Oil sensor SUZUKI SWIFT 2007 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 00-1 Precautions:
Precautions
Precautions
Precautions
Precautions for Vehicles Equipped with a
Supplemental Restraint (Air Bag) System
S7RS0B0000001
WARNING!
• The configuration of air bag system parts are as shown in the figure. When it is
necessary to service (remove, reinstall and
inspect) these parts, be sure to follow
procedures described in Air Bag System
section. Failure to follow proper
procedures could result in possible air bag
system activation, personal injury, damage
to parts or air bag system being unable to
activate when necessary.
• If the air bag system and another vehicle system both need repair, SUZUKI
recommends that the air bag system be
repaired first, to help avoid unintended air
bag system activation.
• Do not modify the steering wheel, dashboard, or any other air bag system
components. Modifications can adversely
affect air bag system performance and
lead to injury.
• If the vehicle will be exposed to temperatures over 93 °C (200 °F) (for
example, during a paint baking process),
remove the air bag system components
beforehand to avoid component damage
or unintended air bag system activation.

Diagnosis
• When troubleshooting air bag system, be sure to follow “Diagnosis” in Air Bag System section.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacement.
• Never use electrical test equipment other than that specified.
WARNING!
Never attempt to measure the resistance of
the air bag (inflator) modules (driver,
passenger, side and curtain) and seat belt
pretensioners (driver and passenger). It is
very dangerous as the electric current from
the tester may deploy the air bag or activate
the pretensioner.

1. Air bag wire harness (in floor, main and instrument panel harness) 6. Driver air bag (inflator) module
2. Passenger air bag (inflator) module 7. Side air bag (inflator) module (if equipped)
3. SDM 8. Curtain air bag (inflator) module (if equipped)
4. Seat belt pretensioner 9. Forward sensor
5. Contact coil 10. Side sensor (if equipped)
1 2
3
4
4
5
6
7 7
8
9
10 10
I4RS0B000001-02
I4RS0A000002-02

Downloaded from www.Manualslib.com manuals search engine 00-3 Precautions:
WARNING!
SDM
• For handling and storage of a SDM, select a place where the ambient temperature
below 65 °C (150 °F), without high humidity
and away from electric noise.
• During service procedures, be very careful when handling a Sensing and Diagnostic
Module (SDM). Never strike or jar the SDM.
• Never power up the air bag system when the SDM is not rigidly attached to the
vehicle. All SDM and mounting bracket
fasteners must be carefully torqued and
the arrow must be pointing toward the
front of the vehicle to ensure proper
operation of the air bag system.
The SDM could be activated when powered
while not rigidly att ached to the vehicle
which could cause deployment and result
in personal injury.

WARNING!
Driver and Passenger Seat Belt
Pretensioners
• For handling and storage of a live seat belt pretensioner, select a place where the
ambient temperature below 65 °C (150 ° F),
without high humidity and away from
electric noise.
• Never carry seat belt pretensioner by wire or connector of pretensioner. When
placing a live seat belt pretensioner on the
workbench or some place like that, never
put something on seat belt pretensioner.
Otherwise, personal injury may result.
• Never dispose of live (inactivated) seat belt pretensioners (drive and passenger). If
disposal is necessary, be sure to activate
them according to activation procedures
described in “Air Bag (Inflator) Module and
Seat Belt Pretensioner Disposal in Section
8B” before disposal.
• The seat belt pretensioner immediately after activation is very hot. Wait for at least
half an hour to cool it off before
proceeding the work.
• With many service procedures, gloves and safety glasses should be worn to prevent
any possible irritation of the skin or eyes.

• Even when the accident was light enough not to cause air bags to activate, be sure to inspect system
parts and other related parts according to instructions
under “Repair and Inspection Required after Accident
in Section 8B”.
• When servicing parts other than air bag system, if shocks may be applied to air bag system component
parts, remove those parts beforehand.
• When handling the air bag (inflator) modules (driver, passenger, side and curtain), seat belt pretensioners
(driver and passenger), forward sensor, side sensors
or SDM, be careful not to drop it or apply an impact to
it. If an excessive impact was applied, never attempt
disassembly or repair but replace it with a new one.
• When grease, cleaning agent, oil, water, etc. has got onto air bag (inflator) modules (driver, passenger, side
and curtain) or seat belt pretensioners (drive and
passenger), wipe off immediately with a dry cloth.
• Air bag wire harness is included in floor and instrument panel wire harnesses. Air bag wire
harness branched off from floor and instrument panel
wire harnesses can be identifie d easily as it is covered
with a yellow protection tube and it has yellow
connectors. Be very ca reful when handling it.
• When an open in air bag wire harness, damaged wire harness, connector or terminal is found, replace wire
harness, connectors and terminals as an assembly.
• Do not apply power to the air bag system unless all components are connected or a diagnostic flow
requests it, as this will set a DTC.
• Never use air bag system component parts from another vehicle.
• When using electric welding, be sure to disconnect all air bag (inflator) module connectors and pretensioner
connectors from air bag wire harness respectively.
• Never expose air bag system component parts directly to hot air (drying or baking the vehicle after
painting) or flames.
• WARNING / CAUTION labels are attached on each
part of air bag system components. Be sure to follow
the instructions.
• After vehicle is completely repaired, perform “Air Bag Diagnostic System Check in Section 8B”.

Downloaded from www.Manualslib.com manuals search engine 00-5 Precautions:
• When performing service to electrical parts that does not require use of battery power, disconnect the
negative cable of the battery.
• When disconnecting the negative cable from the battery, be careful to the following.
– Check and record DTCs in ECM and HVAC control module if necessary before disconnecting.
– Record displayed contents of the clock and/or audio system, etc. before disconnecting and reset it
as before after connecting.
– For vehicle equipped with electric throttle body system, perform electric throttle body system
calibration referring to “Electric Throttle Body
System Calibration in Section 1C” after
reconnecting the negative cable to the battery.
– For vehicle equipped with ESP ®, calibrate steering
angle sensor referring to “Sensor Calibration in
Section 4F” after reconnecting the negative cable
to the battery.
• When removing the battery, be sure to disconnect the negative cable first and then the positive cable. When
reconnecting the battery, connect the positive cable
first and then the negative cable, and replace the
terminal cover. • When removing parts that are to be reused, be sure to
keep them arranged in an orderly manner so that they
may be reinstalled in the proper order and position.
• Whenever you use oil seals, gaskets, packing, O- rings, locking washers, split pins, self-locking nuts,
and certain other parts as specified, be sure to use
new ones. Also, before installing new gaskets,
packing, etc., be sure to remove any residual material
from the mating surfaces.
• Make sure that all parts used in reassembly are perfectly clean.
When use of a certain type of lubricant, bond or
sealant is specified, be sure to use the specified type.
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
I2RH01010026-01
I2RH01010027-01
I2RH01010028-01
I2RH01010029-01
I2RH01010030-01

Downloaded from www.Manualslib.com manuals search engine General Information: 0A-2
SAS: Steering Angle Sensor
SDM: Sensing and Diagnostic Module (Air Bag Controller, Air bag Control Module)
SDT: Smart Diagnostic Tester
SFI: Sequential Multipor t Fuel Injection
SOHC: Single Over Head Camshaft
T:
TBI: Throttle Body Fuel Injection (Single-Point Fuel
Injection, SPI)
TCC: Torque Converter Clutch
TCM: Transmission Control Module (A/T Controller, A/T
Control Module)
TDC: Top Dead Center
TP Sensor: Throttle Position Sensor TVV:
Thermal Vacuum Valve (Thermal Vacuum
Switching Valve, TVSV, Bi metal Vacuum Switching
Valve, BVSV)
TWC: Three Way Catalytic Converter (Three Way
Catalyst)
2WD: 2 Wheel Drive
U:
USB: Universal Serial Bus
V:
VIN: Vehicle Identification Number
VSS: Vehicle Speed Sensor
VVT: Variable Valve Timing (Camshaft Position Control)
W:
WU-OC: Warm Up Oxidation Catalytic Converter
WU-TWC: Warm Up Three Way Catalytic Converter
SymbolsS7RS0B0101002
Wire Color SymbolsS7RS0B0101003
Symbol Definition SymbolDefinition
Tightening torque Apply SUZUKI BOND NO. 1216B
99000-31230
Apply oil (engine, transmission, transfer,
differential) Apply SILICONE SEALANT
99000-31120
Apply fluid (brake, power steering or
automatic transmission fluid) Apply SEALING COMPOUND 366E
99000-31090
Apply SUZUKI SUPER GREASE A
99000-25011
Apply SUZUKI SUPER GREASE C
99000-25030 Apply THREAD LOCK 1322
99000-32110
Apply SUZUKI SUPER GREASE E
99000-25050 Apply THREAD LOCK 1333B
99000-32020
Apply SUZUKI SUPER GREASE H
99000-25121 Apply THREAD LOCK 1342
99000-32050
Apply SUZUKI SUPER GREASE I
99000-25210
Apply SUZUKI BOND NO. 1215
99000-31110 Do not reuse
Apply SUZUKI BO ND NO. 1207F
99000-31250 Note on reassembly
Apply SUZUKI BO ND NO. 1217G
99000-31260
Symbol Wire Color SymbolWire Color
B BLK Black O, Or ORN Orange
Bl BLU Blue RRED Red
Br BRN Brown WWHT White
G GRN Green YYEL Yellow
Gr GRY Gray PPNK Pink
Lbl LT BLU Light blueVPPL Violet
Lg LT GRN Light green

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

Downloaded from www.Manualslib.com manuals search engine Table of Contents 1-iii
EVAP Canister Purge Valve and Its Circuit
Inspection.......................................................... 1B-2
Vacuum Passage Inspection .............................. 1B-3
Vacuum Hose and Purge Valve Chamber Inspection.......................................................... 1B-3
EVAP Canister Purge Valve Inspection .............. 1B-3
EVAP Canister Inspection ... ................................ 1B-4
EGR Valve Removal and Installation .................. 1B-4
EGR Valve Inspection ......................................... 1B-4
PCV Hose Inspection .......................................... 1B-4
PCV Valve Inspection ......................................... 1B-5
Special Tools and Equipmen t ............................. 1B-5
Special Tool ........................................................ 1B-5
Engine Electrical Devices .. ..................... 1C-1
Repair Instructions .............................................. 1C-1
ECM Removal and Installation ............................ 1C-1
MAP Sensor Inspection ...................................... 1C-2
Electric Throttle Body Assembly On-Vehicle
Inspection.......................................................... 1C-2
Electric Throttle Body System Calibration ........... 1C-5
APP Sensor Assembly On-V ehicle Inspection .... 1C-5
APP Sensor Assembly Removal and Installation ......................................................... 1C-5
APP Sensor Assembly Inspection ...................... 1C-6
ECT Sensor Removal and In stallation ................ 1C-6
ECT Sensor Inspection ....................................... 1C-7
HO2S-1 and HO2S-2 Heater On-Vehicle Inspection.......................................................... 1C-7
HO2S-1 and HO2S-2 Removal and Installation ......................................................... 1C-7
CMP Sensor Removal and In stallation ............... 1C-8
Camshaft Position (CMP) Se nsor Inspection ...... 1C-8
CKP Sensor Removal and Installation ................ 1C-9
CKP Sensor Inspection ....................................... 1C-9
Knock Sensor Removal and Installation ........... 1C-10
Main Relay, Fuel Pump Relay and Starting
Motor Control Relay Inspection....................... 1C-10
MAF and IAT Sensor On-Vehicle Inspection .... 1C-11
MAF and IAT Sensor Removal and Installation ....................................................... 1C-11
MAF and IAT Sensor Inspection ....................... 1C-12
Electric Load Current Sensor On-Vehicle Inspection........................................................ 1C-12
Specifications ..................................................... 1C-13
Tightening Torque Specifications ...................... 1C-13
Engine Mechanical ......... ......................... 1D-1
General Description ............................................. 1D-1
Engine Construction Description ......................... 1D-1
Camshaft Position Control (VVT Variable Valve Timing) System Description .................... 1D-2
Diagnostic Information and Procedures ............ 1D-4 Compression Check ............................................ 1D-4
Engine Vacuum Check ....................................... 1D-5
Valve Lash (Clearance) Inspection ..................... 1D-6
Repair Instructions .............................................. 1D-9 Air Cleaner Components ..................................... 1D-9
Air Cleaner Element Removal and Installation .... 1D-9 Air Cleaner Element Ins
pection and Cleaning ..1D-10
Cylinder Head Co ver Removal and
Installation .......................................................1D-10
Throttle Body and Intake Manifold
Components ....................................................1D-12
Throttle Body On-Vehicle Inspection.................1D-13
Electric Throttle Body Assembly Removal and Installation .......................................................1D-13
Throttle Body Cleaning......................................1D-14
Intake Manifold Removal and Installation .........1D-14
Engine Mountings Components ........................1D-16
Engine Assembly Removal and Installation ......1D-17
Timing Chain Cover Components .....................1D-20
Timing Chain Cover Removal and Installation ..1D-21
Timing Chain Cover Inspection .........................1D-23
Oil Control Valve Removal and Installation .......1D-23
Oil Control Valve Inspection ..............................1D-24
Timing Chain and Chain Tensioner Components ....................................................1D-24
Timing Chain and Chain Tensioner Removal and Installation ................................................1D-25
Timing Chain and Chain Tensioner Inspection ..1D-27
Camshaft, Tappet and Shim Components ........1D-28
Camshaft, Tappet and Shim Removal and Installation .......................................................1D-29
Camshaft, Tappet and Shim Inspection ............1D-31
Valves and Cylinder Head Components ...........1D-34
Valves and Cylinder Head Removal and
Installation .......................................................1D-35
Valves and Cylinder Head Disassembly and Assembly.........................................................1D-37
Valves and Valve Guides Inspection.................1D-40
Cylinder Head Inspection . .................................1D-42
Valve Spring Inspection ....................................1D-43
Pistons, Piston Rings , Connecting Rods and
Cylinders Components ....................................1D-44
Pistons, Piston Rings , Connecting Rods and
Cylinders Removal and Installation .................1D-45
Pistons, Piston Rings , Connecting Rods and
Cylinders Disassembly and Assembly ............1D-46
Cylinders, Pistons and Piston Rings Inspection ........................................................1D-47
Piston Pins and Connecting Rods Inspection ...1D-49
Crank Pin and Connecting Rod Bearings Inspection ........................................................1D-50
Main Bearings, Cran kshaft and Cylinder
Block Components ..........................................1D-53
Main Bearings, Cran kshaft and Cylinder
Block Removal and Installa tion .......................1D-54
Crankshaft Inspection .......................................1D-57
Main Bearings Inspection . .................................1D-59
Sensor Plate Inspection ....................................1D-63
Rear Oil Seal Inspection ...................................1D-63
Flywheel Inspection...........................................1D-63
Cylinder Block Inspection ..................................1D-63
Specifications .................... .................................1D-64
Tightening Torque Specifications ......................1D-64
Special Tools and Equipmen t ...........................1D-66
Recommended Service Material .......................1D-66
Special Tool ......................................................1D-66

Downloaded from www.Manualslib.com manuals search engine 1-iv Table of Contents
Engine Lubrication System.....................1E-1
General Description ............................................. 1E-1
Engine Lubrication Description ........................... 1E-1
Diagnostic Information and Procedures ............ 1E-2 Oil Pressure Check ............................................. 1E-2
Repair Instructions ........... ................................... 1E-3
Heat Exchanger Components ............................. 1E-3
Heat Exchanger On-Vehicle Inspection .............. 1E-4
Heat Exchanger Removal and Installation .......... 1E-4
Oil Pan and Oil Pump Strainer Components....... 1E-5
Oil Pan and Oil Pump Strainer Removal and
Installation ......................................................... 1E-5
Oil Pan and Oil Pump Stra iner Cleaning ............. 1E-7
Oil Pump Components ........................................ 1E-8
Oil Pump Removal and Installation ..................... 1E-8
Oil Pump Disassembly and Reassembly ............ 1E-8
Oil Pump Inspection ............................................ 1E-9
Specifications .... ................................................. 1E-11
Tightening Torque Specifications ...................... 1E-11
Special Tools and Equipmen t ........................... 1E-11
Recommended Service Material ....................... 1E-11
Special Tool ...................................................... 1E-11
Engine Cooling System ..... ...................... 1F-1
General Description .......... ................................... 1F-1
Cooling System Descriptio n ................................ 1F-1
Coolant Description ............................................. 1F-1
Schematic and Routing Diagram ........................ 1F-2 Coolant Circulation .............................................. 1F-2
Diagnostic Information and Procedures ............ 1F-4 Engine Cooling Symptom Diagnosis ................... 1F-4
Repair Instructions ........... ................................... 1F-5
Cooling System Components.............................. 1F-5
Coolant Level Check ........................................... 1F-6
Engine Cooling System Inspection and Cleaning ............................................................ 1F-6
Cooling System Draining.. ................................... 1F-6
Cooling System Flush and Refill ......................... 1F-7
Cooling Water Pipes or Hoses Removal and Installation ......................................................... 1F-7
Thermostat Removal and In stallation.................. 1F-8
Thermostat Inspection......................................... 1F-8
Radiator Cooling Fan Motor On-Vehicle Inspection .......................................................... 1F-9
Radiator Cooling Fan Rela y Inspection............... 1F-9
Radiator Cooling Fan Removal and Installation ....................................................... 1F-10
Radiator On-Vehicle Inspection and Cleaning .. 1F-10
Radiator Removal and Inst allation .................... 1F-10
Water Pump Removal and In stallation .............. 1F-11
Water Pump Inspection ..................................... 1F-11
Specifications .... ................................................. 1F-12
Tightening Torque Specifications ...................... 1F-12
Special Tools and Equipmen t ........................... 1F-12
Recommended Service Material ....................... 1F-12
Fuel System ................... .......................... 1G-1
Precautions.......................................................... 1G-1 Precautions on Fuel System Service ................. 1G-1
General Description ............................................ 1G-1 Fuel System Description .................................... 1G-1
Fuel Delivery System Description ...................... 1G-1
Fuel Pump Description ....................................... 1G-2
Schematic and Routing Diagram ....................... 1G-2 Fuel Delivery System Diag ram........................... 1G-2
Diagnostic Information and Procedures ........... 1G-2 Fuel Pressure Inspection ................................... 1G-2
Fuel Cut Operation Inspection ........................... 1G-3
Repair Instructions ............ ................................. 1G-4
Fuel System Components .................................. 1G-4
Fuel Hose Disconnecting and Reconnecting ..... 1G-5
Fuel Pressure Relief Procedure ......................... 1G-7
Fuel Leakage Check Procedure......................... 1G-7
Fuel Lines On-Vehicle Inspection ...................... 1G-7
Fuel Pipe Removal and Installation.................... 1G-7
Fuel Injector On-Vehicle Inspection ................... 1G-8
Fuel Injector Removal and Installation ............... 1G-8
Fuel Injector Inspection ...................................... 1G-9
Fuel Filler Cap Inspection . ............................... 1G-10
Fuel Tank Inlet Valve Removal and Installation ...................................................... 1G-11
Fuel Tank Inlet Valve Inspection ...................... 1G-12
Fuel Tank Removal and Installation ................. 1G-12
Fuel Tank Inspection ........................................ 1G-13
Fuel Tank Purging Procedure .......................... 1G-14
Fuel Pump On-Vehicle Inspection.................... 1G-14
Fuel Pump Assembly Removal and Installation ...................................................... 1G-14
Main Fuel Level Sensor Removal and Installation ...................................................... 1G-15
Fuel Pump Inspection ...................................... 1G-16
Specifications ..................... ............................... 1G-16
Tightening Torque Specifications ..................... 1G-16
Special Tools and Equipmen t .......................... 1G-17
Special Tool ..................................................... 1G-17
Ignition System .............. .......................... 1H-1
General Description .............................................1H-1
Ignition System Construction ..............................1H-1
Schematic and Routing Diagram ........................1H-2 Ignition System Wiring Circuit Diagram...............1H-2
Component Location ............ ...............................1H-3
Ignition System Components Location................1H-3
Diagnostic Information and Procedures ............1H-4 Ignition System Symptom Diagnosis...................1H-4
Reference Waveform of Ignition System.............1H-4
Ignition System Check ........................................1H-4
Ignition Spark Test ..............................................1H-6
Repair Instructions ............ ..................................1H-6
High-Tension Cord Removal and Installation......1H-6
High-Tension Cord Inspection.............................1H-7
Spark Plug Removal and Installation ..................1H-7
Spark Plug Inspection .........................................1H-7
Ignition Coil Assembly (Including ignitor)
Removal and Installation ...................................1H-8
Ignition Coil Assembly (Including ignitor)
Inspection ..........................................................1H-8

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.

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

Downloaded from www.Manualslib.com manuals search engine 1A-8 Engine General Information and Diagnosis:
CAN communication system uses the serial communication in which data is transmitted at a high speed. It uses a
twisted pair of two communication lines for the high-speed da ta transmission. As one of its characteristics, multiple
control modules can communicate simultaneously. In addition, it has a function to detect a communication error
automatically. Each module reads necessary data from the received data and transmits data. ECM communicates
control data with each control module as follows.
ECM Transmission Data
NOTE
• In communication between ECM and combination meter and between ECM and steering angle sensor (ESP ® model), data is transmitted only from ECM to combination meter and steering angle
sensor. (Combination meter and steering angle sensor does not transmit data to ECM.)
• *1: Hong Kong model only.

ECM Reception Data
Engine torque signal
Accelerator pedal position signal
Throttle position signal
Brake pedal switch signal
A/C refrigerant pressure signal
A/C compressor clutch signal
Fuel consumption signal
Immobilizer indicator light control signal
MIL control signal
Diagnostic trouble code (DTC)
Engine coolant temperature signal
Engine speed signal
Vehicle speed signal
ECM-keyless start control module code TCM BCM
Combination
Meter Keyless Start
ControlModule
Transmit DATA
ECM
ESP® Control
Module ABS Control
Module
(Non-ESP® model)
*1
I7RS0B110002-01
TCM BCM Keyless Start
Control Module
DATA
ECM
Torque request signal
A/T select lever position signal
Transmission actual gear position signal
Transmission oil temperature signal
A/C switch ON signal
Electric load signal
ESP® status signal
ABS active signal
Wheel speed signal (front right)
Wheel speed signal (front left)
ECM-keyless start control module code
ID code of keyless start control module
Receive
ABS Control
Module
(Non-ESP® model)
ESP® Control
Module
I7RS0B110003-02