bolt SUZUKI SWIFT 2008 2.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-12
Specifications
Tightening Torque SpecificationsS7RS0B1607001
NOTE
The specified tightening torque is also described in the following.
“Cooling System Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS7RS0B1608001
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Water pump bolt and nut 25 2.5 18.0 )
MaterialSUZUKI recommended product or Specification Note
Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250)

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-4
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
7
I6RS0C170003-01
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 Fuel System: 1G-8
Installation1) Install clamps to marked location on pipes. If clamp is deformed, its claw is bent or broken, replace it with
new one.
2) Install pipes with pipe clamps to vehicle.
3) Connect fuel hoses and pipes to each pipe referring to “Fuel Hose Disconnecting and Reconnecting”.
4) Connect negative cable at battery.
5) With engine OFF, turn igniti on switch to ON position
and check for fuel leaks.
Fuel Injector On-Vehicle InspectionS7RS0B1706007
1) Using sound scope (1) or such, check operating sound of injector (2) when engine is running or
cranking.
Cycle of operating sound should vary according to
engine speed.
If no sound or an unusual sound is heard, check
injector circuit (wire or coupler) or injector.
2) Disconnect connector (1) from injector, connect ohmmeter between terminals of injector and check
resistance.
If resistance is out of specification, replace.
Resistance of fuel injector
11.3 – 13.8 Ω at 20 °C, 68 °F
3) Connect connector to injector securely.
Fuel Injector Removal and InstallationS7RS0B1706008
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 according to “Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Disconnect MAF sensor connector, and detach EVAP canister purge valve.
4) Remove air cleaner assembly with air intake pipe.
5) Disconnect fuel injector couplers.
6) Disconnect fuel feed hose from fuel delivery pipe (1).
7) Remove fuel delivery pipe bolts (2).
8) Remove fuel injector(s) (3).
I2RH0B170007-01
I2RH0B170008-01
2
1
3
3
I3RM0A170010-01

Downloaded from www.Manualslib.com manuals search engine 1G-9 Fuel System:
Installation
Reverse removal procedure for installation noting the
following.
• Replace injector O-ring (1) with new one using care not to damage it.
• Check if cushion (2) is scor ed or damaged. If it is,
replace with new one.
• Apply thin coat of fuel to O-rings (1) and then install injectors (3) into delivery pipe (4) and cylinder head.
Make sure that injectors rota te smoothly (6). If not,
probable cause is incorrect installation of O-ring.
Replace O-ring with new one.
• Tighten delivery pipe bolts (5) to specified torque and make sure that inject ors rotate smoothly.
Tightening torque
Fuel delivery pipe bolt (a): 25 N·m (2.5 kgf-m, 18.0
lb-ft)
• After installation, with engine OFF and ignition switch ON, check for fuel leaks around fuel line connection.Fuel Injector InspectionS7RS0B1706009
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.

1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure” if equipped.
2) Disconnect fuel feed hose from delivery pipe.
3) Set special tools as follows.
Special tool
(A): 09912–58421
(B): 09930–88530
(C): 09912–57610
a) Fit washer (1) (inside diameter 13.5 – 14.5 mm (0.532 – 0.570 in.)) to injector (2), and then
install injector to special tool (A).
b) Connect special tool (B) to injector.
c) Install special tool (C) to special tool (A).
d) Connect fuel feed hose to special tool (A).
I3RM0A170011-01
(B)
(A)
(A) (C)
2
1
I6RW0B170014-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-12
Fuel Tank Inlet Valve InspectionS7RS0B1706012
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.

Check fuel tank inlet valve for the following.
If any damage or malfunction is found, replace.
•Damage
• Smooth opening and closing
Fuel Tank Removal and InstallationS7RS0B1706013
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.

Removal1) Relieve fuel pressure in fuel feed line according to
“Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Hoist vehicle.
4) Remove exhaust center pipe.
5) Disconnect fuel filler hose and breather hose from
filler neck referring to “Fue l Tank Inlet Valve Removal
and Installation”.
6) Due to absence of fuel tank drain plug, drain fuel tank by pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
CAUTION!
• Do not force pump hose into fuel tank, or pump hose may damage fuel tank inlet
valve.
• Never store fuel in an open container due to possibility of fire or explosion.

7) Disconnect fuel pipe joint and fuel hoses (1) from fuel pipes (2) referring to “Fuel Hose Disconnecting
and Reconnecting”.
8) Support fuel tank (1) with jack (2) and remove its mounting bolts.
9) Lower fuel tank a little as to disconnect wire harness at connector (1) and ground wire (2), then remove
fuel tank.
I2RH0B170019-01
12
I4RS0A170008-01
12
I4RS0A170009-01
1
2
I6RS0C170005-02

Downloaded from www.Manualslib.com manuals search engine 1G-13 Fuel System:
Installation
CAUTION!
• When connecting joint, clean outside surfaces of pipe where joint is to be
inserted, push joint into pipe till joint lock
clicks and check to ensure that pipes are
connected securely, or fuel leak may
occur.
• Never let the fuel hoses touch the ABS sensor harness (if equipped).

1) If parts have been removed from fuel tank, install them before installing fuel tank to vehicle.
2) Raise fuel tank (1) with jack (2) and connect fuel pump connector (3), ground wire (4) and clamp wire
harness.
Tightening torque
Ground wire bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Install fuel tank to vehicle. Tightening torque
Fuel tank bolt (b): 45 N·m (4.5 kgf-m, 33.0 lb-ft) 4) Connect fuel filler hose (1
) and breather hose (2) to
filler neck (3) as shown in figure, and clamp them
securely.
Tightening torque
Fuel filler hose clamp (a): 2 N·m (0.2 kgf-m, 1.5
lb-ft)
5) Connect fuel feed hose (1) and vapor hose (2) to each pipe as shown in figure, and clamp them
securely.
6) Install exhaust center pipe referring to “Exhaust Pipe and Muffler Removal and Installation in Section 1K”.
7) Connect negative cable at battery.
8) With engine OFF, turn ignition switch to ON position and check for fuel leaks.
Fuel Tank InspectionS7RS0B1706014
After removing fuel tank, check hoses and pipes
connected to fuel tank for leaks, loose connections,
deterioration or damage. Also check fuel pump
assembly gaskets for leaks, visually inspect fuel tank for
leaks and damage.
Replace any damaged or malconditioned parts.
(b)(b)
1
2
3
4
(a)
I6RS0C170006-02
1
2
(a)
3
I4RS0A170012-01
1
2
I4RS0A170013-01

Downloaded from www.Manualslib.com manuals search engine 1G-15 Fuel System:
3) Remove fuel pump assembly (1) from fuel tank (2).
Installation
CAUTION!
When connecting joint, clean outside surface
of pipe where joint is to be inserted, push
joint into pipe till jo int lock clicks and check
to ensure that pipes are connected securely,
or fuel leak may occur.

1) Clean mating surfaces of fuel pump assembly (1) and fuel tank.
2) Put plate (2) on fuel pump assembly (1) by matching the protrusion of fuel pump assembly (3) to plate
hole (4) as shown.
3) Install new gasket (2) and fuel pump assembly (1) earth bracket (5) with plate (3) to fuel tank (4).
Tightening torque
Fuel pump assembly bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft) 4) Connect fuel feed line (1) (pipe joint) to fuel pump
assembly (2).
5) Install fuel tank to vehi cle. Refer to “Fuel Tank
Removal and Installation”.
Main Fuel Level Sensor Removal and
Installation
S7RS0B1706018
CAUTION!
• Do not touch resister plate (1) and deform arm (2). It may cause main fuel level sensor
to fail.
• Be very careful not to cause damage to fuel tube installed section (sealed section
in bore). If it be damaged, replace it with
new one, or fuel will leak from the part.

1
2
I3RM0A170021-01
3
1
3
2
44
I4RS0A170015-01
3
1 2
(a)
4
5
I6RS0C170009-01
2
1
I4RS0A170014-01
1
2I4RS0A170016-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-16
Removal1) Remove fuel pump assembly from fuel tank referring to “Fuel Pump Assembly Removal and Installation”.
2) Disconnect main fuel level sensor connector (3).
3) With pressing snap-fit part (2), remove main fuel level sensor (1) by sliding it in the arrow direction as
shown in figure.
Installation
Reverse removal procedure for installation.Fuel Pump InspectionS7RS0B1706019
• Check fuel pump assembly for damage.
• Check fuel suction filter for evidence of dirt and contamination. If present, replace or clean and check
for presence of dirt in fuel tank.
• For electrical circuit, refer to “Fuel Pressure Check in Section 1A”.
• For inspection of main fuel level sensor (1), refer to “Fuel Level Sensor Inspection in Section 9C”.
Specifications
Tightening Torque SpecificationsS7RS0B1707001
NOTE
The specified tightening torque is also described in the following.
“Fuel System Components”
“Fuel Hose Disconnecting and Reconnecting”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
1
21
3
I5RS0D170006-031
I5RS0D170008-01
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
Fuel delivery pipe bolt 25 2.5 18.0 )
Ground wire bolt 11 1.1 8.0 )
Fuel tank bolt 45 4.5 33.0 )
Fuel filler hose clamp 2 0.2 1.5 )
Fuel pump assembly bolt 11 1.1 8.0 )

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

Downloaded from www.Manualslib.com manuals search engine 1H-8 Ignition System:
Ignition Coil Assembly (Including ignitor)
Removal and Installation
S7RS0B1806005
Removal1) Disconnect negative (–) cable at battery.
2) Remove air cleaner assembly with air intake pipe and cylinder head upper cover.
3) Disconnect ignition coil coupler.
4) Disconnect high-tension cord (3) from ignition coil assembly (2).
5) Remove ignition coil bolts (1) and then pull out ignition coil assembly.
Installation 1) Install ignition coil assembly (2).
2) Tighten ignition coil bolts (1) to specified torque, and then connect igni tion coil coupler.
Tightening torque
Ignition coil bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
3) Install high-tension cord (3) to ignition coil assembly while gripping its cap.
4) Install cylinder head upper cover and air cleaner assembly with air intake pipe.
5) Connect negative (–) cable to battery.
Ignition Coil Assembly (Including ignitor)
Inspection
S7RS0B1806006
Measure secondary coil for resistance.
If resistance is out of specification, replace ignition coil
assembly.
Secondary coil resistance
7.5 – 10.3 k Ω at 20 °C, 68 ° F
Ignition Timing InspectionS7RS0B1806007
NOTE
• Ignition timing is not adjustable. If ignition
timing is out of specification, check
system related parts.
• Before starting engine, place transmission gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T model), and set
parking brake.

1) Connect scan tool to DLC (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
2) Start engine and warm it up to normal operating temperature.
3) Make sure that all of electrical loads except ignition are switched off.
4) Check to be sure that idle speed is within specification referring to “Idle Speed and IAC
Throttle Valve Opening Inspection in Section 1A”
5) Fix ignition timing by using “Fixed Spark” of “Misc Test” mode on scan tool.
I2RH0B180006-01
I3RM0A180004-01
I2RH0B180007-01
(A)
1
I4RS0B180003-01