ignition SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

6E2
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-1
GENERAL DESCRIPTION6E2- 2 . . . . . . . . . . . . . .
AIR INTAKE SYSTEM 6E2- 6. . . . . . . . . . . . . . . . . .
FUEL DELIVERY SYSTEM 6E2- 7. . . . . . . . . . . . . .
ELECTRONIC CONTROL SYSTEM 6E2- 8. . . . . .
Engine and Emission Control Input /
Output Table 6E2- 9. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSISSee Section 6. . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE6E2-13 . . . . . . . . . . . . . . . .
Accelerator Cable Adjustment 6E2-13. . . . . . . . . .
Idle Speed/Idle Air Control (IAC)
Duty Inspection 6E2-14. . . . . . . . . . . . . . . . . . . . .
AIR INTAKE SYSTEM 6E2-15. . . . . . . . . . . . . . . . . .
Throttle Body 6E2-15. . . . . . . . . . . . . . . . . . . . . . . .
Idle Air Control Valve 6E2-17. . . . . . . . . . . . . . . . .
FUEL DELIVERY SYSTEM 6E2-18. . . . . . . . . . . . . .
Fuel Pressure Inspection 6E2-18. . . . . . . . . . . . . .
Fuel Pump 6E2-21. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pressure Regulator 6E2-22. . . . . . . . . . . . . . .
Fuel Injector 6E2-23. . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRONIC CONTROL SYSTEM 6E2-27. . . . . .
ECM / PCM 6E2-27. . . . . . . . . . . . . . . . . . . . . . . . . .
MAP Sensor 6E2-27. . . . . . . . . . . . . . . . . . . . . . . . .
TP Sensor 6E2-28. . . . . . . . . . . . . . . . . . . . . . . . . . .
IAT Sensor 6E2-29. . . . . . . . . . . . . . . . . . . . . . . . . .
ECT Sensor 6E2-30. . . . . . . . . . . . . . . . . . . . . . . . . Heated Oxygen Sensor -1 and -2 6E2-31. . . . . . .
Camshaft Position Sensor 6E2-32. . . . . . . . . . . . .
Crankshaft Position Sensor 6E2-32. . . . . . . . . . . .
Vehicle Speed Sensor 6E2-33. . . . . . . . . . . . . . . . .
Fuel Level Sensor (gauge) 6E2-33. . . . . . . . . . . . .
Main Relay, Fuel Pump Relay and
Radiator Fan Control Relay 6E2-33. . . . . . . . . . .
Fuel Cut Operation (Inspection) 6E2-34. . . . . . . .
Radiator Fan Control System 6E2-34. . . . . . . . . .
System Inspection 6E2-34. . . . . . . . . . . . . . . . . .
Radiator Fan 6E2-34. . . . . . . . . . . . . . . . . . . . . . .
EMISSION CONTROL SYSTEM 6E2-35. . . . . . . . .
EGR System 6E2-35. . . . . . . . . . . . . . . . . . . . . . . . .
EVAP Control System 6E2-36. . . . . . . . . . . . . . . . .
EVAP Canister Purge Inspection 6E2-36. . . . . .
Vacuum Passage Inspection 6E2-37. . . . . . . . .
Vacuum Hose Inspection 6E2-37. . . . . . . . . . . .
EVAP Canister Purge Valve
Inspection 6E2-37. . . . . . . . . . . . . . . . . . . . . . . .
EVAP Canister Inspection 6E2-38. . . . . . . . . . .
PCV System 6E2-38. . . . . . . . . . . . . . . . . . . . . . . . .
PCV Hose Inspection 6E2-38. . . . . . . . . . . . . . .
PCV Valve Inspection 6E2-38. . . . . . . . . . . . . . .
SPECIAL TOOLS6E2-39 . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS6E2-39 . . . . . . . . . . . . . . . . . . . . .
SECTION 6E2
ENGINE AND EMISSION CONTROL SYSTEM
(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

6E2-8 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
INFORMATION SENSORS
-1. MAP sensor
-2. TP sensor
-3. IAT sensor
-4. ECT sensor
-5. Heated oxygen sensor-1
5-1. Heated oxygen sensor-2
-6. VSS (A / T)
-7. Transmission range switch (A / T)
-8. Battery
-9. CMP sensor
-10. CKP sensor
-11. Fuel level sensor (gauge) (in fuel tank)
-12. PSP switch
-13. A / C control module (if equipped)
-14. VSS (speedometer) (M / T)OTHERS
A: ECM (PCM)
B: Main relay
C: EVAP canister
D: Data link connector CONTROL DEVICES
a: Fuel injector
b: EVAP canister purge valve
c: Fuel pump relay
d: EGR valve (step motor)
e: Malfunction indicator lamp
f: Ignition coil assembly
g: Radiator fan control relay
h: IAC valve
The electronic control system consists of 1) various
sensors which detect the state of engine and driving
conditions, 2) ECM (PCM) which controls various de-
vices according to the signals from the sensors and
3) various controlled devices.
Functionally, it is divided into nine sub systems:

Fuel injection control system

Idle speed control system
Fuel pump control system

A / C control system (if equipped)

Radiator fan control system

EGR system

Evaporative emission control system

Oxygen sensor heater control system

Ignition control system
Also, with A / T model, PCM controls A / T.
ELECTRONIC CONTROL SYSTEM

ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-9
FUEL PUMP RELAY
FUEL INJECTOR
HO2S HEATER
IAC VALVE
IGNITION COIL WITH IGNITER
EGR VALVE
EVAP CANISTER PURGE VALVE
A/C CONTROL MODULE
RADIATOR FAN RELAY
MIL
MAIN RELAY
SIGNAL FROM SENSOR, SWITCH AND CONTROL MODULE
OUTPUT
INPUT
ENGINE & EMISSION CONTROL INPUT / OUTPUT TABLE
ELECTRIC CONTROL DEVICE
FUEL LEVEL SENSORFor detecting fuel level
BAROMETRIC PRESSURE SENSOR
START SWITCH
IGNITION SWITCH
LIGHTING SWITCH
REAR DEFOGGER SWITCH (IF EQUIPPED)
BLOWER SWITCH
A / C SWITCH
VSS
HEATED OXYGEN SENSOR-1
HEATED OXYGEN SENSOR-2For detecting deterioration of
three way catalytic convertor
IAT SENSOR
ECT SENSOR
TP SENSOR
MAP SENSOR
CMP SENSOR
CKP SENSOR

12 W / R “N”-range signal (A / T)
13 R Heated oxygen sensor-2
14 Y / R “D”-range signal (A / T)
15 R / W “R”-range signal (A / T)
16 Lg / B A / C SW signal
17 R / W EGR valve (stepper motor coil 4)
18 P / G Radiator fan relay
19 Y / Bl Fuel pump relay
20 —— ———
21 W / B “P”-range signal (A / T)
22 P / Bl Fuel level gauge
23 R / B “L”-range signal (A / T)
24 —— ———
1 V Malfunction indicator lamp
Vehicle speed sensor (M / T)
Output shaft speed sensor (+)
(A / T)
3 —— ———
4 G / W Shift solenoid – A (A / T)
5 Gr Throttle position (TP) sensor
6 B / W Ignition switch signal
7 Y / B Data link connector
Output shaft speed sensor (–)
(A / T)
9 —— ———
10 G GND for HO2S-2
11 G / Or Shift solenoid – B (A / T)
12 —— ———
13 —— ———
14 —— ———
15 —— ———
16 Br Tachometer signal
17 B / Y Engine start signal
CON-
NECTORTERMINALWIRE
COLORCIRCUITCON-
NECTORTERMINALWIRE
COLORCIRCUIT
20
Br / Y 19
Br / W
C02 C01C02
C03
Wire color
B : Black
B / Or : Black / Orange
B / W : Black / White
B / Y : Black / Yellow
Bl : Blue
Bl / Or : Blue / Orange
Bl / B : Blue / Black
Bl / R : Blue / Red
Bl / Y : Blue / Yellow
Br : Brown
Br / W : Brown / White
Br / Y : Brown / Yellow
G : Green
G / Or : Green / Orange
G / R : Green / Red
G / W : Green / White
Gr : Gray
Gr / R : Gray / Red
Lg / B : Lightgreen / Black
Lg / R : Lightgreen / RedP : Pink
P / Bl : Pink / Blue
P / G : Pink / Green
V : Violet
V / G : Violet / Green
V / R : Violet / Red
V / W : Violet / White
W : White
W / B : White / Black
W / R : White / Red
R : Red
R / B : Red / Black
R / Bl : Red / Blue
R / G : Red / Green
R / W : Red / White
R / Y : Red / Yellow
Y / B : Yellow / Black
Y / Bl : Yellow / Blue
Y / R : Yellow / Red
2
P
8
Bl
6E2-12 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
1 B Ground for ECM / PCM
2 B / Or Ground for drive circuit
3 B / Or Ground for drive circuit
4 V / R Canister purge valve
5 G / W Power steering pressure switch
6 V / W IAC valve
7 Bl Heater of HO2S-1
8 Bl / Or No.4 fuel injector
9 Bl / R No.1 fuel injector
10 G Ground for sensor circuit
11 B / W CMP sensor
12 —— ———
13 R Heated oxygen sensor-1
14 Lg / R Coolant temp. sensor
15 Gr / R Intake air temp. sensor
16 —— ———
17 Br / Y Electric load (+)
18 —— ———
IG coil assembly for
No.2 and 3 spark plugs
IG coil assembly for
No.1 and 4 spark plugs
21 Bl / B No.2 fuel injector
22 P Power supply for sensor
23 W CKP sensor (+)
24 B CKP sensor (–)
25 —— ———
26 G MAP sensor
27 —— ———
28 V / G Immobilizer indicator lamp
29 —— ———
30 —— ———
31 Bl / Y No.3 fuel injector
1 G / R A / C compressor clutch
2 R / Y EGR valve (stepper motor coil 1)
3 R / G Data link connector
4 Lg / B Heater of HO2S-2
5 R / B Power source
6 R / B Power source
7 W Backup power source
8 R EGR valve (stepper motor coil 3)
9 R / Bl EGR valve (stepper motor coil 2)
10 Gr Ground for main relay
11 Y / B “2”-range signal (A / T)

6E2-14 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
IDLE SPEED / IDLE AIR CONTROL (IAC) DUTY
INSPECTION
Before idle speed / IAC duty check, make sure of the following.

Lead wires and hoses of Electronic Fuel Injection and engine
emission control systems are connected securely.

Accelerator cable has some play, that is, it is not tight.

Valve lash is checked and adjusted according to maintenance
schedule.

Ignition timing is within specification.

All accessories (wipers, heater, lights, A / C, etc.) are out of ser-
vice.

Air cleaner has been properly installed and is in good condition.

No abnormal air inhaling from air intake system.
After above items are all confirmed, check idle speed and IAC duty
as follows.
NOTE:
Before starting engine, place transmission gear shift lever in
“Neutral” (shift selector lever to “P” range for A / T vehicle),
and set parking brake and block drive wheels.
1) Connect SUZUKI scan tool (1) to DLC with ignition switch OFF,
if it is available.
2) Warm up engine to normal operating temperature.
3) Check engine idle speed and “IAC duty” as follow:
Select “Data List” mode on scan tool to check “IAC duty” and en-
gine speed.
Special Tool
(A): 09931-76011 (SUZUKI scan tool)
(B): Mass storage cartridge
(C): 09931-76030 (16 / 14 pin DLC cable)
If duty and/or idle speed is out of specifications, inspect idle air
control system referring to Diagnostic Flow Table B-4 IDLE AIR
CONTROL SYSTEM CHECK in Section 6.
ENGINE IDLE SPEED AND IAC DUTY
A/C OFFA/C ON
M / T vehicle750±50 r / min (rpm)875±50 r/minA / T vehicle
at P/N range750 ±50 r/min (rpm)
8 – 25 or *8 – 35%
875 ±50 r/min
(rpm)
NOTE:
Duty values with (*) are applicable to vehicle used at high
altitude (higher than 2,000 m or 6,560 ft).
4) Check that 875 ± 50 r / min. idle speed is obtained with lighting
switch ON and heater blower switch in 2 – 4 position.
If not, check “Electric load (+)” circuit and “Heater blower switch
signal” circuit referring to “ELECTRONIC CONTROL SYSTEM”
in this section and idle air control system.
5) Check that specified engine idle speed is obtained with A / C ON
if vehicle is equipped with A / C.
If not, check A / C ON signal circuit.

21
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-17
2) Connect engine coolant hoses (1).
3) Install throttle body (4) to intake manifold.
4) Connect coupler to TP sensor (2) and IAC valve (3) securely.
5) Install air cleaner outlet hose (1) and pipe.
6) Connect accelerator cable and adjust cable play to specifica-
tion.
7) Refill cooling system.
8) Connect negative cable at battery.
IDLE AIR CONTROL VALVE (IAC VALVE)
Removal
1) Remove throttle body from intake manifold referring to “Throttle
Body Removal” section.
2) Remove IAC valve from throttle body.
Inspection
1) Connect each connector to IAC valve (1), TP sensor and IAT
sensor.
2) Check that rotary valve (2) of lAC valve opens and closes once
and then stops in about 60 ms as soon as ignition switch is
turned ON.
NOTE:

This check should be performed by two people, one per-
son turns on ignition switch while the other checks valve
operation.

As valve operation is momentary, it may be overlooked.
To prevent this, perform this operation check 3 times or
more continuously.
If rotary valve of lAC valve does not operate at all, check
wire harness for open and short. If wire harness is in good
condition, replace lAC valve and recheck.

270 – 310 kPa
2.7 – 3.1 kg / cm2
38.4 – 44.0 psi
At specified
idle speed
With 1 min. after
engine (fuel pump)
stop (Pressure re-
duces as time passes)over 200 kPa
2.0 kg / cm
2
28.4 psi
CONDITION FUEL PRESSURE
With fuel pump
operating and
engine stopped
200 – 240 kPa
2.0 – 2.4 kPa
28.4 – 34.1 psi
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-19
5) Check fuel pressure as follows.
[Not using SUZUKI scan tool]
a) Turn ignition switch ON to operate fuel pump and after 2 seconds
turn it OFF. Repeat this 3 or 4 times and then check fuel pres-
sure.
b) Start engine and warm it up to normal operating temperature.
c) Measure fuel pressure at idling.
If measured pressure doesn’t satisfy specification, refer to
“Diagnostic Flow Table B-3” in “Engine Diagnosis” section and
check each possibly defective part. Replace if found defective.
d) After checking fuel pressure, remove fuel pressure gauge.
CAUTION:
As fuel feed line is still under high fuel pressure, make
sure to release fuel pressure according to following pro-
cedures.

Place fuel container under joint.

Cover joint with rag and loosen joint nut slowly to re-
lease fuel pressure gradually.
e) Remove special tools from fuel delivery pipe.
f) Connect fuel feed hose to fuel delivery pipe and clamp it secure-
ly.
g) With engine OFF and ignition switch ON, check for fuel leaks.

6E2-20 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
[Using SUZUKI scan tool]
a) Connect SUZUKI scan tool to DLC with ignition switch OFF.
b) Turn ignition switch ON and then select “DATA LIST” mode on
scan tool.
c) Make sure that vehicle condition is as following.

Vehicle speed = 0 KPH

Engine speed = 0 RPM

Fuel tank level
15%
d) Clear DTC by using “CLEAR INFO” mode.
e) Check fuel pressure by using “FUEL PUMP CONT” mode in
“MISC TEST” menu.
CONDITIONFUEL PRESSURE
With fuel pump operating
2.7 – 3.1 kg / cm2
270 – 310 kPa
38.4 – 44.0 psi
Within 1 min. after fuel pump
stop (Pressure reduces as
time passes)Over 2.0 kg / cm2
200 kPa
28.4 psi
If measured pressure doesn’t satisfy specification, refer to
“Diagnostic Flow Table B-3” and check each possibly defective
part. Replace if found defective.
f) Start engine and warm it up to normal operating temperature.
And then check fuel pressure.
CONDITIONFUEL PRESSURE
At specified idle speed
2.0 – 2.4 kg / cm2
200 – 240 kPa
28.4 – 34.1 psi
If measured pressure doesn’t satisfy specification, refer to
“Diagnostic Flow Table B-3” and check each possibly defective
part. Replace if found defective.
g) After checking fuel pressure, remove fuel pressure gauge.
CAUTION:
As fuel feed line is still under high fuel pressure, make
sure to release fuel pressure according to following pro-
cedures.

Place fuel container under joint.

Cover joint with rag and loosen joint nut slowly to re-
lease fuel pressure gradually.
h) Remove special tools from fuel delivery pipe.
i) Connect fuel feed hose to fuel delivery pipe and clamp it secure-
ly.
j) With engine OFF and ignition switch ON, check for fuel leaks.
Tightening Torque
Fuel pressure regulator bolt: 11 N
.m (1.1 kg-m, 8.0 lb-ft)

1. Fuel filler
2. Ignition switch
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-21
FUEL PUMP
On-Vehicle Inspection
CAUTION:
When fuel filler cap is removed in any procedure, work must
be done in a well-ventilated area, keep away from any open
flames and without smoking.
NOTE:
The fuel pressure regulator is the one body with the fuel pump
assembly so individual inspection of it is impossible.
1) Remove filler cap and turn ON ignition switch. Then fuel pump
operating sound should be heard from fuel filler for about 2 se-
conds and stop. Be sure to reinstall fuel filler cap after checking.
If above check result is not satisfactory, advance to “Diagnostic
Flow Table B-2”.
2) Turn OFF ignition switch and leave over 10 minutes as it is.
3) Fuel pressure should be felt at fuel return hose (1) for 2 seconds
after ignition switch ON.
If fuel pressure is not felt, advance to “Diagnostic Flow Table
B-3”.
Removal
Remove fuel tank from body according to procedure described in
Section 6C and remove fuel pump from fuel tank.
Inspection
Check fuel pump filter for evidence of dirt and contamination. If
present, clean and check for presence of dirt in fuel tank.
Installation
1) Install fuel pump to its bracket.
2) Install fuel pump to fuel tank and then install fuel tank to body ac-
cording to procedure described in Section 6C.

6E2-22 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
FUEL PRESSURE REGULATOR
Removal
1) Relieve fuel pressure according to procedure described in sec-
tion 6.
2) Disconnect battery negative cable at battery.
3) Disconnect vacuum hose (3) from fuel pressure regulator (1).
4) Disconnect fuel return hose (2) from fuel pressure regulator (1).
CAUTION:
A small amount of fuel may be released when hose is dis-
connected. Cover hose to be disconnected with a shop
cloth.
5) Remove fuel pressure regulator.
CAUTION:
A small amount of fuel may be released when it is from
delivery pipe.
Place a shop cloth under delivery pipe so that released
fuel is absorbed in it.
Installation
For installation, reverse removal procedure and note following pre-
cautions.

Use new O-ring.

Apply thin coat of spindle oil or gasoline to O-ring to facilitate
installation.

With engine OFF and ignition switch ON, check for fuel leaks
around fuel line connection.
Tightening Torque
Fuel pressure regulator bolt: 11 N
.m (1.1 kg-m, 8.0 lb-ft)