Temperature SUZUKI SWIFT 2000 1.G SF310 Service Repair Manual

ENGINE COOLING 6B-5
ANTI-FREEZE PROPOR-
TIONING CHART COOLANT CAPACITY
G13 engine G10 engine
MAINTENANCE
COOLANT
The coolant recovery system is standard. The coolant in the radiator expands with heat, and the overflow is col-
lected in the reservoir tank.
When the system cools down, the coolant is drawn back into the radiator.
The cooling system has been filled at the factory with a quality coolant that is either 50 / 50 mixture of water and
GOLDEN CRUISER 1200 (ethylene glycol antifreeze.) or 30 / 70 mixture of water and GOLDEN CRUISER 1200.
The 50 / 50 mixture coolant solution provides freezing protection to – 36
C (– 33
F), the 30 / 70 mixture coolant solu-
tion provides freezing protection to – 16
C (3
F).
When changing the engine coolant, use mixture of 50% water and 50% GOLDEN CRUISER 1200 for the market
where ambient temperature falls lower than – 16
C (3
F) in winter and mixture of 70% water and 30% GOLDEN
CRUISER 1200 for the market where ambient temperature doesn’t fall lower than – 16
C (3
F).
NOTE:
Alcohol or methanol base coolant or plain water alone should not be used in cooling system at any time
as damage to cooling system could occur.
Even in a market where no freezing temperature is anticipated, mixture of 70% water and 30% ethylene
glycol antifreeze (Antifreeze / Anticorrosion coolant) should be used for the purpose of corrosion protec-
tion and lubrication.
ANTI-FREEZE PROPORTIONING TABLE
Vehicle with M / TVehicle with A / T
Freezing temperature
C–16–36–16–36Freezing temperature
F3–333–33
Anti-freeze / Anti-corrosion
coolant concentration%30503050
G10Itr.1.17 / 2.731.95 / 1.951.20 / 2.802.00 / 2.00G10
engineUS pt.2.47 / 5.774.12 / 4.122.54 / 5.924.23 / 4.23
Ratio of compound to
engineImp pt.2.06 / 4.803.43 / 3.432.11 / 3.703.52 / 3.52
cooling water
G13Itr.1.38 / 3.222.30 / 2.301.41 / 3.292.35 / 2.35G13
engineUS pt.2.92 / 6.804.86 / 4.862.98 / 6.954.96 / 4.96engineImp pt.2.43 / 5.674.05 / 4.052.48 / 5.794.13 / 4.13
Engine radiator and heater3.3 liters
(7.0 / 5.8 US / Imp pt.)3.4 liters
(7.2 / 6.0 US / Imp pt.)
Reservoir tank0.6 liters
(1.3 / 1.1 US / Imp pt.)
Total3.9 liters
(8.2 / 6.9 US / Imp pt.)4.0 liters
(8.5 / 7.0 US / Imp pt.)
Engine radiator and heater4.0 liters
(8.5 / 7.0 US / Imp pt.)4.1 liters
(8.6 / 7.2 US / Imp pt.)
Reservoir tank0.6 liters
(1.3 / 1.1 US / Imp pt.)
Total4.6 liters
(9.7 / 8.1 US / Imp pt.)4.7 liters
(9.9 / 8.3 US / Imp pt.)

1. Radiator hose
2. Clamp
ENGINE COOLING 6B-7
ON-VEHICLE SERVICE
WARNING:
Check to make sure that engine coolant temperature is
cold before removing any part of cooling system.
Also be sure to disconnect negative cord from battery ter-
minal before removing any part.
COOLING WATER PIPES OR HOSES
REMOVAL
1) Drain cooling system.
2) To remove these pipes or hoses, loosen screw on each pipe or
hose clip and pull hose end off.
INSTALLATION
Install removed parts in reverse order of removal procedure, noting
the following.
Tighten each clamp bolt securely.
Refill cooling system with proper coolant, referring to description
on COOLANT of MAINTENANCE.
THERMOSTAT
REMOVAL
1) Disconnect negative cable at battery.
2) Drain cooling system and tighten drain plug.
3) Disconnect thermostat cap (1) from thermostat case (2).

2. Thermostat case
2. Thermometer
3. Heater
Upside
6B-8 ENGINE COOLING
4) Remove thermostat (1).
INSPECTION
1) Make sure that air bleed valve (1) of thermostat is clean.
Should this valve be clogged, engine would tend to overheat.
2) Check to make sure that valve seat is free from foreign matters
which would prevent valve from seating tight.
3) Check thermostatic movement of wax pellet as follows:
Immerse thermostat (1) in water, and heat water gradually.
Check that valve starts to open at specific temperature.
If valve starts to open at a temperature substantially below or
above specific temperature, thermostat unit should be re-
placed with a new one. Such a unit, if reused, will bring about
overcooling or overheating tendency.
INSTALLATION
1) When positioning thermostat on thermostat case, be sure to
position it so that air bleed valve comes uppermost and into the
recession of thermostat case.
2) Install thermostat cap to thermostat case. When installing cap,
align arrow marks on cap and case.
3) Fill cooling system.
4) Connect negative cable.
5) After installation, check each part for leakage.

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.

6E1-20 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10)
1. Plunger
2. Throttle lever screw
2) Check to make sure that plunger of ISC actuator and throttle le-
ver screw are not in contact with each other. If they are, warm
up engine.
3) Loosen TP sensor screws.
a) Connect SUZUKI scan tool to DLC with ignition switch OFF.
b) Select “Data List” mode on SUZUKI scan tool.
c) Observe TP sensor voltage.
4) Turn TP sensor clockwise or counterclockwise and tighten TP
sensor screw at a position where voltage as specified below is
obtained.
TP sensor voltage when lever-to-stop
screw clearance is 3.5 mm (0.14 in.) : 0.98 – 1.02 V
Tightening Torque
(a): 2.0 N
.m (0.20 kg-m, 1.5 lb-ft)
5) Install ECM and connect couplers securely.
INTAKE AIR TEMPERATURE SENSOR (IAT SENSOR)
REMOVAL
1) Disconnect battery negative cable at battery.
2) Disconnect coupler from IAT sensor.
3) Remove IAT sensor and gasket from air cleaner case.

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-21
( ) for reference kΩ
TEMPERATURE 0
3220
6840
10460
14080C
176F (5.88)
2.21–2.69
(1.14)
(0.58)
0.29–0.35
2
1
1. ECT sensor
2. Distributor
INSPECTION
Immerse temperature sensing part of IAT sensor in water (or ice)
and measure resistance between sensor terminals while heating
water gradually.
If measured resistance doesn’t show such characteristic as shown
in left figure, replace IAT sensor.
INSTALLATION
Reverse removal procedure noting the following.

Clean mating surfaces of IAT sensor and air cleaner case.

Connect IAT sensor coupler securely.
ENGINE COOLANT TEMPERATURE SENSOR
(ECT SENSOR)
REMOVAL
1) Disconnect battery negative cable at battery.
2) Drain coolant referring to Section 6B.
WARNING:
To help avoid danger of being burned, do not remove radia-
tor cap while engine and radiator are still hot. Scalding fluid
and steam can be blown out under pressure if cap is taken
off too soon.
3) Disconnect coupler from ECT sensor.
4) Remove ECT sensor from thermostat case.

6E1-22 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10)
( ) for reference kΩ
TEMPERATURE 0
3220
6840
10460
14080C
176F (5.74)
2.28–2.61
(1.15)
(0.584)
0.303–0.326
1. ECT sensor
2. Distributor
INSPECTION
Immerse temperature sensing part of ECT sensor in water (or ice)
and measure resistance between sensor terminals while heating
water gradually.
If measured resistance doesn’t show such characteristic as shown
in left figure, replace ECT sensor.
INSTALLATION
Reverse removal procedure noting the following.

Clean mating surfaces of ECT sensor and thermostat case.

Check O-ring for damage and replace if necessary.

Tighten ECT sensor to specified torque.
Tightening Torque
(a): 15 N
.m (1.5 kg-m, 11.0 lb-ft)

Connect coupler to ECT sensor securely.

Refill coolant referring to Section 6B.

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.