CHECK SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-99
Main
fuseIgnition
switch
Main relay
Fuel pump relay Main relay
Fuel pump
CAUTION: Check to make sure that connection is
made between correct terminals. Wrong connection
can cause damage to ECM (PCM), wire harness, etc.
TABLE B-2 FUEL PUMP AND ITS CIRCUIT CHECK
INSPECTION
STEPACTIONYESNO
1Was “ENGINE DIAG. FLOW TABLE” performed?Go to Step 2.Go to “ENGINE
DIAG. FLOW
TABLE”.
2Check Fuel Pump Control System for Operation. See Fig. 1.
Is fuel pump heard to operate for 2 sec. after ignition switch
ON?Fuel pump circuit
is in good
condition.Go to Step 3.
3Check Fuel Pump for Operation.
1) Remove fuel pump relay from relay box with ignition
switch OFF.
2) Check for proper connection to relay at each terminals.
3) If OK, using service wire, connect terminals C44-3 and
C44-4 of relay connector. See Fig. 2.
Is fuel pump heard to operate at ignition switch ON?Go to Step 4.“P”, “B” or “R/B”
circuit open or fuel
pump malfunction.
4Check Fuel Pump Relay for Operation.
1) Check resistance between each two terminals of fuel
pump relay. See Fig.3.
Between terminals “c” and “d”: Infinity
Between terminals “a” and “b”: 100 – 150 Ω
2) Check that there is continuity between terminals “c” and
“d” when battery is connected to terminals “a” and “b”. See
Fig. 3.
Is fuel pump relay in good condition?“Y/Bl” circuit open
or poor C02-19
connection.
If wire and
connection are
OK, substitute a
known-good ECM
(PCM) and
recheck.Replace fuel pump
relay.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-101
1. Fuel injector
2. Delivery pipe
3. Fuel regulator
4. Fuel filter
5. Fuel pump
Special Tool
(A) Gauge (09912-58441)
(B) Hose (09912-58431)
(C) 3-way joint (09912-58490)
TABLE B-3 FUEL PRESSURE CHECK
INSPECTION
STEPACTIONYESON
11) Release fuel pressure from fuel feed line.
2) Install fuel pressure gauge.
3) Check fuel pressure by repeating ignition switch
ON and OFF.
Is fuel pressure then 270 – 310 kPa
(2.7 – 3.1 kg / cm
2, 38.4 – 44.0 psi)?
Go to Step 2.Go to Step 5.
2Is 200 kPa (2.0 kg / cm2, 28.4 psi) or higher fuel
pressure retained for 1 minute after fuel pump is
stopped at step 1?Go to Step 3.Go to Step 4.
31) Start engine and warm it up to normal operating
temperature.
2) Keep it running at specified idle speed.
Is fuel pressure then within 200 – 240 kPa
(2.0 – 2.4 kg / cm
2, 28.4 – 34.1 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 spec. in step 1?Go to Step 6.Go to Step 7.
61) Disconnect fuel return hose from fuel pressure
regulator and connect new return hose to it.
2) Put 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.

6-1-102 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
1. Fuel delivery pipe
2. Fuel feed hose
3. Fuel return hose
Special Tool
(A) Gauge
(B) Hose
(C) 3-way joint
STEPACTIONYESON
7Was no fuel pressure applied in step 1?Go to Step 8.Go to Step 9.
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
malfunction.
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 pressure
regulator 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 obtained.
While doing so, does fuel come out of return hose?Faulty fuel pressure
regulator.Fuel leakage from
injector, Fuel leakage
from between injector
and delivery pipe,
Faulty fuel pump
(faulty check valve in
fuel pump) or Fuel
leakage from fuel
pressure regulator
diaphragm.
Fig. for STEP 1

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-103
A/C
amplifier(A / C ON output signal)
(A / C input signal)
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 C02-16. See Fig. 1.
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 result as specified?Go to Step 2.“Lg / B” circuit open
or short,
Evaporative
temperature is
1C (34F) below
or faulty A / C
system.
2Check A / C ON (Output) Signal Circuit.
1) Check voltage at terminal C02-1. See Fig. 2.
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 result as specified?A / C control signal
circuits are in good
condition.“G/R” circuit open
or short, Poor
performance of
ECT sensor, TP
sensor, Engine
start signal
inputted or A / C
amplifier
malfunction.
If none of the
above exists,
substitute a
known-good ECM
and recheck.

6-1-104 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
Power steering
pressure
switch
Power steering
pump
Fig. 1 for Step 1 Fig. 2 for Step 2
TABLE B-5 POWER STEERING PRESSURE (PSP) SWITCH SIGNAL CIRCUIT
CHECK (If equipped)
INSPECTION
STEPACTIONYESNO
1Check PSP Switch Signal Circuit.
When using SUZUKI scan tool:
1) Connect SUZUKI scan tool to DLC with ignition switch
OFF.
2) Start engine and select “DATA LIST” mode on scan tool.
3) Check power steering pressure switch. See Fig. 1.
Engine running and steering
wheel at straight-ahead position : OFF, 10 – 14 V
Engine running and steering
wheel turned to the right or
left as far as it stops : ON, 0 – 1 V
Is it in good condition?
When not using SUZUKI scan tool:
1) Turn ignition switch ON.
2) Check for voltage at terminal C01-5 of ECM
connector connected, under above each condition.
Is each voltage as specified?Signal circuit is in
good condition.Go to Step 2.
2Check Wire Harness.
1) Turn ignition switch OFF and disconnect PSP switch
connector.
2) Check for proper connection to PSP switch.
3) If OK, then check voltage at PSP switch wire terminal
with ignition switch ON. See Fig. 2.
Is it 10 – 14V?Power steering
switch malfunction
or power steering
system
malfunction.“G/W” wire open
or shorted to
ground or poor
C01-5 connection.
If wire and
connection are
OK, substitute a
known-good ECM
and recheck.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-105
Heater blower
switchRear defogger
switch Tail light relay
(Lighting switch)
Diodes in junction/
fuse block
Fig. 1 for Step 1 Fig. 2 for Step 1
TABLE B-6 ELECTRIC LOAD SIGNAL CIRCUIT CHECK
INSPECTION
STEPACTIONYESNO
1Check Electric Load Signal Circuit.
When using SUZUKI scan tool:
1) Connect SUZUKI scan tool to DLC with ignition
switch OFF.
2) Start engine and select “DATA LIST” mode on
scan tool.
3) Check electric load signal under following each
condition. See Fig. 1.
Ignition switch ON, Small light,
heater blower fan and rear
defogger all turned OFF : OFF
0 V (C01-17)
Ignition switch ON, Small light,
heater blower fan or rear
defogger turned ON : ON
10 – 14 V (C01-17)
Is check result satisfactory?
When not using SUZUKI scan tool:
1) Turn ignition switch ON.
2) Check voltage at terminals C01-17 of ECM (PCM)
connector connected, under above each condition.
See Fig. 2.
Is each voltage as specified?Electric load signal
circuit is in good
condition.“Br / Y” circuit open
or short, Electric
load diodes
malfunction or
Each electric load
circuit malfunction.

6-1-106 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
Radiator cooling fan relay
To
ECM
Main
relay
Relay
box
“RDTR”
(Radiator fan)Radiator cooling
Fan motor
TABLE B-7 RADIATOR COOLING FAN CONTROL SYSTEM CHECK
INSPECTION
STEPACTIONYESNO
1Check Fan Control System.
1) Connect scan tool to DLC with ignition switch OFF.
2) Start engine and select “DATA LIST” mode on scan tool.
3) Warm up engine until coolant temp. is 97.5C, 208F or
higher and A / C switch turn OFF. (If engine coolant temp.
does not rise, check engine cooling system or ECT sensor.)
See Fig. 1.
Is radiator cooling fan started when engine coolant temp.
reached above temp.?Radiator cooling
fan control
system is in good
condition.Go to Step 2.
2Check Radiator Cooling Fan Relay and Its Circuit.
1) Check DTC and pending DTC with scan tool.
Is DTC P0480 displayed?Go to DTC
P0480 Diag.
Flow Table.Go to Step 3.
3Check Radiator Cooling Fan Relay.
1) Turn ignition switch OFF and remove radiator cooling fan
relay.
2) Check for proper connection to relay at terminals “c” and “d”.
3) If OK, check that there is continuity between “c” and “d” when
battery is connected to terminals “a” and “b”. See Fig. 2.
Is check result satisfactory?Go to Step 4.Replace radiator
fan relay.
4Check Radiator Cooling Fan.
1) Turn ignition switch OFF.
2) Disconnect cooling fan motor connector.
3) Check for proper connection to motor at “Bl / R” and “B”
terminals.
4) If OK, connect battery to motor and check for operation.
See Fig. 3.
Is it in good condition?“Bl / W”, “Bl / R” or
“B” circuit open.Replace radiator
cooling fan
motor.

6-1-108 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
09917-47910
Vacuum pump gauge09930-88530
Injector test lead09931-76011
SUZUKI scan tool (Tech 1 A) kit
Mass storage cartridge09931-76030
16 / 14 pin DLC cable1. Storage case
2. Operator’s manual
3. Tech 1 A
4. DLC cable (14 / 26 pin,
09931-76040)
5. Test lead / probe
6. Power source cable
7. DLC cable adaptor
8. Self-test adaptor -1. Pressure gauge
09912-58441
-2. Pressure hose
09912-58431
-3. 3-way joint & hose
09912-58490
-4. Checking tool set
09912-58421
4-1. Tool body & washer
4-2. Body plug
4-3. Body attachment-1
4-4. Holder
4-5. Return hose & clamp
4-6. Body attachment-2 & washer
4-7. Hose attachment-1
4-8. Hose attachment-2
-5. Checking tool plate
09912-57610
SPECIAL TOOLS

6A
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-1
SECTION 6A
ENGINE MECHANICAL
(G10, 1-CAM 6-VALVES ENGINE)
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).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of Service Manual men-
tioned in FOREWORD of this manual.
CONTENTS
ON-VEHICLE SERVICE6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Vacuum Check6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Check6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover6A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body and Intake Manifold 6A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold6A- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt and Belt Tensioner 6A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Hydraulic Valve Lash Adjuster 6A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Lash Adjuster Noise Diagnosis 6A-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves and Cylinder Head6A-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons, Piston Rings, Connecting Rods and Cylinders 6A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR OVERHAUL6A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly6A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bearings, Crankshaft and Cylinder Block 6A-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS6A-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS6A-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6A-2 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
ON-VEHICLE SERVICE
ENGINE VACUUM CHECK
The engine vacuum that develops in the intake line is a good indica-
tor of the condition of the engine. The vacuum checking procedure
is as follows:
1) Warm up engine to normal operating temperature.
2) With engine stopped, remove blind plug hose from intake man-
ifold and connect special tool (vacuum gauge and joint) to va-
cated threaded hole.
Special Tool
(A): 09915-67311
3) Run engine at specified idle speed (see Section 6E), and read
vacuum gauge. Vacuum should be within the following specifi-
cation.
Vacuum specification: 52.6 – 65.8 kPa (40 – 50 cm
.Hg,
15.7 – 19.7 in
.Hg) at specified
idling speed
4) After checking, apply sealant to thread of blind plug and install
it to intake manifold.
OIL PRESSURE CHECK
NOTE:
Prior to checking oil pressure, check the followings.

Oil level in oil pan.
If oil level is low, add oil up to Full level hole on oil level
gauge.

Oil quality.
If oil is discolored, or deteriorated, change it.
For particular oil to be used, refer to the table in Section 0B.

Oil leaks.
If leak is found, repair it.
1) Using special tool (Oil filter wrench), remove oil filter.
2) After removing oil filter, remove oil pressure switch (1) from cylin-
der block.