Lamp SUZUKI SWIFT 2000 1.G SF310 Service Repair Manual

6C-4 ENGINE FUEL
FUEL PUMP ASSEMBLY
REMOVAL
1) Remove fuel tank (1) from vehicle referring to “FUEL TANK” in
this section.
2) Disconnect fuel feed hose (2), fuel return hose (3) and breather
hose (4) from fuel pump assembly (5).
3) Remove fuel pump assembly from fuel tank by removing
screws.
INSPECTION
Check fuel pump assembly for damage.
Check fuel suction filter (1) for evidence of dirt and contamination.
If present, replace or clean and check for presence of dirt in fuel
tank.
INSTALLATION
Reverse removal procedure for installation noting the followings.

Use new gasket.

Clamp hoses securely.

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-3
1. Tank pressure control valve
2. Fuel liquid separator
3. Fuel tank
4. Fuel pump
5. Fuel level sensor (gauge)
6. Fuel filter
7. Fuel pressure regulator
8. Throttle body
9. Fuel injector
10. MAP sensor
11. TP sensor
12. ISC actuator
(including CTP switch)
13. PCV valve
14. Exhaust manifold
15. Intake manifold
16. Heated oxygen sensor-117. Warm up three way catalytic
convertor (WU-TWC)
(if equipped)
18. Three way catalytic convertor
19. IAT sensor
20. ECT sensor
21. EFE heater
22. EVAP canister purge valve
23. EVAP canister
24. Heated oxygen sensor-2
25. Radiator fan motor
26. Ignition coil
27. Ignitor
28. Electric load
29. A / C amplifier (if equipped)
30. Camshaft position sensor
31. Crankshaft position sensor32. VSS (on A / T)
33. Transmission range sensor
(switch) (A / T)
34. Shift solenoid-A (A / T)
35. Shift solenoid-B (A / T)
36. Data link connector
37. VSS (in combination meter of
M / T vehicle)
38. PSP switch (if equipped)
39. Malfunction indicator lamp
40. Transmission range sensor
(switch) (A / T)
41. Main (Ignition) switch
42. Main fuse
43. Battery
44. Immobilizer indicator lamp

INFORMATION SENSORS
1. MAP sensor
2. TP sensor
3. IAT sensor
4. ECT sensor
5. Heated oxygen sensor-1
6. VSS
7. Ignition coil
8. Battery
9. Distributor (CMP sensor)
10. A / C controller (if equipped)
11. CKP sensor
12. CTP switch (in ISC actuator)
13. Heated oxygen sensor-2CONTROLLED DEVICES
a : Fuel injector
b : EVAP canister purge valve
c : Fuel pump relay
d : Malfunction indicator lamp
e : ISC actuator
f : Radiator fan control relay
g : Ignitor
h : EFE heater relay
i : ISC actuator relayOTHERS
A : ECM (PCM)
B : Main relay
C : EVAP canister
D : Injector resistor
E : EFE heater
F : Electric load diode
G : Data link connector
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-5
The electronic control system consists of 1) various
sensors which detect the state of engine and driving
conditions, 2) ECM which controls various devices
according to the signals from the sensors and 3) vari-
ous controlled devices.
Functionally, it is divided into following sub systems:

Fuel injection control system

Idle speed control system
Fuel pump control system

A/C control system (if equipped)

Radiator fan control system

Evaporative emission control system

EFE heater control system

Oxygen sensor heater control system

Ignition control system

A / T control system
ELECTRONIC CONTROL SYSTEM

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-7
CON-
NECTOR
C02TERMI-
NAL
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26ECM ground
Power source (from main relay)
Blank
Blank
Blank
Blank
EVAP canister purge valve
Shift solenoid-B (A / T)
Shift solenoid-A (A / T)
Igniter
Idle speed control actuator
Fuel injector
Injector ground
Power source (from battery)
Power source (from main relay)
Idle speed control actuator relay
Malfunction indicator lamp
Immobilizer indicator lamp
Heater of HO2S-2
Radiator fan relay
Fuel pump relay
Main relay
Blank
Idle speed control actuator
EFE heater relay
Injector groundC031
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22Data link connector
Vehicle speed sensor (+) (A / T)
Vehicle speed sensor (M / T)
Transmission range sensor (switch)“2”
Transmission range sensor (switch)“N”
Transmission range sensor (switch)“P”
Blank
Blank
Heated oxygen sensor-2
Blank
Fuel level sensor (gauge)
Blank
Data link connector
Vehicle speed sensor (–) (A / T)
Transmission range sensor (switch)“L”
Transmission range sensor (switch)“D”
Transmission range sensor (switch)“R”
A / C ON (output) signal for A / C control module
(if equipped)
Electric load signal
A / C (input) signal from A / C control module
(if equipped)
Ignition switch
Blank
Blank CIRCUITCON-
NECTORTERMI-
NALCIRCUIT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16Power source for sensors
Camshaft position sensor (+)
Crankshaft position sensor (+)
Closed throttle position switch
Manifold absolute pressure sensor
Throttle position sensor
Engine coolant temp. sensor
Heater of HO2S-1
Sensor ground
Camshaft position sensor (–)
Crankshaft position sensor (–)
EFE heater (monitor)
Heated oxygen sensor-1
Intake air temp sensor
Power steering pressure switch (if equipped)
Engine start signal circuit
C01
1. CMP sensor (in Distributor)
2. CKP sensor
3. TP sensor
4. MAP sensor
5. ECT sensor
6. IAT sensor
7. HO2S-1
8. HO2S-2
9. Transmission range switch (A / T)
10. VSS (A / T)
11. A / C control module (if equipped)
12. Heater blower switch
13. Fuel level sensor
14. Speedometer
15. P.SP switch
16. Rear defogger switch
17. Light switch
18. DLC
19. Fuel injector20. Injector resistor
21. Conister purge valve
22. Fuel pump relay
23. Rediator fan relay
24. EFE heater relay
25. ISC actuator relay
26. ISC actuator
27. Ignition coil
28. Igniter
29. Immobilizer indicator lamp
30. MIL
31. Main relay
32. Shift solenoid A (A / T)
33. Shift solenoid B (A / T)
34. Starter motor
35. Ignition switch

6E1-8 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10)
ON-VEHICLE SERVICE
GENERAL
When the hoses have been disconnected and system’s component
removed for service, be sure to reinstall component properly, and
route and connect hoses correctly after service. Refer to Emission
Control Information Label for proper connection of hoses (if
equipped).
ACCELERATOR CABLE ADJUSTMENT
1) Confirm that ambient temperature is higher than 0C, 32F.
2) Warm up engine to normal operating temperature with all elec-
tric loads OFF and stop engine.
3) Confirm that clearance “c” between throttle lever (1) and stop
screw (2) is less than about 1 mm (0.04 in.).
4) Check accelerator cable for play.
Accelerator cable play “a”: 10 – 15 mm (0.4 – 0.6 in.)
Cable play should be within specification. If out of specification,
loosen accelerator cable lock nut and adjust by turning adjusting
nut (3). Be sure to tighten lock nut (4) securely after adjustment.
5) With accelerator pedal depressed fully, check clearance be-
tween throttle lever and lever stopper (5) (throttle body) which
should be within following specification.
Clearance “b”: 0.5 – 2.0 mm (0.02 – 0.07 in.)
(With pedal depressed fully)
If measured value is out of specification, adjust it to specification
by changing height of pedal stopper bolt (6).
IDLE SPEED INSPECTION
Before inspecting idle speed, make sure to the following.

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

After warming up engine, accelerator cable has some play, that
is, it is not tight.

Ignition timing is within specification.

All of electrical loads except ignition are switched off.

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

Malfunction indicator lamp does not light when engine running.
After above items are all confirmed, check idle speed as follows.

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-9
1. Throttle body
2. Fuel feed hose
NOTE:
Before starting engine, place transmission gear shift lever in
“Neutral” (shift selector lever to “P” range for A/T model), and
set parking brake and block drive wheels.
1) Warm up engine to normal operating temperature.
2) Set tachometer.
3) Check idle speed with A/C OFF.
If idle speed is not within specified range, check idle speed con-
trol system and any other system and parts which might affect
idle speed. Refer to “Engine Diagnosis of Section 6” for inspec-
tion.
Engine idle speed: 850
50 r/min
NOTE:
Idle speed is not adjustable manually. If it is out of its speci-
fied range, there is a faulty condition somewhere. Check
each of related systems and parts.
AIR AND FUEL DELIVERY SYSTEM
FUEL PRESSURE
INSPECTION
1) Relieve fuel pressure, referring to Section 6.
2) Separate air cleaner assembly from throttle body and shift its
position.
3) Disconnect fuel feed hose from throttle body.
CAUTION:
A small amount of fuel may be released after fuel line is
disconnected.
In order to reduce chance of personal injury, cover fitting
to be disconnected with a shop cloth. Place that cloth in
an approved container when disconnection is com-
pleted.
4) Connect special tools and hose between throttle body and fuel
feed pipe as shown in figure, and clamp hoses securely to en-
sure no leaks occur during checking.
Special Tool
(A): 09912-58441
(B): 09912-58431
(C): 09912-58490
5) Install air cleaner assembly to throttle body and cylinder head
cover.

6E1-10 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10)
6) Start engine and warm it up to normal operating temperature.
If engine doesn’t start, 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 pressure.
NOTE:
Check that battery voltage is 11 V or more before operating
fuel pump.
7) Measure fuel pressure under each of the following conditions.
CONDITION
FUEL PRESSURE
At specified idle speed
0.9 – 1.4 kg / cm2
90 – 140 kPa
12.8 – 20.0 psi
With fuel pump operating
and engine at stop1.6 – 2.1 kg / cm2
160 – 210 kPa
22.7 – 29.9 psi
Within 1 min. after engine
(fuel pump) stop (Pressure
reduces as time passes)Over 0.9 kg / cm2
90 kPa
12.8 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.
8) Relieve fuel pressure, referring to Section 6.
9) Remove fuel pressure gauge, hose & 3-way joint after remov-
ing air cleaner assembly.
10) Connect fuel feed hose to throttle body and clamp it securely.
11) Install air cleaner assembly.
12) With engine “OFF” and ignition switch “ON”, check for fuel
leaks.

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-15
1. Injector coupler
2. TP sensor
3. Water hose
4. Vacuum hose
5. ISC actuator
6. Fuel return hose
7. Fuel feed hose
1. Injector coupler
Good No good
2) Install throttle body to EFE heater and tighten bolts to specified
torque.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
3) Install accelerator cable to throttle valve lever and cable brack-
et.
4) Connect fuel, cooling water and vacuum hoses to throttle body,
and clamp securely.
5) Connect TP sensor and injector couplers securely.
6) Refill cooling system referring to Section 6B.
7) Connect negative cable at battery.
8) With engine “OFF” and ignition switch “ON”, check for fuel
leaks around fuel line connection.
9) Install air cleaner assembly referring to Section 6A.
10) Upon completion of installation, start engine and check for fuel
leaks and engine coolant leaks.
Adjust cable play to specification according to procedure de-
scribed in ACCELERATOR CABLE ADJUSTMENT.
FUEL INJECTOR
ON-VEHICLE INSPECTION
1) With battery negative cable disconnected, disconnect injector
coupler.
2) Connect ohmmeter to each injector terminal and measure resis-
tance.
Resistance of injector: 0.5 – 1.5 Ω at 20C (68F)
If resistance is out of specification, replace fuel injector.
3) Connect injector coupler.
4) Remove air cleaner assembly without disconnecting IAT sensor
coupler.
5) Check that fuel is injected out in conical shape from fuel injector
when cranking or running engine.
If no fuel is injected, check wiring harness for continuity and cou-
plers for proper connection referring to “DIAGNOSTIC FLOW
TABLE B-1”.
If fuel is not injected out in conical shape, replace injector.
6) Check injector for fuel leakage after injection is stopped (i.e., af-
ter cranking or engine stop).
Replace if leakage exists.
Fuel leakage: Less than 1 drop/min.
7) Install air cleaner assembly.

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) 6E1-35
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.