eco SUZUKI SWIFT 2006 2.G Service Manual Online

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-1
Engine
Ignition System
General Description
Ignition System ConstructionS7RS0B1801001
The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below.
• ECM
It detects the engine and vehicle conditions through the si gnals from the sensors, determines the most suitable
ignition timing and time for electricity to flow to the primar y coil and sends a signal to the ignitor (power unit) in the
ignition coil assembly.
• Ignition coil assembly (including an ignitor)
The ignition coil assembly has a built -in ignitor which turns ON and OFF the current flow to the primary coil
according to the signal from ECM. When the current flow to the primary coil is turned OFF, a high voltage is induced
in the secondary coil.
• High-tension cords and spark plugs
• CMP sensor (Camshaft position sensor) and CKP sensor (Crankshaft position sensor)
Using signals from these sensors, ECM identifies the specific cylinder whose piston is in the compression stroke,
detects the crank angle and adjusts in itial ignition timing automatically.
• TP sensor, ECT sensor, MAP sensor, MAF sensor, IAT sensor, knock sensor and other sensors / switches
Although this ignition system does not have a distributor, it has two ignition coil assemblies (one is for No.1 and No.4
spark plugs and the other is for No.2 and No.3 spark plugs). W hen an ignition signal is sent from ECM to the ignitor in
the ignition coil assembly for No.1 and No.4 spark plugs, a high voltage is induced in the secondary coil and that
passes through the high-tension cords and causes No.1 and No.4 spark plugs to spark simultaneously. Likewise,
when an ignition signal is sent to the ignitor in the ot her ignition coil assembly, No.2 and No.3 spark plugs spark
simultaneously.

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 1H-6 Ignition System:
Ignition Spark TestS7RS0B1804004
1) Remove air cleaner assembly with air intake pipe.
2) Disconnect all injector couplers from injectors.
WARNING!
Without disconnection of injector couplers,
combustible gas may come out from spark
plug holes during this test and may get
ignited in engine room.

3) Remove spark plug and check it for condition and
type referring to “Spark Plug Inspection”.
4) If OK, connect ignition coil coupler to ignition coil assembly and connect spark plug to ignition coil
assembly or high-tension cord. Ground spark plug. 5) Crank engine and check if each spark plug sparks.
6) If no spark is emitted, inspect the related parts as
described in “Ignition System Symptom Diagnosis”.
Repair Instructions
High-Tension Cord Removal and InstallationS7RS0B1806001
Removal
1) Remove air cleaner assembly with air intake pipe and cylinder head upper cover.
2) Disconnect No.1 cylinder (2) and No.3 cylinder (3)
high-tension cords from ignition coil assemblies (1)
while gripping each cap.
3) Pull out high-tension cords from spark plugs while gripping each cap.
CAUTION!
• Removal of high-tension cords together with clamps will be recommended so as
not to damage their inside wire (resistive
conductor).
• For the same reason, pull out each connection by gripping cap portion.

Installation
1) Install No.1 cylinder (2) and No.3 cylinder (3) high-
tension cords to spark plugs and ignition coil
assemblies (1) while gripping each cap.
CAUTION!
• Never attempt to use metal conductor high-tension cords as replacing parts.
• Insert each cap portion fully when installing high-tension cords.

I4RS0A180006-01
I4RS0A180003-01
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Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-7
High-Tension Cord InspectionS7RS0B1806002
Measure resistance of high-tension cord (1) by using
ohmmeter.
If resistance exceeds specification, replace high-tension
cord(s).
High-tension cord resistance
No.1 cylinder high-tension cord resistance: 1.4 – 4.0
k Ω
No.3 cylinder high-tension cord resistance: 0.6 – 2.0
k Ω
Spark Plug Removal and InstallationS7RS0B1806003
Removal
1) Remove air cleaner assembly with air intake pipe and cylinder head upper cover.
2) Pull out high-tension cords by gripping their caps and then remove ignition coil assemblies referring to
“Ignition Coil Assembly (Inc luding ignitor) Removal
and Installation”.
3) Remove spark plugs.
Installation 1) Install spark plugs and tighten them to specified torque.
Tightening torque
Spark plug: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
2) Install ignition coil assemblies referring to “Ignition Coil Assembly (Including ignitor) Removal and
Installation”.
3) Install high-tension cords securely by gripping their caps.
4) Install cylinder head upper cover and air cleaner assembly with air intake pipe.
Spark Plug InspectionS7RS0B1806004
CAUTION!
• When servicing the iridium / platinum
spark plugs (slender center electrode type
plugs), do not touch the center electrode
to avoid damage to it. The electrode is not
strong enough against mechanical force
as it is slender and its material is not
mechanically tough.
• Do not clean or adjust gap for the iridium / platinum spark plugs.

Inspect spark plug for:
• Electrode wear
• Carbon deposits
• Insulator damage
If any abnormality is found for nickel spark plugs, adjust
air gap, clean with spark plug cleaner or replace them
with specified new plugs.
For iridium / platinum spark plugs, replace them with
new plugs.
Spark plug air gap
“a”
: 1.0 – 1.1 mm (0.040 – 0.043 in.)
Spark plug type
NGK: IFR6J11 (Iridium)
NOTE
NGK IFR6J11 is highly recommended for
better engine starting performance under –25
°C (–13 °F).

I2RH0B180005-01
IYSQ01181012-01

Downloaded from www.Manualslib.com manuals search engine 1H-8 Ignition System:
Ignition Coil Assembly (Including ignitor)
Removal and Installation
S7RS0B1806005
Removal1) Disconnect negative (–) cable at battery.
2) Remove air cleaner assembly with air intake pipe and cylinder head upper cover.
3) Disconnect ignition coil coupler.
4) Disconnect high-tension cord (3) from ignition coil assembly (2).
5) Remove ignition coil bolts (1) and then pull out ignition coil assembly.
Installation 1) Install ignition coil assembly (2).
2) Tighten ignition coil bolts (1) to specified torque, and then connect igni tion coil coupler.
Tightening torque
Ignition coil bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
3) Install high-tension cord (3) to ignition coil assembly while gripping its cap.
4) Install cylinder head upper cover and air cleaner assembly with air intake pipe.
5) Connect negative (–) cable to battery.
Ignition Coil Assembly (Including ignitor)
Inspection
S7RS0B1806006
Measure secondary coil for resistance.
If resistance is out of specification, replace ignition coil
assembly.
Secondary coil resistance
7.5 – 10.3 k Ω at 20 °C, 68 ° F
Ignition Timing InspectionS7RS0B1806007
NOTE
• Ignition timing is not adjustable. If ignition
timing is out of specification, check
system related parts.
• Before starting engine, place transmission gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T model), and set
parking brake.

1) Connect scan tool to DLC (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
2) Start engine and warm it up to normal operating temperature.
3) Make sure that all of electrical loads except ignition are switched off.
4) Check to be sure that idle speed is within specification referring to “Idle Speed and IAC
Throttle Valve Opening Inspection in Section 1A”
5) Fix ignition timing by using “Fixed Spark” of “Misc Test” mode on scan tool.
I2RH0B180006-01
I3RM0A180004-01
I2RH0B180007-01
(A)
1
I4RS0B180003-01

Downloaded from www.Manualslib.com manuals search engine 1I-3 Starting System:
Cranking System TestS7RS0B1904002
CAUTION!
Each test must be performed within 3 – 5
seconds to avoid coil from burning.

Pull-In Test
Connect battery to the magnetic switch as shown.
Check that plunger and pinion move outward.
If plunger and pinion don’t move, replace the magnetic
switch.
NOTE
Before testing, disconnect lead wire from
terminal “M” (2).

Hold-In Test
While connected as the figure with plunger out,
disconnect negative lead from terminal “M”.
Check that plunger and pinion remain out.
If plunger and pinion return inward, replace the magnetic
switch. Plunger and Pinion Return Test
Disconnect negative lead from starting motor body.
Check that plunger and pinion return inward.
If plunger and pinion don’t return, replace the magnetic
switch.
No-Load Performance Test
Connect battery and ammeter to starter as shown.
Check that starter rotates
smoothly and steadily with
pinion moving out. Check that ammeter indicates
specified current.
Specified current (No-load performance test)
90 A MAX. at 11 V
1. Terminal “S”
3. Lead wire (switch to motor)
I2RH01190002-01
I2RH01190003-01
I2RH01190004-01
I2RH01190005-01

Downloaded from www.Manualslib.com manuals search engine 1I-9 Starting System:
Specifications
Cranking System SpecificationsS7RS0B1907001
Tightening Torque SpecificationsS7RS0B1907002
NOTE
The specified tightening torque is also described in the following.
“Starting Motor Dismounting and Remounting”
“Starting Motor Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS7RS0B1908001
NOTE
Required service material is also described in the following.
“Starting Motor Components”

Voltage 12 volts
Output 1.2 kW
Rating 30 seconds
Direction of rotation Clockwise as viewed from pinion side
Brush length Standard: 12.3 mm (0.48 in.) Limit: 7.0 mm (0.28 in.)
Number of pinion teeth 8
Performance Condition Guarantee
Around at 20 °C
(68 °F) No load characteristic 11.0 V
90 A maximum
2370 r/min minimum
Load characteristic 7.5 V
300 A 10.65 N
⋅m (1.065 kgf-m, 7.70 lb-ft) minimum
840 r/min minimum
Locked characteristic 4.0 V 780 A maximum
20 N
⋅m (2.0 kgf-m, 14.5 lb-ft) minimum
Magnetic switch operating voltage 8 volts maximum
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Starting motor battery cable nut 9.8 0.98 7.0 )

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Engine
Charging System
General Description
Battery DescriptionS7RS0B1A01001
The battery has three major functions in the electrical
system.
• It is a source of electrical energy for cranking the engine.
• It acts as a voltage stabilizer for the electrical system.
• It can, for a limited time, provide energy when the electrical load exceeds the output of the generator.
Carrier and Hold-Down
The battery carrier should be in good condition so that it
will support the battery securely and keep it level. Before
installing the battery, the ba ttery carrier and hold-down
clamp should be clean and free from corrosion and
make certain there are no parts in carrier.
To prevent the battery from shaking in its carrier, the
hold-down bolts should be tight enough but not over-
tightened.
Electrolyte Freezing
The freezing point of electrolyte depends on its specific
gravity. Since freezing may ruin a battery, it should be
protected against freezing by keeping it in a fully
charged condition. If a battery is frozen accidentally, it
should not be charged until it is warmed.
Sulfation
If the battery is allowed to stand for a long period in
discharged condition, the lead sulfate becomes
converted into a hard, cryst alline substance, which will
not easily turn back to the active material again during
the subsequent recharging. “Sulfation” means the result
as well as the process of that reaction. Such a battery
can be revived by very slow charging and may be
restored to usable condition but its capacity is lower than
before. Built-In Indicator (If Equipped)
The battery has a built-in temperature compensated
indicator in the top of the battery. This indicator is to be
used with the following diagnostic procedure. When
checking the indicator, make sure that the battery has a
clean top. A light may be needed in some poorly-lit
areas.
Three types of indication available under normal
operation are as follows.
•
Green dot
Battery is sufficiently charged for testing.
• Dark
Battery must be charged before testing. If there is a
cranking complaint, battery should be tested as
described in “Battery Inspection”. Charging and
electrical systems should also be checked at this time.
• Clear
This means that fluid level is below the bottom of
hydrometer. Its possible cause is excessive or
prolonged charging, a broken case, excessive tipping
or normal battery deteriorat ion. When the battery is
found in such condition, it is possible that high
charging voltage is caused by the faulty charging
system and therefore, charging and electrical systems
need to be checked. If there is a trouble in cranking
and its cause lies in the battery, it should be replaced.
I2RH011A0001-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-6
• Tighten wheel nuts to specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
• After installation, confirm front wheel alignment.
Front Strut Assembly Disassembly and
Assembly
S7RS0B2206004
WARNING!
Use a regular coil spring compressor and
follow the operation procedure described in
the Instruction Manual.

Disassembly 1) Attach special tool (A) to coil spring as shown. Turn special tool bolts alternat ely until coil spring tension
is released. Rotate the strut around its axis to
confirm that the coil spring is released or not.
Special tool
(A): 09940-71431
2) While keeping coil spring compressed with special
tools as shown, remove strut support lower nut.
Special tool
(B): 09900-00411 socket
(C): 09900-00414 6 mm
3) Disassemble strut assembly. Assembly
For assembly, reverse disassembly procedure, noting
the following instructions.
1) Compress coil spring with special tool (A) until total
length becomes about 280 mm (11.0 in.) as shown.
Special tool
(A): 09940–71431
Length
“a”: 280 mm (11.0 in.)
2) Install compressed coil spring to strut, and place coil
spring end (2) onto spring lower seat (1) as shown.
NOTE
End of coil spring must not interfere with
step of spring lower seat.

I4RS0A220009-01
(B)
(C)
I4RS0A220007-01
U: Upper side (small dia.) L: Lower side (large dia.)
I4RS0A220010-01
I4RS0A220011-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-10
2) Face grooved rubber seal side (1) of new wheel bearing (2) upward as shown in figure and press-fit it
into knuckle (3) using special tool.
Special tool
(A): 09913-75510
(B): 09926–68310
(C): 09951–18210
CAUTION!
When installing wheel bearing, replace wheel
bearing and circlip with new one.

3) Install circlip (1).
4) Drive in dust cover so that dimensions “a” and “b” become equal as shown in the figure.
CAUTION!
When drive in dust cover, be careful not to
deform it.

5) Caulk more than 6 places with a punch.
6) Using special tool and hydraulic press, press fit
wheel hub (1) into wheel bearing (2) (Face grooved
rubber seal side to wheel hub).
Special tool
(A): 09913–75510
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