reverse SUZUKI SWIFT 2005 2.G Service Workshop Manual

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

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

3) Inspect valve (2), valve seat and rod for fault, cracks, bend or other damage.
If found faulty, replace EGR valve assembly.
PCV Hose InspectionS7RS0B1206009
NOTE
Be sure to check that there is no obstruction
in PCV valve or its hoses before checking
IAC duty, for obstructed PCV valve or hose
hampers its accurate adjustment.

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

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Engine
Engine Electrical Devices
Repair Instructions
ECM Removal and InstallationS7RS0B1306001
CAUTION!
As ECM consists of precision parts, be
careful not to expose it to excessive shock.

Removal1) Disconnect negative (–) cable at battery.
2) Remove ECM (1) from its bracket by removing its
mounting bolts (2).
3) Disconnect connectors from ECM as follows. a) Push lock (1) to release locking of lock lever (2).
b) Turn lock lever to arrow direction until it stops. Installation
Reverse removal procedure noting the following:
• Connect connectors to ECM as follows.
a. Make sure that lock lever of ECM connector is unlock position.
b. Insert ECM connectors to ECM until it stops with unlocked lock lever.
c. Lock ECM connectors securely by pulling its lock lever up.
• Tighten ECM mounting bolts to specified torque. Tightening torque
ECM mounting bolt (a): 8 N·m (0.8 kgf-m, 6.0 lb-
ft)
1
2 2
I4RS0A130002-01
1
2I4RS0A130003-01
I4RS0B130021-01
I4RS0B130022-01
I4RS0A130004-01
(a) (a)I4RS0A130005-01

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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 Engine Electrical Devices: 1C-7
Installation
Reverse removal procedure noting the following.
• Clean mating surfaces of ECT sensor and thermostat case.
• Check O-ring for damage and replace, if necessary.
• Tighten ECT sensor (1) to specified torque.
Tightening torque
ECT sensor (a): 15 N·m (1.5 kgf-m, 11.0 lb-ft)
• Connect connector to ECT sensor securely.
• Refill coolant referring to “Cooling System Flush and
Refill in Section 1F”.
ECT Sensor InspectionS7RS0B1306009
Immerse temperature sensing part of ECT sensor (1) in
water (or ice) and measure resistance between sensor
terminals while heating water gradually.
If measured resistance doesn’t show such characteristic
as shown, replace ECT sensor.
HO2S-1 and HO2S-2 Heater On-Vehicle
Inspection
S7RS0B1306010
1) Disconnect sensor connector.
2) Using ohmmeter, measure resistance between terminals “V
B” and “GND” of sensor connector.
If found faulty, replace oxygen sensor.
NOTE
Temperature of sensor affects resistance
value largely. Make sure that sensor heater is
at correct temperature.

Resistance of oxygen sensor heater
HO2S-1: 5.0 – 6.4 Ω at 20 °C (68 °F)
HO2S-2: 11.7 – 14.5 Ω at 20 °C (68 °F)
Viewed from terminal side
3) Connect sensor co nnector securely.
HO2S-1 and HO2S-2 Removal and InstallationS7RS0B1306011
Removal
WARNING!
To avoid danger of being burned, do not
touch exhaust system when system is hot.
Oxygen sensor removal should be performed
when system is cool.

1) Disconnect negative (–) cable at battery.
2) Disconnect connector of heated oxygen sensor and
release its wire harness from clamps.
3) Perform following items before removing heated oxygen sensor.
a) For HO2S-1, remove exhaust manifold referring to “Exhaust Manifold Remo val and Installation in
Section 1K”, if necessary.
b) For HO2S-2, hoist vehicle.
4) Remove heated oxygen sensor from exhaust pipe or exhaust manifold.
[A]: Lower limit [D]: Resistance
[B]: Normal [E]: Temperature
[C]: Upper limit
1,(a)
I2RH0B130009-01
20
0
68
32 104 140 176 40 60 80
[E]
2.29 - 2.62
0.309 - 0.331
[A]
[B]
[C][D]
I5JB0A130037-01
[A]: HO2S-1 [B]: HO2S-2
I4RS0A130006-01

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 1C-10 Engine Electrical Devices:
Knock Sensor Removal and InstallationS7RS0B1306016
Removal1) Disconnect negative (–) cable at battery.
2) Hoist vehicle.
3) Remove right side drive shaft referring to “Front Drive Shaft Assembly Removal and Installation in
Section 3A”.
4) Disconnect knock sensor connector (1).
5) Remove knock sensor (2) from cylinder block.
Installation
Reverse removal procedure for installation.
Tightening torque
Knock sensor (a): 22 N· m (2.2 kgf-m, 16.0 lb-ft)
Main Relay, Fuel Pump Relay and Starting Motor
Control Relay Inspection
S7RS0B1306017
1) Disconnect negative (–) cable at battery.
2) Remove main relay (1), fuel pump relay (3) and/or
starting motor control relay (2) from individual circuit
fuse box No.1.
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. Connect battery negative (–) terminal to
terminal “A” of relay. Ch eck for continuity between
terminal “C” and “D”. If t here is no continuity when
relay is connected to the battery, replace relay.
1 2, (a)
I3RB0A130007-01
"D"
"B" "A"
"C"
2
1
3
I4RS0A130014-01

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MAF and IAT Sensor On-Vehicle InspectionS7RS0B1306018
NOTE
Before performed this inspection, be sure to
read the “Precautions of ECM Circuit
Inspection in Section 1A”.

1) Disconnect negative (–) cable at battery.
2) Disconnect MAF and IAT sensor connector.
3) Connect voltmeter to “BLK/RED” wire terminal (2) of
MAF and IAT sensor connector (1) disconnected and
ground.
4) Turn ON ignition switch position and check that voltage is battery voltage.
If not, check if wire harness is open or connection is
poor.
5) Turn OFF ignition switch position and connect connector to MAF and IAT sensor.
6) Remove ECM from its bracket referring to “ECM Removal and Installation”.
7) Connect special tool between ECM and ECM connector referring to “Inspection of ECM and Its
Circuits in Section 1A”.
8) Turn ON ignition switch position and check MAF signal voltage between “C37-26” terminal circuit and
“C37-27” terminal circuit of special tool.
MAF signal voltage between “C37-26” terminal
circuit and “C37-27” termi nal circuit of special
tool
MAF signal voltage of MAF and IAT sensor with
ignition switch turned ON: 0.5 – 1.0 V
9) Start engine and check that voltage is lower than 5 V and it rises as engine speed increases.
MAF signal voltage between “C37-26” terminal
circuit and “C37-27” termi nal circuit of special
tool
MAF signal reference voltage of MAF and IAT
sensor at specified Idle speed: 1.3 – 1.8 V 10) If check result is not as
specified above, cause may
lie in wire harness, connec tor connection, MAF and
IAT sensor or ECM.
MAF and IAT Sensor Removal and InstallationS7RS0B1306019
CAUTION!
• Do not disassemble MAF and IAT sensor.
• Do not expose MAF and IAT sensor to any shock.
• Do not clean MAF and IAT sensor.
• If MAF and IAT sensor has been dropped, it should be replaced.
• Do not blow compressed air by using air gun or the like.
• Do not put finger or any other object into MAF and IAT sensor. Malfunction may
occur.

Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect MAF and IAT sensor connector.
3) Remove air cleaner case (1).
4) Remove MAF and IAT sensor (2) from air cleaner case.
Installation
Reverse removal procedure noting the followings.
• Tighten MAF and IAT sensor screws to specified torque.
Tightening torque
MAF and IAT sensor screw (a): 1.5 N·m (0.15 kgf-
m, 1.1 lb-ft)
• Connect MAF and IAT sensor connector securely.
1. ECM
I3RB0A130009-01
“C37-27” “C37-26” 1
I4RS0A130009-01
1
2
I4RS0A130010-01
(a)
I4RS0A130011-01

Downloaded from www.Manualslib.com manuals search engine 1D-9 Engine Mechanical:
Repair Instructions
Air Cleaner ComponentsS7RS0B1406001
Air Cleaner Element Removal and InstallationS7RS0B1406002
Removal1) Remove engine cover.
2) Open air cleaner case (1) by unhooking its clamps (2).
3) Remove air cleaner element from case.
Installation
Reverse removal procedure for installation.
(c)
1
2
3
4
5
6
7
8
11
910
8
(a)(a)
(b)
(c)
(e)
(d)
(b)
(b)
I7RS0B140001-01
1. Engine Cover 7. Air cleaner outlet hose : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
2. Cylinder head upper cover 8. Hose clamp : 3 N⋅m (0.3 kgf-m, 2.5 lb-ft)
3. Air cleaner assembly 9. MAF sensor : 1.5 N⋅m (0.15 kgf-m, 1.0 lb-ft)
4. Air intake pipe 10. EVAP canister purge valve : 5 N⋅m (0.5 kgf-m, 4.0 lb-ft)
5. Air suction hose 11. To throttle body
6. Air cleaner suction pipe : 8 N⋅m (0.8 kgf-m, 6.0 lb-ft)
1
2
I3RM0A140007-01

Downloaded from www.Manualslib.com manuals search engine 1D-15 Engine Mechanical:
Installation
Reverse removal procedure for installation noting the
followings.
• Use new intake manifold gasket (1).
• Use new EGR pipe gasket (2).
• Install intake manifold bolts (3) and nuts (4) to specified torque.
Tightening torque
Intake manifold bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
Intake manifold nut (b): 23 N·m (2.3 kgf-m, 17.0
lb-ft) • Install intake manifold rear stiffener (1) as shown in
figure.
• Connect ground terminal (2) to intake manifold to specified torque.
Tightening torque
Intake manifold ground terminal bolt (a): 11 N·m (
1.1 kgf-m, 8.0 lb-ft)
• Install throttle body referrin g to “Electric Throttle Body
Assembly Removal and Installation”.
• Install cowl top plate referring to “Cowl Top Components in Section 9K”.
• Refill cooling system refe rring to “Cooling System
Flush and Refill in Section 1F”.
• Upon completion of installation, turn ignition switch ON but engine OFF and check for fuel leaks.
• Finally, start engine and check for engine coolant leaks.
1
2
3,(a)
4,(b)
I6RS0B141011-01
(a)
12
I6RS0B141012-01

Downloaded from www.Manualslib.com manuals search engine 1D-19 Engine Mechanical:
24) Before removing engine with transaxle from engine compartment, recheck to make sure all hoses,
electric wires and cables are disconnected from
engine and transaxle.
25) Lower engine with transaxle from engine compartment.
CAUTION!
Before lowering engine, to avoid damage to
A/C compressor and clutch operating
cylinder, make clearance by rising them. Be
sure not to damage suspended A/C
compressor and clutch operating cylinder.

26) Disconnect transaxle from engine, referring to “Manual Transaxle Unit Dismounting and
Remounting in Section 5B” or “Automatic Transaxle
Unit Dismounting and Re mounting in Section 5A”.
27) For M/T model, remove clutch cover and clutch disk referring to “Clutch Cover, Clutch Disc and Flywheel
Removal and Installa tion in Section 5C”.
Installation 1) For M/T model, install clutch cover and clutch disk referring to “Clutch Cover, Clutch Disc and Flywheel
Removal and Installa tion in Section 5C”.
2) Connect transaxle to engine referring to “Manual Transaxle Unit Dismounting and Remounting in
Section 5B” or “Automatic Transaxle Unit
Dismounting and Remounting in Section 5A”.
3) Lift engine and transaxle into engine compartment with jack.
4) Install engine left mounting bracket nuts (1) and engine right mounting nuts (2).Tighten these nuts to
specified torque.
Tightening torque
Engine left mounting bracket nut (a): 55 N·m (5.5
kgf-m, 40.0 lb-ft)
Engine right mounting nut (b): 65 N·m (6.5 kgf-
m, 47.0 lb-ft) 5) Support engine assemble by using chain hoist.
6) Install engine rear mounting to engine rear
mountingNo.1 bracket.
Tightening torque
Engine rear mounting bush bolt: 55 N·m (5.5
kgf-m, 40.0 lb-ft)
7) Install suspension frame referring to “Front Suspension Frame, Stabiliz er Bar and/or Bushings
Removal and Installati on in Section 2B”.
8) Remove chain hoist.
9) Install exhaust No.1, No.2 and center pipes referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
10) Connect drive shaft joints referring to “Front Drive Shaft Assembly Removal and Installation in Section
3A”.
11) Reverse disconnected hoses, cables and electric wires for connection noting the followings.
• Tighten nuts to specified torque.
Tightening torque
Starting motor terminal nut: 11 N·m (1.1 kgf-m,
8.0 lb-ft)
Generator terminal nut: 6 N·m (0.6 kgf-m, 4.5 lb-
ft)
Intake manifold ground terminal bolt: 11 N·m (
1.1 kgf-m, 18.0 lb-ft)
12) Install intake manifold rear stiffener to intake
manifold and cylinder block.
13) Install air cleaner assembly referring to “Air Cleaner Components”.
14) Install cowl top referring to “Cowl Top Components in
Section 9K”.
I4RS0A140009-01
1, (a)
2, (b)
I4RS0A140010-01