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

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.

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

HOSE CONNECTION
Clamp securely at a position 3 to
7mm (0.12–0.27 in.) from hose end. With short pipe, fit hose as far as it reaches pipe joint as
shown.
Hose
Pipe
ClampClamps securely at a position
3 to 7 mm (0.12–0.27 in.)
from hose end.
With following type pipe, fit hose as far as its peripheral
projection as shown.
Clamp securely at a position
3 to 7 mm (0.12–0.27 in.)
from hose end.
With bent pipe, fit hose as its bent part as shown or till pipe
is about 20 to 30 mm (0.79–1.18 in.) into the hose.
Clamp securely at a
position 3 to 7 mm
(0.12–0.27 in.) from hose
end.
With straight pipe, fit hose till pipe is, about 20 to 30 mm
(0.79–1.18 in.) into the hose.
Hose
20 to 30 mm
(0.79–1.18 in.)
Clamp
6-1-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
PRECAUTION ON FUEL SYSTEM SERVICE

Work must be done with no smoking, in a well-ventilated area and
away from any open flames.

As fuel feed line (between fuel pump and fuel delivery pipe) is still
under high fuel pressure even after engine was stopped, loosen-
ing or disconnecting fuel feed line directly may cause dangerous
spout of fuel to occur where loosened or disconnected.
Before loosening or disconnecting fuel feed line, make sure to re-
lease fuel pressure according to “FUEL PRESSURE RELIEF
PROCEDURE”. A small amount of fuel may be released after the
fuel line is disconnected. In order to reduce the chance of person-
al injury, cover the fitting to be disconnected with a shop cloth. Put
that cloth in an approved container when disconnection is com-
pleted.

Never run engine with fuel pump relay disconnected when engine
and exhaust system are hot.

Fuel or fuel vapor hose connection varies with each type of pipe.
When reconnecting fuel or fuel vapor hose, be sure to connect
and clamp each hose correctly referring to left figure Hose Con-
nection.
After connecting, make sure that it has no twist or kink.

When installing injector or fuel delivery pipe, lubricate its O-ring
with spindle oil or gasoline.

When connecting fuel pipe flare nut, first tighten flare nut by hand
and then tighten it to specified torque.

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.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-19
Operation
VISUAL INSPECTION
Visually check following parts and systems.
INSPECTION ITEM
REFERRING SECTION

Engine oil ––––– level, leakage

Engine coolant ––––– level, leakage

Fuel ––––– level, leakage

A / T fluid ––––– level, leakage

Air cleaner element ––––– dirt, clogging

Battery ––––– fluid level, corrosion of terminal

Water pump belt ––––– tension, damage

Throttle cable ––––– play, installation

Vacuum hoses of air intake system ––––– disconnection,
looseness, deterioration, bend

Connectors of electric wire harness ––––– disconnection, friction

Fuses ––––– burning

Parts ––––– installation, bolt ––––– looseness

Parts ––––– deformation

Other parts that can be checked visually
Also check following items at engine start, if possible

Malfunction indicator lamp

Charge warning lamp

Engine oil pressure warning lamp

Engine coolant temp. meter

Fuel level meter

Tachometer, if equipped

Abnormal air being inhaled from air intake system

Exhaust system ––––– leakage of exhaust gas, noise

Other parts that can be checked visuallySection 0B
Section 0B
Section 0B
Section 0B
Section 0B
Section 0B
Section 6E2
Section 8
Section 6
Section 6H
Section 8 (Section 6 for pressure check)
Section 8
Section 8

6-1-20 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
ENGINE BASIC INSPECTION
This check is very important for troubleshooting when ECM (PCM) has detected no DTC and no abnormality has
been found in visual inspection.
Follow the flow table carefully.
STEP
ACTIONYESNO
1Was “ENGINE DIAG. FLOW TABLE” performed?Go to Step 2.Go to “ENGINE DIAG.
FLOW TABLE”.
2Check battery voltage.
Is it 11 V or more?Go to Step 3.Charge or replace
battery.
3Is engine cranked?Go to Step 4.Go to “DIAGNOSIS”
in Section 6G.
4Does engine start?Go to Step 5.Go to Step 7.
5Check idle speed as follows:
1) Warm up engine to normal operating temp.
2) Shift transmission to neutral position for M / T
(“P” position for A / T).
3) All of electrical loads are switched off.
4) Check engine idle speed with scan tool.
See Fig. 1.
Is it 700 – 800 r / min?Go to Step 6.“ENGINE DIAGNO-
SIS TABLE” in this
section.
6Check ignition timing as follows:
1) Using SUZUKI scan tool, select “MISC” mode on
SUZUKI scan tool and fix ignition timing to initial
one. See Fig. 2.
2) Remove air cleaner bolt and shift air cleaner
position to observe ignition timing.
3) Using timing light (1), check initial ignition timing.
See Fig. 3.
Is it 5 ± 3 BTDC at specified idle speed?“ENGINE DIAGNO-
SIS TABLE” in this
section.Check ignition control
related parts referring
to Section 6F1.
7Check fuel supply as follows:
1) Check to make sure that enough fuel is filled in fuel
tank.
2) Turn ON ignition switch for 2 seconds and then
OFF. See Fig. 4.
Is fuel return pressure (returning sounds) felt from fuel
feed hose (1) when ignition switch is turned ON?Go to Step 9.Go to Step 8.
8Check fuel pump for operating.
1) Was fuel pump operating sound heard from fuel
filler for about 2 seconds after ignition switch ON
and stop?Go to “DIAG. FLOW
TABLE B-3”.Go to “DIAG. FLOW
TABLE B-2”.
9Check ignition spark as follows:
1) Disconnect injector couplers.
2) Remove spark plugs and connect them to high
tension cords.
3) Ground spark plugs.
4) Crank engine and check if each spark plug sparks.
Is it in good condition?Go to Step 10.Go to “DIAGNOSIS”
in Section 6F1.
10Check fuel injector for operation as follows:
1) Install spark plugs and connect injector
connectors.
2) Using sound scope (1), check operating sound of
each injector (2) when cranking engine. See Fig. 5.
Was injector operating sound heard from all
injectors?“ENGINE DIAGNO-
SIS TABLE” in this
section.Go to “DIAG. FLOW
TABLE B-1”.

6-1-22 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
ENGINE DIAGNOSIS TABLE
Perform troubleshooting referring to following table when ECM (PCM) has detected no DTC and no abnormality
has been found in visual inspection and engine basic inspection previously.
Condition
Possible CauseReferring Item
Hard Starting
(Engine cranks OK)Ignition system out of order

Faulty spark plug

Leaky high-tension cord

Loose connection or disconnection of high-
tension cords or lead wires

Faulty ignition coil
Fuel system out of order

Dirty or clogged fuel hose or pipe

Malfunctioning fuel pump

Air inhaling from intake manifold gasket or
throttle body gasket
Engine and emission control system out of
order

Faulty idle air control system

Faulty ECT sensor or MAP sensor

Faulty ECM (PCM)
Low compression

Poor spark plug tightening or faulty gasket

Compression leak from valve seat

Sticky valve stem

Weak or damaged valve springs

Compression leak at cylinder head gasket

Sticking or damaged piston ring

Worn piston, ring or cylinder
Others

Malfunctioning PCV valve
Spark plugs in Section 6F1
High-tension cords in Section 6F1
High-tension cords in Section 6F1
Ignition coil in Section 6F1
Diagnostic Flow Table B-3
Diagnostic Flow Table B-3
Diagnostic Flow Table B-4
ECT sensor or MAP sensor in
Section 6E2
Compression check in Section
6A1
Spark plugs in Section 6F1
Valves inspection in Section 6A1
Valves inspection in Section 6A1
Valve springs inspection in
Section 6A1
Cylinder head inspection in
Section 6A1
Cylinders, pistons and piston rings
inspection in Section 6A1
Cylinders, pistons and piston rings
inspection in Section 6A1
PCV system in Section 6E2

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-23
ConditionPossible Cause]Referring Item
Low oil pressure
Improper oil viscosity

Malfunctioning oil pressure switch

Clogged oil strainer

Functional deterioration of oil pump

Worn oil pump relief valve

Excessive clearance in various sliding partsEngine oil and oil filter change in
Section 0B
Oil pressure switch inspection in
Section 8
Oil pan and oil pump strainer
cleaning in Section 6A1
Oil pump in Section 6A1
Oil pump in Section 6A1
Engine noise
Note: Before
checking mechanical
noise, make sure
that:

Specified spark
plug in used.

Specified fuel is
used.Valve noise

Improper valve lash

Worn valve stem and guide

Weak or broken valve spring

Warped or bent valve
Piston, ring and cylinder noise

Worn piston, ring and cylinder bore
Connecting rod noise

Worn rod bearing

Worn crank pin

Loose connecting rod nuts

Low oil pressure
Crankshaft noise

Low oil pressure

Worn bearing

Worn crankshaft journal

Loose bearing cap bolts

Excessive crankshaft thrust play
Valve lash in Section 6A1
Valves inspection in Section 6A1
Valve springs inspection in
Section 6A1
Valves inspection in Section 6A1
Pistons and cylinders inspection
in Section 6A1
Crank pin and connecting rod
bearing inspection in Section 6A1
Crank pin and connecting rod
bearing inspection in Section 6A1
Connecting rod installation in
Section 6A1
Previously outlined
Previously outlined
Crankshaft and bearing
inspection in Section 6A1
Crankshaft and bearing
inspection in Section 6A1
Crankshaft inspection in
Section 6A1
Crankshaft thrust play inspection
in Section 6A1

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

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-25
ConditionPossible CauseReferring Item
Engine hesitates
(Momentary lack of
response as
accelerator is
depressed.
Can occur at all
vehicle speeds.
Usually most severe
when first trying to
make vehicle move,
as from a stop sign.)Ignition system out of order

Spark plug faulty or plug gap out of adjustment

Leaky high-tension cord
Fuel system out of order

Fuel pressure out of specification
Engine and emission control system out of
order

Malfunctioning EGR valve

Poor performance of TP sensor, ECT sensor or
MAP sensor

Faulty fuel injector

Faulty ECM (PCM)
Engine overheating
Low compression
Spark plugs in Section 6F1
High-tension cords in Section 6F1
Diagnostic Flow Table B-3
EGR system in section 6E2
TP sensor, ECT sensor or MAP
sensor in Section 6E2
Diagnostic Flow Table B-1
Refer to “Overheating” section
Previously outlined
Surge
(Engine power
variation under
steady throttle or
cruise.
Feels like vehicle
speeds up and down
with no change in
accelerator pedal.)Ignition system out of order

Leaky or loosely connected high-tension cord

Faulty spark plug (excess carbon deposits,
improper gap, and burned electrodes, etc.)
Fuel system out of order

Variable fuel pressure
–Kinky or damaged fuel hose and lines
–Faulty fuel pump (clogged fuel filter)
Engine and emission control system out of
order

Malfunctioning EGR valve

Poor performance of MAP sensor

Faulty fuel injector

Faulty ECM (PCM)
High-tension cords in Section 6F1
Spark plugs in Section 6F1
Diagnostic Flow Table B-3
EGR system in Section 6E2
MAP sensor in Section 6E2
Diagnostic Flow Table B-1
Excessive
detonation
(Engine makes
continuously
sharp metallic
knocks that change
with throttle opening.
Sounds like pop corn
popping.)Engine overheating
Ignition system out of order

Faulty spark plug

Loose connection of high-tension cord
Fuel system out of order

Clogged fuel filter (faulty fuel pump) or fuel lines

Air inhaling from intake manifold or throttle body
gasket
Engine and emission control system out of
order

Malfunctioning EGR valve

Poor performance of ECT sensor or MAP sensor

Faulty fuel injector(s).

Faulty ECM (PCM)

Excessive combustion chamber depositsRefer to “Overheating” section
Spark plugs in Section 6F1
High-tension cords in Section 6F1
Diagnostic Flow Table B-1 or B-2
EGR system in Section 6E2
ECT sensor or MAP sensor in
Section 6E2
Diagnostic Flow Table B-1
Piston and cylinder head cleaning
in Section 6A1