App SUZUKI SWIFT 2005 2.G Service Manual Online

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

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

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

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

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

Downloaded from www.Manualslib.com manuals search engine 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

Downloaded from www.Manualslib.com manuals search engine 1C-8 Engine Electrical Devices:
Installation
Reverse removal procedure noting the following.
• Tighten heated oxygen sensor to specified torque.Tightening torque
Heated oxygen sensor (a): 45 N·m (4.5 kgf-m,
32.5 lb-ft)
• Install exhaust manifold referring to “Exhaust Manifold Removal and Installation in Section 1K”, if removed.
• Connect connector of heated oxygen sensor and clamp wire harness securely.
• After installing heated oxygen sensor, start engine and check that no exhaust gas leakage exists.
CMP Sensor Removal and InstallationS7RS0B1306012
Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect connector from CMP sensor.
3) Remove CMP sensor from cylinder head.
Installation 1) Install CMP sensor to cylinder head.
Tightening torque
CMP sensor bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
2) Connect connector to CMP sensor securely.
3) Connect negative (–) cable to battery.
Camshaft Position (CMP) Sensor InspectionS7RS0B1306013
Visual check
• Check that O-ring is free from damage.
• Check that end face of sensor and signal rotor tooth are free from any metal particles and damage.
Performance check 1) Remove metal particles on end face of CMP sensor, if any.
2) Arrange 12 V battery (1) and connect its positive terminal to “Vin” terminal (2) and negative terminal to
“Ground” terminal (3) of sensor. Then using
ohmmeter, measure resistance between “Vout”
terminal (4) of sensor and negative terminal of
battery by passing magnetic substance (iron) (5)
while keeping approximately 1 mm (0.03 in.) gap
with respect to end face of CMP sensor.
If resistance does not vary as specified below,
replace CMP sensor.
CMP sensor resistance
Resistance varies from less than 220 Ω (ON) to
infinity (OFF) or from infinity (OFF) to less than 220
Ω (ON)
1. EGR valve
(a)
(a)
I6RS0C130003-02
I6RS0C130004-01
I4RS0B130015-01
I6RS0C130005-01

Downloaded from www.Manualslib.com manuals search engine Engine Electrical Devices: 1C-9
CKP Sensor Removal and InstallationS7RS0B1306014
Removal1) Disconnect negative (–) cable at battery.
2) Remove generator drive belt refer to “Water Pump / Generator Drive Belt Remo val and Installation in
Section 1J”.
3) Remove generator bracket bolt (1) and move generator rearward.
4) Disconnect connector from CKP sensor.
5) Remove CKP sensor (2) from cylinder block.
Installation 1) Install CKP sensor to cylinder block. Tighten CKP sensor bolt to specified torque.
Tightening torque
CKP sensor bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
2) Connect connector to CKP sensor securely.
3) Adjust generator drive belt tension referring to “Water Pump / Generator Drive Belt Tension
Inspection and Adjustment in Section 1J”.
4) Connect negative (–) cable to battery.
CKP Sensor InspectionS7RS0B1306015
Visual check
• Check that O-ring is free from damage.
• Check that end face of sensor and signal pulley tooth are free from any metal particles and damage.
Performance check 1) Remove metal particles on end face of CKP sensor, if any.
2) Arrange 12 V battery (1) and connect its positive terminal to “Vin” terminal (2) and negative terminal to
“Ground” terminal (3) of sensor. Then using
ohmmeter, measure resistance between “Vout”
terminal (4) of sensor and negative terminal of
battery by passing magnetic substance (iron) (5)
while keeping approximately 1 mm (0.03 in.) gap
with respect to end face of CKP sensor.
If resistance does not vary as specified below,
replace CKP sensor.
CKP sensor resistance
Resistance varies from less than 220 Ω (ON) to
infinity (OFF) or from infinity (OFF) to less than 220
Ω (ON)
2
1
I6RS0C130006-01
(a)
I4RS0A130007-01
I3RB0A130006-01
I4RS0B130017-01

Downloaded from www.Manualslib.com manuals search engine Engine Electrical Devices: 1C-13
Without Using SUZUKI Scan Tool1) Measure sensor voltage between “C37-23” terminal of ECM connector and vehicle body ground referring
to “Inspection of ECM and Its Circuits in Section 1A”.
If check result is satisfactory, electric load current
sensor is in good condition.
If check result is not satisfactory, check the following
parts and circuit.
• Electric load current sensor circuit (power, ground and output)
• Following charging system components – Battery (refer to “Battery Inspection in Section
1J”)
– Generator (refer to “Generator Inspection in Section 1J”)
– Generator output control circuit (refer to “Generator Test (Undercharged Battery Check)
in Section 1J”)
– Generator field coil monitor circuit (refer to “Generator Inspection in Section 1J”) If electric load current sensor circuit and charging
system is in good condition,
electric load current sensor
(1) is faulty.
Specifications
Tightening Torque SpecificationsS7RS0B1307001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
2. Main fuse box
2
1
I5RS0C130001-01
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
ECM mounting bolt 8 0.8 6.0 )
APP sensor assembly nut 5.5 0.55 4.0 )
ECT sensor 15 1.5 11.0 )
Heated oxygen sensor 45 4.5 32.5 )
CMP sensor bolt 10 1.0 7.5 )
CKP sensor bolt 10 1.0 7.5 )
Knock sensor 22 2.2 16.0 )
MAF and IAT sensor screw 1.5 0.15 1.1 )

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-2
Camshaft Position Control (VVT Variable Valve Timing) System DescriptionS7RS0B1401002
System Description
The VVT system is an electronic control system which continuously vary and optimize the intake valve timing in
response to the engine operating condition.
The optimized intake valve timing produce such an air intake with high efficiency that both the higher power generation
and lower fuel consumption can be attained in the whole engine speed range from low to high. In the area of the
average engine load, low emission of nitrogen oxides (NOx) and high fuel efficiency can also be attained by making
the valve opening overlap between the intake and exhaust valves longer.
For the brief of the system operation, the intake valve timing is varied by the cam timing sprocket (1) which varies the
rotational phase between the intake camshaft (3) and sprocket . The rotor (2) in the cam timing sprocket is actuated by
switching or adjusting the hydraulic pressure applied to the chambers for the timing advancing (7) and/or retarding (6).
To switch or adjust the hydraulic pressure appropriately, ECM operates the oil control valve (12) with detecting the
engine speed, intake air value, throttle opening, engine coolant temperature and camshaft position (angle).
1
4
5
13
10
89
2
7
6
12
11
3
14
60 (variable angle)
Most retarded timing
Most advanced timing
Exhaust valve Intake valve
Crank angle
Overlap of valves
Valve lift
I3RH0B140002-01
4. Oil passage to chamber for timing retarding 8. Oil filter10. Oil pan 13. Oil return
5. Oil passage to chamber for timing advancing 9. Oil pump11. Control signal from ECM 14. Oil flow

Downloaded from www.Manualslib.com manuals search engine 1D-3 Engine Mechanical:
Oil Control Valve
The oil control valve switches and adjusts the hydraulic
pressure applied to the cam timing sprocket by moving
the spool valve (1) according to the duty pulse signals
output from the ECM. By this operation, the intake valve
timing is varied continuously. Signals output from the
ECM are the duty pulse of about 240 Hz.
Cam Timing Sprocket
The cam timing sprocket is equipped with the chambers
for timing advancing (2) and retarding (3) which are
separated by the rotor (5). The rotor rotates receiving the
hydraulic pressure applied to both the chambers. The
sprocket (1) is installed on the housing (4) and the rotor
is secured on the intake camshaft by fastening the bolts.
Therefore, the actuation of the rotor makes the phase
difference between the sprocket and intake camshaft.
Timing Advancing
When the duty ratio of the signal output from the ECM is
heavy, the spool valve (4) of the oil control valve moves
to the left (opposite direction against the coil (5)). By this
spool valve movement, the pressurized oil (1) is led into
the chambers for timing advancing and the oil in the
chambers for timing retarding is drained. This operations
actuate the rotor (3) and result in the advanced timing of
the intake valve. Timing Holding
When the duty ratio of the si
gnal output from the ECM
shows that of holding, the sp ool valve of the oil control
valve is located at hold posi tion. Because this condition
generates no oil pressure changes in both chambers,
the rotor is fixed at a target position.
Timing Retarding
When the duty ratio of the sig nal output from the ECM is
light, the spool valve of the o il control valve moves to the
right (head for the coil). By this spool valve movement,
the pressurized oil is led into the chambers for timing
retarding and the oil in the chambers for timing
advancing is drained. This operations actuate the rotor
and result in the retarded timing of the intake valve.
6. Seal
1
I3RH0B140003-01
1 2
3
4
56
I3RH0B140004-01
2. Drain
12
5
4
3
I3RH0B140005-01
I3RH0B140006-01
I3RH0B140007-01