Can SUZUKI SWIFT 2005 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 1A-214 Engine General Information and Diagnosis:
Troubleshooting
WARNING!
Keep hands, tools, and clothing away from engine cooling fan to help prevent personal injury. This fan
is electric and can come on whether or not the engi ne is running. The fan can start automatically in
response to the ECT sensor with the ig nition switch at the “ON” position.

NOTE
When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special
tool to ECM and/or the ECM connectors referri ng to “Inspection of ECM and Its Circuits”.

StepAction YesNo
1 Is there DTC(s) of ECT sensor circuit (DTC P0116 / P0117 /
P0118) and/or radiator cooling fan circuit (DTC P0480)? Go to corresponding
DTC flow.Go to Step 2.
2 Low speed radiator cooling fan control circuit check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Start engine and select “DATA LIST” mode on scan tool.
3) Warm up engine until coolant temp. is 97.5 °C, 207.5 °F
or higher and A/C switch turns OFF (if equipped with A/
C). (If engine coolant temp. dose not rise, check engine
cooling system or ECT sensor.)
Is radiator cooling fan started at low speed when engine
coolant temp. reached above temp.? Go to Step 3.
Perform from Step 2 to
Step 5 in “Radiator
Cooling Fan Low Speed
Control System Check”.
3 High speed radiator cooling fan control circuit check
1) Start engine and select “DATA LIST” mode on scan tool.
2) Warm up engine until coolant temp. is 102.5 °C, 216.5 °F
or higher and A/C switch turns OFF (if equipped with A/
C). (If engine coolant temp. dose not rise, check engine
cooling system or ECT sensor.)
Is radiator cooling fan started at high speed when engine
coolant temp. reached above temp? Radiator cooling fan
control system is in
good condition.
Perform from Step 9 to
Step 14 in DTC P0480
diag. flow.
If OK, Go to Step 4.
4 Radiator cooling fan control No. 2 and No. 3 check
1) Run engine when ECT is over 102.5 °C, 216.5 °F.
2) Measure voltage between vehicle body ground and “E23-48” terminal of ECM connector.
Is voltage lower than 1.5 V? Go to Step 5.
Faulty ECM.
5 Radiator cooling fan No. 2 wire circuit check
1) Remove radiator cooling fan control relay No.2 with
ignition switch turned OFF.
2) Measure voltage between “GRY” wire terminal of disconnected radiator cooling fan control relay No. 2
connector and vehicle body ground.
Is voltage 10 – 14 V? Go to Step 6.
“GRY” wire is open or
high resistance circuit.
6 Radiator cooling fan No. 2 wire circuit check
1) Disconnect connector from radiator cooling fan motor
with ignition swit ch turned OFF.
2) Measure resistance between “BLU/BLK” wire terminal of disconnected radiator cooling fan control relay No. 2
connector and vehicle body ground.
Is resistance infinity? Go to Step 7.
“BLU/BLK” wire is
shorted to ground
circuit.

Downloaded from www.Manualslib.com manuals search engine 1A-216 Engine General Information and Diagnosis:
Repair Instructions
Idle Speed and IAC Throttle Valve Opening
Inspection
S7RS0B1106001
Before idle speed check, make sure of the following.
• Lead wires and hoses of electronic fuel injection and engine and emission control systems are connected
securely.
• Valve lash is checked according to maintenance schedule.
• Ignition timing is within specification.
• All accessories (wipers, heater, lights, A/C, etc.) are out of service.
• Air cleaner has been properly installed and is in good condition.
• No abnormal air drawn in from air intake system.
After all items are confirmed, check idle speed and IAC
duty as follows.
NOTE
Before starting engine, place transmission
gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T vehicle), and set
parking brake and block drive wheels.

1) Connect SUZUKI scan tool to DLC (1) with ignition
switch turned OFF.
Special tool
(A): SUZUKI scan tool 2) Warm up engine to normal operating temperature.
3) Check engine idle speed and “IAC throttle opening”
by using “Data List” mode on scan tool to check “IAC
throttle opening”.
4) If check result is out of sp ecification, inspect electric
throttle body assembly referring to “Electric Throttle
Body Assembly On-Vehicle Inspection in Section
1C”.
Engine idle speed
A/C OFF: 700 ± 50 rpm (IAC duty: 5 – 55%)
A/C ON: 850 ± 50 rpm
5) Check that specified engine idle speed is obtained with A/C turned ON if vehi cle is equipped with A/C.
If not, check A/C system.
(A)
1
I4RS0B110093-01

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-1 Aux. Emission Control Devices:
Engine
Aux. Emission Control Devices
Diagnostic Information and Procedures
EGR System InspectionS7RS0B1204001
1) Connect SUZUKI scan tool to data link connector (DLC) with ignition switch turned OFF.
2) Turn ON ignition switch and erase DTC using “CLEAR DTC” in “TROUBLE CODES” menu.
3) Start engine and warm it up to normal operating temperature, then select “DATA LIST” mode on scan
tool.
4) Make sure that vehicle condition is as follows.
• Vehicle speed = 0 km/h (0 KPH)
• Engine speed ≤ 900 rpm
• Engine coolant temp. ≥ 90 °C, 164 °F
5) With engine idling (without depressing accelerator pedal), open EGR valve by using “STEP EGR” mode
in “MISC TEST” menu. In this state, as EGR valve
opening increases engine idle speed drops. If not,
possible cause is clogged EGR gas passage, stuck
or faulty EGR valve.
Repair Instructions
EVAP Canister Purge InspectionS7RS0B1206001
NOTE
Before inspection, check to make sure that gear shift lever is in neutral position (with A/T model,
selector lever in “P” range) and that parking brake lever is pulled all the way up.

1) Disconnect purge hose (1) from EVAP canister (2).
2) Place finger against the end of disconne cted hose and check that vacuum is not felt there when engine is cool and
running at idle speed. If check result is not satisfacto ry, check EVAP canister purge valve, wire harness and ECM.
1. SUZUKI scan tool display
2. EGR valve opening (0: Close, 100: Full open)
Step EGR
Step EGR Flow Duty 21 %
Step EGR (con) 23%
Engine Speed 771 RPM
Desired Idle 698 RPM
IAC Flow Duty 20.0 %
Ignition Advance 11.5 BTDC
Closed Throttle Pos ON
1 2
I4RS0B120001-01
1
2
I6RS0C120001-01

Downloaded from www.Manualslib.com manuals search engine Aux. Emission Control Devices: 1B-2
EVAP Canister Purge Valve and Its Circuit
Inspection
S7RS0B1206002
WARNING!
Do not apply vacuum by mouth; otherwise
harmful fuel vapor can be breathed in.

CAUTION!
Do not apply vacuum more than –86 kPa (–
12.47 psi); otherwise EVAP canister purge
valve could be damaged.

1) Prepare to operate EVAP canister purge valve as follows.
a) When using SUZUKI scan tool:
i) Connect SUZUKI scan tool to DLC (1) with ignition switch turned OFF and disconnect
purge valve vacuum hoses from intake
manifold and EVAP canister.
ii) Turn ON ignition switch, clear DTC and select “MISC TEST” mode on SUZUKI scan
tool.
Special tool
(A): SUZUKI scan tool b) When not using SUZUKI scan tool:
NOTE
Before performed this check, be sure to read
the “Precautions of ECM Circuit Inspection in
Section 1A”.

i) Disconnect purge valve vacuum hoses from
intake manifold and EVAP canister.
ii) Remove ECM from it s bracket referring to
“ECM Removal and Inst allation in Section
1C”.
iii) Connect special tool between ECM and ECM connector referring to “Inspection of ECM
and Its Circuits in Section 1A”
iv) Turn ON ignition switch. Using service wire, ground “C37-29” terminal
circuit of special tool (valve ON: “B”) and
unground it (valve OFF: “A”).
2) Check purge valve for operation and vacuum passage for clog when valve is switched ON and
OFF by using SUZUKI scan tool or service wire.
If check result is not satisfactory, check vacuum
hoses, EVAP canister purge valve, wire harness and
connections.
EVAP canister purge valve specification
[A] Valve OFF: When vacuum (–60 kPa (–8.7 psi))
is applied to hose (1), vacuum can be applied.
[B] Valve ON: When vacuum is applied to hose
(1), vacuum can not be applied.
Special tool
(A): 09917–47011
(A)
1
I4RS0B120003-03
“C37-29”“A”
“B”
I4RS0B120006-02
[A] [B]
1
(A)1
(A)
I3RB0A120005-02

Downloaded from www.Manualslib.com manuals search engine 1B-3 Aux. Emission Control Devices:
Vacuum Passage InspectionS7RS0B1206003
Start engine and run it at idle speed. Disconnect vacuum
hose (1) from EVAP canister purge valve (2). With finger
placed against disconnected hose, check that vacuum is
applied.
If it is not applied, clean vacuum passage by blowing
compressed air.
Vacuum Hose and Purge Valve Chamber
Inspection
S7RS0B1206004
Check hoses and purge valv e chamber for connection,
leakage, clog and deterioration.
Replace as necessary.
EVAP Canister Purge Valve InspectionS7RS0B1206005
WARNING!
Do not apply vacuum by mouth; otherwise
harmful fuel vapor can be breathed in.

CAUTION!
Do not apply vacuum more than –86 kPa (–
12.47 psi); otherwise EVAP canister purge
valve could be damaged.

1) With ignition switch turned OFF, disconnect coupler and vacuum hoses from canister purge valve.
2) Remove EVAP canister purge valve from air cleaner assembly.
3) Check resistance between two terminals of EVAP canister purge valve.
If resistance is not as specified, replace EVAP
canister purge valve.
EVAP canister purge valve resistance
30 – 34 Ω at 20 °C (68 °F) 4) With coupler disconnected, apply vacuum (–60 kPa
(–8.7 psi)) to pipe (1). If vacuum can be applied, go
to next step. If vacuum can not be applied, replace
EVAP canister purge valve.
5) In this state, connect 12 V-battery to EVAP canister purge valve terminals. If vacuum can not be applied,
EVAP canister purge valve is in good condition.
If applied, replace EVAP canister purge valve.
WARNING!
Do not suck the air through valve. Fuel vapor
inside valve is harmful.

Special tool
(A): 09917–47011
6) Install EVAP canister purge valve to air cleaner assembly.
I3RM0A120006-01
I3RM0A120008-01
1
1 (A)
(A)
I3RB0A120007-01

Downloaded from www.Manualslib.com manuals search engine Aux. Emission Control Devices: 1B-4
EVAP Canister InspectionS7RS0B1206006
WARNING!
DO NOT SUCK nozzles on EVAP canister.
Fuel vapor inside EVAP canister is harmful.

1) Check outside of EVAP canister visually.
2) Disconnect vacuum hoses from EVAP canister.
3) Check that there is no restriction of flow through purge pipe (1) and air pipe (2) when air is blown (4)
into tank pipe (3).
If any faulty condition is found in this inspection,
replace EVAP canister.
EGR Valve Removal and InstallationS7RS0B1206007
Removal
1) Disconnect negative (–) cable at battery.
2) Remove air intake pipe.
3) Remove EGR pipe.
4) Disconnect EGR valve connector.
5) Remove EGR valve and gasket from cylinder head.
Installation
Reverse removal procedure noting the following.
• Clean mating surface of valve and cylinder head.
• Use new gaskets.
EGR Valve InspectionS7RS0B1206008
1) Check resistance between following terminals of EGR valve (1) in each pair.
If found faulty, replace EGR valve assembly.
EGR valve resistance (A – B, C – B, F – E, D – E
terminal)
20 – 24 Ω
2) Remove carbon from EGR valve gas passage.
CAUTION!
Do not use any sharp-edged tool to remove
carbon.
Be careful not to damage or bend EGR valve
(1), valve seat (3) and rod.

3) Inspect valve (2), valve seat and rod for fault, cracks, bend or other damage.
If found faulty, replace EGR valve assembly.
PCV Hose InspectionS7RS0B1206009
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.

Check hoses for connection, leakage, clog and
deterioration.
Replace as necessary.
I4RS0A120006-01
I2RH0B120005-01
I2RH0B120006-01

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 Engine Electrical Devices: 1C-5
Electric Throttle Body System CalibrationS7RS0B1306004
NOTE
If working the service described under the
“Precautions of Electric Throttle Body
System Calibration in Section 1A” perform
following steps for electric throttle body
system calibration.

1) If electric throttle body assembly and/or APP sensor
assembly are replaced, perform following steps.
a) Disconnect negative cable at battery for 20 seconds or more for the purpose of clearing
calibration data of closed throttle position from
memory in ECM.
b) Connect negative cable to battery.
2) Keep ignition switch at ON position for 5 seconds or more without running engine.
APP Sensor Assembly On-Vehicle InspectionS7RS0B1306005
1) Check that APP sensor a ssembly has been mounted
to vehicle body properly (no pinched floor carpet,
etc.).
If mounting is not pro perly, reinstall APP sensor
assembly properly refe rring to “APP Sensor
Assembly Removal and Installation”.
2) Connect scan tool to DLC with ignition switch turned OFF.
3) Turn ON ignition switch and select “Data List” mode on scan tool.
4) Check that APP sensor voltage varies as the following graph.
If sensor voltage is out of specified value or does not
vary linearly as the fo llowing graph, check APP
sensor assembly referring to “APP Sensor Assembly
Inspection”.
APP Sensor Assembly Removal and InstallationS7RS0B1306006
CAUTION!
• Do not expose APP sensor assembly to
excessive shock like a dropping it. If APP
sensor assembly has been exposed to
excessive shock, it should be replaced.
• Be careful not to expose sensor section of APP sensor assembly to water.

NOTE
After replacing APP sensor assembly,
perform calibration of th rottle valve referring
to “Electric Throttle Body System
Calibration”.

Removal
1) Disconnect negative cable at battery.
2) Disconnect connector from APP sensor assembly.
3) Remove APP sensor asse mbly from its bracket.
Installation
Reverse removal procedure for installation noting the
following.
• Tighten APP sensor assembly upper nut (1) first and then lower nut (2) to specified torque.
Tightening torque
APP sensor assembly nut (a): 5.5 N·m (0.55 kgf-m,
4.0 lb-ft)
• Connect connector to APP sensor assembly securely.
[A]: APP sensor (main) voltage [D]: Idle position of accelerator pedal
[B]: APP sensor (sub) voltage [E]: Full depressed position of
accelerator pedal
[C]: Voltage
[C]
[B]
[D] [E] [A]
4.65 V
3.85 V
1.55 - 1.65 V
0.75 - 0.85 V
I4RS0B130010-02
1, (a)
2, (a)
I4RS0B130011-01

Downloaded from www.Manualslib.com manuals search engine 1C-6 Engine Electrical Devices:
APP Sensor Assembly InspectionS7RS0B1306007
Check APP sensor (main and sub) output voltage as
following steps.
1) For APP sensor (main) , arrange 3 new 1.5 V
batteries (1) in series (check that total voltage is 4.5 -
5.0 V) and connect its positive terminal to “Vin 1”
terminal (2) and negative terminal to “Ground 1”
terminal (3) of sensor. Then using voltmeter, connect
positive terminal to “Vout 1” terminal (4) of sensor
and negative terminal to battery.
2) For APP sensor (s ub), arrange 3 new 1.5 V batteries
(1) in series (check that total voltage is 4.5 - 5.0 V)
and connect its positive terminal to “Vin 2” terminal
(2) and negative terminal to “Ground 2” terminal (3)
of sensor. Then using volt meter, connect positive
terminal to “Vout 2” terminal (4) of sensor and
negative termin al to battery.
3) Measure output voltage variation while accelerator pedal is no depressed and fully depressed as
following specification.
If sensor voltage is out of specified value or does not
vary linearly as the followin g graph, replace APP sensor
assembly.
APP sensor output voltage
APP sensor (main) output voltage [A]: 0.75 – 3.85 V,
varying according to depressed extent of
accelerator pedal
APP sensor (sub) output voltage [B]: 1.55 – 4.65 V,
varying according to depressed extent of
accelerator pedal.
ECT Sensor Removal and InstallationS7RS0B1306008
Removal
1) Disconnect negative (–) cable at battery.
2) Drain coolant referring to “Cooling System Draining in Section 1F”.
WARNING!
To avoid danger of being burned, do not
remove radiator cap while engine and
radiator are still hot.
Scalding fluid and steam can be blown out
under pressure if cap is taken off too soon.

3) Remove air intake pipe.
4) Disconnect connector from ECT sensor (1).
5) Remove ECT sensor from thermostat case.
1
234I4RS0B130012-01
1
234I4RS0B130013-01
[C]: Voltage
[D]: Idle position of accelerator pedal
[E]: Fully depressed position of accelerator pedal
[C]
[B]
[D] [E] [A]
4.65 V
3.85 V
1.55 - 1.65 V
0.75 - 0.85 V
I4RS0B130010-02
1
I2RH0B130008-01