Engine cover SUZUKI SWIFT 2008 2.G Service Service Manual

Downloaded from www.Manualslib.com manuals search engine 1G-3 Fuel System:
4) Check that battery voltage is 11 V or more.
5) Measure fuel pressure at each condition.If measured pressure is out of specification, refer to
“Fuel Pressure Check in Section 1A” and check each
possibly defective part. Replace if found defective.
a) Turn ignition switch ON to operate fuel pump and after 2 seconds turn it OFF. Repeat this 3 or 4
times and then check fuel pressure.
Fuel pressure specification
With fuel pump operating and engine
stopped: 270 – 310 kPa (2.7 – 3.1 kg/cm2, 38.4
– 44.0 psi)
b) Start engine and warm it up to normal operating temperature, and measure fuel pressure at
idling.
Fuel pressure specification
At specified idle speed: 270 – 310 kPa (2.7 –
3.1 kg/cm2, 38.4 – 44.0 psi)
c) Stop engine, and measure fuel pressure at one minute after stopping.
Fuel pressure specification
With 1 min. after engine (fuel pump) stop
(Pressure reduces as time passes): Over 300
kPa (3.0 kg/cm
2, 42.7 psi)
6) After checking fuel pressure, remove fuel pressure gauge.
WARNING!
As fuel feed line is still under high fuel
pressure, make sure to release fuel pressure
according to the following procedures.
• Place fuel container under joint.
• Cover joint with rag and loosen joint nut slowly in order to release fuel pressure
gradually.

7) Remove special tools from fuel delivery pipe and fuel feed hose.
8) Connect fuel feed hose to fuel delivery pipe and clamp it securely.
9) With engine OFF and ignition switch ON, check for fuel leaks.
Fuel Cut Operation InspectionS7RS0B1704002
NOTE
Before inspection, make sure that gear shift
lever is in neutral positi on (shift select lever
is “P” range for A/T vehicle), A/C is OFF and
parking brake lever is pulled all the way up.

1) Warm engine up to normal operating temperature.
2) While listening to sound of injector (2) by using sound scope (1) or such, increase engine speed to
higher than 3,000 r/min.
3) Check to make sure that injector operation sound is stop when throttle valve is closed instantly and it is
heard again when engine speed is reduced to
approx. 2,000 r/min or less.
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Repair Instructions
Fuel System ComponentsS7RS0B1706001
5
14
4
24
8
3
13
23
1
25
21
112
22 10
6
16
26
18
17
19
10
12
9
(b)
(a)
15
(c)
20 27
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1. Fuel tank 12. Fuel tank bolt 23. Main fuel level sensor
2. Fuel pump assembly 13. Fuel pump assembly bolt 24. To fuel vapor line
3. Breather hose 14. Fuel filler neck 25. Fuel feed hose
4. Fuel tank filler hose 15. Fuel delivery pipe 26. Grommet
5. Fuel filler cap 16. Fuel delivery pipe bolt 27. To fuel tank
6. Fuel feed line 17. Fuel injector : Do not reuse.
7. Fuel vapor line 18. Injector cushion : 45 N⋅m (4.5 kgf-m, 33.0 lb-ft)
8. Fuel tank inlet valve 19. Fuel delivery pipe insulator : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
9. Fuel tank protector 20. O-ring : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
10. Fuel tank belt 21. To canister
11. Fuel pump gasket 22. Fuel tank cover

Downloaded from www.Manualslib.com manuals search engine 1G-7 Fuel System:
Fuel Pressure Relief ProcedureS7RS0B1706003
CAUTION!
This work must not be done when engine is
hot. If done so, it may cause adverse effect to
catalyst.

NOTE
If ECM detects DTC(s) after servicing, clear
DTC(s) referring to “DTC Clearance in
Section 1A”.

1) Make sure that engine is cold.
2) Shift transaxle gear shift lever in “Neutral” (shift select lever in “P” range for A/T model), set parking
brake and block drive wheels.
3) Remove relay / fuse box cover.
4) Disconnect fuel pump relay (1) from relay / fuse box (2).
5) Remove fuel filter cap in order to release fuel vapor pressure in fuel tank, and then reinstall it.
6) Start engine and run it until engine stops for lack of fuel. Repeat cranking engine 2 – 3 times for about 3
seconds each time in order to dissipate fuel pressure
in lines. Fuel connections are now safe for servicing.
7) After servicing, connect fuel pump relay (1) to relay / fuse box and install re lay / fuse box cover.
Fuel Leakage Check ProcedureS7RS0B1706004
After performing any service on fuel system, check to
make sure that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump) and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply
fuel pressure to fuel line until fuel pressure is felt by
hand placed on fuel feed hose.
2) In this state, check to see that there are no fuel leakages from any part of fuel system.
Fuel Lines On-Vehicle InspectionS7RS0B1706005
CAUTION!
Due to the fact that fuel feed line (1) is under
high pressure, use special care when
servicing it.

Visually inspect fuel lines for evidence of fuel leakage,
hose crack and deterioration or damage.
Make sure all cl amps are secure.
Replace parts as needed.
Fuel Pipe Removal and InstallationS7RS0B1706006
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal
1) Relieve fuel pressure in fuel feed line according to “Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Disconnect fuel pipe joint and fuel hose (3) from fuel pipe (2) at the front and rear of each fuel pipe
referring to “Fuel Hose Disconnecting and
Reconnecting”.
4) Mark the location of clamps (1) on fuel pipes (2), so that the clamps can be reinstalled to where they
were.
5) Remove pipes (2) with clamp (1) from vehicle.
6) Remove clamp (1) from pipes (2).
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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.

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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).

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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.
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Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-9
6) Set timing light (1) to high-tension cord for No.1 cylinder and check that ignition timing is within
specification.
Initial ignition timing
Fixed with SUZUKI scan tool: 5 ± 3° BTDC (at
specified idle speed)
Ignition order
1 – 3 – 4 – 2
Special tool
(A): 09930–76420 7) If ignition timing is out
of specification, check the
followings.
• CKP sensor
• CKP sensor plate
• CMP sensor
• CMP sensor rotor tooth of camshaft
• VSS
• Timing chain cover installation
8) After checking initial igniti on timing, release ignition
timing fixation by using scan tool.
9) With engine idling (throttl e opening at closed position
and vehicle stopped), check that ignition timing is
about 3 ° – 13° BTDC. (Constant variation within a
few degrees from 3 ° – 13° BTDC indicates no
abnormality but proves operation of electronic timing
control system.) Also, check that increasing engine
speed advances ignition timing.
If the check results are not satisfactory, check CKP
sensor and ECM.
Specifications
Tightening Torque SpecificationsS7RS0B1807001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Special ToolS7RS0B1808001
1, (A)10
0I3RB0A180004-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Spark plug 25 2.5 18.0 )
Ignition coil bolt 10 1.0 7.5 )
09930–76420SUZUKI scan tool
Timing-light (dry cell type) —
) This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12. )

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.

Downloaded from www.Manualslib.com manuals search engine Exhaust System: 1K-2
Repair Instructions
Exhaust System ComponentsS7RS0B1B06001
WARNING!
To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any
service on the exhaust system should be performed when the system is cool.

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[A]: MT model14. Exhaust manifold bolt 29. To vehicle body
[B]: AT model 15. Exhaust manifold nut 30. Damper
1. Exhaust manifold gasket 16. Exhaust No.1 pipe bolt 31. Damper nut
2. Exhaust manifold 17. Exhaust manifold stiffener bolt 32. To exhaust pipe No.1
3. Exhaust manifold stiffener 18. Exhaust No.2 pipe bolt 33. To exhaust manifold stiffener
4. Heated oxygen sensor No.2 (connector color: green) 19. Exhaust center pipe bolt 34. To oil pan
5. Exhaust pipe No.1 gasket 20. Exhaust pipe No.2 gasket : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft)
6. No.1 seal ring 21. Muffler nut : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft)
7. No.2 seal ring 22. Muffler tail pipe : 43 N⋅m (4.3 kgf-m, 31.0 lb-ft)
8. Exhaust No.1 pipe 23. Engine hook : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)
9. Exhaust No.2 pipe 24. Heated oxygen sensor No.1 (connector color: gray) : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
10. Exhaust center pipe 25. Heat insulator : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
11. Muffler 26. Heat insulator bolt : Do not reuse.
12. Center pipe mounting 27. Exhaust manifold cover
13. Muffler mounting 28. To cylinder block

Downloaded from www.Manualslib.com manuals search engine 1K-3 Exhaust System:
Exhaust Manifold Removal and InstallationS7RS0B1B06002
Removal
WARNING!
To avoid danger of being burned, do not
service exhaust system while it is still hot.
Service should be performed after system
cools down.

1) Disconnect negative cable at battery.
2) Remove engine cover.
3) Remove front bumper with front grille referring to
“Front Bumper and Rear Bumper Components in
Section 9K”.
4) Remove radiator referring to “Radiator Removal and Installation in Section 1F ” for equipped with A/C.
5) With hose connected, detach A/C condenser from vehicle body for equipped with A/C.
6) Remove exhaust manifold cover from exhaust manifold.
7) Disconnect heated oxygen sensor No.2 connector (1) (connector color: green) and heated oxygen
sensor No.1 connector (2) (connector color: black),
and then detach it from its stay.
8) Remove exhaust manifold stiffener (1).
9) Remove heated oxygen sensors (3) from exhaust manifold and exhaust No.1 pipe, if necessary.
10) Disconnect exhaust No.1 pipe (2) from exhaust manifold. 11) Remove exhaust manifold (1) and its gasket from
cylinder head.
Installation 1) Install new gasket to cylinder head. Then install exhaust manifold (3).
Tighten manifold bolts (1) and nuts (2) to specified
torque.
Tightening torque
Exhaust manifold bolt (a): 50 N·m (5.0 kgf-m,
36.5 lb-ft)
Exhaust manifold nut (b): 50 N·m (5.0 kgf-m,
36.5 lb-ft)
NOTE
Be sure to install exhaust manifold bolts and
nuts to proper location referring to “Exhaust
System Components”.

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