sae SUZUKI SWIFT 2006 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine FOREWORD
This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service
operations, replacement of components (Service) and for disassembly and reassembly of major components
(Unit Repair-Overhaul).
Applicable Model:
SWIFT (RS416) produced at KOSAI plant in Japan wi th the following vehicle identification numbers
(VINs).

JSAEZC31S############


The contents are classified into sectio ns each of which is given a section number as indicated in the Table of
Contents on following page. And on the first page of ea ch individual section is an index of that section.
This manual should be kept in a handy place for ready reference of the service work.
Strict observance of the so specif ied items will enable one to obtain the full performance of the vehicle.
When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials as specif ied in each description.
All information, illustrations and specif ications contained in this literature are based on the late st product infor-
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specificatio ns among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
JSAEZC31S########

Downloaded from www.Manualslib.com manuals search engine 0A-1 General Information:
General Information
General Information
General Description
AbbreviationsS7RS0B0101001
A:
ABDC: After Bottom Dead Center
ABS: Anti-lock Brake System
AC: Alternating Current
A/C: Air Conditioning
A-ELR: Automatic-Emergency Locking Retractor
A/F: Air Fuel Mixture Ratio
ALR: Automatic Locking Retractor
API: American Petroleum Institute
APP sensor: Accelerator Pedal Position Sensor
A/T: Automatic Transmission , Automatic Transaxle
AT D C : After Top Dead Center
ATF: Automatic Transmission Fluid, Automatic
Transaxle Fluid
B:
B+: Battery Positive Voltage
BBDC: Before Bottom Dead Center
BCM: Body Electrical Control Module
BDC: Bottom Dead Center
BTDC: Before Top Dead Center
C:
CAN: Controller Area Network
CKT: Circuit
CKP Sensor: Crankshaft Position Sensor
CMP Sensor: Camshaft Position Sensor
CO: Carbon Monoxide
CPP Switch: Clutch Pedal Position Switch (Clutch
Switch, Clutch Start Switch)
CPU: Central Processing Unit
CRS: Child Restraint System
D:
DC: Direct Current
DLC: Data Link Connector (Assembly Line Diag. Link,
ALDL, Serial Data Link, SDL)
DOHC: Double Over Head Camshaft
DOJ: Double Offset Joint
DRL: Daytime Running Light
DTC: Diagnostic Trouble Code (Diagnostic Code)
E:
EBCM: Electronic Brake Cont rol Module, ABS Control
Module
EBD: Electronic Brake Force Distribution
ECM: Engine Control Module
ECT Sensor: Engine Coolant Temperature Sensor (Water Temp. Sensor, WTS)
EFE Heater: Early Fuel Evaporation Heater (Positive
Temperature Coefficient, PTC Heater)
EGR: Exhaust Gas Recirculation
EGRT Sensor: EGR Temperature Sensor (Recirculated
Exhaust Gas Temp. Sensor, REGTS)
ELR: Emergency Locking Retractor
ESP ®: Electronic Stability Program
EPS: Electronic Power Steering
EVAP: Evaporative Emission EVAP Canister:
Evaporative Emission Canister
(Charcoal Canister)
F:
4WD: 4 Wheel
Drive
G:
GEN: Generator
GND: Ground
GPS: Global Positioning System
H:
HVAC: Heating, Ventilating and Air Conditioning
HC: Hydrocarbons
HO2S: Heated Oxygen Sensor
I:
IAC Valve: Idle Air Control Valve (Idle Speed Control
Solenoid Valve, ISC Solenoid Valve)
IAT Sensor: Intake Air Temperature Sensor (Air
temperature Sensor, ATS)
ICM: Immobilizer Control Module
IG: Ignition
ISC Actuator: Idle Speed Control Actuator
L:
LH: Left Hand
LHD: Left Hand Drive Vehicle
LSPV: Load Sensing Proportioning Valve
M:
MAF Sensor: Mass Air Flow Sensor (Air Flow Sensor, AFS, Air Flow Meter, AFM)
MAP Sensor: Manifold Absolute Pressure Sensor
(Pressure Sensor, PS)
Max: Maximum
MFI: Multiport Fuel Injection (Mu ltipoint Fuel Injection)
Min: Minimum
MIL: Malfunction Indicator Lamp (“SERVICE ENGINE
SOON” Light)
M/T: Manual Transmission, Manual Transaxle
N:
NOx: Nitrogen Oxides
O:
OBD: On-Board Diagnostic System (Self-Diagnosis
Function)
O/D: Overdrive
OHC: Over Head Camshaft
O2S: Oxygen Sensor
P:
PCM: Powertrain Control Module
PCV: Positive Crankcase Ventilation
PNP: Park / Neutral Position
P/S: Power Steering
PSP Switch: Power Steering Pressure Switch (P/S
Pressure Switch)
R:
RH: Right Hand
RHD: Right Hand Drive Vehicle
S:
SAE: Society of Automotive Engineers

Downloaded from www.Manualslib.com manuals search engine 1A-6 Engine General Information and Diagnosis:
For information about the following items, refer to “Euro
OBD Model: ”.
• Warm-up cycle
• Driving cycle
• 2 driving cycle detection logic
• Pending DTC
Data Link Connector (DLC)S7RS0B1101013
DLC (1) is in compliance with SAE J1962 in the shape of
connector and pin assignment.
OBD serial data line (3) (K line of ISO 9141) is used for
SUZUKI scan tool or OBD generic scan tool to
communicate with ECM, Air bag SDM, HVAC control
module (auto A/C model), immobilizer control module (in
ECM), BCM (Body electrical Control Module), TCM
(Transmission Cont rol Module (A/T model)) and ABS/
ESP ® control module.
Engine and Emission Control System
Description
S7RS0B1101004
The engine and emission control system is divided into 4
major sub-systems: air in take system, fuel delivery
system, electronic control sy stem and emission control
system.
Air intake system includes air cleaner, throttle body, IAC
valve and intake manifold.
Fuel delivery system includes fuel pump, delivery pipe,
etc.
Electronic control system incl udes ECM, various sensors
and controlled devices.
Emission control system includes EGR, EVAP and PCV
system.
2. B + (Unswitched vehicle battery positive)
4. ECM ground (Signal ground)
5. Vehicle body ground (Chassis ground)
2
345
1
910111213141516
12345678
1I4RS0B110002-01

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-217
Special Tools and Equipment
Special ToolS7RS0B1108001
09912–5843209912–58442
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 09930–76420
3-way joint & hose Timing-light (dry cell type)
))
09933–06320 SUZUKI scan tool
ECM check harness (120P) —
) 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 1B-5 Aux. Emission Control Devices:
PCV Valve InspectionS7RS0B1206010
NOTE
Be sure to check that there is no obstruction
in PCV valve or its hoses before checking
IAC duty, for obstructed PCV valve or hose
hampers its accurate adjustment.

1) Detach air cleaner assembly.
2) Disconnect PCV valve from cylinder head cover and install plug to head cover hole.
3) Install air cleaner assembly temporarily.
4) Run engine at idle.
5) Place your finger over end of PCV valve (1) to check for vacuum.
If there is no vacuum, ch eck for clogged valve.
Replace as necessary. 6) After checking vacuum, stop engine and remove
PCV valve (1).
Shake valve and listen for rattle of check needle
inside the valve. If valve does not rattle, replace PCV
valve.
7) After checking, remove plug and install PCV valve.
8) Install air cleaner assembly securely.
Special Tools and Equipment
Special ToolS7RS0B1208001
I2RH0B120007-01
I2RH0B120008-01
09917–47011 SUZUKI scan tool
Vacuum pump gauge —
) / ) 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 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 Ignition System: 1H-9
6) Set timing light (1) to high-tension cord for No.1 cylinder and check that ignition timing is within
specification.
Initial ignition timing
Fixed with SUZUKI scan tool: 5 ± 3° BTDC (at
specified idle speed)
Ignition order
1 – 3 – 4 – 2
Special tool
(A): 09930–76420 7) If ignition timing is out
of specification, check the
followings.
• CKP sensor
• CKP sensor plate
• CMP sensor
• CMP sensor rotor tooth of camshaft
• VSS
• Timing chain cover installation
8) After checking initial igniti on timing, release ignition
timing fixation by using scan tool.
9) With engine idling (throttl e opening at closed position
and vehicle stopped), check that ignition timing is
about 3 ° – 13° BTDC. (Constant variation within a
few degrees from 3 ° – 13° BTDC indicates no
abnormality but proves operation of electronic timing
control system.) Also, check that increasing engine
speed advances ignition timing.
If the check results are not satisfactory, check CKP
sensor and ECM.
Specifications
Tightening Torque SpecificationsS7RS0B1807001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Special ToolS7RS0B1808001
1, (A)10
0I3RB0A180004-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Spark plug 25 2.5 18.0 )
Ignition coil bolt 10 1.0 7.5 )
09930–76420SUZUKI scan tool
Timing-light (dry cell type) —
) 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 4E-35 ABS:
Specifications
Tightening Torque SpecificationsS7RS0B4507001
NOTE
The specified tightening torque is also described in the following.
“Front Wheel Speed Sensor Components Location”
“Rear Wheel Speed Sensor Components Location”
“ABS Hydraulic Unit / Control Module Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Special ToolS7RS0B4508001
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Brake pipe flare nut 16 1.6 11.5 )
ABS hydraulic unit / c ontrol module assembly
bolt 90.9 6.5)
ABS hydraulic unit / c ontrol module assembly
bracket bolt 25 2.5 18.0)
Front wheel speed sensor bolt 25 2.5 18.0 )
Front wheel speed sensor harness clamp bolt 11 1.1 8.0 )
Rear wheel speed sensor bolt 11 1.1 8.0 )
Rear wheel speed sensor har ness clamp bolt 11 1.1 8.0 )
09950–78220SUZUKI scan tool
Flare nut wrench (10 mm) —
) 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 4F-66 Electronic Stability Program:
Specifications
Tightening Torque SpecificationsS7RS0B4607001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
NOTE
The specified tightening torque is also described in the following.
“ESP® Hydraulic Unit / Control Module Assembly Removal and Installation”

Special Tools and Equipment
Special ToolS7RS0B4608001
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Brake pipe flare nut 16 1.6 11.5 )
ESP ® hydraulic unit / control module assembly
bolt 90.9 6.5)
ESP ® hydraulic unit / control module assembly
bracket bolt 25 2.5 18.0)
Front wheel speed sensor bolt 11 1.1 8.0 )
Front wheel speed sensor harness clamp bolt 11 1.1 8.0 )
Rear wheel speed sensor bolt 11 1.1 8.0 )
Rear wheel speed sensor har ness clamp bolt 11 1.1 8.0 )
Yaw rate / G sensor assembly nut 8 0.8 6.0 )
09956–02311SUZUKI scan tool
Brake pressure gauge —
) 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 5A-170 Automatic Transmission/Transaxle:
09928–0605009942–15511
Differential preload adapter Sliding hammer
) / )) / ) / ) / )
09944–78210 09944–88220
Bearing installer sup port Oil seal installer
) / )) / ) / ) / ) / ) / ) / )
09944–96011 09946–06710
Bearing outer race remover Transfer bearing dummy
) / ) / ) / )) / )
09951–18210 09952–06020
Oil seal remover & installer
No. 2 Dial gauge plate No.2
) / )) / ) / ) / )
SUZUKI scan tool
—
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. ) / ) / )