check engine SUZUKI SWIFT 2005 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-9
Reassembly1) Wash, clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to inner and outer rotors, oil seal lip portion, inside surfaces of oil pump case
and plate.
3) Install outer (1) and inner rotors (2) to oil pump case.
4) Apply engine oil to relief valve (1) and spring (2), and install them with retainer (3) and new circlip (4) to
rotor plate (5).
5) Install rotor plate and tighten all bolts to specified torque. After installing plate, check to be sure that
rotors turn smoothly by hand (0.3 N ⋅m (0.03 kgf-m,
0.25 lb-ft) torque or below).
Tightening torque
Oil pump rotor plate bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)Oil Pump InspectionS7RS0B1506010
Oil Seal
Check oil seal lip for fault or other damage. Replace as
necessary.
Oil Pump
• Check outer (1) and inner rotors (2), rotor plate, and oil pump case for excessive wear or damage.
• Check relief valve (1) for excessive wear or damage
and operates smoothly.
I2RH0B150019-01
I3RM0A150005-01
I2RH0B150022-01
I2RH0B150023-01
I2RH0B150019-01
I2RH0B150025-01

Downloaded from www.Manualslib.com manuals search engine 1E-10 Engine Lubrication System:
Radial clearance
Check radial clearance between outer rotor (1) and case
(2) using thickness gauge (3).
If clearance exceeds its limit, replace outer rotor or case.
Radial clearance between outer rotor and case for oil
pump
Limit: 0.310 mm (0.0122 in.)
Side clearance
Using straightedge (1) and thickness gauge (2),
measure side clearance.
If side clearance exceeds its limit, replace oil pump
assembly.
Side clearance for oil pump inner rotor
Limit: 0.15 mm (0.0059 in.)Relief valve spring free length and load
Check relief valve spring free length and load as shown
in the figure. If the measured valve spring length is lower
than the specification, replace relief valve spring.
Relief valve spring free length and load
I2RH0B150026-01
I2RH0B150027-01
Standard Limit
Free length 52.4 mm
(2.06 in.) —
Load at spring length
38.5 mm (1.52 in.) 79 N
(7.9 kgf, 17.5 lb) 69 N
(6.9 kgf, 15.0 lb)
I2RH01150023-01

Downloaded from www.Manualslib.com manuals search engine 1F-1 Engine Cooling System:
Engine
Engine Cooling System
General Description
Cooling System DescriptionS7RS0B1601001
The cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan and
thermostat. The radiator is of tube-and-fin type.
Coolant DescriptionS7RS0B1601002
WARNING!
• Do not remove radiator cap to check engine coolant level; check coolant visually at the see-through coolant reservoir. Coolant should be added only to reservoir as necessary.
• As long as there is pressure in the cooling system, the temperature can be considerably higher than the boiling temperature of the solution in the radiator without causing the solution to boil. Removal
of the radiator cap while engine is hot and pressure is high will cause the solution to boil
instantaneously and possibly with explosive force, spewing the solution over engine, fenders and
person removing cap. If the solution contains flammable anti-freeze such as alcohol (not
recommended for use at any time), there is also the possibility of causing a serious fire.
• Check to make sure that engine coolant temperature is cold before removing any part of cooling system.
• Also be sure to disconnect negative cable from battery terminal before removing any part.

The coolant recovery system is standard. The coolant in the radiator expands with heat, and the coolant is overflowed
to the reservoir.
When the system cools down, the coolant is drawn back into the radiator.
The cooling system has be en filled with a quality coolant that is a 50/50 mixture of water and ethylene glycol
antifreeze.
This 50/50 mixture coolant solution provides freezing protection to –36 °C (–33 °F).
• Maintain cooling system freeze protection at –36 °C (–33 °F) to ensure protection against corrosion and loss of
coolant from boiling. This should be done even if freezing temperatures are not expected.
• Add ethylene glycol base coolant when coolant has to be added because of coolant loss or to provide added protection against freezing at temperature lower than –36 °C (–33 °F).
NOTE
• Alcohol or methanol base coolant or plain water alone should not be used in cooling system at any
time as damage to cooling system could occur.
• Coolant must be mixed with deminerated water or distilled water.

Anti-freeze proportioning table
For M/T model For A/T model
Freezing temperature °
C –36 –36
° F –33 –33
Anti-freeze / Anti-corrosion coolant concentration % 50 50
Ratio of compound to cooling water ltr. 3.10/3.10 3.05/3.05
US pt. 6.55/6.55 6.44/6.44
Imp pt. 5.46/5.46 5.37/5.37

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-4
Diagnostic Information and Procedures
Engine Cooling Symptom DiagnosisS7RS0B1604001
ConditionPossible cause Correction / Reference Item
Engine overheats
(Radiator fan operates) Loose or broken water pump belt
Adjust or replace.
Not enough coolant Check coolant level and add as necessary.
Faulty thermostat Replace.
Faulty water pump Replace.
Dirty or bent radiator fins Clean or remedy.
Coolant leakage on cooling system Repair.
Clogged radiator Check and replace radiator as necessary.
Faulty radiator cap Replace.
Improper ignition timing Adjust.
Dragging brakes Adjust brake.
Slipping clutch Adjust or replace.
Poor charge battery Check and replace as necessary.
Poor generation generator Check and repair.
ECT sensor faulty Check and replace as necessary.
Radiator cooling fan relay No.2 and/or
No.3 faulty Check and replace as necessary.
Radiator fan motor faulty Check and replace as necessary.
ECM faulty Check and replace as necessary.
Wiring or grounding faulty Repair as necessary.
Equipped with too much electric load
part(s) Dismount.
Engine overheats
(Radiator fan does not
operate) Fuse blown
Check 30 A fuse of relay/fuse box and check
for short circuit to ground.
Radiator cooling fan relay No.1 faulty Check and replace as necessary.
ECT sensor faulty Check and replace as necessary.
Radiator cooling fan motor faulty Check and replace as necessary.
Wiring or grounding faulty Repair as necessary.
ECM faulty Check and replace as necessary.

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-6
Coolant Level CheckS7RS0B1606002
WARNING!
To help 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 radiator
cap is taken off too soon.

To check level, lift hood and look at “see-through”
coolant reservoir.
It is not necessary to remove radiator cap to check
coolant level.
When engine is cool, check coolant level in reservoir (1).
A normal coolant level should be between FULL mark
(2) and LOW mark (3) on reservoir (1).
If coolant level is below LOW mark (3), remove reservoir
cap (4) and add proper coolant to reservoir to bring
coolant level up to FULL mark (2).
NOTE
If proper quality antifreeze is used, there is
no need to add extra inhibitors or additives
that claim to improve system. They may be
harmful to proper operation of system, and
are unnecessary expense.

Engine Cooling System Inspection and
Cleaning
S7RS0B1606003
WARNING!
To help 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.

1) Check cooling system for leakage or damage.
2) Wash radiator cap and fille r neck with clean water by
removing radiator cap when engine is cold.
3) Check coolant for proper level and freeze protection.
4) Using a pressure tester (1), check system and radiator cap (2) for proper pressure holding capacity.
If replacement of cap is required, use a proper cap
for this vehicle.
NOTE
After installing radiator cap to radiator, make
sure that the ear of cap lines is parallel to
radiator.

Cooling system and radiator cap holding
pressure (for inspection)
110 kPa (1.1 kg/cm2, 15.6 psi)
5) Tighten hose clamps and inspect all hoses. Replace hoses whenever cracked, swollen or otherwise
deteriorated.
6) Clean frontal area of radiator core.
Cooling System DrainingS7RS0B1606004
1) Remove radiator cap.
2) Drain coolant from radiator drain plug (1).
3) After draining coolant, be sure to tighten drain plug (1) securely.
1
4
1
3
2
4
I4RS0B160002-01
I5RH01160001-01
1I4RS0A160003-01

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-8
Thermostat Removal and InstallationS7RS0B1606007
Removal1) Drain coolant referring to “Cooling System Draining”.
2) Remove intake manifold referring to “Intake Manifold Removal and Installa tion in Section 1D”.
3) Remove generator referring to “Generator Dismounting and Remounting in Section 1J”.
4) Disconnect water hose (1) and heater hose (2) from each pipe.
5) Remove thermostat case (3) with thermostat cap (4)
and water inlet pipe (5).
6) Remove water inlet pipe with thermostat cap from thermostat case.
7) Remove thermostat from thermostat case (3).
Installation
Reverse removal procedure for installation noting the
following points.
• Install thermostat cap (1) to thermostat case (2) by aligning match mark (3) of thermostat case with air
bleed valve (4) of the thermostat (5).
• Use new O-rings when installing.
• Adjust water pump belt tension referring to “Water Pump / Generator Drive Belt Tension Inspection and
Adjustment in Section 1J”.
• Adjust A/C compressor belt tension referring to “Compressor Drive Belt Inspection and Adjustment in
Section 7B” or “Compressor Drive Belt Inspection and
Adjustment in Section 7B”. • Refill cooling system referrin
g to Step 7) to 22) of
“Cooling System Flush and Refill”.
• Verify that there is no coolant leakage at each connection.
Thermostat InspectionS7RS0B1606008
• Make sure that air bleed valve (1) of thermostat is clean.
• Check to make sure that va lve seat (2) is free from
foreign matters which would prevent valve from
seating tight.
• Check thermostat seal (3) for breakage, deterioration or any other damage.
• Check thermostatic movement of wax pellet as follows:
a. Immerse thermostat (1) in water, and heat water gradually.
b. Check that valve starts to open at specific temperature.
Temperature at which valve begins to open
80 – 84 °C (176 – 183 °F)
Temperature at which valve become fully open
95 – 97 °C (203 °F)
Va l v e l i ft
More than 8 mm at 95 °C (203 ° F)
If valve starts to open at a temperature substantially
below or above specific temperature, thermostat unit
should be replaced with a new one. Such a unit, if
reused, will bring about ov ercooling or overheating
tendency.
I3RM0A160007-01
4
5 3
1 2
I7RS0B160006-01
2. Thermometer
3. Heater
I3RM0A160008-01
I2RH01160012-01

Downloaded from www.Manualslib.com manuals search engine 1F-9 Engine Cooling System:
Radiator Cooling Fan Motor On-Vehicle
Inspection
S7RS0B1606009
1) Check low speed operation of radiator cooling fan as follows.
a) Connect battery to fan motor coupler as shown in figure.
b) Check that radiator cooling fan rotates smoothly. If any abnormality is found, replace fan motor.
2) Check high speed operation of radiator cooling fan as follows.
a) Connect battery to fan motor coupler as shown in figure.
b) Check that radiator cooling fan rotates smoothly and its rotational speed is faster than low speed
operation.
If any abnormality is found, replace fan motor.
Reference: Fan motor sp ecified current at 12
V
Low speed operation: 14.0 A maximum
High speed operation: 18.0 A maximum
Radiator Cooling Fan Relay InspectionS7RS0B1606010
1) Disconnect negative (–) cable at battery.
2) Remove radiator cooling fa n relay No.1 (1), No.2 (2)
and/or No.3 (3) from relay box.
3) Check that there is no continuity between terminal “C” and “D”. If there is continuity, replace relay.
4) Connect battery positive (+ ) terminal to terminal “B”
of relay.
5) Connect battery negative (–) terminal “A” of relay.
6) Check continuity between terminal “C” and “D”. If there is no continuity when relay is connected to the
battery, replace relay.
[A]: Low speed operation
[B]: High speed operation
[A] [B]
I7RS0B160007-01
“D”
“B” “A”
“C”
1
2
3
I4RS0B160004-01

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-10
Radiator Cooling Fan Removal and InstallationS7RS0B1606011
Removal1) Disconnect negative (–) cable at battery.
2) Disconnect connector (1) of cooling fan motor.
3) Drain coolant.
4) Remove front bumper, front bumper upper absorber and upper member referring to “Front Bumper and
Rear Bumper Componen ts in Section 9K”.
5) Remove radiator inlet hose and reservoir hose.
6) Remove cooling fan mounting bolts (1).
7) Slide condenser with radiator, and then remove radiator cooling fan.
CAUTION!
Be sure not to damage condenser outlet pipe.

Installation
Reverse removal procedure for installation noting the
following.
• Refill cooling system referring to Step 7) to 22) of “Cooling System Fl ush and Refill”.
• After installation, verify there is no coolant leakage at each connection.
Radiator On-Vehicle Inspection and CleaningS7RS0B1606012
Inspection
Check radiator for leakage or damage. Straighten bent
fins, if any.
Cleaning
Clean frontal area of radiator cores.
Radiator Removal and InstallationS7RS0B1606013
Removal
1) Disconnect negative cable at battery.
2) Drain A/T fluid.
3) Drain coolant.
4) Remove cooling fan assemb ly referring to “Radiator
Cooling Fan Removal and Installation”.
5) Remove A/T fluid cooler inlet and outlet hoses.
6) Remove radiator outlet hose from radiator.
7) Remove radiator from vehicle.
Installation
Reverse removal procedures, noting the following.
• Refill cooling system referrin g to Step 7) to 22) of
“Cooling System Flush and Refill”.
• After installation, verify there is no coolant leakage each connection.
• Refill A/T fluid referring to “A/T Fluid Change in
Section 5A”.
1
I7RS0A160004-01
I4RS0A160009-01
I2RH01160014-01

Downloaded from www.Manualslib.com manuals search engine 1F-11 Engine Cooling System:
Water Pump Removal and InstallationS7RS0B1606014
Removal1) Disconnect negative cable at battery.
2) Drain coolant.
3) Remove water pump / generator drive belt referring to “Water Pump / Generator Drive Belt Removal and
Installation in Section 1J”.
4) Remove water pump assembly (1).
Installation 1) Apply sealant to mating surface of water pump (1) as shown in the figure.
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
Sealant quantity (to mating surface of water
pump)
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.) 2) Install water pump assemb
ly (1) to cylinder block
and tighten bolts and nut to specified torque.
Tightening torque
Water pump bolt and nut (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
3) Install water pump pulley.
4) Install water pump / generator drive belt referring to “Water Pump / Generator Drive Belt Tension
Inspection and Adjustment in Section 1J”.
5) Install A/C compressor belt (if equipped) referring to “Compressor Drive Belt Inspection and Adjustment
in Section 7B” or “Compressor Drive Belt Inspection
and Adjustment in Section 7B”.
6) Refill cooling system referri ng to Step 7) to 22) of
“Cooling System Flush and Refill”.
7) Connect negative cable at battery.
8) Check each part for leakage.
Water Pump InspectionS7RS0B1606015
CAUTION!
Do not disassemble water pump.
If any repair is requir ed on pump, replace it
as assembly.

Rotate water pump by hand to check for smooth
operation. If pump does not rotate smoothly or makes
abnormal noise, replace it.
I2RH0B160016-01
I3RM0A160016-01
I2RH0B160018-01
I2RH0B160019-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-2
Fuel Pump DescriptionS7RS0B1701003
The fuel pump (1) is an in-tank type electric pump.
Incorporated in the pump assembly are;
a fuel filter (2) and a fuel pressure regulator (3) are
included and a fuel level gauge (4) is attached.
Addition of the fuel pressure regulator to the fuel pump
makes it possible to mainta in the fuel pressure at
constant level and ECM controls compensation for
variation in the intake manifold pressure.
Schematic and Routing Diagram
Fuel Delivery System DiagramS7RS0B1702001
Diagnostic Information and Procedures
Fuel Pressure InspectionS7RS0B1704001
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

1) Relieve fuel pressure in fuel feed line referring to
“Fuel Pressure Relief Procedure”.
2) Disconnect fuel feed hose from fuel delivery pipe.
3) Connect special tools and hose between fuel feed hose (1) and fuel delivery pipe as shown in figure,
and clamp hoses securely in order to ensure that no
leaks occur during checking.
Special tool
(A): 09912–58442
(B): 09912–58432
(C): 09912–58490
1
3
2
4
I6RS0C170001-01
4
6 7
8
12
2 3
11
10
5
1
9
I6RS0C170002-01
1. Fuel tank
5. Fuel injector9. EVAP canister
2. Fuel pump 6. Fuel feed line10. Fuel filter
3. Fuel pressure regulator 7. Fuel vapor line 11. Main fuel level sensor
4. Delivery pipe 8. Intake manifold12. EVAP canister purge valve
1
(C) (B)
(A)
I3RM0A170004-01