Shaft SUZUKI SWIFT 2007 2.G Service Manual Online

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-66
Special Tools and Equipment
Recommended Service MaterialS7RS0B1408001
NOTE
Required service material is also described in the following.
“Timing Chain Cover Components”
“Timing Chain and Chain Tensioner Components”
“Camshaft, Tappet and Shim Components”
“Valves and Cylinder Head Components”
“Pistons, Piston Rings, Connecting Rods and Cylinders Components”
“Main Bearings, Crankshaft and Cylinder Block Components”

Special ToolS7RS0B1408002
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260)
Water tight sealant SUZUKI Bond No.1207B P/No.: 99000–31140)
SUZUKI Bond No.1207F P/No.: 99000–31250) / ) / )
09911–97720 09911–97821
Oil seal installer Oil seal installer
))
09913–75810 09915–64512
Bearing installer Compression gauge
))
09915–64530 09915–67010
Compression gauge hose Compression gauge
attachment (C)
))
09915–67311 09916–14510
Vacuum gauge Valve lifter
)) / )
09916–14521 09916–34542
Valve spring compressor
attachment Reamer handle
) / )) / )

Downloaded from www.Manualslib.com manuals search engine 1D-67 Engine Mechanical:
09916–3455009916–37320
Reamer handle Valve guide outer reamer
(10.5 mm)
))
09916–44910 09916–56011
Valve guide installer &
remover Valve guide installer
attachment (protrusion: 11.5
mm)
))
09916–58210 09916–67020
Valve guide installer handle Tappet holder (Overseas)
) / )) / )
09916–67021 09916–77310
Tappet holder Piston ring compressor (50-
125 mm)
) / ))
09916–84511 09917–68221
Forceps Camshaft pulley holder
) / )) / )
09917–98221 09924–17811
Valve guide stem
attachment Flywheel holder
)) / )
09926–58010 09944–36011
Bearing remover attachment Steering wheel remover
))

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-1
Engine
Engine Lubrication System
General Description
Engine Lubrication DescriptionS7RS0B1501001
The oil pump is of a trochoid type, and mounted on the
crankshaft. Oil is drawn up through the oil pump strainer
and passed through the pump to the oil filter.
The filtered oil flows into two paths in cylinder block.
The filtered oil is passed to the passage in heat
exchanger and cylinder block to piston cooling valve of
oil gushed to the lower side of piston. In one path, oil reaches the crankshaft journal bearings.
Oil from the crankshaft journal bearings is supplied to
the connecting rod bearings by means of intersecting
passages drilled in the cran
kshaft, and then injected
from the big end of connecting rod to lubricate piston,
rings and cylinder wall.
In the other path oil goes up to the cylinder head and
lubricates valves and camshafts, etc., after passing
through the internal oil way of camshafts.
An oil relief valve is provided on the oil pump. This valve
starts relieving oil pressure when the pressure exceeds
about 350 kPa (3.5 kg/cm
2, 49.8 psi).
I6RS0C150001-01

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-1
Engine
Ignition System
General Description
Ignition System ConstructionS7RS0B1801001
The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below.
• ECM
It detects the engine and vehicle conditions through the si gnals from the sensors, determines the most suitable
ignition timing and time for electricity to flow to the primar y coil and sends a signal to the ignitor (power unit) in the
ignition coil assembly.
• Ignition coil assembly (including an ignitor)
The ignition coil assembly has a built -in ignitor which turns ON and OFF the current flow to the primary coil
according to the signal from ECM. When the current flow to the primary coil is turned OFF, a high voltage is induced
in the secondary coil.
• High-tension cords and spark plugs
• CMP sensor (Camshaft position sensor) and CKP sensor (Crankshaft position sensor)
Using signals from these sensors, ECM identifies the specific cylinder whose piston is in the compression stroke,
detects the crank angle and adjusts in itial ignition timing automatically.
• TP sensor, ECT sensor, MAP sensor, MAF sensor, IAT sensor, knock sensor and other sensors / switches
Although this ignition system does not have a distributor, it has two ignition coil assemblies (one is for No.1 and No.4
spark plugs and the other is for No.2 and No.3 spark plugs). W hen an ignition signal is sent from ECM to the ignitor in
the ignition coil assembly for No.1 and No.4 spark plugs, a high voltage is induced in the secondary coil and that
passes through the high-tension cords and causes No.1 and No.4 spark plugs to spark simultaneously. Likewise,
when an ignition signal is sent to the ignitor in the ot her ignition coil assembly, No.2 and No.3 spark plugs spark
simultaneously.

Downloaded from www.Manualslib.com manuals search engine 1H-4 Ignition System:
Diagnostic Information and Procedures
Ignition System Symptom DiagnosisS7RS0B1804001
Reference Waveform of Ignition SystemS7RS0B1804002
Refer to “Reference waveform No.5”, “Reference waveform No.6” and “Reference waveform No.7” under “Inspection
of ECM and Its Circuits in Section 1A” for waveform of Ignition trigger signal.
Ignition System CheckS7RS0B1804003
Condition Possible cause Correction / Reference Item
Engine cranks, but will
not start or hard to start
(No spark) Blown fuse for ignition coil
Replace.
Loose connection or disconnection of
lead wire or high-tension cord(s) Connect securely.
Faulty high-tension cord(s) Replace.
Faulty spark plug(s) Replace.
Faulty ignition coil Replace ignition coil assembly.
Faulty CKP sensor or CKP sensor plate Clean, tighten or replace.
Faulty CMP sensor or sensor rotor tooth
of camshaft Clean, tighten or replace.
Faulty ECM Replace.
Poor fuel economy or
engine performance Incorrect ignition timing
Check related sensors and CKP sensor plate.
Faulty spark plug(s) or high-tension
cord(s) Adjust, clean or replace.
Faulty ignition coil assembly Replace.
Faulty CKP sensor or CKP sensor plate Clean, tighten or replace.
Faulty CMP sensor or sensor rotor tooth
of camshaft Clean, tighten or replace.
Faulty knock sensor Replace.
Faulty ECM Replace.
StepAction YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check in
Section 1A”.
2 Ignition spark test
1) Check all spark plugs for condition and type referring to
“Spark Plug Inspection”.
2) If OK, perform ignition spark test referring to “Ignition Spar k Tes t”.
Is spark emitted from all spark plugs? Go to Step 13. Go to Step 3.
3 DTC check
1) Perform DTC check referring to “DTC Check in Section
1A”.
Is DTC stored in ECM? Go to applicable DTC
diag. flow.
Go to Step 4.
4 Electrical connection check
1) Check ignition coil assemblies and high-tension cords
for electrical connection.
Are they connected securely? Go to Step 5.
Connect securely.
5 High-tension cords check
1) Check high-tension cord for resistance referring to
“High-Tension Cord Inspection”.
Is check result satisfactory? Go to Step 6.
Replace high-tension
cord(s).

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-5
6Ignition coil assembly power supply and ground circuit
check
1) Check ignition coil assembly power supply and ground
circuits for open and short.
Are circuits in good condition? Go to Step 7.
Repair or replace.
7 Ignition coil assembly check
1) Check ignition coil for resistance referring to “Ignition
Coil Assembly (Including ignitor) Inspection”.
Is check result satisfactory? Go to Step 8.
Replace ignition coil
assembly.
8 CKP sensor check
1) Check CKP sensor referring to “CKP Sensor Inspection
in Section 1C”.
Is check result satisfactory? Go to Step 9.
Tighten CKP sensor
bolt, replace CKP
sensor or CKP sensor
plate.
9 CMP sensor check
1) Check CMP sensor referring to “Camshaft Position
(CMP) Sensor Inspection in Section 1C”.
Is check result satisfactory? Go to Step 10. Tighten CMP sensor
bolt, replace CMP
sensor or intake
camshaft.
10 Ignition trigger signal circuit check
1) Check ignition trigger signal wire for open, short and
poor connection.
Is circuit in good condition? Go to Step 11. Repair or replace.
11 A known-good ignition coil assembly substitution
1) Substitute a known-good ignition coil assembly and then
repeat Step 2.
Is check result of Step 2 satisfactory? Go to Step 12. Substitute a known-
good ECM and then
repeat Step 2.
12 Knock sensor check
1) Confirm that knock sensor circuit is in good condition
referring to “DTC P0327 / P0328: Knock Sensor 1 Circuit
Low / High in Section 1A”.
2) Check oscilloscope waveform of knock sensor signal
referring to “Reference waveform No.25” and
“Reference waveform No.26” under “Inspection of ECM
and Its Circuits in Section 1A”.
Is check result satisfactory? Go to Step 13. Substitute a known-
good knock sensor and
recheck.
13 Ignition timing check
1) Check initial ignition timing and ignition timing advance
referring to “Ignition Timing Inspection”.
Is check result satisfactory? System is in good
condition.
Check CMP sensor,
CMP sensor rotor tooth
of camshaft, CKP
sensor, CKP sensor
plate and/or input
signals related to this
system.
Step
Action YesNo

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 Starting System: 1I-2
ConditionPossible cause Correction / Reference Item
Motor not running (No
operating sound of
magnetic switch) Shift lever switch is not in P or N, or not
adjusted (A/T)
Shift in P or N, or
adjust switch. (A/T)
Battery run down Recharge battery.
Battery voltage too low due to battery
deterioration Replace battery.
Poor contact in battery terminal
connection Retighten or replace.
Loose grounding cable connection Retighten.
Fuse set loose or blown off Tighten or replace.
Poor contacting action of ignition switch
and magnetic switch Replace.
Lead wire coupler loose in place Retighten.
Open-circuit between ignition switch and
magnetic switch Repair.
Open-circuit in pull-in coil Replace magnetic switch.
Brushes are seating poorly or worn
down Repair or replace.
Poor sliding of plunger and/or pinion Repair.
Faulty starting motor control relay “Main Relay, Fuel Pump Relay and Starting
Motor Control Relay Inspection in Section 1C”.
Faulty ECM and its circuit “Inspection of ECM and Its Circuits in Section
1A”.
Motor not running
(Operating sound of
magnetic switch heard) Battery run down
Recharge battery.
Battery voltage too low due to battery
deterioration Replace battery.
Loose battery cable connections Retighten.
Burnt main contact point, or poor
contacting action of magnetic switch Replace magnetic switch.
Brushes are seating poorly or worn
down Repair or replace.
Weakened brush spring Replace.
Burnt commutator Replace armature.
Layer short-circuit of armature Replace.
Crankshaft rotation obstructed Repair.
Starting motor running
but too slow (small
torque) (If battery and
wiring are satisfactory,
inspect starting motor) Insufficient contact
of magnetic switch
main contacts Replace magnetic switch.
Layer short-circuit of armature Replace.
Disconnected, burnt or worn
commutator Repair commutator or replace armature.
Worn brushes Replace brush.
Weakened brush springs Replace spring.
Burnt or abnormally worn end bush Replace bush.
Starting motor running,
but not cranking engine Worn pinion tip
Replace over-running clutch.
Poor sliding of over-running clutch Repair.
Over-running clutch slipping Replace over-running clutch.
Worn teeth of ring gear Replace flywheel (M/T) or drive plate (A/T).
Noise Abnormally worn bush Replace bush.
Worn pinion or worn teeth of ring gear Replace over-running clutch, flywheel (M/T) or
drive plate (A/T).
Poor sliding of pinion (failure in return
movement) Repair or replace.
Worn internal or planetary gear teeth Replace.
Lack of oil in each part Lubricate.
Starting motor does not
stop running Fused contact points of magnetic switch
Replace magnetic switch.
Short-circuit between turns of magnetic
switch coil (layer short-circuit) Replace magnetic switch.
Failure of returning action in ignition
switch Replace.

Downloaded from www.Manualslib.com manuals search engine 1I-5 Starting System:
Starting Motor ComponentsS7RS0B1906002
I4RS0A190003-01
1. Front housing 7. Plate 13. Planetary gear 19. Rear bush
2. Bush 8. Seal rubber 14. Packing 20. Starting motor battery cable nut
3. Pinion stop ring 9. Magnetic switch 15. Yoke :9.8 N
⋅m (0.98 kgf-m, 7.0 lb-ft)
4. Over-running clutch 10. Ball 16. Armature: Do not reuse.
5. Lever 11. Internal gear 17. Brush assembly : Apply grease 99000-25010 to sliding surface of each part.
6. Plunger 12. Planetary carrier shaft 18. Rear bracket

Downloaded from www.Manualslib.com manuals search engine 1J-8 Charging System:
3) After loosening generator bracket bolts (2) and pivot bolt (3), adjust belt tensio n to specification described
at step 2) by loosening / tightening generator adjust
bolt (1).
4) Tighten generator bracket bolts and pivot bolt as specified torque.
Tightening torque
Generator bracket bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Generator pivot bolt (b): 50 N·m (5.0 kgf-m, 36.0
lb-ft)
5) Check belt tension for specification after turning crankshaft two rotations clockwise.
6) Tighten generator adjusting bolt (1) as specified torque.
Tightening torque
Generator adjusting bolt (c): 7 N·m (0.7 kgf-m,
5.0 lb-ft) by the specified procedure.
7) Connect negative cable at battery.Water Pump / Generator Drive Belt Removal and
Installation
S7RS0B1A06004
Removal 1) Disconnect negative cable at battery.
2) If vehicle equipped with A/C, remove compressor drive belt before removing water pump belt (1). Refer
to “Compressor Drive Belt Removal and Installation
in Section 7B” or “Compr essor Drive Belt Removal
and Installation in Section 7B”.
3) Loosen drive belt adjusting bolt (2) and generator pivot bolt (3).
4) Loosen generator adjusting bolt (4), and then remove water pump belt.
Installation
Reverse removal procedure for installation noting the
following.
• Adjust belt tension referring to “Water Pump / Generator Drive Belt Tension Inspection and
Adjustment” and “Compressor Drive Belt Inspection
and Adjustment in Section 7B” or “Compressor Drive
Belt Inspection and Adjustment in Section 7B”.
1, (c)
2, (a)
3, (b)
I5RW0C160007-01
4
23
1
I6RS0C1A0002-01