MIL SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

GENERAL INFORMATION 0A-23
L
LH : Left Hand
LSPV : Load Sensing Proportioning
Valve
M
MAF Sensor : Mass Air Flow Sensor (Air Flow
Sensor, AFS, Air Flow Meter,
AFM)
MAP Sensor : Manifold Absolute Pressure
Sensor (Pressure Sensor, PS)
Max : Maximum
MFI : Multiport Fuel Injection
(Multipoint Fuel Injection)
Min : Minimum
MIL : Malfunction Indicator Lamp
M / T : Manual Transmission
N
NOx : Nitrogen Oxides
O
OBD : On-Board Diagnostic System
(Self-Diagnosis Function)
O / D : Overdrive
OHC : Over Head Camshaft
P
PNP : Park / Neutral Position
P / S : Power Steering
PSP Switch : Power Steering Pressure Switch
(P / S Pressure Switch)
PCM : Powertrain Control Module
PCV : Positive Crankcase Ventilation
R
RH : Right Hand
S
SAE : Society of Automotive
Engineers
SDM : Sensing and Diagnostic Module
(Air Bag Controller, Air Bag
Control Module)
SFI : Sequential Multiport Fuel
Injection
SOHC : Single Over Head Camshaft
T
TBI : Throttle Body Fuel Injection
(Single-Point Fuel Injection,
SPI)
TCC : Torque Converter Clutch
TCM : Transmission Control Module
(A / T Controller, A / T Control
Module)
TP Sensor : Throttle Position Sensor
TVV : Thermal Vacuum Valve
(Thermal Vacuum Switching
Valve, TVSV, Bimetal Vacuum
Switching Valve, BVSV)
TWC : Three-Way Catalytic Converter
(Three-Way Catalyst)
2WD : 2 Wheel Drive
V
VIN : Vehicle Identification Number
VSS : Vehicle Speed Sensor
W
WU-OC : Warm Up Oxidation Catalytic
Converter
WU-TWC : Warm Up Three-Way Catalytic
Converter

0B-2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE
NORMAL CONDITION SCHEDULE
Interval:
This interval should be
judged by
This table includes services as scheduled up to 90,000 km (54,000 miles)
mileage. Beyond 90,000 km (54,000 miles), carry out the same services at
the same intervals respectively.
jg y
odometer reading or months,Km(
1,000)153045607590
whichever comes first.Miles(
1,000)91827364554
Months122436486072
1. ENGINE
1-1.Drive belt (tension,V-beltIRIRIR
damage)
V-rib belt (Flat type)––I––R
1-2.Camshaft timing beltReplace every 100,000 km (60,000 miles).
1-3.Valve lash (1.3 liter engine)–I–I–I
1-4.Engine oilVehicle with O2S (SG, SH, SJ)RRRRRR
and oil filter
Vehicle with O2S (SE, SF)
Vehicle without O2SReplace every 10,000 km (6,000 miles)
or 8 months
1-5.Engine coolant–R–R–R
1-6.Exhaust system (leakage, damage, tightness)–I–I–I
2. IGNITION SYSTEM
2-1.Spark plugsWhen unleaded
fuel is usedVehicle
without
O2S
–R–R–R
Vehicle
with O2S––R––R
When leaded fuel is usedRefer to “Severe Driving Condition” schedule.
2-2.Distributor cap and rotor (if equipped)––I––I
3. FUEL SYSTEM
3-1.Air cleaner filterPaved-roadIIRIIR
Dusty conditionRefer to “Severe Driving Condition” schedule.
3-2.Fuel lines (deterioration, leakage, damage)–I–I–I
3-3.Fuel tank––I––I
NOTES:

For Item 2-1 “spark plugs”, replace every 50,000 km if the local law requires.

For Sweden, Item 2-1, 4-1 and 4-2 should be performed by odometer reading only.

For Item 1-2 Camshaft timing belt: This belt may be replaced every 90,000 km (54,000 miles) according
to customer’s maintenance convenience.

MAINTENANCE AND LUBRICATION 0B-3
Interval:
This interval should be
judged by
This table includes services as scheduled up to 90,000 km (54,000 miles)
mileage. Beyond 90,000 km (54,000 miles), carry out the same services at
the same intervals respectively.
This interval should be judged by
odometer reading or months,Km(
1,000)153045607590g
whichever comes first.Miles(
1,000)91827364554
Months122436486072
4. EMISSION CONTROL SYSTEM
4-1.PCV (Positive Crankcase Ventilation)
ValveVehicle
without
O2S
––I––I
Vehicle
with O2S–––––I
4-2.Fuel evaporative emission control system–––––I
5. BRAKE
5-1.Brake discs and padsIIIIII
Brake drums and shoes–I–I–I
5-2.Brake hoses and pipes–I–I–I
5-3.Brake fluid–R–R–R
5-4.Brake lever and cableInspect at first 15,000 km (9,000 miles) only.
6. CHASSIS AND BODY
6-1.Clutch pedal (for manual transmission)–I–I–I
6-2.Tires/wheel discsIIIIII
6-3.Propeller shaft (4WD) and drive shafts––I––I
6-4.Suspension system–I–I–I
6-5.Steering system–I–I–I
6-6.Power steering (if equipped)IIIIII
6-7.Manual transmission oilI–R––R
6-8.Automatic transmissionFluid level–I–I–I
Fluid changeReplace every 165,000 km (99,000 miles).
Fluid hose–––R––
6-9.Rear differential oil (4WD) (R: 1st 15,000 km only)R or I–I–I–
6-10. All latches, hinges and locks–I–I–I
NOTES:

“R”: Replace or change

“I”: Inspect and correct or replace if necessary

0B-4 MAINTENANCE AND LUBRICATION
MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS
If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is
recommended that applicable maintenance operation be performed at the particular interval as given in the chart
below.
Severe condition code
A –Repeated short trips F –Leaded fuel use
B –Driving on rough and/or muddy roads G –(For Diesel engine) Town use / Towing a trailer /
C –Driving on dusty roads Sustained high speed driving /
D –Driving in extremely cold weather and/or Hot climates above 30C (86F) /
salted roads Low quality lubricants or fuel
E –Repeated short trips in extremely cold weather H –Trailer towing (if admitted)
Severe
Condition Code
MaintenanceMaintenance
OperationMaintenance Interval
BCDITEM 1-1IEvery 15,000 km (9,000 miles)
or 12 months
– B C D – – – –Drive belt (V-rib belt)REvery 45,000 km (27,000 miles)
or 36 months
A – C D E F – HITEM 1-4
Engine oil and filterREvery 5,000 km (3,000 miles)
or 4 months
A B C – E F – HITEM 2-1
Spark plugsREvery 10,000 km (6,000 miles)
or 8 months
ITEM 3 1IEvery 2,500 km (1,500 miles)
– – C – – – – –ITEM 3-1
Air cleaner filter *1REvery 30,000 km (18,000 miles)
or 24 months
– B C D – – – HITEM 6-2
Wheel bearingsIEvery 15,000 km (9,000 miles)
or 12 months
– B – D E – – H
ITEM 6-3
Propeller shaft (4WD) and drive
shafts
I
Every 15,000 km (9,000 miles)
or 12 months
– B – – E – – H
ITEM 6-7 / 6-8
Manual transmission oil and
differential oil (4WD)
R
Every 30,000 km (18,000 miles)
or 24 months
– B – – E – – HITEM 6-9
Automatic transmission fluidREvery 30,000 km (18,000 miles)
or 24 months
NOTES:

“R”: Replace or change

“I”: Inspect and correct or replace if necessary

*1: Inspect or replace more frequently if necessary

Diagnostic Trouble Code Clearance 6-14. . . . .
Diagnostic Trouble Code Table 6-15. . . . . . . . .
Fail-safe Table 6-18. . . . . . . . . . . . . . . . . . . . . . .
Visual Inspection 6-19. . . . . . . . . . . . . . . . . . . . .
Engine Basic Inspection 6-20. . . . . . . . . . . . . . .
Engine Diagnosis Table 6-22. . . . . . . . . . . . . . .
Scan Tool Data 6-29. . . . . . . . . . . . . . . . . . . . . . .
Scan Tool Data Definitions 6-31. . . . . . . . . . . . .
Inspection of ECM (PCM) and Its Circuits 6-33
Voltage Check 6-33. . . . . . . . . . . . . . . . . . . . .
Resistance Check 6-37. . . . . . . . . . . . . . . . . .
Component Location 6-38. . . . . . . . . . . . . . . . . .
Table A-1 MIL Circuit Check
(Lamp does not come on) 6-39. . . . . . . . . . . .
Table A-2 MIL Circuit Check
(Lamp remains ON) 6-40. . . . . . . . . . . . . . . . . .
Table A-3 ECM (PCM) Power and Ground
Circuit Check 6-42. . . . . . . . . . . . . . . . . . . . . . .
DTC P0105 MAP Circuit Malfunction 6-44. . . .
DTC P0110 IAT Circuit Malfunction 6-46. . . . .
DTC P0115 ECT Circuit Malfunction 6-48. . . .
DTC P0120 Throttle Position Circuit
Malfunction 6-50. . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0121 Throttle Position Circuit
Range / Performance Problem 6-52. . . . . . . . .
DTC P0130 HO2S Circuit Malfunction
(Sensor-1) 6-54. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0133 HO2S Circuit Slow
Response (Sensor-1) 6-56. . . . . . . . . . . . . . . .
DTC P0135 HO2S Heater Circuit
Malfunction (Sensor-1) 6-57. . . . . . . . . . . . . . .
DTC P0136 HO2S Circuit Malfunction
(Sensor-2) 6-59. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0141 HO2S Heater Circuit
Malfunction (Sensor-2) 6-62. . . . . . . . . . . . . . .
DTC P0171 Fuel System Too Lean 6-64. . . . .
DTC P0172 Fuel System Too Rich 6-64. . . . . .
DTC P0300 Random Misfire Detected 6-68. . .
DTC P0301 Cylinder 1 Misfire Detected 6-68. DTC P0302 Cylinder 2 Misfire Detected 6- 68.
DTC P0303 Cylinder 3 Misfire Detected 6- 68.
DTC P0335 CKP Sensor Circuit
Malfunction 6- 72. . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0340 CMP Sensor Circuit
Malfunction 6- 74. . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0420 Catalyst System Efficiency
Below Threshold 6- 76. . . . . . . . . . . . . . . . . . . .
DTC P0443 Purge Control Valve Circuit
Malfunction 6- 79. . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0480 Radiator Fan Control
System Malfunction 6- 80. . . . . . . . . . . . . . . . . .
DTC P0500 Vehicle Speed Sensor
Malfunction (M / T) 6- 82. . . . . . . . . . . . . . . . . . .
DTC P0500 Vehicle Speed Sensor
Malfunction (A / T) 6- 84. . . . . . . . . . . . . . . . . . .
DTC P0505 Idle Control System
Malfunction 6- 86. . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0510 Closed Throttle Position
Switch Malfunction 6- 88. . . . . . . . . . . . . . . . . .
DTC P0601 Internal Control Module
Memory Check Sum Error 6- 89. . . . . . . . . . . .
DTC P1250 EFE Heater Circuit
Malfunction 6- 90. . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1450 Barometric Pressure
Sensor Low / High Input 6- 92. . . . . . . . . . . . . .
DTC P1451 Barometric Pressure Sensor
Performance Problem 6- 92. . . . . . . . . . . . . . . .
DTC P1500 Engine Starter Signal
Circuit Malfunction 6- 93. . . . . . . . . . . . . . . . . . .
DTC P1510 ECM (PCM) Back-up Power
Supply Malfunction 6- 94. . . . . . . . . . . . . . . . . .
Table B-1 Fuel Injector Circuit Check 6- 96. . . .
Table B-2 Fuel Pump and Its Circuit
Check 6- 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-3 Fuel Pressure Check 6-100. . . . . . . . .
Table B-4 A / C Signal Circuits Check 6-102. . . .
Table B-5 Power Steering Pressure
Switch Signal Circuit Check 6-103. . . . . . . . . . .
SPECIAL TOOL6-104 . . . . . . . . . . . . . . . . . . . . . . .
6-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)

1. No.1 cylinder
2. No.2 cylinder
3. No.3 cylinder
123
ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-3
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) and No.3 (3) 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.

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.)

6-12 ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10)
CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE)
User name:Model:VIN:
Date of issue:Date Reg.Date of problem:Mileage:
PROBLEM SYMPTOMS
Difficult Starting
No cranking
No initial combustion
No combustion
Poor starting at
(cold warm always)
OtherPoor Driveability
Hesitation on acceleration
Back fire /After fire
Lack of power
Surging
abnormal knocking
Other
Poor Idling
Poor fast idle
Abnormal idling speed
(High Low) ( r / min.)
Unstable
Hunting ( r / min. to r / min.)
OtherEngine Stall when
Immediately after start
Accel. pedal is depressed
Accel. pedal is released
Load is applied
A/C Electric load P/S
Other
Other
OTHERS:
VEHICLE / ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS
Environmental Condition
Weather
Temperature
Frequency
RoadFair Cloudy Rain Snow Always Other
Hot Warm Cool Cold (F/C) Always
Always Sometimes ( times/ day, month) Only once Under certain condition
Urban Suburb Highway Mountainous (Uphill Downhill) Tarmacadam Gravel
Other
Vehicle Condition
Engine
conditionCold Warming up phase Warmed up Always Other at starting
Immediately after start Racing without load Engine speed ( r / min.)
Vehicle
conditionDuring driving: Constant speed Accelerating Decelerating
Right hand corner Left hand corner When shifting (Lever position ) At stop
Vehicle speed when problem occurs ( km/h, Mile / h) Other
Malfunction indicator
lamp conditionAlways ON Sometimes ON Always OFF Good condition
Diagnostic troubleFirst check:No code Malfunction code ( )g
codeSecond check:No code Malfunction code ( )
NOTE:
The above form is a standard sample. It should be modified according to conditions characteristic of each
market.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-13
MALFUNCTION INDICATOR LAMP (MIL)
CHECK
1) Turn ON ignition switch (but the engine at stop) and check that
MIL lights.
If MIL does not light up (or MIL dims), go to “Diagnostic Flow
Table A-1” for troubleshooting.
2) Start engine and check that MIL turns OFF.
If MIL remains ON and no DTC is stored in ECM (PCM), go to
“Diagnostic Flow Table A-2” for troubleshooting.
DIAGNOSTIC TROUBLE CODE (DTC) CHECK
1) Prepare SUZUKI scan tool (Tech-1) or generic scan tool.
2) With ignition switch OFF, connect it to data link connector (DLC)
(1) located on underside of instrument panel at driver’s seat side.
Special Tool:
(A): SUZUKI scan tool
(B): Mass storage cartridge
(C): 16 / 14 pin DLC cable
3) Turn ignition switch ON and confirm that MIL lights.
4) Read DTC, pending DTC and freeze frame data according to
instructions displayed on scan tool and print it or write it down.
Refer to scan tool operator’s manual for further details.
If communication between scan tool and ECM (PCM) is not pos-
sible, check if scan tool is communicable by connecting it to
ECM (PCM) in another vehicle. If communication is possible in
this case, scan tool is in good condition. Then check data link
connector and serial data line (circuit) in the vehicle with which
communication was not possible.
5) After completing the check, turn ignition switch off and discon-
nect scan tool from data link connector.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-15
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DTC
NO.DETECTING ITEMDETECTING CONDITION
(DTC will set when detecting:)MIL
P0105Manifold absolute pressure
circuit malfunction
Low pressure-high vacuum-low voltage
(or MAP sensor circuit shorted to ground)
High pressure-low vacuum-high voltage
(or MAP sensor circuit open)
1 driving cycle
P0110Intake air temp. circuit
malfunctionIntake air temp. circuit low input
Intake air temp. circuit high input1 driving cycle
P0115Engine coolant temp. circuit
malfunctionEngine coolant temp. circuit low input
Engine coolant temp. circuit high input1 driving cycle
P0120Throttle position circuit
malfunctionThrottle position circuit low input
Throttle position circuit high input1 driving cycle
P0121Throttle position circuit
performance problemPoor performance of TP sensor2 driving cycles
P0130HO2S circuit malfunction
(Sensor-1)
Min. output voltage of HO2S-higher than
specification
Max. output voltage of HO2S-lower than
specification
2 driving cycles
P0133HO2S circuit slow response
(Sensor-1)Response time of HO2S-1 output voltage
between rich and lean is longer than
specification.
2 driving cycles
P0135HO2S heater circuit
malfunction (Sensor-1)Terminal voltage is lower than specification
at heater OFF or it is higher at heater ON.2 driving cycles
P0136HO2S circuit malfunction
(Sensor-2)Max. voltage of HO2S-2 is lower than
specification or its min. voltage is higher than
specification
2 driving cycles
P0141HO2S heater circuit
malfunction (Sensor-2)Terminal voltage is lower than specification
at heater OFF or it is higher at heater ON.
(or heater circuit or short)
2 driving cycles
P0171Fuel system too lean
Short term fuel trim or total fuel trim (short
and long terms added) is larger than
specification for specified time or longer.
(fuel trim toward rich side is large.)
2 driving cycles
P0172Fuel system too rich
Short term fuel trim or total fuel trim (short
and long term added) is smaller than
specification for specified time or longer.
(fuel trim toward lean side is large.)
2 driving cycles
P0300
P0301
P0302
Random misfire detected
Cylinder 1 misfire detected
Cylinder 2 misfire detected
Misfire of such level as to cause damage to
three way catalystMIL flashing
during misfire
detection
P0302
P0303
Cylinder 2 misfire detected
Cylinder 3 misfire detectedMisfire of such level as to deteriorate emission
but not to cause damage to three way catalyst2 driving cycles