Back up SUZUKI SWIFT 2006 2.G Service Workshop Manual
[x] Cancel search | Manufacturer: SUZUKI, Model Year: 2006, Model line: SWIFT, Model: SUZUKI SWIFT 2006 2.GPages: 1496, PDF Size: 34.44 MB
Page 14 of 1496

Downloaded from www.Manualslib.com manuals search engine 00-9 Precautions: 
• Be careful not to touch the electrical terminals of parts which use microcomputers (e.g. electronic control unit 
like as ECM, PCM, P/S controller, etc.). The static 
electricity from your body  can damage these parts.
• Never connect any tester (voltmeter, ohmmeter, or  whatever) to electronic control unit when its coupler is 
disconnected. Attempt to do it may cause damage to 
it.
• Never connect an ohmmeter to electronic control unit  with its coupler connected to  it. Attempt to do it may 
cause damage to electronic control unit and sensors.
• Be sure to use a specified voltmeter / ohmmeter.  Otherwise, accurate measurements may not be 
obtained or personal injury ma y result. If not specified, 
use a voltmeter with high impedance (M  Ω/V 
minimum) or a digital type voltmeter.
• When taking measurements at electrical connectors  using a tester probe, be sure to insert the probe (2) 
from the wire harness side (backside) of the 
connector (1). • When connecting meter probe (2) from terminal side 
of coupler (1) because it can’t be connected from 
harness side, use extra care not to bend male 
terminal of coupler of force its female terminal open 
for connection.
In case of such coupler as shown connect probe as 
shown to avoid opening female terminal.
Never connect probe where male terminal is 
supposed to fit.
• When checking connection  of terminals, check its 
male half for bend and female half for excessive 
opening and both for locking (looseness), corrosion, 
dust, etc.
• Before measuring voltage at each terminal, check to  make sure that battery voltage is 11 V or higher. Such 
terminal voltage check at lo w battery voltage will lead 
to erroneous diagnosis.
I3RM0A000004-01
I2RH01010046-01
I2RH01010047-01
I2RH01010048-01  
Page 18 of 1496

Downloaded from www.Manualslib.com manuals search engine 00-13 Precautions: 
Short Circuit Check (Wire Harness to Ground)1) Disconnect negative (–) cable at battery.
2) Disconnect connectors at bot h ends of the circuit to 
be checked.
NOTE
If the circuit to be checked is connected to 
other parts (1), disconnect all connectors of 
those parts.
Otherwise, diagnosis will be misled.
 
3) Measure resistance between terminal at one end of  circuit (“A-1” terminal in the figure) and body ground. 
If continuity is indicated, it  means that there is a short 
to ground between terminals “A-1” and “C-1” of the 
circuit. 4) Disconnect the connector included in circuit 
(connector-B) and measure resistance between “A-
1” and body ground. If continuity is indicated, it 
means that the circuit is  shorted to the ground 
between terminals “A-1” and “B-1”.
Intermittent and Poor Connection InspectionS7RS0B0006002
Most intermittent are caused by faulty electrical 
connections or wiring, although a sticking relay or 
solenoid can occasionally be at fault. When checking it 
for proper connection, perfor m careful check of suspect 
circuits for:
• Poor mating of connector halves, or terminals not fully  seated in the connector body (backed out).
• Dirt or corrosion on the terminals. The terminals must  be clean and free of any foreign material which could 
impede proper terminal contact. However, cleaning 
the terminal with a sand paper or the like is prohibited. 
• Damaged connector body, exposing the terminals to  moisture and dirt, as well  as not maintaining proper 
terminal orientation with the component or mating 
connector.
I5RH01000006-01
1. To other parts
I2RH01010056-01
I2RH01010057-01  
Page 41 of 1496

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication:  0B-11
Automatic Transaxle Fluid Level InspectionS7RS0B0206028
1) Inspect transaxle case for evidence of fluid leakage.Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level  check.
3) Check fluid level under spec ified conditions referring 
to “A/T Fluid Level Check in Section 5A”.
If fluid level is low, replenish specified fluid.
Automatic Transaxle Fluid ReplacementS7RS0B0206029
1) Inspect transaxle case for evidence of fluid leakage. Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level  check.
3) Change fluid. For its procedure, refer to “A/T Fluid  Change in Section 5A”.
Automatic Transaxle Fluid Cooler Hose 
Inspection
S7RS0B0206030
Check automatic transaxle fluid cooler hose for fluid 
leakage, cracks, damage and deterioration.
Replace hose and/or clamp if any faulty condition is 
found.
All Latches, Hinges and Locks InspectionS7RS0B0206031
Doors
Check that each door of front, rear and back doors 
opens and closes smoothly  and locks securely when 
closed.
If any malfunction is found,  lubricate hinge and latch or 
repair door lock system.
Engine Hood
Check that secondary latch  operates properly (check 
that secondary latch keeps hood from opening all the 
way even when pulling hood release handle inside 
vehicle.) Also check that hood opens and closes 
smoothly and properly and hood locks securely when 
closed.
If any malfunction is found, l ubricate hinge and latch, or 
repair hood lock system.
1. Dipstick 3. FULL HOT mark
2. Clamp 4. LOW HOT mark
1. Drain plug
I4RS0A020016-01
I4RS0A020017-01
I4RS0A020020-01
I2RH01020033-01  
Page 42 of 1496

Downloaded from www.Manualslib.com manuals search engine 0B-12 Maintenance and Lubrication: 
HVAC Air Filter (If Equipped) InspectionS7RS0B0206032
1) Remove HVAC air filter from HVAC unit referring to 
“HVAC Air Filter Removal and Installation (If 
Equipped) in Section 7A”.
2) Check for dirt and dust. If HVAC air filter is  excessively dirty, replace HVAC air filter with new 
one. If not, go to next step.
3) Blow compressed air on the air outlet side of HVAC  air filter for removing dust.
4) Install HVAC air filter in to HVAC unit referring to 
“HVAC Air Filter Removal and Installation (If 
Equipped) in Section 7A”.
HVAC Air Filter (If Equipped) ReplacementS7RS0B0206033
Replace HVAC air filter with new one referring to “HVAC 
Air Filter Removal and Installation (If Equipped) in 
Section 7A”.
Final Inspection for Maintenance ServiceS7RS0B0206034
WARNING! 
When carrying out road tests, select a safe 
place where no man or no running vehicle is 
seen so as to prevent any accident.
 
Seats
Check that seat slides smoot hly and locks securely at 
any position. Also check that reclining mechanism of 
front seat back allows it to be locked at any angle.
Seat Belt
Inspect belt system including webbing, buckles, latch 
plates, retractors and anchors for damage or wear.
Check that seat belt is securely locked. If “REPLACE 
BELT” label on seat belt is visible, replace belt.
Battery Electrolyte Level Check
Check that the electrolyte le vel of all battery cells is 
between the upper and lower level lines on the case. If 
battery is equipped with built-in indicator, check battery 
condition by the indicator. Accelerator Pedal Operation
Check that pedal operates
 smoothly without getting 
caught or interfered by any other part.
Engine Start
Check engine start for readiness.
WARNING! 
Before performing th e following check, be 
sure to have enough room around the 
vehicle. Then, firmly  apply both the parking 
brake and the regular brakes. Do not use the 
accelerator pedal. If the engine starts, be 
ready to turn off the ignition promptly. Take 
these precautions because the vehicle could 
move without warning and possibly cause 
personal injury or property damage.
 
On automatic transaxle vehicles, try to start the engine in 
each select lever  position. The starting motor should 
crank only in “P” (Park) or “N” (Neutral).
On manual transaxle vehicles, place the shift lever in 
“Neutral,” depress clutch pedal fully and try to start. 
On Automated Manual Transaxl e vehicles, try to start 
the engine in each select le ver position. The starting 
motor should crank only when select lever is in “N” 
(Neutral) and brake pedal is depressed.
Exhaust System Check
Check for leakage, cracks or loose supports.
Clutch (for Manual Transaxle)
Check for the following.
• Clutch is completely released when depressing clutch  pedal,
• No slipping clutch occurs when releasing pedal and  accelerating.
• Clutch itself is free fr om any abnormal condition.
Gearshift or Select Lever (Transaxle)
Check gear shift or select lever for smooth shifting to all 
positions and for good performance of transaxle in any 
position.
With automatic transaxle or Automated Manual 
Transaxle equipped vehicle, also check that shift 
indicator indicates properly according to which position 
select lever is shifted to.
With automatic transaxle equipped vehicle, make sure 
that vehicle is at complete stop when shifting select lever 
to “P” range position and release all brakes.
I4RS0A020018-01  
Page 46 of 1496

Downloaded from www.Manualslib.com manuals search engine 1-ii Table of Contents
DTC P0123: Throttle / Pedal Position Sensor / Switch “A” (Main) Circuit  High ....................... 1A-85
DTC P0131 / P0132: O2 Sensor (HO2S)  Circuit Low Voltage / High Voltage (Sensor-
1) ..................................................................... 1A-88
DTC P0133: O2 Sensor  (HO2S) Circuit Slow 
Response (Sensor- 1) ...................................... 1A-91
DTC P0134: O2 Sensor (HO2S) Circuit No  Activity Detected (Sensor -1) ........................... 1A-92
DTC P0137 / P0138: O2 Sensor (HO2S)  Circuit Low Voltage / High Voltage (Sensor-
2) ..................................................................... 1A-94
DTC P0140: O2 Sensor (HO2S) Circuit No  Activity Detected (Sensor -2) ........................... 1A-97
DTC P0171 / P0172: Fuel System Too Lean /  Rich ................................................................. 1A-98
DTC P0222: Throttle / Pedal Position Sensor  / Switch “B” (Sub) Circuit Low ....................... 1A-100
DTC P0223: Throttle / Pedal Position Sensor  / Switch “B” (Sub) Circuit High ...................... 1A-102
DTC P0300 / P0301 / P0302 / P0303 / P0304:  Random / Multiple Cylin der Misfire Detected 
/ Cylinder 1 / Cylinder 2 / Cylinder 3 / 
Cylinder 4 Misfire Detected ........................... 1A-105
DTC P0327 / P0328: Knoc k Sensor 1 Circuit 
Low / High ..................................................... 1A-107
DTC P0335: Crankshaft Position (CKP)  Sensor “A” Circuit .......................................... 1A-109
DTC P0340: Camshaft Position (CMP)  Sensor “A” Circuit .......................................... 1A-111
DTC P0350: Ignition Coil Primary / Secondary  Circuit ............................................................ 1A-114
DTC P0401 / P0402: Exhaust Gas  Recirculation Flow Insufficient Detected / 
Excessive Detected ...................................... 1A-116
DTC P0403: Exhaust Gas Recirculation  Control Circuit ................... ............................ 1A-118
DTC P0420: Catalyst  System Efficiency 
below Threshold ................ ............................ 1A-120
DTC P0443: Evaporativ e Emission System 
Purge Control Valve Circuit ........................... 1A-122
DTC P0480: Fan 1 (Radiator Cooling Fan)  Control Circuit ................... ............................ 1A-124
DTC P0500: Vehicle Speed Sensor “A”  Malfunction .................................................... 1A-128
DTC P0532: A/C Refrigerant Pressure  Sensor “A” Circuit Low ... ............................... 1A-130
DTC P0533: A/C Refrigerant Pressure  Sensor “A” Circuit High ................................. 1A-132
DTC P0601 / P0602 / P0607: Internal Control  Module Memory Check Sum Error / Control 
Module Programming Error / Control Module 
Performance ................................................. 1A-134
DTC P0616: Starter Relay  Circuit Low............ 1A-135
DTC P0617: Starter Relay  Circuit High ........... 1A-136
DTC P0620: Generator Control Circuit ........... 1A-137
DTC P0625 / P0626: Generator Field  Terminal Circuit Low / High . .......................... 1A-139
DTC P1501 / P1502: Electric Load Current  Sensor Circuit Low / High . ............................ 1A-141 DTC P1510: ECM Back-Up Power Supply 
Malfunction .................................................... 1A-143
DTC P1603: TCM Trouble Code Detected ..... 1A-144
DTC P1674: CAN Communication (Bus Off  Error) ............................................................. 1A-145
DTC P1676: CAN Communication (Reception  Error for TCM) ............................................... 1A-148
DTC P1678: CAN Communication (Reception  Error for BCM) ............................................... 1A-149
DTC P1685: CAN Communication (Reception  Error for ABS/ESP ® Control Module) ........... 1A-150
DTC P2101: Throttle Actuator Control Motor  Circuit Range / Performance ......................... 1A-152
DTC P2102: Throttle Actuator Control Motor  Circuit Low .................................................... 1A-154
DTC P2103: Throttle Actuator Control Motor  Circuit High.................................................... 1A-155
DTC P2111 / P2112: Throttle Actuator Control  System - Stuck Open / Closed ...................... 1A-156
DTC P2119: Throttle Actu ator Control Throttle 
Body Range / Performance ........................... 1A-157
DTC P2122: Throttle / Pedal Position Sensor  / Switch “D” (Main) Circuit Low Input............. 1A-159
DTC P2123: Throttle / Pedal Position Sensor  / Switch “D” (Main) Circuit High Input ............ 1A-161
DTC P2127: Throttle Pedal Position Sensor /  Switch “E” (Sub) Circuit  Low Input ................ 1A-164
DTC P2128: Throttle / Pedal Position Sensor 
/ Switc
 h “E” (Sub) Circuit High Input ............. 1A-166
DTC P2135: Throttle / Pedal Position Sensor  / Switch “A”/“B” (Main / Sub) Voltage 
Correlation..................................................... 1A-168
DTC P2138: Throttle / Pedal Position Sensor  / Switch “D”/“E” (Main / Sub) Voltage 
Correlation..................................................... 1A-171
DTC P2227 / P2228 / P2229: Barometric  Pressure Circuit Malfunction ......................... 1A-173
Inspection of ECM and Its Circuits .................. 1A-175
ECM Power and Ground Circuit Check........... 1A-194
Fuel Injector Circuit Check .............................. 1A-198
Fuel Pump and Its Circuit Check..................... 1A-200
Fuel Pressure Check....................................... 1A-203
A/C System Circuits Check ............................. 1A-205
Electric Load Signal Circuit Check .................. 1A-209
Radiator Cooling Fan Low Speed Control  System Check ............................................... 1A-211
Radiator Cooling Fan High Speed Control  System Check ............................................... 1A-213
Repair Instructions ......... .................................1A-216
Idle Speed and IAC Throttle Valve Opening  Inspection ...................................................... 1A-216
Special Tools and Equipmen t .........................1A-217
Special Tool .................................................... 1A-217
Aux. Emission Control  Devices ............. 1B-1
Diagnostic Information and Procedures ............1B-1
EGR System Inspection ...................................... 1B-1
Repair Instructions ............ ..................................1B-1
EVAP Canister Purge Inspec tion ........................ 1B-1  
Page 52 of 1496

Downloaded from www.Manualslib.com manuals search engine 1A-2 Engine General Information and Diagnosis: 
• Be sure to read “Precautions for Electrical Circuit Service in Section 00” befo re inspection and observe 
what is written there.
• ECM replacement: When substituting a known-good ECM, check for the 
following conditions. Neglec ting this check may cause 
damage to a known-good ECM.
– Resistance value of all relays, actuators is as  specified respectively.
– MAP sensor, A/C refrigerant pressure sensor and  TP sensor are in good condition and none of power 
circuits of these sensors is shorted to ground.
• Communication of  ECM, BCM, ABS/ESP ® control 
module, combination meter,  keyless start control 
module, steering angle sensor (ESP ® model) and 
TCM (A/T model), is esta blished by CAN (Controller 
Area Network). (For more detail of CAN 
communication for ECM, refer to “CAN 
Communication System Description”). Therefore, 
handle CAN communication line with care referring to 
“Precaution for CAN Communication System in 
Section 00”.
• Immobilizer transponder  code registration after 
replacing ECM
When ECM is replaced with new one or with another 
one, make sure to register  immobilizer transponder 
code to ECM correctly according to “Procedure after 
ECM Replacement in Section 10C”.Precautions of ECM Circuit InspectionS7RS0B1100003
• ECM connectors are waterproofed. Each terminal of  the ECM connectors is sealed up with the grommet. 
Therefore, when measuring ci rcuit voltage, resistance 
and/or pulse signal at ECM connector, do not insert 
the tester’s probe into th e sealed terminal at the 
harness side. When measuring circuit voltage, 
resistance and/or pulse signal at ECM connector, 
connect the special tool to the ECM connectors. And, 
insert the tester’s probe into the special tool’s 
connectors at the harness side, and then measure 
voltage, resistance and/or pulse signal. Or, ECM and 
its circuits may be damaged by water.
• Wire colors of the special tool’s connectors are  different from the ones of the ECM connectors. 
However, the circuit arrangement of the special tool’s 
connectors is same as the one of the ECM 
connectors. Therefore, measure circuit voltage and 
resistance by identifying the terminal location subject 
to the measurement.
Precautions of Electric Throttle Body System 
Calibration
S7RS0B1100004
After performing one of works described below, it is 
necessary to re-register the completely closed throttle 
valve reference position stored in memory of ECM. (For 
detailed information, refer to  “Description of Electric 
Throttle Body System Calibration”.) For the procedure to 
register such data in ECM, refer to “Electric Throttle 
Body System Calibration in Section 1C”.
• To shut off backup power of ECM for such purposes of  battery replacement or “DOME” fuse removal
• To erase DTCs P0122, P01 23, P0222, P0223, P2101, 
P2102, P2103, P2111, P2112, P2113, P2119, P2123, 
P2127, P2128, P2135 and/or P2138
• To replace ECM
• To replace throttle body and/or accelerator pedal  position (APP) sensor assembly
General Description
Statement on Cleanliness and CareS7RS0B1101001
An automobile engine is a combination of many 
machined, honed, polished and lapped surfaces with 
tolerances that are measured  in the thousands of an 
millimeter (ten thous ands of an inch).
Accordingly, when any internal engine parts are 
serviced, care and cleanliness are important.
It should be understood that proper cleaning and 
protection of machined surfaces and friction areas is part 
of the repair procedure. This is considered standard 
shop practice even if not  specifically stated.
• A liberal coating of engine oil should be applied to  friction areas during assembly to protect and lubricate 
the surfaces on initial operation. • Whenever valve train components, pistons, piston 
rings, connecting rods, rod bearings, and crankshaft 
journal bearings are removed for service, they should 
be retained in order.
At the time of installation,  they should be installed in 
the same locations and with the same mating 
surfaces as when removed.
• Battery cables should be disconnected before any  major work is performed on the engine.
Failure to disconnect cables  may result in damage to 
wire harness or other electrical parts.  
Page 55 of 1496

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis:  1A-5
Freeze frame data clearance:
The freeze frame data is cleared at the same time as 
clearance of DTC.
Non-Euro-OBD
ECM diagnosis troubles which may occur in the area 
including the following parts w hen the ignition switch is 
ON and the engine is running, and indicates the result by 
turning on or flashing malfunction indicator lamp (1).
• Heated oxygen sensor
• ECT sensor
•TP sensor
• APP sensor
• MAF sensor
• IAT sensor
• MAP sensor
• CMP sensor
• CKP sensor
• Knock sensor
• Wheel speed sensor (VSS)
• CPU (Central Processing Unit) of ECM
• Oil control valve
• EGR valve
• EVAP canister purge valve
• Ignition coil
• Starter relay
• Radiator fan relay
• CAN communication
• Barometric pressure sensor
• ECM back up power supply
ECM and malfunction indicator lamp (1) operate as 
follows.
• Malfunction indicator lamp (1) lights when the ignition  switch is turned ON (but t he engine at stop) with the 
diagnosis switch terminal ungrounded regardless of 
the condition of Engine and Emission control system. 
This is only to check the ma lfunction indicator lamp (1) 
in the combination meter and its circuit.
• If the above areas of Engine and Emission control  system is free from any trouble after the engine start 
(while engine is running), malfunction indicator lamp 
(1) turns OFF. • When ECM detects a trouble which has occurred in 
the above areas, it makes malfunction indicator lamp 
(1) turn ON while the engi ne is running to warn the 
driver of such occurrence of trouble and at the same 
time it stores the trouble area in ECM back-up 
memory. (The memory is kept as it is even if the 
trouble was only temporary and disappeared 
immediately. And it is not erased unless the power to 
ECM is shut off for specified  time or it is cleared by 
SUZUKI scan tool (2).)
For Hong Kong model, DTC can be read by not only 
using SUZUKI scan tool but also displayed on 
odometer (5) of the combination meter. (i.e. when 
diagnosis switch terminal (3) is grounded with a 
service wire (4) and ignition  switch is turned ON.) For 
further detail of the checking procedure, refer to “DTC 
Check”.
6. Diagnosis connector
2
1
6 3
5
4
I5RS0C110021-01  
Page 61 of 1496

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis:  1A-11
Generator Control System DescriptionS7RS0B1101010
Generator Control System consists of a generator (1), electric load current sensor (7) located in the main fuse box (4) 
and ECM (5).
ECM controls generated electricity (adjusting  voltage of IC regulator (2)) so that it is suitable for the engine and electric 
load conditions. When the electric load increases quickly,  generation load of the generator increases quickly and 
causes idling to change. To  prevent this, ECM makes generated electricity volume vary gradually  to stabilize idling. 
Also, it reduces the engine load caused by temporary incr ease in electricity generation to cope with the engine 
condition (such as when accelerating).
Operation
ECM controls the generated voltage of the generator using “C” terminal (generator control terminal) duty, based on 
following information.
• Engine condition (ECT, vehicle speed, engine speed, TP, etc.) (9)
• Battery voltage (ECM backup power voltage) (10)
• Electric load condition (blower motor, rear defogger, head lights, radiator fan, A/C, etc.) (11)
• “FR” terminal output (field coil (3) cont rol duty) which indicates the operation rate  (electricity generation condition) of 
the generator.
Then the generator uses “C” terminal duty to regulate the adju sting voltage of the IC regulator with the field coil control 
duty so as to control its generated voltage (“B” terminal output voltage).
(For more information of the generated voltage, refer  to “Charging System Specifications in Section 1J”.)
Furthermore, the generation condition of the generator is co ntrolled to the optimum level by the electric load current 
sensor (7) which detects the electrical load condition (cur rent consumption) linearly even when a sudden electrical 
load variation occurs and thus the engine load is reduced.
B
IG
L
C
E
6
2
3
FR
5
12 13
14
1IG1
7
4
8
11
10 9
CMO
FCD
GCD 
I6RW0H110005-01
6. Ignition switch
12. BCM 14. CAN driver
8. Battery 13. Combination meter