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Suzuki Swift User Manual
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ENGINE MECHANICAL (G13B, 1-CAM 16-V
AL
VES ENGINE)
6A1-55
DISASSEMBL
Y
1)
Using piston ring expander
, remove two compression rings (T
op
and 2nd) and oil ring from piston.
2)
Remove piston pin from connecting rod.
D
Ease out piston pin circlips (1), as shown.
D
Force piston pin out.
CLEANING
Clean carbon from piston head and ring grooves, using a suitable
tool.
349
351
Table of Contents
Related Manuals
3
Table of Contents
4
General Information
5
How to Use this Manual
6
Diagnosis
7
Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System
7
Handling and Servicing
8
General Precautions
10
Precautions for Catalytic Converter
13
Precautions for Electrical Circuit Service
13
Electrical Circuit Inspection Procedure
16
Open Circuit Check
16
Continuity Check
17
Voltage Check
17
Short Circuit Check (Wire Harness to Ground)
18
Voltage between
18
Intermittent and Poor Connection
19
Precaution for Installing Mobile Communication Equipment
20
Precaution in Servicing Full-Time 4Wd Vehicle
21
Switching from 4Wd to 2Wd
21
Identification Information
22
Vehicle Identification Number
22
Engine Identification Number
22
Transmission Identification Number
22
Identification Whether Vehicle Equipped with WU-TWC or Not
22
Warning, Caution and Information Labels
23
Vehicle Lifting Points
24
Abbreviations and Symbols May be Used in this Manual
26
Symbols
28
Wire Color Symbols
28
Fastener Strength Identification
29
Metric Fasteners
29
Fastener Information 0A-25
29
Standard Tightening Torque
30
Tightening Torque Chart
30
General Information
31
Maintenance and Lubrication
31
Maintenance Schedule
32
Normal Condition Schedule
32
Maintenance Recommended under Severe Driving Conditions
34
Severe Condition Code
34
Maintenance Service
35
Drive Belt Inspection and Replacement
35
A/C Compressor And/Or Power Steering Pump Drive Belt Inspection (if Equipped)
35
A/C Compressor And/Or Power Steering Pump Drive Belt Replacement
35
Water Pump Belt Replacement
36
Camshaft Timing Belt Replacement
36
Valve Lash Inspection (1.3 Liter Engine Only)
36
Engine Oil and Filter Change
37
Engine Oil Capacity
38
Engine Coolant Change
38
Exhaust System Inspection
39
Ignition System
40
Spark Plugs Replacement
40
Distributor Cap and Rotor Inspection (if Equipped)
40
Air Cleaner Filter Inspection
40
Fuel System
40
Air Cleaner Filter Replacement
41
Fuel Lines Inspection
41
Fuel Tank Inspection
41
Emission Control System
42
Brake
42
PCV (Positive Crankcase Ventilation) Valve Inspection
42
Fuel Evaporative Emission Control System Inspection
42
Brake Hoses and Pipes Inspection
43
Brake Fluid Change
43
Brake Lever and Cable Inspection
44
Parking Brake Lever
44
Parking Brake Cable
44
Clutch Pedal Free Travel Inspection
44
Wheel Bearing Inspection
45
Propeller Shaft Inspection (4WD Vehicle Only)
45
Drive Shaft Boot Inspction
45
Suspension System Inspection
45
Steering System Inspection
46
Power Steering (P/S) System Inspection (if Equipped)
46
Manual Transmission Oil Inspection and Change
47
Rear Differential Oil Inspection and Change
47
Automatic Transmission
48
All Latches, Hinges and Locks Inspection
49
Doors
49
Engine Hood
49
Final Inspection
50
Seats
50
Seat Belt
50
Battery Electrolyte Level Check
50
Recommended Fluids and Lubricants
51
Body, Wheels and Power Transmitting System
51
Meters and Gauge
51
Windshield Defroster
51
Engine General Information and Diagnosis (Tbi for G10)
52
Statement on Cleanliness and Care
54
General Information on Engine Service
54
Precaution on Fuel System Service
55
Hose Connection
55
Fuel Pressure Relief Procedure
56
Fuel Leakage Check Procedure
56
Engine Diagnosis
57
General Description
57
On-Board Diagnostic System
57
Warm-Up Cycle
58
Driving Cycle
58
2 Driving Cycles Detection Logic
58
Pending DTC
58
Freeze Frame Data Clearance
59
Data Link Connector (DLC)
59
Precaution in Diagnosing Trouble
60
Engine Diagnostic Flow Table
61
Customer Complaint Analysis
62
Visual Inspection
62
Trouble Symptom Confirmation
62
Engine Basic Inspection and Engine Diagnosis Table
62
Customer Problem Inspection Form (Example)
63
Vehicle/Environmental Condition When Problem Occurs
63
Malfunction Indicator Lamp (MIL) Check
64
Diagnostic Trouble Code (DTC) Check
64
Diagnostic Trouble Code (DTC) Clearance
65
Diagnostic Trouble Code (DTC) Table
66
Fail-Safe Table
69
Engine Basic Inspection
71
Engine Diagnosis Table
73
Scan Tool Data
80
Scan Tool Data Definitions
83
Calc Load (Calculated Load Value, %)
83
Short Ft B1 (Short Term Fuel Trim, %)
83
Long Ft B1 (Long Term Fuel Trim, %)
83
Closed Throttle Position (On/Off)
84
Fuel Cut (On/Off)
84
Electric Load (On/Off)
84
Fuel Tank Level (%)
84
Inspection of Ecm (Pcm) and Its Circuits
85
Resistance Check
89
Component Location
90
Malfunction Indicator Lamp Circuit Check – Lamp Does Not Come “On” at Ignition Switch on (but Engine at Stop)
91
Malfunction Indicator Lamp Circuit Check – Lamp Remains “On” after Engine Starts
92
Ecm (Pcm) Power and Ground Circuit Check – Mil Doesn’t Light at Ignition Switch on and Engine Doesn’t Start Though It Is Cranked up
93
Manifold Absolute Pressure (Map) Circuit Malfunction
95
Intake Air Temp. (IAT) Circuit Malfunction
97
Engine Coolant Temperature (ECT) Circuit Malfunction
99
Throttle Position Circuit Malfunction
101
Throttle Position Circuit Range/Performance Problem
103
Heated Oxygen Sensor (Ho2S) Circuit Malfunction (Sensor-1)
105
Heated Oxygen Sensor (Ho2S) Circuit Slow Response (Sensor-1)
106
Heated Oxygen Sensor (Ho2S) Circuit no Activity Detected (Sensor-1)
107
Heated Oxygen Sensor (Ho2S) Heater Circuit Malfunction (Sensor-1)
108
Heated Oxygen Sensor (Ho2S) Circuit Malfunction (Sensor-2)
110
Heated Oxygen Sensor (Ho2S) Heater Circuit Malfunction (Sensor-2)
113
DTC P0171 Fuel System too Lean
115
DTC P0172 Fuel System too Rich
115
DTC P0300 Random Misfire Detected (Misfire Detected at 2 or more Cylinders)
119
DTC P0301 Cylinder 1 Misfire Detected
119
DTC P0302 Cylinder 2 Misfire Detected
119
DTC P0303 Cylinder 3 Misfire Detected
119
DTC P0335 Crankshaft Position (Ckp) Sensor Circuit Malfunction
123
DTC P0340 Camshaft Position (Cmp) Sensor Circuit Malfunction
125
DTC P0420 Catalyst System Efficiency below Threshold
127
DTC P0443 Purge Control Valve Circuit Malfunction
130
DTC P0480 Radiator Fan Control System Malfunction
131
DTC P0500 Vehicle Speed Sensor (Vss) Malfunction (M/T)
133
DTC P0500 Vehicle Speed Sensor (Vss) Malfunction for A/T Vehicle (A/T)
135
DTC P0505 Idle Control System Malfunction
137
DTC P0510 Closed Throttle Position (Ctp) Switch Malfunction
139
DTC P0601 Internal Control Module Memory Check Sum Error
140
DTC P1250 Early Fuel Evaporation (Efe) Heater Circuit Malfunction
141
DTC P1450 Barometric Pressure Sensor Low/High Input
143
DTC P1451 Barometric Pressure Sensor Performance Problem
143
DTC P1500 Engine Starter Signal Circuit Malfunction
144
DTC P1510 ECM (PCM) Back-Up Power Supply Malfunction
145
Table B-1 Fuel Injector Circuit Check
147
Table B-2 Fuel Pump and Its Circuit Check
149
Table B-3 Fuel Pressure Check
151
Table B-4 A/C Signal Circuits Check (Vehicle with A/C)
153
Table B-5 Power Steering Pressure (PSP) Switch Signal Circuit Check (if Equipped)
154
Special Tool
155
Engine General Information and Diagnosis (TBI for G13)
156
Engine General Information and Diagnosis (SFI for G13)
157
MAP Sensor Individual Check
200
DTC P0110 Intake Air Temp. (IAT) Circuit Malfunction
202
DTC P0115 Engine Coolant Temperature (Ect) Circuit Malfunction
204
DTC P0120 Throttle Position Circuit Malfunction
206
DTC P0121 Throttle Position Circuit Range/Performance Problem
208
DTC P0130 Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-1)
210
DTC P0133 Heated Oxygen Sensor (Ho2S) Circuit Slow Response (Sensor-1)
212
DTC P0135 Heated Oxygen Sensor (Ho2S) Heater Circuit Malfunction (Sensor-1)
214
DTC P0136 Heated Oxygen Sensor (Ho2S) Circuit Malfunction (Sensor-2)
216
DTC P0141 Heated Oxygen Sensor (Ho2S) Heater Circuit Malfunction (Sensor-2)
219
DTC P0443 Evap Purge Control Valve Circuit Malfunction
240
DTC P0480 Radiator Cooling Fan Control System Malfunction
241
DTC P0500 Vehicle Speed Sensor (Vss) Malfunction for M/T Vehicle
243
DTC P0500 Vehicle Speed Sensor (Vss) Malfunction for A/T Vehicle
245
Special Tools
264
Engine Mechanical
265
Oil Pressure Check
266
Cylinder Head Cover
268
Exhaust Manifold
272
Unit Repair Overhaul
288
Engine Assembly
288
Special Tools
294
Engine Mechanical (G13B, 1-CAM 16-VALVES ENGINE)
296
General Description
298
Engine Lubrication
298
Cylinder Block
299
Crankshaft and Main Bearings
299
Pistons, Rings, Piston Pins and Connecting Rods
299
Cylinder Head and Valve Train
299
On Vehicle Service
300
On-Vehicle Service
300
Compression Check
300
Engine Vacuum Check
301
Oil Pressure Check
302
Valve Lash (Clearance)
304
Air Cleaner Element Removal
306
Air Cleaner Element Inspection
306
Air Cleaner Element Clean
306
Air Cleaner Element Installation
306
Air Cleaner Outlet Hose Removal
307
Air Cleaner Outlet Hose Installation
307
Cylinder Head Cover Removal
308
Cylinder Head Cover Installation
308
Throttle Body and Intake Manifold
309
Exhaust Manifold Removal
312
Exhaust Manifold Installation
313
Timing Belt and Belt Tensioner Removal
314
Timing Belt and Belt Tensioner Inspection
316
Timing Belt and Belt Tensioner Installation
316
Oil Pan and Oil Pump Strainer Removal
320
Oil Pan and Oil Pump Strainer Cleaning
321
Oil Pan and Oil Pump Strainer Installation
321
Oil Pump Removal
323
Oil Pump Disassembly
324
Oil Pump Measurement
325
Oil Pump Assembly
325
Oil Pump Installation
326
Rocker Arms, Rocker Arm Shaft and Camshaft Removal
328
Rocker Arms, Rocker Arm Shaft and Camshaft Inspection
330
Adjusting Screw and Rocker Arm
330
Rocker Arm Shaft Runout
330
Rocker Arm-To-Rocker Arm Shaft Clearance
331
Cam Wear
331
Camshaft Runout
331
Camshaft Journal Wear
331
Rocker Arms, Rocker Arm Shaft and Camshaft Installation
333
Valves and Cylinder Head Removal
336
Valves and Cylinder Head Disassembly
339
Valves and Cylinder Head Inspection
340
Valve Guides
340
Valve Springs
344
Valves and Cylinder Head Assembly
345
Valves and Cylinder Head Installation
347
Piston, Piston Rings, Connecting Rods and Cylinders
349
Piston Pin
352
Ring Groove Clearance
352
Piston Rings
353
Connecting Rod
353
Crank Pin and Connecting Rod Bearings
354
Flywheel
371
Distortion of Gasketed Surface
371
Honing or Reboring Cylinders
371
Engine Cooling
378
Cooling System Circulation
379
Thermostat
380
Cooling Fan
380
Coolant (Water) Temp. Gauge
381
Coolant Maintenance
382
Anti-Freeze Proportioning Table
382
Cooling System Flush and Refill
383
Cooling Water Pipes or Hoses Removal/Installation
384
Thermostat Removal
384
Thermostat Inspection
385
Thermostat Installation
385
Water Pump Inspection
386
Water Pump Installation
386
Engine Fuel
388
Fuel System
388
Fuel Pump Assembly (with Fuel Level Gauge)
388
Fuel Tank Removal
389
Fuel Lines
389
Fuel Tank Installation
390
Fuel Pump Assembly Removal
391
Fuel Pump Assembly Inspection
391
Fuel Pump Assembly Installation
391
Engine and Emission Control System (TBI for G10)
392
Air and Fuel Delivery System
395
Electronic Control System
396
On-Vehicle Service
399
Diagnosis
399
Accelerator Cable Adjustment
399
Idle Speed Inspection
399
Fuel Pressure Inspection
400
Fuel Pump On-Vehicle Inspection
402
Fuel Pump Removal
402
Fuel Pump Inspection
402
Fuel Pump Installation
402
Throttle Body On-Vehicle Inspection
403
Throttle Body Removal
403
Throttle Body Disassembly
404
Throttle Body Cleaning
404
Throttle Body Assembly
405
Throttle Body Installation
405
Fuel Injector On-Vehicle Inspection
406
Fuel Injector Removal
407
Fuel Injector Inspection
407
Fuel Injector Installation
407
Engine Control Module (Ecm) Removal
408
Engine Control Module (Ecm) Installation
408
Manifold Absolute Pressure Sensor (Map Sensor)
409
Throttle Position Sensor (Tp Sensor) Inspection
410
Throttle Position Sensor (Tp Sensor) Removal
410
Throttle Position Sensor (Tp Sensor) Installation
410
Throttle Position Sensor (Tp Sensor) Adjustment
410
Intake Air Temperature Sensor (IAT Sensor) Removal
411
Intake Air Temperature Sensor (IAT Sensor) Inspection
412
Intake Air Temperature Sensor (IAT Sensor) Installation
412
Engine Coolant Temperature Sensor (ECT Sensor) Removal
412
Engine Coolant Temperature Sensor (ECT Sensor) Inspection
413
Engine Coolant Temperature Sensor (ECT Sensor) Installation
413
Heated Oxygen Sensor (Sensor-1 and Sensor-2)
414
Oxygen Sensor Heater Inspection
414
Vehicle Speed Sensor (VSS) for M/T
415
Vehicle Speed Sensor (VSS) for A/T
415
Crankshaft Position Sensor Inspection
416
Crankshaft Position Sensor Removal
416
Crankshaft Position Sensor Installation
416
Main Relay Inspection
416
Fuel Pump Relay Inspection
417
Fuel Injector Resistor Inspection
417
Fuel Cut Operation Inspection
417
Idle Speed Control System Inspection
417
ISC Actuator Inspection
418
Closed Throttle Position (CTP) Switch, Idle Switch (in Isc Actuator)
419
Isc Actuator Relay Inspection
420
Efe Heater Control System Circuit Inspection
420
Efe Heater On-Vehicle Inspection
420
Efe Heater Removal
420
Efe Heater Inspection
421
Efe Heater Installation
421
Efe Heater Relay Inspection
421
Radiator Fan Control System Inspection
421
Radiator Fan Control Relay Inspection
422
Radiator Fan Inspection
422
Evaporative Emission Control System
423
EVAP Canister Purge Inspection
423
Vacuum Passage Inspection
423
Vacuum Hose Inspection
423
EVAP Canister Purge Valve Inspection
424
EVAP Canister Inspection
425
Tank Pressure Control Valve Inspection
425
PCV System
425
PCV Hose Inspection
425
PCV Valve Inspection
426
Engine and Emission Control System (TBI for G13)
428
Engine and Emission Control System (SFI for G13)
429
General Description
434
Air Intake System
434
Fuel Delivery System
435
Engine & Emission Control Input/Output Table
437
Fuel Pressure Inspection
446
Fuel Pressure Regulator
450
Engine Control Module (Powertrain Control Module) [Ecm (Pcm)]
455
Throttle Position Sensor (Tp Sensor)
456
Intake Air Temperature Sensor (Iat Sensor)
457
Engine Coolant Temperature Sensor (Ect Sensor)
458
Heater Oxygen Sensor (Sensor-1 and Sensor-2)
459
Camshaft Position Sensor Inspection
460
Camshaft Position Sensor Installation
460
Vehicle Speed Sensor (VSS)
461
Fuel Level Sensor (Gauge)
461
Main Relay, Fuel Pump Relay and Radiator Fan Control Relay
461
Fuel Cut Operation
462
Radiator Fan Control System
462
EGR System
463
Ignition Spark Test
472
High-Tension Cords
472
Spark Plugs
473
Noise Suppressor
473
Ignition Coil
474
Igniter
474
Distributor Cap and Rotor
475
Signal Rotor Air Gap
475
Cmp Sensor (Pickup Coil) Resistance
475
Ignition Timing
476
Distributor Unit
477
Ignition System (TBI for G13)
479
Ignition System (SFI for G13)
480
System Wiring Diagram
482
Ignition System Diagnostic Flow Table
483
Crankshaft Position Sensor
486
Exhaust System
489
Automatic Transmission (3 A/T) (Vehicle with Wu-Twc)
492
General Description
494
Electronic Shift Control System
496
Output Shaft Speed Sensor (A/T VSS)
500
Automatic Shift Diagram
500
Diagnosis
502
On-Board Diagnostic System
502
Precaution in Diagnosing Trouble
503
Automatic Transmission Diagnostic Flow Table
504
Customer Problem Inspection Form (Example)
506
Malfunction Indicator Lamp (MIL) Check
507
Diagnostic Trouble Code(S) Check
507
Diagnostic Trouble Code(S) Clearance
507
Diagnostic Trouble Code (DTC) Table
508
Fail-Safe Table
508
Visual Inspection
509
Automatic Transmission Basic Check
510
Symptom-To-Inspection Table
511
DTC P0705 Transmission Range Sensor (Switch) Circuit Malfunction
512
DTC P0720 Output Speed Sensor (A/T VSS) Circuit Malfunction
515
DTC P0753 Shift Solenoid-A (No.1) Electrical
517
DTC P0758 Shift Solenoid-B (No.2) Electrical
517
DTC P0751 SHIFT SOLENOID-A (No.1) PERFORMANCE or STUCK off
519
DTC P0756 SHIFT SOLENOID-B (No.2) PERFORMANCE or STUCK off
519
Table A-1 no Starting or Slipping in any Drive Range
521
Table A-2 Gear Change Failure
522
Table A-3 Excessive Shock at Range Selection or Gear Change
522
Stall Test
523
Line Pressure Test
524
Road Test
526
Manual Road Test
527
Engine Brake Test
527
"P" Range Test
528
Shift Solenoid Valve Check
528
Table B-1 Gear Shift Failure in “D” or “2” Range
529
Table B-2 Gear Is Shifted to 2Nd Gear in “L” Range Vehicle Does Not Move Backward in “R” Range
529
Transmission Range Sensor Check
530
Output Shaft Speed Sensor Check
530
Shift Solenoid Valve Circuit Check
531
Throttle Position Sensor Check
532
Tightening Torque Specifications
533
Special Tools
533
Differential
534
Body Electrical System
534
Combination Meter
535
Keyless Entry System (if Equipped)
536
Engine Coolant Temp. (ETC) Meter and Sensor
536
Keyless Entry System (if Equipped) Transmitter
537
Replacement of the Battery
537
Receiver Inspection
537
Code Registration Procedure
538
Immobilizer Control System
539
General Description
540
On-Board Diagnostic System (Self-Diagnosis Function)
542
Diagnosis
544
Precautions in Diagnosing Troubles
544
Diagnostic Flow Table
546
Diagnostic Trouble Code Check
546
Diagnostic Trouble Code (DTC) Check (ECM)
548
Diagnostic Trouble Code (DTC) Check (Immobilizer Control Module)
548
Diagnostic Trouble Code Table
550
A-1 Code (DTC) Is Not Outputted from Diagnostic Output Terminal of Immobilizer Diagnostic Coupler
551
A-2 Immobilizer Indicator Lamp Check (Immobilizer Indicator Lamp Dose Not Light at Ignition Switch On)
552
A-3 Immobilizer Indicator Lamp Check
553
ON after Engine Starts)
553
How to Register Ignition Key
554
Procedure after Immobilizer Control Module Replacement
555
Procedure after ECM Replacement
556
Special Tools
556
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Suzuki Swift Specifications
General
Brand
Suzuki
Model
Swift
Category
Automobile
Language
English
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