Fuel fuse SUZUKI SWIFT 2006 2.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-201
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 referri ng to “Inspection of ECM and Its Circuits”.

StepAction YesNo
1 Fuel pump control system check for operation
Is fuel pump heard to operate 2 sec. after ignition switch is
turned ON? Fuel pump circuit is in
good condition.
Go to Step 2.
2 Fuel pump relay po wer supply check
1) Disconnect fuel pump relay from individual circuit fuse box No.1 with ignition switch turned OFF.
2) Check for proper connection to fuel pump relay at each terminal.
3) If OK, turn ON ignition switch, measure voltage between “BLK/WHT” wire terminal of fuel pump relay connector
and engine ground.
Is voltage 10 – 14 V? Go to Step 3.
“BLK/WHT” wire is open
or shorted to ground
circuit.
3 Fuel pump relay po wer supply check
1) Turn ON ignition switch, measure voltage between “BLK/ RED” wire terminal of fuel pump relay connector and
engine ground.
Is voltage 10 – 14 V? Go to Step 4.
“BLK/RED” wire is open
circuit.
4 Fuel pump relay check
1) Check fuel pump relay referring to “Main Relay, Fuel
Pump Relay and Starting Moto r Control Relay Inspection
in Section 1C”.
Is relay in good condition? Go to Step 5.
Faulty relay.
5 Fuel pump relay drive signal check
1) Connect fuel pump relay to individual circuit fuse box
No.1.
2) Connect voltmeter between “E23-15” terminal of ECM connector and vehicle body ground.
3) Measure voltage 2 second after ignition switch is turned ON.
Is voltage 10 – 14 V? Go to Step 6.
“GRN/WHT” wire is
open circuit or shorted
to ground circuit.
I2RH01110132-01

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

Downloaded from www.Manualslib.com manuals search engine 1D-17 Engine Mechanical:
Engine Assembly Removal and InstallationS7RS0B1406011
NOTE
After replacing electric throttle body
assembly, perform calibration of throttle
valve referring to “Electric Throttle Body
System Calibration in Section 1C”.

Removal1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure in Section 1G”.
2) Disconnect negative and pos itive cable at battery.
3) Remove battery and tray.
4) Remove engine hood after disconnecting windshield washer hose.
5) Remove right and left side engine under covers.
6) Remove A/C compressor belt by referring to “Compressor Drive Belt Remo val and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
7) Drain engine oil, transaxle oil and coolant.
8) Remove cowl top plate referring to “Cowl Top Components in Section 9K”.
9) Remove air cleaner assembly referring to “Air Cleaner Components”.
10) With hose connected, detach A/C compressor from its bracket (A/C model) referring to “Compressor
Assembly Removal and Installation in Section 7B” or
“Compressor Assembly Removal and Installation in
Section 7B”.
CAUTION!
Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

11) Remove intake manifold rear stiffener (1) from intake manifold and cylinder block. 12) Disconnect the following electric wires:
• MAP sensor (1)
• ECT sensor (2)
•EGR valve (3)
• CMP sensor (4)
• Electric throttle body assembly (5)
• Ignition coil assembly (6)
• Injectors (7)
• Heated oxygen sensor No. 2 (8) and No. 1 (9)
• Oil control valve (10)
• Engine oil pressure switch (11)
• CKP sensor (12)
• Knock sensor (13)
• Back up light switch (14)
• Generator (15)
• Starting motor (16)
• Ground terminal (17) from intake manifold
• Battery ground terminal (18) from exhaust manifold
• Battery ground cable (19) from transaxle
• Magnet clutch switch of A/C compressor (A/C model)
• Each wire harness clamps
• Output shaft speed sensor (VSS) (34) (A/T model)
• Solenoid valve (33) (A/T model)
• Transmission range sensor (32) (A/T model)
• Input shaft speed sensor (31) (A/T model)
13) Remove fuse box from its bracket.
14) Disconnect the following cables: • Gear select control cable (23) (M/T model)
• Gear shift control cable (24) (M/T model)
• A/T select cable (A/T model)
15) Disconnect the following hoses: • Brake booster hose (26) from intake manifold
• Radiator inlet and outlet hoses (20) from each pipe
• Heater inlet and outlet hoses (21) from each pipe
• Fuel feed hoses (22) from fuel feed pipe
• EVAP canister purge valve hose (30) from purge pipe
• A/T fluid cooler hoses (A/T model)
16) With hose connected, detach clutch operating cylinder (25). (M/T model)
CAUTION!
Suspend removed clutch operating cylinder
at a place where no damage will be caused
during removal and installation of engine
assembly.

1
I6RS0B141014-01

Downloaded from www.Manualslib.com manuals search engine 1G-7 Fuel System:
Fuel Pressure Relief ProcedureS7RS0B1706003
CAUTION!
This work must not be done when engine is
hot. If done so, it may cause adverse effect to
catalyst.

NOTE
If ECM detects DTC(s) after servicing, clear
DTC(s) referring to “DTC Clearance in
Section 1A”.

1) Make sure that engine is cold.
2) Shift transaxle gear shift lever in “Neutral” (shift select lever in “P” range for A/T model), set parking
brake and block drive wheels.
3) Remove relay / fuse box cover.
4) Disconnect fuel pump relay (1) from relay / fuse box (2).
5) Remove fuel filter cap in order to release fuel vapor pressure in fuel tank, and then reinstall it.
6) Start engine and run it until engine stops for lack of fuel. Repeat cranking engine 2 – 3 times for about 3
seconds each time in order to dissipate fuel pressure
in lines. Fuel connections are now safe for servicing.
7) After servicing, connect fuel pump relay (1) to relay / fuse box and install re lay / fuse box cover.
Fuel Leakage Check ProcedureS7RS0B1706004
After performing any service on fuel system, check to
make sure that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump) and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply
fuel pressure to fuel line until fuel pressure is felt by
hand placed on fuel feed hose.
2) In this state, check to see that there are no fuel leakages from any part of fuel system.
Fuel Lines On-Vehicle InspectionS7RS0B1706005
CAUTION!
Due to the fact that fuel feed line (1) is under
high pressure, use special care when
servicing it.

Visually inspect fuel lines for evidence of fuel leakage,
hose crack and deterioration or damage.
Make sure all cl amps are secure.
Replace parts as needed.
Fuel Pipe Removal and InstallationS7RS0B1706006
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.

Removal
1) Relieve fuel pressure in fuel feed line according to “Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Disconnect fuel pipe joint and fuel hose (3) from fuel pipe (2) at the front and rear of each fuel pipe
referring to “Fuel Hose Disconnecting and
Reconnecting”.
4) Mark the location of clamps (1) on fuel pipes (2), so that the clamps can be reinstalled to where they
were.
5) Remove pipes (2) with clamp (1) from vehicle.
6) Remove clamp (1) from pipes (2).
1
I4RS0A170004-01
1
I4RS0A170005-01
2
13
I4RS0A170020-01

Downloaded from www.Manualslib.com manuals search engine 1H-4 Ignition System:
Diagnostic Information and Procedures
Ignition System Symptom DiagnosisS7RS0B1804001
Reference Waveform of Ignition SystemS7RS0B1804002
Refer to “Reference waveform No.5”, “Reference waveform No.6” and “Reference waveform No.7” under “Inspection
of ECM and Its Circuits in Section 1A” for waveform of Ignition trigger signal.
Ignition System CheckS7RS0B1804003
Condition Possible cause Correction / Reference Item
Engine cranks, but will
not start or hard to start
(No spark) Blown fuse for ignition coil
Replace.
Loose connection or disconnection of
lead wire or high-tension cord(s) Connect securely.
Faulty high-tension cord(s) Replace.
Faulty spark plug(s) Replace.
Faulty ignition coil Replace ignition coil assembly.
Faulty CKP sensor or CKP sensor plate Clean, tighten or replace.
Faulty CMP sensor or sensor rotor tooth
of camshaft Clean, tighten or replace.
Faulty ECM Replace.
Poor fuel economy or
engine performance Incorrect ignition timing
Check related sensors and CKP sensor plate.
Faulty spark plug(s) or high-tension
cord(s) Adjust, clean or replace.
Faulty ignition coil assembly Replace.
Faulty CKP sensor or CKP sensor plate Clean, tighten or replace.
Faulty CMP sensor or sensor rotor tooth
of camshaft Clean, tighten or replace.
Faulty knock sensor Replace.
Faulty ECM Replace.
StepAction YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check in
Section 1A”.
2 Ignition spark test
1) Check all spark plugs for condition and type referring to
“Spark Plug Inspection”.
2) If OK, perform ignition spark test referring to “Ignition Spar k Tes t”.
Is spark emitted from all spark plugs? Go to Step 13. Go to Step 3.
3 DTC check
1) Perform DTC check referring to “DTC Check in Section
1A”.
Is DTC stored in ECM? Go to applicable DTC
diag. flow.
Go to Step 4.
4 Electrical connection check
1) Check ignition coil assemblies and high-tension cords
for electrical connection.
Are they connected securely? Go to Step 5.
Connect securely.
5 High-tension cords check
1) Check high-tension cord for resistance referring to
“High-Tension Cord Inspection”.
Is check result satisfactory? Go to Step 6.
Replace high-tension
cord(s).

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-2
ConditionPossible cause Correction / Reference Item
Motor not running (No
operating sound of
magnetic switch) Shift lever switch is not in P or N, or not
adjusted (A/T)
Shift in P or N, or
adjust switch. (A/T)
Battery run down Recharge battery.
Battery voltage too low due to battery
deterioration Replace battery.
Poor contact in battery terminal
connection Retighten or replace.
Loose grounding cable connection Retighten.
Fuse set loose or blown off Tighten or replace.
Poor contacting action of ignition switch
and magnetic switch Replace.
Lead wire coupler loose in place Retighten.
Open-circuit between ignition switch and
magnetic switch Repair.
Open-circuit in pull-in coil Replace magnetic switch.
Brushes are seating poorly or worn
down Repair or replace.
Poor sliding of plunger and/or pinion Repair.
Faulty starting motor control relay “Main Relay, Fuel Pump Relay and Starting
Motor Control Relay Inspection in Section 1C”.
Faulty ECM and its circuit “Inspection of ECM and Its Circuits in Section
1A”.
Motor not running
(Operating sound of
magnetic switch heard) Battery run down
Recharge battery.
Battery voltage too low due to battery
deterioration Replace battery.
Loose battery cable connections Retighten.
Burnt main contact point, or poor
contacting action of magnetic switch Replace magnetic switch.
Brushes are seating poorly or worn
down Repair or replace.
Weakened brush spring Replace.
Burnt commutator Replace armature.
Layer short-circuit of armature Replace.
Crankshaft rotation obstructed Repair.
Starting motor running
but too slow (small
torque) (If battery and
wiring are satisfactory,
inspect starting motor) Insufficient contact
of magnetic switch
main contacts Replace magnetic switch.
Layer short-circuit of armature Replace.
Disconnected, burnt or worn
commutator Repair commutator or replace armature.
Worn brushes Replace brush.
Weakened brush springs Replace spring.
Burnt or abnormally worn end bush Replace bush.
Starting motor running,
but not cranking engine Worn pinion tip
Replace over-running clutch.
Poor sliding of over-running clutch Repair.
Over-running clutch slipping Replace over-running clutch.
Worn teeth of ring gear Replace flywheel (M/T) or drive plate (A/T).
Noise Abnormally worn bush Replace bush.
Worn pinion or worn teeth of ring gear Replace over-running clutch, flywheel (M/T) or
drive plate (A/T).
Poor sliding of pinion (failure in return
movement) Repair or replace.
Worn internal or planetary gear teeth Replace.
Lack of oil in each part Lubricate.
Starting motor does not
stop running Fused contact points of magnetic switch
Replace magnetic switch.
Short-circuit between turns of magnetic
switch coil (layer short-circuit) Replace magnetic switch.
Failure of returning action in ignition
switch Replace.

Downloaded from www.Manualslib.com manuals search engine 9A-11 Wiring Systems:
C: Engine harnessNo./Color Connective position No./Color Connective positionC01/GRY IAC valve C22/- Generator #2
C02/GRY IG Coil #1 C23/BLK Starting motor #1
C03/GRY IG Coil #2 C24/- Starting motor #2
C04/GRY Fuel injector #1 C25/GR Y VSS (Vehicle speed sensor)
C05/GRY Fuel injector #2 C26/GRY Knock sensor
C06/GRY Fuel injector #3 C27/BLU (A/
T) Input shaft speed sensor
C07/GRY Fuel injector #4 C28/GRY
(A/T) Trans axle range sensor
C08/BLK or GRY CMP sensor C29/GRY
(A/T) Shift solenoid
C09/BLK ECT sensor C30/BLK
(M/T) Back-up light switch
C10/GRY EGR stepper motor C31/- Main fuse box C11/BLK Throttle position sensor C32/GRY
(IF EQPD) Current sensor
C12/BLK MAP sensor C33/- Main fuse box
C13/BLK MAF sensor C34/N (A/T) TCM
C14/BLK EVAP canister purge valve C35/N (A/T) TCM
C15/GRY Heated oxygen sensor #1 C36/N Main harness (To E24)
C16/GRN Heated oxygen sensor #2 C37/GRY ECM C17/BLK A/C compressor C38/- Weld splice C18/N Oil pressure switch C39/- Weld splice
C19/BLU VVT solenoid C40/- Weld splice
C20/GRY CKP sensor C41/- Weld splice
C21/GRY or BLK Generator #1

Downloaded from www.Manualslib.com manuals search engine 9A-13 Wiring Systems:
C: Engine harness
D: Oil pressure switch wireNo./Color Connective position No./Color Connective position
C02/GRY IG Coil #1 C24/- Starting motor #2
C03/GRY IG Coil #2 C23/BLK Starting motor #1
C04/GRY Fuel injector #1 C25/GRY
(A/T) VSS (Vehicle speed sensor)
C05/GRY Fuel injector #2 C26/GRY Knock shaft speed sensor
C06/GRY Fuel injector #3 C27/BLU (A/
T) Input shaft speed sensor
C07/GRY Fuel injector #4 C28/GRY
(A/T) Trans axle range sensor
C08/BLK CMP sensor C29/GRY
(A/T) Shift solenoid
C09/BLK ECT sensor C30/BLK
(M/T) Back-up light switch
C10/GRY EGR stepper motor C31/- Main fuse box C12/BLK MAP sensor C32/GRY Current sensor
C13/BLK MAF sensor C33/- Main fuse box
C14/BLK EVAP canister purge valve C34/N (A/T) TCM
C15/BLK Heated oxygen sensor #1 C35/N (A/T) TCM
C16/GRN Heated oxygen sensor #2 C36/N Main harness (To E24) C17/BLK A/C compressor C37/GRY ECM C18/N Oil pressure switch wire (To D02) C38/- Weld splice
C19/BLU VVT solenoid C39/- Weld splice
C20/GRY CKP sensor C40/- Weld splice C21/BLK Generator #1 C42/BLK Electric throttle body C22/- Generator #2
No./Color Connective position No./ColorConnective position
D01/N Oil pressure switch D02/GRY Engine harness (To C18)

Downloaded from www.Manualslib.com manuals search engine Wiring Systems: 9A-14
E: Main harness (RHD)
E: Main harness
56
E06E12
E03or
E85
E07
E09
E08
E13
E10
E11E05 E04
E01 E02
E19
7
22
E34E31
E32
E57
E24
(TO C36)
E33
E36
E35
E30
E29
E28
E20
E21
E22
E27
E26
E23
E25E17E56
E18
E14 E15
E55
E
I7RS0B910902-02
No./Color
Connective position No./ColorConnective position
E01/GRY Windshield wiper motor E22/N Front position light (L)
E02/GRY Brake fluid level switch E23/GRY ECM
E03/BLK ABS control module E24/N Engine Harness (To C36)
E04/BLK A/C pressure sensor E25/BLK Wheel speed sensor (FL)
E05/BLK Wheel speed sensor (FR) E26/N Main fuse box
E06/N Side turn signal light (R) E27/BLK Main fuse box
E07/N Front position light (R) E28/BLK Radiator fan relay #1
E08/BLK Head light (R) E29/BLK Radiator fan relay #2
E09/GRY Front turn signal light (R) E30/BLK Radiator fan relay #3
E10/GRN Rear washer motor E31/BLK Starting motor relay
E11/BLU Windshield washer motor E32/BLK Main relay
E12/BLK (IF EQPD) Front fog light (R)
E33/BLK A/T relay
E13/YEL Forward sensor E34/BLK (IF
EQPD) Front fog light relay
E14/BLK Outside air temperature sensor E35/BLK Fuel pump relay
E15/BLK Horn E36/BLK A/C compressor relay
E17/BLK Radiator fan motor E55/- Weld splice
E18/BLK (IF EQPD) Front fog light (L) E56/BLK
(M16A
engine) Throttle actuator control relay
E19/N Side turn signal light (L) E57/BLK Diagnosis connector #1
E20/GRY Front turn signal light (L) E85/BLK (IF
EQPD) ESP
® control module
E21/BLK Headlight (R)

Downloaded from www.Manualslib.com manuals search engine 9A-15 Wiring Systems:
E: Main harness (LHD)
E: Main harness
56
E06E12
E
E03
E07
E09
E59E08
E13
E10
E11E05 E04
E01
E02E197
E34
E31
E32
E24
(TO C36)
E33
E36
E35
E30
E29
E28
E20
E21
E22
E58
E27
E26
E23
E25E17
E18
E14 E15
E55
I7RS0B910903-02
No./Color
Connective position No./ColorConnective position
E01/GRY Windshield wiper motor E21/BLK Headlight (R)
E02/BRN Brake fluid level switch E22/N Front position light (L)
E03/BLK ABS control module E23/GRY ECM
E04/BLK A/C pressure sensor E24/N Engine Harness (To C36)
E05/BLK Wheel speed sensor (FR) E25/BLK Wheel speed sensor (FL)
E06/N Side turn signal light (R) E26/N Main fuse box
E07/N Front position light (R) E27/BLK Main fuse box
E08/BLK Head light (R) E28/BLK Radiator fan relay #1
E09/GRY Front turn signal light (R) E29/BLK Radiator fan relay #2
E10/GRN Rear washer motor E30/BLK Radiator fan relay #3
E11/BLU Windshield washer motor E31/BLK Starting motor relay
E12/BLK (IF EQPD) Front fog light (R)
E32/BLK Main relay
E13/YEL Forward sensor E33/BLK A/T relay
E14/BLK Outside air temperature sensor E34/BLK (IF
EQPD) Front fog light relay
E15/BLK Horn E35/BLK Fuel pump relay
E17/BLK Radiator fan motor E36/BLK A/C compressor relay
E18/BLK (IF
EQPD) Front fog light (L)
E55/- Weld splice
E19/N Side turn signal light (L) E58/GRY (IF
EQPD) Headlight beam leveling actuator (L)
E20/GRY Front turn signal light (L) E59/GRY (IF
EQPD) Headlight beam leveling actuator (R)