timing vvt SUZUKI SWIFT 2005 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine General Information: 0A-2
SAS: Steering Angle Sensor
SDM: Sensing and Diagnostic Module (Air Bag Controller, Air bag Control Module)
SDT: Smart Diagnostic Tester
SFI: Sequential Multipor t Fuel Injection
SOHC: Single Over Head Camshaft
T:
TBI: Throttle Body Fuel Injection (Single-Point Fuel
Injection, SPI)
TCC: Torque Converter Clutch
TCM: Transmission Control Module (A/T Controller, A/T
Control Module)
TDC: Top Dead Center
TP Sensor: Throttle Position Sensor TVV:
Thermal Vacuum Valve (Thermal Vacuum
Switching Valve, TVSV, Bi metal Vacuum Switching
Valve, BVSV)
TWC: Three Way Catalytic Converter (Three Way
Catalyst)
2WD: 2 Wheel Drive
U:
USB: Universal Serial Bus
V:
VIN: Vehicle Identification Number
VSS: Vehicle Speed Sensor
VVT: Variable Valve Timing (Camshaft Position Control)
W:
WU-OC: Warm Up Oxidation Catalytic Converter
WU-TWC: Warm Up Three Way Catalytic Converter
SymbolsS7RS0B0101002
Wire Color SymbolsS7RS0B0101003
Symbol Definition SymbolDefinition
Tightening torque Apply SUZUKI BOND NO. 1216B
99000-31230
Apply oil (engine, transmission, transfer,
differential) Apply SILICONE SEALANT
99000-31120
Apply fluid (brake, power steering or
automatic transmission fluid) Apply SEALING COMPOUND 366E
99000-31090
Apply SUZUKI SUPER GREASE A
99000-25011
Apply SUZUKI SUPER GREASE C
99000-25030 Apply THREAD LOCK 1322
99000-32110
Apply SUZUKI SUPER GREASE E
99000-25050 Apply THREAD LOCK 1333B
99000-32020
Apply SUZUKI SUPER GREASE H
99000-25121 Apply THREAD LOCK 1342
99000-32050
Apply SUZUKI SUPER GREASE I
99000-25210
Apply SUZUKI BOND NO. 1215
99000-31110 Do not reuse
Apply SUZUKI BO ND NO. 1207F
99000-31250 Note on reassembly
Apply SUZUKI BO ND NO. 1217G
99000-31260
Symbol Wire Color SymbolWire Color
B BLK Black O, Or ORN Orange
Bl BLU Blue RRED Red
Br BRN Brown WWHT White
G GRN Green YYEL Yellow
Gr GRY Gray PPNK Pink
Lbl LT BLU Light blueVPPL Violet
Lg LT GRN Light green

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 1A-36 Engine General Information and Diagnosis:
O2S B1 S1 ACT (HEATED OXYGEN SENSOR-1,
ACTIVE / INACTIVE)
This parameter indicates activation condition of HO2S-1.
ACTIVE: Activating
INACTIVE: warming up or at stop
O2S SENSOR B1 S2 (HEATED OXYGEN SENSOR-2,
V)
It indicates output voltage of HO2S-2 installed on
exhaust pipe (post-catalyst). It is used to detect catalyst
deterioration.
O2S B1 S2 ACT (HEATED OXYGEN SENSOR-2,
ACTIVE / INACTIVE)
This parameter indicates acti vation condition of HO2S-2.
ACTIVE: Activating
INACTIVE: warming up or at stop
FUEL SYSTEM (FUEL SYSTEM STATUS)
Air/fuel ratio feedback loop status displayed as one of
the followings.
OPEN: Open-loop has not yet satisfied conditions to go
closed loop.
CLOSED: Closed-loop using oxygen sensor(s) as
feedback for fuel control.
OPEN-DRIVE COND: Open-loop due to driving
conditions (Power enrichment, etc.).
OPEN SYS FAULT: Open-loop due to detected system
fault.
MAP (MANIFOLD ABSOLUTE PRESSURE, in.Hg,
kPa)
This value indicates how much correction is necessary
to keep the air/fuel mixture stoichiometrical.
It is detected by manifold absolute pressure sensor.
BAROMETRIC PRESS (kPa, in.Hg)
This parameter represents a measurement of barometric
air pressure and is used for al titude correction of the fuel
injection quantity and IAC valve control.
STEP EGR FLOW DUTY (%)
This parameter indicates opening rate of EGR valve
which controls the amount of EGR flow.
FUEL CUT (ON/OFF)
ON: Fuel being cut (output signal to injector is stopped)
OFF: Fuel not being cut
A/C PRESSURE (A/C REFRIGERANT ABSOLUTE
PRESSURE, kPa)
This parameter indicates A/C refrigerant absolute
pressure calculated by ECM.
CLOSED THROTTLE PO S (CLOSED THROTTLE
POSITION, ON/OFF)
This parameter reads ON wh en throttle valve is fully
closed, or OFF when it is not fully closed. CANIST PRG DUTY (EVAP CANISTER PURGE FLOW
DUTY, %)
This parameter indicates valve ON (valve open) time
rate within a certain set cycle of EVAP canister purge
valve which controls the amount of EVAP purge.
IGNITION ADVANCE (IGNITION TIMING ADVANCE
FOR NO.1 CYLINDER,
°)
Ignition timing of No.1 cylinder is commanded by ECM.
The actual ignition timing should be checked by using
the timing light.
BATTERY VOLTAGE (V)
This parameter indicates battery positive voltage
inputted from main relay to ECM.
FUEL PUMP (ON/OFF)
ON is displayed when ECM activates the fuel pump via
the fuel pump relay switch.
ELECTRIC LOAD (ON/OFF)
ON: Headlight or small light ON signal inputted.
OFF: Above electric loads all turned OFF.
BRAKE SW (ON/OFF)
This parameter indicates the state of the brake switch.
RADIATOR COOLING FAN (RADIATOR COOLING
FAN CONTROL RELAY, ON/OFF)
ON: Command for radiator cooling fan control relay
operation being output.
OFF: Command for relay operation not being output.
BLOWER FAN (ON/OFF)
This parameter indicates the state of the blower fan
motor switch.
A/C SWITCH (ON/OFF)
ON: Command for A/C operatio n being output from ECM
to HVAC.
OFF: Command for A/C oper ation not being output.
A/C COMP RELAY (A/C COMPRESSOR RELAY, ON/
OFF)
This parameter indicates the state of the A/C switch.
VEHICLE SPEED (km/h, mph)
It is computed based on pulse signals from vehicle
speed sensor.
VVT GAP (TARGET-ACTUAL POSITION, °)
It is calculated using the formula: target valve timing
advance – actual valve timing advance.
TP SENSOR 1 VOLT (THROTTLE POSITION SENSOR
(MAIN) OUTPUT VOLTAGE, V)
The TP sensor (main) reading provides throttle valve
opening information in the form of voltage.

Downloaded from www.Manualslib.com manuals search engine 1A-46 Engine General Information and Diagnosis:
Excessive hydrocarbon
(HC) emission or carbon
monoxide (CO)Faulty spark plug
“Spark Plug Inspection in Section 1H”
Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation
in Section 1H”
Faulty ignition coil with ignitor “Ignition Coil Assembly (Including ignitor)
Inspection in Section 1H”
Low compression “Compression Check in Section 1D”
Lead contamination of three way
catalytic converter Check for absence of f
iller neck restrictor.
Faulty evaporative emission control
system “EVAP Canister Purge Inspection in Section
1B”
Fuel pressure out of specification “Fuel Pressure Check”
Closed loop system (A/F feedback
compensation) fails (Faulty TP sensor,
Poor performance of ECT sensor or
MAF sensor) “Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”, “ECT Sensor
Inspection in Section 1C” or “MAF and IAT
Sensor Inspection in Section 1C”
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly “APP Sensor Assembly Inspection in Section
1C”
Faulty injector(s) “Fuel Injector Circuit Check”
Faulty ECM
Engine not at normal operating
temperature
Clogged air cleaner “Air Cleaner Element Inspection and Cleaning
in Section 1D”
Vacuum leaks “Engine Vacuum Check in Section 1D”
Camshaft position control (VVT) system
out of order “Oil Control Valve Inspection in Section 1D”
Excessive nitrogen
oxides (NOx) emission Improper ignition timing
“Ignition Timing Inspection in Section 1H”
Lead contamination of catalytic
converter Check for absence of f
iller neck restrictor.
Faulty EGR system “EGR System Inspection in Section 1B”
Fuel pressure out of specification “Fuel Pressure Check”
Closed loop system (A/F feedback
compensation) fails (Faulty TP sensor,
Poor performance of ECT sensor or
MAF sensor) “Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”, “ECT Sensor
Inspection in Section 1C” or “MAF and IAT
Sensor Inspection in Section 1C”
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly “APP Sensor Assembly Inspection in Section
1C”
Faulty injector(s) “Fuel Injector Circuit Check”
Faulty ECM
Camshaft position control (VVT) system
out of order “Oil Control Valve Inspection in Section 1D”
Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 1A-52 Engine General Information and Diagnosis:
DTC P0011 / P0012: “A” Camshaft Position - Timing Over-Advanced or System Performance / -
Retarded
S7RS0B1104014
System Description
Actual value of advanced valve timing does not reach target value.
Valve timing is advanced although ECM command is most retarding.
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 tester, on a level road.

NOTE
Check to make sure that the following conditions are satisfied when using this “DTC Confirmation
Procedure”.
• Altitude (barometric pressure): 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)

1) Clear DTC. Refer to “DTC Clearance”.
2) Start engine and drive vehicle under usual driving condition for 5 minutes or longer until engine is warmed up to normal operating temperature.
3) Stop vehicle.
4) Run engine at idle speed for 1 minute.
5) Start vehicle and increase vehicle speed up to 80 km/h (50 mile/h).
6) Keep vehicle speed at 80 km/h (50 mile/h) for 1 minute or longer at 5th gear position or D range.
7) Decrease vehicle speed gradually.
8) Stop vehicle and turn OFF ignition switch.
9) Repeat Step 4) to 7) one time.
10) Stop vehicle. 11) Check DTC and pending DTC. DTC detecting condition
Trouble area
Actual value of advanced valve timing does not reach
target value, or valve timi ng is advanced although ECM
command is most retarding.
(2 driving cycle detection logic) • Oil control valve
• Oil galleries of timing sprocket
• Intake camshaft timing sprocket (Camshaft position
control (VVT) actuator)
• Oil control valve circuit
•ECM

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-53
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 Is DTC P0010 detected together? Go to “DTC P0010: “A”
Camshaft Position
Actuator Circuit”.Go to Step 2.
2 Do you have SUZUKI scan tool? Go to Step 3.Go to Step 5.
3 Camshaft position control check
1) With ignition switch turned OFF, connect SUZUKI scan
tool to DLC.
2) Start engine and warm up to normal operating temperature.
3) Select menu to DATA LIST.
4) Check that “VVT GAP” displayed on SUZUKI scan tool is 0 – 5 °.
Is it OK? Go to Step 4.
Check valve timing
referring to “Timing
Chain and Chain
Tensioner Removal and
Installation in Section
1D”. If OK, go to Step 5.
4 Camshaft position control check
1) Drive vehicle under following conditions.
• Vehicle speed at 80 km/h (50 mile/h).
• Gear position at 5th or D range.
2) Check that “VVT GAP” displayed on SUZUKI scan tool is 0 – 5 °.
Is it OK? Substitute a known-
good ECM and recheck.
Go to Step 5.
5 Oil control circuit visual inspection
1) Remove cylinder head cover referring to “Cylinder Head
Cover Removal and Insta llation in Section 1D”.
2) Check oil pressure leakage from oil control circuit.
Is it in good condition? Go to Step 6.
Repair or replace.
6 Oil control valve and oil gallery pipe check
1) Remove oil control valve re ferring to “Oil Control Valve
Removal and Installation in Section 1D”.
2) Remove oil gallery pipe refe rring to “Timing Chain Cover
Removal and Installation in Section 1D”.
3) Check oil gallery pipe and o il control valve for clog or
sludge.
Are they in good condition? Go to Step 7.
Clean oil control valve
and oil gallery pipe.
Replace oil control valve
if a problem is not
solved after cleaning oil
control valve and oil
gallery pipe.
7 Oil control valve electrical circuit check
1) Check that oil control valve circuit is in good condition
referring to “DTC P0010: “A” Camshaft Position Actuator
Circuit”.
Is circuit in good condition? Go to Step 8.
Repair circuit.
8 Oil control valve check
1) Check oil control valve refe rring to “Oil Control Valve
Inspection in Section 1D”.
Is it in good condition? Replace camshaft
timing sprocket.
Replace oil control
valve.

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-23 Engine Mechanical:
8) Install new O-ring (1) to oil gallery pipes No.2 (2) and
No.3 (3).
9) Install oil gallery pipes No.2 and No.3 to cylinder
head (4) and timing chain cover (5).
Tighten bolts to specified torque.
Tightening torque
Oil gallery pipe No.2 and No.3 bolt (a): 11 N·m (
1.1 kgf-m, 8.0 lb-ft)
10) Install water pump pulley. 11) Install cylinder head cover referring to “Cylinder Head Cover Removal and Installation”.
12) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
13) Install crankshaft pulley (1). Tighten bolt (2) to specified torque. To lock crankshaft pulley, use
special tool with it as shown in figure.
Special tool
(A): 09917–68221
Tightening torque
Crankshaft pulley bolt (a): 150 N·m (15.0 kgf-m,
108.5 lb-ft)
14) Install engine assembly to vehicle referring to “Engine Assembly Removal and Installation”.
Timing Chain Cover InspectionS7RS0B1406014
Oil Seal
Check oil seal lip for fault or other damage. Replace as
necessary. Timing Chain Cover
Inspect strainer (1) of oil passage for driving intake cam
timing sprocket assembly (VVT actuator).
If clog or foreign matter exists, clean strainer.
Oil Control Valve Removal and InstallationS7RS0B1406015
Removal
Remove oil gallery pipe No.1
(1) and oil control valve (2)
from timing chain cover (3).
Installation
1) Install new O-ring (4) to oil control valve.
2) Install oil control valve to timing chain cover. Tighten nuts to specification.
Tightening torque
Oil control valve mounting nut (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
3) Install oil gallery pipe No .1 with new copper washers
(5) to timing chain cover.
Tighten bolts to specification.
Tightening torque
Oil gallery pipe No.1 bolt (b): 30 N·m (3.0 kgf-m,
21.5 lb-ft)
(a)
(a) 1
2
3
4
5
I3RH0B140027-01
I2RH0B140056-01
1
I3RH0B140028-01
1
5
(b) 3
(a)
2 4
5
I3RM0A140027-01