2000 SUZUKI SWIFT RG413 Service Workshop Manual

5E-44 ANTILOCK BRAKE SYSTEM (ABS)
SPECIAL TOOL
09913-65135 09913-75520 09913-75840 09927-18411
Bearing puller Bearing installing tool Sensor ring installer Universal puller
09921-57810 09931-76011 09931-76030
Countershaft holder Tech 1A kit
(See NOTE below.)Mass storage cartridge 16/14 pin DLC cable
09950-78220
Flare nut wrench (10 mm)
NOTE:
This kit includes the following items.
1. Storage case, 2. Operator's manual, 3. Tech 1A, 4. DLC cable, 5. Test lead/probe,
6. Power source cable, 7. DLC cable adaptor, 8. Self-test adaptor

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-1
6
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10A
10B
SECTION 6
ENGINE GENERAL INFORMATION AND
DIAGNOSIS
ENGINE GENERAL INFORMATION AND ENGINE DIAGNOSIS................................................. Section 6
ENGINE MECHANICAL ................................................................................................................. Section 6A1
ENGINE COOLING......................................................................................................................... Section 6B
ENGINE FUEL ................................................................................................................................ Section 6C
ENGINE AND EMISSION CONTROL SYSTEM ............................................................................ Section 6E1
IGNITION SYSTEM ........................................................................................................................ Section 6F1
CRANKING SYSTEM ..................................................................................................................... Section 6G
CHARGING SYSTEM ..................................................................................................................... Section 6H
EXHAUST SYSTEM ....................................................................................................................... Secton 6K
CONTENTS
GENERAL INFORMATION ................................ 6-4
STATEMENT ON CLEANLINESS AND
CARE .............................................................. 6-4
GENERAL INFORMATION ON ENGINE
SERVICE ........................................................ 6-4PRECAUTION ON FUEL SYSTEM
SERVICE .................................................... 6-5
FUEL PRESSURE RELIEF
PROCEDURE ............................................. 6-6
FUEL LEAKAGE CHECK PROCEDURE.... 6-6 WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System :
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
Whether the following systems (parts) are used in the particular vehicle or not depends on vehicle
specifications. Be sure to bear this in mind when performing service work.
EGR valve
Heated oxygen sensor(s) or CO adjusting resistor
Three way catalytic converter
Immobilizer indicator lamp (vehicle with immobilizer indicator lamp can be identified also by HO2S-
2)
Knock sensor

6-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS
ENGINE DIAGNOSIS ......................................... 6-6
GENERAL DESCRIPTION ............................. 6-6
ON-BOARD DIAGNOSTIC SYSTEM
(VEHICLE WITH IMMOBILIZER INDICATOR
LAMP) ............................................................. 6-7
ON-BOARD DIAGNOSTIC SYSTEM
(VEHICLE WITHOUT IMMOBILIZER
INDICATOR LAMP) ...................................... 6-10
PRECAUTION IN DIAGNOSING
TROUBLE ..................................................... 6-11
ENGINE DIAGNOSTIC FLOW TABLE ......... 6-12
CUSTOMER PROBLEM INSPECTION
FORM (EXAMPLE) ................................... 6-14
MALFUNCTION INDICATOR LAMP (MIL)
CHECK...................................................... 6-15
DIAGNOSTIC TROUBLE CODE (DTC)
CHECK...................................................... 6-15
DIAGNOSTIC TROUBLE CODE (DTC)
CLEARANCE ............................................ 6-16
DIAGNOSTIC TROUBLE CODE (DTC)
TABLE ....................................................... 6-17
FAIL-SAFE TABLE.................................... 6-20
VISUAL INSPECTION .............................. 6-22
ENGINE BASIC INSPECTION.................. 6-23
ENGINE DIAGNOSIS TABLE ................... 6-26
SCAN TOOL DATA....................................... 6-31
INSPECTION OF ECM AND ITS
CIRCUITS ..................................................... 6-36
ECM VOLTAGE VALUES TABLE............. 6-37
TERMINAL RESISTANCE TABLE............ 6-43
COMPONENT LOCATION ........................... 6-45
TABLE A-1 MALFUNCTION INDICATOR
LAMP CIRCUIT CHECK - LAMP DOES NOT
COME “ON” AT IGNITION SWITCH ON
(BUT ENGINE AT STOP) ............................. 6-46
TABLE A-2 MALFUNCTION INDICATOR
LAMP CIRCUIT CHECK - LAMP REMAINS
“ON” AFTER ENGINE STARTS ................... 6-47
TABLE A-3 MIL CHECK - MIL FLASHES
AT IGNITION SWITCH ON (VEHICLE
WITHOUT IMMOBILIZER INDICATOR
LAMP) ........................................................... 6-48
TABLE A-4 MIL CHECK - MIL DOES NOT
FLASH OR JUST REMAINS ON EVEN
WITH GROUNDING DIAGNOSIS SWITCH
TERMINAL (VEHICLE WITHOUT
IMMOBILIZER INDICATOR LAMP) .............. 6-48
TABLE A-5 ECM POWER AND GROUND
CIRCUIT CHECK - MIL DOESN’T LIGHT
AT IGNITION SWITCH ON AND ENGINE
DOESN’T START THOUGH IT IS
CRANKED UP .............................................. 6-49
DTC P0105 (DTC NO.11) MANIFOLD
ABSOLUTE PRESSURE (MAP) CIRCUIT
MALFUNCTION ............................................ 6-52
DTC P0110 (DTC NO.18) INTAKE AIR
TEMP. (IAT) CIRCUIT MALFUNCTION ....... 6-55
DTC P0115 (DTC NO.19) ENGINE
COOLANT TEMPERATURE (ECT) CIRCUIT
MALFUNCTION ............................................ 6-57DTC P0120 (DTC NO.13) THROTTLE
POSITION CIRCUIT MALFUNCTION ........... 6-60
DTC P0121 THROTTLE POSITION CIRCUIT
RANGE/PERFORMANCE PROBLEM .......... 6-63
DTC P0130 (DTC NO.14) HEATED OXYGEN
SENSOR (HO2S) CIRCUIT MALFUNCTION
(SENSOR-1) .................................................. 6-66
DTC P0133 HEATED OXYGEN SENSOR
(HO2S) CIRCUIT SLOW RESPONSE
(SENSOR-1) .................................................. 6-68
DTC P0134 HEATED OXYGEN SENSOR
(HO2S) CIRCUIT NO ACTIVITY DETECTED
(SENSOR-1) .................................................. 6-69
DTC P0135 (DTC NO.14) HEATED OXYGEN
SENSOR (HO2S) HEATER CIRCUIT
MALFUNCTION (SENSOR-1) ....................... 6-70
DTC P0136 HEATED OXYGEN SENSOR
(HO2S) CIRCUIT MALFUNCTION
(SENSOR-2) .................................................. 6-72
DTC P0141 HEATED OXYGEN SENSOR
(HO2S) HEATER CIRCUIT MALFUNCTION
(SENSOR-2) .................................................. 6-74
DTC P0171 FUEL SYSTEM TOO LEAN ....... 6-76
DTC P0172 FUEL SYSTEM TOO RICH ....... 6-76
DTC P0300 RANDOM MISFIRE DETECTED
(MISFIRE DETECTED AT 2 OR MORE
CYLINDERS) ................................................. 6-81
DTC P0301 CYLINDER 1 MISFIRE
DETECTED ................................................... 6-81
DTC P0302 CYLINDER 2 MISFIRE
DETECTED ................................................... 6-81
DTC P0303 CYLINDER 3 MISFIRE
DETECTED ................................................... 6-81
DTC P0304 CYLINDER 4 MISFIRE
DETECTED ................................................... 6-81
DTC P0325 (DTC NO.17) KNOCK SENSOR
CIRCUIT MALFUNCTION ............................. 6-86
DTC P0335 (DTC NO.23) CRANKSHAFT
POSITION (CKP) SENSOR CIRCUIT
MALFUNCTION ............................................. 6-88
DTC P0340 (DTC NO.15) CAMSHAFT
POSITION (CMP) SENSOR CIRCUIT
MALFUNCTION ............................................. 6-91
DTC P0400 EXHAUST GAS
RECIRCULATION FLOW MALFUNCTION ... 6-94
DTC P0420 CATALYST SYSTEM
EFFICIENCY BELOW THRESHOLD ............ 6-97
DTC P0443 PURGE CONTROL VALVE
CIRCUIT MALFUNCTION ........................... 6-100
DTC P0480 RADIATOR COOLING FAN
CONTROL SYSTEM MALFUNCTION ........ 6-101
DTC P0500 (DTC NO.16) VEHICLE SPEED
SENSOR (VSS) MALFUNCTION ................ 6-103
DTC P0505 (DTC NO.26) IDLE CONTROL
SYSTEM MALFUNCTION ........................... 6-105
DTC P1450 BAROMETRIC PRESSURE
SENSOR LOW/HIGH INPUT....................... 6-108
DTC P1451 BAROMETRIC PRESSURE
SENSOR PERFORMANCE PROBLEM ...... 6-108

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-3
DTC P1500 ENGINE STARTER SIGNAL
CIRCUIT MALFUNCTION ........................... 6-110
DTC P1510 ECM BACK-UP POWER
SUPPLY MALFUNCTION ........................... 6-111
DTC P1600 SERIAL COMMUNICATION
PROBLEM BETWEEN ECM AND TCM...... 6-112
DTC P1717 A/T DRIVE RANGE (PARK/
NEUTRAL POSITION) SIGNAL CIRCUIT
MALFUNCTION .......................................... 6-114
TABLE B-1 FUEL INJECTOR CIRCUIT
CHECK ........................................................ 6-117
TABLE B-2 FUEL PUMP AND ITS CIRCUIT CHECK ....................................................... 6-118
TABLE B-3 FUEL PRESSURE CHECK ..... 6-120
TABLE B-4 IDLE AIR CONTROL
SYSTEM CHECK........................................ 6-122
TABLE B-5 A/C SIGNAL CIRCUITS
CHECK (VEHICLE WITH A/C) ................... 6-124
TABLE B-6 ELECTRIC LOAD SIGNAL
CIRCUIT CHECK ........................................ 6-126
TABLE B-7 RADIATOR FAN CONTROL
SYSTEM CHECK........................................ 6-128
SPECIAL TOOL ............................................. 6-130

6-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS
GENERAL INFORMATION
STATEMENT ON CLEANLINESS AND CARE
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances
that are measured in the thousands of an millimeter (ten thousands of an inch).
Accordingly, when any internal engine parts are serviced, care and cleanliness are important.
Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and
friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically
stated.
A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the
surfaces on initial operation.
Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft jour-
nal bearings are removed for service, they should be retained in order.
At the time of installation, they should be installed in the same locations and with the same mating surfaces
as when removed.
Battery cables should be disconnected before any major work is performed on the engine.
Failure to disconnect cables may result in damage to wire harness or other electrical parts.
Throughout this manual, the four cylinders of the engine are
identified by numbers; No.1 (1), No.2 (2), No.3 (3) and No.4
(4) counted from crankshaft pulley side to flywheel side.
GENERAL INFORMATION ON ENGINE SERVICE
THE FOLLOWING INFORMATION ON ENGINE SERVICE SHOULD BE NOTED CAREFULLY, AS IT IS
IMPORTANT IN PREVENTING DAMAGE, AND IN CONTRIBUTING TO RELIABLE ENGINE PERFOR-
MANCE.
When raising or supporting engine for any reason, do not use a jack under oil pan. Due to small clearance
between oil pan and oil pump strainer, jacking against oil pan may cause it to be bent against strainer result-
ing in damaged oil pick-up unit.
It should be kept in mind, while working on engine, that 12-volt electrical system is capable of violent and
damaging short circuits.
When performing any work where electrical terminals can be grounded, ground cable of the battery should
be disconnected at battery.
Any time the air cleaner, throttle body or intake manifold is removed, the intake opening should be covered.
This will protect against accidental entrance of foreign material which could follow intake passage into cylin-
der and cause extensive damage when engine is started.
1
2
3
4

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-5
PRECAUTION ON FUEL SYSTEM SERVICE
Work must be done with no smoking, in a well-ventilated
area and away from any open flames.
As fuel feed line (between fuel pump and fuel delivery pipe)
is still under high fuel pressure even after engine was
stopped, loosening or disconnecting fuel feed line directly
may cause dangerous spout of fuel to occur where loosened
or disconnected.
Before loosening or disconnecting fuel feed line, make sure
to release fuel pressure according to “FUEL PRESSURE
RELIEF PROCEDURE”. A small amount of fuel may be
released after the fuel line is disconnected. In order to
reduce the chance of personal injury, cover the fitting to be
disconnected with a shop cloth. Put that cloth in an approved
container when disconnection is completed.
Never run engine with fuel pump relay disconnected when
engine and exhaust system are hot.
Fuel or fuel vapor hose connection varies with each type of
pipe. When reconnecting fuel or fuel vapor hose, be sure to
connect and clamp each hose correctly referring to figure
Hose Connection.
After connecting, make sure that it has no twist or kink.
When installing injector or fuel delivery pipe, lubricate its O-
ring with spindle oil or gasoline.
When connecting fuel pipe flare nut, first tighten flare nut by
hand and then tighten it to specified torque.
[A] : With short pipe, fit hose as far as it reaches pipe joint as shown.
[B] : With following type pipe, fit hose as far as its peripheral projection as shown.
[C] : With bent pipe, fit hose as its bent part as shown or till pipe is about 20 to 30 mm
(0.79–1.18 in.) into the hose.
[D] : With straight pipe, fit hose till pipe is, about 20 to 30 mm (0.79–1.18 in.) into the
hose.
1. Hose
2. Pipe
3. Clamp
4. Clamp securely at a position 3 to 7 mm (0.1 2–0.27 in.) from hose end.
5. 20 to 30 mm (0.79–1.18 in.)

6-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS
FUEL PRESSURE RELIEF PROCEDURE
After making sure that engine is cold, release fuel pressure as fol-
lows.
1) Place transmission gear shift lever in “Neutral” (Shift selector
lever 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 pres-
sure 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 DIAGNOSIS
GENERAL DESCRIPTION
This vehicle is equipped with an engine and emission control system which are under control of ECM.
The engine and emission control system in this vehicle are controlled by ECM. ECM has an On-Board Diagnos-
tic system which detects a malfunction in this system and abnormality of those parts that influence the engine
exhaust emission. When diagnosing engine troubles, be sure to have full understanding of the outline of “On-
Board Diagnostic System” and each item in “Precaution in Diagnosing Trouble” and execute diagnosis accord-
ing to “ENGINE DIAGNOSTIC FLOW TABLE”.
There is a close relationship between the engine mechanical, engine cooling system, ignition system, exhaust
system, etc. and the engine and emission control system in their structure and operation. In case of an engine
trouble, even when the malfunction indicator lamp (MIL) doesn’t turn ON, it should be diagnosed according to
this flow table.CAUTION:
This work must not be done when engine is hot. If done
so, it may cause adverse effect to catalyst.
1

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-7
ON-BOARD DIAGNOSTIC SYSTEM (VEHICLE
WITH IMMOBILIZER INDICATOR LAMP)
ECM in this vehicle has following functions.
When the ignition switch is turned ON with the engine at a
stop, malfunction indicator lamp (MIL) (1) turns ON to check
the bulb of the malfunction indicator lamp (1).
When ECM detects a malfunction which gives an adverse
effect to vehicle emission while the engine is running, it
makes the malfunction indicator lamp (1) in the meter cluster
of the instrument panel turn ON or flash (flashing only when
detecting a misfire which can cause damage to the catalyst)
and stores the malfunction area in its memory.
(If it detects that continuously 3 driving cycles are normal
after detecting a malfunction, however, it makes MIL (1) turn
OFF although DTC stored in its memory will remain.)
As a condition for detecting a malfunction in some areas in
the system being monitored by ECM and turning ON the
malfunction indicator lamp (1) due to that malfunction, 2 driv-
ing cycle detection logic is adopted to prevent erroneous
detection.
When a malfunction is detected, engine and driving condi-
tions then are stored in ECM memory as freeze frame data.
(For the details, refer to description on Freeze frame data.)
It is possible to communicate by using not only SUZUKI scan
tool (Tech-1) (2) but also generic scan tool. (Diagnostic infor-
mation can be accessed by using a scan tool.)
WARM-UP CYCLE
A warm-up cycle means sufficient vehicle operation such that the
coolant temperature has risen by at least 22°C (40°F) from
engine starting and reaches a minimum temperature of 70°C
(160°F).
DRIVING CYCLE
A “Driving Cycle” consists of engine startup, driving mode where
a malfunction would be detected if present, and engine shutoff.
2 DRIVING CYCLES DETECTION LOGIC
The malfunction detected in the first driving cycle is stored in
ECM memory (in the form of pending DTC and freeze frame data)
but the malfunction indicator lamp does not light at this time. It
lights up at the second detection of same malfunction also in the
next driving cycle.
PENDING DTC
Pending DTC means a DTC detected and stored temporarily at
the first driving cycle of the DTC which is detected in the 2 driving
cycle detection logic.
3. Immobilizer indicator lamp
ODO TRIP AB
3 1
2