2005 SUZUKI SWIFT Cord inspection

Downloaded from www.Manualslib.com manuals search engine 00-3 Precautions:
WARNING!
SDM
• For handling and storage of a SDM, select a place where the ambient temperature
below 65 °C (150 °F), without high humidity
and away from electric noise.
• During service procedures, be very careful when handling a Sensing and Diagnostic
Module (SDM). Never strike or jar the SDM.
• Never power up the air bag system when the SDM is not rigidly attached to the
vehicle. All SDM and mounting bracket
fasteners must be carefully torqued and
the arrow must be pointing toward the
front of the vehicle to ensure proper
operation of the air bag system.
The SDM could be activated when powered
while not rigidly att ached to the vehicle
which could cause deployment and result
in personal injury.

WARNING!
Driver and Passenger Seat Belt
Pretensioners
• For handling and storage of a live seat belt pretensioner, select a place where the
ambient temperature below 65 °C (150 ° F),
without high humidity and away from
electric noise.
• Never carry seat belt pretensioner by wire or connector of pretensioner. When
placing a live seat belt pretensioner on the
workbench or some place like that, never
put something on seat belt pretensioner.
Otherwise, personal injury may result.
• Never dispose of live (inactivated) seat belt pretensioners (drive and passenger). If
disposal is necessary, be sure to activate
them according to activation procedures
described in “Air Bag (Inflator) Module and
Seat Belt Pretensioner Disposal in Section
8B” before disposal.
• The seat belt pretensioner immediately after activation is very hot. Wait for at least
half an hour to cool it off before
proceeding the work.
• With many service procedures, gloves and safety glasses should be worn to prevent
any possible irritation of the skin or eyes.

• Even when the accident was light enough not to cause air bags to activate, be sure to inspect system
parts and other related parts according to instructions
under “Repair and Inspection Required after Accident
in Section 8B”.
• When servicing parts other than air bag system, if shocks may be applied to air bag system component
parts, remove those parts beforehand.
• When handling the air bag (inflator) modules (driver, passenger, side and curtain), seat belt pretensioners
(driver and passenger), forward sensor, side sensors
or SDM, be careful not to drop it or apply an impact to
it. If an excessive impact was applied, never attempt
disassembly or repair but replace it with a new one.
• When grease, cleaning agent, oil, water, etc. has got onto air bag (inflator) modules (driver, passenger, side
and curtain) or seat belt pretensioners (drive and
passenger), wipe off immediately with a dry cloth.
• Air bag wire harness is included in floor and instrument panel wire harnesses. Air bag wire
harness branched off from floor and instrument panel
wire harnesses can be identifie d easily as it is covered
with a yellow protection tube and it has yellow
connectors. Be very ca reful when handling it.
• When an open in air bag wire harness, damaged wire harness, connector or terminal is found, replace wire
harness, connectors and terminals as an assembly.
• Do not apply power to the air bag system unless all components are connected or a diagnostic flow
requests it, as this will set a DTC.
• Never use air bag system component parts from another vehicle.
• When using electric welding, be sure to disconnect all air bag (inflator) module connectors and pretensioner
connectors from air bag wire harness respectively.
• Never expose air bag system component parts directly to hot air (drying or baking the vehicle after
painting) or flames.
• WARNING / CAUTION labels are attached on each
part of air bag system components. Be sure to follow
the instructions.
• After vehicle is completely repaired, perform “Air Bag Diagnostic System Check in Section 8B”.

Downloaded from www.Manualslib.com manuals search engine 0B-6 Maintenance and Lubrication:
Exhaust System InspectionS7RS0B0206006
WARNING!
To avoid danger of being burned, do not
touch exhaust system when it is still hot.
Any service on exhaust system should be
performed when it is cool.

When carrying out periodic maintenance, or the vehicle
is raised for other service, check exhaust system as
follows:
• Check rubber mountings for damage, deterioration, and out of position.
• Check exhaust system for leakage, loose connections, dents and damages.
If bolts or nuts are loose, tighten them to specification.
• Check nearby body areas for damaged, missing or mispositioned parts, ope n seams, holes, loose
connections or other defects which could permit
exhaust fumes to seep into the vehicle.
• Make sure that exhaust system components have enough clearance from the underbody to avoid
overheating and possible damage to floor carpet.
• Any defects should be fixed at once.
Spark Plug ReplacementS7RS0B0206007
Replace spark plugs with new ones referring to “Spark
Plug Removal and Installation in Section 1H”.
Air Cleaner Filter InspectionS7RS0B0206008
1) Remove air cleaner case clamps.
2) Take air cleaner filter out of case.
3) Check that filter is not excessively dirty, damaged or oily, clean filter with compressed air from air outlet
side of filter.
4) Install air cleaner filter and Clamp cap securely.
Air Cleaner Filter ReplacementS7RS0B0206009
Replace air cleaner filter with new one according to
Steps 1), 2) and 4) of “Air Cleaner Filter Inspection”.
Fuel Lines and Connections InspectionS7RS0B0206010
Visually inspect fuel lines and connections for evidence
of fuel leakage, hose cracking and damage. Make sure
all clamps are secure.
Repair leaky joints, if any.
Replace hoses that are suspected of being cracked.
I4RS0A020003-01
I2RH01140007-01
I4RS0B020001-01
I4RS0A020005-01

Downloaded from www.Manualslib.com manuals search engine 0B-12 Maintenance and Lubrication:
HVAC Air Filter (If Equipped) InspectionS7RS0B0206032
1) Remove HVAC air filter from HVAC unit referring to
“HVAC Air Filter Removal and Installation (If
Equipped) in Section 7A”.
2) Check for dirt and dust. If HVAC air filter is excessively dirty, replace HVAC air filter with new
one. If not, go to next step.
3) Blow compressed air on the air outlet side of HVAC air filter for removing dust.
4) Install HVAC air filter in to HVAC unit referring to
“HVAC Air Filter Removal and Installation (If
Equipped) in Section 7A”.
HVAC Air Filter (If Equipped) ReplacementS7RS0B0206033
Replace HVAC air filter with new one referring to “HVAC
Air Filter Removal and Installation (If Equipped) in
Section 7A”.
Final Inspection for Maintenance ServiceS7RS0B0206034
WARNING!
When carrying out road tests, select a safe
place where no man or no running vehicle is
seen so as to prevent any accident.

Seats
Check that seat slides smoot hly and locks securely at
any position. Also check that reclining mechanism of
front seat back allows it to be locked at any angle.
Seat Belt
Inspect belt system including webbing, buckles, latch
plates, retractors and anchors for damage or wear.
Check that seat belt is securely locked. If “REPLACE
BELT” label on seat belt is visible, replace belt.
Battery Electrolyte Level Check
Check that the electrolyte le vel of all battery cells is
between the upper and lower level lines on the case. If
battery is equipped with built-in indicator, check battery
condition by the indicator. Accelerator Pedal Operation
Check that pedal operates
smoothly without getting
caught or interfered by any other part.
Engine Start
Check engine start for readiness.
WARNING!
Before performing th e following check, be
sure to have enough room around the
vehicle. Then, firmly apply both the parking
brake and the regular brakes. Do not use the
accelerator pedal. If the engine starts, be
ready to turn off the ignition promptly. Take
these precautions because the vehicle could
move without warning and possibly cause
personal injury or property damage.

On automatic transaxle vehicles, try to start the engine in
each select lever position. The starting motor should
crank only in “P” (Park) or “N” (Neutral).
On manual transaxle vehicles, place the shift lever in
“Neutral,” depress clutch pedal fully and try to start.
On Automated Manual Transaxl e vehicles, try to start
the engine in each select le ver position. The starting
motor should crank only when select lever is in “N”
(Neutral) and brake pedal is depressed.
Exhaust System Check
Check for leakage, cracks or loose supports.
Clutch (for Manual Transaxle)
Check for the following.
• Clutch is completely released when depressing clutch pedal,
• No slipping clutch occurs when releasing pedal and accelerating.
• Clutch itself is free fr om any abnormal condition.
Gearshift or Select Lever (Transaxle)
Check gear shift or select lever for smooth shifting to all
positions and for good performance of transaxle in any
position.
With automatic transaxle or Automated Manual
Transaxle equipped vehicle, also check that shift
indicator indicates properly according to which position
select lever is shifted to.
With automatic transaxle equipped vehicle, make sure
that vehicle is at complete stop when shifting select lever
to “P” range position and release all brakes.
I4RS0A020018-01

Downloaded from www.Manualslib.com manuals search engine 1-iv Table of Contents
Engine Lubrication System.....................1E-1
General Description ............................................. 1E-1
Engine Lubrication Description ........................... 1E-1
Diagnostic Information and Procedures ............ 1E-2 Oil Pressure Check ............................................. 1E-2
Repair Instructions ........... ................................... 1E-3
Heat Exchanger Components ............................. 1E-3
Heat Exchanger On-Vehicle Inspection .............. 1E-4
Heat Exchanger Removal and Installation .......... 1E-4
Oil Pan and Oil Pump Strainer Components....... 1E-5
Oil Pan and Oil Pump Strainer Removal and
Installation ......................................................... 1E-5
Oil Pan and Oil Pump Stra iner Cleaning ............. 1E-7
Oil Pump Components ........................................ 1E-8
Oil Pump Removal and Installation ..................... 1E-8
Oil Pump Disassembly and Reassembly ............ 1E-8
Oil Pump Inspection ............................................ 1E-9
Specifications .... ................................................. 1E-11
Tightening Torque Specifications ...................... 1E-11
Special Tools and Equipmen t ........................... 1E-11
Recommended Service Material ....................... 1E-11
Special Tool ...................................................... 1E-11
Engine Cooling System ..... ...................... 1F-1
General Description .......... ................................... 1F-1
Cooling System Descriptio n ................................ 1F-1
Coolant Description ............................................. 1F-1
Schematic and Routing Diagram ........................ 1F-2 Coolant Circulation .............................................. 1F-2
Diagnostic Information and Procedures ............ 1F-4 Engine Cooling Symptom Diagnosis ................... 1F-4
Repair Instructions ........... ................................... 1F-5
Cooling System Components.............................. 1F-5
Coolant Level Check ........................................... 1F-6
Engine Cooling System Inspection and Cleaning ............................................................ 1F-6
Cooling System Draining.. ................................... 1F-6
Cooling System Flush and Refill ......................... 1F-7
Cooling Water Pipes or Hoses Removal and Installation ......................................................... 1F-7
Thermostat Removal and In stallation.................. 1F-8
Thermostat Inspection......................................... 1F-8
Radiator Cooling Fan Motor On-Vehicle Inspection .......................................................... 1F-9
Radiator Cooling Fan Rela y Inspection............... 1F-9
Radiator Cooling Fan Removal and Installation ....................................................... 1F-10
Radiator On-Vehicle Inspection and Cleaning .. 1F-10
Radiator Removal and Inst allation .................... 1F-10
Water Pump Removal and In stallation .............. 1F-11
Water Pump Inspection ..................................... 1F-11
Specifications .... ................................................. 1F-12
Tightening Torque Specifications ...................... 1F-12
Special Tools and Equipmen t ........................... 1F-12
Recommended Service Material ....................... 1F-12
Fuel System ................... .......................... 1G-1
Precautions.......................................................... 1G-1 Precautions on Fuel System Service ................. 1G-1
General Description ............................................ 1G-1 Fuel System Description .................................... 1G-1
Fuel Delivery System Description ...................... 1G-1
Fuel Pump Description ....................................... 1G-2
Schematic and Routing Diagram ....................... 1G-2 Fuel Delivery System Diag ram........................... 1G-2
Diagnostic Information and Procedures ........... 1G-2 Fuel Pressure Inspection ................................... 1G-2
Fuel Cut Operation Inspection ........................... 1G-3
Repair Instructions ............ ................................. 1G-4
Fuel System Components .................................. 1G-4
Fuel Hose Disconnecting and Reconnecting ..... 1G-5
Fuel Pressure Relief Procedure ......................... 1G-7
Fuel Leakage Check Procedure......................... 1G-7
Fuel Lines On-Vehicle Inspection ...................... 1G-7
Fuel Pipe Removal and Installation.................... 1G-7
Fuel Injector On-Vehicle Inspection ................... 1G-8
Fuel Injector Removal and Installation ............... 1G-8
Fuel Injector Inspection ...................................... 1G-9
Fuel Filler Cap Inspection . ............................... 1G-10
Fuel Tank Inlet Valve Removal and Installation ...................................................... 1G-11
Fuel Tank Inlet Valve Inspection ...................... 1G-12
Fuel Tank Removal and Installation ................. 1G-12
Fuel Tank Inspection ........................................ 1G-13
Fuel Tank Purging Procedure .......................... 1G-14
Fuel Pump On-Vehicle Inspection.................... 1G-14
Fuel Pump Assembly Removal and Installation ...................................................... 1G-14
Main Fuel Level Sensor Removal and Installation ...................................................... 1G-15
Fuel Pump Inspection ...................................... 1G-16
Specifications ..................... ............................... 1G-16
Tightening Torque Specifications ..................... 1G-16
Special Tools and Equipmen t .......................... 1G-17
Special Tool ..................................................... 1G-17
Ignition System .............. .......................... 1H-1
General Description .............................................1H-1
Ignition System Construction ..............................1H-1
Schematic and Routing Diagram ........................1H-2 Ignition System Wiring Circuit Diagram...............1H-2
Component Location ............ ...............................1H-3
Ignition System Components Location................1H-3
Diagnostic Information and Procedures ............1H-4 Ignition System Symptom Diagnosis...................1H-4
Reference Waveform of Ignition System.............1H-4
Ignition System Check ........................................1H-4
Ignition Spark Test ..............................................1H-6
Repair Instructions ............ ..................................1H-6
High-Tension Cord Removal and Installation......1H-6
High-Tension Cord Inspection.............................1H-7
Spark Plug Removal and Installation ..................1H-7
Spark Plug Inspection .........................................1H-7
Ignition Coil Assembly (Including ignitor)
Removal and Installation ...................................1H-8
Ignition Coil Assembly (Including ignitor)
Inspection ..........................................................1H-8

Downloaded from www.Manualslib.com manuals search engine 1A-2 Engine General Information and Diagnosis:
• Be sure to read “Precautions for Electrical Circuit Service in Section 00” befo re inspection and observe
what is written there.
• ECM replacement: When substituting a known-good ECM, check for the
following conditions. Neglec ting this check may cause
damage to a known-good ECM.
– Resistance value of all relays, actuators is as specified respectively.
– MAP sensor, A/C refrigerant pressure sensor and TP sensor are in good condition and none of power
circuits of these sensors is shorted to ground.
• Communication of ECM, BCM, ABS/ESP ® control
module, combination meter, keyless start control
module, steering angle sensor (ESP ® model) and
TCM (A/T model), is esta blished by CAN (Controller
Area Network). (For more detail of CAN
communication for ECM, refer to “CAN
Communication System Description”). Therefore,
handle CAN communication line with care referring to
“Precaution for CAN Communication System in
Section 00”.
• Immobilizer transponder code registration after
replacing ECM
When ECM is replaced with new one or with another
one, make sure to register immobilizer transponder
code to ECM correctly according to “Procedure after
ECM Replacement in Section 10C”.Precautions of ECM Circuit InspectionS7RS0B1100003
• ECM connectors are waterproofed. Each terminal of the ECM connectors is sealed up with the grommet.
Therefore, when measuring ci rcuit voltage, resistance
and/or pulse signal at ECM connector, do not insert
the tester’s probe into th e sealed terminal at the
harness side. When measuring circuit voltage,
resistance and/or pulse signal at ECM connector,
connect the special tool to the ECM connectors. And,
insert the tester’s probe into the special tool’s
connectors at the harness side, and then measure
voltage, resistance and/or pulse signal. Or, ECM and
its circuits may be damaged by water.
• Wire colors of the special tool’s connectors are different from the ones of the ECM connectors.
However, the circuit arrangement of the special tool’s
connectors is same as the one of the ECM
connectors. Therefore, measure circuit voltage and
resistance by identifying the terminal location subject
to the measurement.
Precautions of Electric Throttle Body System
Calibration
S7RS0B1100004
After performing one of works described below, it is
necessary to re-register the completely closed throttle
valve reference position stored in memory of ECM. (For
detailed information, refer to “Description of Electric
Throttle Body System Calibration”.) For the procedure to
register such data in ECM, refer to “Electric Throttle
Body System Calibration in Section 1C”.
• To shut off backup power of ECM for such purposes of battery replacement or “DOME” fuse removal
• To erase DTCs P0122, P01 23, P0222, P0223, P2101,
P2102, P2103, P2111, P2112, P2113, P2119, P2123,
P2127, P2128, P2135 and/or P2138
• To replace ECM
• To replace throttle body and/or accelerator pedal position (APP) sensor assembly
General Description
Statement on Cleanliness and CareS7RS0B1101001
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousands of an
millimeter (ten thous ands of an inch).
Accordingly, when any internal engine parts are
serviced, care and cleanliness are important.
It should be understood that proper cleaning and
protection of machined surfaces and friction areas is part
of the repair procedure. This is considered standard
shop practice even if not specifically stated.
• A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate
the surfaces on initial operation. • Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.
At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.
• Battery cables should be disconnected before any major work is performed on the engine.
Failure to disconnect cables may result in damage to
wire harness or other electrical parts.

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.

Downloaded from www.Manualslib.com manuals search engine 1A-24 Engine General Information and Diagnosis:
Step 1: Customer Complaint Analysis
Record details of the problem (failure, co mplaint) and how it occurred as described by the customer. For this purpose,
use of such an inspection form will fac ilitate collecting information to the point required for proper analysis and
diagnosis. Customer problem inspection form (Example)
NOTE
This form is a standard sample. It should be modified according to conditions characteristic of each
market.

I2RH01110010-02

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-25
Step 2: DTC / Freeze Frame Data Check, Record and
Clearance
First, check DTC (including pending DTC), referring to
“DTC Check”. If DTC is indicated, print it and freeze
frame data or write them down and then clear them by
referring to “DTC Clearance”. DTC indicates malfunction
that occurred in the system but does not indicate
whether it exists now or it occurred in the past and the
normal condition has been restored now. To check which
case applies, check the sy mptom in question according
to Step 5 and recheck DTC according to Step 6 and 7.
Attempt to diagnose a trouble based on DTC in this step
only or failure to clear the DTC in this step will lead to
incorrect diagnosis, trouble diagnosis of a normal circuit
or difficulty in troubleshooting.
Step 3 and 4: Visual Inspection
As a preliminary step, be sure to perform visual check of
the items that support proper function of the engine
referring to “Visual Inspection”.
Step 5: Trouble Symptom Confirmation
Based on information obtained in “Step 1: Customer
Complaint Analysis: ” and “Step 2: DTC / Freeze Frame
Data Check, Record and Clearance: ”, confirm trouble
symptoms. Also, reconfirm DTC according to “DTC
Confirmation Procedure” described in each DTC diag.
flow.
Step 6 and 7: Rechecking and Record of DTC /
Freeze Frame Data
Refer to “DTC Check” for checking procedure.
Step 8: Engine Basic Inspection and Engine
Symptom Diagnosis
Perform basic engine check according to “Engine Basic
Inspection” first. When the end of the flow has been
reached, check the parts of the system suspected as a
possible cause referring to “Engine Symptom Diagnosis”
and based on symptoms appearing on the vehicle
(symptoms obtained through steps of customer
complaint analysis, trouble symptom confirmation and/or
basic engine check) and repair or replace faulty parts, if
any.
Step 9: Troubleshooting for DTC (See each DTC
Diag. Flow)
Based on the DTC indicated in Step 6 or 7 and referring
to the applicable DTC diag. flow, locate the cause of the
trouble, namely in a sensor, switch, wire harness,
connector, actuator, ECM or other part and repair or
replace faulty parts. Step 10: Intermittent Problems Check
Check parts where an intermit
tent trouble is easy to
occur (e.g., wire harness, connector, etc.), referring to
“Intermittent and Poor Connec tion Inspection in Section
00” and related circuit of DTC recorded in Step 2.
Step 11: Final Confirmation Test
Confirm that the problem symptom has gone and the
engine is free from any abnormal conditions. If what has
been repaired is re lated to the DTC, clear the DTC once,
perform DTC confirmation procedure and confirm that no
DTC is indicated.
Malfunction Indicator Lamp (MIL) CheckS7RS0B1104002
1) Turn ON ignition switch (with engine at stop) and check that MIL (1) lights.
If MIL does not light up (or MIL dims) but engine can
be starting, go to “MIL Does Not Come ON with
Ignition Switch ON and Engine Stop (but Engine Can
Be Started)” for troubleshooting.
If MIL does not light with ignition switch ON and
engine does not start though it is cranked up, go to
“ECM Power and Ground Circuit Check”.
2) Start engine and check that MIL turns OFF. If MIL remains ON and no DTC is stored in ECM, go
to “Malfunction Indicator Lamp Remains ON after
Engine Starts” for troubleshooting.
1
I4RS0A110012-01