CHECK SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

1. Fuel pump
2. Fuel filter
3. Throttle body
4. Fuel injector
5. Fuel pressure regulator6. Special tool
(Fuel pressure gauge &
3-way joint)
7. Fuel feed line
8. Fuel return line
6-100 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)
TABLE B-3 FUEL PRESSURE CHECK
INSPECTION
STEPACTIONYESNO
1Check Fuel Pressure (Refer to Section 6E1 for details).
1) Release fuel pressure from fuel feed line.
2) Install fuel pressure gauge.
3) Check fuel pressure by repeating ignition switch
ON and OFF. See Fig. 1.
Is fuel pressure then 160 – 210 kPa (1.6 – 2.1 kg / cm
2,
22.7 – 29.9 psi)?
Go to Step 2.Go to Step 4.
2Is 90 kPa (0.9 kg / cm2, 12.8 psi) or higher fuel
pressure retained for 1 minute after fuel pump is
stopped at Step 1?Normal fuel pressure.Go to Step 3.
31) Start engine and warm it up to normal operating
temperature.
2) Keep it running at specified idle speed.
Is fuel pressure then within 90 – 140 kPa
(0.9 – 1.4 kg / cm
2, 12.8 – 20.0 psi)?
Normal fuel pressure.
Clogged vacuum
passage for fuel
pressure regulator
or

Faulty fuel pressure
regulator.
4Is there fuel leakage from fuel feed line hose, pipe or
their joint?Fuel leakage from
hose, pipe or joint.Go to Step 10.
5Was fuel pressure higher than specification in Step 1?Go to Step 6.Go to Step 7.
61) Disconnect fuel return hose from throttle body and
connect new return hose to it.
2) Insert the other end of new return hose into
approved gasoline container.
3) Operate fuel pump.
Is specified fuel pressure obtained then?Restricted fuel return
hose or pipe.Faulty fuel pressure
regulator.
7Was no fuel pressure supplied in Step 1?Go to Step 8.Go to Step 9.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-101
Fig. 1 for Step 1
1. Fuel pressure gauge & 3way joint
STEPACTIONYESNO
8With fuel pump operated and fuel return hose
blocked by pinching it, is fuel pressure applied?Faulty fuel pressure
regulator.Shortage of fuel or fuel
pump or its circuit
defective (refer to B-2
FUEL PUMP ANDITS
CIRCUIT CHECK).
91) Operate fuel pump.
2) With fuel return hose blocked by pinching it, check
fuel pressure.
Is it 450 kPa (4.5 kg / cm
2, 63.9 psi) or more?
Faulty fuel pressure
regulator.
Clogged fuel filter,

Restricted fuel feed
hose or pipe,

Faulty fuel pump or

Fuel leakage from
hose connection in
fuel tank.
101) Disconnect fuel return hose from throttle body and
connect new return hose to it.
2) Insert the other end of new return hose into
approved gasoline container.
3) Check again if specified pressure is retained.
While doing so, does fuel come out of return hose?Faulty fuel pressure
regulator.
Fuel leakage from
injector,

Fuel leakage from
between injector
and throttle body,

Faulty fuel pump
(faulty check valve
in fuel pump) or

Fuel leakage from
fuel pressure
regulator
diaphragm.

A/C
amplifier(A / C ON output signal)
(A / C input signal)
6-102 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)
TABLE B-4 A / C SIGNAL CIRCUITS CHECK (VEHICLE WITH A / C)
INSPECTION
STEPACTIONYESNO
1Check A / C (Input) Signal Circuit.
1) Check voltage at terminal C03-19.
While engine running and A / C switch
and / or heater blower switch OFF
(A / C is not operating) : 10 – 14 V
While engine running and both A / C
switch and heater blower switch ON
(A / C is operating) : About 0 V
Are check results as specified?Go to Step 2.
“Bl / R” wire open or
short.

Poor C03-19
connection.

Poor A / C amplifier
coupler connection
or faulty A / C
system.
2Check A / C ON (Output) Signal Circuit.
1) Check voltage at terminal C03-17.
While engine running and A / C switch
and / or heater blower switch OFF
(A / C is not operating) : About 0 V
While engine running at idle speed
and both A / C switch and heater blower
switch ON (A / C is operating) : 10 – 14 V
Are check results as specified?A / C control signal
circuits are in good
condition.
“Lg / R” wire open or
short.

Poor performance of
ECT sensor, TP
sensor.

Engine start signal
inputted or

Poor C03-17
connection.
If none of the above
exists, substitute a
known-good ECM
(PCM) and recheck.

Power steering
pressure
switch
ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-103
TABLE B-5 POWER STEERING PRESSURE (PSP) SWITCH SIGNAL CIRCUIT
CHECK (IF EQUIPPED)
INSPECTION
STEPACTIONYESNO
1Check PSP Switch Signal Circuit.
1) Connect SUZUKI scan tool to DLC with ignition
switch OFF.
2) Start engine and select “DATA LIST” mode on
scan tool.
3) Check PSP switch signal under following each
condition. See Fig. 1.
Engine running and steering
wheel at straight-ahead position : OFF
Engine running and steering wheel
turned to the right on left as far as it stops : ON
Is check result satisfactory?PSP switch signal
circuit is in good
condition.“Bl / W” circuit open or
short, PSP switch
malfunction or power
steering system
malfunction.
Fig. 1 for Step 1

6-1
ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-1
GENERAL INFORMATION6-1- 3 . . . . . . . . . . . . . .
ENGINE DIAGNOSIS6-1- 6 . . . . . . . . . . . . . . . . . . .
General Description 6-1- 6. . . . . . . . . . . . . . . . . . .
On-Board Diagnostic System 6-1- 6. . . . . . . . . .
Precaution in Diagnosing Trouble 6-1- 9. . . . . . .
Engine Diagnostic Flow Table 6-1-10. . . . . . . . . .
Customer Problem Inspection From 6-1-12. . .
Malfunction Indicator Lamp Check 6-1-13. . . .
Diagnostic Trouble Code Check 6-1-13. . . . . .
Diagnostic Trouble Code Clearance 6-1-14. . .
Diagnostic Trouble Code Table 6-1-15. . . . . . .
Fail-safe Table 6-1-18. . . . . . . . . . . . . . . . . . . . .
Visual Inspection 6-1-19. . . . . . . . . . . . . . . . . . .
Engine Basic Inspection 6-1-20. . . . . . . . . . . . .
Engine Diagnosis Table 6-1-22. . . . . . . . . . . . .
Scan Tool Data 6-1-29. . . . . . . . . . . . . . . . . . . . . . .
Inspection of ECM (PCM) and Its
Circuits 6-1-33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Check 6-1-33. . . . . . . . . . . . . . . . . . . . .
Resistance Check 6-1-37. . . . . . . . . . . . . . . . . .
Component Location 6-1-38. . . . . . . . . . . . . . . . . .
Table A-1 MIL Circuit Check
(Lamp does not come on) 6-1-39. . . . . . . . . . . . Table A-2 MIL Circuit Check
(Lamp remains ON) 6-1-40. . . . . . . . . . . . . . . . . .
Table A-3 ECM (PCM) Power and
Ground Circuit Check 6-1-41. . . . . . . . . . . . . . . .
DTC P0105 MAP Circuit Malfunction 6-1-43. . . .
DTC P0110 IAT Circuit Malfunction 6-1-46. . . . .
DTC P0115 ECT Circuit Malfunction 6-1-48. . . .
DTC P0120 Throttle Position Circuit
Malfunction 6-1-50. . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0121 Throttle Position Circuit
Range / Performance Problem 6-1-52. . . . . . . . .
DTC P0130 HO2S Circuit Malfunction
(Sensor-1) 6-1-54. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0133 HO2S Circuit Slow
Response (Sensor-1) 6-1-56. . . . . . . . . . . . . . . .
DTC P0134 HO2S Circuit No Activity
Detected 6-1-57. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0135 HO2S Heater Circuit
Malfunction (Sensor-1) 6-1-58. . . . . . . . . . . . . . .
DTC P0136 HO2S Circuit Malfunction
(Sensor-2) 6-1-60. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0141 HO2S Heater Circuit
Malfunction (Sensor-2) 6-1-63. . . . . . . . . . . . . . .
DTC P0171 Fuel System Too Lean 6-1-65. . . . .
DTC P0172 Fuel System Too Rich 6-1-65. . . . . .
SECTION 6-1
ENGINE GENERAL INFORMATION
AND DIAGNOSIS
(SFI FOR G13)
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 autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” 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 Precau-
tions” 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).
CONTENTS

6-1-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
DTC P0300 Random Misfire
Detected 6-1- 69. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0301 Cylinder 1 Misfire
Detected 6-1- 69. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0302 Cylinder 2 Misfire
Detected 6-1- 69. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0303 Cylinder 3 Misfire
Detected 6-1- 69. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0304 Cylinder 4 Misfire
Detected 6-1- 69. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0335 CKP Sensor Circuit
Malfunction 6-1- 73. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0340 CMP Sensor Circuit
Malfunction 6-1- 75. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0400 EGR Flow Malfunction 6-1- 78. . . .
DTC P0420 Catalyst System
Efficiency Below Threshold 6-1- 81. . . . . . . . . .
DTC P0443 Purge Control Valve Circuit
Malfunction 6-1- 84. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0480 Radiator Fan Control
System Malfunction 6-1- 85. . . . . . . . . . . . . . . . .
DTC P0500 Vehicle Speed Sensor
Malfunction 6-1- 87. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0505 Idle Control System
Malfunction 6-1- 91. . . . . . . . . . . . . . . . . . . . . . . . DTC P0601 Internal Control Module
Memory Check Sum Error 6-1- 93. . . . . . . . . . .
DTC P1450 Barometric Pressure
Sensor Low / High Input 6-1- 94. . . . . . . . . . . . .
DTC P1451 Barometric Pressure Sensor
Performance Problem 6-1- 94. . . . . . . . . . . . . . .
DTC P1500 Engine Starter Signal
Circuit Malfunction 6-1- 96. . . . . . . . . . . . . . . . . .
DTC P1510 ECM (PCM) Back-up
Power Supply Malfunction 6-1- 97. . . . . . . . . . .
Table B-1 Fuel Injector Circuit Check 6-1- 98. . .
Table B-2 Fuel Pump and Its Circuit
Check 6-1- 99. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-3 Fuel Pressure Check 6-1-101. . . . . . . .
Table B-4 A / C Signal Circuits Check 6-1-103. . .
Table B-5 PSP Switch Signal Circuit
Check 6-1-104. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-6 Electric Load Signal Circuit
Check 6-1-105. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-7 Radiator Cooling Fan Control
System Check 6-1-106. . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS6-1-108 . . . . . . . . . . . . . . . . . . . . .

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-5
FUEL PRESSURE RELIEF PROCEDURE
CAUTION:
This work must not be done when engine is hot. If done so,
it may cause adverse effect to catalyst.
After making sure that engine is cold, release fuel pressure as fol-
lows.
1) Place transmission gear shift lever in “Neutral” (Shift selector le-
ver to “P” range for A / T model), set parking brake, and block
drive wheels.
2) Remove relay box cover.
3) Disconnect fuel pump relay (1) from relay box.
4) Remove fuel filler cap to release fuel vapor pressure in fuel tank
and then reinstall it.
5) Start engine and run it till it stops for lack of fuel. Repeat cranking
engine 2-3 times for about 3 seconds each time to dissipate fuel
pressure in lines. Fuel connections are now safe for servicing.
6) Upon completion of servicing, connect fuel pump relay (1) to
relay box and install relay box cover.
FUEL LEAKAGE CHECK PROCEDURE
After performing any service on fuel system, check to make sure
that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump) and
then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply fuel pressure
to fuel line. (till fuel pressure is felt by hand placed on fuel feed
hose.)
2) In this state, check to see that there are no fuel leakages from
any part of fuel system.

6-1-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
ENGINE DIAGNOSIS
GENERAL DESCRIPTION
This vehicle is equipped with an engine and emission control system which are under control of ECM (PCM).
The engine and emission control system in this vehicle are controlled by ECM (PCM). ECM (PCM) has an On-
Board Diagnostic system which detects a malfunction in this system and abnormality of those parts that influence
the engine exhaust emission. When diagnosing engine troubles, be sure to have full understanding of the outline
of “On-Board Diagnostic System” and each item in “Precaution in Diagnosing Trouble” and execute diagnosis ac-
cording to “ENGINE DIAGNOSTIC FLOW TABLE”.
There is a close relationship between the engine mechanical, engine cooling system, ignition system, exhaust sys-
tem, etc. and the engine and emission control system in their structure and operation. In case of an engine trouble,
even when the malfunction indicator lamp (MIL) doesn’t turn ON, it should be diagnosed according to this flow table.
ON-BOARD DIAGNOSTIC SYSTEM
ECM (PCM) in this vehicle has following functions.

When the ignition switch is turned ON with the engine at a stop,
malfunction indicator lamp (MIL) (1) turns ON to check the bulb
of the malfunction indicator lamp (1).

When ECM (PCM) detects a malfunction which gives an adverse
effect to vehicle emission while the engine is running, it makes the
malfunction indicator lamp (1) in the meter cluster of the instru-
ment panel turn ON or flash (flashing only when detecting a mis-
fire which can cause damage to the catalyst) and stores the mal-
function area in its memory.
(If it detects that continuously 3 driving cycles are normal after de-
tecting a malfunction, however, it makes MIL (1) turn OFF al-
though DTC stored in its memory will remain.)

As a condition for detecting a malfunction in some areas in the
system being monitored by ECM (PCM) and turning ON the mal-
function indicator lamp (1) due to that malfunction, 2 driving cycle
detection logic is adopted to prevent erroneous detection.

When a malfunction is detected, engine and driving conditions
then are stored in ECM (PCM) memory as freeze frame data. (For
the details, refer to description on Freeze frame data.)

It is possible to communicate by using not only SUZUKI scan tool
(Tech-1) (2) but also generic scan tool. (Diagnostic information
can be accessed by using a scan tool.)

An Example of Freeze Frame Data
1. Trouble Code P0102 (1st)
2. Engine Speed 782 RPM
3. Eng Cool Tmp. 80C
4. Vehicle Spd. 0 km/h
5. MAP Sensor 39 kPa
6. St. Term FT1– 0.8% Lean
7. Lg. Term FT1– 1.6% Lean
8. Fuel 1 Stat. Closed Loop
9. Fuel 2 Stat. Not used
10. Load value 25.5%
1st, 2nd or 3rd in parentheses here represents which
position in the order the malfunction is detected.
ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-7
Warm-up Cycle
A warm-up cycle means sufficient vehicle operation such that the
coolant temperature has risen by at least 22C (40F) from engine
starting and reaches a minimum temperature of 70C (160F).
Driving Cycle
A “Driving Cycle” consists of engine startup and engine shutoff.
2 Driving Cycle Detection Logic
The malfunction detected in the first driving cycle is stored in ECM
(PCM) memory (in the form of pending DTC and freeze frame data)
but the malfunction indicator lamp does not light at this time. It lights
up at the second detection of same malfunction also in the next driv-
ing cycle.
Pending DTC
Pending DTC means a DTC detected and stored temporarily at 1
driving cycle of the DTC which is detected in the 2 driving cycle
detection logic.
Freeze Frame Data
ECM (PCM) stores the engine and driving conditions (in the from
of data as shown at the left) at the moment of the detection of a mal-
function in its memory. This data is called “Freeze frame data”.
Therefore, it is possible to know engine and driving conditions (e.g.,
whether the engine was warm or not, where the vehicle was running
or stopped, where air / fuel mixture was lean or rich) when a mal-
function was detected by checking the freeze frame data. Also,
ECM (PCM) has a function to store each freeze frame data for three
different malfunctions in the order as the malfunction is detected.
Utilizing this function, it is possible to know the order of malfunctions
that have been detected. Its use is helpful when rechecking or diag-
nosing a trouble.
Priority of freeze frame data:
ECM (PCM) has 4 frames where the freeze frame data can be
stored. The first frame stores the freeze frame data of the malfunc-
tion which was detected first. However, the freeze frame data
stored in this frame is updated according to the priority described
below. (If malfunction as described in the upper square “1” below
is detected while the freeze frame data in the lower square “2” has
been stored, the freeze frame data “2” will be updated by the freeze
frame data “1”.)
PRIORITY
FREEZE FRAME DATA IN FRAME 1
1
Freeze frame data at initial detection of malfunction
among misfire detected (P0300-P0304), fuel
system too lean (P0171) and fuel system too rich
(P0172)
2Freeze frame data when a malfunction other than
those in “1” above is detected

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-9
PRECAUTION IN DIAGNOSING TROUBLE

Don’t disconnect couplers from ECM (PCM), battery cable from
battery, ECM (PCM) ground wire harness from engine or main
fuse before confirming diagnostic information (DTC, freeze frame
data, etc.) stored in ECM (PCM) memory. Such disconnection will
erase memorized information in ECM (PCM) memory.

Diagnostic information stored in ECM (PCM) memory can be
cleared as well as checked by using SUZUKI scan tool (Tech-1)
or generic scan tool. 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
If two or more DTCs are stored, proceed to the flow table of the
DTC which was detected earliest in the order and follow the
instruction in that table.
If no instructions are given, troubleshoot DTCs according to the
following priorities.
1. 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)
2. DTC P0171 / P0172 (Fuel system too lean / too rich) and DTC
P0400 (EGR flow malfunction)
3. DTC P0300 / P0301 / P0302 / P0303 / P0304 (Misfire detected)

Be sure to read “Precautions for Electrical Circuit Service” in Sec-
tion 0A before inspection and observe what is written there.

ECM (PCM) Replacement
When substituting a known-good ECM (PCM), check for following
conditions. Neglecting this check may cause damage to a known-
good ECM (PCM).
–Resistance value of all relays, actuators is as specified respec-
tively.
–MAP sensor and TP sensor are in good condition and none of
power circuits of these sensors is shorted to ground.