checking engine SUZUKI SWIFT 2008 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 00-9 Precautions:
• Be careful not to touch the electrical terminals of parts which use microcomputers (e.g. electronic control unit
like as ECM, PCM, P/S controller, etc.). The static
electricity from your body can damage these parts.
• Never connect any tester (voltmeter, ohmmeter, or whatever) to electronic control unit when its coupler is
disconnected. Attempt to do it may cause damage to
it.
• Never connect an ohmmeter to electronic control unit with its coupler connected to it. Attempt to do it may
cause damage to electronic control unit and sensors.
• Be sure to use a specified voltmeter / ohmmeter. Otherwise, accurate measurements may not be
obtained or personal injury ma y result. If not specified,
use a voltmeter with high impedance (M Ω/V
minimum) or a digital type voltmeter.
• When taking measurements at electrical connectors using a tester probe, be sure to insert the probe (2)
from the wire harness side (backside) of the
connector (1). • When connecting meter probe (2) from terminal side
of coupler (1) because it can’t be connected from
harness side, use extra care not to bend male
terminal of coupler of force its female terminal open
for connection.
In case of such coupler as shown connect probe as
shown to avoid opening female terminal.
Never connect probe where male terminal is
supposed to fit.
• When checking connection of terminals, check its
male half for bend and female half for excessive
opening and both for locking (looseness), corrosion,
dust, etc.
• Before measuring voltage at each terminal, check to make sure that battery voltage is 11 V or higher. Such
terminal voltage check at lo w battery voltage will lead
to erroneous diagnosis.
I3RM0A000004-01
I2RH01010046-01
I2RH01010047-01
I2RH01010048-01

Downloaded from www.Manualslib.com manuals search engine 00-11 Precautions:
Precaution for Vehicle Equipped with ESP®
System
S7RS0B0000015
• When testing with any of the following equipments
(when vehicle is tested by rotating wheels (tires)
under vehicle stop), be sure to deactivate ESP ®
system referring to “Precautions in Speedometer Test
or Other Tests in Section 4F” to obtain correct data.
– 2 or 4-wheel chassis dynamometer
– Speedometer tester
– Brake tester
–Etc.
ESP ® control module
• When ESP ® control module is removed / installed, do
not use impact wrenches which generate shock or
impact to avoid damaging sensors in ESP ® control
module.
• When any of the following operation is done, calibrate steering angle sensor referring to “Sensor Calibration
in Section 4F”.
– When battery or dome fuse is removed.
– When steering angle sensor is replaced.
Brake CautionS7RS0B0000014
CAUTION!
All brake fasteners are important attaching
parts in that they could affect the
performance of vital parts and systems, and/
or could result in major repair expense. They
must be replaced with one of same part
number or with an eq uivalent part if
replacement becomes necessary. Do not use
a replacement part of lesser quality or
substitute design. Torque values must be
used as specified during reassembly to
assure proper retention of all parts. There is
to be no welding as it may result in extensive
damage and weakening of the metal.

Repair Instructions
Electrical Circuit Inspection ProcedureS7RS0B0006001
While there are various electrical circuit inspection
methods, described here is a general method to check
its open and short circuit by using an ohmmeter and a
voltmeter.
Open Circuit Check
Possible causes for the open circuit are as follows. As
the cause is in the connector or terminal in many cases,
they need to be checked particularly carefully.
• Loose connection of connector
• Poor contact of terminal (due to dirt, corrosion or rust
on it, poor contact tension, entry of foreign object etc.)
• Wire harness being open
When checking system circuits including an electronic
control unit such as ECM, TCM, ABS control module,
etc., it is important to perfor m careful check, starting with
items which are easier to check.
1) Disconnect negative (–) cable from battery
2) Check each connector at both ends of the circuit being checked for loose connection. Also check lock
condition of connector if equipped with connector
lock. 3) Using a test male terminal
, check both terminals of
the circuit being checked for contact tension of its
female terminal. Check each terminal visually for
poor contact (possibly caused by dirt, corrosion, rust
entry of foreign object, etc.). At the same time, check
to make sure that each te rminal is locked in the
connector fully.
1. Check contact tension by inserting and removing just for once.
I2RH01010049-01
I2RH01010050-01

Downloaded from www.Manualslib.com manuals search engine 00-13 Precautions:
Short Circuit Check (Wire Harness to Ground)1) Disconnect negative (–) cable at battery.
2) Disconnect connectors at bot h ends of the circuit to
be checked.
NOTE
If the circuit to be checked is connected to
other parts (1), disconnect all connectors of
those parts.
Otherwise, diagnosis will be misled.

3) Measure resistance between terminal at one end of circuit (“A-1” terminal in the figure) and body ground.
If continuity is indicated, it means that there is a short
to ground between terminals “A-1” and “C-1” of the
circuit. 4) Disconnect the connector included in circuit
(connector-B) and measure resistance between “A-
1” and body ground. If continuity is indicated, it
means that the circuit is shorted to the ground
between terminals “A-1” and “B-1”.
Intermittent and Poor Connection InspectionS7RS0B0006002
Most intermittent are caused by faulty electrical
connections or wiring, although a sticking relay or
solenoid can occasionally be at fault. When checking it
for proper connection, perfor m careful check of suspect
circuits for:
• Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
• Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could
impede proper terminal contact. However, cleaning
the terminal with a sand paper or the like is prohibited.
• Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper
terminal orientation with the component or mating
connector.
I5RH01000006-01
1. To other parts
I2RH01010056-01
I2RH01010057-01

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-5
4) Screw new filter on oil filter stand by hand until the filter O-ring contacts mounting surface.
CAUTION!
To tighten oil filter prop erly, it is important to
accurately identify the position at which filter
O-ring first contacts mounting surface.

5) Tighten the filter (1) 3/4 tu rn from the point of contact
with the mounting surface using an oil filter wrench
(2).
Tightening torque
Oil filter (b): 14 N·m (1 .4 kgf-m, 10.5 lb-ft) for
reference
6) Replenish oil until oil leve l is brought to FULL level
mark on dipstick (oil pan and oil filter capacity). The
filler inlet is at the top of the cylinder head cover. It is
recommended to use engine oil of SG, SH, SJ, SL or
SM grade. Select the appropriate oil viscosity
according to the proper engine oil viscosity chart [A].
NOTE
Engine oil capacity is specified as the
following.
However, note that the amount of oil required
when actually changing oil may somewhat
differ from the data depending on various
conditions (temperature, viscosity, etc.).

Engine oil specification
Oil pan capacity: About 3.7 liters (7.8 / 6.5 US /
lmp pt.)
Oil filter capacity: About 0.2 liter (0.4 / 0.3 US /
lmp pt.)
Others: About 0.3 liter (0 .6 / 0.5 US / lmp pt.)
Total: About 4.2 liters (8.9 / 7.4 US / lmp pt.) 7) Check oil filter and drain plug for oil leakage.
8) Start engine and run it for 3 minutes. Stop it and wait
another 5 minutes before checking oil level. Add oil,
as necessary, to bring oil le vel to FULL level mark (1)
on dipstick.
Engine Coolant ChangeS7RS0B0206005
WARNING!
To help avoid danger of being burned, do not
remove radiator cap while engine and
radiator are still hot. Scalding fluid and steam
can be blown out under pressure if cap is
taken off too soon.

CAUTION!
When changing engine coolant, use mixture
of 50% specified water and 50% ANTIFREEZE
/ ANTICORROSION COOLANT for the
purpose of corrosion protection and
lubrication.

Change engine coolant with new one referring to
“Cooling System Flush and Refill in Section 1F”.
IYSQ01020010-01
Co
Fo-30
-22 -20
-4 -10
14 32 50 68 86 104 010203040
5W-30
20W-40
15W-40
10W-30, 10W-40
[A]
I7RS0B020001-02
2. Low level mark (hole)
IYSQ01020012-01

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-7
Fuel Filter ReplacementS7RS0B0206011
Fuel filter is installed in fuel pump assembly in fuel tank.
Replace fuel filter or fuel pump assembly with new one,
referring to “Fuel Pump Assembly Removal and
Installation in Section 1G” for proper procedure.
Fuel Tank InspectionS7RS0B0206012
Check fuel tank damage, cracks, fuel leakage, corrosion
and tank bolts looseness.
If a problem is found, repair or replace.
PCV Valve InspectionS7RS0B0206013
Check crankcase ventilation hose and PCV hose for
leaks, cracks or clog, and PCV valve for stick or clog.
Refer to “PCV Valve Inspection in Section 1B” for PCV
valve checking procedure.
Fuel Evaporative Emission Control System
Inspection
S7RS0B0206014
1) Visually inspect hoses for cracks, damage, or excessive bends. Inspect a ll clamps for damage and
proper position.
2) Check EVAP canister for operation and clog, referring to “EVAP Canister Inspection in Section
1B”.
If a malfunction is found, repair or replace.
Brake Discs and Pads InspectionS7RS0B0206015
1) Remove wheel and caliper but don’t disconnect brake hose from caliper. 2) Check disc brake pads and discs for excessive wear,
damage and deflection. Replace parts as necessary.
For details, refer to “Front Disc Brake Pad Inspection
in Section 4B”, “Front Brake Disc Inspection in
Section 4B”, “Rear Disc Brake Pad Inspection in
Section 4C” and/or “Rear Brake Disc Inspection in
Section 4C”.
Be sure to torque caliper pin bolts to specification.
Brake Hoses and Pipes InspectionS7RS0B0206016
Perform this inspection where these is enough light and
use a mirror as necessary.
• Check brake hoses and pipes for proper hookup, leaks, cracks, chafing and other damage.
• Check that hoses and pipes are clear of sharp edges and moving parts.
Repair or replace any of these parts as necessary.
CAUTION!
After replacing any brake pipe or hose, be
sure to carry out air purge operation.

I4RS0B020002-02
I4RS0A020006-01
I3RM0A020006-01
I4RS0A020008-01

Downloaded from www.Manualslib.com manuals search engine 0B-8 Maintenance and Lubrication:
Brake Fluid InspectionS7RS0B0206035
1) Check around master cylinder and reservoir for fluid leakage. If found leaky, correct.
2) Check fluid level. If fluid level is lower than the minimum level of
reservoir, refilling is necessary. Fill reservoir with
specified brake fluid.
For the details, refer to “Brake Fluid Level Inspection
in Section 4A”.
CAUTION!
Since brake system of this vehicle is factory-
filled with brake fluid indicated on reservoir
tank cap, do not use or mix different type of
fluid when refilling; otherwise serious
damage will occur.
Do not use old or used brake fluid, or any
fluid from an unsealed container.

Brake fluid
Refer to reservoir cap of brake master cylinder.
Brake Fluid ReplacementS7RS0B0206017
Change brake fluid as follows.
Drain existing fluid from brake system completely, fill
system with specified fluid and carry out air purge
operation.
For air purging procedure, refer to“Air Bleeding of Brake
System in Section 4A”.
Brake Lever and Cable InspectionS7RS0B0206018
1) Inspect brake cable for damage and smooth movement.
Replace cable if it is in deteriorated condition. 2) Check tooth tip of each notch for damage or wear. If
any damage or wear is found, replace parking lever.
3) Check parking brake lever for proper operation and stroke, and adjust it if necessary.
For checking and adjusting procedures, refer to
“Parking Brake Inspection and Adjustment in Section
4D”.
Parking brake lever stroke
“a”: 4 – 9 notches (with 200 N (20 kg, 44 lbs) of pull
pressure)
Clutch Fluid InspectionS7RS0B0206019
1) Check clutch system for evidence of fluid leakage. Repair leaky point if any.
2) Check reservoir for fluid level referring to “Clutch
Fluid Level Inspection in Section 5C”.
If fluid is lower than minimum level of reservoir, refill
reservoir with specified brake fluid indicated on
reservoir cap.
I7RW01020002-01
I4RS0A020009-01
I4RS0B020005-01
I4RS0A410006-01

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-1
Engine
Engine General Information and Diagnosis
Precautions
Precautions on Engine ServiceS7RS0B1100001
CAUTION!
The following information on engine service
should be noted carefully, as it is important in
preventing damage, and in contributing to
reliable engine performance.

• When raising or supporting engine for any reason, do
not use a jack under oil pan. Due to small clearance
between oil pan and oil pump strainer, jacking against
oil pan may cause it to be bent against strainer,
resulting in damaged oil pick-up unit.
• It should be kept in mind , while working on engine,
that 12-volt electrical syste m is capable of violent and
damaging short circuits.
When performing any work where electrical terminals
can be grounded, ground cable of the battery should
be disconnected at battery.
• Any time the air cleaner, throttle body or intake manifold is removed, the intake opening should be
covered. This will protect against accidental entrance
of foreign material which could follow intake passage
into cylinder and cause extensive damage when
engine is started.
Precaution on On-Board Diagnostic (OBD)
System
S7RS0B1100005
There are two types of On -Board Diagnostic (OBD)
system, Euro OBD system and non-Euro-OBD system,
depending on the vehicle specification.
As the diagnosis function is different between these two
types, be sure to fully understand the OBD system
referring to “On-Board Diagnostic System Description”.
OBD System Summary Table
Precautions in Diagnosing TroubleS7RS0B1100002
NOTE
There are two types of OBD system
depending on the vehicle specification.
For details, refer to “Precaution on On-Board
Diagnostic (OBD) System”.

• Don’t disconnect couplers from ECM, battery cable
from battery, ECM ground wire harness from engine
or main fuse before confirming diagnostic information
(DTC, freeze frame data, etc.) stored in ECM memory.
Such disconnection will erase memorized information
in ECM memory.
• Diagnostic information stored in ECM memory can be cleared as well as checke d by using SUZUKI scan
tool or OBD generic scan tool. Before using scan tool,
read its Operator’s (Instruction) Manual carefully to
have good understanding as to what functions are
available and how to use it.
For Euro OBD model it is indistinguishable which
module turns on MIL because not only ECM but also
TCM (A/T model) turns on MIL (For details of on-
board diagnostic system for A/T model, refer to “On-
Board Diagnostic System Description in Section 5A”).
Therefore, check both ECM and TCM (A/T model) for
DTC when MIL lights on.
When checking ECM for DTC, keep in mind that DTC
is displayed on the scan tool as follows depending on
the scan tool used.
– SUZUKI scan tool displays DTC detected by ECM.
– OBD generic scan tool displays DTC detected by each of ECM and TCM (A/T model) simultaneously.
• Priorities for diagnosing troubles If two or more DTCs are stored, proceed to the DTC
flow which has been detected earliest in the order and
follow the instructi on in that flow.
If no instructions are given, troubleshoot DTCs
according to the following priorities.
a. DTCs other than DTC P0171 / P0172 (Fuel system too lean / too rich), DTC P0300 / P0301 /
P0302 / P0303 / P0304 (Misfire detected) and
DTC P0401 / P0402 (EGR flow malfunction)
b. DTC P0171 / P0172 (Fuel system too lean / too rich) and DTC P0401 / P0402 (EGR flow
malfunction)
c. DTC P0300 / P0301 / P0302 / P0303 / P0304 (Misfire detected)
Euro OBD
model Non-Euro-OBD
model
Quantity of DTC
related to engine
control Approx. 80 Approx. 60
Freeze frame
data Available Not available
SUZUKI scan
tool Available Available
OBD generic
scan tool Available Not available

Downloaded from www.Manualslib.com manuals search engine 1A-4 Engine General Information and Diagnosis:
Driving Cycle
A “Driving Cycle” consists of engine startup and engine
shutoff.
2 Driving Cycle Detection Logic
The malfunction detected in the first driving cycle is
stored in ECM memory (in t he form of pending DTC) but
the malfunction indicator lamp does not light at this time.
It lights up at the second detection of same malfunction
also in the next driving cycle.
Pending DTC
Pending DTC means a DTC detected and stored
temporarily at 1 driving cycle of the DTC which is
detected in the 2 driving cycle detection logic.
Freeze Frame Data
ECM stores the engine and driving conditions (in the
form of data as shown in the figure) at the moment of the
detection of a malfunction in its memory. This data is
called “Freeze frame data”.
Therefore, it is possible to know engine and driving
conditions (e.g., whether the engine was warm or not,
where the vehicle was running or stopped, where air/fuel
mixture was lean or rich) when a malfunction was
detected by checking the freeze frame data. Also, ECM
has a function to store each freeze frame data for three
different malfunctions in the order as each malfunction is detected. Utilizing this function,
it is possible to know the
order of malfunctions that ha ve been detected. Its use is
helpful when rechecking or diagnosing a trouble.
Priority of freeze frame data:
ECM has 4 frames where the freeze frame data can be stor ed. The first frame stores the freeze frame data of the
malfunction which was detected first. Howe ver, the freeze frame data stored in this frame is updated according to the
priority described. (If malfunction as described in the upper square “1” is detected while the freeze frame data in the
lower square “2” has been stored, the freeze frame data “2” will be updated by the freeze frame data “1”.)
In the 2nd through the 4th frames, the freeze frame data of each malfunction is stored in the order as each malfunction
is detected. These data are not updated.
Shown in the table are examples of how freeze frame data are stored when two or more malfunctions are detected.
[A]: 1st or 2nd in parentheses here represents which position in the order
the malfunction is detected.
[A]
I3RB0A110002-01
Priority Freeze frame data in frame 1
1 Freeze frame data at initial detection of malfuncti
on among misfire detected (P0300 – P0304), fuel
system too lean (P0171) and fuel system too rich (P0172)
2 Freeze frame data when a malfunctio n other than those in “1” is detected
Malfunction detected order Frame
Frame 1 Frame 2 Frame 3 Frame 4
Freeze frame data to be updated 1st freeze frame
data 2nd freeze frame
data 3rd freeze frame
data
No malfunction No freeze frame data
1 P0401 (EGR)
detected Data at P0401
detectionData at P0401
detection
——
2 P0171 (Fuel system)
detected Data at P0171
detectionData at P0401
detectionData at P0171
detection
—
3 P0300 (Misfire)
detected Data at P0171
detectionData at P0401
detectionData at P0171
detectionData at P0300
detection
4 P0301 (Misfire)
detected Data at P0171
detectionData at P0401
detectionData at P0171
detectionData at P0300
detection

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-22 Engine General Information and Diagnosis:
Diagnostic Information and Procedures
Engine and Emission Control System CheckS7RS0B1104001
Refer to the following items for the details of each step.Step Action Yes No 1 ) Customer complaint analysis
1) Perform customer complaint analysis referring to “Customer Complaint Analysis”.
Was customer complaint analysis performed? Go to Step 2. Perform customer
complaint analysis.
2 ) DTC / Freeze frame data check, record and clearance
1) Check for DTC (including pending DTC) referring to “DTC / Freeze Frame Data Check, Record and
Clearance”.
Is there any DTC(s)? Print DTC and freeze
frame data or write them
down and clear them by
referring to “DTC
Clearance”, and go to
St ep 3 .Go to Step 4.
3 ) Visual inspection
1) Perform visual inspection referring to “Visual Inspection”.
Is there any faulty condition? Repair or replace
malfunction part, and go
to Step 11.
Go to Step 5.
4 ) Visual inspection
1) Perform visual inspection referring to “Visual Inspection”.
Is there any faulty condition? Repair or replace
malfunction part, and go
to Step 11.
Go to Step 8.
5 ) Trouble symptom confirmation
1) Confirm trouble symptom referring to “Trouble Symptom Confirmation”.
Is trouble symptom identified? Go to Step 6.
Go to Step 7.
6 ) Rechecking and record of DTC / Freeze frame data
1) Recheck for DTC and freeze frame data referring to “DTC Check”.
Is there any DTC(s)? Go to Step 9.
Go to Step 8.
7 ) Rechecking and record of DTC / Freeze frame data
1) Recheck for DTC and freeze frame data referring to “DTC Check”.
Is there any DTC(s)? Go to Step 9.
Go to Step 10.
8 ) Engine basic inspection and engine symptom
diagnosis
1) Check and repair according to “Engine Basic Inspection”
and “Engine Symptom Diagnosis”.
Are check and repair complete? Go to Step 11. Check and repair
malfunction part(s), and
go to Step 11.
9 ) Troubleshooting for DTC
1) Check and repair according to applicable DTC diag. flow.
Are check and repair complete? Go to Step 11. Check and repair
malfunction part(s), and
go to Step 11.
10 ) Intermittent problems check
1) Check for intermittent problems referring to “Intermittent Problems Check”.
Is there any faulty condition? Repair or replace
malfunction part(s), and
go to Step 11.
Go to Step 11.