ECU SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

1. Slit on workbench
2. Workbench vise
3. Lower mounting bracket
ALWAYS CARRY AIR BAG (INFLATOR) MODULE
WITH TRIM COVER (AIR BAG OPENING) AWAY
FROM BODY.
ALWAYS PLACE AIR BAG (INFLATOR) MODULE
ON WORKBENCH WITH TRIM COVER (AIR BAG
OPENING) UP, AWAY FROM LOOSE OBJECTS.
0A-4 GENERAL INFORMATION
HANDLING AND SERVICING
WARNING:

Many of service procedures require disconnection of
“AIR BAG” fuse and air bag (inflator) modules (driver and
passenger) from deployment loop to avoid an accidental
deployment.
Driver and Passenger Air Bag (Inflator) Modules

For handling and storage of a live air bag (inflator) module,
select a place where the ambient temperature below 65C
(150F), without high humidity and away from electric
noise.

When carrying a live air bag (inflator) module, make sure
the bag opening is pointed away from you. In case of an
accidental deployment, the bag will then deploy with mini-
mal chance of injury. Never carry the air bag (inflator)
module by the wires or connector on the underside of the
module. When placing a live air bag (inflator) module on
a bench or other surface, always face the bag up, away
from the surface. As the live passenger air bag (inflator)
module must be placed with its bag (trim cover) facing up,
place it on the workbench with a slit or use the workbench
vise to hold it securely at its lower mounting bracket. This
is necessary so that a free space is provided to allow the
air bag to expand in the unlikely event of accidental de-
ployment. Otherwise, personal injury may result.

Never dispose of live (undeployed) air bag (inflator) mod-
ules (driver and passenger). If disposal is necessary, be
sure to deploy them according to deployment procedures
described in Section 9J before disposal.

The air bag (inflator) module immediately after deploy-
ment is very hot. Wait for at least half an hour to cool it off
before proceeding the work.

After an air bag (inflator) module has been deployed, the
surface of the air bag may contain a powdery residue.
This powder consists primarily of cornstarch (used to lu-
bricate the bag as it inflates) and by-products of the chem-
ical reaction. As with many service procedures, gloves
and safety glasses should be worn.
SDM

During service procedures, be very careful when handling
a Sensing and Diagnostic Module (SDM). Never strike or
jar the SDM. Never power up the air bag system when the
SDM is not rigidly attached to the vehicle. All SDM and
mounting bracket fasteners must be carefully torqued
and the arrow must be pointing toward the front of the ve-
hicle to ensure proper operation of the air bag system. The
SDM could be activated when powered while not rigidly at-
tached to the vehicle which could cause deployment and
result in personal injury.

0A-10 GENERAL INFORMATION

When disconnecting connectors, never pull the wiring har-
ness. Unlock the connector lock first and then pull them
apart by holding connectors themselves.

When connecting connectors, also hold connectors and put
them together until they lock securely (a click is heard).

When installing the wiring harness, fix it with clamps so that
no slack is left.

When installing vehicle parts, be careful so that the wiring
harness is not interfered with or caught by any other part.

When using floor jack:
GENERAL INFORMATION 0A-21
In raising front or rear vehicle end off the floor by jacking, be sure
to put the jack against the center portion of front cross member (1)
or rear cross member (2).
WARNING:

Never apply jack against suspension parts (i.e., stabilizer,
etc.) or vehicle floor, or it may get deformed.

If the vehicle to be jacked up only at the front or rear end,
be sure to block the wheels on ground in order to ensure
safety.
After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on the
vehicle raised on jack alone.
To perform service with either front or rear vehicle end jacked up,
be sure to place safety stands under body so that body is securely
supported. And then check to ensure that body does not slide on
safety stands and the vehicle is held stable for safety’s sake.

MAINTENANCE AND LUBRICATION 0B-7
Proper Engine Oil Viscosity Chart
1. Oil pan
2. Oil drain plug
1. Oil filter
ITEM 1-4
Engine Oil and Filter Change
WARNING:
New and used engine oil can be hazardous.
Be sure to read “WARNING” in General Precaution in SEC-
TION 0A and observe what in written there.
Use engine oil of SE, SF, SG, SH or SJ grade.
Select the appropriate oil viscosity according to the left chart.
Before draining engine oil, check engine for oil leakage. If any evi-
dence of leakage is found, make sure to correct defective part be-
fore proceeding to following work.
1) Drain engine oil by removing drain plug.
2) After draining oil, wipe drain plug clean. Reinstall drain plug, and
tighten it securely as specified below.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)
3) Loosen oil filter by using oil filter wrench (Special tool).
Special Tool
(A): 09915-47330
4) Apply engine oil to new oil filter O-ring.
5) Screw new filter on oil filter stand by hand until filter O-ring con-
tacts mounting surface.
CAUTION:
To tighten oil filter properly, it is important to accurately
identify the position at which filter O-ring first contacts
mounting surface.
6) Tighten filter 3 / 4 turn from the point of contact with mounting sur-
face using an oil filter wrench.
Special Tool
(A): 09915-47330
Tightening Torque (Reference)
(a): 14 N
.m (1.4 kg-m, 10.5 lb-ft)

For A / TFor M / T
MAINTENANCE AND LUBRICATION 0B-9
1) Remove radiator cap when engine is cool.
2) Loosen radiator drain plug (1) to drain coolant.
3) Remove reservoir and drain.
4) Tighten drain plug securely. Also install reservoir.
5) Slowly pour specified amount of coolant to the base of radiator
filler neck, and run engine, with radiator cap removed, until ra-
diator upper hose is hot. This drives out any air which may still
be trapped within cooling system. Add coolant as necessary un-
til coolant level reaches filler throat of radiator. Reinstall radiator
cap.
6) Add coolant to reservoir (1) so that its level aligns with Full mark
(2). Then, reinstall cap to reservoir aligning match marks (3) on
reservoir and cap.
ITEM 1-6
Exhaust System Inspection
WARNING:
To avoid danger of being burned, do not touch exhaust sys-
tem when it is still hot.
Any service on exhaust system should be performed when
it is cool.
When carrying out periodic maintenance or vehicle is raised for oth-
er service, check exhaust system as follows:

Check rubber mountings for damage and deterioration.

Check exhaust system for leakage, loose connections, dents,
and damages.
If bolts or nuts are loose, tighten them to specification. Refer to
SECTION 6K for torque specification of bolts and nuts.

Check nearby body areas for damaged, missing or mispositioned
parts, open seams, holes, loose connections or other defects
which could permit exhaust fumes to seep into vehicle.

Make sure that exhaust system components have enough clear-
ance from underbody to avoid overheating and possible damage
to floor carpet.

Any defects should be fixed at once.

1.0 liter engine
1.3 liter engine
MAINTENANCE AND LUBRICATION 0B-11
2) Visually check that air cleaner filter is not excessively dirty, dam-
aged or oily.
3) Clean filter with compressed air from air outlet side of filter.
4) Install air cleaner filter into case.
5) Clamp case cap securely and install hose to case and bracket
if removed.
Air Cleaner Filter Replacement
Replace air cleaner filter with new one according to steps 1), 4) and
5) of Air Cleaner Filter Inspection.
ITEM 3-2
Fuel Lines Inspection

Check fuel lines for loose connection, deterioration or damage
which could cause leakage.
Make sure all clamps are secure.

Replace any damaged or deteriorate parts.
There should be no sign of fuel leakage or moisture at any fuel
connection.
ITEM 3-3
Fuel Tank Inspection
Check fuel tank for damage, cracks, fuel leakage, corrosion and
tank bolts looseness.
If a problem is found, repair or replace.

“A”: Oil point
1. Upper hinge
2. Lower hinge
3. Door
4. Body
MAINTENANCE AND LUBRICATION 0B-19
ITEM 6-10
All Latches, Hinges and Locks Inspection
Doors
Check that each door of front, rear and back doors opens and
closes smoothly and locks securely when closed.
If any malfunction is found, lubricate hinge and latch or repair door
lock system.
Engine hood
Check that secondary latch operates properly (check that second-
ary latch keeps hood from opening all the way even when pulling
hood release handle inside vehicle.). Also check that hood opens
and closes smoothly and properly and hood locks securely when
closed.
If any malfunction is found, lubricate hinge and latch, or repair hood
lock system.

0B-20 MAINTENANCE AND LUBRICATION
FINAL INSPECTION
Seats
Check that seat slides smoothly and locks securely at
any position. Also check that reclining mechanism of
front seat back allows it to be locked at any angle.
Seat Belt
Inspect belt system including webbing, buckles, latch
plates, retractors and anchors for damage or wear.
If “REPLACE BELT” label on belt is visible, replace
belt.
Check that seat belt is securely locked.
Battery Electrolyte Level Check
Check that the electrolyte level of all battery cells is
between the upper and lower level lines on the case.
If battery is equipped with built-in indicator, check bat-
tery condition by the indicator.
Accelerator Pedal Operation
Check that pedal operates smoothly without getting
caught or interfered by and other part.
Engine Start
Check engine start for readiness.
On automatic transmission vehicles, try to start the
engine in each gear. The starter should crank only in
“P” (Park) or “N” (Neutral).
On manual transmission vehicles, place the shift le-
ver in “Neutral,” depress clutch pedal fully and try to
start.
Exhaust System Check
Check for leakage, cracks or loose supports.
Clutch (For manual transmission)
Check for the following.

Clutch is completely released when depressing
clutch pedal.

No slipping clutch occurs when releasing pedal and
accelerating.

Clutch itself is free from any abnormal condition.
Gearshift or Select Lever (Transmission)
Check gear shift or select lever for smooth shifting to
all positions and for good performance of transmis-
sion in any position.
With automatic transmission equipped vehicle, also
check that shift indicator indicates properly according
to which position select lever is shifted to.
CAUTION:
With automatic transmission equipped ve-
hicle, make sure that vehicle is at complete
stop when shifting select lever to “P” range
position and release all brakes.
Brake
[Foot brake]
Check the following;

that brake pedal has proper travel,

that brake works properly,

that it is free from noise,

that vehicle does not pull to one side when brake is
applied,

and that brake does not drag.
WARNING:
When carrying out road tests, select a safe
place where no man or no running vehicle is
seen so as to prevent any accident.
WARNING:
Before performing the following check, be
sure to have enough room around the vehicle.
Then, firmly apply both the parking brake and
the regular brakes. Do not use the accelerator
pedal. If the engine starts, be ready to turn off
the ignition promptly. Take these precautions
because the car could move without warning
and possibly cause personal injury or proper-
ty damage.

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
6-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)
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.

6-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)
ENGINE DIAGNOSIS
GENERAL DESCRIPTION
This vehicle is equipped with an engine and emission control system which are under control of ECM (PCM).
The engine and emission control system in this vehicle are controlled by ECM (PCM). ECM (PCM) has an On-
Board Diagnostic system which detects a malfunction in this system and abnormality of those parts that influence
the engine exhaust emission. When diagnosing engine troubles, be sure to have full understanding of the outline
of “On-Board Diagnostic System” and each item in “Precaution in Diagnosing Trouble” and execute diagnosis ac-
cording to “ENGINE DIAGNOSTIC FLOW TABLE”.
There is a close relationship between the engine mechanical, engine cooling system, ignition system, exhaust sys-
tem, etc. and the engine and emission control system in their structure and operation. In case of an engine trouble,
even when the malfunction indicator lamp (MIL) doesn’t turn ON, it should be diagnosed according to this flow table.
ON-BOARD DIAGNOSTIC SYSTEM
ECM (PCM) in this vehicle has following functions.

When the ignition switch is turned ON with the engine at a stop,
malfunction indicator lamp (MIL) (1) turns ON to check the bulb
of the malfunction indicator lamp (1).

When ECM (PCM) detects a malfunction which gives an adverse
effect to vehicle emission while the engine is running, it makes the
malfunction indicator lamp (1) in the meter cluster of the instru-
ment panel turn ON or flash (flashing only when detecting a mis-
fire which can cause damage to the catalyst) and stores the mal-
function area in its memory.
(If it detects that continuously 3 driving cycles are normal after de-
tecting a malfunction, however, it makes MIL (1) turn OFF al-
though DTC stored in its memory will remain.)

As a condition for detecting a malfunction in some areas in the
system being monitored by ECM (PCM) and turning ON the mal-
function indicator lamp (1) due to that malfunction, 2 driving cycle
detection logic is adopted to prevent erroneous detection.

When a malfunction is detected, engine and driving conditions
then are stored in ECM (PCM) memory as freeze frame data. (For
the details, refer to description on Freeze frame data.)

It is possible to communicate by using not only SUZUKI scan tool
(Tech-1) (2) but also generic scan tool. (Diagnostic information
can be accessed by using a scan tool.)