2006 SUZUKI SWIFT eco

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-6
Clamp other than around fuel tankFor Quick Joint
Disconnecting1) Remove mud, dust and/or foreign material between pipe (1) and quick joint (2) by blowing compressed
air.
2) Unlock joint lock by insert ing special tool between
pipe and quick joint.
Special tool
(A): 09919–47020
3) Disconnect quick joint from pipe.
Reconnecting
Insert quick joint to fuel pipe until they lock securely (a
click is heard), and confi rm that quick joint is not
disconnected by hand.
I3RM0A170001-01
[A]: With short pipe, fit hose as far as it reaches pipe joint as shown.
[B]: With the following type pipe, fit hose as far as its peripheral projection
as shown.
[C]: With bent pipe, fit hose as its bent part as shown or till depth “b”.
[D]: With straight pipe, fit hose till depth “b”.
[E]: With red marked pipe, fit hose end reaches red mark on pipe.
[F]: For fuel tank filler hose, insert it to spool or welding-bead.
“a”: Clamp securely at a position 3 – 7 mm (0.12 – 0.27 in.) from hose end.
“b”: 20 – 30 mm (0.79 – 1.18 in.) “c”: 0 – 5 mm (0 – 0.19 in.)
“d”: 5 – 12 mm (0.2 – 0.47 in.)
“e”: 40 mm (1.57 in.) 1. Pipe
2. Hose
3. Clamp
4. Red mark
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2 1
2
(A)
I4RS0A170019-01

Downloaded from www.Manualslib.com manuals search engine 1G-7 Fuel System:
Fuel Pressure Relief ProcedureS7RS0B1706003
CAUTION!
This work must not be done when engine is
hot. If done so, it may cause adverse effect to
catalyst.

NOTE
If ECM detects DTC(s) after servicing, clear
DTC(s) referring to “DTC Clearance in
Section 1A”.

1) Make sure that engine is cold.
2) Shift transaxle gear shift lever in “Neutral” (shift select lever in “P” range for A/T model), set parking
brake and block drive wheels.
3) Remove relay / fuse box cover.
4) Disconnect fuel pump relay (1) from relay / fuse box (2).
5) Remove fuel filter cap in order to release fuel vapor pressure in fuel tank, and then reinstall it.
6) Start engine and run it until engine stops for lack of fuel. Repeat cranking engine 2 – 3 times for about 3
seconds each time in order to dissipate fuel pressure
in lines. Fuel connections are now safe for servicing.
7) After servicing, connect fuel pump relay (1) to relay / fuse box and install re lay / fuse box cover.
Fuel Leakage Check ProcedureS7RS0B1706004
After performing any service on fuel system, check to
make sure that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump) and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply
fuel pressure to fuel line until fuel pressure is felt by
hand placed on fuel feed hose.
2) In this state, check to see that there are no fuel leakages from any part of fuel system.
Fuel Lines On-Vehicle InspectionS7RS0B1706005
CAUTION!
Due to the fact that fuel feed line (1) is under
high pressure, use special care when
servicing it.

Visually inspect fuel lines for evidence of fuel leakage,
hose crack and deterioration or damage.
Make sure all cl amps are secure.
Replace parts as needed.
Fuel Pipe Removal and InstallationS7RS0B1706006
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal
1) Relieve fuel pressure in fuel feed line according to “Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Disconnect fuel pipe joint and fuel hose (3) from fuel pipe (2) at the front and rear of each fuel pipe
referring to “Fuel Hose Disconnecting and
Reconnecting”.
4) Mark the location of clamps (1) on fuel pipes (2), so that the clamps can be reinstalled to where they
were.
5) Remove pipes (2) with clamp (1) from vehicle.
6) Remove clamp (1) from pipes (2).
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I4RS0A170005-01
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Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-8
Installation1) Install clamps to marked location on pipes. If clamp is deformed, its claw is bent or broken, replace it with
new one.
2) Install pipes with pipe clamps to vehicle.
3) Connect fuel hoses and pipes to each pipe referring to “Fuel Hose Disconnecting and Reconnecting”.
4) Connect negative cable at battery.
5) With engine OFF, turn igniti on switch to ON position
and check for fuel leaks.
Fuel Injector On-Vehicle InspectionS7RS0B1706007
1) Using sound scope (1) or such, check operating sound of injector (2) when engine is running or
cranking.
Cycle of operating sound should vary according to
engine speed.
If no sound or an unusual sound is heard, check
injector circuit (wire or coupler) or injector.
2) Disconnect connector (1) from injector, connect ohmmeter between terminals of injector and check
resistance.
If resistance is out of specification, replace.
Resistance of fuel injector
11.3 – 13.8 Ω at 20 °C, 68 °F
3) Connect connector to injector securely.
Fuel Injector Removal and InstallationS7RS0B1706008
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal 1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Disconnect MAF sensor connector, and detach EVAP canister purge valve.
4) Remove air cleaner assembly with air intake pipe.
5) Disconnect fuel injector couplers.
6) Disconnect fuel feed hose from fuel delivery pipe (1).
7) Remove fuel delivery pipe bolts (2).
8) Remove fuel injector(s) (3).
I2RH0B170007-01
I2RH0B170008-01
2
1
3
3
I3RM0A170010-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-10
4) Install suitable vinyl tube onto injector nozzle to
prevent fuel from splashing out when injecting.
5) Put graduated cylinder under injector.
6) Operate fuel pump and apply fuel pressure to
injector as follows:
a) When using scan tool:
i) Connect scan tool to DLC with ignition switch OFF.
ii) Turn ignition switch ON, clear DTC and select “MISC TEST” mode on scan tool.
iii) Turn fuel pump ON by using scan tool.
Special tool
(A): SUZUKI scan tool
b) When not using scan tool: i) Remove fuel pump relay from connector.
ii) Connect two terminals of relay connector using service wire (1) as shown in figure.
CAUTION!
Check to make sure that connection is made
between correct terminals. Wrong
connection can cause damage to ECM, wire
harness, etc.

iii) Turn ignition switch ON. 7) Apply battery voltage to in
jector (1) for 15 seconds
and measure injected fuel volume with graduated
cylinder. Test each injector two or three times. If not
within specification, replace injector.
Injected fuel volume
43 – 47 cc/15 sec. (1.45/1.51 – 1.58/1.65 US/lmp
oz/15 sec.)
8) Check fuel leakage from injector nozzle. Do not operate injector for this check (but fuel pump should
be at work). If fuel leaks (1) more than the following
specifications, replace.
Fuel leakage
Less than 1 drop/min.
Fuel Filler Cap InspectionS7RS0B1706010
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Remove cap (1), and che ck gasket for even filler neck
imprint, and deterioration or any damage. If gasket (2) is
in malcondition, replace cap.
NOTE
If cap requires replacement, only a cap with
the same features should be used. Failure to
use correct cap can result in fire and
personal injury.

(A)I4RS0A170021-01
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I4RS0A170006-02
I2RH0B170013-01
I2RH01170008-01

Downloaded from www.Manualslib.com manuals search engine 1G-11 Fuel System:
Fuel Tank Inlet Valve Removal and InstallationS7RS0B1706011
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal1) Remove fuel filler cap.
2) Insert hose of a hand oper ated pump into fuel filler
hose (1) and drain fuel in space “A” as shown in
figure.
CAUTION!
Do not force pump hose into fuel tank, or
pump hose may damage to fuel tank inlet
valve (2).

3) Hoist vehicle, and remove clamp (2) and fuel filler
hose (1) from fuel tank. 4) Remove fuel tank inlet valve (1) using flat head rod
(2) or the like.
CAUTION!
Be careful not to damage fuel tank inlet valve
(1) with flat head rod (2) or the like.

Installation
1) Install fuel tank inlet valve (1) to fuel tank.
2) Install fuel filler hose (1) to fuel tank and secure it
with clamp (2).
For proper installation, refer to “Fuel Hose
Disconnecting and Reconnecting”.
3) Lower vehicle and install fuel filler cap.
IYSQ01170010-01
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2
I4RS0A170007-01
I6RS0C170007-01
I2RH0B170018-01
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2
I4RS0A170007-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-12
Fuel Tank Inlet Valve InspectionS7RS0B1706012
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Check fuel tank inlet valve for the following.
If any damage or malfunction is found, replace.
•Damage
• Smooth opening and closing
Fuel Tank Removal and InstallationS7RS0B1706013
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

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

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

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-14
Fuel Tank Purging ProcedureS7RS0B1706015
WARNING!
• Before starting the following procedure, be sure to observe “Precautions on Fuel
System Service” in order to reduce the risk
or fire and personal injury.
• This purging procedure will not remove all fuel vapor.
Do not attempt any repair on tank using
heat of flame as an explosion resulting in
personal injury could occur.

CAUTION!
Never remain water in fu el tank after washing,
or fuel tank inside will get corrosion.

The following procedure are used for purging fuel tank.
1) After removing fuel tank, remove all hoses, pipes and fuel pump assembly from fuel tank.
2) Drain all remaining fuel from tank.
3) Place fuel tank to flushing area.
4) Fill tank with warm water or tap water, and agitate
vigorously and drain. Repeat this washing until
inside of tank is clean. Replace tank if its inside is
rusty.
5) Completely flush out rema ining water after washing.
Fuel Pump On-Vehicle InspectionS7RS0B1706016
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

NOTE
The fuel pressure regulator is incorporated
with the fuel pump assembly so individual
inspection of it is impossible.

1) Remove filler cap and turn ON ignition switch (2).
Then fuel pump operating sound should be heard
from fuel filler (1) for about 2 seconds and stop. Be
sure to reinstall fuel filler cap after checking.
If the check result is not satisfactory, go to “Fuel
Pump and Its Circuit Check in Section 1A”. 2) Turn OFF ignition switch and leave over 10 minutes
as it is.
3) Fuel pressure should be felt at fuel feed hose (1) for about 2 seconds after ignition switch ON.
If fuel pressure is not felt, go to “Fuel Pressure
Check in Section 1A”.
Fuel Pump Assembly Removal and InstallationS7RS0B1706017
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal
1) Remove fuel tank from vehicle. Refer to “Fuel Tank Removal and Installation”.
2) Disconnect fuel feed pipe (1) from fuel pump assembly (2) referring to “Fuel Hose Disconnecting
and Reconnecting”.
IVSY01170013-01
1I3RM0A170019-01
1
2
I6RS0C170008-02

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

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