manual transmission 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.

GENERAL INFORMATION 0A-1
0ASECTION 0A
GENERAL INFORMATION
CONTENTS
HOW TO USE THIS MANUAL0A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS0A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System 0A- 3. . . . . . . . . . . . . . . .
General Precautions0A- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Catalytic Converter 0A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Electrical Circuit Service 0A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Circuit Inspection Procedure 0A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermittent and Poor Connection 0A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precaution for Installing Mobile Communication Equipment 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precaution in Servicing Full-Time 4WD Vehicle 0A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDENTIFICATION INFORMATION0A-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Identification Number0A-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Whether Vehicle Equipped with WU-TWC or Not 0A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Identification Number0A-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Identification Number 0A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING, CAUTION AND INFORMATION LABELS0A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE LIFTING POINTS0A-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL0A-22 . . . . . . . . . . . . . . . . . . . . . . . . . . .
FASTENER INFORMATION0A-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric Fasteners0A-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fasteners Strength Identification 0A-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tightening Torque0A-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0A-6 GENERAL INFORMATION
GENERAL PRECAUTIONS
The WARNING and CAUTION below describe some general precautions that you should observe when servicing
a vehicle. These general precautions apply to many of the service procedures described in this manual, and they
will not necessarily be repeated with each procedure to which they apply.
WARNING:

Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING
POINTS” on SECTION 0A.

When it is necessary to do service work with the engine running, make sure that the parking brake
is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for automatic
transmission vehicles). Keep hands, hair, clothing, tools, etc. away from the fan and belts when the
engine is running.

When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.

Do not perform service work in areas where combustible materials can come in contact with a hot
exhaust system. When working with toxic or flammable materials (such as gasoline and refrigerant),
make sure that the area you work in is well-ventilated.

To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail-
pipe, muffler, etc.

New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or
used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory animals.
Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a
long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing engine
oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or
rags if wet with oil, recycle or properly dispose of used oil and filters.

Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly
during driving, obstructing your view and resulting in an accident.
CAUTION:

Before staring any service work, cover fenders, seats and
any other parts that are likely to get scratched or stained dur-
ing servicing. Also, be aware that what you wear (e.g. but-
tons) may cause damage to the vehicle’s finish.

When performing service to electrical parts that does not re-
quire use of battery power, disconnect the negative cable of
the battery.

0A-22 GENERAL INFORMATION
A
ABS : Anti-Lock Brake System
ATDC : After Top Dead Center
API : American Petroleum Institute
ATF : Automatic Transmission Fluid
ALR : Automatic Locking Retractor
AC : Alternating Current
A / T : Automatic Transmission
A / C : Air Conditioning
ABDC : After Bottom Dead Center
A / F : Air Fuel Mixture Ratio
A-ELR : Automatic-Emergency Locking
Retractor
B
B+ : Battery Positive Voltage
BTDC : Before Top Dead Center
BBDC : Before Bottom Dead Center
C
CKT : Circuit
CMP Sensor : Camshaft Position Sensor
(Crank Angle Sensor, CAS)
CO : Carbon Monoxide
CPP Switch : Clutch Pedal Position Switch
(Clutch Switch, Clutch Start
Switch)
CPU : Central Processing Unit
CRS : Child Restraint System
D
DC : Direct Current
DLC : Data Link Connector (Assembly
Line Diag. Link, ALDL, Serial
Data Link, SDL)
DOHC : Double Over Head Camshaft
DOJ : Double Offset Joint
DRL : Daytime Running Light
DTC : Diagnostic Trouble Code
(Diagnostic Code)
E
EBCM : Electronic Brake Control
Module, ABS Control Module
ECM : Engine Control Module
ECT Sensor : Engine Coolant Temperature
Sensor (Water Temp. Sensor,
WTS)
EGR : Exhaust Gas Recirculation
EGRT Sensor : EGR Temperature Sensor
(Recirculated Exhaust
Gas Temp. Sensor, REGTS)
EFE Heater : Early Fuel Evaporation Heater
(Positive Temperature
Coefficient, PTC Heater)
ELR : Emergency Locking Retractor
EPS : Electronic Power Steering
EVAP : Evaporative Emission
EVAP Canister : Evaporative Emission Canister
(Charcoal Canister)
F
4WD : 4 Wheel Drive
G
GEN : Generator
GND : Ground
H
HC : Hydrocarbons
HO2S : Heated Oxygen Sensor
I
IAC Valve : Idle Air Control Valve (Idle
Speed Control Solenoid Valve,
ISC Solenoid Valve)
IAT Sensor : Intake Air Temperature Sensor
(Air temperature Sensor, ATS)
ICM : Immobilizer Control Module
IG : Ignition
ISC Actuator : Idle Speed Control Actuator
(Motor)
ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL
ABBREVIATIONS

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

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

2WD
4WD
1. Oil filler / level plug
2. Oil drain plug
MAINTENANCE AND LUBRICATION 0B-17
ITEM 6-7
Manual Transmission Oil Inspection and Change
[Inspection]
1) Inspect transmission case for evidence of oil leakage.
Repair leaky point if any.
2) Make sure that vehicle is placed level for oil level check.
3) Remove oil level plug of transmission.
4) Check oil level.
Oil level can be checked roughly by means of filler / level plug
hole. That is, if oil flows out of level plug hole or if oil level is found
up to hole when level plug is removed, oil is properly filled.
If oil is found insufficient, pour specified oil up to level hole.
For specified oil, refer to description of oil change under ON-VE-
HICLE SERVICE in SECTION 7A or 7A1.
5) Tighten level plug to specified torque.
[Change]
1) Place the vehicle level and drain oil by removing drain plug.
2) Apply sealant to drain plug and tighten drain plug to specified
torque.
3) Pour specified oil up to level hole.
4) Tighten filler plug to specified torque.
For recommended oil, its amount and tightening torque data, re-
fer to ON-VEHICLE SERVICE of SECTION 7A or 7A1.
ITEM 6-8
Rear Differential Oil Inspection and Change
(4WD vehicle only)
[Inspection]
1) Inspect rear differential case for evidence of oil leakage.
Repair leaky point, if any.
2) Make sure that the vehicle is placed level for oil level check.
3) Remove level plug (1) of differential. Oil level can be checked
roughly by means of level plug hole.
That is, if oil flows out of level plug hole or if oil level is found up
to hole when level plug is removed, oil is properly filled.
If oil is found insufficient, pour specified amount of specified oil
as given in SECTION 7E.
4) Tighten it to specified torque.
[Change]
Place the vehicle level and drain oil by removing drain plug (2). Pour
specified amount of specified oil, tighten drain plug and filler plug
to specified torque, referring to ON-VEHICLE SERVICE in SEC-
TION 7E.

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.

MAINTENANCE AND LUBRICATION 0B-21
[Parking brake]
Check that lever has proper travel.
Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and
brake lever is pulled all the way.
Steering

Check to ensure that steering wheel is free from in-
stability, or abnormally heavy feeling.

Check that the vehicle does not wander or pull to
one side.
Engine

Check that engine responds readily at all speeds.

Check that engine is free from abnormal noise and
abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting sys-
tem are free from abnormal noise and abnormal
vibration or any other abnormal condition.
Meters and Gauge
Check that speedometer, odometer, fuel meter, tem-
perature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set fan switch lever to “HI” position and mode lever to
defroster position for this check. WARNING:
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property damage.
Be prepared to apply regular brake quickly
even if vehicle should start to move.
RECOMMENDED FLUIDS AND LUBRICANTS
Engine oilSE, SF, SG, SH or SJ (Refer to engine oil viscosity chart in item 1-4.)
Engine coolantEthylene-glycol base coolant (“Antifreeze / Anticorrosion coolant”)
Brake fluidDOT3
Manual transmission oilSee SECTION 7A
Rear differential oilSee SECTION 7E
Automatic transmission fluidAn equivalent of DEXRON-IIE or DEXRON-III
Power steering fluidSee material table on SECTION 3B1
Door hingesEngine oil
Engine hood latchEngine oil
Key lock cylinderSpray lubricant