precautions on fuel SUZUKI SWIFT 2006 2.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine Aux. Emission Control Devices: 1B-2
EVAP Canister Purge Valve and Its Circuit
Inspection
S7RS0B1206002
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) Prepare to operate EVAP canister purge valve as follows.
a) When using SUZUKI scan tool:
i) Connect SUZUKI scan tool to DLC (1) with ignition switch turned OFF and disconnect
purge valve vacuum hoses from intake
manifold and EVAP canister.
ii) Turn ON ignition switch, clear DTC and select “MISC TEST” mode on SUZUKI scan
tool.
Special tool
(A): SUZUKI scan tool b) When not using SUZUKI scan tool:
NOTE
Before performed this check, be sure to read
the “Precautions of ECM Circuit Inspection in
Section 1A”.

i) Disconnect purge valve vacuum hoses from
intake manifold and EVAP canister.
ii) Remove ECM from it s bracket referring to
“ECM Removal and Inst allation in Section
1C”.
iii) Connect special tool between ECM and ECM connector referring to “Inspection of ECM
and Its Circuits in Section 1A”
iv) Turn ON ignition switch. Using service wire, ground “C37-29” terminal
circuit of special tool (valve ON: “B”) and
unground it (valve OFF: “A”).
2) Check purge valve for operation and vacuum passage for clog when valve is switched ON and
OFF by using SUZUKI scan tool or service wire.
If check result is not satisfactory, check vacuum
hoses, EVAP canister purge valve, wire harness and
connections.
EVAP canister purge valve specification
[A] Valve OFF: When vacuum (–60 kPa (–8.7 psi))
is applied to hose (1), vacuum can be applied.
[B] Valve ON: When vacuum is applied to hose
(1), vacuum can not be applied.
Special tool
(A): 09917–47011
(A)
1
I4RS0B120003-03
“C37-29”“A”
“B”
I4RS0B120006-02
[A] [B]
1
(A)1
(A)
I3RB0A120005-02

Downloaded from www.Manualslib.com manuals search engine 1G-1 Fuel System:
Engine
Fuel System
Precautions
Precautions on Fuel System ServiceS7RS0B1700001
WARNING!
Before attempting service of any type on fuel system, the following should be always observed in
order to reduce the risk of fire and personal injury.
• Disconnect negative cable at battery.
• Do not smoke, and place no smoking signs near work area.
• Be sure to have CO
2 fire extinguisher handy.
• Be sure to perform work in a well-ventilated area and away from any open flames (such as gas hot heater).
• Wear safety glasses.
• To relieve fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then
reinstall it.
• As fuel feed line is still under high fuel pr essure even after stopping engine, loosening or
disconnecting fuel feed line directly may cause dangerous spout of fuel. Before loosening or
disconnecting fuel feed line, make sure to relieve fuel pressure referring to “Fuel Pressure Relief
Procedure”.
• A small amount of fuel may be released when the fuel line is disconnected. In order to reduce the risk of personal injury, cover a shop cloth to the fitting to be disconnected. Be sure to put that cloth
in an approved container after disconnecting.
• Never run engine with fuel pump relay disconnected when engine and exhaust system are hot.
• Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each hose correctly referring to “Fuel Hose Disconnecting and Reconnecting”.
After connecting, make sure that it has no twist or kink.
• When installing inje ctor or fuel feed pipe, lubr icate its O-ring with gasoline.

General Description
Fuel System DescriptionS7RS0B1701001
CAUTION!
This engine requires the unleaded fuel only.
The leaded and/or low lead fuel can result in
engine damage and reduce the effectiveness
of the emission control system.

The main components of the fuel system are fuel tank,
fuel pump assembly (with fuel filter, fuel level gauge, fuel
pressure regulator, fuel feed line and fuel vapor line.
For the details of fuel flow, refer to “Fuel Delivery System
Diagram”.
Fuel Delivery System DescriptionS7RS0B1701002
The fuel delivery system consists of the fuel tank, fuel
pump assembly (with built-in f uel filter and fuel pressure
regulator), delivery pipe, injectors and fuel feed line.
The fuel in the fuel tank is pumped up by the fuel pump,
sent into delivery pipe and injected by the injectors.
As the fuel pump assembly is equipped with built-in fuel
filter and fuel pressure regulator, the fuel is filtered and
its pressure is regulated before being sent to the feed
pipe.
The excess fuel at fuel pressure regulation process is
returned back into the fuel tank.
Also, fuel vapor generated in fuel tank is led through the
fuel vapor line into the EVAP canister.
For system diagram, refer to “Fuel Delivery System
Diagram”.

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Fuel Pump DescriptionS7RS0B1701003
The fuel pump (1) is an in-tank type electric pump.
Incorporated in the pump assembly are;
a fuel filter (2) and a fuel pressure regulator (3) are
included and a fuel level gauge (4) is attached.
Addition of the fuel pressure regulator to the fuel pump
makes it possible to mainta in the fuel pressure at
constant level and ECM controls compensation for
variation in the intake manifold pressure.
Schematic and Routing Diagram
Fuel Delivery System DiagramS7RS0B1702001
Diagnostic Information and Procedures
Fuel Pressure InspectionS7RS0B1704001
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.

1) Relieve fuel pressure in fuel feed line referring to
“Fuel Pressure Relief Procedure”.
2) Disconnect fuel feed hose from fuel delivery pipe.
3) Connect special tools and hose between fuel feed hose (1) and fuel delivery pipe as shown in figure,
and clamp hoses securely in order to ensure that no
leaks occur during checking.
Special tool
(A): 09912–58442
(B): 09912–58432
(C): 09912–58490
1
3
2
4
I6RS0C170001-01
4
6 7
8
12
2 3
11
10
5
1
9
I6RS0C170002-01
1. Fuel tank
5. Fuel injector9. EVAP canister
2. Fuel pump 6. Fuel feed line10. Fuel filter
3. Fuel pressure regulator 7. Fuel vapor line 11. Main fuel level sensor
4. Delivery pipe 8. Intake manifold12. EVAP canister purge valve
1
(C) (B)
(A)
I3RM0A170004-01

Downloaded from www.Manualslib.com manuals search engine 1G-5 Fuel System:
Fuel Hose Disconnecting and ReconnectingS7RS0B1706002
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.

Be sure to connect and clamp each hose correctly as shown in figure.
For Connection Other Than Quick Joint
Clamp around fuel tank
NOTE
Be sure to install hose to spool of pipe surely.

I6RS0C170004-01
1. Pipe “a” 3 – 7 mm (0.12 – 0.28 in.)“e” 38 mm (1.50 in.)
2. Hose “b” 5 – 12 mm (0.20 – 0.48 in.): 2 N⋅m (0.2 kgf-m, 1.5 lb-ft)
3. Clamp “c” 33 mm (1.30 in.)
4. Fuel filler hose clamp screw “d” 30 mm (1.18 in.)

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

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Installation1) Install clamps to marked location on pipes. If clamp is deformed, its claw is bent or broken, replace it with
new one.
2) Install pipes with pipe clamps to vehicle.
3) Connect fuel hoses and pipes to each pipe referring to “Fuel Hose Disconnecting and Reconnecting”.
4) Connect negative cable at battery.
5) With engine OFF, turn igniti on switch to ON position
and check for fuel leaks.
Fuel Injector On-Vehicle InspectionS7RS0B1706007
1) Using sound scope (1) or such, check operating sound of injector (2) when engine is running or
cranking.
Cycle of operating sound should vary according to
engine speed.
If no sound or an unusual sound is heard, check
injector circuit (wire or coupler) or injector.
2) Disconnect connector (1) from injector, connect ohmmeter between terminals of injector and check
resistance.
If resistance is out of specification, replace.
Resistance of fuel injector
11.3 – 13.8 Ω at 20 °C, 68 °F
3) Connect connector to injector securely.
Fuel Injector Removal and InstallationS7RS0B1706008
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 according to “Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Disconnect MAF sensor connector, and detach EVAP canister purge valve.
4) Remove air cleaner assembly with air intake pipe.
5) Disconnect fuel injector couplers.
6) Disconnect fuel feed hose from fuel delivery pipe (1).
7) Remove fuel delivery pipe bolts (2).
8) Remove fuel injector(s) (3).
I2RH0B170007-01
I2RH0B170008-01
2
1
3
3
I3RM0A170010-01

Downloaded from www.Manualslib.com manuals search engine 1G-9 Fuel System:
Installation
Reverse removal procedure for installation noting the
following.
• Replace injector O-ring (1) with new one using care not to damage it.
• Check if cushion (2) is scor ed or damaged. If it is,
replace with new one.
• Apply thin coat of fuel to O-rings (1) and then install injectors (3) into delivery pipe (4) and cylinder head.
Make sure that injectors rota te smoothly (6). If not,
probable cause is incorrect installation of O-ring.
Replace O-ring with new one.
• Tighten delivery pipe bolts (5) to specified torque and make sure that inject ors rotate smoothly.
Tightening torque
Fuel delivery pipe bolt (a): 25 N·m (2.5 kgf-m, 18.0
lb-ft)
• After installation, with engine OFF and ignition switch ON, check for fuel leaks around fuel line connection.Fuel Injector InspectionS7RS0B1706009
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.

1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure” if equipped.
2) Disconnect fuel feed hose from delivery pipe.
3) Set special tools as follows.
Special tool
(A): 09912–58421
(B): 09930–88530
(C): 09912–57610
a) Fit washer (1) (inside diameter 13.5 – 14.5 mm (0.532 – 0.570 in.)) to injector (2), and then
install injector to special tool (A).
b) Connect special tool (B) to injector.
c) Install special tool (C) to special tool (A).
d) Connect fuel feed hose to special tool (A).
I3RM0A170011-01
(B)
(A)
(A) (C)
2
1
I6RW0B170014-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-10
4) Install suitable vinyl tube onto injector nozzle to
prevent fuel from splashing out when injecting.
5) Put graduated cylinder under injector.
6) Operate fuel pump and apply fuel pressure to
injector as follows:
a) When using scan tool:
i) Connect scan tool to DLC with ignition switch OFF.
ii) Turn ignition switch ON, clear DTC and select “MISC TEST” mode on scan tool.
iii) Turn fuel pump ON by using scan tool.
Special tool
(A): SUZUKI scan tool
b) When not using scan tool: i) Remove fuel pump relay from connector.
ii) Connect two terminals of relay connector using service wire (1) as shown in figure.
CAUTION!
Check to make sure that connection is made
between correct terminals. Wrong
connection can cause damage to ECM, wire
harness, etc.

iii) Turn ignition switch ON. 7) Apply battery voltage to in
jector (1) for 15 seconds
and measure injected fuel volume with graduated
cylinder. Test each injector two or three times. If not
within specification, replace injector.
Injected fuel volume
43 – 47 cc/15 sec. (1.45/1.51 – 1.58/1.65 US/lmp
oz/15 sec.)
8) Check fuel leakage from injector nozzle. Do not operate injector for this check (but fuel pump should
be at work). If fuel leaks (1) more than the following
specifications, replace.
Fuel leakage
Less than 1 drop/min.
Fuel Filler Cap InspectionS7RS0B1706010
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.

Remove cap (1), and che ck gasket for even filler neck
imprint, and deterioration or any damage. If gasket (2) is
in malcondition, replace cap.
NOTE
If cap requires replacement, only a cap with
the same features should be used. Failure to
use correct cap can result in fire and
personal injury.

(A)I4RS0A170021-01
1
I4RS0A170006-02
I2RH0B170013-01
I2RH01170008-01

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Fuel Tank Inlet Valve Removal and InstallationS7RS0B1706011
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.

Removal1) Remove fuel filler cap.
2) Insert hose of a hand oper ated pump into fuel filler
hose (1) and drain fuel in space “A” as shown in
figure.
CAUTION!
Do not force pump hose into fuel tank, or
pump hose may damage to fuel tank inlet
valve (2).

3) Hoist vehicle, and remove clamp (2) and fuel filler
hose (1) from fuel tank. 4) Remove fuel tank inlet valve (1) using flat head rod
(2) or the like.
CAUTION!
Be careful not to damage fuel tank inlet valve
(1) with flat head rod (2) or the like.

Installation
1) Install fuel tank inlet valve (1) to fuel tank.
2) Install fuel filler hose (1) to fuel tank and secure it
with clamp (2).
For proper installation, refer to “Fuel Hose
Disconnecting and Reconnecting”.
3) Lower vehicle and install fuel filler cap.
IYSQ01170010-01
1
2
I4RS0A170007-01
I6RS0C170007-01
I2RH0B170018-01
1
2
I4RS0A170007-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-12
Fuel Tank Inlet Valve InspectionS7RS0B1706012
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.

Check fuel tank inlet valve for the following.
If any damage or malfunction is found, replace.
•Damage
• Smooth opening and closing
Fuel Tank Removal and InstallationS7RS0B1706013
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.

Removal1) Relieve fuel pressure in fuel feed line according to
“Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Hoist vehicle.
4) Remove exhaust center pipe.
5) Disconnect fuel filler hose and breather hose from
filler neck referring to “Fue l Tank Inlet Valve Removal
and Installation”.
6) Due to absence of fuel tank drain plug, drain fuel tank by pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
CAUTION!
• Do not force pump hose into fuel tank, or pump hose may damage fuel tank inlet
valve.
• Never store fuel in an open container due to possibility of fire or explosion.

7) Disconnect fuel pipe joint and fuel hoses (1) from fuel pipes (2) referring to “Fuel Hose Disconnecting
and Reconnecting”.
8) Support fuel tank (1) with jack (2) and remove its mounting bolts.
9) Lower fuel tank a little as to disconnect wire harness at connector (1) and ground wire (2), then remove
fuel tank.
I2RH0B170019-01
12
I4RS0A170008-01
12
I4RS0A170009-01
1
2
I6RS0C170005-02