camshaft SUZUKI SWIFT 2000 1.G SF310 Service User Guide

6-1-16 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
DTC
NO.DETECTING ITEMDETECTING CONDITION
(DTC will set when detecting:)MIL
P0335Crankshaft position sensor
circuit malfunctionNo signal for 2 sec. During engine cranking1 driving
cycle
P0340Camshaft position sensor circuit
malfunctionNo signal during engine running1 driving
cycle
P0400Exhaust gas recirculation
flow malfunction detectedExcessive or insufficient EGR flow2 driving
cycles
P0420Catalyst system efficiency below
threshold
Output waveforms of HO2S-1 and HO2S-2 are
similar.
(Time from output voltage change of HO2S-1 to that
of HO2S-2 is shorter than specification.)
2 driving
cycles
P0443Purge control valve circuit
malfunctionPurge control valve circuit is open or shorted to
ground2 driving
cycles
P0480Radiator fan control circuit
malfunctionRadiator cooling fan relay terminal voltage is low
when cooling temp. is lower than specification2 driving
cycles
P0500Vehicle speed sensor
malfunctionNo signal while running in “D” range or during fuel cut
at decelerating2 driving
cycles
P0505Idle control system malfunctionNo closed signal to IAC valve is detected2 driving
cycles
P0601Internal control module memory
check sum errorData write error (or check sum error) when written
into ECM (PCM)1 driving
cycle
P1450Barometric pressure sensor
circuit malfunctionBarometric pressure is lower or higher than
specification. (or sensor malfunction)1 driving
cycle
P1451Barometric pressure sensor
performance problem
Difference between manifold absolute pressure
(MAP sensor value) and barometric pressure
(barometric pressure sensor value) is larger than
specification during cranking.
2 driving
cycles
P1500Starter signal circuit malfunctionStarter signal is not inputted from engine cranking till
its start and after or it is always inputted2 driving
cycles
P1510ECM (PCM) backup power
source malfunctionNo backup power after starting engine1 driving
cycle

6-1-18 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
FAIL-SAFE TABLE
When any of the following DTCs is detected, ECM (PCM) enters fail-safe mode as long as malfunction continues
to exist but that mode is canceled when ECM (PCM) detects normal condition after that.
DTC NO.
DETECTED ITEMFAIL-SAFE OPERATION
P0105Manifold absolute pressure circuit
malfunction

ECM (PCM) uses value determined by throttle
opening and engine speed.

ECM (PCM) stops EGR, EVAP purge and idle air
control.
P0110Intake air temp. circuit malfunctionECM (PCM) controls actuators assuming that
intake air temperature is 20C (68F).
P0115Engine coolant temp. circuit malfunctionECM (PCM) controls actuators assuming that
engine coolant temperature is 80C (176F).
P0120Throttle position circuit malfunctionECM (PCM) controls actuators assuming that
throttle opening is 20.
P0340Camshaft position sensor circuit
malfunctionECM (PCM) controls injection system sequential
injection to synchronous injection.
P0500Vehicle speed sensor malfunctionECM (PCM) stops idle air control.
P1450Barometric pressure sensor low /
high inputECM (PCM) controls actuators assuming that
barometric pressure is 100 kPa (760 mmHg).

6-1-24 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
ConditionPossible CauseReferring Item
Overheating
Inoperative thermostat

Poor water pump performance

Clogged or leaky radiator

Improper engine oil grade

Clogged oil filter or oil strainer

Poor oil pump performance

Faulty radiator fan control system

Dragging brakes

Slipping clutch

Blown cylinder head gasketThermostat in Section 6B
Water pump in Section 6B
Radiator in Section 6B
Engine oil and oil filter change in
Section 0B
Oil pressure check in Section 6A1
Oil pressure check in Section 6A1
Radiator fan control system in
Section 6E2
Trouble diagnosis in Section 5
Trouble diagnosis in Section 7C
Cylinder head in Section 6A1
Poor gasoline
mileageIgnition system out of order

Leaks or loose connection of high-tension cord

Faulty spark plug (improper gap, heavy deposits
and burned electrodes, etc.)
Engine and emission control system out of
order

Malfunctioning EGR valve

High idle speed

Poor performance of TP sensor, ECT sensor or
MAP sensor

Faulty EGR valve

Faulty fuel injector(s)

Faulty ECM (PCM)
Low compression
Others

Poor valve seating

Dragging brakes

Slipping clutch

Thermostat out of order

Improper tire pressure
High-tension cords in Section 6F1
Spark plugs in Section 6F1
EGR system in Section 6E2
Refer to item “Improper engine
idle speed” previously outlined
TP sensor, ECT sensor or MAP
sensor in Section 6E2
EGR system in Section 6E2
Diagnostic Flow Table B-1
Previously outlined
Valves inspection in Section 6A1
Trouble diagnosis in Section 5
Trouble diagnosis in Section 7C
Thermostat in Section 6B
Refer to Section 3F
Excessive engine
oil consumptionOil leakage

Blown cylinder head gasket

Leaky camshaft oil seals
Oil entering combustion chamber

Sticky piston ring

Worn piston and cylinder

Worn piston ring groove and ring

Improper location of piston ring gap

Worn or damaged valve stem seal

Worn valve stem
Cylinder head in Section 6A1
Camshaft in Section 6A1
Piston cleaning in Section 6A1
Pistons and cylinders inspection
in Section 6A1
Pistons inspection in Section 6A1
Pistons assembly in Section 6A1
Valves removal and installation in
Section 6A1
Valves inspection in Section 6A1

6-1-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
CONNECTOR “C01”
TERMINAL
NO.CIRCUITNORMAL
VOLTAGECONDITION
1Ground——
2Ground——
3Ground——
4EVAP canister purge valve10 – 14 VIgnition switch ON
Indication
deflection
5Power steering switch
deflection
repeated
0 V and
Ignition switch ON
0 V and
10 – 14 V
6Idle air control valve0 – 13 VAt specified idle speed after engine warmed
up
7Heater of HO2S-110 – 14 VIgnition switch ON
8Fuel injector NO.410 – 14 VIgnition switch ON
9Fuel injector NO.110 – 14 VIgnition switch ON
10Sensor ground——
11Camshaft position sensor0 – 0.8 V
and 4 – 6 VIgnition switch ON
12Blank——
13Heater oxygen sensor-1Refer to DTC P0130 diag. flow table
14Engine coolant temp. sensor0.55 – 0.95 VIgnition switch ON
Engine coolant temp.: 80C (176F)
15Intake air temp. sensor2.0 – 2.7 VIgnition switch ON
Intake air temp.: 20C (68F)
16Blank——
17Electric load signal (+)
0 – 1 VIgnition switch ON
Small light and rear defogger OFF
17Electric load signal (+)
10 – 14 VIgnition switch ON
Small light and rear defogger ON
18Blank——
19Ignition coil #2——
20Ignition coil #1——
21Fuel injector NO.210 – 14 VIgnition switch ON
22Power source for sensor4.75 – 5.25 VIgnition switch ON
23Crankshaft position sensor (+)——
24Crankshaft position sensor (–)——
25Blank——
26Manifold absolute pressure
sensor3.3 – 4.0 VIgnition switch ON
Barometric pressure: 100 kPa (760 mmHg)
27Blank——
28Immobilizer indicator lamp0 – 2 VIgnition switch ON28Immobilizer indicator lamp10 – 14 VWhen engine running
29Blank——
30Blank——
31Fuel injector NO.310 – 14 VIgnition switch ON

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-69
Ignition coil assembly
for No.1 & No.4 spark plugs
Ignition coil assembly
for No.2 & No.3 spark plugs
Ignition switch
Main relay
Main
fuseRelay box
To ignition switch
CKP sensorCMP sensorNo.1 injector
No.2 injector
No.3 injector
No.4 injector Fuse box
DTC P0300 RANDOM MISFIRE DETECTED (Misfire detected at 2 or more
cylinders)
DTC P0301 CYLINDER 1 MISFIRE DETECTED
DTC P0302 CYLINDER 2 MISFIRE DETECTED
DTC P0303 CYLINDER 3 MISFIRE DETECTED
DTC P0304 CYLINDER 4 MISFIRE DETECTED
CIRCUIT DESCRIPTION
ECM (PCM) monitors crankshaft revolution speed and engine speed via the crankshaft position sensor and cylin-
der No. via the camshaft position sensor. Then it calculates the change in the crankshaft revolution speed and from
how many times such change occurred in every 200 or 1000 engine revolutions, it detects occurrence of misfire.
When ECM (PCM) detects a misfire (misfire rate per 200 revolutions) which can cause overheat and damage to
the three way catalytic converter, it makes the malfunction indicator lamp (MIL) flash as long as misfire occurs at
that rate.
After that, however, when the misfire rate drops, MIL remains ON until it has been judged as normal 3 times under
the same driving conditions.
Also, when ECM (PCM) detects a misfire (misfire rate per 1000 revolutions) which will not cause damage to three
way catalytic converter but can cause exhaust emission to be deteriorated, it makes MIL light according to the 2
driving cycle detection logic.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-75
To ignition
switch
Signal rotor
on CamshaftCamshaft
position
sensor
Waveforms at specified idle speed
Oscilloscope Waveforms
2 V / Div.
Crank
angle20 ms / Div.
180
720
DTC P0340 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT
MALFUNCTION
CIRCUIT DESCRIPTION
DTC DETECTING CONDITIONPOSSIBLE CAUSE

No CMP sensor signal during engine running
(CKP sensor signal is inputted).
CMP sensor circuit open or short.

Signal rotor teeth damaged.

CMP sensor malfunction, foreign material being
attached or improper installation.

ECM (PCM) malfunction.
Reference
Connect oscilloscope between terminals C01-11 of ECM (PCM) connector connected to ECM (PCM) and body
ground and check CKP sensor signal.
DTC CONFIRMATION PROCEDURE
1) Clear DTC.
2) Start engine and keep it at idle for 1 min.
3) Select “DTC” mode on scan tool and check DTC.

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Timing belt
2. Tensioner
3. Tensioner plate
4. Tensioner spring
5. Spring damper
6. Camshaft timing pulley
7. Pin
8. Pulley bolt
9. Seal
10. Inside cover seal
11. Inside cover
12. Outside cover seal
13. Outside cover
14. Tensioner stud
15. Tensioner bolt
16. Tensioner spring screw
: Tightening Torque
6A-10 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
TIMING BELT AND BELT TENSIONER
REMOVAL
1) Disconnect negative cable at battery.
2) Hoist vehicle.
3) Remove clip (2) after pushing center pin, and then remove fend-
er apron extension (1) on right side.
NOTE:
Do not push center pin (3) too far in, or it will fall off into
fender.
4) Remove air cleaner assembly as previously outlined.
5) Remove A / C compressor drive belt, if equipped.
6) Loosen water pump pulley bolts (1).
7) Loosen generator pivot bolts (3) and its adjusting bolt (2) and re-
move water pump belt (4) and its pulley (5).

1.“V” mark on cylinder head cover
2. Timing mark on camshaft timing belt pulley
3. Arrow mark on oil pump case
4. Punch mark on crankshaft timing belt pulley
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-11
8) Loosen crankshaft pulley bolts (1) and remove crankshaft
pulley (2).
9) Remove timing belt outside cover (1).
10) Align 4 timing marks as shown in figure to facilitate its installa-
tion.
11) Loosen tensioner bolt (3) and stud (4), and remove belt (1) from
crankshaft timing belt pulley and camshaft timing belt pulley af-
ter pushing up the tensioner plate (2) fully by finger as shown
figure.
CAUTION:
Never bend timing belt.

6A-12 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
1. Camshaft allowable turning range – – – By timing
mark, within 90 from “V” mark on head cover on
both right and left.
2. Crankshaft allowable turning range – – – by punch
mark, within 90 from arrow mark on oil pump case
on both right and left.
CAUTION:
After timing belt is removed, never turn camshaft and crank-
shaft independently more than such an extent as shown be-
low. If turned, interference may occur among piston and
valves, and parts related to piston and valves may be dam-
aged.
12) Remove tensioner, tensioner plate, tensioner spring and
spring damper.
INSPECTION

Check timing belt for wear or crack. Replace it as necessary.

Check tensioner for smooth rotation and rattle.
INSTALLATION
1) Install tensioner plate (1) to tensioner (2).
Insert lug (3) of tensioner plate into hole (4) of tensioner.
2) Install tensioner (2) and tensioner plate (3).
Do not tighten the tensioner bolt (1) and stud by wrench yet.
Hand tighten only at this time.
Check to ensure that plate movement in arrow direction as
shown in figure causes tensioner to move in the same direction.
If no associated movement between plate and tensioner occurs,
remove tensioner and plate again and reinsert the plate lug into
tensioner hole.