fan SUZUKI SWIFT 2000 1.G SF310 Service Owner's Manual

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-35
CONNECTOR “C02”
TERMINAL
NO.CIRCUITNORMAL
VOLTAGECONDITION
1A / C ON output signal0 VIgnition switch ON
2EGR valve (stepper motor10 – 14 VIgnition switch ON2coil 1)0 – 1 VEngine running at idle speed
3Data link connector10 – 14 VIgnition switch ON
4Heater of HO2S-210 – 14 VIgnition switch ON
5Power source10 – 14 VIgnition switch ON
6Power source10 – 14 VIgnition switch ON
7Power source for buck-up10 – 14 VIgnition switch ON and OFF
8EGR valve (stepper motor10 – 14 VIgnition switch ON8coil 3)10 – 14 VEngine running at idle speed
9EGR valve (stepper motor10 – 14 VIgnition switch ON9coil 2)10 – 14 VEngine running at idle speed
10Main relay10 – 14 VIgnition switch OFF10Main relay0.4 – 1.5 VIgnition switch ON
112-range signal (A / T)10 – 14 VIgnition switch ON, Select lever at 2-range
12N-range signal (A / T)10 – 14 VIgnition switch ON, Select lever at N-range
13Heated oxygen sensor-2Refer to DTC P0130 diag. flow table
14D-range signal (A / T)10 – 14 VIgnition switch ON, Select lever at D-range
15R-range signal (A / T)10 – 14 VIgnition switch ON, Select lever at R-range
16A/C input signal
10 – 14 VIgnition switch ON
A / C switch OFF
16A/C in ut signal
0 – 2 VIgnition switch ON
A / C switch ON
17EGR valve (stepper motor10 – 14 VIgnition switch ON17coil 4)0 – 1 VEngine running at idle speed
18Radiator fan control relay
10 – 14 V
Ignition switch ON
Engine coolant temp.: Below 92.5C
(199F)
18Radiator fan control relay
0 – 1 V
Ignition switch ON
Engine coolant temp.: Below 97.5C
(208F) or higher
19Fuelpumprelay0 – 1 VFor 2 seconds after ignition switch ON19Fuel um relay10 – 14 VAfter the above time
20Blank——
21P-range signal (A / T)
Indication
deflection
repeated
0 V and
10 – 14 V
Ignition switch ON
22Fuel level sensor (gauge)
0 – 2 VIgnition switch ON
Fuel tank fully filled
22Fuel level sensor (gauge)
4.5 – 7.5 VIgnition switch ON
Fuel tank emptied
23L-range signal (A / T)10 – 14 VIgnition switch ON, Select lever at L-range
24Blank——

1 2
1. ECM (PCM) coupler disconnected
2. Ohmmeter
ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-37
Resistance Check
1) Disconnect ECM (PCM) couplers from ECM (PCM) with ignition
switch OFF.
CAUTION:
Never touch terminals of ECM (PCM) itself or connect
voltmeter or ohmmeter.
2) Check resistance between each terminal of couplers discon-
nected.
CAUTION:

Be sure to connect ohmmeter probe from wire harness
side of coupler.

Be sure to turn OFF ignition switch for this check.

Resistance in table below represents that when parts
temperature is 20C (68F).
TERMINALSCIRCUITSTANDARD RESISTANCE
C01-7 to C03-6HO2S-1 heater11.7 – 15.6 Ω
C02-4 to C03-6HO2S-2 heater11.7 – 15.6 Ω
C01-9 to C02-5 / 6No.1 injector12.0 – 13.0 Ω
C01-21 to C02-5 / 6No.2 injector12.0 – 13.0 Ω
C01-31 to C02-5 / 6No.3 injector12.0 – 13.0 Ω
C01-8 to C02-5 / 6No.4 injector12.0 – 13.0 Ω
C02-2 to C02-5 / 6EGR valve (stepper motor coil 4)20 – 24 Ω
C02-9 to C02-5 / 6EGR valve (stepper motor coil 3)20 – 24 Ω
C02-8 to C02-5 / 6EGR valve (stepper motor coil 2)20 – 24 Ω
C02-17 to C02-5 / 6EGR valve (stepper motor coil 1)20 – 24 Ω
C01-4 to C02-5 / 6EVAP canister purge valve30 – 34 Ω
C02-19 to C03-6Fuel pump relay70 – 110 Ω
C02-1 to Body groundA / C control moduleNo continuity
C02-18 to C02-5 / 6Radiator fan control relay70 – 110 Ω
C02-10 to C02-7Main relay70 – 110 Ω
C01-1 to Body groundGroundContinuity
C01-2 to Body groundGroundContinuity
C01-3 to Body groundGroundContinuity

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
6-1-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
COMPONENT LOCATION

Radiator cooling fan relay
To
ECM
Main
relay
Relay
box
“RDTR”
(Radiator fan)Radiator cooling
Fan motor
ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-85
DTC P0480 RADIATOR COOLING FAN CONTROL SYSTEM MALFUNCTION
CIRCUIT DESCRIPTION
DTC DETECTING CONDITIONPOSSIBLE CAUSE

Low voltage at terminal C02-18 when engine coolant
temp. is 92C, 197F below.
2 driving cycle detection logic, continuous monitoring.
“B/W” or “P/G” circuit open or short

Radiator cooling fan relay malfunction

ECM (PCM) malfunction
DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF.
2) Clear DTC with ignition switch ON.
3) Warm up engine until radiator cooling fan starts to operate.
4) Check pending DTC in “ON BOARD TEST” or “PENDING DTC” mode and DTC in “DTC” mode.

6-1-86 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
Fig. 1 for Step 2 Fig. 2 for Step 3 Fig. 3 for Step 3
INSPECTION
STEPACTIONYESNO
1Was “ENGINE DIAG. FLOW TABLE” performed?Go to Step 2.Go to “ENGINE DIAG.
FLOW TABLE”.
2Check Radiator Cooling Fan Relay and Its Circuit.
1) Turn ignition switch ON.
2) Check for voltage at terminal C02-18 of ECM
(PCM) connector connected, under following
condition. See Fig. 1.
When engine coolant temp. is lower than
92C, 197F and A / C switch turns OFF:
10 – 14 V
Is voltage as specified?Intermittent trouble or
faulty ECM (PCM).
Check for intermittent
referring to “Intermittent
and Poor Connection”
in Section 0A.Go to Step 3.
3Check Radiator Cooling Fan Control Relay.
1) Turn ignition switch OFF and remove radiator
cooling fan relay.
2) Check for proper connection to the relay at
“B/W” and “P/G” wire terminals.
3) If OK, then measure resistance between
terminals a and b. See Fig. 2 and 3.
Is it 100 – 150 Ω?“B/W” or “P/G” circuit
open or short.
If wires and connections
are OK, substitute a
known-good ECM
(PCM) and recheck.Replace radiator
cooling fan relay.

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.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-107
Fig. 1 for Step 1 Fig. 2 for Step 3
Fig. 3 for Step 4When using SUZUKI scan tool:
1. Radiator cooling fan relay
1. Battery
2. Radiator fan motor coupler

6A-24 ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE)
UNIT REPAIR OVERHAUL
ENGINE ASSEMBLY
REMOVAL
1) Relieve fuel pressure according to procedure described in
“FUEL PRESSURE RELIEF PROCEDURE” of Section 6.
2) Remove engine hood after disconnecting front window washer
hose.
3) Disconnect battery cables at battery and remove battery and
its tray.
4) Drain cooling system.
5) Remove air cleaner assembly.
6) Remove radiator with cooling fan. Refer to Section 6B for re-
moval.
7) Disconnect the following electric wire harness.

High-tension cord from ignition coil

Distributor

EGR valve

ECT sensor

ISC actuator

Ground wire harness from intake manifold

TP sensor

Fuel injector

Oil pressure gauge

A / C compressor pressure switch (if equipped)

Heated oxygen sensor

Generator

Starter

Back-up light switch (For M / T model)

Battery negative cable from transmission

Shift switch of A / T (For A / T model)

Direct clutch and 2nd brake solenoids of A / T (For A / T model)

Vehicle speed sensor on A / T (For A / T model)
And release above wire harness from clamps.
8) Disconnect the following vacuum hose.

Brake booster hose from intake manifold.

Canister purge hose from EVAP canister purge valve.

Pressure sensor hose from intake manifold.
9) Disconnect fuel return hose and fuel feed hose from fuel feed
and return pipes.
10) Disconnect heater inlet and outlet hoses.

1
2
6A1-64 ENGINE MECHANICAL (G13B, 1-CAM 16-VALVES ENGINE)
UNIT REPAIR OVERHAUL
ENGINE ASSEMBLY
REMOVAL
1) Release fuel pressure in fuel feed line by referring to Section
6.
2) Remove battery.
3) Remove engine hood after disconnecting windshield washer
hose.
4) Drain cooling system.
WARNING:
To help avoid danger of being burned, do not remove
drain plug (2) and radiator cap while engine and radiator
(1) are still hot. Scalding fluid and steam can be blown
out under pressure if plug and cap are taken off too
soon.
5) Disconnect coupler of cooling fan motor.
6) Disconnect radiator inlet hose from thermostat case.
7) Disconnect A / T fluid hoses from A / T fluid pipes (for A / T mod-
el)
8) Remove outlet hose from water inlet pipe and radiator.
9) Remove radiator referring to Section 6B.
10) Remove air cleaner case and air cleaner outlet hose as pre-
viously outlined.
11) Disconnect the following cables.

Accelerator cable (1) from throttle body.

A / T throttle pressure control cable from A / T.

Clutch cable from transmission (M / T).

Gear select cable from transmission (A / T).

Speedometer cable