AIR CON SUZUKI SWIFT 2008 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-107
DTC P0327 / P0328: Knock Sensor 1 Circuit Low / HighS7RS0B1104040
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure1) Connect scan tool to DLC with ignition switch turned OFF.
2) Turn ON ignition switch and clear DTC by using scan tool.
3) Start engine and run it for 10 sec.
4) Check DTC by using scan tool. 11
Engine mechanical system check
1) Check engine mechanical parts or system which can
cause engine rough idle or poor performance.
• Engine compression (Refer to “Compression Check in Section 1D”.)
• Valve lash (Refer to “Valve Lash (Clearance) Inspection in Section 1D”.)
• Valve timing (Refer to “Timing Chain and Chain Tensioner Removal and Installation in Section 1D”.)
Are they in good condition? Check wire harness and
connection of ECM
ground, ignition system
and fuel injector for
intermittent open and
short.
Repair or replace
defective part.
Step
Action YesNo
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
1 2
REDC37-56
5 V
I4RS0A110031-01
1. Knock sensor
2. ECM
DTC detecting condition Trouble area
DTC P0327:
Voltage of knock sensor is less than 1.23 V for 0.5 seconds
continuously.
(1 driving cycle detection logic)
DTC P0328:
Voltage of knock sensor is 3.91 V or more for 0.5 seconds
continuously
(1 driving cycle detection logic) • Knock sensor circuit (open or short)
• Knock sensor
•ECM

Downloaded from www.Manualslib.com manuals search engine 1A-108 Engine General Information and Diagnosis:
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 Knock sensor circuit check
1) Remove ECM from its br acket with ECM connectors
connected.
2) Measure voltage between “C37-56” terminal of ECM connector and vehicle body ground with engine running.
Is voltage within 1.23 – 3.91 V? Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”. If OK, substitute a
known-good ECM and
recheck.Go to Step 3.
3 Knock sensor circuit for open check
1) Disconnect connector from knock sensor with ignition
switch turned OFF.
2) Turn ON ignition switch, measure voltage between “RED” wire of knock sensor connector and engine
ground.
Is voltage 4 – 6 V? Go to Step 6.
Go to Step 4.
4 Knock sensor circuit for open check
1) Turn ON ignition switch, measure voltage between “C37-
56” terminal of ECM connector and engine ground
Is voltage 4 – 6 V? “RED” wire is open
circuit.
Go to Step 5.
5 Knock sensor circuit for short check
1) Disconnect connectors from ECM with ignition switch
turned OFF.
2) Measure resistance between “C37-56” terminal of ECM connector and vehicle body ground.
Is resistance infinity? Go to Step 6.
“RED” wire is shorted to
ground circuit.
If wire is OK, substitute
a known-good ECM and
recheck.
6 Knock sensor circuit for short check
1) Disconnect connectors from ECM with ignition switch
turned OFF.
2) Turn ON ignition switch, measure voltage between “C37- 56” terminal of ECM connector and vehicle body ground.
Is voltage 0 V? Go to Step 7.
“RED” wire is shorted to
other circuit.
I2RH01110089-01

Downloaded from www.Manualslib.com manuals search engine 1A-110 Engine General Information and Diagnosis:
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 CKP sensor and connector for proper installation check
Is CKP sensor installed properly and connector connected
securely? Go to Step 3.
Correct.
3 Wire harness and connection check
1) Disconnect connector from CKP sensor with ignition
switch turned OFF.
2) Check for proper connection to CKP sensor at “BLK/ RED”, “PNK” and “BLK/ORN” wire terminals.
3) If OK, turn ON ignition switch and check voltage at “BLK/ RED”, “PNK” and “BLK/ORN” wire terminals of
disconnected CKP sensor connector.
CKP sensor voltage
Terminal “B+”: 10 – 14 V
Terminal “Vout”: 4 – 5 V
Terminal “GND”: 0 V
Is check result satisfactory? Go to Step 7. Go to Step 4.
4 Was terminal “Vout” voltage in Step 3 within specification? Go to Step 5. “PNK” wire is open or
shorted to ground /
power supply circuit.
If wire and connection
are OK, substitute a
known-good ECM and
recheck.
5 Ground circuit check
1) Turn ignition switch to OFF position.
2) Measure resistance between “BLK/ORN” wire terminal
of CKP sensor connector and engine ground.
Is measured resistance value less than 3
Ω? Go to Step 6. “BLK/ORN” wire is open
or high resistance.
I2RH0B110048-01

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-111
DTC P0340: Camshaft Position (CMP) Sensor “A” CircuitS7RS0B1104042
Wiring Diagram6
Was terminal “B+” voltage in Step 3 within specification? Go to Step 7. “BLK/RED” wire is open
circuit. If wire and
connection are OK,
substitute a known-
good ECM and recheck.
7 Engine start signal check
1) Check starting motor circuit for opening and short
referring to Step 2 of “DTC P0616: Starter Relay Circuit
Low” and Step 3 and 4 of “DTC P0617: Starter Relay
Circuit High”.
Is check result satisfactory? Go to Step 8. Repair or replace.
8 CKP sensor check
1) Check CKP sensor and sensor plate tooth referring to
“Camshaft Position (CMP) Sensor Inspection in Section
1C”.
Is check result satisfactory? Substitute a known-
good ECM and recheck.
Replace CKP sensor
and/or sensor plate.
Step Action Yes No
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
12V
5V
BLK/RED
BLK/RED
BLK/YELBLK/YEL
BLK/YEL
BRN/WHT
5
6 4
8
3
C37-30C37-15
C37-58
E23-31
BLK/ORN
BLKBLKBLK
BLK/RED
BLK/RED
E23-16
E23-60
E23-1
BLK/ORN
1
10
C37-20 5V
GRNBLK/WHT
9
7
RED/YEL
2
WHTE23-29
I6RS0C110017-01
1. CMP sensor 4. Main relay 7. “FI” fuse 10. To CKP sensor
2. Signal rotor 5. Ignition switch 8. “IG COIL” fuse
3. ECM 6. Main fuse box 9. “IG ACC” fuse

Downloaded from www.Manualslib.com manuals search engine 1A-112 Engine General Information and Diagnosis:
System Description
The CMP sensor located on the transmission side of cylinder head consists of the signal generator (magnetic sensor)
and signal rotor (intake camshaft portion).
The signal generator generates reference signal through slits in the slit plate which turns together with the camshaft.
Reference signal
The CMP sensor generates 6 pulses of si gnals each of which has a different waveform length while the camshaft
makes one full rotation. Refer to “Inspection of ECM and Its Circuits”.
Based on these signals, ECM judges which cylinder pist on is in the compression stroke and the engine speed.
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Crank engine for 5 sec.
4) Check DTC.
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/ or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

DTC detecting condition Trouble area
• CMP sensor pulse is less than 20 pulses per crankshaft 8 revolutions
• CMP sensor pulse is more than 28 pulses per crankshaft 8 revolutions
• CMP sensor pulse is less than 20 pulses between BTDC 155 ° crank angle and BTDC 5 ° crank angle
with crankshaft 8 revolutions from engine start.
(1 driving cycle detection logic) • CMP sensor circuit open or short
• Signal rotor teeth damaged
• CMP sensor malfunction, foreign material being attached
or improper installation
•ECM
Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 CMP sensor and connector for proper installation check
Is CMP sensor installed properly and connector connected
securely? Go to Step 3.
Correct.

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-115
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 Ignition spark check
1) Check that each spark plug sparks referring to “Ignition
Spark Test in Section 1H”.
Is check result satisfactory? Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.Go to Step 3.
3 Ignition coil power, output and ground circuit check
1) Disconnect ignition coil connector of the cylinder found
as faulty in Step 2.
2) Check ignition coil circuit of the cylinder found as faulty in Step 2 for the following.
• Voltage between power circuit wire terminal of ignition coil connector and vehicle body ground is 10 – 14 V
with ignition switch turned ON.
• Voltage between output circuit wire terminal of ignition coil connector and vehicle body ground is 4 – 6 V with
ignition switch turned ON.
• Resistance between ground circuit wire terminal of ignition coil connector and vehicle body ground is less
than 2 Ω.
Are they in good condition? Go to Step 4.
Repair or replace
defective wire.
4 Ignition coil check
1) Replace ignition coil for No.1 and No.4 spark plugs with
ignition coil for No.2 and No.3 spark plugs.
Is the cylinder found as faulty in good condition now? Faulty ignition coil. Go to Step 5.
5 Ignition coil output circuit check
1) Disconnect connectors from ECM.
2) Check ignition coil circuit of the cylinder found as faulty
in Step 2 for the following.
• Resistance of output wire circuit between ignition coil
connector and ECM connector is less than 2 Ω.
• Resistance of output wire circuit between ignition coil connector and vehicle b ody ground is infinity.
Are they in good condition? Substitute a known-
good ECM and recheck.
Repair or replace
defective wire.

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-117
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

NOTE
Check to make sure that following conditions ar e satisfied when using this “DTC confirmation
procedure”.
• Intake air temperature at engine start: –10 °C (14 ° F) to 80 °C (176 °F)
• Intake air temperature: –10 °C (14 °F) to 70 °C (158 °F)
• Engine coolant temperature: 70 °C (158 °F) to 150 °C (302 °F)
• Altitude (barometric pressure): 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)

1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and warm up to normal operating temperature.
4) Run engine at idle for 10 min.
5) Drive vehicle and increase engine speed 3000 rpm in 3rd gear.
6) Release accelerator pedal and with engine brake applied, keep vehicle coasting for 5 sec. or more. (Keep fuel cut condition for 5 sec. or more) If fuel cut condition is not ke pt for 5 sec. or more, coast down a slope in engine speed
1000 – 3000 rpm for 5 sec. or more.
7) Stop vehicle and run engine at idle.
8) Check DTC and pending DTC by using scan tool.
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/ or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

DTC detecting condition Trouble area
DTC P0401:
Difference in intake manifold absolute pressure between opened EGR valve
and closed EGR valve is smaller than specified value.
(*2 driving cycle detection logic, monitoring once per driving cycle)
DTC P0402:
Difference in intake manifold absolute pressure between opened EGR valve
and closed EGR valve is la rger than specified value.
(*2 driving cycle detection logic, monitoring once per driving cycle) •EGR valve
• EGR passage
• MAP sensor
•ECM
Step
Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 Do you have SUZUKI scan tool? Go to Step 3.Go to Step 5.

Downloaded from www.Manualslib.com manuals search engine 1A-118 Engine General Information and Diagnosis:
DTC P0403: Exhaust Gas Recirculation Control CircuitS7RS0B1104045
Wiring Diagram
Refer to “DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected”.
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

1) With ignition switch turned OFF, connect scan tool to DLC.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and run it for 30 seconds.
4) Check DTC. 3
EGR valve operation check
1) With ignition switch turned OF F, install SUZUKI scan tool
to DTC.
2) Check EGR system referring to “EGR System Inspection
in Section 1B”.
Is it in good condition? Go to Step 4. Go to Step 5.
4 MAP sensor check
1) Check MAP sensor for performance referring to “MAP
Sensor Inspection in Section 1C”.
Is check result satisfactory? Intermittent trouble or
faulty ECM.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.Replace MAP sensor.
5 EGR valve control circuit check
1) Check that EGR valve control circuits are in good
condition referring to Step 2 to 5 of “DTC P0403:
Exhaust Gas Recirculation Control Circuit”
Are circuits in good condition? Go to Step 6. Repair or replace EGR
valve control circuit(s).
6 EGR valve check
1) Check EGR valve referring to “EGR Valve Inspection in
Section 1B”.
Is check result satisfactory? Go to Step 7. Faulty EGR valve.
7 MAP sensor check
1) Check MAP sensor for performance referring to “MAP
Sensor Inspection in Section 1C”.
Is check result satisfactory? EGR passage clogged.
If OK, substitute a
known-good ECM and
recheck.
Replace MAP sensor.
Step Action Yes No
DTC detecting condition
Trouble area
EGR valve output voltage is differ ent from output command with more
than one pole out of 4 poles.
(1 driving cycle detection logic) • EGR valve circuit open
•EGR valve
•ECM

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-119
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Description”.
2 EGR valve power supply circuit check
1) Remove air intake pipe.
2) With ignition switch turned OFF, disconnect EGR valve
connector.
3) With ignition switch turned ON, measure voltage between “BLK/RED” wire terminal of EGR valve
connector and vehicle body ground.
Is check voltage 10 – 14 V? Go to Step 3.
“BLK/RED” wire is open
circuit.
3 Wire circuit check
1) Disconnect connectors from ECM with ignition switch
turned OFF.
2) Turn ON ignition switch.
3) Measure voltage between engine ground and each “GRN/RED”, “GRN/ORN”, “W HT/RED”, “BRN/YEL” wire
terminals of EGR valve connector.
Is each voltage 0 V? Go to Step 4.
Faulty wire(s) are
shorted to other circuit.
If wires are OK,
substitute a known-
good ECM and recheck.
4 Wire circuit check
1) With ignition switch turned OFF, measure resistance
between engine ground and each “GRN/RED”, “GRN/
ORN”, “WHT/RED”, “BRN/YEL” wire terminals of EGR
valve connector.
Is resistance infinity? Go to Step 5.
Faulty wire(s) are
shorted to ground
circuit.
If wires are OK,
substitute a known-
good ECM and recheck.
5 Short circuit check for EGR valve control circuit
1) With ignition turned OFF, measure resistance between
each EGR valve control circ uit wire (“GRN/RED”, “GRN/
ORN”, “WHT/RED” and “BRN/ YEL” wire) and each EGR
valve control circuit wire.
Is each resistance infinity? Go to Step 6.
Faulty wire(s) are short
circuit.
6 EGR valve stepper motor coil circuit check
1) With ignition switch turned OFF, connect EGR valve
connector.
2) Measure resistance between “E23-1/16” and each “C37- 4”, “C37-3”, “C37-19”, “C37-18” terminals of ECM
connector.
Is each resistance 20 – 31
Ω at 20 °C, 68 °F? Faulty ECM. Substitute
a known-good ECM and
recheck.
Go to Step 7.
7 EGR valve check
1) Check EGR valve resistance referring to “EGR Valve
Inspection in Section 1B”.
Is resistance within specified value? Faulty wire(s) are open
or high resistance
circuit. If wires are OK,
substitute a known-
good ECM and recheck.Faulty EGR valve.

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-121
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

NOTE
Check to make sure that following conditions ar e satisfied when using this “DTC Confirmation
Procedure”.
• Intake air temperature at engine start: –10 °C (14 ° F) to 80 °C (176 °F)
• Intake air temperature: –10 °C (14 °F) to 70 °C (158 °F)
• Engine coolant temp.: 70 °C, 158 °F to 150 °C (302 °F)
• Altitude (barometric pressure): 2400 m, 8000 ft or less (500 mmHg, 75 kPa or more)

1) Connect scan tool to DLC with ignition switch turned OFF.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Increase vehicle speed to 37 – 62 mph, 60 – 100 km/h. (engine speed: 2500 – 3000 r/min.)
4) Keep above vehicle speed for 10 min. or more (Thr ottle valve opening is kept constant in this step).
5) Stop vehicle and check if DTC / pending DTC exists using sc an tool. If not, check if catalyst monitoring test has
been completed using scan tool. If not in both of above checks (i.e., no DTC / pending DTC and catalyst
monitoring test not completed), check vehicle cond ition (environmental) and repeat Step 3) through 5).
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/ or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

DTC detecting condition Trouble area
Response delay of HO2S-2 signal (shifting delay from rich to lean and
from lean to rich with threshold at 0.45 V) compared to switching cycle
(rich-lean) of A/F feed back is less than specified while vehicle is
running at constant speed and except with high engine load after
warmed up.
(*2 driving cycle detection logic, monitoring once per driving cycle) • Exhaust gas leak
• Warm up three way catalytic converter
malfunction
• HO2S-2 malfunction
• HO2S-1 malfunction
Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 Exhaust system visual check
1) Check exhaust system for leaks, damage and loose
connection.
Is it in good condition? Go to Step 3.
Repair or replace
defective part.