Fuel pump relay SUZUKI SWIFT 2004 2.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine 1G-7 Fuel System:
Fuel Pressure Relief ProcedureS7RS0B1706003
CAUTION!
This work must not be done when engine is
hot. If done so, it may cause adverse effect to
catalyst.

NOTE
If ECM detects DTC(s) after servicing, clear
DTC(s) referring to “DTC Clearance in
Section 1A”.

1) Make sure that engine is cold.
2) Shift transaxle gear shift lever in “Neutral” (shift select lever in “P” range for A/T model), set parking
brake and block drive wheels.
3) Remove relay / fuse box cover.
4) Disconnect fuel pump relay (1) from relay / fuse box (2).
5) Remove fuel filter cap in order to release fuel vapor pressure in fuel tank, and then reinstall it.
6) Start engine and run it until engine stops for lack of fuel. Repeat cranking engine 2 – 3 times for about 3
seconds each time in order to dissipate fuel pressure
in lines. Fuel connections are now safe for servicing.
7) After servicing, connect fuel pump relay (1) to relay / fuse box and install re lay / fuse box cover.
Fuel Leakage Check ProcedureS7RS0B1706004
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 until 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.
Fuel Lines On-Vehicle InspectionS7RS0B1706005
CAUTION!
Due to the fact that fuel feed line (1) is under
high pressure, use special care when
servicing it.

Visually inspect fuel lines for evidence of fuel leakage,
hose crack and deterioration or damage.
Make sure all cl amps are secure.
Replace parts as needed.
Fuel Pipe Removal and InstallationS7RS0B1706006
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal
1) Relieve fuel pressure in fuel feed line according to “Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Disconnect fuel pipe joint and fuel hose (3) from fuel pipe (2) at the front and rear of each fuel pipe
referring to “Fuel Hose Disconnecting and
Reconnecting”.
4) Mark the location of clamps (1) on fuel pipes (2), so that the clamps can be reinstalled to where they
were.
5) Remove pipes (2) with clamp (1) from vehicle.
6) Remove clamp (1) from pipes (2).
1
I4RS0A170004-01
1
I4RS0A170005-01
2
13
I4RS0A170020-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-10
4) Install suitable vinyl tube onto injector nozzle to
prevent fuel from splashing out when injecting.
5) Put graduated cylinder under injector.
6) Operate fuel pump and apply fuel pressure to
injector as follows:
a) When using scan tool:
i) Connect scan tool to DLC with ignition switch OFF.
ii) Turn ignition switch ON, clear DTC and select “MISC TEST” mode on scan tool.
iii) Turn fuel pump ON by using scan tool.
Special tool
(A): SUZUKI scan tool
b) When not using scan tool: i) Remove fuel pump relay from connector.
ii) Connect two terminals of relay connector using service wire (1) as shown in figure.
CAUTION!
Check to make sure that connection is made
between correct terminals. Wrong
connection can cause damage to ECM, wire
harness, etc.

iii) Turn ignition switch ON. 7) Apply battery voltage to in
jector (1) for 15 seconds
and measure injected fuel volume with graduated
cylinder. Test each injector two or three times. If not
within specification, replace injector.
Injected fuel volume
43 – 47 cc/15 sec. (1.45/1.51 – 1.58/1.65 US/lmp
oz/15 sec.)
8) Check fuel leakage from injector nozzle. Do not operate injector for this check (but fuel pump should
be at work). If fuel leaks (1) more than the following
specifications, replace.
Fuel leakage
Less than 1 drop/min.
Fuel Filler Cap InspectionS7RS0B1706010
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Remove cap (1), and che ck gasket for even filler neck
imprint, and deterioration or any damage. If gasket (2) is
in malcondition, replace cap.
NOTE
If cap requires replacement, only a cap with
the same features should be used. Failure to
use correct cap can result in fire and
personal injury.

(A)I4RS0A170021-01
1
I4RS0A170006-02
I2RH0B170013-01
I2RH01170008-01

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-2
ConditionPossible cause Correction / Reference Item
Motor not running (No
operating sound of
magnetic switch) Shift lever switch is not in P or N, or not
adjusted (A/T)
Shift in P or N, or
adjust switch. (A/T)
Battery run down Recharge battery.
Battery voltage too low due to battery
deterioration Replace battery.
Poor contact in battery terminal
connection Retighten or replace.
Loose grounding cable connection Retighten.
Fuse set loose or blown off Tighten or replace.
Poor contacting action of ignition switch
and magnetic switch Replace.
Lead wire coupler loose in place Retighten.
Open-circuit between ignition switch and
magnetic switch Repair.
Open-circuit in pull-in coil Replace magnetic switch.
Brushes are seating poorly or worn
down Repair or replace.
Poor sliding of plunger and/or pinion Repair.
Faulty starting motor control relay “Main Relay, Fuel Pump Relay and Starting
Motor Control Relay Inspection in Section 1C”.
Faulty ECM and its circuit “Inspection of ECM and Its Circuits in Section
1A”.
Motor not running
(Operating sound of
magnetic switch heard) Battery run down
Recharge battery.
Battery voltage too low due to battery
deterioration Replace battery.
Loose battery cable connections Retighten.
Burnt main contact point, or poor
contacting action of magnetic switch Replace magnetic switch.
Brushes are seating poorly or worn
down Repair or replace.
Weakened brush spring Replace.
Burnt commutator Replace armature.
Layer short-circuit of armature Replace.
Crankshaft rotation obstructed Repair.
Starting motor running
but too slow (small
torque) (If battery and
wiring are satisfactory,
inspect starting motor) Insufficient contact
of magnetic switch
main contacts Replace magnetic switch.
Layer short-circuit of armature Replace.
Disconnected, burnt or worn
commutator Repair commutator or replace armature.
Worn brushes Replace brush.
Weakened brush springs Replace spring.
Burnt or abnormally worn end bush Replace bush.
Starting motor running,
but not cranking engine Worn pinion tip
Replace over-running clutch.
Poor sliding of over-running clutch Repair.
Over-running clutch slipping Replace over-running clutch.
Worn teeth of ring gear Replace flywheel (M/T) or drive plate (A/T).
Noise Abnormally worn bush Replace bush.
Worn pinion or worn teeth of ring gear Replace over-running clutch, flywheel (M/T) or
drive plate (A/T).
Poor sliding of pinion (failure in return
movement) Repair or replace.
Worn internal or planetary gear teeth Replace.
Lack of oil in each part Lubricate.
Starting motor does not
stop running Fused contact points of magnetic switch
Replace magnetic switch.
Short-circuit between turns of magnetic
switch coil (layer short-circuit) Replace magnetic switch.
Failure of returning action in ignition
switch Replace.

Downloaded from www.Manualslib.com manuals search engine Wiring Systems: 9A-14
E: Main harness (RHD)
E: Main harness
56
E06E12
E03or
E85
E07
E09
E08
E13
E10
E11E05 E04
E01 E02
E19
7
22
E34E31
E32
E57
E24
(TO C36)
E33
E36
E35
E30
E29
E28
E20
E21
E22
E27
E26
E23
E25E17E56
E18
E14 E15
E55
E
I7RS0B910902-02
No./Color
Connective position No./ColorConnective position
E01/GRY Windshield wiper motor E22/N Front position light (L)
E02/GRY Brake fluid level switch E23/GRY ECM
E03/BLK ABS control module E24/N Engine Harness (To C36)
E04/BLK A/C pressure sensor E25/BLK Wheel speed sensor (FL)
E05/BLK Wheel speed sensor (FR) E26/N Main fuse box
E06/N Side turn signal light (R) E27/BLK Main fuse box
E07/N Front position light (R) E28/BLK Radiator fan relay #1
E08/BLK Head light (R) E29/BLK Radiator fan relay #2
E09/GRY Front turn signal light (R) E30/BLK Radiator fan relay #3
E10/GRN Rear washer motor E31/BLK Starting motor relay
E11/BLU Windshield washer motor E32/BLK Main relay
E12/BLK (IF EQPD) Front fog light (R)
E33/BLK A/T relay
E13/YEL Forward sensor E34/BLK (IF
EQPD) Front fog light relay
E14/BLK Outside air temperature sensor E35/BLK Fuel pump relay
E15/BLK Horn E36/BLK A/C compressor relay
E17/BLK Radiator fan motor E55/- Weld splice
E18/BLK (IF EQPD) Front fog light (L) E56/BLK
(M16A
engine) Throttle actuator control relay
E19/N Side turn signal light (L) E57/BLK Diagnosis connector #1
E20/GRY Front turn signal light (L) E85/BLK (IF
EQPD) ESP
® control module
E21/BLK Headlight (R)

Downloaded from www.Manualslib.com manuals search engine 9A-15 Wiring Systems:
E: Main harness (LHD)
E: Main harness
56
E06E12
E
E03
E07
E09
E59E08
E13
E10
E11E05 E04
E01
E02E197
E34
E31
E32
E24
(TO C36)
E33
E36
E35
E30
E29
E28
E20
E21
E22
E58
E27
E26
E23
E25E17
E18
E14 E15
E55
I7RS0B910903-02
No./Color
Connective position No./ColorConnective position
E01/GRY Windshield wiper motor E21/BLK Headlight (R)
E02/BRN Brake fluid level switch E22/N Front position light (L)
E03/BLK ABS control module E23/GRY ECM
E04/BLK A/C pressure sensor E24/N Engine Harness (To C36)
E05/BLK Wheel speed sensor (FR) E25/BLK Wheel speed sensor (FL)
E06/N Side turn signal light (R) E26/N Main fuse box
E07/N Front position light (R) E27/BLK Main fuse box
E08/BLK Head light (R) E28/BLK Radiator fan relay #1
E09/GRY Front turn signal light (R) E29/BLK Radiator fan relay #2
E10/GRN Rear washer motor E30/BLK Radiator fan relay #3
E11/BLU Windshield washer motor E31/BLK Starting motor relay
E12/BLK (IF EQPD) Front fog light (R)
E32/BLK Main relay
E13/YEL Forward sensor E33/BLK A/T relay
E14/BLK Outside air temperature sensor E34/BLK (IF
EQPD) Front fog light relay
E15/BLK Horn E35/BLK Fuel pump relay
E17/BLK Radiator fan motor E36/BLK A/C compressor relay
E18/BLK (IF
EQPD) Front fog light (L)
E55/- Weld splice
E19/N Side turn signal light (L) E58/GRY (IF
EQPD) Headlight beam leveling actuator (L)
E20/GRY Front turn signal light (L) E59/GRY (IF
EQPD) Headlight beam leveling actuator (R)

Downloaded from www.Manualslib.com manuals search engine 9A-35 Wiring Systems:
Individual Circuit Fuse Box No. 2 (In J/B)S7RS0B910D006
22
28
23
29
37
24
30
38
25
31
39
26
32
40
27
33
41
34
42
35
43
36
44
45USE THE DESINGNATED FUSES AND RELAYS ONLY.
*1: DEICER / RR FOG *2: DIESEL / HID L *3: MTA / HID R
I5RS0B910919-02
No. Fuse Description on the coverProtected circuit
BLANK BLANK BLANK
15 A IG COILCurrent sensor
ECM
Fuel pump relay
Generator
Heated oxygen relay #1
Heated oxygen relay #2
ICM
IG coil #1
IG coil #2
10 A BACKAuto A/C unit
Back-up light switch (M/T)
Air intake control actuator
HVAC control switch
Headlight leveling switch
Headlight leveling actuator (R)
Headlight leveling actuator (L)
KLS ECM
Transaxle range sensor (A/T)
10 A METERBCM
COMB meter
Flasher relay
15 A ACC 1BCM
Power mirror
15 A ACC 2ACC socket or Cigar lighter
Audio
Multi information display
KLS ECM
15 A WIPERCOMB switch
DRL controller
Rear washer motor
Rear wiper motor
Rear wiper relay
Windshield washer motor
Windshield wiper motor
10 A IG1 SIGA/T relay (A/T)
Power steering control module