tightening torque SUZUKI SWIFT 2008 2.G Service User Guide

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Electric Throttle Body System CalibrationS7RS0B1306004
NOTE
If working the service described under the
“Precautions of Electric Throttle Body
System Calibration in Section 1A” perform
following steps for electric throttle body
system calibration.

1) If electric throttle body assembly and/or APP sensor
assembly are replaced, perform following steps.
a) Disconnect negative cable at battery for 20 seconds or more for the purpose of clearing
calibration data of closed throttle position from
memory in ECM.
b) Connect negative cable to battery.
2) Keep ignition switch at ON position for 5 seconds or more without running engine.
APP Sensor Assembly On-Vehicle InspectionS7RS0B1306005
1) Check that APP sensor a ssembly has been mounted
to vehicle body properly (no pinched floor carpet,
etc.).
If mounting is not pro perly, reinstall APP sensor
assembly properly refe rring to “APP Sensor
Assembly Removal and Installation”.
2) Connect scan tool to DLC with ignition switch turned OFF.
3) Turn ON ignition switch and select “Data List” mode on scan tool.
4) Check that APP sensor voltage varies as the following graph.
If sensor voltage is out of specified value or does not
vary linearly as the fo llowing graph, check APP
sensor assembly referring to “APP Sensor Assembly
Inspection”.
APP Sensor Assembly Removal and InstallationS7RS0B1306006
CAUTION!
• Do not expose APP sensor assembly to
excessive shock like a dropping it. If APP
sensor assembly has been exposed to
excessive shock, it should be replaced.
• Be careful not to expose sensor section of APP sensor assembly to water.

NOTE
After replacing APP sensor assembly,
perform calibration of th rottle valve referring
to “Electric Throttle Body System
Calibration”.

Removal
1) Disconnect negative cable at battery.
2) Disconnect connector from APP sensor assembly.
3) Remove APP sensor asse mbly from its bracket.
Installation
Reverse removal procedure for installation noting the
following.
• Tighten APP sensor assembly upper nut (1) first and then lower nut (2) to specified torque.
Tightening torque
APP sensor assembly nut (a): 5.5 N·m (0.55 kgf-m,
4.0 lb-ft)
• Connect connector to APP sensor assembly securely.
[A]: APP sensor (main) voltage [D]: Idle position of accelerator pedal
[B]: APP sensor (sub) voltage [E]: Full depressed position of
accelerator pedal
[C]: Voltage
[C]
[B]
[D] [E] [A]
4.65 V
3.85 V
1.55 - 1.65 V
0.75 - 0.85 V
I4RS0B130010-02
1, (a)
2, (a)
I4RS0B130011-01

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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

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CKP Sensor Removal and InstallationS7RS0B1306014
Removal1) Disconnect negative (–) cable at battery.
2) Remove generator drive belt refer to “Water Pump / Generator Drive Belt Remo val and Installation in
Section 1J”.
3) Remove generator bracket bolt (1) and move generator rearward.
4) Disconnect connector from CKP sensor.
5) Remove CKP sensor (2) from cylinder block.
Installation 1) Install CKP sensor to cylinder block. Tighten CKP sensor bolt to specified torque.
Tightening torque
CKP sensor bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
2) Connect connector to CKP sensor securely.
3) Adjust generator drive belt tension referring to “Water Pump / Generator Drive Belt Tension
Inspection and Adjustment in Section 1J”.
4) Connect negative (–) cable to battery.
CKP Sensor InspectionS7RS0B1306015
Visual check
• Check that O-ring is free from damage.
• Check that end face of sensor and signal pulley tooth are free from any metal particles and damage.
Performance check 1) Remove metal particles on end face of CKP 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 CKP sensor.
If resistance does not vary as specified below,
replace CKP sensor.
CKP sensor resistance
Resistance varies from less than 220 Ω (ON) to
infinity (OFF) or from infinity (OFF) to less than 220
Ω (ON)
2
1
I6RS0C130006-01
(a)
I4RS0A130007-01
I3RB0A130006-01
I4RS0B130017-01

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Knock Sensor Removal and InstallationS7RS0B1306016
Removal1) Disconnect negative (–) cable at battery.
2) Hoist vehicle.
3) Remove right side drive shaft referring to “Front Drive Shaft Assembly Removal and Installation in
Section 3A”.
4) Disconnect knock sensor connector (1).
5) Remove knock sensor (2) from cylinder block.
Installation
Reverse removal procedure for installation.
Tightening torque
Knock sensor (a): 22 N· m (2.2 kgf-m, 16.0 lb-ft)
Main Relay, Fuel Pump Relay and Starting Motor
Control Relay Inspection
S7RS0B1306017
1) Disconnect negative (–) cable at battery.
2) Remove main relay (1), fuel pump relay (3) and/or
starting motor control relay (2) from individual circuit
fuse box No.1.
3) Check that there is no continuity between terminal “C” and “D”. If there is continuity, replace relay.
4) Connect battery positive (+ ) terminal to terminal “B”
of relay. Connect battery negative (–) terminal to
terminal “A” of relay. Ch eck for continuity between
terminal “C” and “D”. If t here is no continuity when
relay is connected to the battery, replace relay.
1 2, (a)
I3RB0A130007-01
"D"
"B" "A"
"C"
2
1
3
I4RS0A130014-01

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MAF and IAT Sensor On-Vehicle InspectionS7RS0B1306018
NOTE
Before performed this inspection, be sure to
read the “Precautions of ECM Circuit
Inspection in Section 1A”.

1) Disconnect negative (–) cable at battery.
2) Disconnect MAF and IAT sensor connector.
3) Connect voltmeter to “BLK/RED” wire terminal (2) of
MAF and IAT sensor connector (1) disconnected and
ground.
4) Turn ON ignition switch position and check that voltage is battery voltage.
If not, check if wire harness is open or connection is
poor.
5) Turn OFF ignition switch position and connect connector to MAF and IAT sensor.
6) Remove ECM from its bracket referring to “ECM Removal and Installation”.
7) Connect special tool between ECM and ECM connector referring to “Inspection of ECM and Its
Circuits in Section 1A”.
8) Turn ON ignition switch position and check MAF signal voltage between “C37-26” terminal circuit and
“C37-27” terminal circuit of special tool.
MAF signal voltage between “C37-26” terminal
circuit and “C37-27” termi nal circuit of special
tool
MAF signal voltage of MAF and IAT sensor with
ignition switch turned ON: 0.5 – 1.0 V
9) Start engine and check that voltage is lower than 5 V and it rises as engine speed increases.
MAF signal voltage between “C37-26” terminal
circuit and “C37-27” termi nal circuit of special
tool
MAF signal reference voltage of MAF and IAT
sensor at specified Idle speed: 1.3 – 1.8 V 10) If check result is not as
specified above, cause may
lie in wire harness, connec tor connection, MAF and
IAT sensor or ECM.
MAF and IAT Sensor Removal and InstallationS7RS0B1306019
CAUTION!
• Do not disassemble MAF and IAT sensor.
• Do not expose MAF and IAT sensor to any shock.
• Do not clean MAF and IAT sensor.
• If MAF and IAT sensor has been dropped, it should be replaced.
• Do not blow compressed air by using air gun or the like.
• Do not put finger or any other object into MAF and IAT sensor. Malfunction may
occur.

Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect MAF and IAT sensor connector.
3) Remove air cleaner case (1).
4) Remove MAF and IAT sensor (2) from air cleaner case.
Installation
Reverse removal procedure noting the followings.
• Tighten MAF and IAT sensor screws to specified torque.
Tightening torque
MAF and IAT sensor screw (a): 1.5 N·m (0.15 kgf-
m, 1.1 lb-ft)
• Connect MAF and IAT sensor connector securely.
1. ECM
I3RB0A130009-01
“C37-27” “C37-26” 1
I4RS0A130009-01
1
2
I4RS0A130010-01
(a)
I4RS0A130011-01

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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-8
For example of intake side:
When thickness of removed shim is 2.40 mm (0.094
in.), and measured valve clearance is 0.45 mm
(0.018 in.).
A = 2.40 mm (0.094 in.) + 0.45 mm (0.018 in.) – 0.20
mm (0.008 in.) = 2.65 mm (0.104 in.)
Calculated thickness of new shim = 2.65 mm (0.104
in.)
6) Select new shim No. (1) with a thickness as close as possible to calculated value.
Available new shims No.
7) Install new shim facing shim No. side with tappet. 8) Lift valve by turning crankshaft counterclockwise (in
opposite direction against above Step 4)) and
remove special tool.
Special tool
(A): 09916–67020
(A): 09916–67021
9) Install camshaft housing (1) and tighten bolts to specified torque.
Tightening torque
Camshaft housing bolt (a ): 11 N·m (1.1 kgf-m,
8.0 lb-ft)
10) Check valve clearance again after adjusting it. 11) After checking and adjusting all valves.
12) Install cylinder head cover referring to “Cylinder Head Cover Removal and Installation”.
Thickness
mm (in.) Shim No.Thickness
mm (in.) Shim No.
2.175 (0.0856) 218 2.600 (0.1024) 260
2.200 (0.0866) 220 2.625 (0.1033) 263
2.225 (0.0876) 223 2.650 (0.1043) 265
2.250 (0.0886) 225 2.675 (0.1053) 268
2.275 (0.0896) 228 2.700 (0.1063) 270
2.300 (0.0906) 230 2.725 (0.1073) 273
2.325 (0.0915) 233 2.750 (0.1083) 275
2.350 (0.0925) 235 2.775 (0.1093) 278
2.375 (0.0935) 238 2.800 (0.1102) 280
2.400 (0.0945) 240 2.825 (0.1112) 283
2.425 (0.0955) 243 2.850 (0.1122) 285
2.450 (0.0965) 245 2.875 (0.1132) 288
2.475 (0.0974) 248 2.900 (0.1142) 290
2.500 (0.0984) 250 2.925 (0.1152) 293
2.525 (0.0994) 253 2.950 (0.1161) 295
2.550 (0.1004) 255 2.975 (0.1171) 298
2.575 (0.1014) 258 3.000 (0.1181) 300
I2RH0B140015-01
1. Tappet
2. Camshaft
(A)2
1
I3RM0A140006-01
I2RH0B140149-01

Downloaded from www.Manualslib.com manuals search engine 1D-11 Engine Mechanical:
2) Remove oil, old sealant, and dust from sealing surfaces on cylinder head and cover. After cleaning,
apply sealant “A” to the following point.
• Cylinder head cover gasket (1) sealing surface area (2) as shown.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F)
• Timing chain cover (1) and cylinder head (2) mating surface as shown.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F) 3) Install cylinder head cover to cylinder head.
NOTE
When installing cylinder head cover, use care
so that cylinder head cover gasket or spark
plug hole gaskets will not get out of place or
fall off.

4) Tighten cylinder head cover bolts as follows.
a) Tighten cylinder head cover bolts to 3 N ⋅m (0.3
kgf-m, 2.5 lb-ft) according to numerical order (“1”
through “7”) as shown in figure.
b) In the same manner as in Step, a) tighten them
to 5 N ⋅m (0.5 kgf-m, 4.0 lb-ft).
c) Retighten them by turning through 8 N ⋅m (0.8
kgf-m, 6.0 lb-ft) in same manner as Step a).
Tightening torque
Cylinder head cover bolt (a): Tighten 3 N ⋅m (0.3
kgf-m, 2.5 lb-ft), 5 N ⋅m (0.5 kgf-m, 4.0 lb-ft) and 8
N ⋅m (0.8 kgf-m, 6.0 lb-ft) by the specified
procedure
5) Connect PCV hose (2) to PCV valve (3).
6) Connect breather hose (4).
7) Install oil level gauge (1).
8) Install wire harness clamp to cylinder head cover.
9) Install ignition coil assemb lies with high-tension cord
referring to “Ignit ion Coil Assembly (Including ignitor)
Removal and Installati on in Section 1H”.
10) Connect ignition coil couplers and clamp harness securely.
11) Install cylinder head upper cover.
12) Install air cleaner case and resonator.
13) Connect negative cable at battery.
I2RH0B140036-01
I2RH0B140037-01
I3RH0B140016-01

Downloaded from www.Manualslib.com manuals search engine 1D-15 Engine Mechanical:
Installation
Reverse removal procedure for installation noting the
followings.
• Use new intake manifold gasket (1).
• Use new EGR pipe gasket (2).
• Install intake manifold bolts (3) and nuts (4) to specified torque.
Tightening torque
Intake manifold bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
Intake manifold nut (b): 23 N·m (2.3 kgf-m, 17.0
lb-ft) • Install intake manifold rear stiffener (1) as shown in
figure.
• Connect ground terminal (2) to intake manifold to specified torque.
Tightening torque
Intake manifold ground terminal bolt (a): 11 N·m (
1.1 kgf-m, 8.0 lb-ft)
• Install throttle body referrin g to “Electric Throttle Body
Assembly Removal and Installation”.
• Install cowl top plate referring to “Cowl Top Components in Section 9K”.
• Refill cooling system refe rring to “Cooling System
Flush and Refill in Section 1F”.
• Upon completion of installation, turn ignition switch ON but engine OFF and check for fuel leaks.
• Finally, start engine and check for engine coolant leaks.
1
2
3,(a)
4,(b)
I6RS0B141011-01
(a)
12
I6RS0B141012-01