2006 SUZUKI SWIFT clearance

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0
Section 0
CONTENTS
General Information
General Information ................................ 0A-1
General Description ............................................. 0A-1
Abbreviations ...................................................... 0A-1
Symbols .............................................................. 0A-2
Wire Color Symbols ............................................ 0A-2
Fasteners Information ......................................... 0A-3
Vehicle Lifting Points ........................................... 0A-5
Engine Supporting Points ................................... 0A-7
Vehicle Identification Number ............................. 0A-7
Engine Identification Number .............................. 0A-7
Transmission Identification Number .................... 0A-7
Component Locatio n ........................................... 0A-8
Warning, Caution and Information Labels Location ............................................................ 0A-8
Maintenance and Lubricat ion ................. 0B-1
Precautions........................................................... 0B-1
Precautions for Maintenance and Lubrication ..... 0B-1
Scheduled Maintenance ...................................... 0B-1 Maintenance Schedule under Normal Driving Conditions ......................................................... 0B-1
Maintenance Recommended under Severe Driving Conditions ............................................. 0B-2
Repair Instructions .............................................. 0B-3 Accessory Drive Belt Inspection.......................... 0B-3
Accessory Drive Belt Repl acement ..................... 0B-4
Valve Lash (Clearance) Inspection ..................... 0B-4
Engine Oil and Filter Change .............................. 0B-4
Engine Coolant Change ...... ................................ 0B-5
Exhaust System Inspection ................................. 0B-6
Spark Plug Replacement .................................... 0B-6
Air Cleaner Filter Inspection ................................ 0B-6
Air Cleaner Filter Replac ement ........................... 0B-6 Fuel Lines and Connections Inspection .............. 0B-6
Fuel Filter Replacement ...................................... 0B-7
Fuel Tank Inspection ........................................... 0B-7
PCV Valve Inspection ......................................... 0B-7
Fuel Evaporative Emission Control System
Inspection .......................................................... 0B-7
Brake Discs and Pads Inspection ....................... 0B-7
Brake Hoses and Pipes Inspection ..................... 0B-7
Brake Fluid Inspection......................................... 0B-8
Brake Fluid Replacement .................................... 0B-8
Brake Lever and Cable Inspection ...................... 0B-8
Clutch Fluid Inspection ........................................ 0B-8
Tires Inspection ................................................... 0B-9
Wheel Discs Inspection ....................................... 0B-9
Wheel Bearing Inspection ................................... 0B-9
Suspension System Inspection ........................... 0B-9
Steering System Inspection .............................. 0B-10
Drive Shaft (Axle) Boots Inspection .................. 0B-10
Manual Transaxle Oil Inspection ....................... 0B-10
Manual Transaxle Oil Replacement .................. 0B-10
Automatic Transaxle Fluid Level Inspection...... 0B-11
Automatic Transaxle Fluid Replacement .......... 0B-11
Automatic Transaxle Fluid Cooler Hose Inspection ........................................................ 0B-11
All Latches, Hinges and Locks Inspection......... 0B-11
HVAC Air Filter (If Equipped) Inspection ........... 0B-12
HVAC Air Filter (If Equipped) Replacement ...... 0B-12
Final Inspection for Maint enance Service ......... 0B-12
Specifications .................... .................................0B-13
Tightening Torque Specifications ...................... 0B-13
Special Tools and Equipmen t ...........................0B-13
Recommended Fluids and Lubricants............... 0B-13
Special Tool ...................................................... 0B-14

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-1
General Information
Maintenance and Lubrication
Precautions
Precautions for Maintenance and LubricationS7RS0B0200001
Air Bag Warning
Refer to “Air Bag Warning in Section 00”.
Scheduled Maintenance
Maintenance Schedule under Normal Driving ConditionsS7RS0B0205001
NOTE
• This interval should be judged by odometer reading or months, whichever comes first.
• This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km
(54,000 miles), carry out the same services at the same intervals respectively.

Interval Km (x 1,000) 15 30 45 60 75 90
Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
Engine
Accessory drive belt (I: ), R: ))——I——R
Valve lash (clearance) (I: )) —I—I—I
Engine oil and oil filter (R: )) RRRRRR
Engine coolant (R: ))— —R— — R
Exhaust system (I: )) —I—I—I
Ignition system
Spark plugs (R: ) )When unleaded fuel is used Iridium Plug
Replace every 60,000 km (36,000
miles) or 48 months
When leaded fuel is used, refer to “Maintenance Recommended under Severe Driving
Conditions”.
Fuel system
Air cleaner filter (R: ), I: )) Paved-road
I I R I I R
Dusty conditions Refer to “Maintenance Recommended
under Severe Driv
ing Conditions”.
Fuel lines and connections (I: )) —I—I—I
Fuel filter (R: )) (See NOTE below) Replace every 105,000 km (63,000
miles)
Fuel tank (I: ))— —I— — I
Emission control system
PCV valve (I: )) ————— I
Fuel evaporative emission control system (I: )) ————— I
Brake
Brake discs and pads (thickness, wear, damage) (I: )) IIIIII
Brake hoses and pipes (leakage, damage, clamp) (I: )) —I—I—I
Brake fluid (R: )) —R—R—R
Brake lever and cable (damage, stroke, operation) (I: )) Inspect at first 15,000 km (9,000 miles
only)
Chassis and body
Clutch (fluid leakage, level) (I: )) —I—I—I
Tires (wear, damage, rotation) / wheels (damage) (I: ) / ) ) IIIIII
Suspension system (tightness, damage, rattle, breakage) (I: )) —I—I—I
Steering system (tightness, damage, breakage, rattle) (I: )) —I—I—I
Drive shaft (axle) boots (I: ))— —I— — I
Manual transaxle oil (leakage, level) (I: ) 1st 15,000 km only) (R: ))I—R——R

Downloaded from www.Manualslib.com manuals search engine 0B-4 Maintenance and Lubrication:
Accessory Drive Belt ReplacementS7RS0B0206002
Water Pump and Generator Drive Belt
Replace belt with new one referring to “Water Pump /
Generator Drive Belt Removal and Installation in Section
1J”.
A/C Compressor Drive Belt
Replace belt with new one referring to “Compressor
Drive Belt Removal and Inst allation in Section 7B”.
Valve Lash (Clearance) InspectionS7RS0B0206003
Inspect intake and exhaust valve lash and adjust as
necessary.
Refer to “Valve Lash (Clearance) Inspection in Section
1D” for valve lash inspection and adjustment procedure.
Engine Oil and Filter ChangeS7RS0B0206004
WARNING!
• New and used engine oil can be
hazardous.
Be sure to read “WARNING” in “General
Precautions in Section 00” and observe
what is written there.
• Step 1) – 7) outlined below must be performed with ENGINE NOT RUNNING.
For Step 8), be sure to have adequate
ventilation while engine is running.

Before draining engine oil, check engine for oil leakage.
If any evidence of leakage is found, make sure to correct
defective part before proceeding to the following work.
1) Drain engine oil by removing drain plug.
2) After draining oil, wipe drain plug clean. Reinstall drain plug.
Tightening torque
Engine oil drain plug (a): 35 N·m (3.5 kgf-m, 25.5
lb-ft)
3) Loosen oil filter by using oil filter wrench (special
tool).
Special tool
(A): 09915–47331
NOTE
Before fitting new oil filter, be sure to oil its
O-ring. Use engine oil for this purpose.

1. Camshaft 2. Thickness gauge
I2RH0B020003-02
I2RH0B020004-01
I2RH0B020005-01
IYSQ01020009-01

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 Table of Contents 1- i
1
Section 1
CONTENTS
Engine
Precautions ................................................. 1-1
Precautions............................................................. 1-1
Precautions for Engine .......................................... 1-1
Engine General Information and
Diagnosis ............. .................................... 1A-1
Precautions........................................................... 1A-1
Precautions on Engine Service ........................... 1A-1
Precaution on On-Board Diagnostic (OBD) System .............................................................. 1A-1
Precautions in Diagnosing Trouble ..................... 1A-1
Precautions of ECM Circuit Inspection................ 1A-2
Precautions of Electric Throttle Body System
Calibration ......................................................... 1A-2
General Description ............................................. 1A-2 Statement on Cleanliness and Care ................... 1A-2
Engine Diagnosis General Description ............... 1A-3
On-Board Diagnostic System Description ........... 1A-3
Data Link Connector (DLC) ................................. 1A-6
Engine and Emission Control System Description ........................................................ 1A-6
CAN Communication System Description........... 1A-7
Air Intake System Description ............................. 1A-9
Description of Electric Throttle Body System ...... 1A-9
Description of Electric Throttle Body System Calibration ....................................................... 1A-10
Fuel Cut Control Description ............................. 1A-10
Generator Control System Description ............. 1A-11
Electronic Control System Description .............. 1A-12
Engine and Emission Control Input / Output Table ............................................................... 1A-18
Schematic and Routing Diagram ...................... 1A-19 Engine and Emission Control System Diagram .......................................................... 1A-19
Component Locatio n ......................................... 1A-21
Electronic Control System Components Location .......................................................... 1A-21
Diagnostic Information and Procedures .......... 1A-22 Engine and Emission Control System Check.... 1A-22
Malfunction Indicator Lamp (MIL) Check .......... 1A-25
DTC Check ....................................................... 1A-26
DTC Clearance ................................................. 1A-27
DTC Table ......................................................... 1A-27
Fail-Safe Table ................ .................................. 1A-31 Scan Tool Data ................................................. 1A-33
Visual Inspection ............................................... 1A-37
Engine Basic Inspection .................................... 1A-38
Engine Symptom Diagnosis .............................. 1A-41
MIL Does Not Come ON with Ignition Switch
ON and Engine Stop (but Engine Can Be
Started) ........................................................... 1A-47
Malfunction Indicator Lamp Remains ON after Engine Starts................................................... 1A-48
DTC P0010: “A” Camshaft Position Actuator Circuit .............................................................. 1A-49
DTC P0011 / P0012: “A” Camshaft Position - Timing Over-Advanced or System
Performance / -Retarded................................. 1A-52
DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1) .......................... 1A-54
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2) .......................... 1A-56
DTC P0101: Mass or Volume Air Flow Circuit Range / Performance ...................................... 1A-58
DTC P0102: Mass or Volume Air Flow Circuit Low Input......................................................... 1A-61
DTC P0103: Mass or Volume Air Flow Circuit High Input ........................................................ 1A-63
DTC P0106: Manifold Absolute Pressure /
Barometric Pressure Circuit Range /
Performance.................................................... 1A-64
DTC P0107: Manifold Absolute Pressure /
Barometric Pressure Circ uit Low Input............ 1A-66
DTC P0108: Manifold Absolute Pressure /
Barometric Pressure Circ uit High Input ........... 1A-67
DTC P0111: Intake Air Temperature Sensor 1 Circuit Range / Performance ........................... 1A-69
DTC P0112: Intake Air Temperature Sensor 1 Circuit Low ...................................................... 1A-72
DTC P0113: Intake Air Temperature 1 Sensor Circuit High...................................................... 1A-74
DTC P0116: Engine Coolant Temperature Circuit Range / Performance ........................... 1A-76
DTC P0117: Engine Coolant Temperature Circuit Low ...................................................... 1A-79
DTC P0118: Engine Coolant Temperature Circuit High...................................................... 1A-81
DTC P0122: Throttle / Pedal Position Sensor / Switch “A” (Main) Circuit Low ........................ 1A-83

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EVAP Canister Purge Valve and Its Circuit
Inspection.......................................................... 1B-2
Vacuum Passage Inspection .............................. 1B-3
Vacuum Hose and Purge Valve Chamber Inspection.......................................................... 1B-3
EVAP Canister Purge Valve Inspection .............. 1B-3
EVAP Canister Inspection ... ................................ 1B-4
EGR Valve Removal and Installation .................. 1B-4
EGR Valve Inspection ......................................... 1B-4
PCV Hose Inspection .......................................... 1B-4
PCV Valve Inspection ......................................... 1B-5
Special Tools and Equipmen t ............................. 1B-5
Special Tool ........................................................ 1B-5
Engine Electrical Devices .. ..................... 1C-1
Repair Instructions .............................................. 1C-1
ECM Removal and Installation ............................ 1C-1
MAP Sensor Inspection ...................................... 1C-2
Electric Throttle Body Assembly On-Vehicle
Inspection.......................................................... 1C-2
Electric Throttle Body System Calibration ........... 1C-5
APP Sensor Assembly On-V ehicle Inspection .... 1C-5
APP Sensor Assembly Removal and Installation ......................................................... 1C-5
APP Sensor Assembly Inspection ...................... 1C-6
ECT Sensor Removal and In stallation ................ 1C-6
ECT Sensor Inspection ....................................... 1C-7
HO2S-1 and HO2S-2 Heater On-Vehicle Inspection.......................................................... 1C-7
HO2S-1 and HO2S-2 Removal and Installation ......................................................... 1C-7
CMP Sensor Removal and In stallation ............... 1C-8
Camshaft Position (CMP) Se nsor Inspection ...... 1C-8
CKP Sensor Removal and Installation ................ 1C-9
CKP Sensor Inspection ....................................... 1C-9
Knock Sensor Removal and Installation ........... 1C-10
Main Relay, Fuel Pump Relay and Starting
Motor Control Relay Inspection....................... 1C-10
MAF and IAT Sensor On-Vehicle Inspection .... 1C-11
MAF and IAT Sensor Removal and Installation ....................................................... 1C-11
MAF and IAT Sensor Inspection ....................... 1C-12
Electric Load Current Sensor On-Vehicle Inspection........................................................ 1C-12
Specifications ..................................................... 1C-13
Tightening Torque Specifications ...................... 1C-13
Engine Mechanical ......... ......................... 1D-1
General Description ............................................. 1D-1
Engine Construction Description ......................... 1D-1
Camshaft Position Control (VVT Variable Valve Timing) System Description .................... 1D-2
Diagnostic Information and Procedures ............ 1D-4 Compression Check ............................................ 1D-4
Engine Vacuum Check ....................................... 1D-5
Valve Lash (Clearance) Inspection ..................... 1D-6
Repair Instructions .............................................. 1D-9 Air Cleaner Components ..................................... 1D-9
Air Cleaner Element Removal and Installation .... 1D-9 Air Cleaner Element Ins
pection and Cleaning ..1D-10
Cylinder Head Co ver Removal and
Installation .......................................................1D-10
Throttle Body and Intake Manifold
Components ....................................................1D-12
Throttle Body On-Vehicle Inspection.................1D-13
Electric Throttle Body Assembly Removal and Installation .......................................................1D-13
Throttle Body Cleaning......................................1D-14
Intake Manifold Removal and Installation .........1D-14
Engine Mountings Components ........................1D-16
Engine Assembly Removal and Installation ......1D-17
Timing Chain Cover Components .....................1D-20
Timing Chain Cover Removal and Installation ..1D-21
Timing Chain Cover Inspection .........................1D-23
Oil Control Valve Removal and Installation .......1D-23
Oil Control Valve Inspection ..............................1D-24
Timing Chain and Chain Tensioner Components ....................................................1D-24
Timing Chain and Chain Tensioner Removal and Installation ................................................1D-25
Timing Chain and Chain Tensioner Inspection ..1D-27
Camshaft, Tappet and Shim Components ........1D-28
Camshaft, Tappet and Shim Removal and Installation .......................................................1D-29
Camshaft, Tappet and Shim Inspection ............1D-31
Valves and Cylinder Head Components ...........1D-34
Valves and Cylinder Head Removal and
Installation .......................................................1D-35
Valves and Cylinder Head Disassembly and Assembly.........................................................1D-37
Valves and Valve Guides Inspection.................1D-40
Cylinder Head Inspection . .................................1D-42
Valve Spring Inspection ....................................1D-43
Pistons, Piston Rings , Connecting Rods and
Cylinders Components ....................................1D-44
Pistons, Piston Rings , Connecting Rods and
Cylinders Removal and Installation .................1D-45
Pistons, Piston Rings , Connecting Rods and
Cylinders Disassembly and Assembly ............1D-46
Cylinders, Pistons and Piston Rings Inspection ........................................................1D-47
Piston Pins and Connecting Rods Inspection ...1D-49
Crank Pin and Connecting Rod Bearings Inspection ........................................................1D-50
Main Bearings, Cran kshaft and Cylinder
Block Components ..........................................1D-53
Main Bearings, Cran kshaft and Cylinder
Block Removal and Installa tion .......................1D-54
Crankshaft Inspection .......................................1D-57
Main Bearings Inspection . .................................1D-59
Sensor Plate Inspection ....................................1D-63
Rear Oil Seal Inspection ...................................1D-63
Flywheel Inspection...........................................1D-63
Cylinder Block Inspection ..................................1D-63
Specifications .................... .................................1D-64
Tightening Torque Specifications ......................1D-64
Special Tools and Equipmen t ...........................1D-66
Recommended Service Material .......................1D-66
Special Tool ......................................................1D-66

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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 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