankshaft Position Sensor ICM Immobilizer Control Module
CMP sensor Camshaft Position Sensor IG Ignition
CO Carbon Monoxide ISC Actuator Idle Speed Control Actuator
CPP switch Clutch Pedal Position Switch
(Clutch Switch, Clutch Start
Switch)LLH Left Hand
LSPV Load Sensing Proportioning Valve
CPU Central Processing Unit
MMAF Sensor Mass Air Flow Sensor (Air Flow
Sensor, AFS, Air Flow Meter,
AFM) CRS Child Restraint System
DDC Direct Current
DLC Data Link Connector (Assembly
Line Diag. Link, ALDL, Serial Data
Link, SDL)MAP Sensor Manifold Absolute Pressure Sen-
sor (Pressure Sensor, PS)
Max Maximum
DOHC Double Over Head Camshaft MFI Multiport Fuel Injection
(Multipoint Fuel Injection)
DOJ Double Offset Joint
DRL Daytime Running Light MIN Minimum
DTC Diagnostic Trouble Code (Diag-
nostic Code)MIL Malfunction Indicator Lamp
(“SERVICE ENGINE SOON”
Light)
EEBCM Electronic Brake Control Module,
ABS Control Module M/T Manual Transmission
EBD Electronic Brake Force Distribu-
tionNNOx Nitrogen Oxides
ECM Engine Control Module
OOBD On-Board Diagnostic System
(Self-Diagnosis Function)
ECT sensor Engine Coolant Temperature Sen-
sor (Water Temp. Sensor, WTS)
O/D Overdrive
EGR Exhaust Gas Recirculation OHC Over Head Camshaft
EGRT sensor EGR Temperature Sensor (Recir-
culated Exhaust Gas Temp. Sen-
sor, REGTS)O2S Oxygen Sensor
PPNP Park/Neutral Position
P/S Power Steering

GENERAL INFORMATION 0A-23
PPSP Switch Power Steering Pressure Switch
(P/S Pressure Switch)
PCM Powertrain Control Module
PCV Positive Crankcase Ventilation
R
RH Right Hand
SSAE Society of Automotive Engineers
SDM Sensing and Diagnostic Module
(Air bag controller, Air bag con-
trol module)
SFI Sequential Multiport Fuel Injec-
tion
SOHC Single over Head Camshaft
TTBI Throttle Body Fuel Injection
(Single-Point Fuel Injection, SPI)
TCC Torque Converter Clutch
TCM Transmission Control Module
(A/T Controller, A/T Control
Module)
TP Sensor Throttle Position Sensor
TVV Thermal Vacuum Valve (Ther-
mal Vacuum Switching Valve,
TVSV, Bimetal Vacuum Switch-
ing Valve, BVSV)
TWC Three Way Catalytic Converter
(Three Way Catalyst)
2WD 2 Wheel Drive
VVIN Vehicle Identification Number
VSS Vehicle Speed Sensor
WWU-OC Warm Up Oxidation Catalytic
Converter
WU-TWC Warm Up Three Way Catalytic
Converter

0A-24 GENERAL INFORMATION
SYMBOLS
WIRE COLOR SYMBOLS
There are two kinds of colored wire used in this vehicle. One is
single-colored wire and the other is dual-colored (striped) wire.
The single-colored wire uses only one color symbol (i.e. “GRN”).
The dual-colored wire uses two color symbols (i.e. “GRN/YEL”).
The first symbol represents the base color of the wire (“GRN” in
the figure) and the second symbol represents the color of the
stripe (“YEL” in the figure). SYMBOL DEFINITION SYMBOL DEFINITION
Tightening torque Apply SUZUKI BOND NO. 1216
99000-31160
Apply oil (engine, transmission, trans-
fer, differential)Apply SILICONE SEALANT
99000-31120
Apply fluid (brake, power steering or
automatic transmission fluid)Apply SEALING COMPOUND 366E
99000-31090
Apply SUZUKI SUPER GREASE A
99000-25010
Apply SUZUKI SUPER GREASE C
99000-25030Apply THREAD LOCK 1322
99000-32110
Apply SUZUKI SUPER GREASE E
99000-25050Apply THREAD LOCK 1333B
99000-32020
Apply SUZUKI SUPER GREASE H
99000-25120Apply THREAD LOCK 1342
99000-32050
Apply SUZUKI SUPER GREASE I
99000-25210
Apply SUZUKI BOND NO. 1215
99000-31110Do not reuse
Apply SUZUKI BOND NO. 1207C
99000-31150Note on reassembly
Symbol Wire Color Symbol Wire Color
B BLK Black O, Or ORN Orange
Bl BLU Blue R RED Red
Br BRN Brown W WHT White
GGRN Green Y YEL Yellow
Gr GRY Gray P PNK Pink
Lbl LT BLU Light blue V PPL Violet
Lg LT GRN Light green

MAINTENANCE AND LUBRICATION 0B-1
0A 6F1
0B
0B
6G
1A 6H
1B 6K
37A
3A 7A1
3B1 7B1
3C1 7C1
3D 7D
3E 7E
3F 7F
4A2 8A
4B 8B
8C
58D
5A 8E
5B
5C 9
5E
5E1 10
10A
610B
6-1
6A1
6A2
6A4
6B
6C
6E1
6E2
SECTION 0B
MAINTENANCE AND LUBRICATION
CONTENTS
MAINTENANCE SCHEDULE .......................... 0B-2
MAINTENANCE SCHEDULE UNDER
NORMAL DRIVING CONDITIONS .............. 0B-2
MAINTENANCE RECOMMENDED UNDER
SEVERE DRIVING CONDITIONS ............... 0B-4
MAINTENANCE SERVICE .............................. 0B-5
ENGINE ....................................................... 0B-5
DRIVE BELT ............................................ 0B-5
VALVE LASH (CLEARANCE) .................. 0B-6
ENGINE OIL AND OIL FILTER ................ 0B-6
ENGINE COOLANT ................................. 0B-8
EXHAUST SYSTEM............................... 0B-10
IGNITION SYSTEM ................................... 0B-10
SPARK PLUGS ...................................... 0B-10
FUEL SYSTEM .......................................... 0B-10
AIR CLEANER FILTER .......................... 0B-10
FUEL LINES AND CONNECTIONS....... 0B-11
FUEL FILTER ......................................... 0B-11
FUEL TANK............................................ 0B-12
EMISSION CONTROL SYSTEM ............... 0B-12
PCV VALVE ........................................... 0B-12
FUEL EVAPORATIVE EMISSION
CONTROL SYSTEM .............................. 0B-12BRAKE ....................................................... 0B-12
BRAKE DISCS AND PADS (FRONT) .... 0B-12
BRAKE DRUMS AND SHOES
(REAR) ................................................... 0B-13
BRAKE HOSES AND PIPES ................. 0B-13
BRAKE FLUID........................................ 0B-13
BRAKE LEVER AND CABLE ................. 0B-13
CHASSIS AND BODY ............................... 0B-14
CLUTCH................................................. 0B-14
TIRES / WHEELS .................................. 0B-14
SUSPENSION SYSTEM ........................ 0B-15
STEERING SYSTEM ............................. 0B-15
DRIVE SHAFT (AXLE) BOOTS /
PROPELLER SHAFTS (4WD) ............... 0B-16
MANUAL TRANSMISSION OIL ............. 0B-17
AUTOMATIC TRANSMISSION FLUID .. 0B-17
TRANSFER OIL (4WD) AND REAR
DIFFERENTIAL OIL (4WD) ................... 0B-18
ALL LATCHES, HINGES AND
LOCKS ................................................... 0B-19
FINAL INSPECTION ..................................... 0B-19
RECOMMENDED FLUIDS AND
LUBRICANTS................................................ 0B-21

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).