Connectors SUZUKI SWIFT 2005 2.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 1A-104 Engine General Information and Diagnosis:
4Wire harness check
1) Disconnect connectors from ECM with ignition switch
turned OFF.
2) Check for proper connection of ECM connector at “C37- 43” terminal.
3) Measure voltage between “C37-43” terminal of ECM connector and engine ground with ignition switch turned
ON.
Is voltage 0 V? Substitute a known-
good ECM and recheck.
“RED” wire is shorted to
power circuit.
5 Wire harness check
1) Measure voltage between “WHT” wire terminal of
electric throttle body connector and engine ground with
ignition switch turned ON.
Is voltage 4 – 6 V? Go to Step 9.
Go to Step 6.
6 Wire harness check
1) Turn OFF ignition switch.
2) Remove ECM from its br acket with ECM connectors
connected.
3) Check for proper connection of ECM connector at “C37- 43” and “C37-40” terminals.
4) If OK, measure voltage between “C37-40” terminal of ECM connector and engine ground with ignition switch
turned ON.
Is voltage 4 – 6 V? “WHT” wire is open or
high resistance circuit.
Go to Step 7.
7 Wire harness check
1) Disconnect connectors from ECM with ignition switch
turned OFF.
2) Measure resistance between “WHT” and “RED” wire terminals of electric thrott le body assembly connector.
Is resistance infinity? Go to Step 8.
“WHT” wire is shorted to
“RED” wire.
8 Wire harness check
1) Turn ON ignition switch.
2) Measure voltage between “C37-40” terminal of ECM
connector and engine ground.
Is voltage 0 V? Substitute a known-
good ECM and recheck.
“WHT” wire is shorted to
power circuit.
9 Ground circuit check
1) Turn OFF ignition switch.
2) Measure resistance between “BLK” wire terminal of
electric throttle body connector and engine ground.
Is resistance below 5
Ω? Go to Step 11. Go to Step 10.
10 Ground circuit check
1) Remove ECM from its br acket with ECM connectors
connected.
2) Check for proper connection of ECM connector at “C37- 42” terminal.
3) Measure resistance between “C37-42” terminal of ECM connector and engine ground with ignition switch turned
OFF.
Is resistance below 5
Ω? “BLK” wire is open or
high resistance circuit.
Faulty ECM ground
circuit. If circuit is OK,
substitute a known-
good ECM and recheck.
Step Action Yes No

Downloaded from www.Manualslib.com manuals search engine 1A-106 Engine General Information and Diagnosis:
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 Does fuel level meter in dicate “E” level (empty)? Add fuel and recheck. Go to Step 3.
3 Fuel quality check
1) Check that there is fuel of good quality in the fuel tank.
Is it OK? Go to Step 4.
Clean in fuel system
circuit and change fuel.
4 Ignition system check
1) Check spark plug and ignition spark of cylinder where
misfire occurs, referring to “Spark Plug Inspection in
Section 1H” and “Ignition Spark Test in Section 1H”.
Are they in good condition? Go to Step 5.
Faulty ignition coil, wire
harness, spark plug or
other system parts.
5 Fuel injector circuit check
1) Using sound scope, check each injector operating sound
at engine cranking or idling.
Do all injectors ma ke operating sound? Go to Step 6.
Check coupler
connection and wire
harness of injector not
making operating sound
and injector itself. If OK,
substitute a known-
good ECM and recheck.
6 Fuel pressure check
1) Check fuel pressure referring to “Fuel Pressure Check”.
Is check result satisfactory? Go to Step 7.
Repair or replace fuel
system.
7 Fuel injector check
1) Check fuel injector(s) re ferring to “Fuel Injector
Inspection in Section 1G”.
Is check result satisfactory? Go to Step 8.
Replace defective
injector.
8 Ignition timing check
1) Check ignition timing referring to “Ignition Timing
Inspection in Section 1H”.
Is check result satisfactory? Go to Step 9.
Check related sensors.
9 EGR system check
1) Check EGR system referring to “EGR System Inspection
in Section 1B”.
Is check result satisfactory? Go to Step 10. Repair or replace EGR
system.
10 Exhaust system check
1) Check exhaust system for exhaust gas clogged.
Is it OK? Go to Step 11. Repair clogged of
exhaust system.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-123
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

1) With ignition switch OFF, connect scan tool to DLC.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and warm up normal operating temperature.
4) Drive vehicle at more than 40 km/h, 25 mph for 5 min. or more.
5) Check DTC and pending DTC.
DTC Troubleshooting
WARNING!
In order to reduce risk of fire and personal injury, this work must be performed in a well ventilated area
and away from any open flames such as gas water heater.

NOTE
• When measuring circuit voltage, resistance and/ or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 EVAP canister purge power supply circuit check
1) Turn OFF ignition switch and disconnect connector from
EVAP canister purge valve.
2) Measure voltage between engine ground and “BLK/ RED” wire terminal of EVAP canister purge valve
connector with ignition switch turned ON.
Is it voltage 10 – 14 V? Go to Step 3.
“BLK/RED” wire is open
circuit.
3 Wire circuit check
1) Disconnect connectors from ECM with ignition switch
turned OFF.
2) Measure resistance between “C37-29” terminal of ECM connector and vehicle body ground.
Is resistance infinity? Go to Step 4.
“BLU/BLK” wire is
shorted to ground
circuit.
4 Wire circuit check
1) Measure voltage between “C37-29” terminal of ECM
connector and vehicle body ground with ignition switch
turned ON.
Is voltage 0 V? Go to Step 5.
“BLU/BLK” wire is
shorted to other circuit.