2006 SUZUKI SWIFT Control system

Downloaded from www.Manualslib.com manuals search engine Engine Electrical Devices: 1C-13
Without Using SUZUKI Scan Tool1) Measure sensor voltage between “C37-23” terminal of ECM connector and vehicle body ground referring
to “Inspection of ECM and Its Circuits in Section 1A”.
If check result is satisfactory, electric load current
sensor is in good condition.
If check result is not satisfactory, check the following
parts and circuit.
• Electric load current sensor circuit (power, ground and output)
• Following charging system components – Battery (refer to “Battery Inspection in Section
1J”)
– Generator (refer to “Generator Inspection in Section 1J”)
– Generator output control circuit (refer to “Generator Test (Undercharged Battery Check)
in Section 1J”)
– Generator field coil monitor circuit (refer to “Generator Inspection in Section 1J”) If electric load current sensor circuit and charging
system is in good condition,
electric load current sensor
(1) is faulty.
Specifications
Tightening Torque SpecificationsS7RS0B1307001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
2. Main fuse box
2
1
I5RS0C130001-01
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
ECM mounting bolt 8 0.8 6.0 )
APP sensor assembly nut 5.5 0.55 4.0 )
ECT sensor 15 1.5 11.0 )
Heated oxygen sensor 45 4.5 32.5 )
CMP sensor bolt 10 1.0 7.5 )
CKP sensor bolt 10 1.0 7.5 )
Knock sensor 22 2.2 16.0 )
MAF and IAT sensor screw 1.5 0.15 1.1 )

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-2
Camshaft Position Control (VVT Variable Valve Timing) System DescriptionS7RS0B1401002
System Description
The VVT system is an electronic control system which continuously vary and optimize the intake valve timing in
response to the engine operating condition.
The optimized intake valve timing produce such an air intake with high efficiency that both the higher power generation
and lower fuel consumption can be attained in the whole engine speed range from low to high. In the area of the
average engine load, low emission of nitrogen oxides (NOx) and high fuel efficiency can also be attained by making
the valve opening overlap between the intake and exhaust valves longer.
For the brief of the system operation, the intake valve timing is varied by the cam timing sprocket (1) which varies the
rotational phase between the intake camshaft (3) and sprocket . The rotor (2) in the cam timing sprocket is actuated by
switching or adjusting the hydraulic pressure applied to the chambers for the timing advancing (7) and/or retarding (6).
To switch or adjust the hydraulic pressure appropriately, ECM operates the oil control valve (12) with detecting the
engine speed, intake air value, throttle opening, engine coolant temperature and camshaft position (angle).
1
4
5
13
10
89
2
7
6
12
11
3
14
60 (variable angle)
Most retarded timing
Most advanced timing
Exhaust valve Intake valve
Crank angle
Overlap of valves
Valve lift
I3RH0B140002-01
4. Oil passage to chamber for timing retarding 8. Oil filter10. Oil pan 13. Oil return
5. Oil passage to chamber for timing advancing 9. Oil pump11. Control signal from ECM 14. Oil flow

Downloaded from www.Manualslib.com manuals search engine 1D-17 Engine Mechanical:
Engine Assembly Removal and InstallationS7RS0B1406011
NOTE
After replacing electric throttle body
assembly, perform calibration of throttle
valve referring to “Electric Throttle Body
System Calibration in Section 1C”.

Removal1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure in Section 1G”.
2) Disconnect negative and pos itive cable at battery.
3) Remove battery and tray.
4) Remove engine hood after disconnecting windshield washer hose.
5) Remove right and left side engine under covers.
6) Remove A/C compressor belt by referring to “Compressor Drive Belt Remo val and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
7) Drain engine oil, transaxle oil and coolant.
8) Remove cowl top plate referring to “Cowl Top Components in Section 9K”.
9) Remove air cleaner assembly referring to “Air Cleaner Components”.
10) With hose connected, detach A/C compressor from its bracket (A/C model) referring to “Compressor
Assembly Removal and Installation in Section 7B” or
“Compressor Assembly Removal and Installation in
Section 7B”.
CAUTION!
Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

11) Remove intake manifold rear stiffener (1) from intake manifold and cylinder block. 12) Disconnect the following electric wires:
• MAP sensor (1)
• ECT sensor (2)
•EGR valve (3)
• CMP sensor (4)
• Electric throttle body assembly (5)
• Ignition coil assembly (6)
• Injectors (7)
• Heated oxygen sensor No. 2 (8) and No. 1 (9)
• Oil control valve (10)
• Engine oil pressure switch (11)
• CKP sensor (12)
• Knock sensor (13)
• Back up light switch (14)
• Generator (15)
• Starting motor (16)
• Ground terminal (17) from intake manifold
• Battery ground terminal (18) from exhaust manifold
• Battery ground cable (19) from transaxle
• Magnet clutch switch of A/C compressor (A/C model)
• Each wire harness clamps
• Output shaft speed sensor (VSS) (34) (A/T model)
• Solenoid valve (33) (A/T model)
• Transmission range sensor (32) (A/T model)
• Input shaft speed sensor (31) (A/T model)
13) Remove fuse box from its bracket.
14) Disconnect the following cables: • Gear select control cable (23) (M/T model)
• Gear shift control cable (24) (M/T model)
• A/T select cable (A/T model)
15) Disconnect the following hoses: • Brake booster hose (26) from intake manifold
• Radiator inlet and outlet hoses (20) from each pipe
• Heater inlet and outlet hoses (21) from each pipe
• Fuel feed hoses (22) from fuel feed pipe
• EVAP canister purge valve hose (30) from purge pipe
• A/T fluid cooler hoses (A/T model)
16) With hose connected, detach clutch operating cylinder (25). (M/T model)
CAUTION!
Suspend removed clutch operating cylinder
at a place where no damage will be caused
during removal and installation of engine
assembly.

1
I6RS0B141014-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-20
15) Install A/C compressor to its bracket (if equipped) referring to “Compressor Assembly Removal and
Installation in Section 7B” or “Compressor Assembly
Removal and Installa tion in Section 7B”.
16) Adjust A/C compressor belt tension (if equipped) referring to “Compressor Drive Belt Inspection and
Adjustment in Section 7B” or “Compressor Drive Belt
Inspection and Adjustment in Section 7B”.
17) Check to ensure that a ll removed parts are back in
place.
Reinstall any necessary parts which have not been
reinstalled.
18) Refill cooling system with coolant referring to “Cooling System Flush and Refill in Section 1F”. 19) Refill engine with engine oil
referring to “Engine Oil
and Filter Change in Section 0B”.
20) Refill transaxle with transa xle oil referring to“Manual
Transaxle Oil Change in Section 5B” or “A/T Fluid
Change in Section 5A”.
21) Install battery and tray.
22) Connect positive and negative cable at battery.
23) Install engine hood and connect windshield washer hose.
24) Verify that there is no fu el leakage, coolant leakage,
oil leakage and exhaust gas leakage at each
connection.
Timing Chain Cover ComponentsS7RS0B1406012
I6RS0C140015-02
1. Crankshaft pulley bolt 13. Oil gallery pipe No.2 bolt
2. Crankshaft pulley 14. Oil gallery pipe No.3
3. Oil seal : Apply engine oil to oil seal lip. 15. Oil gallery pipe No.3 bolt
4. Timing chain cover : Apply sealant 99000-31140 to the mating surface of cylinder and cylinder head.
: Apply sealant 99000-31260 to the mating surface of timing chain cover referring to the
figure of Step 4) of “Installation” under “Timing Chain Cover Removal and Installation”. 16. O-ring
: Apply engine oil.
5. Pin 17. Oil control valve
6. Cap bolt 18. Oil control valve mounting nut
7. Timing chain cover mounting bolts 19. Cap
8. Timing chain cover mounting nut : 11 N ⋅m (1.1 kgf-m, 8.0 lb-ft)
9. Oil gallery pipe No.1 :25 N⋅m (2.5 kgf-m, 18.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 1G-1 Fuel System:
Engine
Fuel System
Precautions
Precautions on Fuel System ServiceS7RS0B1700001
WARNING!
Before attempting service of any type on fuel system, the following should be always observed in
order to reduce the risk of fire and personal injury.
• Disconnect negative cable at battery.
• Do not smoke, and place no smoking signs near work area.
• Be sure to have CO
2 fire extinguisher handy.
• Be sure to perform work in a well-ventilated area and away from any open flames (such as gas hot heater).
• Wear safety glasses.
• To relieve fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then
reinstall it.
• As fuel feed line is still under high fuel pr essure even after stopping engine, loosening or
disconnecting fuel feed line directly may cause dangerous spout of fuel. Before loosening or
disconnecting fuel feed line, make sure to relieve fuel pressure referring to “Fuel Pressure Relief
Procedure”.
• A small amount of fuel may be released when the fuel line is disconnected. In order to reduce the risk of personal injury, cover a shop cloth to the fitting to be disconnected. Be sure to put that cloth
in an approved container after disconnecting.
• Never run engine with fuel pump relay disconnected when engine and exhaust system are hot.
• Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each hose correctly referring to “Fuel Hose Disconnecting and Reconnecting”.
After connecting, make sure that it has no twist or kink.
• When installing inje ctor or fuel feed pipe, lubr icate its O-ring with gasoline.

General Description
Fuel System DescriptionS7RS0B1701001
CAUTION!
This engine requires the unleaded fuel only.
The leaded and/or low lead fuel can result in
engine damage and reduce the effectiveness
of the emission control system.

The main components of the fuel system are fuel tank,
fuel pump assembly (with fuel filter, fuel level gauge, fuel
pressure regulator, fuel feed line and fuel vapor line.
For the details of fuel flow, refer to “Fuel Delivery System
Diagram”.
Fuel Delivery System DescriptionS7RS0B1701002
The fuel delivery system consists of the fuel tank, fuel
pump assembly (with built-in f uel filter and fuel pressure
regulator), delivery pipe, injectors and fuel feed line.
The fuel in the fuel tank is pumped up by the fuel pump,
sent into delivery pipe and injected by the injectors.
As the fuel pump assembly is equipped with built-in fuel
filter and fuel pressure regulator, the fuel is filtered and
its pressure is regulated before being sent to the feed
pipe.
The excess fuel at fuel pressure regulation process is
returned back into the fuel tank.
Also, fuel vapor generated in fuel tank is led through the
fuel vapor line into the EVAP canister.
For system diagram, refer to “Fuel Delivery System
Diagram”.

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Fuel Pump DescriptionS7RS0B1701003
The fuel pump (1) is an in-tank type electric pump.
Incorporated in the pump assembly are;
a fuel filter (2) and a fuel pressure regulator (3) are
included and a fuel level gauge (4) is attached.
Addition of the fuel pressure regulator to the fuel pump
makes it possible to mainta in the fuel pressure at
constant level and ECM controls compensation for
variation in the intake manifold pressure.
Schematic and Routing Diagram
Fuel Delivery System DiagramS7RS0B1702001
Diagnostic Information and Procedures
Fuel Pressure InspectionS7RS0B1704001
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.

1) Relieve fuel pressure in fuel feed line referring to
“Fuel Pressure Relief Procedure”.
2) Disconnect fuel feed hose from fuel delivery pipe.
3) Connect special tools and hose between fuel feed hose (1) and fuel delivery pipe as shown in figure,
and clamp hoses securely in order to ensure that no
leaks occur during checking.
Special tool
(A): 09912–58442
(B): 09912–58432
(C): 09912–58490
1
3
2
4
I6RS0C170001-01
4
6 7
8
12
2 3
11
10
5
1
9
I6RS0C170002-01
1. Fuel tank
5. Fuel injector9. EVAP canister
2. Fuel pump 6. Fuel feed line10. Fuel filter
3. Fuel pressure regulator 7. Fuel vapor line 11. Main fuel level sensor
4. Delivery pipe 8. Intake manifold12. EVAP canister purge valve
1
(C) (B)
(A)
I3RM0A170004-01

Downloaded from www.Manualslib.com manuals search engine 1H-4 Ignition System:
Diagnostic Information and Procedures
Ignition System Symptom DiagnosisS7RS0B1804001
Reference Waveform of Ignition SystemS7RS0B1804002
Refer to “Reference waveform No.5”, “Reference waveform No.6” and “Reference waveform No.7” under “Inspection
of ECM and Its Circuits in Section 1A” for waveform of Ignition trigger signal.
Ignition System CheckS7RS0B1804003
Condition Possible cause Correction / Reference Item
Engine cranks, but will
not start or hard to start
(No spark) Blown fuse for ignition coil
Replace.
Loose connection or disconnection of
lead wire or high-tension cord(s) Connect securely.
Faulty high-tension cord(s) Replace.
Faulty spark plug(s) Replace.
Faulty ignition coil Replace ignition coil assembly.
Faulty CKP sensor or CKP sensor plate Clean, tighten or replace.
Faulty CMP sensor or sensor rotor tooth
of camshaft Clean, tighten or replace.
Faulty ECM Replace.
Poor fuel economy or
engine performance Incorrect ignition timing
Check related sensors and CKP sensor plate.
Faulty spark plug(s) or high-tension
cord(s) Adjust, clean or replace.
Faulty ignition coil assembly Replace.
Faulty CKP sensor or CKP sensor plate Clean, tighten or replace.
Faulty CMP sensor or sensor rotor tooth
of camshaft Clean, tighten or replace.
Faulty knock sensor Replace.
Faulty ECM Replace.
StepAction YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check in
Section 1A”.
2 Ignition spark test
1) Check all spark plugs for condition and type referring to
“Spark Plug Inspection”.
2) If OK, perform ignition spark test referring to “Ignition Spar k Tes t”.
Is spark emitted from all spark plugs? Go to Step 13. Go to Step 3.
3 DTC check
1) Perform DTC check referring to “DTC Check in Section
1A”.
Is DTC stored in ECM? Go to applicable DTC
diag. flow.
Go to Step 4.
4 Electrical connection check
1) Check ignition coil assemblies and high-tension cords
for electrical connection.
Are they connected securely? Go to Step 5.
Connect securely.
5 High-tension cords check
1) Check high-tension cord for resistance referring to
“High-Tension Cord Inspection”.
Is check result satisfactory? Go to Step 6.
Replace high-tension
cord(s).

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-9
6) Set timing light (1) to high-tension cord for No.1 cylinder and check that ignition timing is within
specification.
Initial ignition timing
Fixed with SUZUKI scan tool: 5 ± 3° BTDC (at
specified idle speed)
Ignition order
1 – 3 – 4 – 2
Special tool
(A): 09930–76420 7) If ignition timing is out
of specification, check the
followings.
• CKP sensor
• CKP sensor plate
• CMP sensor
• CMP sensor rotor tooth of camshaft
• VSS
• Timing chain cover installation
8) After checking initial igniti on timing, release ignition
timing fixation by using scan tool.
9) With engine idling (throttl e opening at closed position
and vehicle stopped), check that ignition timing is
about 3 ° – 13° BTDC. (Constant variation within a
few degrees from 3 ° – 13° BTDC indicates no
abnormality but proves operation of electronic timing
control system.) Also, check that increasing engine
speed advances ignition timing.
If the check results are not satisfactory, check CKP
sensor and ECM.
Specifications
Tightening Torque SpecificationsS7RS0B1807001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Special ToolS7RS0B1808001
1, (A)10
0I3RB0A180004-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Spark plug 25 2.5 18.0 )
Ignition coil bolt 10 1.0 7.5 )
09930–76420SUZUKI scan tool
Timing-light (dry cell type) —
) This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12. )