Injector SUZUKI SWIFT 2000 1.G SF310 Service Manual PDF

6E2
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-1
GENERAL DESCRIPTION6E2- 2 . . . . . . . . . . . . . .
AIR INTAKE SYSTEM 6E2- 6. . . . . . . . . . . . . . . . . .
FUEL DELIVERY SYSTEM 6E2- 7. . . . . . . . . . . . . .
ELECTRONIC CONTROL SYSTEM 6E2- 8. . . . . .
Engine and Emission Control Input /
Output Table 6E2- 9. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSISSee Section 6. . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE6E2-13 . . . . . . . . . . . . . . . .
Accelerator Cable Adjustment 6E2-13. . . . . . . . . .
Idle Speed/Idle Air Control (IAC)
Duty Inspection 6E2-14. . . . . . . . . . . . . . . . . . . . .
AIR INTAKE SYSTEM 6E2-15. . . . . . . . . . . . . . . . . .
Throttle Body 6E2-15. . . . . . . . . . . . . . . . . . . . . . . .
Idle Air Control Valve 6E2-17. . . . . . . . . . . . . . . . .
FUEL DELIVERY SYSTEM 6E2-18. . . . . . . . . . . . . .
Fuel Pressure Inspection 6E2-18. . . . . . . . . . . . . .
Fuel Pump 6E2-21. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pressure Regulator 6E2-22. . . . . . . . . . . . . . .
Fuel Injector 6E2-23. . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRONIC CONTROL SYSTEM 6E2-27. . . . . .
ECM / PCM 6E2-27. . . . . . . . . . . . . . . . . . . . . . . . . .
MAP Sensor 6E2-27. . . . . . . . . . . . . . . . . . . . . . . . .
TP Sensor 6E2-28. . . . . . . . . . . . . . . . . . . . . . . . . . .
IAT Sensor 6E2-29. . . . . . . . . . . . . . . . . . . . . . . . . .
ECT Sensor 6E2-30. . . . . . . . . . . . . . . . . . . . . . . . . Heated Oxygen Sensor -1 and -2 6E2-31. . . . . . .
Camshaft Position Sensor 6E2-32. . . . . . . . . . . . .
Crankshaft Position Sensor 6E2-32. . . . . . . . . . . .
Vehicle Speed Sensor 6E2-33. . . . . . . . . . . . . . . . .
Fuel Level Sensor (gauge) 6E2-33. . . . . . . . . . . . .
Main Relay, Fuel Pump Relay and
Radiator Fan Control Relay 6E2-33. . . . . . . . . . .
Fuel Cut Operation (Inspection) 6E2-34. . . . . . . .
Radiator Fan Control System 6E2-34. . . . . . . . . .
System Inspection 6E2-34. . . . . . . . . . . . . . . . . .
Radiator Fan 6E2-34. . . . . . . . . . . . . . . . . . . . . . .
EMISSION CONTROL SYSTEM 6E2-35. . . . . . . . .
EGR System 6E2-35. . . . . . . . . . . . . . . . . . . . . . . . .
EVAP Control System 6E2-36. . . . . . . . . . . . . . . . .
EVAP Canister Purge Inspection 6E2-36. . . . . .
Vacuum Passage Inspection 6E2-37. . . . . . . . .
Vacuum Hose Inspection 6E2-37. . . . . . . . . . . .
EVAP Canister Purge Valve
Inspection 6E2-37. . . . . . . . . . . . . . . . . . . . . . . .
EVAP Canister Inspection 6E2-38. . . . . . . . . . .
PCV System 6E2-38. . . . . . . . . . . . . . . . . . . . . . . . .
PCV Hose Inspection 6E2-38. . . . . . . . . . . . . . .
PCV Valve Inspection 6E2-38. . . . . . . . . . . . . . .
SPECIAL TOOLS6E2-39 . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS6E2-39 . . . . . . . . . . . . . . . . . . . . .
SECTION 6E2
ENGINE AND EMISSION CONTROL SYSTEM
(SFI FOR G13)
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CONTENTS

6. EVAP canister purge valve
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-7
The fuel delivery system consists of the fuel tank (11),
fuel pump (12), fuel filter (10), fuel pressure regulator
(3), delivery pipe (2) and fuel injectors (1).
The fuel in the fuel tank (11) is pumped up by the fuel
pump (12), filtered by the fuel filter (10) and fed under
pressure to each injector through the delivery pipe
(2). As the fuel pressure applied to the injector (the
fuel pressure in the fuel feed line (7)) is always kept
a certain amount higher than the pressure in the in-take manifold (4) by the fuel pressure regulator (3),
the fuel is injected into the intake port of the cylinder
head when the injector opens according to the injec-
tion signal from ECM (PCM).
The fuel relieved by the fuel pressure regulator re-
turns through the fuel return line (8) to the fuel tank
(11).
Also, fuel vapor generated in fuel tank is led through
the fuel vapor line (9) into the EVAP canister (5).
FUEL DELIVERY SYSTEM

6E2-8 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
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
The electronic control system consists of 1) various
sensors which detect the state of engine and driving
conditions, 2) ECM (PCM) which controls various de-
vices according to the signals from the sensors and
3) various controlled devices.
Functionally, it is divided into nine sub systems:

Fuel injection control system

Idle speed control system
Fuel pump control system

A / C control system (if equipped)

Radiator fan control system

EGR system

Evaporative emission control system

Oxygen sensor heater control system

Ignition control system
Also, with A / T model, PCM controls A / T.
ELECTRONIC CONTROL SYSTEM

ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-9
FUEL PUMP RELAY
FUEL INJECTOR
HO2S HEATER
IAC VALVE
IGNITION COIL WITH IGNITER
EGR VALVE
EVAP CANISTER PURGE VALVE
A/C CONTROL MODULE
RADIATOR FAN RELAY
MIL
MAIN RELAY
SIGNAL FROM SENSOR, SWITCH AND CONTROL MODULE
OUTPUT
INPUT
ENGINE & EMISSION CONTROL INPUT / OUTPUT TABLE
ELECTRIC CONTROL DEVICE
FUEL LEVEL SENSORFor detecting fuel level
BAROMETRIC PRESSURE SENSOR
START SWITCH
IGNITION SWITCH
LIGHTING SWITCH
REAR DEFOGGER SWITCH (IF EQUIPPED)
BLOWER SWITCH
A / C SWITCH
VSS
HEATED OXYGEN SENSOR-1
HEATED OXYGEN SENSOR-2For detecting deterioration of
three way catalytic convertor
IAT SENSOR
ECT SENSOR
TP SENSOR
MAP SENSOR
CMP SENSOR
CKP SENSOR

12 W / R “N”-range signal (A / T)
13 R Heated oxygen sensor-2
14 Y / R “D”-range signal (A / T)
15 R / W “R”-range signal (A / T)
16 Lg / B A / C SW signal
17 R / W EGR valve (stepper motor coil 4)
18 P / G Radiator fan relay
19 Y / Bl Fuel pump relay
20 —— ———
21 W / B “P”-range signal (A / T)
22 P / Bl Fuel level gauge
23 R / B “L”-range signal (A / T)
24 —— ———
1 V Malfunction indicator lamp
Vehicle speed sensor (M / T)
Output shaft speed sensor (+)
(A / T)
3 —— ———
4 G / W Shift solenoid – A (A / T)
5 Gr Throttle position (TP) sensor
6 B / W Ignition switch signal
7 Y / B Data link connector
Output shaft speed sensor (–)
(A / T)
9 —— ———
10 G GND for HO2S-2
11 G / Or Shift solenoid – B (A / T)
12 —— ———
13 —— ———
14 —— ———
15 —— ———
16 Br Tachometer signal
17 B / Y Engine start signal
CON-
NECTORTERMINALWIRE
COLORCIRCUITCON-
NECTORTERMINALWIRE
COLORCIRCUIT
20
Br / Y 19
Br / W
C02 C01C02
C03
Wire color
B : Black
B / Or : Black / Orange
B / W : Black / White
B / Y : Black / Yellow
Bl : Blue
Bl / Or : Blue / Orange
Bl / B : Blue / Black
Bl / R : Blue / Red
Bl / Y : Blue / Yellow
Br : Brown
Br / W : Brown / White
Br / Y : Brown / Yellow
G : Green
G / Or : Green / Orange
G / R : Green / Red
G / W : Green / White
Gr : Gray
Gr / R : Gray / Red
Lg / B : Lightgreen / Black
Lg / R : Lightgreen / RedP : Pink
P / Bl : Pink / Blue
P / G : Pink / Green
V : Violet
V / G : Violet / Green
V / R : Violet / Red
V / W : Violet / White
W : White
W / B : White / Black
W / R : White / Red
R : Red
R / B : Red / Black
R / Bl : Red / Blue
R / G : Red / Green
R / W : Red / White
R / Y : Red / Yellow
Y / B : Yellow / Black
Y / Bl : Yellow / Blue
Y / R : Yellow / Red
2
P
8
Bl
6E2-12 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
1 B Ground for ECM / PCM
2 B / Or Ground for drive circuit
3 B / Or Ground for drive circuit
4 V / R Canister purge valve
5 G / W Power steering pressure switch
6 V / W IAC valve
7 Bl Heater of HO2S-1
8 Bl / Or No.4 fuel injector
9 Bl / R No.1 fuel injector
10 G Ground for sensor circuit
11 B / W CMP sensor
12 —— ———
13 R Heated oxygen sensor-1
14 Lg / R Coolant temp. sensor
15 Gr / R Intake air temp. sensor
16 —— ———
17 Br / Y Electric load (+)
18 —— ———
IG coil assembly for
No.2 and 3 spark plugs
IG coil assembly for
No.1 and 4 spark plugs
21 Bl / B No.2 fuel injector
22 P Power supply for sensor
23 W CKP sensor (+)
24 B CKP sensor (–)
25 —— ———
26 G MAP sensor
27 —— ———
28 V / G Immobilizer indicator lamp
29 —— ———
30 —— ———
31 Bl / Y No.3 fuel injector
1 G / R A / C compressor clutch
2 R / Y EGR valve (stepper motor coil 1)
3 R / G Data link connector
4 Lg / B Heater of HO2S-2
5 R / B Power source
6 R / B Power source
7 W Backup power source
8 R EGR valve (stepper motor coil 3)
9 R / Bl EGR valve (stepper motor coil 2)
10 Gr Ground for main relay
11 Y / B “2”-range signal (A / T)

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.

6E2-24 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
Inspection
WARNING:
As fuel is injected in this inspection, perform in a well venti-
lated area and away from open flames.
Use special care to prevent sparking when connecting and
disconnecting test lead to and from battery.
1) Install injector (1) and fuel pressure regulator (2) to special tool
(injector checking tool).
Special Tool
(A): 09912-58421
2) Connect special tools (hose and attachment) to fuel feed hose
(3) of vehicle.
Special Tool
(B): 09912-58431
3) Connect special tool (test lead) to injector.
Special Tool
(C): 09930-88530

When not using
SUZUKI scan tool : When using
SUZUKI scan tool :
4. Keep as far apart
as possible
ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13) 6E2-25
4) Install suitable vinyl tube onto injector nozzle to prevent fuel from
splashing out when injecting.
5) Put graduated cylinder under injector as shown.
6) Operate fuel pump and apply fuel pressure to injector as follows:
When using SUZUKI scan tool :
a) Connect SUZUKI scan tool to DLC with ignition switch OFF.
b) Turn ignition switch ON, clear DTC and select “MISC TEST”
mode on SUZUKI scan tool.
c) Turn fuel pump ON by using SUZUKI scan tool.
Special Tool
(A): 09931-76011 (SUZUKI scan tool)
(B): Mass storage cartridge
(C): 09931-76030 (16 / 14 pin DLC cable)
When not using SUZUKI scan tool :
a) Remove fuel pump relay from connector.
b) Connect two terminals of relay connector using service wire
(1) as shown in figure.
CAUTION:
Check to make sure that connection is made between
correct terminals. Wrong connection can cause dam-
age to ECM, wire harness, etc.
c) Turn ignition switch ON.
7) Apply battery voltage (3) to injector (2) for 15 seconds and mea-
sure injected fuel volume with graduated cylinder.
Test each injector two or three times.
If not within specification, replace injector.
Injected fuel volume:
38 – 48 cc / 15 sec. (1.28 / 1.34 – 1.62 / 1.69 US / Imp. oz / 15 sec.)
8) Check fuel leakage from injector nozzle. Do not operate injector
for this check (but fuel pump should be at work).
If fuel leaks (1) more than following specifications, replace.
Fuel leakage (1): Less than 1 drop / min.

6E2-26 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
Installation
For installation, reverse removal procedure and note following pre-
cautions.

Replace injector O-ring (1) with new one using care not to dam-
age it.

Check if cushion (2) is scored or damaged. If it is, replace with
new one.

Apply thin coat of fuel to O-rings (1) and then install injectors (3)
into delivery pipe (4) and intake manifold.
Make sure that injectors (3) rotate smoothly (6). If not, probable
cause is incorrect installation of O-ring (1). Replace O-ring (1)
with new one.

Tighten delivery pipe bolts (5) and make sure that injectors (3) ro-
tate smoothly (6).
Tightening Torque
(a): 25 N
.m (2.5 kg-m, 18.0 lb-ft)

After installation, with engine OFF and ignition switch ON, check
for fuel leaks around fuel line connection.

6E2-34 ENGINE AND EMISSION CONTROL SYSTEM (SFI FOR G13)
FUEL CUT OPERATION
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), A / C is OFF and that parking brake lever is pulled all the
way up.
1) Warm up engine to normal operating temperature.
2) While listening to sound of injector (1) by using sound scope (2)
or such, increase engine speed to higher than 3,000 r / min.
3) Check to make sure that sound to indicate operation of injector
stops when throttle valve is closed instantly and it is heard again
when engine speed is reduced to less than about 2,000 r / min.
RADIATOR FAN CONTROL SYSTEM
System Inspection
WARNING:
Keep hands, tools, and clothing away from engine cooling
fan to help prevent personal injury. This fan is electric and
can come on whether or not the engine is running. The fan
can start automatically in response to the ECT sensor with
the ignition switch in the ON position.
Check system for operation referring to Flow Table B-8 in Section
6.
If radiator fan fails to operate properly, check relay, radiator fan and
electrical circuit.
Radiator Fan
Inspection
1) Check continuity between each two terminals.
If there is no continuity, replace radiator fan motor.