oil spec SUZUKI SWIFT 2005 2.G Service User Guide

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 0B-10 Maintenance and Lubrication:
Steering System InspectionS7RS0B0206024
1) Check steering wheel for play and rattle, holding vehicle straight on ground.
Steering wheel play
“a”: 0 – 30 mm (0 – 1.1 in.)
2) Check bolts and nuts for tightness and retighten them as necessary. Repair or replace defective
parts, if any.
3) Check steering linkage for looseness and damage. Repair or replace defective parts, if any.
4) Check boots (1) and (2) of steering linkage and steering gear case for damage (leak, detachment,
tear, etc.). If damage is fo und, replace defective boot
with new one.
If any dent is found on steering gear case boots,
correct it to original shape by turning steering wheel
to the right or left as far as it stops and holding it for a
few seconds.
5) Check universal joints (3) of steering shaft for rattle and damage. If rattle or damage is found, replace
defective part with a new one.
6) Check that steering wheel can be turned fully to the
right and left. Repair or replace defective parts, if
any.
7) If equipped with power steering system, check also, in addition to check items, that steering wheel can be
turned fully to the right and left more lightly when
engine is running at idle speed than when it is
stopped. Repair, if found faulty.
8) Check wheel alignment referring to “Front Wheel Alignment Inspection and Adjustment in Section 2B”.
Drive Shaft (Axle) Boots InspectionS7RS0B0206025
Check drive shaft boots (wheel side and differential side)
for leaks, detachment, tear or other damage.
Replace defective parts as necessary.
Manual Transaxle Oil InspectionS7RS0B0206026
1) Inspect transaxle case for evidence of oil leakage. Repair leaky point if any.
2) Make sure that vehicle is placed level for oil level
check.
3) Remove oil filler/leve l plug (1) of transaxle.
4) Check oil level. Oil level can be checked roughly by means of filler/
level plug hole. That is, if oil flows out of level plug
hole or if oil level is found up to hole when level plug
is removed, oil is properly filled.
If oil is found insufficient, po ur specified oil up to level
hole. For specified oil, refe r to “Manual Transaxle Oil
Change in Section 5B”.
5) Apply sealant to filler/leve l plug and tighten it to
specified torque.
Manual Transaxle Oil ReplacementS7RS0B0206027
Change transaxle oil with new specified oil referring to
“Manual Transaxle Oil Change in Section 5B”.
I2RH01020026-01
2
3
2
1
1
I4RS0B020007-01
I2RH01310001-01
I6RS0C020001-01

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-13
Brake
Foot brake
Check the following:
• that brake pedal has proper travel,
• that brake works properly,
• that it is free from noise,
• that vehicle does not pull to one side when brake is applied.
• and that brake do not drag.
Parking brake
Check that lever has proper travel.
WARNING!
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property
damage. Be prepared to apply regular brake
quickly even if vehicle should start to move.

Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and brake
lever is pulled all the way.
Steering
• Check to ensure that steering wheel is free from instability, or abnormally heavy feeling. • Check that the vehicle does not wander or pull to one
side.
Engine
• Check that engine responds readily at all speeds.
• Check that engine is free from abnormal noise and abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting system
are free from abnormal noise and abnormal vibration or
any other abnormal condition.
Meters and Gauge
Check that speedometer, odometer, fuel meter,
temperature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that ai r comes out from defroster
outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan
switch lever to “HI” position for this check.
Specifications
Tightening Torque SpecificationsS7RS0B0207001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Fluids and LubricantsS7RS0B0208001
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Engine oil drain plug 35 3.5 25.5 )
Oil filter 14 1.4 10.5 for reference )
Engine oilSG, SH, SJ, SL or SM grade (Refer to “Engine Oil and Filter Change” for engine
oil viscosity.)
Engine coolant
(Ethylene glycol base coolant) “Antifreeze/Antico
rrosion coolant”
Brake fluid Refer to reservoir cap of brake master cylinder.
Manual transaxle oil Refer to “Manual Transaxle Oil Change in Section 5B”.
Automatic transaxle fluid Refer to “A/T Fluid Change in Section 5A”.
Door hinges Engine oil or water resistance chassis grease
Hood latch assembly Engine oil or water resistance chassis grease
Key lock cylinder Spray lubricant

Downloaded from www.Manualslib.com manuals search engine 0B-14 Maintenance and Lubrication:
Special ToolS7RS0B0208002
09915–47331
Oil filter wrench
)

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 1-iv Table of Contents
Engine Lubrication System.....................1E-1
General Description ............................................. 1E-1
Engine Lubrication Description ........................... 1E-1
Diagnostic Information and Procedures ............ 1E-2 Oil Pressure Check ............................................. 1E-2
Repair Instructions ........... ................................... 1E-3
Heat Exchanger Components ............................. 1E-3
Heat Exchanger On-Vehicle Inspection .............. 1E-4
Heat Exchanger Removal and Installation .......... 1E-4
Oil Pan and Oil Pump Strainer Components....... 1E-5
Oil Pan and Oil Pump Strainer Removal and
Installation ......................................................... 1E-5
Oil Pan and Oil Pump Stra iner Cleaning ............. 1E-7
Oil Pump Components ........................................ 1E-8
Oil Pump Removal and Installation ..................... 1E-8
Oil Pump Disassembly and Reassembly ............ 1E-8
Oil Pump Inspection ............................................ 1E-9
Specifications .... ................................................. 1E-11
Tightening Torque Specifications ...................... 1E-11
Special Tools and Equipmen t ........................... 1E-11
Recommended Service Material ....................... 1E-11
Special Tool ...................................................... 1E-11
Engine Cooling System ..... ...................... 1F-1
General Description .......... ................................... 1F-1
Cooling System Descriptio n ................................ 1F-1
Coolant Description ............................................. 1F-1
Schematic and Routing Diagram ........................ 1F-2 Coolant Circulation .............................................. 1F-2
Diagnostic Information and Procedures ............ 1F-4 Engine Cooling Symptom Diagnosis ................... 1F-4
Repair Instructions ........... ................................... 1F-5
Cooling System Components.............................. 1F-5
Coolant Level Check ........................................... 1F-6
Engine Cooling System Inspection and Cleaning ............................................................ 1F-6
Cooling System Draining.. ................................... 1F-6
Cooling System Flush and Refill ......................... 1F-7
Cooling Water Pipes or Hoses Removal and Installation ......................................................... 1F-7
Thermostat Removal and In stallation.................. 1F-8
Thermostat Inspection......................................... 1F-8
Radiator Cooling Fan Motor On-Vehicle Inspection .......................................................... 1F-9
Radiator Cooling Fan Rela y Inspection............... 1F-9
Radiator Cooling Fan Removal and Installation ....................................................... 1F-10
Radiator On-Vehicle Inspection and Cleaning .. 1F-10
Radiator Removal and Inst allation .................... 1F-10
Water Pump Removal and In stallation .............. 1F-11
Water Pump Inspection ..................................... 1F-11
Specifications .... ................................................. 1F-12
Tightening Torque Specifications ...................... 1F-12
Special Tools and Equipmen t ........................... 1F-12
Recommended Service Material ....................... 1F-12
Fuel System ................... .......................... 1G-1
Precautions.......................................................... 1G-1 Precautions on Fuel System Service ................. 1G-1
General Description ............................................ 1G-1 Fuel System Description .................................... 1G-1
Fuel Delivery System Description ...................... 1G-1
Fuel Pump Description ....................................... 1G-2
Schematic and Routing Diagram ....................... 1G-2 Fuel Delivery System Diag ram........................... 1G-2
Diagnostic Information and Procedures ........... 1G-2 Fuel Pressure Inspection ................................... 1G-2
Fuel Cut Operation Inspection ........................... 1G-3
Repair Instructions ............ ................................. 1G-4
Fuel System Components .................................. 1G-4
Fuel Hose Disconnecting and Reconnecting ..... 1G-5
Fuel Pressure Relief Procedure ......................... 1G-7
Fuel Leakage Check Procedure......................... 1G-7
Fuel Lines On-Vehicle Inspection ...................... 1G-7
Fuel Pipe Removal and Installation.................... 1G-7
Fuel Injector On-Vehicle Inspection ................... 1G-8
Fuel Injector Removal and Installation ............... 1G-8
Fuel Injector Inspection ...................................... 1G-9
Fuel Filler Cap Inspection . ............................... 1G-10
Fuel Tank Inlet Valve Removal and Installation ...................................................... 1G-11
Fuel Tank Inlet Valve Inspection ...................... 1G-12
Fuel Tank Removal and Installation ................. 1G-12
Fuel Tank Inspection ........................................ 1G-13
Fuel Tank Purging Procedure .......................... 1G-14
Fuel Pump On-Vehicle Inspection.................... 1G-14
Fuel Pump Assembly Removal and Installation ...................................................... 1G-14
Main Fuel Level Sensor Removal and Installation ...................................................... 1G-15
Fuel Pump Inspection ...................................... 1G-16
Specifications ..................... ............................... 1G-16
Tightening Torque Specifications ..................... 1G-16
Special Tools and Equipmen t .......................... 1G-17
Special Tool ..................................................... 1G-17
Ignition System .............. .......................... 1H-1
General Description .............................................1H-1
Ignition System Construction ..............................1H-1
Schematic and Routing Diagram ........................1H-2 Ignition System Wiring Circuit Diagram...............1H-2
Component Location ............ ...............................1H-3
Ignition System Components Location................1H-3
Diagnostic Information and Procedures ............1H-4 Ignition System Symptom Diagnosis...................1H-4
Reference Waveform of Ignition System.............1H-4
Ignition System Check ........................................1H-4
Ignition Spark Test ..............................................1H-6
Repair Instructions ............ ..................................1H-6
High-Tension Cord Removal and Installation......1H-6
High-Tension Cord Inspection.............................1H-7
Spark Plug Removal and Installation ..................1H-7
Spark Plug Inspection .........................................1H-7
Ignition Coil Assembly (Including ignitor)
Removal and Installation ...................................1H-8
Ignition Coil Assembly (Including ignitor)
Inspection ..........................................................1H-8

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-1
Engine
Engine General Information and Diagnosis
Precautions
Precautions on Engine ServiceS7RS0B1100001
CAUTION!
The following information on engine service
should be noted carefully, as it is important in
preventing damage, and in contributing to
reliable engine performance.

• When raising or supporting engine for any reason, do
not use a jack under oil pan. Due to small clearance
between oil pan and oil pump strainer, jacking against
oil pan may cause it to be bent against strainer,
resulting in damaged oil pick-up unit.
• It should be kept in mind , while working on engine,
that 12-volt electrical syste m is capable of violent and
damaging short circuits.
When performing any work where electrical terminals
can be grounded, ground cable of the battery should
be disconnected at battery.
• Any time the air cleaner, throttle body or intake manifold is removed, the intake opening should be
covered. This will protect against accidental entrance
of foreign material which could follow intake passage
into cylinder and cause extensive damage when
engine is started.
Precaution on On-Board Diagnostic (OBD)
System
S7RS0B1100005
There are two types of On -Board Diagnostic (OBD)
system, Euro OBD system and non-Euro-OBD system,
depending on the vehicle specification.
As the diagnosis function is different between these two
types, be sure to fully understand the OBD system
referring to “On-Board Diagnostic System Description”.
OBD System Summary Table
Precautions in Diagnosing TroubleS7RS0B1100002
NOTE
There are two types of OBD system
depending on the vehicle specification.
For details, refer to “Precaution on On-Board
Diagnostic (OBD) System”.

• Don’t disconnect couplers from ECM, battery cable
from battery, ECM ground wire harness from engine
or main fuse before confirming diagnostic information
(DTC, freeze frame data, etc.) stored in ECM memory.
Such disconnection will erase memorized information
in ECM memory.
• Diagnostic information stored in ECM memory can be cleared as well as checke d by using SUZUKI scan
tool or OBD generic scan tool. Before using scan tool,
read its Operator’s (Instruction) Manual carefully to
have good understanding as to what functions are
available and how to use it.
For Euro OBD model it is indistinguishable which
module turns on MIL because not only ECM but also
TCM (A/T model) turns on MIL (For details of on-
board diagnostic system for A/T model, refer to “On-
Board Diagnostic System Description in Section 5A”).
Therefore, check both ECM and TCM (A/T model) for
DTC when MIL lights on.
When checking ECM for DTC, keep in mind that DTC
is displayed on the scan tool as follows depending on
the scan tool used.
– SUZUKI scan tool displays DTC detected by ECM.
– OBD generic scan tool displays DTC detected by each of ECM and TCM (A/T model) simultaneously.
• Priorities for diagnosing troubles If two or more DTCs are stored, proceed to the DTC
flow which has been detected earliest in the order and
follow the instructi on in that flow.
If no instructions are given, troubleshoot DTCs
according to the following priorities.
a. DTCs other than DTC P0171 / P0172 (Fuel system too lean / too rich), DTC P0300 / P0301 /
P0302 / P0303 / P0304 (Misfire detected) and
DTC P0401 / P0402 (EGR flow malfunction)
b. DTC P0171 / P0172 (Fuel system too lean / too rich) and DTC P0401 / P0402 (EGR flow
malfunction)
c. DTC P0300 / P0301 / P0302 / P0303 / P0304 (Misfire detected)
Euro OBD
model Non-Euro-OBD
model
Quantity of DTC
related to engine
control Approx. 80 Approx. 60
Freeze frame
data Available Not available
SUZUKI scan
tool Available Available
OBD generic
scan tool Available Not available

Downloaded from www.Manualslib.com manuals search engine 1A-2 Engine General Information and Diagnosis:
• Be sure to read “Precautions for Electrical Circuit Service in Section 00” befo re inspection and observe
what is written there.
• ECM replacement: When substituting a known-good ECM, check for the
following conditions. Neglec ting this check may cause
damage to a known-good ECM.
– Resistance value of all relays, actuators is as specified respectively.
– MAP sensor, A/C refrigerant pressure sensor and TP sensor are in good condition and none of power
circuits of these sensors is shorted to ground.
• Communication of ECM, BCM, ABS/ESP ® control
module, combination meter, keyless start control
module, steering angle sensor (ESP ® model) and
TCM (A/T model), is esta blished by CAN (Controller
Area Network). (For more detail of CAN
communication for ECM, refer to “CAN
Communication System Description”). Therefore,
handle CAN communication line with care referring to
“Precaution for CAN Communication System in
Section 00”.
• Immobilizer transponder code registration after
replacing ECM
When ECM is replaced with new one or with another
one, make sure to register immobilizer transponder
code to ECM correctly according to “Procedure after
ECM Replacement in Section 10C”.Precautions of ECM Circuit InspectionS7RS0B1100003
• ECM connectors are waterproofed. Each terminal of the ECM connectors is sealed up with the grommet.
Therefore, when measuring ci rcuit voltage, resistance
and/or pulse signal at ECM connector, do not insert
the tester’s probe into th e sealed terminal at the
harness side. When measuring circuit voltage,
resistance and/or pulse signal at ECM connector,
connect the special tool to the ECM connectors. And,
insert the tester’s probe into the special tool’s
connectors at the harness side, and then measure
voltage, resistance and/or pulse signal. Or, ECM and
its circuits may be damaged by water.
• Wire colors of the special tool’s connectors are different from the ones of the ECM connectors.
However, the circuit arrangement of the special tool’s
connectors is same as the one of the ECM
connectors. Therefore, measure circuit voltage and
resistance by identifying the terminal location subject
to the measurement.
Precautions of Electric Throttle Body System
Calibration
S7RS0B1100004
After performing one of works described below, it is
necessary to re-register the completely closed throttle
valve reference position stored in memory of ECM. (For
detailed information, refer to “Description of Electric
Throttle Body System Calibration”.) For the procedure to
register such data in ECM, refer to “Electric Throttle
Body System Calibration in Section 1C”.
• To shut off backup power of ECM for such purposes of battery replacement or “DOME” fuse removal
• To erase DTCs P0122, P01 23, P0222, P0223, P2101,
P2102, P2103, P2111, P2112, P2113, P2119, P2123,
P2127, P2128, P2135 and/or P2138
• To replace ECM
• To replace throttle body and/or accelerator pedal position (APP) sensor assembly
General Description
Statement on Cleanliness and CareS7RS0B1101001
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousands of an
millimeter (ten thous ands of an inch).
Accordingly, when any internal engine parts are
serviced, care and cleanliness are important.
It should be understood that proper cleaning and
protection of machined surfaces and friction areas is part
of the repair procedure. This is considered standard
shop practice even if not specifically stated.
• A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate
the surfaces on initial operation. • Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.
At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.
• Battery cables should be disconnected before any major work is performed on the engine.
Failure to disconnect cables may result in damage to
wire harness or other electrical parts.

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-5
Freeze frame data clearance:
The freeze frame data is cleared at the same time as
clearance of DTC.
Non-Euro-OBD
ECM diagnosis troubles which may occur in the area
including the following parts w hen the ignition switch is
ON and the engine is running, and indicates the result by
turning on or flashing malfunction indicator lamp (1).
• Heated oxygen sensor
• ECT sensor
•TP sensor
• APP sensor
• MAF sensor
• IAT sensor
• MAP sensor
• CMP sensor
• CKP sensor
• Knock sensor
• Wheel speed sensor (VSS)
• CPU (Central Processing Unit) of ECM
• Oil control valve
• EGR valve
• EVAP canister purge valve
• Ignition coil
• Starter relay
• Radiator fan relay
• CAN communication
• Barometric pressure sensor
• ECM back up power supply
ECM and malfunction indicator lamp (1) operate as
follows.
• Malfunction indicator lamp (1) lights when the ignition switch is turned ON (but t he engine at stop) with the
diagnosis switch terminal ungrounded regardless of
the condition of Engine and Emission control system.
This is only to check the ma lfunction indicator lamp (1)
in the combination meter and its circuit.
• If the above areas of Engine and Emission control system is free from any trouble after the engine start
(while engine is running), malfunction indicator lamp
(1) turns OFF. • When ECM detects a trouble which has occurred in
the above areas, it makes malfunction indicator lamp
(1) turn ON while the engi ne is running to warn the
driver of such occurrence of trouble and at the same
time it stores the trouble area in ECM back-up
memory. (The memory is kept as it is even if the
trouble was only temporary and disappeared
immediately. And it is not erased unless the power to
ECM is shut off for specified time or it is cleared by
SUZUKI scan tool (2).)
For Hong Kong model, DTC can be read by not only
using SUZUKI scan tool but also displayed on
odometer (5) of the combination meter. (i.e. when
diagnosis switch terminal (3) is grounded with a
service wire (4) and ignition switch is turned ON.) For
further detail of the checking procedure, refer to “DTC
Check”.
6. Diagnosis connector
2
1
6 3
5
4
I5RS0C110021-01