Engine and emission SUZUKI SWIFT 2004 2.G Service Repair Manual

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DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 Ignition spark check
1) Check that each spark plug sparks referring to “Ignition
Spark Test in Section 1H”.
Is check result satisfactory? Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.Go to Step 3.
3 Ignition coil power, output and ground circuit check
1) Disconnect ignition coil connector of the cylinder found
as faulty in Step 2.
2) Check ignition coil circuit of the cylinder found as faulty in Step 2 for the following.
• Voltage between power circuit wire terminal of ignition coil connector and vehicle body ground is 10 – 14 V
with ignition switch turned ON.
• Voltage between output circuit wire terminal of ignition coil connector and vehicle body ground is 4 – 6 V with
ignition switch turned ON.
• Resistance between ground circuit wire terminal of ignition coil connector and vehicle body ground is less
than 2 Ω.
Are they in good condition? Go to Step 4.
Repair or replace
defective wire.
4 Ignition coil check
1) Replace ignition coil for No.1 and No.4 spark plugs with
ignition coil for No.2 and No.3 spark plugs.
Is the cylinder found as faulty in good condition now? Faulty ignition coil. Go to Step 5.
5 Ignition coil output circuit check
1) Disconnect connectors from ECM.
2) Check ignition coil circuit of the cylinder found as faulty
in Step 2 for the following.
• Resistance of output wire circuit between ignition coil
connector and ECM connector is less than 2 Ω.
• Resistance of output wire circuit between ignition coil connector and vehicle b ody ground is infinity.
Are they in good condition? Substitute a known-
good ECM and recheck.
Repair or replace
defective wire.

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DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

NOTE
Check to make sure that following conditions ar e satisfied when using this “DTC confirmation
procedure”.
• Intake air temperature at engine start: –10 °C (14 ° F) to 80 °C (176 °F)
• Intake air temperature: –10 °C (14 °F) to 70 °C (158 °F)
• Engine coolant temperature: 70 °C (158 °F) to 150 °C (302 °F)
• Altitude (barometric pressure): 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)

1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and warm up to normal operating temperature.
4) Run engine at idle for 10 min.
5) Drive vehicle and increase engine speed 3000 rpm in 3rd gear.
6) Release accelerator pedal and with engine brake applied, keep vehicle coasting for 5 sec. or more. (Keep fuel cut condition for 5 sec. or more) If fuel cut condition is not ke pt for 5 sec. or more, coast down a slope in engine speed
1000 – 3000 rpm for 5 sec. or more.
7) Stop vehicle and run engine at idle.
8) Check DTC and pending DTC by using scan tool.
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/ or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

DTC detecting condition Trouble area
DTC P0401:
Difference in intake manifold absolute pressure between opened EGR valve
and closed EGR valve is smaller than specified value.
(*2 driving cycle detection logic, monitoring once per driving cycle)
DTC P0402:
Difference in intake manifold absolute pressure between opened EGR valve
and closed EGR valve is la rger than specified value.
(*2 driving cycle detection logic, monitoring once per driving cycle) •EGR valve
• EGR passage
• MAP sensor
•ECM
Step
Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 Do you have SUZUKI scan tool? Go to Step 3.Go to Step 5.

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DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Description”.
2 EGR valve power supply circuit check
1) Remove air intake pipe.
2) With ignition switch turned OFF, disconnect EGR valve
connector.
3) With ignition switch turned ON, measure voltage between “BLK/RED” wire terminal of EGR valve
connector and vehicle body ground.
Is check voltage 10 – 14 V? Go to Step 3.
“BLK/RED” wire is open
circuit.
3 Wire circuit check
1) Disconnect connectors from ECM with ignition switch
turned OFF.
2) Turn ON ignition switch.
3) Measure voltage between engine ground and each “GRN/RED”, “GRN/ORN”, “W HT/RED”, “BRN/YEL” wire
terminals of EGR valve connector.
Is each voltage 0 V? Go to Step 4.
Faulty wire(s) are
shorted to other circuit.
If wires are OK,
substitute a known-
good ECM and recheck.
4 Wire circuit check
1) With ignition switch turned OFF, measure resistance
between engine ground and each “GRN/RED”, “GRN/
ORN”, “WHT/RED”, “BRN/YEL” wire terminals of EGR
valve connector.
Is resistance infinity? Go to Step 5.
Faulty wire(s) are
shorted to ground
circuit.
If wires are OK,
substitute a known-
good ECM and recheck.
5 Short circuit check for EGR valve control circuit
1) With ignition turned OFF, measure resistance between
each EGR valve control circ uit wire (“GRN/RED”, “GRN/
ORN”, “WHT/RED” and “BRN/ YEL” wire) and each EGR
valve control circuit wire.
Is each resistance infinity? Go to Step 6.
Faulty wire(s) are short
circuit.
6 EGR valve stepper motor coil circuit check
1) With ignition switch turned OFF, connect EGR valve
connector.
2) Measure resistance between “E23-1/16” and each “C37- 4”, “C37-3”, “C37-19”, “C37-18” terminals of ECM
connector.
Is each resistance 20 – 31
Ω at 20 °C, 68 °F? Faulty ECM. Substitute
a known-good ECM and
recheck.
Go to Step 7.
7 EGR valve check
1) Check EGR valve resistance referring to “EGR Valve
Inspection in Section 1B”.
Is resistance within specified value? Faulty wire(s) are open
or high resistance
circuit. If wires are OK,
substitute a known-
good ECM and recheck.Faulty EGR valve.

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DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

NOTE
Check to make sure that following conditions ar e satisfied when using this “DTC Confirmation
Procedure”.
• Intake air temperature at engine start: –10 °C (14 ° F) to 80 °C (176 °F)
• Intake air temperature: –10 °C (14 °F) to 70 °C (158 °F)
• Engine coolant temp.: 70 °C, 158 °F to 150 °C (302 °F)
• Altitude (barometric pressure): 2400 m, 8000 ft or less (500 mmHg, 75 kPa or more)

1) Connect scan tool to DLC with ignition switch turned OFF.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Increase vehicle speed to 37 – 62 mph, 60 – 100 km/h. (engine speed: 2500 – 3000 r/min.)
4) Keep above vehicle speed for 10 min. or more (Thr ottle valve opening is kept constant in this step).
5) Stop vehicle and check if DTC / pending DTC exists using sc an tool. If not, check if catalyst monitoring test has
been completed using scan tool. If not in both of above checks (i.e., no DTC / pending DTC and catalyst
monitoring test not completed), check vehicle cond ition (environmental) and repeat Step 3) through 5).
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/ or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

DTC detecting condition Trouble area
Response delay of HO2S-2 signal (shifting delay from rich to lean and
from lean to rich with threshold at 0.45 V) compared to switching cycle
(rich-lean) of A/F feed back is less than specified while vehicle is
running at constant speed and except with high engine load after
warmed up.
(*2 driving cycle detection logic, monitoring once per driving cycle) • Exhaust gas leak
• Warm up three way catalytic converter
malfunction
• HO2S-2 malfunction
• HO2S-1 malfunction
Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 Exhaust system visual check
1) Check exhaust system for leaks, damage and loose
connection.
Is it in good condition? Go to Step 3.
Repair or replace
defective part.

Downloaded from www.Manualslib.com manuals search engine 1A-122 Engine General Information and Diagnosis:
DTC P0443: Evaporative Emission System Purge Control Valve CircuitS7RS0B1104047
Wiring Diagram
DTC Detecting Condition and Trouble Area3
HO2S-2 output voltage check
1) Check output voltage of HO2S-2 referring to “DTC
P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage /
High Voltage (Sensor-2)” and “DTC P0137 / P0138: O2
Sensor (HO2S) Circuit Low Voltage / High Voltage
(Sensor-2)”.
Is check result satisfactory? Replace exhaust
manifold (built in warm
up three way catalytic
converter) and exhaust
center pipe (built in
three way catalytic
converter).
Check “BRN” and / or
“YEL” wires for open
and short, and
connections for poor
connection.
If wires and connections
are OK, replace HO2S-
2.
Step Action Yes No
E23
C37
34
1819
567
1011
17
20
47 46
495051
2122
52 16
25 9
24
14
29
55
57 54 53
59
60 58 2
262728
15
30
56 4832 31
34353637
40
42 39 38
44
45 43 41 33 1
1213
238
34
1819
567
1011
17
20
47 46
495051
2122
52 16
25 9
24
14
29
55
57 54 53
59
60 58 2
262728
15
30
56 48 32 31
34353637
40
42 39 38
44
45 43 41 331
1213
238
BLK/WHT
BLK/RED
BLK/RED
WHTBLK/YELBLK/YEL
BLK/YEL
GRN
BRN/WHT
12V 5V
5
4 2
3 6E23-29
E23-1
E23-60
C37-58
C37-15 C37-30
BLK/ORN
BLKBLKE23-31 BLK
7
8
BLK/REDBLK/REDE23-16
1
C37-29 BLU/BLK
I6RS0C110020-02
1. EVAP canister purge valve
4. Main fuse box7. “FI” fuse
2. Main relay 5. Ignition switch8. “IG ACC” fuse
3. “IG COIL” fuse 6. ECM
DTC detecting conditionTrouble area
Monitor signal of EVAP canister purge valve is different from
command signal. (Circuit open or short)
(2 driving cycle detection logic) • EVAP canister purge valve
• EVAP canister purge valve circuit
•ECM

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-123
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

1) With ignition switch OFF, connect scan tool to DLC.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and warm up normal operating temperature.
4) Drive vehicle at more than 40 km/h, 25 mph for 5 min. or more.
5) Check DTC and pending DTC.
DTC Troubleshooting
WARNING!
In order to reduce risk of fire and personal injury, this work must be performed in a well ventilated area
and away from any open flames such as gas water heater.

NOTE
• When measuring circuit voltage, resistance and/ or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 EVAP canister purge power supply circuit check
1) Turn OFF ignition switch and disconnect connector from
EVAP canister purge valve.
2) Measure voltage between engine ground and “BLK/ RED” wire terminal of EVAP canister purge valve
connector with ignition switch turned ON.
Is it voltage 10 – 14 V? Go to Step 3.
“BLK/RED” wire is open
circuit.
3 Wire circuit check
1) Disconnect connectors from ECM with ignition switch
turned OFF.
2) Measure resistance between “C37-29” terminal of ECM connector and vehicle body ground.
Is resistance infinity? Go to Step 4.
“BLU/BLK” wire is
shorted to ground
circuit.
4 Wire circuit check
1) Measure voltage between “C37-29” terminal of ECM
connector and vehicle body ground with ignition switch
turned ON.
Is voltage 0 V? Go to Step 5.
“BLU/BLK” wire is
shorted to other circuit.

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DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure1) Turn OFF ignition switch.
2) Clear DTC with ignition switch turned ON.
3) Run engine at idle speed.
4) Check DTC.
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/ or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

DTC detecting condition Trouble area
Monitor signal of radiator cooling fan relay is different from
command signal.
(1 driving cycle detection logic) • Radiator cooling fan relay circuit malfunction
• Radiator cooling fa
n relay malfunction
• ECM malfunction
Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 Circuit fuse check
1) Check “RDTR FAN” fuse (1) in individual circuit fuse box
No.1 with ignition switch turned OFF.
Is “RDTR FAN” fuse in good condition? Go to Step 3.
Check for short in
circuits connected to
this fuse.
1
I4RS0A110022-01

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DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester.

1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Warm up engine to normal operating temperature.
4) M/T model
a) Drive vehicle at 4000 rpm (e ngine speed) with 3rd gear.
b) Release accelerator pedal and with engine brake applied, keep vehicle coasting for 6 sec. or more (fuel cut condition for 5 sec. or more) and stop vehicle.
A/T model
a) Drive vehicle at more than 3000 rpm for 10 sec.
5) Check pending DTC and DTC.
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/ or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

DTC detecting condition Trouble area
• Vehicle speed signal is not input while fuel is cut at deceleration for 4 seconds continuously at 3600 rpm or
less.
• Vehicle speed signal is not input even if engine is running with more than 3000 rpm at D-Range for 4 sec. (A/T model).
(2 driving cycle detection logic) • Wheel speed sensor and/or its circuit
• ABS/ESP®
control module
•ECM
Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 Vehicle speed signal check
Is vehicle speed displayed on scan tool in Step 4) and 5) of
“DTC Confirmation Procedure”? Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.Go to Step 3.
3 DTC check in ABS/ESP ® control module
1) Check ABS/ESP ® control module for DTC.
Is there any DTC of wheel speed sensor or CAN
communication system? Go to applicable DTC
diag. flow.
Substitute a know-good
ECM and recheck.

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DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 A/C refrigerant pressure sensor power supply circuit
check
1) Disconnect connector from A/C refrigerant pressure
sensor with ignition switch turned OFF.
2) Check for proper connection of A/C refrigerant pressure sensor at “GRY/RED”, “RED ” and “ORN” wire terminals.
3) Turn ON ignition switch, measure voltage between engine ground and “GRY/RED” wire terminal of A/C
refrigerant pressure sensor connector.
Is voltage 4 – 6 V? Go to Step 5.
Go to Step 3.
3 A/C refrigerant pressure sensor power supply circuit
check
1) Disconnect connectors from MAP sensor with ignition
switch turned OFF.
2) Turn ON ignition switch, measure voltage between engine ground and “GRY/RED” wire terminal of A/C
refrigerant pressure sensor connector.
Is voltage 4 – 6 V? Faulty MAP sensor. Go to Step 4.
4 A/C refrigerant pressure sensor power supply circuit
check
1) Disconnect connectors from ECM with ignition switch
turned OFF.
2) Measure resistance between engine ground and “C37- 14” terminal of ECM connector.
Is resistance infinity? Go to Step 6.
“GRY/RED” wire is
shorted to ground
circuit.
5 A/C refrigerant pressure sensor signal circuit check
1) Connect connectors to ECM.
2) Turn ON ignition switch, measure voltage between
engine ground and “RED” wire terminal of A/C
refrigerant pressure sensor connector.
Is voltage 4 – 6 V? Go to Step 7.
Go to Step 6.
6 A/C refrigerant pressure sensor signal circuit check
1) Disconnect connectors from ECM with ignition switch
turned OFF.
2) Measure resistance between engine ground and “E23- 55” terminal of ECM connector.
Is resistance infinity? Go to Step 7.
“RED” wire is shorted to
ground circuit.

Downloaded from www.Manualslib.com manuals search engine 1A-132 Engine General Information and Diagnosis:
DTC P0533: A/C Refrigerant Pressure Sensor “A” Circuit HighS7RS0B1104053
Wiring Diagram
Refer to “DTC P0532: A/C Refrigerant Pressure Sensor “A” Circuit Low”.
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure1) Connect scan tool to DLC with ignition switch turned OFF.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Check DTC.
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/ or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

7 A/C refrigerant pressure sensor check
1) Check A/C refrigerant pressure sensor referring to “A/C
Refrigerant Pressure Sensor and Its Circuit Inspection in
Section 7B” or “A/C Refrigerant Pressure Sensor and Its
Circuit Inspection in Section 7B”.
Is it in good condition? Substitute a known-
good ECM and recheck.
Faulty A/C refrigerant
pressure sensor.
Step Action Yes No
DTC detecting condition
Trouble area
A/C refrigerant pressure sensor signal voltage is higher
than 4.93 V for 0.5 sec. continuously.
(1 driving detection logic but MIL does not light up) • A/C refrigerant pressure sensor circuit
• A/C refrigerant pressure sensor
• MAP sensor
•ECM
Step
Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 A/C refrigerant pressure sensor power supply circuit
check
1) Disconnect connector from A/C refrigerant pressure
sensor with ignition switch turned OFF.
2) Check for proper connection of A/C refrigerant pressure sensor at “GRY/RED”, “RED ” and “ORN” wire terminals.
3) Turn ON ignition switch, measure voltage between engine ground and “GRY/RED” wire terminal of A/C
refrigerant pressure sensor connector.
Is voltage 4 – 6 V? Go to Step 4.
Go to Step 3.