exhaust SUZUKI SWIFT 2007 2.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine 1A-120 Engine General Information and Diagnosis:
DTC P0420: Catalyst System Efficiency below ThresholdS7RS0B1104046
System and Wiring Diagram
Circuit Description
ECM monitors oxygen concentration in the exhaust gas which has passed the warm up three way catalytic converter
by HO2S-2. When the catalyst is functioning properly, the variation cycle of HO2S-2 output voltage (oxygen
concentration) is slower than that of HO2S-1 output voltage because of the amount of oxygen in the exhaust gas
which has been stored in warm up three way catalytic converter.
Reference
Oscilloscope waveforms
C37-11
C37-10
C37-57
WHT
BRN
1
3 2
4
5 VYELYEL
BLUWHTBLUWHT 5
I4RS0A110037-01
1. HO2S-1
3. Warm up three way catalytic converter 5. ECM
2. HO2S-2 4. Three way catalytic converter
I2RH01110102-01

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-121
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 temp.: 70 °C, 158 °F to 150 °C (302 °F)
• Altitude (barometric pressure): 2400 m, 8000 ft or less (500 mmHg, 75 kPa or more)

1) Connect scan tool to DLC with ignition switch turned OFF.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Increase vehicle speed to 37 – 62 mph, 60 – 100 km/h. (engine speed: 2500 – 3000 r/min.)
4) Keep above vehicle speed for 10 min. or more (Thr ottle valve opening is kept constant in this step).
5) Stop vehicle and check if DTC / pending DTC exists using sc an tool. If not, check if catalyst monitoring test has
been completed using scan tool. If not in both of above checks (i.e., no DTC / pending DTC and catalyst
monitoring test not completed), check vehicle cond ition (environmental) and repeat Step 3) through 5).
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 delay of HO2S-2 signal (shifting delay from rich to lean and
from lean to rich with threshold at 0.45 V) compared to switching cycle
(rich-lean) of A/F feed back is less than specified while vehicle is
running at constant speed and except with high engine load after
warmed up.
(*2 driving cycle detection logic, monitoring once per driving cycle) • Exhaust gas leak
• Warm up three way catalytic converter
malfunction
• HO2S-2 malfunction
• HO2S-1 malfunction
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 Exhaust system visual check
1) Check exhaust system for leaks, damage and loose
connection.
Is it in good condition? Go to Step 3.
Repair or replace
defective part.

Downloaded from www.Manualslib.com manuals search engine 1A-122 Engine General Information and Diagnosis:
DTC P0443: Evaporative Emission System Purge Control Valve CircuitS7RS0B1104047
Wiring Diagram
DTC Detecting Condition and Trouble Area3
HO2S-2 output voltage check
1) Check output voltage of HO2S-2 referring to “DTC
P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage /
High Voltage (Sensor-2)” and “DTC P0137 / P0138: O2
Sensor (HO2S) Circuit Low Voltage / High Voltage
(Sensor-2)”.
Is check result satisfactory? Replace exhaust
manifold (built in warm
up three way catalytic
converter) and exhaust
center pipe (built in
three way catalytic
converter).
Check “BRN” and / or
“YEL” wires for open
and short, and
connections for poor
connection.
If wires and connections
are OK, replace HO2S-
2.
Step Action Yes No
E23
C37
34
1819
567
1011
17
20
47 46
495051
2122
52 16
25 9
24
14
29
55
57 54 53
59
60 58 2
262728
15
30
56 4832 31
34353637
40
42 39 38
44
45 43 41 33 1
1213
238
34
1819
567
1011
17
20
47 46
495051
2122
52 16
25 9
24
14
29
55
57 54 53
59
60 58 2
262728
15
30
56 48 32 31
34353637
40
42 39 38
44
45 43 41 331
1213
238
BLK/WHT
BLK/RED
BLK/RED
WHTBLK/YELBLK/YEL
BLK/YEL
GRN
BRN/WHT
12V 5V
5
4 2
3 6E23-29
E23-1
E23-60
C37-58
C37-15 C37-30
BLK/ORN
BLKBLKE23-31 BLK
7
8
BLK/REDBLK/REDE23-16
1
C37-29 BLU/BLK
I6RS0C110020-02
1. EVAP canister purge valve
4. Main fuse box7. “FI” fuse
2. Main relay 5. Ignition switch8. “IG ACC” fuse
3. “IG COIL” fuse 6. ECM
DTC detecting conditionTrouble area
Monitor signal of EVAP canister purge valve is different from
command signal. (Circuit open or short)
(2 driving cycle detection logic) • EVAP canister purge valve
• EVAP canister purge valve circuit
•ECM

Downloaded from www.Manualslib.com manuals search engine Engine Electrical Devices: 1C-7
Installation
Reverse removal procedure noting the following.
• Clean mating surfaces of ECT sensor and thermostat case.
• Check O-ring for damage and replace, if necessary.
• Tighten ECT sensor (1) to specified torque.
Tightening torque
ECT sensor (a): 15 N·m (1.5 kgf-m, 11.0 lb-ft)
• Connect connector to ECT sensor securely.
• Refill coolant referring to “Cooling System Flush and
Refill in Section 1F”.
ECT Sensor InspectionS7RS0B1306009
Immerse temperature sensing part of ECT sensor (1) in
water (or ice) and measure resistance between sensor
terminals while heating water gradually.
If measured resistance doesn’t show such characteristic
as shown, replace ECT sensor.
HO2S-1 and HO2S-2 Heater On-Vehicle
Inspection
S7RS0B1306010
1) Disconnect sensor connector.
2) Using ohmmeter, measure resistance between terminals “V
B” and “GND” of sensor connector.
If found faulty, replace oxygen sensor.
NOTE
Temperature of sensor affects resistance
value largely. Make sure that sensor heater is
at correct temperature.

Resistance of oxygen sensor heater
HO2S-1: 5.0 – 6.4 Ω at 20 °C (68 °F)
HO2S-2: 11.7 – 14.5 Ω at 20 °C (68 °F)
Viewed from terminal side
3) Connect sensor co nnector securely.
HO2S-1 and HO2S-2 Removal and InstallationS7RS0B1306011
Removal
WARNING!
To avoid danger of being burned, do not
touch exhaust system when system is hot.
Oxygen sensor removal should be performed
when system is cool.

1) Disconnect negative (–) cable at battery.
2) Disconnect connector of heated oxygen sensor and
release its wire harness from clamps.
3) Perform following items before removing heated oxygen sensor.
a) For HO2S-1, remove exhaust manifold referring to “Exhaust Manifold Remo val and Installation in
Section 1K”, if necessary.
b) For HO2S-2, hoist vehicle.
4) Remove heated oxygen sensor from exhaust pipe or exhaust manifold.
[A]: Lower limit [D]: Resistance
[B]: Normal [E]: Temperature
[C]: Upper limit
1,(a)
I2RH0B130009-01
20
0
68
32 104 140 176 40 60 80
[E]
2.29 - 2.62
0.309 - 0.331
[A]
[B]
[C][D]
I5JB0A130037-01
[A]: HO2S-1 [B]: HO2S-2
I4RS0A130006-01

Downloaded from www.Manualslib.com manuals search engine 1C-8 Engine Electrical Devices:
Installation
Reverse removal procedure noting the following.
• Tighten heated oxygen sensor to specified torque.Tightening torque
Heated oxygen sensor (a): 45 N·m (4.5 kgf-m,
32.5 lb-ft)
• Install exhaust manifold referring to “Exhaust Manifold Removal and Installation in Section 1K”, if removed.
• Connect connector of heated oxygen sensor and clamp wire harness securely.
• After installing heated oxygen sensor, start engine and check that no exhaust gas leakage exists.
CMP Sensor Removal and InstallationS7RS0B1306012
Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect connector from CMP sensor.
3) Remove CMP sensor from cylinder head.
Installation 1) Install CMP sensor to cylinder head.
Tightening torque
CMP sensor bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
2) Connect connector to CMP sensor securely.
3) Connect negative (–) cable to battery.
Camshaft Position (CMP) Sensor InspectionS7RS0B1306013
Visual check
• Check that O-ring is free from damage.
• Check that end face of sensor and signal rotor tooth are free from any metal particles and damage.
Performance check 1) Remove metal particles on end face of CMP sensor, if any.
2) Arrange 12 V battery (1) and connect its positive terminal to “Vin” terminal (2) and negative terminal to
“Ground” terminal (3) of sensor. Then using
ohmmeter, measure resistance between “Vout”
terminal (4) of sensor and negative terminal of
battery by passing magnetic substance (iron) (5)
while keeping approximately 1 mm (0.03 in.) gap
with respect to end face of CMP sensor.
If resistance does not vary as specified below,
replace CMP sensor.
CMP sensor resistance
Resistance varies from less than 220 Ω (ON) to
infinity (OFF) or from infinity (OFF) to less than 220
Ω (ON)
1. EGR valve
(a)
(a)
I6RS0C130003-02
I6RS0C130004-01
I4RS0B130015-01
I6RS0C130005-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-2
Camshaft Position Control (VVT Variable Valve Timing) System DescriptionS7RS0B1401002
System Description
The VVT system is an electronic control system which continuously vary and optimize the intake valve timing in
response to the engine operating condition.
The optimized intake valve timing produce such an air intake with high efficiency that both the higher power generation
and lower fuel consumption can be attained in the whole engine speed range from low to high. In the area of the
average engine load, low emission of nitrogen oxides (NOx) and high fuel efficiency can also be attained by making
the valve opening overlap between the intake and exhaust valves longer.
For the brief of the system operation, the intake valve timing is varied by the cam timing sprocket (1) which varies the
rotational phase between the intake camshaft (3) and sprocket . The rotor (2) in the cam timing sprocket is actuated by
switching or adjusting the hydraulic pressure applied to the chambers for the timing advancing (7) and/or retarding (6).
To switch or adjust the hydraulic pressure appropriately, ECM operates the oil control valve (12) with detecting the
engine speed, intake air value, throttle opening, engine coolant temperature and camshaft position (angle).
1
4
5
13
10
89
2
7
6
12
11
3
14
60 (variable angle)
Most retarded timing
Most advanced timing
Exhaust valve Intake valve
Crank angle
Overlap of valves
Valve lift
I3RH0B140002-01
4. Oil passage to chamber for timing retarding 8. Oil filter10. Oil pan 13. Oil return
5. Oil passage to chamber for timing advancing 9. Oil pump11. Control signal from ECM 14. Oil flow

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-4
Targeted Timing Varying Operation
Diagnostic Information and Procedures
Compression CheckS7RS0B1404001
Check compression pressure on all 4 cylinders as
follows:
1) Warm up engine to normal operating temperature.
2) Stop engine after warming up.
NOTE
After warming up engine, place transaxle
gear shift lever in “Neutral”, and set parking
brake and block drive wheels.

3) Disconnect negative cable at battery.
4) Remove engine cover.
5) Remove air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
6) Remove cylinder head upper cover.
7) Disconnect ignition coil couplers (1).
8) Remove ignition coil assemblies (2) with high- tension cord (3).
9) Remove all spark plugs.
10) Disconnect fuel injector wires (4) at the coupler. Driving condition Valve timing Target of control Effect
Engine running at idle
speed Most retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to in
take manifold. Stabilization of the engine
rotation at idle speed.
Average engine load
range To the advanced
sideTo lengthen the valve opening overlap
in order to enhance the internal
exhaust gas recirculation and reduce
the pumping loss. Improvement of the fuel
efficiency.
Lowering of the exhaust
emission.
Light engine load
range To the retarded sideTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to in
take manifold. Keeping of the engine stability.
Low or average
engine speed range
with heavy engine
load To the advanced
side
To advance the closing timing of the
intake valve in order to improve the
volumetric efficiency. Improvement of generating the
engine torque at low and
average engine speed.
High engine speed
range with heavy
engine load To the retarded sideTo retard the closing timing of the
intake valve in order to improve the
volumetric efficiency. Improvement of generating the
engine power.
Low engine coolant
temperature Most retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to intake manifold and
reduce the fuel increasing.
To slow the fast idle speed of the
engine as a result of stabilizing the
engine idling. Stabilization of the fast idling of
the engine.
Improvement of the fuel
efficiency.
At engine starting and
stopping Most retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to in
take manifold. Improvement of start ability.I2RH0B140003-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-6
6) Connect special tool (Vacuum gauge) to PCV hose (1).
Special tool
(A): 09915–67311
7) Blind PCV valve (2) using tape (3) or the like.
8) Install air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
9) Run engine at specified idle speed and read vacuum gauge. Vacuum should be within specification.
Vacuum specification (at sea level)
59 – 73 kPa (45 – 55 cmHg, 17.7 – 21.6 in.Hg) at
specified idle speed
10) Remove air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
11) Disconnect special tool (vacuum gage) from PCV valve.
12) Detach blind cap from PCV valve, and connect PCV hose to PCV valve.
13) Install air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
14) Install engine cover.
Valve Lash (Clearance) InspectionS7RS0B1404003
1) Remove negative cable at battery.
2) Remove cylinder head cover referring to “Cylinder Head Cover Removal and Installation”.
3) Remove right side engine under cover, if necessary.
4) Using 17 mm wrench, turn crankshaft pulley (1) clockwise until cam lobes (2) become perpendicular
to shim faces (3) at valves “1” and “7” as shown in
the figure. 5) Check valve lashes with thickness gauge (4)
according to the following procedure.
a) Check valve lashes at valves “1” and “7”.
b) Turn camshafts by 90 ° (by turning crankshaft
with wrench).
c) Make sure that cam lobes are perpendicular to shim faces at valves to be checked (in this case,
“3” and “8”), if not, adjust it by turning crankshaft.
Check valve lashes.
d) In the same manner as b) – c), check valve
lashes at valves “4” and “6”.
e) In the same manner as b) – c) again, check valve lashes at valves “2” and “5”.
If valve lash is out of specification, record valve lash and
adjust it to specification by replacing shim.
Valve clearance specification
When cold (Coolant te mperature is 15 – 25 °C (59 –
77 °F)):
• Intake: 0.18 – 0.22 mm (0.007 – 0.009 in.)
• Exhaust: 0.28 – 0.32 mm (0.011 – 0.013 in.)
When hot (Coolant temperature is 60 – 68 °C (140 –
154 °F)):
• Intake: 0.21 – 0.27 mm (0.008 – 0.011 in.)
• Exhaust: 0.30 – 0.36 mm (0.012 – 0.014 in.)
(A)
13 2
I3RM0A140003-01
I3RM0A140004-01

Downloaded from www.Manualslib.com manuals search engine 1D-7 Engine Mechanical:
Replacement of Shim1) Close the valve whose shim (2) is to be replaced by turning crankshaft, then tu rn tappet (3) till its cut
section (1) faces inside as shown in the figure.
2) Lift down the valve by turning crankshaft to 360° .
3) Hold tappet at that position using special tool as follows.
a) Remove its housing bolts.
b) Check housing No. and select special tool corresponding to housing No., referring to
“Special tool selection table”.
Special tool selection table
c) Hold down the tappet so as not to contact the shim by installing special tool on camshaft
housing with housing bolt (1) tighten housing
bolts by hand.
Special tool
(A): 09916–67020
(A): 09916–67021 4) Turn camshaft by approximately 90
° clockwise and
remove shim (3).
WARNING!
Never put in the hand between camshaft and
tappet.

5) Using a micrometer (2), measure the thickness of the removed shim (1), and determine replacement
shim by calculating the thickness of new shim with
the following formula and table.
Shim thickness specification
Intake side:
A = B + C – 0.20 mm (0.008 in.)
Exhaust side:
A = B + C – 0.30 mm (0.012 in.)
A: Thickness of new shim
B: Thickness of removed shim
C: Measured valve clearance
No. on camshaft
housing Embossed mark on
special tool
I2 IN2
I3, I4, I5 IN345
E2 EX2
E3, E4, E5 EX345
A: I: Intake side or E: Exhaust side
B: Position from timing chain side
C: Pointing to timing chain side
I2RH0B140006-01
I2RH0B140011-01
1. Special tool
2. Magnet
I6RS0B141028-01
I2RH0B140013-01
I2RH0B140014-01

Downloaded from www.Manualslib.com manuals search engine 1D-17 Engine Mechanical:
Engine Assembly Removal and InstallationS7RS0B1406011
NOTE
After replacing electric throttle body
assembly, perform calibration of throttle
valve referring to “Electric Throttle Body
System Calibration in Section 1C”.

Removal1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure in Section 1G”.
2) Disconnect negative and pos itive cable at battery.
3) Remove battery and tray.
4) Remove engine hood after disconnecting windshield washer hose.
5) Remove right and left side engine under covers.
6) Remove A/C compressor belt by referring to “Compressor Drive Belt Remo val and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
7) Drain engine oil, transaxle oil and coolant.
8) Remove cowl top plate referring to “Cowl Top Components in Section 9K”.
9) Remove air cleaner assembly referring to “Air Cleaner Components”.
10) With hose connected, detach A/C compressor from its bracket (A/C model) referring to “Compressor
Assembly Removal and Installation in Section 7B” or
“Compressor Assembly Removal and Installation in
Section 7B”.
CAUTION!
Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

11) Remove intake manifold rear stiffener (1) from intake manifold and cylinder block. 12) Disconnect the following electric wires:
• MAP sensor (1)
• ECT sensor (2)
•EGR valve (3)
• CMP sensor (4)
• Electric throttle body assembly (5)
• Ignition coil assembly (6)
• Injectors (7)
• Heated oxygen sensor No. 2 (8) and No. 1 (9)
• Oil control valve (10)
• Engine oil pressure switch (11)
• CKP sensor (12)
• Knock sensor (13)
• Back up light switch (14)
• Generator (15)
• Starting motor (16)
• Ground terminal (17) from intake manifold
• Battery ground terminal (18) from exhaust manifold
• Battery ground cable (19) from transaxle
• Magnet clutch switch of A/C compressor (A/C model)
• Each wire harness clamps
• Output shaft speed sensor (VSS) (34) (A/T model)
• Solenoid valve (33) (A/T model)
• Transmission range sensor (32) (A/T model)
• Input shaft speed sensor (31) (A/T model)
13) Remove fuse box from its bracket.
14) Disconnect the following cables: • Gear select control cable (23) (M/T model)
• Gear shift control cable (24) (M/T model)
• A/T select cable (A/T model)
15) Disconnect the following hoses: • Brake booster hose (26) from intake manifold
• Radiator inlet and outlet hoses (20) from each pipe
• Heater inlet and outlet hoses (21) from each pipe
• Fuel feed hoses (22) from fuel feed pipe
• EVAP canister purge valve hose (30) from purge pipe
• A/T fluid cooler hoses (A/T model)
16) With hose connected, detach clutch operating cylinder (25). (M/T model)
CAUTION!
Suspend removed clutch operating cylinder
at a place where no damage will be caused
during removal and installation of engine
assembly.

1
I6RS0B141014-01