G13 SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

6
6
6-1
6A
6A1
6B
6C
6E1
6E1
6E2
6F
6F
6F1
6G
6H
6K
GENERAL INFORMATION
General Information
Maintenance and Lubrication
1A
1B
TABLE OF CONTENTS SECTION
0A
0B
7B
8
8A
8G HEATING AND AIR CONDITIONING
Heater and Ventilation
Air Conditioning (Oprional)
ENGINE
General Information and Diagnosis
(TBI for G10)
General Information and Diagnosis
(TBI for G13)
General lnformation and Diagnosis
(SFI for G13)
Engine Mechanical (G10 Engine)
Engine Mechanical
(G13 1-cam 16-valves Engine)
Engine Cooling
Engine Fuel
Engine and Emission Control System
(TBI for G10)
Engine and Emission Control System
(TBI for G13)
Engine and Emission Control System
(SFI for G13)
Ignition System (TBI for G10)
Ignition System (TBI for G13)
Ignition System (SFI for G13)
Cranking System
Charging System
Exhaust System
TRANSMISSION, CLUTCH AND
DIFFERENTIAL
Automatic Transmission
BODY ELECTRICAL SYSTEM
Wiring Diagram
IMMOBILIZER CONTROL SYSTEM
1B
0B
0A
1A
6
6B
6C
6E1
6A1
6F
6G
6H
6K
7B
8
8A
8G
6-1
6A
6E2
6F1
6
6E1
6F
NOTE:
The screen toned Section 8A is contained in WIRING DIAGRAM MANUAL mentioned in
RELATED MANUALS.

M/T A/T
G10 G13
[A] [A]
[B] [B]
0A-18 GENERAL INFORMATION
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER
The number is punched on the front dash panel in the engine room.
IDENTIFICATION WHETHER VEHICLE
EQUIPPED WITH WU-TWC OR NOT
It can be identified by the shape of exhaust manifold (1) and ex-
haust pipe (2).
[A]: Vehicle equipped with WU-TWC (3)
[B]: Vehicle not equipped with WU-TWC
ENGINE IDENTIFICATION NUMBER
The number is punched on the cylinder block.
TRANSMISSION IDENTIFICATION NUMBER
The number is punched on the transmission case.

6
ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-1
GENERAL INFORMATION6- 3 . . . . . . . . . . . . . .
Statement on Cleanliness and Care 6- 3. . . . .
General Information on Engine Service 6- 3. .
Precaution on Fuel System Service 6- 4. . . . .
Fuel Pressure Relief Procedure 6- 5. . . . . . . .
Fuel Leakage Check Procedure 6- 5. . . . . . . .
ENGINE DIAGNOSIS6- 6 . . . . . . . . . . . . . . . . . . . General Description 6- 6. . . . . . . . . . . . . . . . . . .
On-Board Diagnostic System 6- 6. . . . . . . . . .
Precaution in Diagnosing Trouble 6- 9. . . . . . .
Engine Diagnostic Flow Table 6-10. . . . . . . . . .
Customer Problem Inspection From 6-12. . . . .
Malfunction Indicator Lamp Check 6-13. . . . . .
Diagnostic Trouble Code Check 6-13. . . . . . . .
SECTION 6
ENGINE GENERAL INFORMATION
AND DIAGNOSIS
(TBI FOR G10)
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).
ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI for G10)6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI for G13)6-1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MECHANICAL (G10)6A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MECHANICAL (G13 1 cam 16 valves)6A1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE COOLING6B-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE FUEL6C-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE AND EMISSION CONTROL SYSTEM (TBI for G10)6E1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE AND EMISSION CONTROL SYSTEM (SFI for G13)6E2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION SYSTEM (G10 ENGINE)6F-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION SYSTEM (G13 ENGINE)6F1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKING SYSTEM6G-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING SYSTEM6H-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM6K-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTE:
For the descriptions for vehicle without warm up three way catalytic converter (WUTWC), refer to Section
6 and 6E1 of the Service Manual mentioned in the FOREWORD of this manual.
CONTENTS

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G13) 6-1
SECTION 6
ENGINE GENERAL INFORMATION
AND DIAGNOSIS
(TBI FOR G13)
NOTE:
For the details of this section, refer to same section of the Service Manual mentioned in the FOREWORD
of this manual.

6-1
ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-1
GENERAL INFORMATION6-1- 3 . . . . . . . . . . . . . .
ENGINE DIAGNOSIS6-1- 6 . . . . . . . . . . . . . . . . . . .
General Description 6-1- 6. . . . . . . . . . . . . . . . . . .
On-Board Diagnostic System 6-1- 6. . . . . . . . . .
Precaution in Diagnosing Trouble 6-1- 9. . . . . . .
Engine Diagnostic Flow Table 6-1-10. . . . . . . . . .
Customer Problem Inspection From 6-1-12. . .
Malfunction Indicator Lamp Check 6-1-13. . . .
Diagnostic Trouble Code Check 6-1-13. . . . . .
Diagnostic Trouble Code Clearance 6-1-14. . .
Diagnostic Trouble Code Table 6-1-15. . . . . . .
Fail-safe Table 6-1-18. . . . . . . . . . . . . . . . . . . . .
Visual Inspection 6-1-19. . . . . . . . . . . . . . . . . . .
Engine Basic Inspection 6-1-20. . . . . . . . . . . . .
Engine Diagnosis Table 6-1-22. . . . . . . . . . . . .
Scan Tool Data 6-1-29. . . . . . . . . . . . . . . . . . . . . . .
Inspection of ECM (PCM) and Its
Circuits 6-1-33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Check 6-1-33. . . . . . . . . . . . . . . . . . . . .
Resistance Check 6-1-37. . . . . . . . . . . . . . . . . .
Component Location 6-1-38. . . . . . . . . . . . . . . . . .
Table A-1 MIL Circuit Check
(Lamp does not come on) 6-1-39. . . . . . . . . . . . Table A-2 MIL Circuit Check
(Lamp remains ON) 6-1-40. . . . . . . . . . . . . . . . . .
Table A-3 ECM (PCM) Power and
Ground Circuit Check 6-1-41. . . . . . . . . . . . . . . .
DTC P0105 MAP Circuit Malfunction 6-1-43. . . .
DTC P0110 IAT Circuit Malfunction 6-1-46. . . . .
DTC P0115 ECT Circuit Malfunction 6-1-48. . . .
DTC P0120 Throttle Position Circuit
Malfunction 6-1-50. . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0121 Throttle Position Circuit
Range / Performance Problem 6-1-52. . . . . . . . .
DTC P0130 HO2S Circuit Malfunction
(Sensor-1) 6-1-54. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0133 HO2S Circuit Slow
Response (Sensor-1) 6-1-56. . . . . . . . . . . . . . . .
DTC P0134 HO2S Circuit No Activity
Detected 6-1-57. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0135 HO2S Heater Circuit
Malfunction (Sensor-1) 6-1-58. . . . . . . . . . . . . . .
DTC P0136 HO2S Circuit Malfunction
(Sensor-2) 6-1-60. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0141 HO2S Heater Circuit
Malfunction (Sensor-2) 6-1-63. . . . . . . . . . . . . . .
DTC P0171 Fuel System Too Lean 6-1-65. . . . .
DTC P0172 Fuel System Too Rich 6-1-65. . . . . .
SECTION 6-1
ENGINE GENERAL INFORMATION
AND DIAGNOSIS
(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

6-1-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
DTC P0300 Random Misfire
Detected 6-1- 69. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0301 Cylinder 1 Misfire
Detected 6-1- 69. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0302 Cylinder 2 Misfire
Detected 6-1- 69. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0303 Cylinder 3 Misfire
Detected 6-1- 69. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0304 Cylinder 4 Misfire
Detected 6-1- 69. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0335 CKP Sensor Circuit
Malfunction 6-1- 73. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0340 CMP Sensor Circuit
Malfunction 6-1- 75. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0400 EGR Flow Malfunction 6-1- 78. . . .
DTC P0420 Catalyst System
Efficiency Below Threshold 6-1- 81. . . . . . . . . .
DTC P0443 Purge Control Valve Circuit
Malfunction 6-1- 84. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0480 Radiator Fan Control
System Malfunction 6-1- 85. . . . . . . . . . . . . . . . .
DTC P0500 Vehicle Speed Sensor
Malfunction 6-1- 87. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0505 Idle Control System
Malfunction 6-1- 91. . . . . . . . . . . . . . . . . . . . . . . . DTC P0601 Internal Control Module
Memory Check Sum Error 6-1- 93. . . . . . . . . . .
DTC P1450 Barometric Pressure
Sensor Low / High Input 6-1- 94. . . . . . . . . . . . .
DTC P1451 Barometric Pressure Sensor
Performance Problem 6-1- 94. . . . . . . . . . . . . . .
DTC P1500 Engine Starter Signal
Circuit Malfunction 6-1- 96. . . . . . . . . . . . . . . . . .
DTC P1510 ECM (PCM) Back-up
Power Supply Malfunction 6-1- 97. . . . . . . . . . .
Table B-1 Fuel Injector Circuit Check 6-1- 98. . .
Table B-2 Fuel Pump and Its Circuit
Check 6-1- 99. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-3 Fuel Pressure Check 6-1-101. . . . . . . .
Table B-4 A / C Signal Circuits Check 6-1-103. . .
Table B-5 PSP Switch Signal Circuit
Check 6-1-104. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-6 Electric Load Signal Circuit
Check 6-1-105. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-7 Radiator Cooling Fan Control
System Check 6-1-106. . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS6-1-108 . . . . . . . . . . . . . . . . . . . . .

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-3
GENERAL INFORMATION
STATEMENT ON CLEANLINESS AND CARE
An automobile engine is a combination of many machined, honed,
polished and lapped surfaces with tolerances that are measured in
the thousands of an millimeter (ten thousands of an inch).
Accordingly, when any internal engine parts are serviced, care and
cleanliness are important.
Throughout this section, it should be understood that proper clean-
ing and protection of machined surfaces and friction areas is part
of the repair procedure. This is considered standard shop practice
even if not specifically stated.

A liberal coating of engine oil should be applied to friction areas
during assembly to protect and lubricate the surfaces on initial op-
eration.

Whenever valve train components, pistons, piston rings, con-
necting rods, rod bearings, and crankshaft journal bearings are
removed for service, they should be retained in order.
At the time of installation, they should be installed in the same
locations and with the same mating surfaces as when removed.

Battery cables should be disconnected before any major work is
performed on the engine.
Failure to disconnect cables may result in damage to wire har-
ness or other electrical parts.

Throughout this manual, the four cylinders of the engine are iden-
tified by numbers; No.1 (1), No.2 (2), No.3 (3) and No.4 (4)
counted from crankshaft pulley side to flywheel side.
GENERAL INFORMATION ON ENGINE SERVICE
THE FOLLOWING INFORMATION ON ENGINE SERVICE
SHOULD BE NOTED CAREFULLY, AS IT IS IMPORTANT IN PRE-
VENTING DAMAGE, AND IN CONTRIBUTING TO RELIABLE EN-
GINE PERFORMANCE.

When raising or supporting engine for any reason, do not use a
jack under oil pan. Due to small clearance between oil pan and
oil pump strainer, jacking against oil pan may cause it to be bent
against strainer resulting in damaged oil pick-up unit.

It should be kept in mind, while working on engine, that 12-volt
electrical system is capable of violent and damaging short cir-
cuits.
When performing any work where electrical terminals can be
grounded, ground cable of the battery should be disconnected at
battery.

Any time the air cleaner, throttle body or intake manifold is re-
moved, the intake opening should be covered. This will protect
against accidental entrance of foreign material which could follow
intake passage into cylinder and cause extensive damage when
engine is started.

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
6-1-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
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.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-5
FUEL PRESSURE RELIEF PROCEDURE
CAUTION:
This work must not be done when engine is hot. If done so,
it may cause adverse effect to catalyst.
After making sure that engine is cold, release fuel pressure as fol-
lows.
1) Place transmission gear shift lever in “Neutral” (Shift selector le-
ver to “P” range for A / T model), set parking brake, and block
drive wheels.
2) Remove relay box cover.
3) Disconnect fuel pump relay (1) from relay box.
4) Remove fuel filler cap to release fuel vapor pressure in fuel tank
and then reinstall it.
5) Start engine and run it till it stops for lack of fuel. Repeat cranking
engine 2-3 times for about 3 seconds each time to dissipate fuel
pressure in lines. Fuel connections are now safe for servicing.
6) Upon completion of servicing, connect fuel pump relay (1) to
relay box and install relay box cover.
FUEL LEAKAGE CHECK PROCEDURE
After performing any service on fuel system, check to make sure
that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump) and
then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply fuel pressure
to fuel line. (till fuel pressure is felt by hand placed on fuel feed
hose.)
2) In this state, check to see that there are no fuel leakages from
any part of fuel system.

6-1-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
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.)