2000 SUZUKI SWIFT oil valve

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-27
ConditionPossible CauseReferring Item
Improper engine
idling or engine
fails to idleIgnition system out of order

Faulty spark plug

Leaky or disconnected high-tension cord

Faulty ignition coil with ignitor
Fuel system out of order

Fuel pressure out of specification

Leaky manifold, throttle body, or cylinder head
gasket
Engine and emission control system out of
order

Malfunctioning EGR valve

Faulty idle air control system

Faulty evaporative emission control system

Faulty EGR system

Faulty fuel injector(s)

Poor performance of ECT sensor, TP sensor or
MAP sensor

Faulty ECM (PCM)
Engine overheating
Low compression
Others

Loose connection or disconnection of vacuum
hoses

Malfunctioning PCV valve
Spark plugs in Section 6F
High-tension cords in Section 6F
Ignition coil in Section 6F
Diagnostic Flow Table B-3
EGR system in Section 6E2
Diagnostic Flow Table B-4
EVAP control system in Section
6E2
EGR system in Section 6E2
Diagnostic Flow Table B-1
ECT sensor, TP sensor or MAP
sensor in Section 6E2
Refer to “Overheating” section
Previously outlined
PCV system in Section 6E2

6-1-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
CONNECTOR “C01”
TERMINAL
NO.CIRCUITNORMAL
VOLTAGECONDITION
1Ground——
2Ground——
3Ground——
4EVAP canister purge valve10 – 14 VIgnition switch ON
Indication
deflection
5Power steering switch
deflection
repeated
0 V and
Ignition switch ON
0 V and
10 – 14 V
6Idle air control valve0 – 13 VAt specified idle speed after engine warmed
up
7Heater of HO2S-110 – 14 VIgnition switch ON
8Fuel injector NO.410 – 14 VIgnition switch ON
9Fuel injector NO.110 – 14 VIgnition switch ON
10Sensor ground——
11Camshaft position sensor0 – 0.8 V
and 4 – 6 VIgnition switch ON
12Blank——
13Heater oxygen sensor-1Refer to DTC P0130 diag. flow table
14Engine coolant temp. sensor0.55 – 0.95 VIgnition switch ON
Engine coolant temp.: 80C (176F)
15Intake air temp. sensor2.0 – 2.7 VIgnition switch ON
Intake air temp.: 20C (68F)
16Blank——
17Electric load signal (+)
0 – 1 VIgnition switch ON
Small light and rear defogger OFF
17Electric load signal (+)
10 – 14 VIgnition switch ON
Small light and rear defogger ON
18Blank——
19Ignition coil #2——
20Ignition coil #1——
21Fuel injector NO.210 – 14 VIgnition switch ON
22Power source for sensor4.75 – 5.25 VIgnition switch ON
23Crankshaft position sensor (+)——
24Crankshaft position sensor (–)——
25Blank——
26Manifold absolute pressure
sensor3.3 – 4.0 VIgnition switch ON
Barometric pressure: 100 kPa (760 mmHg)
27Blank——
28Immobilizer indicator lamp0 – 2 VIgnition switch ON28Immobilizer indicator lamp10 – 14 VWhen engine running
29Blank——
30Blank——
31Fuel injector NO.310 – 14 VIgnition switch ON

ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-35
CONNECTOR “C02”
TERMINAL
NO.CIRCUITNORMAL
VOLTAGECONDITION
1A / C ON output signal0 VIgnition switch ON
2EGR valve (stepper motor10 – 14 VIgnition switch ON2coil 1)0 – 1 VEngine running at idle speed
3Data link connector10 – 14 VIgnition switch ON
4Heater of HO2S-210 – 14 VIgnition switch ON
5Power source10 – 14 VIgnition switch ON
6Power source10 – 14 VIgnition switch ON
7Power source for buck-up10 – 14 VIgnition switch ON and OFF
8EGR valve (stepper motor10 – 14 VIgnition switch ON8coil 3)10 – 14 VEngine running at idle speed
9EGR valve (stepper motor10 – 14 VIgnition switch ON9coil 2)10 – 14 VEngine running at idle speed
10Main relay10 – 14 VIgnition switch OFF10Main relay0.4 – 1.5 VIgnition switch ON
112-range signal (A / T)10 – 14 VIgnition switch ON, Select lever at 2-range
12N-range signal (A / T)10 – 14 VIgnition switch ON, Select lever at N-range
13Heated oxygen sensor-2Refer to DTC P0130 diag. flow table
14D-range signal (A / T)10 – 14 VIgnition switch ON, Select lever at D-range
15R-range signal (A / T)10 – 14 VIgnition switch ON, Select lever at R-range
16A/C input signal
10 – 14 VIgnition switch ON
A / C switch OFF
16A/C in ut signal
0 – 2 VIgnition switch ON
A / C switch ON
17EGR valve (stepper motor10 – 14 VIgnition switch ON17coil 4)0 – 1 VEngine running at idle speed
18Radiator fan control relay
10 – 14 V
Ignition switch ON
Engine coolant temp.: Below 92.5C
(199F)
18Radiator fan control relay
0 – 1 V
Ignition switch ON
Engine coolant temp.: Below 97.5C
(208F) or higher
19Fuelpumprelay0 – 1 VFor 2 seconds after ignition switch ON19Fuel um relay10 – 14 VAfter the above time
20Blank——
21P-range signal (A / T)
Indication
deflection
repeated
0 V and
10 – 14 V
Ignition switch ON
22Fuel level sensor (gauge)
0 – 2 VIgnition switch ON
Fuel tank fully filled
22Fuel level sensor (gauge)
4.5 – 7.5 VIgnition switch ON
Fuel tank emptied
23L-range signal (A / T)10 – 14 VIgnition switch ON, Select lever at L-range
24Blank——

1 2
1. ECM (PCM) coupler disconnected
2. Ohmmeter
ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13) 6-1-37
Resistance Check
1) Disconnect ECM (PCM) couplers from ECM (PCM) with ignition
switch OFF.
CAUTION:
Never touch terminals of ECM (PCM) itself or connect
voltmeter or ohmmeter.
2) Check resistance between each terminal of couplers discon-
nected.
CAUTION:

Be sure to connect ohmmeter probe from wire harness
side of coupler.

Be sure to turn OFF ignition switch for this check.

Resistance in table below represents that when parts
temperature is 20C (68F).
TERMINALSCIRCUITSTANDARD RESISTANCE
C01-7 to C03-6HO2S-1 heater11.7 – 15.6 Ω
C02-4 to C03-6HO2S-2 heater11.7 – 15.6 Ω
C01-9 to C02-5 / 6No.1 injector12.0 – 13.0 Ω
C01-21 to C02-5 / 6No.2 injector12.0 – 13.0 Ω
C01-31 to C02-5 / 6No.3 injector12.0 – 13.0 Ω
C01-8 to C02-5 / 6No.4 injector12.0 – 13.0 Ω
C02-2 to C02-5 / 6EGR valve (stepper motor coil 4)20 – 24 Ω
C02-9 to C02-5 / 6EGR valve (stepper motor coil 3)20 – 24 Ω
C02-8 to C02-5 / 6EGR valve (stepper motor coil 2)20 – 24 Ω
C02-17 to C02-5 / 6EGR valve (stepper motor coil 1)20 – 24 Ω
C01-4 to C02-5 / 6EVAP canister purge valve30 – 34 Ω
C02-19 to C03-6Fuel pump relay70 – 110 Ω
C02-1 to Body groundA / C control moduleNo continuity
C02-18 to C02-5 / 6Radiator fan control relay70 – 110 Ω
C02-10 to C02-7Main relay70 – 110 Ω
C01-1 to Body groundGroundContinuity
C01-2 to Body groundGroundContinuity
C01-3 to Body groundGroundContinuity

INFORMATION SENSORS
-1. MAP sensor
-2. TP sensor
-3. IAT sensor
-4. ECT sensor
-5. Heated oxygen sensor-1
5-1. Heated oxygen sensor-2
-6. VSS (A / T)
-7. Transmission range switch (A / T)
-8. Battery
-9. CMP sensor
-10. CKP sensor
-11. Fuel level sensor (gauge) (in fuel tank)
-12. PSP switch
-13. A / C control module (if equipped)
-14. VSS (speedometer) (M / T)OTHERS
A: ECM (PCM)
B: Main relay
C: EVAP canister
D: Data link connector CONTROL DEVICES
a: Fuel injector
b: EVAP canister purge valve
c: Fuel pump relay
d: EGR valve (step motor)
e: Malfunction indicator lamp
f: Ignition coil assembly
g: Radiator fan control relay
h: IAC valve
6-1-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
COMPONENT LOCATION

Below
specified value
6-1-70 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
1. CKP sensor signal
2. No.1 fuel injector signal
3. No.3 fuel injector signal
4. Fuel injection time
Display of fuel injection signal using oscilloscope
Waveforms at specified idle speed5ms/Div
DTC DETECTING CONDITIONPOSSIBLE CAUSE

Engine under other than high revolution condition

Not on rough road

Engine speed changing rate

Manifold absolute
pressure changing rate

Throttle opening changing rate

Misfire rate per 200 or 1000 engine revolutions (how
much and how often crankshaft revolution speed
changes) is higher than specified value
Engine overheating

Vacuum leaks (air inhaling) from air intake system

Ignition system malfunction (spark plug(s), high-
tension cord(s), ignition coil assembly)

Fuel pressure out of specification

Fuel injector malfunction (clogged or leakage)

Engine compression out of specification

Valve lash (clearance) out of specification

Manifold absolute pressure sensor malfunction

Engine coolant temp. sensor malfunction

PCV valve malfunction

EVAP control system malfunction

EGR system malfunction
DTC CONFIRMATION PROCEDURE
NOTE:
Among different types of random misfire, if misfire occurs at cylinders 1 and 4 or cylinders 3 and 2 simulta-
neously, it may not possible to reconfirm DTC by using the following DTC confirmation procedure. When
diagnosing the trouble of DTC P0300 (Random misfire detected) of the engine which is apparently misfir-
ing, even if DTC P0300 cannot be reconfirmed by using the following DTC confirmation procedure, pro-
ceed to the following Diag. Flow Table.
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 with 2 persons, a driver and a tester.
1) Turn ignition switch OFF.
2) Clear DTC with ignition switch ON.
3) Check vehicle and environmental condition for:
–Altitude (barometric pressure): 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)
–Intake air temp.: between –10C and 80C (14F and 176F)
–Engine coolant temp.: –10C, 14F or higher
4) Start engine and keep it at idle for 2 min. or more.
5) Check DTC in “DTC” mode and pending DTC in “ON BOARD TEST” or “PENDING DTC” mode.
6) If DTC is not detected at idle, consult usual driving based on information obtained in “Customer complaint analy-
sis” and “Freeze frame data check”.
Reference

6-1-80 ENGINE GENERAL INFORMATION AND DIAGNOSIS (SFI FOR G13)
1. EGR valve coupler
INSPECTION
STEPACTIONYESNO
1Was ENGINE DIAG. FLOW TABLE performed?Go to Step 2.Go to ENGINE
DIAG. FLOW
TABLE.
2Do you have SUZUKI scan tool?Go to Step 3.Go to Step 5.
3EGR Valve Operation Check
1) With ignition switch OFF, install SUZUKI scan tool.
2) Check EGR system referring to section 6E2.
Is it in good condition?Go to Step 4.Go to Step 5.
4MAP Sensor Check
1) Check MAP sensor for performance referring to “MAP
Sensor Check” in DTC P0105 Diag. Flow Table.
Is check result satisfactory?Intermittent trouble
or faulty ECM
(PCM) Check for in-
termittent referring
to “Intermittent and
Poor Connection” in
section 0A.Repair or replace.
5EGR Valve Power Supply Circuit Check
1) With ignition switch OFF, disconnect EGR valve
coupler.
2) With ignition switch ON, check voltage between C13-2
and ground, C13-5 and ground. See Fig. 1.
Is each voltage 10 – 14 V?Go to Step 6.“R/B” wire.
6EGR Valve Stepping Motor Coil Circuit Check
1) With ignition switch OFF, connect EGR valve coupler
and disconnect ECM (PCM) couplers.
2) Check resistance between C02-6 and C02-2, C02-8,
C02-9, C02-17.
Is each resistance 20 – 24 Ω at 20C, 68F?Go to Step 7.Faulty “R/Y”,
“R/Bl”, “R”, “R/W”
wire or EGR valve.
7MAP Sensor Check
1) Check MAP sensor for performance referring to
“MAP Sensor Check” in DTC P0105 Diag. Flow Table.
Is check result satisfactory?EGR passage
clogged or EGR
valve malfunction.
If all above are OK,
intermittent trouble
or faulty ECM.
Check for intermit-
tent referring to
“Intermittent and
Poor Connection” in
section 0A.Repair or replace.
Fig. 1 for step 5

6A
ENGINE MECHANICAL (G10, 1-CAM 6-VALVES ENGINE) 6A-1
SECTION 6A
ENGINE MECHANICAL
(G10, 1-CAM 6-VALVES ENGINE)
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 autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” 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:
For the descriptions (items) not found in this section, refer to the same section of Service Manual men-
tioned in FOREWORD of this manual.
CONTENTS
ON-VEHICLE SERVICE6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Vacuum Check6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Check6A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover6A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body and Intake Manifold 6A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold6A- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt and Belt Tensioner 6A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Hydraulic Valve Lash Adjuster 6A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Lash Adjuster Noise Diagnosis 6A-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves and Cylinder Head6A-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons, Piston Rings, Connecting Rods and Cylinders 6A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR OVERHAUL6A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly6A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bearings, Crankshaft and Cylinder Block 6A-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS6A-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS6A-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .