2000 SUZUKI SWIFT ESP

6-92 ENGINE GENERAL INFORMATION AND DIAGNOSIS
INSPECTION
Step Action Yes No
1Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE
DIAG.
FLOW TABLE”.
2 Check CMP Sensor and connector for proper installa-
tion.
Is CMP sensor installed properly and connector con-
nected securely?Go to Step 3. Correct.
3 Check Wire Harness and Connection.
1) Disconnect connector from CMP sensor.
2) Check for proper connection to CMP sensor at
each terminal.
3) If OK, turn ignition switch ON and check for volt-
age at each terminal of sensor connector discon-
nected. See Fig. 1.
Terminal “B+” : 10 – 14 V
Terminal “Vout” : 4 – 5 V
Terminal “GND” : 0 V
Is check result satisfactory?Go to Step 5. Go to Step 4.
4Was terminal “Vout” voltage out of specification in
Step 3 check?“RED/YEL” wire open,
short or poor connection.
If wire and connection
are OK, substitute a
known-good ECM and
recheck.“BLK/RED” or “BLK/
ORN” wire open,
short or poor con-
nection.
5 Check Ground Circuit for open.
1) Turn ignition switch OFF.
2) Check for continuity between “GND” terminal of
CMP sensor connector and engine ground.
Is continuity indicated?Go to Step 6.“BLK/ORN” wire
open or poor ground
connection.
6 Check CMP Sensor for operation.
1) Remove CMP sensor from sensor case.
2) Remove metal particles on end face of CMP sen-
sor, if any.
3) Connect each connector to ECM and CMP sensor.
4) Turn ignition switch ON.
5) Check for voltage at terminal C42-11 of connector
connected to ECM by passing magnetic sub-
stance (iron) while keeping approximately 1 mm
(0.03 in.) gap with respect to end face of CMP
sensor. See Fig. 2 and 3.
Does voltage vary from low (0 – 1 V) to high (4 – 5 V)
or from high to low?Go to Step 7. Replace CMP sen-
sor.
7 Check Signal Rotor for the following.
See Fig. 4.
Damage
No foreign material attached
Is it in good condition?Intermittent trouble or
faulty ECM.
Check for intermittent
referring to “Intermittent
and Poor Connection” in
Section 0A.Clean rotor teeth or
replace CMP sensor.

6-112 ENGINE GENERAL INFORMATION AND DIAGNOSIS
DTC P1600 SERIAL COMMUNICATION PROBLEM BETWEEN ECM AND TCM
WIRING DIAGRAM
CIRCUIT DESCRIPTION
The serial data line is pulled up to about 12 V by ECM and TCM transmits information to ECM through it by con-
trolling its grounding.
TCM constantly sends information while ignition switch is ON as to whether judgement was made or not with
respect to all detectable DTCs as well as whether or not abnormality exists after judgement.
DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF.
2) Clear DTC with ignition switch ON.
3) Start engine and run it at idle for 1 min.
4) Select “DTC” mode on scan tool and check DTC.
INSPECTION
ECM
TCMIG1
BLK/WHT
12V
C42 (31P) C41 (24P) G02 (17P)1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 28 27 29 30 315 6
1 2 3 4 5 6 7
11 12
9 10 11 13 12 14 15 16
16 171 2
7 8
13 14 3 4
9 10
15 17 188
19 20 21 22 23 24
C44-20
C41-23
DTC DETECTING CONDITION POSSIBLE CAUSE
No signal inputted from TCM to ECM or check sum
error while engine running“BLK/WHT” circuit open or short
TCM power or ground circuit open
TCM malfunction
ECM malfunction
Step Action Yes No
1Was “ENGINE DIAG. FLOW TABLE” per-
formed?Go to Step 2. Go to “ENGINE DIAG.
FLOW TABLE”.
2 Check Signal Voltage.
Check voltage between terminal C41-23 and
body ground with ignition switch ON.
Does it change between 0 – 12 V? See Fig. 1.Intermittent trouble or
faulty ECM or TCM.
Check for intermittent
trouble referring to “Inter-
mittent and poor connec-
tion” in Section 0A.Go to Step 3.

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-117
TABLE B-1 FUEL INJECTOR CIRCUIT CHECK
WIRING DIAGRAM
INSPECTION
1. No.1 injector 3. No.3 injector
2. No.2 injector 4. No.4 injector
ECM
1
2
3
4
+B
C42-9
C42-21
C42-8 C42-31 BLU/YEL
BLU/WHT
BLU/RED
BLU/ORN
BLK/RED
C42 (31P) C41 (24P) G02 (17P)1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 28 27 29 30 315 6
1 2 3 4 5 6 7
11 12
9 10 11 13 12 14 15 16
16 171 2
7 8
13 14 3 4
9 10
15 17 188
19 20 21 22 23 24
Step Action Yes No
1Was “ENGINE DIAG. FLOW TABLE” per-
formed?Go to Step 2. Go to “ENGINE DIAG.
FLOW TABLE”.
2 Check Injector for operating sound.
Using sound scope, check each injector for
operating sound at engine cranking.
Do all 4 injector make operating sound?Fuel injector circuit is in
good condition.Go to Step 3.
3 Dose none of 4 injectors make operating sound
at Step 2?Go to Step 4. Check coupler connec-
tion and wire harness of
injector not making oper-
ating sound and injector
itself (Refer to Section
6E1).
4 Check power circuit of injectors for open and
short.
Is it normal?Check all 4 injectors for
resistance respectively.
If resistance is OK, substi-
tute a known-good ECM
and recheck.Power circuit open or
short.

6A1-10 ENGINE MECHANICAL (M13 ENGINE)
b) Check housing No. and select special tool corresponding to
housing No., referring to “special tool selection table”.
Special tool selection table
c) Hold down the tappet so as not to hang to the shim with
special tool by installing it on camshaft housing with hous-
ing bolt (1) to specified torque.
Special tool
(A) : 09916-67020
Tightening torque
Camshaft housing bolts (for tightening of special tool )
(a) : 8 N·m (0.8 kg-m, 6.0 lb-ft)
4) Turn camshaft by approximately 90° clockwise and remove
shim (3).
5) Using a micrometer (2), measure the thickness of the
removed shim (1), and determine replacement shim by cal-
culating the thickness of new shim with the following formula
and table.
Intake side:
A = B + (C – 0.20 mm (0.008 in.))
Exhaust side:
A = B + (C – 0.30 mm (0.012 in.))
A : Thickness of new shim
B : Thickness of removed shim
C : Measured valve clearance No. on camshaft
housingEmbossed mark
on special tool
I2 IN2
I3, I4, I5 IN345
E2 EX2
E3, E4, E5 EX345
A: I : Intake side or E : Exhaust side
B: Position from timing chain side
C: Pointing to timing chain side
WARNING:
Never put in the hand between cam shaft and tappet.
1. Special tool
2. Magnet

6A1-34 ENGINE MECHANICAL (M13 ENGINE)
TIMING CHAIN AND CHAIN TENSIONER
REMOVAL
1) Disconnect negative cable at battery.
2) Drain engine oil.
3) Remove oil pan referring to “OIL PAN AND OIL PUMP
STRAINER”.
4) Remove cylinder head cover referring to “CYLINDER HEAD
COVER”.
5) Remove timing chain cover referring to “TIMING CHAIN
COVER”.
6) Align both intake and exhaust camshaft timing sprocket
marks (1) with notches (2) of cylinder head respectively by
turning crankshaft.
7) Remove timing chain tensioner adjuster assembly (3).
8) Remove timing chain tensioner (4).
9) Remove timing chain No.1 guide (5).
10) Remove timing chain (6) with crankshaft timing sprocket (7).
1. Crankshaft timing sprocket 4. Timing chain tensioner
: Apply engine oil to sliding surface.7. Chain tensioner mounting bolt
2. Timing chain
: Apply engine oil.5. Timing chain tensioner adjuster assembly 8. Chain guide mounting bolt
3. Timing chain No.1 guide
: Apply engine oil to sliding surface.6. Chain tensioner adjuster mounting bolt Tightening torque
CAUTION:
After timing chain is removed, never turn crankshaft and
camshafts independently more than its allowable turning
range described in “INSTALLATION” section.
If turned, interference may occur between piston and
valves and valves themselves, and parts related to piston
and valves may be damaged.

6A1-64 ENGINE MECHANICAL (M13 ENGINE)
6) If clearance can not be brought to within its limit even by
using a new standard size bearing, regrind crankpin to
undersize and use 0.25 mm undersize bearing.
ASSEMBLY
1) Install piston pin to piston (1) and connecting rod (2) :
a) After applying engine oil to piston pin and piston pin holes
in piston and connecting rod.
b) Fit connecting rod as shown in figure.
c) Insert piston pin to piston and connecting rod.
d) Install piston pin circlips (3).
2) Install piston rings to piston :
a) As indicated in figure, 1st and 2nd rings have “T” mark
respectively. When installing these piston rings to piston,
direct marked side of each ring toward top of piston.
b) 1st ring (1) differs from 2nd ring (2) in thickness, shape and
color of surface contacting cylinder wall.
Distinguish 1st ring from 2nd ring by referring to figure.
c) When installing oil ring (3) install spacer first and then two
rails.
3) After installing three rings (1st, 2nd and oil rings), distribute
their end gaps as shown in figure. NOTE:
After checking the rod bearing clearance, make sure that
checking for Connecting rod bolt deformation.
Refer to “INSPECTION” of “CONNECTING ROD”.
NOTE:
Circlip should be installed with its cut part facing as
shown in figure. Install so that circlip end gap comes
within such range as indicated by arrow.
1. 1st ring
2. 2nd ring
3. Oil ring
1. Arrow mark
2. 1st ring end gap
3. 2nd ring end gap and oil ring spacer gap
4. Oil ring upper rail gap
5. Oil ring lower rail gap

6A1-78 ENGINE MECHANICAL (M13 ENGINE)
Selection of main bearings
STANDARD BEARING :
If bearing is in malcondition, or bearing clearance is out of specifi-
cation, select a new standard bearing according to the following
procedure and install it.
1) First check journal diameter. As shown in figure, crank web
No.2 has stamped numbers.
Three kinds of numbers (“1”, “2” and “3”) represent the fol-
lowing journal diameters.
Stamped numbers on crank web No.2 represent journal
diameters marked with an arrow in figure respectively.
For example, stamped number “1” indicates that correspond-
ing journal diameter is 44.994 – 45.000 mm (1.7714 –
1.7717 in.).
Crankshaft journal diameter
2) Next, check bearing cap bore diameter without bearing. On
mating surface of cylinder block, five alphabets are stamped
as shown in figure.
Three kinds of alphabets (“A”, “B” and “C”) represent the fol-
lowing cap bore diameters.
Stamped alphabets on cylinder block represent bearing cap
bore diameter marked with an arrow in figure respectively.
For example, stamped “A” indicates that corresponding bear-
ing cap bore diameter is 49.000 – 49.006 mm (1.9291 –
1.9294 in.).
Crankshaft bearing cap boreStamped
numbersJournal diameter
1 44.994 – 45.000 mm (1.7714 – 1.7717 in.)
2 44.988 – 44.994 mm (1.7712 – 1.7714 in.)
3 44.982 – 44.988 mm (1.7709 – 1.7712 in.)
Stamped
alphabetBearing cap bore diameter
(without bearing)
A 49.000 - 49.006 mm (1.9291 - 1.9294 in.)
B 49.006 - 49.012 mm (1.9294 - 1.9296 in.)
C 49.012 - 49.018 mm (1.9296 - 1.9298 in.)

ENGINE AND EMISSION CONTROL SYSTEM 6E1-5
AIR INTAKE SYSTEM
The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), throttle body (3),
idle air control valve (4) and intake manifold (5).
The air (by the amount corresponding to the throttle valve (6) opening and engine speed) is filtered by the air
cleaner (1), passes through the throttle body (3), is distributed by the intake manifold (5) and finally drawn into
each combustion chamber.
When the idle air control valve (4) is opened according to the signal from ECM, the air (7) bypasses the throttle
valve (6) through bypass passage and is finally drawn into the intake manifold (5).
1. Air Cleaner 16. Immobilizer indicator lamp (if equipped) 31. Monitor connector (vehicle without immobi-
lizer indicator lamp)
2. EVAP canister purge valve 17. Knock sensor (if equipped) 31-1. Diagnosis switch terminal (vehicle without
immobilizer indicator lamp)
3. IAT sensor 18. ECT sensor 31-2. Test switch terminal (vehicle without immobi-
lizer indicator lamp)
4. TP sensor 19. CMP sensor 31-3. Duty output terminal (vehicle without immobi-
lizer indicator lamp)
5. IAC valve 20. CKP sensor 32. Stop lamp
6. MAP sensor 21. VSS 33. Stop lamp switch
7. EGR valve (if equipped) 22. Radiation fan 34. ECM
8. EVAP canister 23. Malfunction indicator lamp in combination meter 35. Barometric pressure sensor (if equipped)
9. Tank pressure control valve (built-in fuel pump) 24. Park/Neutral position switch (A/T) 36. Battery
10. Fuel pump (with pressure regulator) 25. Ignition switch 37. CO adjusting resistor (if equipped)
11. Fuel level sensor (vehicle with immobilizer indi-
cator lamp)26. Starter magnetic switch 38. A/C compressor clutch (if equipped)
12. Ignition coil assembly 27. TCM 39. A/C switch (if equipped)
13. Fuel injector 28. Transmission range switch (A/T) 40. A/C evaporator temp. sensor (if equipped)
14. Heated Oxygen Sensor (HO2S)-1
(if equipped)29. DLC 41. Immobilizer control module (if equipped)
15. Heated Oxygen Sensor (HO2S)-2
(if equipped)30. Electric load 42. Main relay
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6
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