fuel cap SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

GENERAL INFORMATION 0A-9

Always be careful not to handle electrical parts (computer,
relay, etc.) in a rough manner or drop them.
PRECAUTIONS FOR CATALYTIC CONVERTER
For vehicles equipped with a catalytic converter, use only un-
leaded gasoline and be careful not to let a large amount of un-
burned gasoline enter the converter or it can be damaged.
–Conduct a spark jump test only when necessary, make it as
short as possible, and do not open the throttle.
–Conduct engine compression checks within the shortest
possible time.
–Avoid situations which can result in engine misfire (e.g.
starting the engine when the fuel tank is nearly empty.).
PRECAUTIONS FOR ELECTRICAL CIRCUIT
SERVICE

When replacing a fuse, make sure to use a fuse of the speci-
fied capacity. Use of a fuse with a larger capacity will cause
a damage to the electrical parts and a fire.

When disconnecting and connecting coupler, make sure to
turn ignition switch OFF, or electronic parts may get dam-
aged.

NOTE:
Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only.
Air bag
caution
labelTire information
placard
Child lock caution label
Fuel limitation
Emission control
information label
(if equipped)
A / C warning label
(if equipped with A / C)
Engine cooling fan
warning label
Air bag warning label on driver air bag
(inflator) module
Air bag warning label on combination
switch / contact coil assembly
Air bag caution label
on steering columnAir bag warning
label on passenger
air bag (inflator)
module
Air bag warning
label on SDMRadiator cap
warning label
GENERAL INFORMATION 0A-19
WARNING, CAUTION AND INFORMATION LABELS
The figure below shows main labels among others that are attached to vehicle component parts.
When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels.
If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.

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.

0B-10 MAINTENANCE AND LUBRICATION
IGNITION SYSTEM
ITEM 2-1
Spark Plugs Replacement
Replace spark plugs with new ones referring to SECTION 6F or
6F1.
ITEM 2-2
Distributor Cap and Rotor Inspection (if equipped)

Check distributor cap and rubber caps for cracks.

Clean dusty and stained parts using a dry, soft cloth.

Check center electrode and terminals for wear.

Check rotor for cracks and its electrode for wear.
Repair or replace any component which is found to be in malcondi-
tion.
FUEL SYSTEM
ITEM 3-1
Air Cleaner Filter Inspection
1) Take out air cleaner filter as follows.
For 1.0 liter engine:
i) Remove air cleaner upper case after removing case nut and
clamps.
ii) Remove air cleaner filter.
For 1.3 liter engine:
i) Disconnect air cleaner outlet hose from case after loosening
its clamp and removing bolt (1) shown in figure.
ii) Remove air cleaner case cap (3) from case by unhooking its
clamps (2), then take out air cleaner filter.

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.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-5
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 (2).
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 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 2 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.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-23
ConditionPossible CauseReferring Item
Low oil pressure
Improper oil viscosity

Malfunctioning oil pressure switch

Clogged oil strainer

Functional deterioration of oil pump

Worn oil pump relief valve

Excessive clearance in various sliding partsEngine oil and oil filter change in
Section 0B
Oil pressure switch inspection in
Section 8
Oil pan and oil pump strainer
cleaning in Section 6A
Oil pump in Section 6A
Oil pump in Section 6A
Engine noise
Note: Before
checking mechanical
noise, make sure
that:

Specified spark
plug in used.

Specified fuel is
used.Valve noise

Improper valve lash

Worn valve stem and guide

Weak or broken valve spring

Warped or bent valve
Piston, ring and cylinder noise

Worn piston, ring and cylinder bore
Connecting rod noise

Worn rod bearing

Worn crank pin

Loose connecting rod nuts

Low oil pressure
Crankshaft noise

Low oil pressure

Worn bearing

Worn crankshaft journal

Loose bearing cap bolts

Excessive crankshaft thrust play
Valve lash in Section 6A
Valves inspection in Section 6A
Valve springs inspection in
Section 6A
Valves inspection in Section 6A
Pistons and cylinders inspection
in Section 6A
Crank pin and connecting rod
bearing inspection in Section 6A
Crank pin and connecting rod
bearing inspection in Section 6A
Connecting rod installation in
Section 6A
Previously outlined
Previously outlined
Crankshaft and bearing
inspection in Section 6A
Crankshaft and bearing
inspection in Section 6A
Crankshaft inspection in
Section 6A
Crankshaft thrust play inspection
in Section 6A

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-33
CANIST PURGE DUTY (EVAP CANISTER
PURGE FLOW DUTY, %)
This parameter indicates valve ON (valve open) time
rate within a certain set cycle of EVAP purge solenoid
valve which controls the amount of EVAP purge.
0% means that the purge valve is completely closed
while 100% is a fully open valve.
CLOSED THROTTLE POSITION (ON / OFF)
This parameter will read ON when throttle valve is ful-
ly closed, or OFF when the throttle is not fully closed.
FUEL CUT (ON / OFF)
ON : Fuel being cut (output signal to injector is
stopped)
OFF : Fuel not being cut
RAD FAN
(RADIATOR FAN CONTROL RELAY, ON / OFF)
ON : Command for radiator fan control relay opera-
tion being output.
OFF : Command for relay operation not being out-
put.
ELECTRIC LOAD (ON / OFF)
ON : Headlight, small light, heater fan or rear win-
dow defogger ON signal inputted.
OFF : Above electric loads all turned OFF.
A / C SWITCH (ON / OFF)
ON : Command for A / C operation being output
from ECM (PCM) to A / C amplifier.
OFF : Command for A / C operation not being output.
FUEL TANK LEVEL (%)
This parameter indicates approximate fuel level in the
fuel tank. As the detectable range of the fuel level sen-
sor is set as 0 to 100%, however, with some models
whose fuel tank capacity is smaller, the indicated fuel
level may be only 70% even when the fuel tank is full.
PSP SWITCH (ON / OFF)
ON : PSP switch detects P / S operation (high PS
pressure).
OFF : PSP switch not detects P / S operation.
BAROMETRIC PRESS (kPa, inHg)
This parameter represents a measurement of baro-
metric air pressure and is used for altitude correction
of the fuel injection quantity and ISC actuator control.
FUEL PUMP (ON / OFF)
ON is displayed when the ECM (or PCM) activates the
fuel pump via the fuel pump relay switch.
VSS (A / T) (km / h, MPH)
If is computed by using pulse signals from vehicle
(output) speed sensor on automatic transmission.
TRANS RANGE (TRANSMISSION RANGE
SENSOR, P, R, N, D, 2 OR L)
It is indicated transmission range detected by trans-
mission range sensor.
SHIFT SOL 1-CON (SHIFT SOLENOID-1,
ON / OFF)
ON : ON command being output to shift solenoid-1
OFF : ON command not being output.
SHIFT SOL 2-CON (SHIFT SOLENOID-2,
ON / OFF)
ON : ON command being output to shift solenoid-2
OFF : ON command not being output.
SHIFT SOL 1-MON (SHIFT SOLENOID-1,
ON / OFF)
The monitor result of the shift solenoid-1 circuit is dis-
played.
ON : Electricity being passed to shift solenoid-1 or
circuit open.
OFF : Electricity not being passed or circuit short.
SHIFT SOL 2-MON (SHIFT SOLENOID-2,
ON / OFF)
The monitor result of the shift solenoid-2 circuit is dis-
played.
ON : Electricity being passed to shift solenoid-2 or
circuit open.
OFF : Electricity not being passed or circuit short.
THROT POS LEVEL (THROTTLE POSITION
LEVEL FOR A / T, “0”, “1”, “2”, “3”, “4”, “5”, “6”
or “7”)
This parameter indicates which level (zone) the
throttle valve opening is in. The throttle opening is di-
vided into 8 levels (zones) from “0” (about idle posi-
tion) to “7” (about full open) and signals are assigned
to each opening level (zone). ECM (PCM) control the
automatic gear change of the automatic transmission
by using these signals according to the signal from
the TP sensor.
GEAR POSITION
This parameter indicates the A / T gear position which
is computed on signals from the Transmission Range
Switch, VSS, TP Sensor, and so forth.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (TBI FOR G10) 6-79
Main
fuseMain relay
To other valves
EVAP canister
purge valve
EVAP canister
purge valveSurge
tank
Tank pressure
control valveFuel vapor separator
Fuel filter cap
Fuel
level
sensor
Fuel tank EVAP
canister
DTC P0443 PURGE CONTROL VALVE CIRCUIT MALFUNCTION
CIRCUIT DESCRIPTION
DTC DETECTING CONDITIONPOSSIBLE CAUSE
Canister Purge control valve circuit is opened
or shorted.
“R/G” circuit open or short

“W/BI” circuit open

Canister purge valve malfunction
DTC CONFIRMATION PROCEDURE
1) Clear DTC with ignition switch ON.
2) Select “DTC” mode on scan tool and check DTC.
INSPECTION
STEPACTIONYESNO
1Check EVAP canister purge valve operation
1) With ignition switch OFF, disconnect coupler
from canister purge valve.
2) Check resistance of EVAP canister purge
valve. See Fig. 1.
Resistance between
two terminals : 30 – 34 Ω at 20C (68F)
Resistance between
terminal and body : 1M Ω or higher
Is it as specified?“R/G” circuit open or
short.Replace EVAP canister
purge valve.

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.