Ig coil inspection SUZUKI SWIFT 2007 2.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine Engine Electrical Devices: 1C-13
Without Using SUZUKI Scan Tool1) Measure sensor voltage between “C37-23” terminal of ECM connector and vehicle body ground referring
to “Inspection of ECM and Its Circuits in Section 1A”.
If check result is satisfactory, electric load current
sensor is in good condition.
If check result is not satisfactory, check the following
parts and circuit.
• Electric load current sensor circuit (power, ground and output)
• Following charging system components – Battery (refer to “Battery Inspection in Section
1J”)
– Generator (refer to “Generator Inspection in Section 1J”)
– Generator output control circuit (refer to “Generator Test (Undercharged Battery Check)
in Section 1J”)
– Generator field coil monitor circuit (refer to “Generator Inspection in Section 1J”) If electric load current sensor circuit and charging
system is in good condition,
electric load current sensor
(1) is faulty.
Specifications
Tightening Torque SpecificationsS7RS0B1307001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
2. Main fuse box
2
1
I5RS0C130001-01
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
ECM mounting bolt 8 0.8 6.0 )
APP sensor assembly nut 5.5 0.55 4.0 )
ECT sensor 15 1.5 11.0 )
Heated oxygen sensor 45 4.5 32.5 )
CMP sensor bolt 10 1.0 7.5 )
CKP sensor bolt 10 1.0 7.5 )
Knock sensor 22 2.2 16.0 )
MAF and IAT sensor screw 1.5 0.15 1.1 )

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-10
Air Cleaner Element Inspection and CleaningS7RS0B1406003
Inspection
Check air cleaner element for dirt. Replace excessive
dirty element.
Cleaning
Blow off dust by compressed air from air outlet side of
element.
Cylinder Head Cover Removal and InstallationS7RS0B1406004
Removal1) Disconnect negative cable at battery.
2) Remove air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
3) Remove cylinder head upper cover.
4) Disconnect ignition coil couplers (1).
5) Remove ignition coil assemblies (2) with high- tension cord (3).
6) Remove wire harness clamp from cylinder head cover.
7) Remove oil level gauge (1).
8) Disconnect PCV hose (2) from PCV valve (3) and disconnect breather hose (4) from cylinder head
cover.
9) Remove cylinder head cove r mounting bolts in such
order as indicated in the figure. 10) Remove cylinder head cover (1) with cylinder head
cover gasket (2).
Installation 1) Install new cylinder head cover gasket (2) to cylinder
head cover (1) as shown in figure.
I2RH0B140150-01
I2RH0B140032-01
I2RH0B140033-01
I6RS0B141004-01
I6RS0B141005-01

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 Ignition System: 1H-5
6Ignition coil assembly power supply and ground circuit
check
1) Check ignition coil assembly power supply and ground
circuits for open and short.
Are circuits in good condition? Go to Step 7.
Repair or replace.
7 Ignition coil assembly check
1) Check ignition coil for resistance referring to “Ignition
Coil Assembly (Including ignitor) Inspection”.
Is check result satisfactory? Go to Step 8.
Replace ignition coil
assembly.
8 CKP sensor check
1) Check CKP sensor referring to “CKP Sensor Inspection
in Section 1C”.
Is check result satisfactory? Go to Step 9.
Tighten CKP sensor
bolt, replace CKP
sensor or CKP sensor
plate.
9 CMP sensor check
1) Check CMP sensor referring to “Camshaft Position
(CMP) Sensor Inspection in Section 1C”.
Is check result satisfactory? Go to Step 10. Tighten CMP sensor
bolt, replace CMP
sensor or intake
camshaft.
10 Ignition trigger signal circuit check
1) Check ignition trigger signal wire for open, short and
poor connection.
Is circuit in good condition? Go to Step 11. Repair or replace.
11 A known-good ignition coil assembly substitution
1) Substitute a known-good ignition coil assembly and then
repeat Step 2.
Is check result of Step 2 satisfactory? Go to Step 12. Substitute a known-
good ECM and then
repeat Step 2.
12 Knock sensor check
1) Confirm that knock sensor circuit is in good condition
referring to “DTC P0327 / P0328: Knock Sensor 1 Circuit
Low / High in Section 1A”.
2) Check oscilloscope waveform of knock sensor signal
referring to “Reference waveform No.25” and
“Reference waveform No.26” under “Inspection of ECM
and Its Circuits in Section 1A”.
Is check result satisfactory? Go to Step 13. Substitute a known-
good knock sensor and
recheck.
13 Ignition timing check
1) Check initial ignition timing and ignition timing advance
referring to “Ignition Timing Inspection”.
Is check result satisfactory? System is in good
condition.
Check CMP sensor,
CMP sensor rotor tooth
of camshaft, CKP
sensor, CKP sensor
plate and/or input
signals related to this
system.
Step
Action YesNo

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
I4RS0A180004-01

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 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 Starting System: 1I-6
Starting Motor InspectionS7RS0B1906003
Plunger
Inspect plunger for wear. Replace if necessary.
Magnetic Switch
Push in plunger and release it. The plunger should
return quickly to its original position. Replace if
necessary.
Pull-in coil open circuit test
Check for continuity across magnetic switch “S” terminal
(1) and “M” terminal (2). If no continuity, coil is open and
should be replaced. Hold-in coil open circuit test
Check for continuity across ma
gnetic switch “S” terminal
(1) and coil case. If no continuity, coil is open and should
be replaced.
Rear Bracket Bush
Inspect bush for wear or damage. Replace if necessary.
Brush
• Check brushes for wear. Measure length of brushes and if below the limit,
replace the brush.
Brush length
Standard: 12.3 mm (0.48 in.)
Limit: 7.0 mm (0.28 in.)
• Install brushes to each brush holder and check for smooth movement.
I2RH01190008-01
I2RH01190009-01
I2RH01190010-01
I2RH01190011-01
I2RH01190012-01
I2RH01190013-01

Downloaded from www.Manualslib.com manuals search engine 1J-4 Charging System:
Diagnostic Information and Procedures
Battery InspectionS7RS0B1A04001
Common Causes of Failure
A battery is not designed to last indefinitely; however, with proper care, it will provide many years of service. If the
battery performs satisfactorily during te st but fails to operate properly for no apparent reason, the following are some
factors that may point to the cause of trouble:
• Accessories left on overnight or for an extended period without the generator operating.
• Slow average driving speeds for short periods.
• Electrical load exceeding generator output partic ularly with addition of aftermarket equipment.
• Defects in charging system such as high resistance, s lipping drive belt, loose generator output terminal, faulty
generator or voltage regulator, Refer to “Generator Symptom Diagnosis”.
• Battery abuse, including failure to keep battery cable terminals clean and tight or loose battery hold down.
• Mechanical problems in electrical sys tem such as shorted or pinched wires.
Visual Inspection
Check for obvious damage, such as cracked or broken case or cover, that could permit loss of electrolyte. If obvious
damage is noted, replace battery. Determine cause of damage and correct as needed.
Generator Symptom DiagnosisS7RS0B1A04002
CAUTION!
• Do not mistake polarities of “IG” terminal and “L” terminal.
• Do not create short circuit between “IG” and “L” terminals. Always connect these terminals through a lamp.
• Do not connect any load between “L” and “E” terminals.
• When connecting charger or booster battery to vehicle battery, refer to “Jump Starting in Case of Emergency”.

Trouble in charging system will show up as one or more of the following conditions:
1) Faulty indicator lamp operation.
2) An undercharged battery as evidenced by slow cranking or indicator dark.
3) An overcharged battery as evidenced by ex cessive spewing of electrolyte from vents.
Condition Possible cause Correction / Reference Item
Noisy generator Loose drive belt Adjust or replace drive belt.
Loose drive belt pulley Tighten by specified torque.
Loose mounting bolts Tighten by specified torque.
Worn or dirty bearings Replace.
Defective diode or stator Replace.
Charge light does not
light with ignition ON and
engine off Fuse blown
Replace fuse and check for shorted circuit.
Indicator lamp (LED) faulty Replace combination meter.
Wiring connection loose Tighten loose connection.
IC regulator or field coil faulty Replace.
Poor contact between brush and slip
ring Repair or replace.
Charge light does not go
out with engine running
(battery requires frequent
recharging) Drive belt loose or worn
Adjust or replace drive belt.
IC regulator or generator faulty Replace.
Wiring faulty Repair wiring.