Cam SUZUKI SWIFT 2007 2.G Service Workshop Manual

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 General Information: 0A-2
SAS: Steering Angle Sensor
SDM: Sensing and Diagnostic Module (Air Bag Controller, Air bag Control Module)
SDT: Smart Diagnostic Tester
SFI: Sequential Multipor t Fuel Injection
SOHC: Single Over Head Camshaft
T:
TBI: Throttle Body Fuel Injection (Single-Point Fuel
Injection, SPI)
TCC: Torque Converter Clutch
TCM: Transmission Control Module (A/T Controller, A/T
Control Module)
TDC: Top Dead Center
TP Sensor: Throttle Position Sensor TVV:
Thermal Vacuum Valve (Thermal Vacuum
Switching Valve, TVSV, Bi metal Vacuum Switching
Valve, BVSV)
TWC: Three Way Catalytic Converter (Three Way
Catalyst)
2WD: 2 Wheel Drive
U:
USB: Universal Serial Bus
V:
VIN: Vehicle Identification Number
VSS: Vehicle Speed Sensor
VVT: Variable Valve Timing (Camshaft Position Control)
W:
WU-OC: Warm Up Oxidation Catalytic Converter
WU-TWC: Warm Up Three Way Catalytic Converter
SymbolsS7RS0B0101002
Wire Color SymbolsS7RS0B0101003
Symbol Definition SymbolDefinition
Tightening torque Apply SUZUKI BOND NO. 1216B
99000-31230
Apply oil (engine, transmission, transfer,
differential) Apply SILICONE SEALANT
99000-31120
Apply fluid (brake, power steering or
automatic transmission fluid) Apply SEALING COMPOUND 366E
99000-31090
Apply SUZUKI SUPER GREASE A
99000-25011
Apply SUZUKI SUPER GREASE C
99000-25030 Apply THREAD LOCK 1322
99000-32110
Apply SUZUKI SUPER GREASE E
99000-25050 Apply THREAD LOCK 1333B
99000-32020
Apply SUZUKI SUPER GREASE H
99000-25121 Apply THREAD LOCK 1342
99000-32050
Apply SUZUKI SUPER GREASE I
99000-25210
Apply SUZUKI BOND NO. 1215
99000-31110 Do not reuse
Apply SUZUKI BO ND NO. 1207F
99000-31250 Note on reassembly
Apply SUZUKI BO ND NO. 1217G
99000-31260
Symbol Wire Color SymbolWire Color
B BLK Black O, Or ORN Orange
Bl BLU Blue RRED Red
Br BRN Brown WWHT White
G GRN Green YYEL Yellow
Gr GRY Gray PPNK Pink
Lbl LT BLU Light blueVPPL Violet
Lg LT GRN Light green

Downloaded from www.Manualslib.com manuals search engine 0B-4 Maintenance and Lubrication:
Accessory Drive Belt ReplacementS7RS0B0206002
Water Pump and Generator Drive Belt
Replace belt with new one referring to “Water Pump /
Generator Drive Belt Removal and Installation in Section
1J”.
A/C Compressor Drive Belt
Replace belt with new one referring to “Compressor
Drive Belt Removal and Inst allation in Section 7B”.
Valve Lash (Clearance) InspectionS7RS0B0206003
Inspect intake and exhaust valve lash and adjust as
necessary.
Refer to “Valve Lash (Clearance) Inspection in Section
1D” for valve lash inspection and adjustment procedure.
Engine Oil and Filter ChangeS7RS0B0206004
WARNING!
• New and used engine oil can be
hazardous.
Be sure to read “WARNING” in “General
Precautions in Section 00” and observe
what is written there.
• Step 1) – 7) outlined below must be performed with ENGINE NOT RUNNING.
For Step 8), be sure to have adequate
ventilation while engine is running.

Before draining engine oil, check engine for oil leakage.
If any evidence of leakage is found, make sure to correct
defective part before proceeding to the following work.
1) Drain engine oil by removing drain plug.
2) After draining oil, wipe drain plug clean. Reinstall drain plug.
Tightening torque
Engine oil drain plug (a): 35 N·m (3.5 kgf-m, 25.5
lb-ft)
3) Loosen oil filter by using oil filter wrench (special
tool).
Special tool
(A): 09915–47331
NOTE
Before fitting new oil filter, be sure to oil its
O-ring. Use engine oil for this purpose.

1. Camshaft 2. Thickness gauge
I2RH0B020003-02
I2RH0B020004-01
I2RH0B020005-01
IYSQ01020009-01

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-9
Tires InspectionS7RS0B0206020
1) Check tires for uneven or excessive wear, or damage. If defective, replace.
Refer to “Irregular and/or Premature Wear
Description in Section 2D” and “Wear Indicators
Description in Section 2D” for details.
2) Check inflating pressure of each tire and adjust pressure to specification as necessary.
NOTE
• Tire inflation pressure should be checked when tires are cool.
• Specified tire inflation pressure should be found on tire placard or in owner’s manual
which came with the vehicle.

3) Rotate tires. For details, refer to “Tire Rotation in Section 2D”.
Wheel Discs InspectionS7RS0B0206021
Inspect each wheel disc for de nts, distortion and cracks.
A disc in badly damaged condition must be replaced.
Wheel Bearing InspectionS7RS0B0206022
1) Check front wheel bearing for wear, damage, abnormal noise or rattles. For details, refer to “Front
Wheel Hub, Disc, Nut and Bearing Check in Section
2B”.
2) Check rear wheel bearing for wear, damage, abnormal noise or rattles. For details, refer to“Rear
Wheel Disc, bolt and Bearing Inspection in Section
2C”.
Suspension System InspectionS7RS0B0206023
• Inspect front struts and rear shock absorbers for evidence of oil leakage, dents or any other damage on
sleeves; and inspect anchor ends for deterioration.
Replace defective parts, if any.
• Check front and rear suspension systems for damaged, loose or missing parts; also for parts
showing signs of wear or lack of lubrication.
Repair or replace defective parts, if any.
• Check front suspension arm ball joint stud dust seals for leakage, detachment, tear or any other damage.
Replace defective boot, if any.
1. Wear indicator
I2RH01020022-01
I2RH01020023-01
I4RS0A020011-01
I4RS0A020012-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 1- i
1
Section 1
CONTENTS
Engine
Precautions ................................................. 1-1
Precautions............................................................. 1-1
Precautions for Engine .......................................... 1-1
Engine General Information and
Diagnosis ............. .................................... 1A-1
Precautions........................................................... 1A-1
Precautions on Engine Service ........................... 1A-1
Precaution on On-Board Diagnostic (OBD) System .............................................................. 1A-1
Precautions in Diagnosing Trouble ..................... 1A-1
Precautions of ECM Circuit Inspection................ 1A-2
Precautions of Electric Throttle Body System
Calibration ......................................................... 1A-2
General Description ............................................. 1A-2 Statement on Cleanliness and Care ................... 1A-2
Engine Diagnosis General Description ............... 1A-3
On-Board Diagnostic System Description ........... 1A-3
Data Link Connector (DLC) ................................. 1A-6
Engine and Emission Control System Description ........................................................ 1A-6
CAN Communication System Description........... 1A-7
Air Intake System Description ............................. 1A-9
Description of Electric Throttle Body System ...... 1A-9
Description of Electric Throttle Body System Calibration ....................................................... 1A-10
Fuel Cut Control Description ............................. 1A-10
Generator Control System Description ............. 1A-11
Electronic Control System Description .............. 1A-12
Engine and Emission Control Input / Output Table ............................................................... 1A-18
Schematic and Routing Diagram ...................... 1A-19 Engine and Emission Control System Diagram .......................................................... 1A-19
Component Locatio n ......................................... 1A-21
Electronic Control System Components Location .......................................................... 1A-21
Diagnostic Information and Procedures .......... 1A-22 Engine and Emission Control System Check.... 1A-22
Malfunction Indicator Lamp (MIL) Check .......... 1A-25
DTC Check ....................................................... 1A-26
DTC Clearance ................................................. 1A-27
DTC Table ......................................................... 1A-27
Fail-Safe Table ................ .................................. 1A-31 Scan Tool Data ................................................. 1A-33
Visual Inspection ............................................... 1A-37
Engine Basic Inspection .................................... 1A-38
Engine Symptom Diagnosis .............................. 1A-41
MIL Does Not Come ON with Ignition Switch
ON and Engine Stop (but Engine Can Be
Started) ........................................................... 1A-47
Malfunction Indicator Lamp Remains ON after Engine Starts................................................... 1A-48
DTC P0010: “A” Camshaft Position Actuator Circuit .............................................................. 1A-49
DTC P0011 / P0012: “A” Camshaft Position - Timing Over-Advanced or System
Performance / -Retarded................................. 1A-52
DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1) .......................... 1A-54
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2) .......................... 1A-56
DTC P0101: Mass or Volume Air Flow Circuit Range / Performance ...................................... 1A-58
DTC P0102: Mass or Volume Air Flow Circuit Low Input......................................................... 1A-61
DTC P0103: Mass or Volume Air Flow Circuit High Input ........................................................ 1A-63
DTC P0106: Manifold Absolute Pressure /
Barometric Pressure Circuit Range /
Performance.................................................... 1A-64
DTC P0107: Manifold Absolute Pressure /
Barometric Pressure Circ uit Low Input............ 1A-66
DTC P0108: Manifold Absolute Pressure /
Barometric Pressure Circ uit High Input ........... 1A-67
DTC P0111: Intake Air Temperature Sensor 1 Circuit Range / Performance ........................... 1A-69
DTC P0112: Intake Air Temperature Sensor 1 Circuit Low ...................................................... 1A-72
DTC P0113: Intake Air Temperature 1 Sensor Circuit High...................................................... 1A-74
DTC P0116: Engine Coolant Temperature Circuit Range / Performance ........................... 1A-76
DTC P0117: Engine Coolant Temperature Circuit Low ...................................................... 1A-79
DTC P0118: Engine Coolant Temperature Circuit High...................................................... 1A-81
DTC P0122: Throttle / Pedal Position Sensor / Switch “A” (Main) Circuit Low ........................ 1A-83

Downloaded from www.Manualslib.com manuals search engine 1-ii Table of Contents
DTC P0123: Throttle / Pedal Position Sensor / Switch “A” (Main) Circuit High ....................... 1A-85
DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-
1) ..................................................................... 1A-88
DTC P0133: O2 Sensor (HO2S) Circuit Slow
Response (Sensor- 1) ...................................... 1A-91
DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor -1) ........................... 1A-92
DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-
2) ..................................................................... 1A-94
DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor -2) ........................... 1A-97
DTC P0171 / P0172: Fuel System Too Lean / Rich ................................................................. 1A-98
DTC P0222: Throttle / Pedal Position Sensor / Switch “B” (Sub) Circuit Low ....................... 1A-100
DTC P0223: Throttle / Pedal Position Sensor / Switch “B” (Sub) Circuit High ...................... 1A-102
DTC P0300 / P0301 / P0302 / P0303 / P0304: Random / Multiple Cylin der Misfire Detected
/ Cylinder 1 / Cylinder 2 / Cylinder 3 /
Cylinder 4 Misfire Detected ........................... 1A-105
DTC P0327 / P0328: Knoc k Sensor 1 Circuit
Low / High ..................................................... 1A-107
DTC P0335: Crankshaft Position (CKP) Sensor “A” Circuit .......................................... 1A-109
DTC P0340: Camshaft Position (CMP) Sensor “A” Circuit .......................................... 1A-111
DTC P0350: Ignition Coil Primary / Secondary Circuit ............................................................ 1A-114
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected /
Excessive Detected ...................................... 1A-116
DTC P0403: Exhaust Gas Recirculation Control Circuit ................... ............................ 1A-118
DTC P0420: Catalyst System Efficiency
below Threshold ................ ............................ 1A-120
DTC P0443: Evaporativ e Emission System
Purge Control Valve Circuit ........................... 1A-122
DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit ................... ............................ 1A-124
DTC P0500: Vehicle Speed Sensor “A” Malfunction .................................................... 1A-128
DTC P0532: A/C Refrigerant Pressure Sensor “A” Circuit Low ... ............................... 1A-130
DTC P0533: A/C Refrigerant Pressure Sensor “A” Circuit High ................................. 1A-132
DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control
Module Programming Error / Control Module
Performance ................................................. 1A-134
DTC P0616: Starter Relay Circuit Low............ 1A-135
DTC P0617: Starter Relay Circuit High ........... 1A-136
DTC P0620: Generator Control Circuit ........... 1A-137
DTC P0625 / P0626: Generator Field Terminal Circuit Low / High . .......................... 1A-139
DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High . ............................ 1A-141 DTC P1510: ECM Back-Up Power Supply
Malfunction .................................................... 1A-143
DTC P1603: TCM Trouble Code Detected ..... 1A-144
DTC P1674: CAN Communication (Bus Off Error) ............................................................. 1A-145
DTC P1676: CAN Communication (Reception Error for TCM) ............................................... 1A-148
DTC P1678: CAN Communication (Reception Error for BCM) ............................................... 1A-149
DTC P1685: CAN Communication (Reception Error for ABS/ESP ® Control Module) ........... 1A-150
DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance ......................... 1A-152
DTC P2102: Throttle Actuator Control Motor Circuit Low .................................................... 1A-154
DTC P2103: Throttle Actuator Control Motor Circuit High.................................................... 1A-155
DTC P2111 / P2112: Throttle Actuator Control System - Stuck Open / Closed ...................... 1A-156
DTC P2119: Throttle Actu ator Control Throttle
Body Range / Performance ........................... 1A-157
DTC P2122: Throttle / Pedal Position Sensor / Switch “D” (Main) Circuit Low Input............. 1A-159
DTC P2123: Throttle / Pedal Position Sensor / Switch “D” (Main) Circuit High Input ............ 1A-161
DTC P2127: Throttle Pedal Position Sensor / Switch “E” (Sub) Circuit Low Input ................ 1A-164
DTC P2128: Throttle / Pedal Position Sensor
/ Switc
h “E” (Sub) Circuit High Input ............. 1A-166
DTC P2135: Throttle / Pedal Position Sensor / Switch “A”/“B” (Main / Sub) Voltage
Correlation..................................................... 1A-168
DTC P2138: Throttle / Pedal Position Sensor / Switch “D”/“E” (Main / Sub) Voltage
Correlation..................................................... 1A-171
DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction ......................... 1A-173
Inspection of ECM and Its Circuits .................. 1A-175
ECM Power and Ground Circuit Check........... 1A-194
Fuel Injector Circuit Check .............................. 1A-198
Fuel Pump and Its Circuit Check..................... 1A-200
Fuel Pressure Check....................................... 1A-203
A/C System Circuits Check ............................. 1A-205
Electric Load Signal Circuit Check .................. 1A-209
Radiator Cooling Fan Low Speed Control System Check ............................................... 1A-211
Radiator Cooling Fan High Speed Control System Check ............................................... 1A-213
Repair Instructions ......... .................................1A-216
Idle Speed and IAC Throttle Valve Opening Inspection ...................................................... 1A-216
Special Tools and Equipmen t .........................1A-217
Special Tool .................................................... 1A-217
Aux. Emission Control Devices ............. 1B-1
Diagnostic Information and Procedures ............1B-1
EGR System Inspection ...................................... 1B-1
Repair Instructions ............ ..................................1B-1
EVAP Canister Purge Inspec tion ........................ 1B-1

Downloaded from www.Manualslib.com manuals search engine Table of Contents 1-iii
EVAP Canister Purge Valve and Its Circuit
Inspection.......................................................... 1B-2
Vacuum Passage Inspection .............................. 1B-3
Vacuum Hose and Purge Valve Chamber Inspection.......................................................... 1B-3
EVAP Canister Purge Valve Inspection .............. 1B-3
EVAP Canister Inspection ... ................................ 1B-4
EGR Valve Removal and Installation .................. 1B-4
EGR Valve Inspection ......................................... 1B-4
PCV Hose Inspection .......................................... 1B-4
PCV Valve Inspection ......................................... 1B-5
Special Tools and Equipmen t ............................. 1B-5
Special Tool ........................................................ 1B-5
Engine Electrical Devices .. ..................... 1C-1
Repair Instructions .............................................. 1C-1
ECM Removal and Installation ............................ 1C-1
MAP Sensor Inspection ...................................... 1C-2
Electric Throttle Body Assembly On-Vehicle
Inspection.......................................................... 1C-2
Electric Throttle Body System Calibration ........... 1C-5
APP Sensor Assembly On-V ehicle Inspection .... 1C-5
APP Sensor Assembly Removal and Installation ......................................................... 1C-5
APP Sensor Assembly Inspection ...................... 1C-6
ECT Sensor Removal and In stallation ................ 1C-6
ECT Sensor Inspection ....................................... 1C-7
HO2S-1 and HO2S-2 Heater On-Vehicle Inspection.......................................................... 1C-7
HO2S-1 and HO2S-2 Removal and Installation ......................................................... 1C-7
CMP Sensor Removal and In stallation ............... 1C-8
Camshaft Position (CMP) Se nsor Inspection ...... 1C-8
CKP Sensor Removal and Installation ................ 1C-9
CKP Sensor Inspection ....................................... 1C-9
Knock Sensor Removal and Installation ........... 1C-10
Main Relay, Fuel Pump Relay and Starting
Motor Control Relay Inspection....................... 1C-10
MAF and IAT Sensor On-Vehicle Inspection .... 1C-11
MAF and IAT Sensor Removal and Installation ....................................................... 1C-11
MAF and IAT Sensor Inspection ....................... 1C-12
Electric Load Current Sensor On-Vehicle Inspection........................................................ 1C-12
Specifications ..................................................... 1C-13
Tightening Torque Specifications ...................... 1C-13
Engine Mechanical ......... ......................... 1D-1
General Description ............................................. 1D-1
Engine Construction Description ......................... 1D-1
Camshaft Position Control (VVT Variable Valve Timing) System Description .................... 1D-2
Diagnostic Information and Procedures ............ 1D-4 Compression Check ............................................ 1D-4
Engine Vacuum Check ....................................... 1D-5
Valve Lash (Clearance) Inspection ..................... 1D-6
Repair Instructions .............................................. 1D-9 Air Cleaner Components ..................................... 1D-9
Air Cleaner Element Removal and Installation .... 1D-9 Air Cleaner Element Ins
pection and Cleaning ..1D-10
Cylinder Head Co ver Removal and
Installation .......................................................1D-10
Throttle Body and Intake Manifold
Components ....................................................1D-12
Throttle Body On-Vehicle Inspection.................1D-13
Electric Throttle Body Assembly Removal and Installation .......................................................1D-13
Throttle Body Cleaning......................................1D-14
Intake Manifold Removal and Installation .........1D-14
Engine Mountings Components ........................1D-16
Engine Assembly Removal and Installation ......1D-17
Timing Chain Cover Components .....................1D-20
Timing Chain Cover Removal and Installation ..1D-21
Timing Chain Cover Inspection .........................1D-23
Oil Control Valve Removal and Installation .......1D-23
Oil Control Valve Inspection ..............................1D-24
Timing Chain and Chain Tensioner Components ....................................................1D-24
Timing Chain and Chain Tensioner Removal and Installation ................................................1D-25
Timing Chain and Chain Tensioner Inspection ..1D-27
Camshaft, Tappet and Shim Components ........1D-28
Camshaft, Tappet and Shim Removal and Installation .......................................................1D-29
Camshaft, Tappet and Shim Inspection ............1D-31
Valves and Cylinder Head Components ...........1D-34
Valves and Cylinder Head Removal and
Installation .......................................................1D-35
Valves and Cylinder Head Disassembly and Assembly.........................................................1D-37
Valves and Valve Guides Inspection.................1D-40
Cylinder Head Inspection . .................................1D-42
Valve Spring Inspection ....................................1D-43
Pistons, Piston Rings , Connecting Rods and
Cylinders Components ....................................1D-44
Pistons, Piston Rings , Connecting Rods and
Cylinders Removal and Installation .................1D-45
Pistons, Piston Rings , Connecting Rods and
Cylinders Disassembly and Assembly ............1D-46
Cylinders, Pistons and Piston Rings Inspection ........................................................1D-47
Piston Pins and Connecting Rods Inspection ...1D-49
Crank Pin and Connecting Rod Bearings Inspection ........................................................1D-50
Main Bearings, Cran kshaft and Cylinder
Block Components ..........................................1D-53
Main Bearings, Cran kshaft and Cylinder
Block Removal and Installa tion .......................1D-54
Crankshaft Inspection .......................................1D-57
Main Bearings Inspection . .................................1D-59
Sensor Plate Inspection ....................................1D-63
Rear Oil Seal Inspection ...................................1D-63
Flywheel Inspection...........................................1D-63
Cylinder Block Inspection ..................................1D-63
Specifications .................... .................................1D-64
Tightening Torque Specifications ......................1D-64
Special Tools and Equipmen t ...........................1D-66
Recommended Service Material .......................1D-66
Special Tool ......................................................1D-66

Downloaded from www.Manualslib.com manuals search engine 1A-12 Engine General Information and Diagnosis:
Electronic Control System DescriptionS7RS0B1101011
The electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2)
ECM which controls various devices ac cording to the signals from the sensors and 3) various controlled devices.
Functionally, it is divided into the following sub systems:
• Fuel injection control system
• Ignition control system
• Electric throttle body control system
• Fuel pump control system
• Radiator cooling fan control system
• Evaporative emission control system
• EGR system
• Oxygen sensor heater control system
• A/C control system (A/C model)
• Camshaft position control system
• Immobilizer control system
• Generator control system
• Controller (computer) communication system
Especially, ECM, BCM, combination meter, TCM (A/T model), ABS/ESP ® control module, steering angle sensor
(ESP® model) and keyless start control module (if equipped) intercommunicate by means of CAN communication.

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-15
Terminal Arrangement of ECM Coupler (Viewed from Harness Side)
[A]: Manual A/C model24. ABS / ESP® control module 49. Radiator cooling fan motor
[B]: Auto A/C model 25. TCM 50. “RDTR FAN” fuse
1. ECM 26. To other control module connected CAN 51. A/C compressor relay
2. APP sensor assembly 27. Generator 52. Magnet clutch of compressor (A/C model)
3. Shield wire 28. Electric load current sensor (if equipped) 53. “A/C CPRSR” fuse
4. CMP sensor 29. Brake light 54. Ignition coil assembly (for No.1 and No.4 spark
plugs)
5. CKP sensor 30. Brake light switch 55. Ignition coil assembly (for No.2 and No.3 spark
plugs)
6. MAF and IAT sensor 31. Diagnosis connector (Hong Kong model) 56. P/S control module
7. MAP sensor 32. Throttle actuator control relay 57. “RADIO” fuse
8. ECT sensor 33. “THR MOT” fuse 58. Main relay
9. A/C refrigerant pressure sensor 34. Throttle throttle body assembly 59. “IG COIL” fuse
10. A/C evaporator outlet air temp. sensor (Manual A/C model) 35. Throttle actuator
60. Ignition switch
11. HO2S-1 36. TP sensor 61. “IG ACC” fuse
12. HO2S-2 37. Injector No.1 62. “FI” fuse
13. Knock sensor 38. Injector No.2 63. Starting motor control relay
14. Blower motor relay 39. Injector No.3 64. “ST SIG” fuse
15. Blower motor 40. Injector No.4 65. “ST MOT” fuse
16. Blower motor resistor 41. EVAP canister purge valve66. Transmission range switch (A/T model) or CPP
switch (Hong Kong model with M/T)
17. Blower speed selector 42. EGR valve 67. Starting motor
18. A/C switch 43. Oil control valve (Camshaft position
control) (VVT model) 68. Immobilizer coil antenna
19. Blower motor controller 44. Fuel pump relay 69. Main fuse box
20. HVAC control module 45. Fuel pump 70. Battery
21. Data link connector (DLC) 46. Radiator cooling fan motor relay No.1 71. Barometric pressure sensor
22. To other control module connected with DLC 47. Radiator cooling fan motor relay No.2
72. Engine ground
23. BCM 48. Radiator cooling fan motor relay No.3 73. Body ground
E23 C37
34
1819
567
1011
17
20
47 46
495051
2122
52 16
25 9
24
14
29
55
57 54 53
59
60 58 2
262728
15
30
56 4832 31
34353637
40
42 39 38
44
45 43 41 331
1213
238
34
1819
567
1011
17
20
47 46
495051
2122
52 16
25 9
24
14
29
55
57 54 53
59
60 58 2
262728
15
30
56 4832 31
34353637
40
42 39 38
44
45 43 41 331
1213
238
I4RS0A110008-01

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-27
DTC ClearanceS7RS0B1104004
NOTE
There are two types of OBD system
depending on the vehicle specification.
For details, refer to “Precaution on On-Board
Diagnostic (OBD) System”.

Using Scan Tool1) Connect OBD generic scan to ol or SUZUKI scan tool
to data link connector in the same manner as when
making this connection for DTC check.
2) Turn ignition switch OFF and then ON.
3) Erase DTC and pending DTC according to instructions displayed on scan tool. Refer to scan
tool operator’s manual for further details.
4) After completing the clear ance, turn ignition switch
OFF and disconnect scan tool from data link
connector.
NOTE
DTC and freeze frame data stored in ECM
memory are also cleared in the following
cases. Be careful not to clear them before
keeping their record.
• When power to ECM is cut off (by disconnecting battery cable, removing
fuse or disconnecting ECM connectors).
• When the same malfunction (DTC) is not detected again during 40 engine warm-up
cycles. (See “Warm-Up Cycle” of “On-
Board Diagnostic System Description”.)

Without Using Scan Tool (Hong Kong Model)
1) Turn ignition switch to OFF position.
2) Disconnect battery negative cable for specified time below to erase diagnostic trouble code stored in
ECM memory and reconnect it.
Time required to erase DTC
DTC TableS7RS0B1104005
NOTE
• There are two types of OBD system depending on the vehicle specification.
• For details, refer to “Precaution on On-Board Diagnostic (OBD) System”.
• For non-Euro-OBD model, some of DTC No. with delta ( U) mark in the following table can not be
detected by ECM depending on vehicl e specification and local regulation.
• DTC with square ( †) mark in the following table can be detected only for Hong Kong model.
• DTC with circle ( {) mark in the following table can be detected only for Euro OBD model and Hong
Kong model.
• For Euro OBD model, with the generic scan tool, onl y star (*) marked DTC No. in the following table
can be read.
• 1 driving cycle: MIL lights up when DTC is detected during 1 driving cycle.
• 2 driving cycles: MIL lights up when the same DTC is detected also in the next driving cycle after DTC is detected and stored temporarily in the first driving cycle.
• *2 driving cycles: MIL blinks or lights up. Refer to “DTC P0300 / P0301 / P0302 / P0303 / P0304: Random / Multiple
Cylinder Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected” for
details.

Ambient temperature Time to cut power to ECM
Over 0 °C (32 ° F) 30 sec. or longer
Under 0 °C (32 °F) Not specifiable.
Select a place with higher
than 0 °C (32 °F)
temperature.
DTC No. Detecting item Detecting condition
(DTC will set when detecting:) MIL
) *P0010 “A” camshaft position actuator
circuit Oil control valve circuit open or short. 1 driving
cycle
) *P0011 “A” camshaft position – timing
over-advanced or system
performance Actual value of advanced va
lve timing does not reach
target value, or valve timi ng is advanced although ECM
command is most retarding. 2 driving
cycles
) *P0012 “A” camshaft position – timing
over-retarded 2 driving
cycles