Injector SUZUKI SWIFT 2005 2.G Service Service Manual

Downloaded from www.Manualslib.com manuals search engine 1G-3 Fuel System:
4) Check that battery voltage is 11 V or more.
5) Measure fuel pressure at each condition.If measured pressure is out of specification, refer to
“Fuel Pressure Check in Section 1A” and check each
possibly defective part. Replace if found defective.
a) Turn ignition switch ON to operate fuel pump and after 2 seconds turn it OFF. Repeat this 3 or 4
times and then check fuel pressure.
Fuel pressure specification
With fuel pump operating and engine
stopped: 270 – 310 kPa (2.7 – 3.1 kg/cm2, 38.4
– 44.0 psi)
b) Start engine and warm it up to normal operating temperature, and measure fuel pressure at
idling.
Fuel pressure specification
At specified idle speed: 270 – 310 kPa (2.7 –
3.1 kg/cm2, 38.4 – 44.0 psi)
c) Stop engine, and measure fuel pressure at one minute after stopping.
Fuel pressure specification
With 1 min. after engine (fuel pump) stop
(Pressure reduces as time passes): Over 300
kPa (3.0 kg/cm
2, 42.7 psi)
6) After checking fuel pressure, remove fuel pressure gauge.
WARNING!
As fuel feed line is still under high fuel
pressure, make sure to release fuel pressure
according to the following procedures.
• Place fuel container under joint.
• Cover joint with rag and loosen joint nut slowly in order to release fuel pressure
gradually.

7) Remove special tools from fuel delivery pipe and fuel feed hose.
8) Connect fuel feed hose to fuel delivery pipe and clamp it securely.
9) With engine OFF and ignition switch ON, check for fuel leaks.
Fuel Cut Operation InspectionS7RS0B1704002
NOTE
Before inspection, make sure that gear shift
lever is in neutral positi on (shift select lever
is “P” range for A/T vehicle), A/C is OFF and
parking brake lever is pulled all the way up.

1) Warm engine up to normal operating temperature.
2) While listening to sound of injector (2) by using sound scope (1) or such, increase engine speed to
higher than 3,000 r/min.
3) Check to make sure that injector operation sound is stop when throttle valve is closed instantly and it is
heard again when engine speed is reduced to
approx. 2,000 r/min or less.
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Repair Instructions
Fuel System ComponentsS7RS0B1706001
5
14
4
24
8
3
13
23
1
25
21
112
22 10
6
16
26
18
17
19
10
12
9
(b)
(a)
15
(c)
20 27
7
I6RS0C170003-01
1. Fuel tank 12. Fuel tank bolt 23. Main fuel level sensor
2. Fuel pump assembly 13. Fuel pump assembly bolt 24. To fuel vapor line
3. Breather hose 14. Fuel filler neck 25. Fuel feed hose
4. Fuel tank filler hose 15. Fuel delivery pipe 26. Grommet
5. Fuel filler cap 16. Fuel delivery pipe bolt 27. To fuel tank
6. Fuel feed line 17. Fuel injector : Do not reuse.
7. Fuel vapor line 18. Injector cushion : 45 N⋅m (4.5 kgf-m, 33.0 lb-ft)
8. Fuel tank inlet valve 19. Fuel delivery pipe insulator : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
9. Fuel tank protector 20. O-ring : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
10. Fuel tank belt 21. To canister
11. Fuel pump gasket 22. Fuel tank cover

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Installation1) Install clamps to marked location on pipes. If clamp is deformed, its claw is bent or broken, replace it with
new one.
2) Install pipes with pipe clamps to vehicle.
3) Connect fuel hoses and pipes to each pipe referring to “Fuel Hose Disconnecting and Reconnecting”.
4) Connect negative cable at battery.
5) With engine OFF, turn igniti on switch to ON position
and check for fuel leaks.
Fuel Injector On-Vehicle InspectionS7RS0B1706007
1) Using sound scope (1) or such, check operating sound of injector (2) when engine is running or
cranking.
Cycle of operating sound should vary according to
engine speed.
If no sound or an unusual sound is heard, check
injector circuit (wire or coupler) or injector.
2) Disconnect connector (1) from injector, connect ohmmeter between terminals of injector and check
resistance.
If resistance is out of specification, replace.
Resistance of fuel injector
11.3 – 13.8 Ω at 20 °C, 68 °F
3) Connect connector to injector securely.
Fuel Injector Removal and InstallationS7RS0B1706008
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal 1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Disconnect MAF sensor connector, and detach EVAP canister purge valve.
4) Remove air cleaner assembly with air intake pipe.
5) Disconnect fuel injector couplers.
6) Disconnect fuel feed hose from fuel delivery pipe (1).
7) Remove fuel delivery pipe bolts (2).
8) Remove fuel injector(s) (3).
I2RH0B170007-01
I2RH0B170008-01
2
1
3
3
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Installation
Reverse removal procedure for installation noting the
following.
• Replace injector O-ring (1) with new one using care not to damage it.
• Check if cushion (2) is scor ed or damaged. If it is,
replace with new one.
• Apply thin coat of fuel to O-rings (1) and then install injectors (3) into delivery pipe (4) and cylinder head.
Make sure that injectors rota te smoothly (6). If not,
probable cause is incorrect installation of O-ring.
Replace O-ring with new one.
• Tighten delivery pipe bolts (5) to specified torque and make sure that inject ors rotate smoothly.
Tightening torque
Fuel delivery pipe bolt (a): 25 N·m (2.5 kgf-m, 18.0
lb-ft)
• After installation, with engine OFF and ignition switch ON, check for fuel leaks around fuel line connection.Fuel Injector InspectionS7RS0B1706009
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure” if equipped.
2) Disconnect fuel feed hose from delivery pipe.
3) Set special tools as follows.
Special tool
(A): 09912–58421
(B): 09930–88530
(C): 09912–57610
a) Fit washer (1) (inside diameter 13.5 – 14.5 mm (0.532 – 0.570 in.)) to injector (2), and then
install injector to special tool (A).
b) Connect special tool (B) to injector.
c) Install special tool (C) to special tool (A).
d) Connect fuel feed hose to special tool (A).
I3RM0A170011-01
(B)
(A)
(A) (C)
2
1
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Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-10
4) Install suitable vinyl tube onto injector nozzle to
prevent fuel from splashing out when injecting.
5) Put graduated cylinder under injector.
6) Operate fuel pump and apply fuel pressure to
injector as follows:
a) When using scan tool:
i) Connect scan tool to DLC with ignition switch OFF.
ii) Turn ignition switch ON, clear DTC and select “MISC TEST” mode on scan tool.
iii) Turn fuel pump ON by using scan tool.
Special tool
(A): SUZUKI scan tool
b) When not using scan tool: i) Remove fuel pump relay from connector.
ii) Connect two terminals of relay connector using service wire (1) as shown in figure.
CAUTION!
Check to make sure that connection is made
between correct terminals. Wrong
connection can cause damage to ECM, wire
harness, etc.

iii) Turn ignition switch ON. 7) Apply battery voltage to in
jector (1) for 15 seconds
and measure injected fuel volume with graduated
cylinder. Test each injector two or three times. If not
within specification, replace injector.
Injected fuel volume
43 – 47 cc/15 sec. (1.45/1.51 – 1.58/1.65 US/lmp
oz/15 sec.)
8) Check fuel leakage from injector nozzle. Do not operate injector for this check (but fuel pump should
be at work). If fuel leaks (1) more than the following
specifications, replace.
Fuel leakage
Less than 1 drop/min.
Fuel Filler Cap InspectionS7RS0B1706010
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Remove cap (1), and che ck gasket for even filler neck
imprint, and deterioration or any damage. If gasket (2) is
in malcondition, replace cap.
NOTE
If cap requires replacement, only a cap with
the same features should be used. Failure to
use correct cap can result in fire and
personal injury.

(A)I4RS0A170021-01
1
I4RS0A170006-02
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Downloaded from www.Manualslib.com manuals search engine 1G-17 Fuel System:
Special Tools and Equipment
Special ToolS7RS0B1708001
09912–5761009912–58421
Injector checking tool plate Checking tool set
) This kit includes the
following items. 1. Tool body
and washer, 2. Body plug, 3.
Body attachment-1, 4.
Holder, 5. Return hose and
clamp, 6. Body attachment-2
and washer, 7. Hose
attachment-1, 8. Hose
attachment-2)
09912–58432 09912–58442
Fuel pressure gauge hose Fuel pressure gauge
This tool is included in fuel
pressure gauge set (09912-
58413). ) This tool is included in fuel
pressure gauge set (09912-
58413).
)
09912–58490 09919–47020
3-way joint & hose Quick joint remover
))
09930–88530 SUZUKI scan tool
Injector test lead —
) This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12.)

Downloaded from www.Manualslib.com manuals search engine 1H-6 Ignition System:
Ignition Spark TestS7RS0B1804004
1) Remove air cleaner assembly with air intake pipe.
2) Disconnect all injector couplers from injectors.
WARNING!
Without disconnection of injector couplers,
combustible gas may come out from spark
plug holes during this test and may get
ignited in engine room.

3) Remove spark plug and check it for condition and
type referring to “Spark Plug Inspection”.
4) If OK, connect ignition coil coupler to ignition coil assembly and connect spark plug to ignition coil
assembly or high-tension cord. Ground spark plug. 5) Crank engine and check if each spark plug sparks.
6) If no spark is emitted, inspect the related parts as
described in “Ignition System Symptom Diagnosis”.
Repair Instructions
High-Tension Cord Removal and InstallationS7RS0B1806001
Removal
1) Remove air cleaner assembly with air intake pipe and cylinder head upper cover.
2) Disconnect No.1 cylinder (2) and No.3 cylinder (3)
high-tension cords from ignition coil assemblies (1)
while gripping each cap.
3) Pull out high-tension cords from spark plugs while gripping each cap.
CAUTION!
• Removal of high-tension cords together with clamps will be recommended so as
not to damage their inside wire (resistive
conductor).
• For the same reason, pull out each connection by gripping cap portion.

Installation
1) Install No.1 cylinder (2) and No.3 cylinder (3) high-
tension cords to spark plugs and ignition coil
assemblies (1) while gripping each cap.
CAUTION!
• Never attempt to use metal conductor high-tension cords as replacing parts.
• Insert each cap portion fully when installing high-tension cords.

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Downloaded from www.Manualslib.com manuals search engine 9A-3 Wiring Systems:
Ignition switch Keyless entry Immobilizer system Combination meter Lighting switch
Headlight leveling Hazard warning light Front fog light Rear fog light Spark plug Radiator fan Fuel pumpFuel injectorXX control module Windshield wiper
Windshield washer Rear wiper Rear washer Rear defogger Power window
Power door lock Power mirror A/BPretensioner Passenger side
Driver side Seat heater A/CPower steering Side air-bag (R)
Side air-bag (L) Side curtain air-bag (R) Side curtain air bag (L) Glow plug
I2RH01910912-01I3JA01910902-01I5RH01910901-01I2RH01910915-01I2RH01910916-01
I3JA01910904-01I3JA01910905-01I3JA01910906-01I3JA01910907-01I2RH01910921-01
I2RH01910922-01I3JA01910908-01I5RW0A910987-01
XX
Cont M
I2RH01910925-01I3JA01910909-01
I3JA01910910-01I3JA01910911-01I3JA01910912-01I2RH01910930-01I3JA01910913-01
I3JA01910914-01I3JA01910915-01I3JA01910916-01I3JA01910917-01I3JA01910918-01
I3JA01910919-01I2RH01910938-01I3JA01910920-01I3JA01910921-01I4JA01910901-01
I4JA01910902-01I5RS0A910958-01I5RS0A910959-01
I5RW0A910986-01

Downloaded from www.Manualslib.com manuals search engine Wiring Systems: 9A-4
How to Read Connector Layout DiagramS7RS0B9101004
[A-1]: Harness symbol and corresponding harness name
A: Battery harness
B: A/C harness
C: Engine harness
D: Injector harness
E: Main harness, Oil pressure switch wire, Console wire
G: Instrument panel harness
J: Side door wire (Power window)
K: Interior light harness, Rear speaker wire, Roof wire
L: Floor harness, G sensor wire (Fuel pump harness)
M: Rear bumper harness
O: Rear end door harness
Q: Air bag/Pretensioner harness
R: (Fuel pump wire)
[A-2]: Connector Number
[B]: Ground point No.
12
11
[B] [B]
Connector code
[A-1] [A-2]L 36
L13 L15
R01
L14
L12
L11L10
L09 L36
R02
L24
L25
L33
L28
L20 L26 (TO O01)
{
L05
L16
L32
L19
L01 (TO G01)
L02 (TO E04)
L03 (TO E05)
L42
R05
R04
L07 (TO K02)
I2RH01910901-01

Downloaded from www.Manualslib.com manuals search engine 9A-11 Wiring Systems:
C: Engine harnessNo./Color Connective position No./Color Connective positionC01/GRY IAC valve C22/- Generator #2
C02/GRY IG Coil #1 C23/BLK Starting motor #1
C03/GRY IG Coil #2 C24/- Starting motor #2
C04/GRY Fuel injector #1 C25/GR Y VSS (Vehicle speed sensor)
C05/GRY Fuel injector #2 C26/GRY Knock sensor
C06/GRY Fuel injector #3 C27/BLU (A/
T) Input shaft speed sensor
C07/GRY Fuel injector #4 C28/GRY
(A/T) Trans axle range sensor
C08/BLK or GRY CMP sensor C29/GRY
(A/T) Shift solenoid
C09/BLK ECT sensor C30/BLK
(M/T) Back-up light switch
C10/GRY EGR stepper motor C31/- Main fuse box C11/BLK Throttle position sensor C32/GRY
(IF EQPD) Current sensor
C12/BLK MAP sensor C33/- Main fuse box
C13/BLK MAF sensor C34/N (A/T) TCM
C14/BLK EVAP canister purge valve C35/N (A/T) TCM
C15/GRY Heated oxygen sensor #1 C36/N Main harness (To E24)
C16/GRN Heated oxygen sensor #2 C37/GRY ECM C17/BLK A/C compressor C38/- Weld splice C18/N Oil pressure switch C39/- Weld splice
C19/BLU VVT solenoid C40/- Weld splice
C20/GRY CKP sensor C41/- Weld splice
C21/GRY or BLK Generator #1