change time SUZUKI SWIFT 2006 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine FOREWORD
This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service
operations, replacement of components (Service) and for disassembly and reassembly of major components
(Unit Repair-Overhaul).
Applicable Model:
SWIFT (RS416) produced at KOSAI plant in Japan wi th the following vehicle identification numbers
(VINs).

JSAEZC31S############


The contents are classified into sectio ns each of which is given a section number as indicated in the Table of
Contents on following page. And on the first page of ea ch individual section is an index of that section.
This manual should be kept in a handy place for ready reference of the service work.
Strict observance of the so specif ied items will enable one to obtain the full performance of the vehicle.
When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials as specif ied in each description.
All information, illustrations and specif ications contained in this literature are based on the late st product infor-
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specificatio ns among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
JSAEZC31S########

Downloaded from www.Manualslib.com manuals search engine 0B-2 Maintenance and Lubrication:
NOTE
• “R”: Replace or change
• “I”: Inspect and correct, replace or lubricate if necessary
• For spark plugs, replace every 50,000 km if the local law requires.
• Periodic replacement of fuel filter is not necessary if it is not instructed in “Periodic Maintenance Schedule” section of the Owner’s manual. The scheduled maintenance varies depending on the
vehicle specification.

Maintenance Recommended under Severe Driving ConditionsS7RS0B0205002
If the vehicle is usually used under the conditions corres ponding to any severe condition code given below, IT IS
RECOMMENDED that applicable maintenance operation be per formed at the particular interval as shown in the
following table.
Severe condition code:
A: Repeated short trips
B: Driving on rough and/or muddy roads
C: Driving on dusty roads
D: Driving in extremely cold weather and/or salted roads
E: Repeated short trips in extremely cold weather
F: Leaded fuel use
G: – – – – –
H: Towing a trailer (if admitted) Automatic transaxle fluid
Fluid level (I:
)) —I—I—I
Fluid change (R: )) Replace every 165,000 km (99,000
miles)
Fluid hose (I: ))———I——
All latches, hinges and locks (I: )) —I—I—I
HVAC air filter (if equipped) (I: ) ) (R: ))— IR — IR
Interval
Km (x 1,000)
15 30 45 60 75 90
Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
Severe
condition code MaintenanceMaintenance
operation Maintenance interval
– B C D – – – – Accessory drive belt )
I Every 15,000 km
(9,000 miles) or 12 months
) R Every 45,000 km
(27,000 miles) or 36 months
A – C D E F – H Engine oil and oil filter ) R Every 7,500 km
(4,500 miles) or 6 months
– – C – – – – – Air cleaner filter *1 )
I Every 2,500 km
(1,500 miles)
) R Every 30,000 km
(18,000 miles) or 24 months
A B C – E F – H Spark plugs Iridium plug ) R Every 30,000 km (18,000 miles) or
24 months
– B C D – – – H Wheel bearings ) I Every 15,000 km
(9,000 miles) or 12 months
– B – D E – – H Drive shaft (axle) boots ) I Every 15,000 km
(9,000 miles) or 12 months
– B – – E – – H Manual transaxle oil ) R First time only:
15,000 km (9,000 miles) or 12
months
Second time and after:
Every 30,000 km (18,000 miles) or
24 months reckoning from 0 km (0
mile) or 0 month

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-91
DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)S7RS0B1104032
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 a tester, on a level road.

NOTE
Check to make sure that following conditions ar e satisfied when using this “DTC Confirmation
Procedure”.
• Intake air temperature at engine start: –10 °C (14 ° F) to 80 °C (176 °F)
• Intake air temperature: –10 °C (14 °F) to 70 °C (158 °F)
• Engine coolant temperature: 70 °C (158 °F) to 150 °C (302 °F)
• Altitude (barometric pressure): 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)

1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and warm up to normal operating temperature.
4) Drive vehicle at 40 mph (60 km/h) or higher. (engine speed: 2500 – 3000 r/min.)
5) Keep above vehicle speed for 6 min. or more. (Throt tle valve opening is kept constant in this step.)
6) Release accelerator pedal and with engine brake applied, keep vehicle coasting (with fuel cut for 3 sec. or more)
and then stop vehicle.
7) Check if DTC and pending DTC exist by using scan tool. If not, check if oxygen sensor monitoring test has been
completed by using scan tool. If not in both of above c hecks (i.e., no DTC and pending DTC and oxygen sensor
monitoring test not completed), check vehicle cond ition (environmental) and repeat Step 3) through 6).
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.

DTC detecting condition Trouble area
Response time (time to change from lean to rich or from rich to lean) of HO2S-1 output
voltage is about 1 sec. at minimum or aver age time of 1 cycle is 5 sec. at minimum.
(*2 driving cycle detection logic, monitoring once per driving cycle) Heated oxygen sensor-1
Step
Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 Is there DTC(s) other than HO2S-1 (DTC P0133)? Go to applicable DTC
diag. flow.Replace HO2S-1.

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-7
6) After fitting oil pan to cylinder block, run in securing bolts and start tightening at the center: move wrench
outward, tightening one bolt at a time. Tighten bolts
and nuts to specified torque.
Tightening torque
Oil pan bolt (M6) (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Oil pan bolt (M10) (c): 55 N·m (5.5 kgf-m, 40.0 lb-
ft)
Oil pan nut (e): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
7) Install new gasket and drain plug to oil pan. Tighten drain plug to specified torque.
Tightening torque
Oil pan drain plug (b): 35 N·m (3.5 kgf-m, 25.5 lb-
ft)
8) Tighten transaxle stiffener bolts to specified torque. Tightening torque
Transaxle stiffener bolt (d): 55 N·m (5.5 kgf-m,
40.0 lb-ft)
9) Install exhaust manifold stiffener (2) and exhaust No.1 pipe (1) and heated oxygen sensor No.2
(connector color: green) (3) referring to “Exhaust
System Components in Section 1K”. 10) Install clutch housing lower plate (1).
11) Install oil level gauge.
12) Refill engine with engine oil referring to “Engine Oil
and Filter Change in Section 0B”.
13) Verify that there is no en gine oil leakage and exhaust
gas leakage at each connection.
Oil Pan and Oil Pump Strainer CleaningS7RS0B1506006
• Clean sealing surface between oil pan and cylinder block.
Remove oil, old sealant, and dust from sealing
surface.
• Clean oil pump strainer screen (1).(a)
(b)
(c)(e)
(d)I4RS0A150008-01
2
1
3
I4RS0A150003-01
1I4RS0A150004-01
I2RH0B150016-01

Downloaded from www.Manualslib.com manuals search engine 4A-16 Brake Control System and Diagnosis:
Booster Operation InspectionS7RS0B4106016
There are two ways to perform this inspection, with and
without a tester. Ordinarily, it is possible to roughly
determine its condition without using a tester.
NOTE
For this check, make su re that no air is in
hydraulic line.

Check Air Tightness
1) Start engine.
2) Stop engine after running for 1 to 2 minutes.
3) Depress brake pedal several times with the same load as in ordinary braking and observe pedal travel.
If pedal goes down deep the first time but its travel
decreases as it is depressed the second and more
times, air tightness is obtained.
4) If pedal travel doesn’t change, air tightness isn’t obtained.
NOTE
If defective, inspect vacuum lines and sealing
parts, and replace any faulty part. When this
has been done, repeat the entire test.

Check Operation
1) With engine stopped, depress brake pedal several times with the same load and make sure that pedal
travel doesn’t change.
2) Start engine while depressing brake pedal. If pedal travel increases a little, operation is satisfactory. But
no change in pedal travel indicates malfunction.
Check Air Tightness Under Load 1) With engine running, depress brake pedal. Then stop engine while holding brake pedal depressed.
1. 1st 2. 2nd3. 3rd
1. 1st, 2nd, 3rd
I2RH01410005-01
I2RH01410006-01
H: Hold
I2RH01410007-01
I2RH01410008-01
I2RH01410009-01

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-2
General Description
ABS DescriptionS7RS0B4501001
The ABS (Antilock Brake System) controls the fluid
pressure applied to the wheel cylinder of each brake
from the master cylinder so that each wheel is not locked
even when hard braking is applied.
This ABS has also the following function.
While braking is applied, but before ABS control
becomes effective, braking force is distributed between
the front and rear so as to prevent the rear wheels from
being locked too early for better stability of the vehicle.
The main component parts of this ABS include the
following parts in addition to those of the conventional
brake system.
• Wheel speed sensor which senses revolution speed of each wheel and outputs its signal.
• ABS warning light which light s to inform abnormality
when system fails to operate properly.
• ABS hydraulic unit / cont rol module assembly is
incorporated ABS co ntrol module, ABS hydraulic unit
(actuator assembly), solenoid valve power supply
driver (transistor), solenoid valve driver (transistor),
pump motor driver (transistor).
– ABS control module which sends operation signal to ABS hydraulic unit to control fluid pressure
applied to each wheel cylinder based on signal
from each wheel speed sensor so as to prevent
wheel from locking.
– ABS hydraulic unit which operates according to signal from ABS control module to control fluid
pressure applied to wheel cylinder of each 4
wheels.
– Solenoid valve power supp ly driver (transistor)
which supplies power to solenoid valve in ABS
hydraulic unit.
– Solenoid valve driver (transistor) which controls each solenoid valves in ABS hydraulic unit.
– Pump motor driver (transistor) which supplies power to pump motor in ABS hydraulic unit.
This ABS is equipped with Electronic Brake force
Distribution (EBD) system that controls a fluid pressure
of rear wheels to best condition, which is the same
function as that of proportion ing valve, by the signal from
wheel sensor independently of change of load due to
load capacity and so on. An d if the EBD system fails to
operate properly, the brake warning light lights to inform
abnormality.
ABS Hydraulic Unit / Control Module Assembly
Description
S7RS0B4501002
ABS control module is a component of ABS hydraulic
unit / control module asse mbly and has the following
functions.
Self-Diagnosis Function
ABS control module diagnose s conditions of the system
component parts (whether or not there is any
abnormality) all the time and indicates the results
(warning of abnormality occurrence and DTC) through
the ABS warning light as described.
• When ignition switch is turned ON, ABS warning light lights for 2 seconds to check its circuit.
• When no abnormality has been detected (the system is in good condition), ABS warning light turns OFF
after 2 seconds.
• When an abnormality in th e system is detected, ABS
warning light lights and the area where that
abnormality lies is stored in the memory of EEPROM
in ABS control module.
1
I4RS0A450001-01

Downloaded from www.Manualslib.com manuals search engine 4E-31 ABS:
2) Bleed air from brake system referring to “Air Bleeding of Brake System in Section 4A”.
3) Check each installed part for fluid leakage and perform “ABS Hydraulic Un it Operation Check”.
NOTE
For new ABS hydraulic unit / control module
assembly, if “ABS Hydraulic Unit Operation
Check” has not been performed, ABS
warning light may flash when ignition switch
is turned ON position.
Accordingly preform “ABS Hydraulic Unit
Operation Check” to stop flashing of ABS
warning light.

Front / Rear Wheel Speed Sensor On-Vehicle
Inspection
S7RS0B4506005
Output Voltage Inspection
1) Disconnect negative cable from battery.
2) Hoist vehicle a little.
3) Disconnect wheel speed sensor connector.
4) Disconnect wheel speed grommet from vehicle body.
5) Set up measuring devices as shown in figure, the resistance to 115 Ω and the power supply voltage to
12 V.
CAUTION!
Incorrect voltage and/or wrong connection
cause damage to wheel speed sensor.

6) Measure voltage at resistance without wheel rotation.
If voltage is out of specification, check sensor,
mating encoder and their installation conditions.
Voltage at the resistance (115
Ω) without wheel
rotation
680 to 960 mV
7) Measure voltage at resistance with wheel rotation and confirm voltage alternately changes between
high and low voltages.
If voltage does not change with wheel rotation, check
sensor, mating encoder and their installation
conditions.
Voltage at the resistance (115
Ω) with wheel
rotation
High voltage “a”: 1360 to 1930 mV
Low voltage “b”: 680 to 960 mV
Reference
When using oscilloscope for this check, check if peak-to-
peak voltage and waveform meet specification.
Peak-to-peak Voltage at the resistance (115
Ω) with
wheel rotation
High voltage “a”: 1360 to 1930 mV
Low voltage “b”: 680 to 960 mV
[A]: Front wheel speed sensor 3. “WHT” wire terminal
[B]: Rear wheel speed sensor 4. “BLK” wire terminal
1. Wheel speed sensor connector 5. Power supply (12 V)
2. Resistance (115 Ω )
V
2
5
41
3
43
1
[A]
[B]
I6RS0B460031-02
[A]: Voltage [B]: Time
I5JB0A450027-01
I5JB0A450028-02

Downloaded from www.Manualslib.com manuals search engine 4F-16 Electronic Stability Program:
) C1022 Right-front wheel speed
sensor or encoder failure Abnormal wheel speed sensor
signal is detected.
{
*1 {
) C1023 Yaw rate sensor failure • Yaw rate sensor signal is out of
range.
• Vehicle behavior and yaw rate signal is disagreed. ——
{
) C1024 Steering angle sensor circuit
failure • Steering angle sensor internal
defect is detected by CPU in
steering angle sensor.
• Steering angle sensor signal is out of specified range. ——
{
) C1025 Left-front wheel speed
sensor circuit failure Wheel sensor signal is out of
specified range.
{
*1 {
) C1026 Left-front wheel speed
sensor or encoder failure Abnormal wheel speed sensor
signal is detected.
{
*1 {
) C1027 ESP
® OFF switch circuit
failure Mechanical switch failure, failure in
switch wiring is shorted to ground.
———
) C1028 Master cylinder pressure
sensor circuit failure Input signal voltage from master
cylinder pressure sensor in ESP
®
control module is too high or low. ——
{
) C1031 Right-rear wheel speed
sensor circuit failure Wheel sensor signal is out of
specified range.
{
*1 {
) C1032 Right-rear wheel speed
sensor or encoder failure Abnormal wheel speed sensor
signal is detected.
{
*1 {
) C1034 Yaw rate / G sensor
assembly power supply
failure Power supply voltage of yaw rate /
G sensor assembly is too high when
ignition switch OFF.
——{
Power supply voltage of yaw rate /
G sensor assembly is too low when
ignition switch ON.
) C1035 Left-rear wheel speed
sensor circuit failure Wheel sensor signal is out of
specified range.
{
*1 {
) C1036 Lef

t-rear wheel speed
sensor or encoder failure Abnormal wheel speed sensor
signal is detected.
{
*1 {
) C1037 Steering angle sensor power
supply failure Power supply voltage to steering
angle sensor is too low.
——
{
) C1038 Steering angle sensor detect
rolling counter failure from
ESP
® control module ESP
® control module rolling
counter failure is detected by
steering angle sensor. ——
{
) C1039 Yaw rate / G sensor
assembly internal failure Yaw rate / G sensor assembly
internal failure is detected.
——
{
) C1040 Stability control system
function failure Stability control is active for more
than specified time
without yaw rate
change. ——
{
DTC (displayed
on SUZUKI scan tool) Diagnostic Items
Detecting condition (DTC will
beset when detecting) ABS
warning lamp EBD
warning lamp ESP
®
warning lamp

Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-39
DTC Troubleshooting
DTC C1039: Yaw Rate / G Sensor Assembly Internal FailureS7RS0B4604035
DTC Detecting Condition and Trouble Area
DTC Troubleshooting
DTC C1040: Stability Control System Function FailureS7RS0B4604036
DTC Detecting Condition and Trouble Area
DTC TroubleshootingStep Action Yes No
1 Was “Electronic Stability Pr ogram Check” performed? Go to Step 2. Go to “Electronic
Stability Program
System Check”.
2 Check DTC
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Turn ignition switch ON and check DTC.
Is there any DTC(s) other than C1038 and C1090? Go to applicable DTC
diag. flow.
Substitute a known-
good steering angle
sensor and recheck. If
DTC C1038 is still
detected, substitute a
known-good ESP
®
hydraulic unit control
module assembly and
recheck.
DTC Detecting Condition Trouble Area
Yaw rate / G sensor as sembly internal failure is detect ed. • Yaw rate / G sensor assembly
• ESP ® control module
Step Action YesNo
1 Was “Electronic Stability Pr ogram Check” performed? Go to Step 2.Go to “Electronic
Stability Program
System Check”.
2 DTC check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Turn ignition switch ON and check DTC.
Are DTC C1034 and/or C1073 detected? Go to applicable DTC
diag. flow.
Go to step 3.
3 Check yaw rate / G sensor assembly
1) Check yaw rate / G sensor assembly referring to “Yaw
Rate / G Sensor Assembly On-Vehicle Inspection”.
Is it good condition? Substitute a known-
good ESP
® hydraulic
unit / control module
assembly and recheck. Substitute a known-
good yaw rate / G
sensor assembly and
recheck.
DTC Detecting Condition
Trouble Area
Stability control is active fo r more than specified time
without yaw rate change. • ESP
® control module
Step Action YesNo
1 Was “Electronic Stability Pr ogram Check” performed Go to Step 2.Go to “Electronic
Stability Program
System Check”.
2 Check DTC for ESP ®
1) Connect scan tool to DLC with ignition switch turned OFF.
2) Turn ignition switch ON and check DTC for ESP ®.
Is there any DTC(s) other than C1040? Go to applicable DTC
diag. flow.
Substitute a known-
good ESP
® hydraulic
unit / control module
assembly and recheck.

Downloaded from www.Manualslib.com manuals search engine 4F-58 Electronic Stability Program:
6) Measure voltage at resistance without wheel rotation.
If voltage is out of specification, check sensor,
mating encoder and their installation conditions.
Voltage at the resistance (115
Ω) without wheel
rotation
680 to 960 mV
7) Measure voltage at resistance with wheel rotation and confirm voltage alternately changes between
high and low voltages.
If voltage does not change with wheel rotation, check
sensor, mating encoder and their installation
conditions.
Voltage at the resistance (115
Ω) with wheel
rotation
High voltage “a”: 1360 to 1930 mV
Low voltage “b”: 680 to 960 mV
Reference
When using oscilloscope for this check, check if peak-to-
peak voltage and waveform meet specification.
Peak-to-peak Voltage at the resistance (115
Ω) with
wheel rotation
High voltage “a”: 1360 to 1930 mV
Low voltage “b”: 680 to 960 mV
Front Wheel Speed Sensor Removal and
Installation
S7RS0B4606029
Removal
1) Disconnect negative (–) cable from battery.
2) Disconnect front wheel speed sensor coupler (1).
3) Hoist vehicle and remove wheel.
4) Remove harness clamp, clamp bolts (2) and grommet (3).
5) Remove front wheel speed sensor (4) from knuckle.
NOTE
• Do not pull wire harness when removing front wheel speed sensor.
• Do not cause damage to surface of front wheel speed sensor and do not allow dust,
etc. to enter its installation hole.

[A]: Voltage [B]: Time
I5JB0A450027-01
I5JB0A450028-02
3
2
4 1
I6RS0B460032-02