2005 SUZUKI SWIFT Control arm

Downloaded from www.Manualslib.com manuals search engine 1A-212 Engine General Information and Diagnosis:
Troubleshooting
WARNING!
Keep hands, tools, and clothing away from engine cooling fan to help prevent personal injury. This fan
is electric and can come on whether or not the engi ne is running. The fan can start automatically in
response to the ECT sensor with the ig nition switch at the “ON” position.

NOTE
When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special
tool to ECM and/or the ECM connectors referri ng to “Inspection of ECM and Its Circuits”.

StepAction YesNo
1 Is there DTC(s) of ECT sensor circuit (DTC P0116 / P0117 /
P0118) and/or radiator cooling fan circuit (DTC P0480)? Go to corresponding
DTC flow.Go to Step 2.
2 Low speed radiator cooling fan control circuit check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Start engine and select “DATA LIST” mode on scan tool.
3) Warm up engine until coolant temp. is 97.5 °C, 207.5 °F
or higher and A/C switch turns OFF (if equipped with A/
C). (If engine coolant temp. dose not rise, check engine
cooling system or ECT sensor.)
Is radiator cooling fan started at low speed when engine
coolant temp. reached above temp.? Radiator cooling fan low
speed control system is
in good condition.
Perform from Step 2 to
Step 8 in DTC P0480
diag. flow. If OK, Go to
Ste p 3.
3 Radiator cooling fan control check
1) Disconnect radiator cooling fan control relays No. 2, and
No. 3 from individual circuit fuse box No.1 with ignition
switch turned OFF.
2) Run engine when ECT is over 97.5 °C, 207.5 °F.
3) Measure voltage between vehicle body ground and “BLU/RED” wire terminal of disconnected radiator
cooling fan motor connector.
Is voltage 10 – 14 V? Go to Step 4.
“BLU/RED” wire is open
or high resistance
circuit.
4 Check radiator cooling fan wire circuit check
1) Turn ignition switch to OFF position.
2) Measure resistance between “BLK” wire terminal of
disconnected radiator coolin g fan motor connector and
vehicle body ground.
Is resistance below 1
Ω? Go to Step 5. “BLK” wire is open or
high resistance circuit.
5 Radiator cooling fan check
1) Check radiator cooling fan referring to “Radiator Cooling
Fan Motor On-Vehicle Inspection in Section 1F”.
Is it in good condition? Substitute a known-
good ECM and recheck.
Faulty radiator cooling
fan.

Downloaded from www.Manualslib.com manuals search engine 1A-214 Engine General Information and Diagnosis:
Troubleshooting
WARNING!
Keep hands, tools, and clothing away from engine cooling fan to help prevent personal injury. This fan
is electric and can come on whether or not the engi ne is running. The fan can start automatically in
response to the ECT sensor with the ig nition switch at the “ON” position.

NOTE
When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special
tool to ECM and/or the ECM connectors referri ng to “Inspection of ECM and Its Circuits”.

StepAction YesNo
1 Is there DTC(s) of ECT sensor circuit (DTC P0116 / P0117 /
P0118) and/or radiator cooling fan circuit (DTC P0480)? Go to corresponding
DTC flow.Go to Step 2.
2 Low speed radiator cooling fan control circuit check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Start engine and select “DATA LIST” mode on scan tool.
3) Warm up engine until coolant temp. is 97.5 °C, 207.5 °F
or higher and A/C switch turns OFF (if equipped with A/
C). (If engine coolant temp. dose not rise, check engine
cooling system or ECT sensor.)
Is radiator cooling fan started at low speed when engine
coolant temp. reached above temp.? Go to Step 3.
Perform from Step 2 to
Step 5 in “Radiator
Cooling Fan Low Speed
Control System Check”.
3 High speed radiator cooling fan control circuit check
1) Start engine and select “DATA LIST” mode on scan tool.
2) Warm up engine until coolant temp. is 102.5 °C, 216.5 °F
or higher and A/C switch turns OFF (if equipped with A/
C). (If engine coolant temp. dose not rise, check engine
cooling system or ECT sensor.)
Is radiator cooling fan started at high speed when engine
coolant temp. reached above temp? Radiator cooling fan
control system is in
good condition.
Perform from Step 9 to
Step 14 in DTC P0480
diag. flow.
If OK, Go to Step 4.
4 Radiator cooling fan control No. 2 and No. 3 check
1) Run engine when ECT is over 102.5 °C, 216.5 °F.
2) Measure voltage between vehicle body ground and “E23-48” terminal of ECM connector.
Is voltage lower than 1.5 V? Go to Step 5.
Faulty ECM.
5 Radiator cooling fan No. 2 wire circuit check
1) Remove radiator cooling fan control relay No.2 with
ignition switch turned OFF.
2) Measure voltage between “GRY” wire terminal of disconnected radiator cooling fan control relay No. 2
connector and vehicle body ground.
Is voltage 10 – 14 V? Go to Step 6.
“GRY” wire is open or
high resistance circuit.
6 Radiator cooling fan No. 2 wire circuit check
1) Disconnect connector from radiator cooling fan motor
with ignition swit ch turned OFF.
2) Measure resistance between “BLU/BLK” wire terminal of disconnected radiator cooling fan control relay No. 2
connector and vehicle body ground.
Is resistance infinity? Go to Step 7.
“BLU/BLK” wire is
shorted to ground
circuit.

Downloaded from www.Manualslib.com manuals search engine 1A-216 Engine General Information and Diagnosis:
Repair Instructions
Idle Speed and IAC Throttle Valve Opening
Inspection
S7RS0B1106001
Before idle speed check, make sure of the following.
• Lead wires and hoses of electronic fuel injection and engine and emission control systems are connected
securely.
• Valve lash is checked according to maintenance schedule.
• Ignition timing is within specification.
• All accessories (wipers, heater, lights, A/C, etc.) are out of service.
• Air cleaner has been properly installed and is in good condition.
• No abnormal air drawn in from air intake system.
After all items are confirmed, check idle speed and IAC
duty as follows.
NOTE
Before starting engine, place transmission
gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T vehicle), and set
parking brake and block drive wheels.

1) Connect SUZUKI scan tool to DLC (1) with ignition
switch turned OFF.
Special tool
(A): SUZUKI scan tool 2) Warm up engine to normal operating temperature.
3) Check engine idle speed and “IAC throttle opening”
by using “Data List” mode on scan tool to check “IAC
throttle opening”.
4) If check result is out of sp ecification, inspect electric
throttle body assembly referring to “Electric Throttle
Body Assembly On-Vehicle Inspection in Section
1C”.
Engine idle speed
A/C OFF: 700 ± 50 rpm (IAC duty: 5 – 55%)
A/C ON: 850 ± 50 rpm
5) Check that specified engine idle speed is obtained with A/C turned ON if vehi cle is equipped with A/C.
If not, check A/C system.
(A)
1
I4RS0B110093-01

Downloaded from www.Manualslib.com manuals search engine 1B-1 Aux. Emission Control Devices:
Engine
Aux. Emission Control Devices
Diagnostic Information and Procedures
EGR System InspectionS7RS0B1204001
1) Connect SUZUKI scan tool to data link connector (DLC) with ignition switch turned OFF.
2) Turn ON ignition switch and erase DTC using “CLEAR DTC” in “TROUBLE CODES” menu.
3) Start engine and warm it up to normal operating temperature, then select “DATA LIST” mode on scan
tool.
4) Make sure that vehicle condition is as follows.
• Vehicle speed = 0 km/h (0 KPH)
• Engine speed ≤ 900 rpm
• Engine coolant temp. ≥ 90 °C, 164 °F
5) With engine idling (without depressing accelerator pedal), open EGR valve by using “STEP EGR” mode
in “MISC TEST” menu. In this state, as EGR valve
opening increases engine idle speed drops. If not,
possible cause is clogged EGR gas passage, stuck
or faulty EGR valve.
Repair Instructions
EVAP Canister Purge InspectionS7RS0B1206001
NOTE
Before inspection, check to make sure that gear shift lever is in neutral position (with A/T model,
selector lever in “P” range) and that parking brake lever is pulled all the way up.

1) Disconnect purge hose (1) from EVAP canister (2).
2) Place finger against the end of disconne cted hose and check that vacuum is not felt there when engine is cool and
running at idle speed. If check result is not satisfacto ry, check EVAP canister purge valve, wire harness and ECM.
1. SUZUKI scan tool display
2. EGR valve opening (0: Close, 100: Full open)
Step EGR
Step EGR Flow Duty 21 %
Step EGR (con) 23%
Engine Speed 771 RPM
Desired Idle 698 RPM
IAC Flow Duty 20.0 %
Ignition Advance 11.5 BTDC
Closed Throttle Pos ON
1 2
I4RS0B120001-01
1
2
I6RS0C120001-01

Downloaded from www.Manualslib.com manuals search engine Aux. Emission Control Devices: 1B-2
EVAP Canister Purge Valve and Its Circuit
Inspection
S7RS0B1206002
WARNING!
Do not apply vacuum by mouth; otherwise
harmful fuel vapor can be breathed in.

CAUTION!
Do not apply vacuum more than –86 kPa (–
12.47 psi); otherwise EVAP canister purge
valve could be damaged.

1) Prepare to operate EVAP canister purge valve as follows.
a) When using SUZUKI scan tool:
i) Connect SUZUKI scan tool to DLC (1) with ignition switch turned OFF and disconnect
purge valve vacuum hoses from intake
manifold and EVAP canister.
ii) Turn ON ignition switch, clear DTC and select “MISC TEST” mode on SUZUKI scan
tool.
Special tool
(A): SUZUKI scan tool b) When not using SUZUKI scan tool:
NOTE
Before performed this check, be sure to read
the “Precautions of ECM Circuit Inspection in
Section 1A”.

i) Disconnect purge valve vacuum hoses from
intake manifold and EVAP canister.
ii) Remove ECM from it s bracket referring to
“ECM Removal and Inst allation in Section
1C”.
iii) Connect special tool between ECM and ECM connector referring to “Inspection of ECM
and Its Circuits in Section 1A”
iv) Turn ON ignition switch. Using service wire, ground “C37-29” terminal
circuit of special tool (valve ON: “B”) and
unground it (valve OFF: “A”).
2) Check purge valve for operation and vacuum passage for clog when valve is switched ON and
OFF by using SUZUKI scan tool or service wire.
If check result is not satisfactory, check vacuum
hoses, EVAP canister purge valve, wire harness and
connections.
EVAP canister purge valve specification
[A] Valve OFF: When vacuum (–60 kPa (–8.7 psi))
is applied to hose (1), vacuum can be applied.
[B] Valve ON: When vacuum is applied to hose
(1), vacuum can not be applied.
Special tool
(A): 09917–47011
(A)
1
I4RS0B120003-03
“C37-29”“A”
“B”
I4RS0B120006-02
[A] [B]
1
(A)1
(A)
I3RB0A120005-02

Downloaded from www.Manualslib.com manuals search engine 1B-3 Aux. Emission Control Devices:
Vacuum Passage InspectionS7RS0B1206003
Start engine and run it at idle speed. Disconnect vacuum
hose (1) from EVAP canister purge valve (2). With finger
placed against disconnected hose, check that vacuum is
applied.
If it is not applied, clean vacuum passage by blowing
compressed air.
Vacuum Hose and Purge Valve Chamber
Inspection
S7RS0B1206004
Check hoses and purge valv e chamber for connection,
leakage, clog and deterioration.
Replace as necessary.
EVAP Canister Purge Valve InspectionS7RS0B1206005
WARNING!
Do not apply vacuum by mouth; otherwise
harmful fuel vapor can be breathed in.

CAUTION!
Do not apply vacuum more than –86 kPa (–
12.47 psi); otherwise EVAP canister purge
valve could be damaged.

1) With ignition switch turned OFF, disconnect coupler and vacuum hoses from canister purge valve.
2) Remove EVAP canister purge valve from air cleaner assembly.
3) Check resistance between two terminals of EVAP canister purge valve.
If resistance is not as specified, replace EVAP
canister purge valve.
EVAP canister purge valve resistance
30 – 34 Ω at 20 °C (68 °F) 4) With coupler disconnected, apply vacuum (–60 kPa
(–8.7 psi)) to pipe (1). If vacuum can be applied, go
to next step. If vacuum can not be applied, replace
EVAP canister purge valve.
5) In this state, connect 12 V-battery to EVAP canister purge valve terminals. If vacuum can not be applied,
EVAP canister purge valve is in good condition.
If applied, replace EVAP canister purge valve.
WARNING!
Do not suck the air through valve. Fuel vapor
inside valve is harmful.

Special tool
(A): 09917–47011
6) Install EVAP canister purge valve to air cleaner assembly.
I3RM0A120006-01
I3RM0A120008-01
1
1 (A)
(A)
I3RB0A120007-01

Downloaded from www.Manualslib.com manuals search engine Aux. Emission Control Devices: 1B-4
EVAP Canister InspectionS7RS0B1206006
WARNING!
DO NOT SUCK nozzles on EVAP canister.
Fuel vapor inside EVAP canister is harmful.

1) Check outside of EVAP canister visually.
2) Disconnect vacuum hoses from EVAP canister.
3) Check that there is no restriction of flow through purge pipe (1) and air pipe (2) when air is blown (4)
into tank pipe (3).
If any faulty condition is found in this inspection,
replace EVAP canister.
EGR Valve Removal and InstallationS7RS0B1206007
Removal
1) Disconnect negative (–) cable at battery.
2) Remove air intake pipe.
3) Remove EGR pipe.
4) Disconnect EGR valve connector.
5) Remove EGR valve and gasket from cylinder head.
Installation
Reverse removal procedure noting the following.
• Clean mating surface of valve and cylinder head.
• Use new gaskets.
EGR Valve InspectionS7RS0B1206008
1) Check resistance between following terminals of EGR valve (1) in each pair.
If found faulty, replace EGR valve assembly.
EGR valve resistance (A – B, C – B, F – E, D – E
terminal)
20 – 24 Ω
2) Remove carbon from EGR valve gas passage.
CAUTION!
Do not use any sharp-edged tool to remove
carbon.
Be careful not to damage or bend EGR valve
(1), valve seat (3) and rod.

3) Inspect valve (2), valve seat and rod for fault, cracks, bend or other damage.
If found faulty, replace EGR valve assembly.
PCV Hose InspectionS7RS0B1206009
NOTE
Be sure to check that there is no obstruction
in PCV valve or its hoses before checking
IAC duty, for obstructed PCV valve or hose
hampers its accurate adjustment.

Check hoses for connection, leakage, clog and
deterioration.
Replace as necessary.
I4RS0A120006-01
I2RH0B120005-01
I2RH0B120006-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-4
Targeted Timing Varying Operation
Diagnostic Information and Procedures
Compression CheckS7RS0B1404001
Check compression pressure on all 4 cylinders as
follows:
1) Warm up engine to normal operating temperature.
2) Stop engine after warming up.
NOTE
After warming up engine, place transaxle
gear shift lever in “Neutral”, and set parking
brake and block drive wheels.

3) Disconnect negative cable at battery.
4) Remove engine cover.
5) Remove air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
6) Remove cylinder head upper cover.
7) Disconnect ignition coil couplers (1).
8) Remove ignition coil assemblies (2) with high- tension cord (3).
9) Remove all spark plugs.
10) Disconnect fuel injector wires (4) at the coupler. Driving condition Valve timing Target of control Effect
Engine running at idle
speed Most retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to in
take manifold. Stabilization of the engine
rotation at idle speed.
Average engine load
range To the advanced
sideTo lengthen the valve opening overlap
in order to enhance the internal
exhaust gas recirculation and reduce
the pumping loss. Improvement of the fuel
efficiency.
Lowering of the exhaust
emission.
Light engine load
range To the retarded sideTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to in
take manifold. Keeping of the engine stability.
Low or average
engine speed range
with heavy engine
load To the advanced
side
To advance the closing timing of the
intake valve in order to improve the
volumetric efficiency. Improvement of generating the
engine torque at low and
average engine speed.
High engine speed
range with heavy
engine load To the retarded sideTo retard the closing timing of the
intake valve in order to improve the
volumetric efficiency. Improvement of generating the
engine power.
Low engine coolant
temperature Most retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to intake manifold and
reduce the fuel increasing.
To slow the fast idle speed of the
engine as a result of stabilizing the
engine idling. Stabilization of the fast idling of
the engine.
Improvement of the fuel
efficiency.
At engine starting and
stopping Most retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to in
take manifold. Improvement of start ability.I2RH0B140003-01