2000 SUZUKI SWIFT Adjust

ENGINE COOLING 6B-9
WATER PUMP
1) Disconnect negative cable at battery.
2) Drain cooling system.
3) Remove timing belt and tensioner according to procedure de-
scribed in “TIMING BELT AND TENSIONER” of Section 6A or
6A1.
4) Remove water pump belt adjusting arm.
5) Remove water pump assembly (1).
INSPECTION
NOTE:
Do not disassemble water pump.
If any repair is required on pump, replace it as assembly.
Rotate water pump by hand to check for smooth operation.
If pump does not rotate smoothly or makes abnormal noise, replace
it.
INSTALLATION
1) Install new pump gasket to cylinder block.
2) Install water pump to cylinder block.
Tightening Torque
(a): 12 N
.m (1.2 kg-m, 9.0 lb-ft)
3) After installing water pump, install rubber seal (1) between water
pump and oil pump, and another between water pump and cylin-
der head.
4) Install timing belt tensioner, timing belt and timing belt outside
covers according to procedure described in “TIMING BELT AND
TENSIONER” of Section 6A or 6A1.
NOTE:
Special care must be used when installing belt tensioner
and timing belt.
Torque each bolt and nut to specification.
Before installing outside covers, check to make sure that
cover seal is fitted in groove of each cover properly.

6B-10 ENGINE COOLING
5) Install crankshaft pulley, water pump pulley, and pump drive
belt referring to Section 6A or 6A1.
6) Adjust water pump belt tension.
7) Install fender apron extension on right side.
8) Install air cleaner assembly.
9) Connect negative cable at battery.
10) Fill cooling system.
11) After installation, check each part for leakage.

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-1
GENERAL DESCRIPTION6E1- 2 . . . . . . . . . . . . . .
AIR AND FUEL DELIVERY SYSTEM 6E1- 4. . . . .
ELECTRONIC CONTROL SYSTEM 6E1- 5. . . . . .
ON-VEHICLE SERVICE6E1- 8 . . . . . . . . . . . . . . . .
General 6E1- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accelerator Cable Adjustment 6E1- 8. . . . . . . . . .
Idle Speed Inspection 6E1- 8. . . . . . . . . . . . . . . . .
AIR AND FUEL DELIVERY SYSTEM 6E1- 9. . . . .
Fuel Pressure 6E1- 9. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump 6E1-11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body 6E1-12. . . . . . . . . . . . . . . . . . . . . . . .
Fuel injector 6E1-15. . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRONIC CONTROL SYSTEM 6E1-17. . . . . .
ECM 6E1-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAP Sensor 6E1-18. . . . . . . . . . . . . . . . . . . . . . . . .
TP Sensor 6E1-19. . . . . . . . . . . . . . . . . . . . . . . . . . .
IAT Sensor 6E1-20. . . . . . . . . . . . . . . . . . . . . . . . . .
ECT Sensor 6E1-21. . . . . . . . . . . . . . . . . . . . . . . . .
Heated Oxygen Sensor -1 and -2 6E1-23. . . . . . .
Vehicle Speed Sensor 6E1-24. . . . . . . . . . . . . . . . .
Fuel Level Sensor (Gauge) 6E1-24. . . . . . . . . . . . Crankshaft Position Sensor 6E1-25. . . . . . . . . . . .
Main Relay 6E1-25. . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Relay 6E1-26. . . . . . . . . . . . . . . . . . . . .
Fuel Injector Resistor 6E1-26. . . . . . . . . . . . . . . . .
Fuel Cut Operation 6E1-26. . . . . . . . . . . . . . . . . . .
ISC System 6E1-26. . . . . . . . . . . . . . . . . . . . . . . . . .
ISC Actuator 6E1-27. . . . . . . . . . . . . . . . . . . . . . . . .
CTP Switch 6E1-28. . . . . . . . . . . . . . . . . . . . . . . . . .
ISC Actuator Relay 6E1-29. . . . . . . . . . . . . . . . . . .
EFE Heater Control System 6E1-29. . . . . . . . . . . .
EFE Heater 6E1-29. . . . . . . . . . . . . . . . . . . . . . . . . .
EFE Heater Relay 6E1-30. . . . . . . . . . . . . . . . . . . .
Radiator Fan Control System 6E1-30. . . . . . . . . .
Radiator Fan Control Relay 6E1-31. . . . . . . . . . . .
Radiator Fan 6E1-31. . . . . . . . . . . . . . . . . . . . . . . . .
EMISSION CONTROL SYSTEM 6E1-32. . . . . . . . .
EVAP Control System 6E1-32. . . . . . . . . . . . . . . . .
PCV System 6E1-34. . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS6E1-36 . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS6E1-36 . . . . . . . . . . . . . . . . . . . .
SECTION 6E1
ENGINE AND EMISSION CONTROL SYSTEM
(TBI FOR G10)
WARNING:
For vehicles equipped with a Supplemental Inflatable Restraint Air Bag System:

Service on or around Air Bag System Components or Wiring must be performed only by an authorized
Suzuki dealer. Please observe all WARNINGS and SERVICE PRECAUTIONS in Section 9J under “On-
Vehicle Service” and the Air Bag System Component and Wiring Location view in Section 9J before
performing service on or around Air Bag System Components or Wiring. Failure to follow WARNINGS
could result in unintended air bag deployment or could render the air bag inoperative. Either of these
two conditions may result in severe injury.

SDM can maintain sufficient voltage to cause a deployment of air bags for up to 15 seconds after igni-
tion switch is turned to “LOCK” position, battery is disconnected or fuse powering SDM is removed.
Work must be started after 15 seconds from the time.
NOTE:
For the descriptions for vehicle without warm up three way catalytic converter (WU TWC), refer to the same
section of the Service Manual mentioned in the FOREWORD of this manual.
CONTENTS

6E1-8 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10)
ON-VEHICLE SERVICE
GENERAL
When the hoses have been disconnected and system’s component
removed for service, be sure to reinstall component properly, and
route and connect hoses correctly after service. Refer to Emission
Control Information Label for proper connection of hoses (if
equipped).
ACCELERATOR CABLE ADJUSTMENT
1) Confirm that ambient temperature is higher than 0C, 32F.
2) Warm up engine to normal operating temperature with all elec-
tric loads OFF and stop engine.
3) Confirm that clearance “c” between throttle lever (1) and stop
screw (2) is less than about 1 mm (0.04 in.).
4) Check accelerator cable for play.
Accelerator cable play “a”: 10 – 15 mm (0.4 – 0.6 in.)
Cable play should be within specification. If out of specification,
loosen accelerator cable lock nut and adjust by turning adjusting
nut (3). Be sure to tighten lock nut (4) securely after adjustment.
5) With accelerator pedal depressed fully, check clearance be-
tween throttle lever and lever stopper (5) (throttle body) which
should be within following specification.
Clearance “b”: 0.5 – 2.0 mm (0.02 – 0.07 in.)
(With pedal depressed fully)
If measured value is out of specification, adjust it to specification
by changing height of pedal stopper bolt (6).
IDLE SPEED INSPECTION
Before inspecting idle speed, make sure to the following.

Lead wires and hoses of Electronic Fuel Injection and engine
emission control systems are connected securely.

After warming up engine, accelerator cable has some play, that
is, it is not tight.

Ignition timing is within specification.

All of electrical loads except ignition are switched off.

Air cleaner has been properly installed and is in good condition.

Malfunction indicator lamp does not light when engine running.
After above items are all confirmed, check idle speed as follows.

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-9
1. Throttle body
2. Fuel feed hose
NOTE:
Before starting engine, place transmission gear shift lever in
“Neutral” (shift selector lever to “P” range for A/T model), and
set parking brake and block drive wheels.
1) Warm up engine to normal operating temperature.
2) Set tachometer.
3) Check idle speed with A/C OFF.
If idle speed is not within specified range, check idle speed con-
trol system and any other system and parts which might affect
idle speed. Refer to “Engine Diagnosis of Section 6” for inspec-
tion.
Engine idle speed: 850
50 r/min
NOTE:
Idle speed is not adjustable manually. If it is out of its speci-
fied range, there is a faulty condition somewhere. Check
each of related systems and parts.
AIR AND FUEL DELIVERY SYSTEM
FUEL PRESSURE
INSPECTION
1) Relieve fuel pressure, referring to Section 6.
2) Separate air cleaner assembly from throttle body and shift its
position.
3) Disconnect fuel feed hose from throttle body.
CAUTION:
A small amount of fuel may be released after fuel line is
disconnected.
In order to reduce chance of personal injury, cover fitting
to be disconnected with a shop cloth. Place that cloth in
an approved container when disconnection is com-
pleted.
4) Connect special tools and hose between throttle body and fuel
feed pipe as shown in figure, and clamp hoses securely to en-
sure no leaks occur during checking.
Special Tool
(A): 09912-58441
(B): 09912-58431
(C): 09912-58490
5) Install air cleaner assembly to throttle body and cylinder head
cover.

6E1-12 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10)
1. Fuel injector wire
2. Fuel injector
3. Upper O-ring
4. Lower O-ring
5. Throttle upper body
6. Gasket
7. Throttle lower body
8. ISC actuator
9. TP sensor
10. Injector sub wire coupler
11. O-ring
12. Injector wire cover
CAUTION:
As throttle stop screw and throttle lever screw are fac-
tory adjusted precisely, don’t remove or adjust them.
Throttle
stop
screw
Throttle lever
screwPositive
terminal Negative
terminal
Viewed from “A”
1. Throttle body
2. Vacuum nozzle
1. Injector coupler
2. TP sensor
3. Water hose
4. Vacuum hose
5. ISC actuator
6. Fuel return hose
7. Fuel feed hose
THROTTLE BODY
ON-VEHICLE INSPECTION

Check that throttle valve lever moves smoothly.

Vacuum passage inspection.
With fingers placed against vacuum nozzle, increase engine
speed a little and check that vacuum is applied.
REMOVAL
1) Relieve fuel pressure, referring to Section 6.
2) Disconnect battery negative cable at battery.
3) Remove air cleaner assembly referring to Section 6A.
4) Drain cooling system.
5) Disconnect following wire harness couplers:

TP sensor

Fuel injector

ISC actuator
6) Disconnect following hoses from throttle body.

Fuel feed and return hoses

Engine cooling water hoses

Vacuum hoses
7) Disconnect accelerator cable from throttle valve lever and cable
bracket.
8) Remove throttle body from intake manifold.

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-13
1. Fuel injector wire
2. Fuel pressure regulator
3. TP sensor
4. Screws
5. ISC actuator
1. Injector chamber
2. Fuel return passage
3. Fuel feed passage
4. Vacuum passage for fuel pressure regulator
5. Vacuum passage for MAP sensor
6. Air induction passage
7. Vacuum passage
8. Fresh air passage
DISASSEMBLY
NOTE:

Be sure not to remove either fuel pressure regulator or idle
speed control actuator from throttle body. They are factory
adjusted precisely.

Be sure to replace gaskets and O-rings as well as worn or
damaged parts.

While disassembling and assembling throttle body, use spe-
cial care not to deform levers on throttle valve shaft or cause
damage to any other parts.
1) Remove fuel injector from throttle body according to procedure
described in FUEL INJECTOR REMOVAL.
2) Remove TP sensor.
3) After removing screws, separate upper and lower bodies.
CLEANING
Clean passages and fuel injector chamber by blowing compressed
air.
NOTE:

TP sensor, fuel pressure regulator, fuel injector, ISC actua-
tor, other components containing rubber (resin) or throttle
valve shaft seal must not be placed in a solvent or cleaner
bath. Chemical reaction will cause these parts to swell, hard-
en or get distorted.

Don’t put drills or wires into passages for cleaning. It causes
damage in passages.

ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-15
1. Injector coupler
2. TP sensor
3. Water hose
4. Vacuum hose
5. ISC actuator
6. Fuel return hose
7. Fuel feed hose
1. Injector coupler
Good No good
2) Install throttle body to EFE heater and tighten bolts to specified
torque.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
3) Install accelerator cable to throttle valve lever and cable brack-
et.
4) Connect fuel, cooling water and vacuum hoses to throttle body,
and clamp securely.
5) Connect TP sensor and injector couplers securely.
6) Refill cooling system referring to Section 6B.
7) Connect negative cable at battery.
8) With engine “OFF” and ignition switch “ON”, check for fuel
leaks around fuel line connection.
9) Install air cleaner assembly referring to Section 6A.
10) Upon completion of installation, start engine and check for fuel
leaks and engine coolant leaks.
Adjust cable play to specification according to procedure de-
scribed in ACCELERATOR CABLE ADJUSTMENT.
FUEL INJECTOR
ON-VEHICLE INSPECTION
1) With battery negative cable disconnected, disconnect injector
coupler.
2) Connect ohmmeter to each injector terminal and measure resis-
tance.
Resistance of injector: 0.5 – 1.5 Ω at 20C (68F)
If resistance is out of specification, replace fuel injector.
3) Connect injector coupler.
4) Remove air cleaner assembly without disconnecting IAT sensor
coupler.
5) Check that fuel is injected out in conical shape from fuel injector
when cranking or running engine.
If no fuel is injected, check wiring harness for continuity and cou-
plers for proper connection referring to “DIAGNOSTIC FLOW
TABLE B-1”.
If fuel is not injected out in conical shape, replace injector.
6) Check injector for fuel leakage after injection is stopped (i.e., af-
ter cranking or engine stop).
Replace if leakage exists.
Fuel leakage: Less than 1 drop/min.
7) Install air cleaner assembly.