ECU SUZUKI SWIFT 2000 1.G SF310 Service Service Manual

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-23
1. Viewed from terminal side
1. Exhaust manifold
2. Heated oxygen sensor
Sensor-1
Sensor-2
HEATED OXYGEN SENSOR (SENSOR-1 AND
SENSOR-2)
OXYGEN SENSOR HEATER INSPECTION
1) Disconnect sensor coupler.
2) Using ohmmeter, measure resistance between terminals “V
B”
and “GND” of sensor coupler.
NOTE:
Temperature of sensor affects resistance value largely.
Make sure that sensor heater is at correct temperature.
Resistance of oxygen sensor heater:
11.7 – 14.3 Ω at 20C, 68F
If found faulty, replace oxygen sensor.
3) Connect sensor coupler securely.
REMOVAL
WARNING:
To avoid danger of being burned, do not touch exhaust system
when system is hot. Oxygen sensor removal should be per-
formed when system is cool.
1) Disconnect negative cable from battery.
2) Hoist vehicle when removing sensor-2.
3) Disconnect coupler of heated oxygen sensor and release its
wire harness from clamps.
4) Remove heated oxygen sensor from exhaust manifold.
INSTALLATION
Reverse removal procedure noting the following.

Tighten heated oxygen sensor to specified torque.
Tightening Torque for heated oxygen sensor
45 N
.m (4.5 kg-m, 32.5 lb-ft)

Connect coupler of heated oxygen sensor and clamp wire har-
ness securely.

After installing heated oxygen sensor, start engine and check that
no exhaust gas leakage exists.

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-25
1. Main relay
2. Relay box
CRANKSHAFT POSITION SENSOR
INSPECTION
Check crankshaft position sensor referring to step 1 and 2 of DTC
P0335 Flow Chart. If malfunction is found, replace.
REMOVAL
1) Hoist vehicle.
2) Remove fender apron extension on right side.
3) Disconnect connector from crankshaft position sensor.
4) Remove crankshaft position sensor from oil pan.
INSTALLATION
1) Check to make sure that crankshaft position sensor and pulley
tooth is free from any metal particles and damage.
2) Install crankshaft position sensor to oil pan.
3) Connect connector to it securely.
4) Install fender apron extension.
MAIN RELAY
INSPECTION
1) Disconnect negative cable at battery.
2) Remove main relay from relay box.
3) Check resistance between each two terminals as in table below.
If check results are as specified, proceed to next operation
check. If not, replace.
TERMINALS
RESISTANCE
Between A and B∞ (infinity)
Between C and D100 – 120 Ω
4) Check that there is continuity between terminals “A” and “B”
when battery is connected to terminals “C” and “D”.
If found defective, replace.

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-29
1. ISC actuator relay
2. Relay box
1. EFE heater
2. Rubber cover
3.“Red” wire
4.“Black” wire
ISC ACTUATOR RELAY
INSPECTION
1) Disconnect negative cable at battery.
2) Remove ISC actuator relay from relay box.
3) Structure of ISC actuator relay is the same as that of main relay.
Check its resistance and operation using the same procedure as
that for main relay.
EFE HEATER CONTROL SYSTEM
SYSTEM CIRCUIT INSPECTION
NOTE:
Before inspection, check to make sure that gear shift lever is
in neutral position (with A/T model, selector lever in “P” range)
and that parking brake lever is pulled all the way up.
1) Turn up rubber cover of EFE heater to expose terminal-to-wire
connections.
2) Connect voltmeter to EFE terminals and check for voltage under
each condition given below.
CONDITION
VOLTAGE
Fast idle condition
Coolant temp.: below 80C (176F)
Engine speed: over 750 r/min.Battery
voltage
After warming up (other than above)No voltage
If check results are not as specified in above table, check EFE
heater, relay and wire harness.
3) Cover EFE heater connections with rubber cover.
EFE HEATER
CAUTION:
Do not bend wire harness of EFE heater excessively.
ON-VEHICLE INSPECTION
1) Disconnect EFE heater coupler.
2) Check resistance of EFE heater.
If it is not as specified below, replace.
EFE heater resistance: 0.5 – 3.0 Ω at 20C (68F)
3) Connect EFE heater coupler securely.
REMOVAL
1) Remove throttle body according to procedure described pre-
viously.
In this case, however, it is not necessary to disconnect fuel
hoses and engine cooling water hoses from throttle body.
2) Disconnect EFE heater coupler.
3) Remove EFE heater from intake manifold.

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-33
EVAP CANISTER PURGE VALVE INSPECTION
WARNING:
Do not suck the air through valve. Fuel vapor inside valve
is harmful.
1) With the ignition switch OFF position, disconnect coupler from
EVAP canister purge valve.
2) Check resistance between two terminals of EVAP canister
purge valve.
Resistance of EVAP canister purge valve:
33 – 39 Ω at 20C (68F)
If resistance is as specified, proceed to next operation check.
If not, replace.
3) Disconnect vacuum hoses from intake manifold and its pipe.
4) With coupler disconnected, blow into pipe “A”. Air should not
come out of pipe “B”.
5) Connect 12 V-battery to EVAP canister purge valve terminals.
In this state, blow pipe “A”.
Air should come out of pipe “B”.
If check result is not as described, replace canister purge valve.
6) Connect vacuum hoses.
7) Connect EVAP canister purge valve coupler securely.

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-35
1. PCV valve
1. Proper size hose
2. Blow air
3. PCV valve
PCV VALVE INSPECTION
1) Disconnect PCV hose from PCV valve.
2) Run engine at idle.
3) Place your finger over end of PCV valve to check for vacuum.
If there is no vacuum, check for clogged valve. Replace as nec-
essary.
4) After checking vacuum, stop engine and check PCV valve for
sticking.
With engine stopped, connect a new hose to PCV valve for in-
spection.
Blow air into the hose and check that air flows with difficulty from
cylinder head side to intake manifold side.
If air flows without difficulty, valve is stuck in “Open” position. Re-
place PCV valve.
WARNING:
Do not suck air through PCV valve. Petroleum substances
inside the valve and fuel vapor inside the intake manifold
are harmful.
5) After removing the hose, connect PCV hose and clamp securely.

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)

ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-23
FUEL INJECTOR
On-Vehicle Inspection
1) Using sound scope (1) or such, check operating sound of injec-
tor (2) when engine is running or cranking.
Cycle of operating sound should vary according to engine
speed.
If no sound or an unusual sound is heard, check injector circuit
(wire or coupler) or injector (2).
2) Disconnect coupler (1) from injector, connect ohmmeter be-
tween terminals of injector and check resistance.
Resistance of injector: 12.0 – 13.0 Ω at 20C, 68F
If resistance is out of specification, replace.
3) Connect coupler (1) to injector securely.
Removal
1) Relieve fuel pressure according to procedure described in Sec-
tion 6.
2) Disconnect battery negative cable at battery.
3) Disconnect fuel injector couplers.
4) Disconnect vacuum hose from fuel pressure regulator (1).
5) Remove fuel delivery pipe bolts (2).
6) Remove fuel injector(s) (3).
CAUTION:
A small amount of fuel may come out after removal of fuel
injectors, cover them with shop cloth.