Actuator SUZUKI SWIFT 2008 2.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine 1A-168 Engine General Information and Diagnosis:
DTC P2135: Throttle / Pedal Position Sensor / Switch “A”/“B” (Main / Sub) Voltage CorrelationS7RS0B1104076
Wiring Diagram9
Ground circuit check
1) Remove ECM from its br acket with ECM connectors
connected.
2) Check for proper connection of ECM connector at “E23- 51” terminal.
3) If OK, measure resistance between “E23-51” terminal of ECM connector and engine ground.
Is resistance below 5
Ω? “WHT” wire is open or
high resistance circuit.
Faulty ECM ground
circuit. If circuit is OK,
substitute a known-
good ECM and recheck.
10 APP sensor check
1) Check APP sensor (sub) re ferring to “APP Sensor
Assembly Inspection in Section 1C”.
Is output voltage within specified value? Substitute a known-
good ECM and recheck.
Replace APP sensor.
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
5VBLK/REDBLK/RED
BLK/YEL
12BLK/YEL
BLK/YEL
BRN/WHT
E23-1
E23-60
C37-58
C37-15 C37-30
BLK/ORN
BLKBLKE23-31 BLK
BLK/RED
BLU/ORN
RED/YELYEL/BLU
LT GRN/RED
LT GRN/BLK
RED
GRN
WHT
BLK
E23-16
E23-45
E23-32
C37-45
C37-44
C37-41C37-42
C37-40
C37-54
C37-43
1-1
1-2
1-3 3
4
5
8 67
10
9
E23-29 GRNBLK/WHTWHT
BLK/RED
I6RS0C110045-01
1. Electric throttle body assembly
3. ECM 8. “IG ACC” fuse
1-1. Throttle actuator 4. Main relay9. “IG COIL” fuse
1-2. TP sensor (main) 5. Individual circuit fuse box No.110. Ignition switch
1-3. TP sensor (sub) 6. “TH MOT” fuse
2. Throttle actuator control relay 7. “FI” fuse

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-179
C37-32 ——— — —
C37-33 — —— — —
C37-34 — —— — —
C37-35 — —— — —
C37-36 — —— — —
C37-37 — —— — —
C37-38 — —— — —
C37-39 — —— — —
C37-40 WHT TP sensor (sub)
signal 1.57 – 1.09 V
Ignition switch turned ON
and accelerator pedal at
idle position after warmed
up engine.
—
3.88 – 4.45 V Ignition switch turned ON
and accelerator pedal at
full depressed position
after warmed up engine.
C37-41 — Ground for shield
wire of TP sensor
circuit Below 0.3 V Ignition switch turned ON.
—
C37-42 BLK Ground for TP
sensor Below 0.3 V Ignition switch turned ON.
—
C37-43 RED Output for 5 V
power source of TP
sensor 4.5 – 5.5 V Ignition switch turned ON.
—
C37-44 LT
GRN/ BLK Output of throttle
actuator 0 – 1 V
Ignition switch turned ON
and accelerator pedal at
idle position after warmed
up engine.
Output signal is pulse.
Duty ratio varies
depending on throttle
valve and accelerator pedal position.
*0 – 1 V
↑↓
10 – 14 V
(“Reference
waveform No.21: ”) Ignition switch turned ON
and accelerator pedal at
full depressed position
after warmed up engine.
C37-45 LT
GRN/ RED Output of throttle
actuator 0 – 1 V
Ignition switch turned ON
and accelerator pedal at
full depressed position
after warmed up engine.
Output signal is pulse.
Duty ratio varies
depending on throttle
valve and accelerator pedal position.
*0 – 1 V
↑↓
10 – 14 V
(“Reference
waveform No.21: ”) Ignition switch turned ON
and accelerator pedal at
idle position after warmed
up engine.
C37-46 BLK/
RED Heater output of
HO2S-1 10 – 14 V Ignition switch turned ON.
—
*0 – 2 V ↑↓
10 – 14 V
(“Reference
waveform No.10: ” and “Reference
waveform No.11: ”) Engine running at idle
after warmed up engine.
Output signal is active low
duty pulse. Duty ratio
varies depending on
engine condition.
C37-47 RED/
BLU Heater output of
HO2S-2 10 – 14 V Ignition switch turned ON.
—
0 – 1 V
(“Reference
waveform No.12: ”) Engine running at idle
after vehicle running over
30 km/h, 19 mph for 5 min.
C37-48 YEL/
GRN Starting motor
signal 0 – 1 V Ignition switch turned ON.
—
6 – 14 V While engine cranking.
C37-

49 — —— — —
Terminal
No. Wire
color Circuit Normal voltage
ConditionRemarks

Downloaded from www.Manualslib.com manuals search engine 1A-182 Engine General Information and Diagnosis:
E23-25 PPLVehicle speed
signal output for P/
S control module *0 – 1 V
↑↓
10 – 14 V
(“Reference
waveform No.32: ”) Vehicle running. Sensor signal is pulse.
Pulse frequency varies
depending on vehicle
speed.
(21 pulses are generated
per sec. at 30 km/h, 19
mph.) (2561 pulses/km)
E23-26 RED/
BLU EPS signal 10 – 14 V Ignition switch turned ON.
—
0 – 1 V With engine running at idle
speed, and steering wheel
turned to the right or left as
far as it stops.
E23-27 — — — — —
E23-28 YEL/
BLK Serial
communication line
for immobilizer coil
antenna
10 – 14 V Ignition switch turned ON. —
E23-29 BLK/
WHT Ignition switch
signal 0 – 1 V Ignition switch turned OFF.
—
10 – 14 V Ignition switch turned ON.
E23-30 WHT Starting motor
control relay output 0 – 1 V Ignition switch turned ON.
—
0 – 1 V Ignition switch is turned to
ST (engine cranking)
position.
E23-31 BLK Ground for ECM Below 0.3 V Ignition switch turned ON. —
E23-32 RED/
YEL Power supply of
throttle actuator
drive circuit
10 – 14 V Ignition switch turned ON. —
E23-33 — — — — —
E23-34 RED Output for 5 V
power source of
APP sensor (sub) 4.5 – 5.5 V Ignition switch turned ON. —
E23-35 BRN Output for 5 V
power source of
APP sensor (main) 4.5 – 5.5 V Ignition switch turned ON. —
E23-36 YEL APP sensor (sub)
signal 1.55 – 1.65 V
Ignition switch turned ON
and accelerator pedal at
idle position after warmed
up engine.
—
4.18 – 5.12 V Ignition switch turned ON
and accelerator pedal at
full depressed position
after warmed up engine.
E23-37 YEL APP sensor (main)
signal 0.75 – 0.85 V
Ignition switch turned ON
and accelerator pedal at
idle position after warmed
up engine.
—
3.46 – 4.24 V Ignition switch turned ON
and accelerator pedal at
full depressed position
after warmed up engine.
E23-38 — — — — —
E23-39 — — — — —
E23-40 — — — — —
E23-41 — — — — —
E23-42 — — — — —
E23-43 — — — — —
E23-44 — — — — —
Terminal
No. Wire
color Circuit Normal voltage Condition Remarks

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-183
E23-45BLU/
ORNThrottle actuator
control relay output
0 – 1 V Ignition switch turned ON. —
E23-46 LT GRN Radiator cooling
fan relay No.1
output 10 – 14 V
Ignition switch turned ON,
engine coolant temp.:
below 95
°C (203 ° F), or
A/C refrigerant pressure (if
equipped with A/C): below
600 kPa (87 psi) with A/C
switch turned ON while
engine is running. —
0 – 2 V Ignition switch turned ON,
engine coolant temp.: 97.5
°
C (207.5 ° F) or higher, or
A/C refrigerant pressure (if
equipped with A/C): 1100
kPa (159.5 psi) or higher
with A/C switch turned ON
while engine is running.
E23-47 GRY A/C compressor
relay output 10 – 14 V
Engine running, A/C
switch OFF and blower
selector at OFF position.
—
0 – 1 V Engine running, A/C
switch ON and blower
selector at 1st position or
more.
E23-48 GRN Radiator cooling
fan relay No.2 and
No.3 output 10 – 14 V
Ignition switch turned ON,
engine coolant temp.:
below 100
°C (212 °F), or
A/C refrigerant pressure (if
equipped with A/C): below
1200 kPa (174 psi) with A/
C switch turned ON while
engine is running. —
0 – 2 V Ignition switch turned ON,
engine coolant temp.:
102.5
°C (216.5 °F) or
higher, or A/C refrigerant
pressure (if equipped with
A/C): 1500 kPa (217.5 psi)
or higher with A/C switch
turned ON while engine is
running.
E23-49 — — — — —
E23-50 — Ground for shield
wire of APP sensor Below 0.3 V Ignition switch turned ON. —
E23-51 WHT Ground for APP
sensor (sub) Below 0.3 V Ignition switch turned ON. —
E23-52 BLU Ground for APP
sensor (main) Below 0.3 V Ignition switch turned ON. —
E23-53 — — — — —
E23-54 ORN Ground for sensors Below 0.3 V Ignition switch turned ON. —
Terminal
No. Wire
color Circuit Normal voltage Condition Remarks

Downloaded from www.Manualslib.com manuals search engine 1A-186 Engine General Information and Diagnosis:
Reference waveform No.6
Ignition coil signal (1) with engine idling
Reference waveform No.7
Ignition coil No.1 and No.4 signal (2) with engine idlingReference waveform No.8
Generator field coil monitor signal (1) at engine idling
Reference waveform No.9
Throttle actuator output signal with ignition switch turned
ON
Measurement
terminal
CH1: “C37-6” to “C37-58”
Oscilloscope
setting CH1: 2 V/DIV
TIME: 4 ms/DIV
Measurement
condition • After warmed up to normal
operating temperature
• Engine at specified idle speed
2. 4 – 6 V
3. Ignition coil pulse width: 4 – 5 msec.
Measurement
terminal CH1: “C37-20” to “C37-58”
CH2: “C37-6” to “C37-58”
Oscilloscope
setting CH1: 2 V/DIV, CH2: 2 V/DIV
TIME: 40 ms/DIV
Measurement
condition • After warmed up to normal
operating temperature
• Engine at specified idle speed
1. Cylinder reference signal (CMP reference signal)
3. 720 ° crank angle
I4RS0B110055-02
I6RS0C110031-01
Measurement
terminal CH1: “C37-8” to “C37-58”
Oscilloscope
setting CH1: 5 V/DIV
TIME: 10 ms/DIV
Measurement
condition • After warmed up to normal
operating temperature
• Engine at specified idle speed
• Lighting switch at CLEARANCE position
Measurement
terminal CH1: “C37-45” to “C37-58”
CH2: “C37-44” to “C37-58”
Oscilloscope
setting CH1: 5 V/DIV, CH2: 5 V/DIV
TIME: 2 ms/DIV
Measurement
condition • After warmed up to normal
operating temperature
• Ignition switch turned ON and accelerator pedal at idle position
1. Throttle actuator drive signal (“C37-45” terminal)
2. Throttle actuator drive signal (“C37-44” terminal)
3. ON signal
4. OFF signal
5. One duty cycle
I5RS0C110016-01
I4RS0B110081-02

Downloaded from www.Manualslib.com manuals search engine 1A-190 Engine General Information and Diagnosis:
Reference waveform No.21
Throttle actuator output signal with ignition switch turned
ONReference waveform No.22
Ignition coil signal and fuel injector signal with engine
cranking
Reference waveform No.23
MAP sensor signal (1) with ignition switch turned ON
Measurement
terminal
CH1: “C37-45” to “C37-58”
CH2: “C37-44” to “C37-58”
Oscilloscope
setting CH1: 5 V/DIV, CH2: 5 V/DIV
TIME: 2 ms/DIV
Measurement
condition • After warmed up to normal
operating temperature
• Ignition switch turned ON and accelerator pedal at full
depressed position
1. Throttle actuator drive signal (“C37-45” terminal)
2. Throttle actuator drive signal (“C37-44” terminal)
3. ON signal
4. OFF signal
5. One duty cycle
I4RS0B110082-02
Measurement
terminal CH1: “C37-20” to “C37-58”
CH2: “C37-6” to “C37-58”
CH3: “C37-1” to “C37-58”
CH4: “C37-48” to “C37-58”
Oscilloscope
setting CH1: 5 V/DIV, CH2: 5 V/DIV
CH3: 50 V/DIV, CH4: 10 V/DIV
TIME: 200 ms/DIV
Measurement
condition • After warmed up to normal
operating temperature
• Engine at cranking
1. Cylinder reference signal (CMP reference signal)
2. Ignition coil No.1 and No.4 signal
3. No.1 fuel injector signal
4. Engine start signal
Measurement
terminal CH1: “C37-53” to “C37-55”
CH2: “C37-54” to “C37-55”
Oscilloscope
setting CH1: 2 V/DIV, CH2: 1 V/DIV
TIME: 200 ms/DIV
Measurement
condition • After warmed up to normal
operating temperature
• Ignition switch turned ON
2. TP sensor signal
I6RS0C110038-01
I4RS0B110070-01

Downloaded from www.Manualslib.com manuals search engine 1A-194 Engine General Information and Diagnosis:
ECM Power and Ground Circuit CheckS7RS0B1104080
Wiring DiagramC37-3 to E23-1/16 EGR valve
(stepping motor No.2 coil)
20 – 31 Ω —
C37-18 to E23-1/16 EGR valv e (stepping motor No.4 coil)
C37-19 to E23-1/16 EGR valv e (stepping motor No.3 coil)
C37-46 to E23-29 Heater of HO2S-1 2 – 11 Ω—
C37-1 to E23-1/16 No.1 fuel injector 10.8 – 18.2 Ω —
E23-47 to E23-1/16 A/C compressor relay 160 – 240 Ω —
C37-60 to C37-59 Oil control valve 6 – 15 Ω —
E23-45 to E23-1/16 Throttle actuator control relay 160 – 240 Ω —
Terminals
CircuitStandard resistance Condition
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
BLK/RED
BLK/REDBLK/RED
BLK/YELBLK/YEL
BLK/YEL
GRN
BRN/WHT
12V
5VE23-1
E23-60
E23-16
WHT 2
4
11
6
3
12
13 14
7
1
16
17
89
15
10
5
WHT/REDE23-2
C37-58
C37-15C37-30
BLK/ORN
BLKBLKE23-31BLK
WHT
GRY/REDRED/BLK
ORN
C37-14C37-53
C37-55E23-54
REDE23-55
GRNBRN
BLU
REDYELWHT
E23-35E23-37E23-52
E23-51
E23-34E23-36
E23-50
LT GRN/REDLT GRN/BLKC37-45C37-44
C37-43
C37-54C37-40C37-42C37-41
RED
GRN
WHTBLK
ORN
BLK/WHTE23-29
I6RS0C110039-01
1. Main fuse box 7. Individual circuit fuse box No.1 13. A/C refrigerant pressure sensor (if equipped with A/C)
2. Ignition switch 8. “IG ACC” fuse14. APP sensor (main)
3. Main relay 9. “FI” fuse15. APP sensor (sub)
4. BCM (included in junction block assembly) 10. “RADIO” fuse 16. TP sensor (main)
5. “IG COIL” fuse 11. DLC17. TP sensor (sub)
6. ECM 12. MAP sensor

Downloaded from www.Manualslib.com manuals search engine 1C-2 Engine Electrical Devices:
MAP Sensor InspectionS7RS0B1306002
1) Remove air cleaner assembly.
2) Disconnect connector from MAP sensor.
3) Remove MAP sensor.
4) Arrange 3 new 1.5 V batteries (2) in series (check that total voltage is 4.5 – 5.0 V) and connect its
positive terminal to “Vin ” terminal of sensor and
negative terminal to “Ground” terminal. Then check
voltage between “Vout” and “Ground”. Also, check if
voltage reduces when vacuum is applied up to 400
mmHg by using vacuum pump (3).
If check result is not satisfactory, replace MAP
sensor (1).
Output voltage (When input voltage is 4.5 – 5.5 V,
ambient temp. 20 – 30 °C, 68 – 86 °F)
5) Install MAP sensor securely.
6) Connect MAP sensor connector securely.
7) Install air cleaner assembly.
Electric Throttle Body Assembly On-Vehicle
Inspection
S7RS0B1306003
WARNING!
Never touch throttle valve with finger while
ignition switch is turned ON and accelerator
pedal is depressed. Otherwise, injury may
result by pinching the finger between throttle
valve and throttle body housing.

CAUTION!
• Do not disassemble electric throttle body assembly.
• Do not expose electric throttle body assembly to excessive shock like a
dropping it. If electric throttle body
assembly has been exposed to excessive
shock, it should be replaced.
• Be careful not to accurate a foreign material (like dust and/ or metallic particle)
to the throttle body housing and/or throttle
valve.
Otherwise, the throttle body assembly is
breaking down by throttle valve accretion.
• Do not apply excessive moving force to throttle valve for thro ttle valve operation
check and/or TP sensor performance
check.
Otherwise, the throttle body assembly is
breaking down by damaging the internal
resinous gear of throttle valve actuator.

NOTE
After replacing electric throttle body
assembly, perform calibration of electric
throttle body assembly referring to “Electric
Throttle Body System Calibration”.

Throttle Valve Visual Check
1) Remove air cleaner outlet hose.
2) Check that there isn’t any foreign matter caught between throttle valve and throttle body housing. If
there is, take it out after removing throttle body
referring to “Electric Th rottle Body Assembly
Removal and Installation in Section 1D” and clean
inside of throttle body thoroughly.
Altitude (Reference) Barometric pressure
Output
voltage
(ft) (m) (mmHg) (kPa) (V)
0 – 2000 0 – 610 760 – 707 100 – 94 3.3 – 4.3 2001 – 5000 611 –
1524 Under 707
over 634 94 – 85 3.0 – 4.1
5001 – 8000 1525 –
2438 Under 634
over 567 85 – 76 2.7 – 3.7
8001 – 10000 2439 –
3048 Under 567
over 526 76 – 70 2.5 – 3.3
I3RM0A130005-01

Downloaded from www.Manualslib.com manuals search engine Engine Electrical Devices: 1C-3
Throttle Valve Operation Check1) Remove air cleaner outlet hose.
2) Turn OFF ignition switch.
3) Move throttle valve with finger to its full open position and check that it moves smoothly.
4) Move throttle valve with fi nger to its completely
closed position and check that it moves smoothly.
5) Take off finger from throttle valve (1) which is at full open position and check that it moves smoothly by
its return spring and open spring force back to
default position (2) (positio n where throttle valve is
open by 6 ° from completely closed position).
6) Take off finger from throttle valve (1) which is at completely closed position and check that it moves
smoothly by its return spring and open spring force
back to default position.
If check result is not satisfactory, replace electric
throttle body assembly. Electric Throttle Body
Assembly Operation Check
1) Remove air cleaner outlet hose.
2) Turn ON ignition switch.
3) Depress accelerator pedal gradually and check that throttle valve moves smoo thly until it opens fully.
4) Release accelerator pedal depressed in Step 3) and check that throttle valve (1) moves back to default
position (2) (position where throttle valve is open by
6° from its completely closed position).
If check result is satisfactory, electric throttle body
system is in good condition. If check result is not
satisfactory, proceed to next step.
5) Perform “Accelerator Pe dal Position (APP) Sensor
Assembly On-Vehicle Inspection (Electric throttle
body model)”, “Throttle Actuator (Motor) Check” and
if check results are not satisfactory, replace electric
throttle body assembly.
If check results are satisfactory, wire circuit and/or
ECM are faulty.
Throttle Actuator (Motor) Check 1) Turn OFF ignition switch.
2) Disconnect connector from electric throttle body assembly.
3) Measure resistance between “M1” terminal (1) and “M2” terminal (2) of electric throttle body assembly.
If measured resistance is out of specified value,
replace electric throttle body assembly.
Throttle actuator (motor) resistance
0.3 – 100 Ω at 20 °C, 68 °F
I4RS0B130004-01
1
2
I4RS0B130005-01
1
2
I4RS0B130005-01
2 1
I4RS0B130023-01

Downloaded from www.Manualslib.com manuals search engine 1D-23 Engine Mechanical:
8) Install new O-ring (1) to oil gallery pipes No.2 (2) and
No.3 (3).
9) Install oil gallery pipes No.2 and No.3 to cylinder
head (4) and timing chain cover (5).
Tighten bolts to specified torque.
Tightening torque
Oil gallery pipe No.2 and No.3 bolt (a): 11 N·m (
1.1 kgf-m, 8.0 lb-ft)
10) Install water pump pulley. 11) Install cylinder head cover referring to “Cylinder Head Cover Removal and Installation”.
12) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
13) Install crankshaft pulley (1). Tighten bolt (2) to specified torque. To lock crankshaft pulley, use
special tool with it as shown in figure.
Special tool
(A): 09917–68221
Tightening torque
Crankshaft pulley bolt (a): 150 N·m (15.0 kgf-m,
108.5 lb-ft)
14) Install engine assembly to vehicle referring to “Engine Assembly Removal and Installation”.
Timing Chain Cover InspectionS7RS0B1406014
Oil Seal
Check oil seal lip for fault or other damage. Replace as
necessary. Timing Chain Cover
Inspect strainer (1) of oil passage for driving intake cam
timing sprocket assembly (VVT actuator).
If clog or foreign matter exists, clean strainer.
Oil Control Valve Removal and InstallationS7RS0B1406015
Removal
Remove oil gallery pipe No.1
(1) and oil control valve (2)
from timing chain cover (3).
Installation
1) Install new O-ring (4) to oil control valve.
2) Install oil control valve to timing chain cover. Tighten nuts to specification.
Tightening torque
Oil control valve mounting nut (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
3) Install oil gallery pipe No .1 with new copper washers
(5) to timing chain cover.
Tighten bolts to specification.
Tightening torque
Oil gallery pipe No.1 bolt (b): 30 N·m (3.0 kgf-m,
21.5 lb-ft)
(a)
(a) 1
2
3
4
5
I3RH0B140027-01
I2RH0B140056-01
1
I3RH0B140028-01
1
5
(b) 3
(a)
2 4
5
I3RM0A140027-01