2006 SUZUKI SWIFT torque sensor

Downloaded from www.Manualslib.com manuals search engine 1C-8 Engine Electrical Devices:
Installation
Reverse removal procedure noting the following.
• Tighten heated oxygen sensor to specified torque.Tightening torque
Heated oxygen sensor (a): 45 N·m (4.5 kgf-m,
32.5 lb-ft)
• Install exhaust manifold referring to “Exhaust Manifold Removal and Installation in Section 1K”, if removed.
• Connect connector of heated oxygen sensor and clamp wire harness securely.
• After installing heated oxygen sensor, start engine and check that no exhaust gas leakage exists.
CMP Sensor Removal and InstallationS7RS0B1306012
Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect connector from CMP sensor.
3) Remove CMP sensor from cylinder head.
Installation 1) Install CMP sensor to cylinder head.
Tightening torque
CMP sensor bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
2) Connect connector to CMP sensor securely.
3) Connect negative (–) cable to battery.
Camshaft Position (CMP) Sensor InspectionS7RS0B1306013
Visual check
• Check that O-ring is free from damage.
• Check that end face of sensor and signal rotor tooth are free from any metal particles and damage.
Performance check 1) Remove metal particles on end face of CMP sensor, if any.
2) Arrange 12 V battery (1) and connect its positive terminal to “Vin” terminal (2) and negative terminal to
“Ground” terminal (3) of sensor. Then using
ohmmeter, measure resistance between “Vout”
terminal (4) of sensor and negative terminal of
battery by passing magnetic substance (iron) (5)
while keeping approximately 1 mm (0.03 in.) gap
with respect to end face of CMP sensor.
If resistance does not vary as specified below,
replace CMP sensor.
CMP sensor resistance
Resistance varies from less than 220 Ω (ON) to
infinity (OFF) or from infinity (OFF) to less than 220
Ω (ON)
1. EGR valve
(a)
(a)
I6RS0C130003-02
I6RS0C130004-01
I4RS0B130015-01
I6RS0C130005-01

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CKP Sensor Removal and InstallationS7RS0B1306014
Removal1) Disconnect negative (–) cable at battery.
2) Remove generator drive belt refer to “Water Pump / Generator Drive Belt Remo val and Installation in
Section 1J”.
3) Remove generator bracket bolt (1) and move generator rearward.
4) Disconnect connector from CKP sensor.
5) Remove CKP sensor (2) from cylinder block.
Installation 1) Install CKP sensor to cylinder block. Tighten CKP sensor bolt to specified torque.
Tightening torque
CKP sensor bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
2) Connect connector to CKP sensor securely.
3) Adjust generator drive belt tension referring to “Water Pump / Generator Drive Belt Tension
Inspection and Adjustment in Section 1J”.
4) Connect negative (–) cable to battery.
CKP Sensor InspectionS7RS0B1306015
Visual check
• Check that O-ring is free from damage.
• Check that end face of sensor and signal pulley tooth are free from any metal particles and damage.
Performance check 1) Remove metal particles on end face of CKP sensor, if any.
2) Arrange 12 V battery (1) and connect its positive terminal to “Vin” terminal (2) and negative terminal to
“Ground” terminal (3) of sensor. Then using
ohmmeter, measure resistance between “Vout”
terminal (4) of sensor and negative terminal of
battery by passing magnetic substance (iron) (5)
while keeping approximately 1 mm (0.03 in.) gap
with respect to end face of CKP sensor.
If resistance does not vary as specified below,
replace CKP sensor.
CKP sensor resistance
Resistance varies from less than 220 Ω (ON) to
infinity (OFF) or from infinity (OFF) to less than 220
Ω (ON)
2
1
I6RS0C130006-01
(a)
I4RS0A130007-01
I3RB0A130006-01
I4RS0B130017-01

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Knock Sensor Removal and InstallationS7RS0B1306016
Removal1) Disconnect negative (–) cable at battery.
2) Hoist vehicle.
3) Remove right side drive shaft referring to “Front Drive Shaft Assembly Removal and Installation in
Section 3A”.
4) Disconnect knock sensor connector (1).
5) Remove knock sensor (2) from cylinder block.
Installation
Reverse removal procedure for installation.
Tightening torque
Knock sensor (a): 22 N· m (2.2 kgf-m, 16.0 lb-ft)
Main Relay, Fuel Pump Relay and Starting Motor
Control Relay Inspection
S7RS0B1306017
1) Disconnect negative (–) cable at battery.
2) Remove main relay (1), fuel pump relay (3) and/or
starting motor control relay (2) from individual circuit
fuse box No.1.
3) Check that there is no continuity between terminal “C” and “D”. If there is continuity, replace relay.
4) Connect battery positive (+ ) terminal to terminal “B”
of relay. Connect battery negative (–) terminal to
terminal “A” of relay. Ch eck for continuity between
terminal “C” and “D”. If t here is no continuity when
relay is connected to the battery, replace relay.
1 2, (a)
I3RB0A130007-01
"D"
"B" "A"
"C"
2
1
3
I4RS0A130014-01

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MAF and IAT Sensor On-Vehicle InspectionS7RS0B1306018
NOTE
Before performed this inspection, be sure to
read the “Precautions of ECM Circuit
Inspection in Section 1A”.

1) Disconnect negative (–) cable at battery.
2) Disconnect MAF and IAT sensor connector.
3) Connect voltmeter to “BLK/RED” wire terminal (2) of
MAF and IAT sensor connector (1) disconnected and
ground.
4) Turn ON ignition switch position and check that voltage is battery voltage.
If not, check if wire harness is open or connection is
poor.
5) Turn OFF ignition switch position and connect connector to MAF and IAT sensor.
6) Remove ECM from its bracket referring to “ECM Removal and Installation”.
7) Connect special tool between ECM and ECM connector referring to “Inspection of ECM and Its
Circuits in Section 1A”.
8) Turn ON ignition switch position and check MAF signal voltage between “C37-26” terminal circuit and
“C37-27” terminal circuit of special tool.
MAF signal voltage between “C37-26” terminal
circuit and “C37-27” termi nal circuit of special
tool
MAF signal voltage of MAF and IAT sensor with
ignition switch turned ON: 0.5 – 1.0 V
9) Start engine and check that voltage is lower than 5 V and it rises as engine speed increases.
MAF signal voltage between “C37-26” terminal
circuit and “C37-27” termi nal circuit of special
tool
MAF signal reference voltage of MAF and IAT
sensor at specified Idle speed: 1.3 – 1.8 V 10) If check result is not as
specified above, cause may
lie in wire harness, connec tor connection, MAF and
IAT sensor or ECM.
MAF and IAT Sensor Removal and InstallationS7RS0B1306019
CAUTION!
• Do not disassemble MAF and IAT sensor.
• Do not expose MAF and IAT sensor to any shock.
• Do not clean MAF and IAT sensor.
• If MAF and IAT sensor has been dropped, it should be replaced.
• Do not blow compressed air by using air gun or the like.
• Do not put finger or any other object into MAF and IAT sensor. Malfunction may
occur.

Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect MAF and IAT sensor connector.
3) Remove air cleaner case (1).
4) Remove MAF and IAT sensor (2) from air cleaner case.
Installation
Reverse removal procedure noting the followings.
• Tighten MAF and IAT sensor screws to specified torque.
Tightening torque
MAF and IAT sensor screw (a): 1.5 N·m (0.15 kgf-
m, 1.1 lb-ft)
• Connect MAF and IAT sensor connector securely.
1. ECM
I3RB0A130009-01
“C37-27” “C37-26” 1
I4RS0A130009-01
1
2
I4RS0A130010-01
(a)
I4RS0A130011-01

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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 1D-55 Engine Mechanical:
Installation
NOTE
• Use new bearing cap No.1 bolts. They are deformed once they are used because they
are plastic deformation tightening bolts.
• All parts to be insta lled must be perfectly
clean.
• Be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins,
connecting rod bearings, pistons, piston
rings and cylinder bores.
• Journal bearings, bearing caps, connecting rods, rod bearings, rod bearing
caps, pistons and piston rings are in
combination sets. Do not disturb such
combination and make sure that each part
goes back to where it came from, when
installing.

1) Install sensor plate (1) to crankshaft (2) and tighten bolts to spec ified torque.
NOTE
When installing sensor plate, align spring pin
(3) on crankshaft and hole of sensor plate.

Tightening torque
Sensor plate bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft) 2) Install piston cooling valves and nozzles, if removed.
NOTE
Install piston cooling valve while matching
piston cooling nozzle (1) to positioning (3) of
cylinder block when installed piston cooling
valve (2).

Tightening torque
Piston cooling valve (a): 11 N·m (1.1 kgf-m, 8.0
lb-ft)
3) Install main bearings to cylinder block. Upper half of bearing (1), has an oil groove (2).
Install it to cylinder block (3), and the other half
without oil groove to bearing cap.
Make sure that two halves are painted in the same
color.
4) Confirm that dowel pins (3 ) are installed to intake
side of each journal.
I2RH0B140128-01
I6RS0B141022-02
I2RH0B140129-01
I2RH0B140130-01

Downloaded from www.Manualslib.com manuals search engine 1D-65 Engine Mechanical:
NOTE
The specified tightening torque is also described in the following.
“Air Cleaner Components”
“Throttle Body and Intake Manifold Components”
“Engine Mountings Components”
“Timing Chain Cover Components”
“Timing Chain and Chain Tensioner Components”
“Camshaft, Tappet and Shim Components”
“Valves and Cylinder Head Components”
“Pistons, Piston Rings, Connecting Rods and Cylinders Components”
“Main Bearings, Crankshaft and Cylinder Block Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Connecting rod bearing cap bolt
15 N⋅m (1.5 kgf-m, 11.0 lb-ft) and then
retighten by turning through 45 ° twice )
/ )
Sensor plate bolt 111.1 8.0 )
Piston cooling valve 111.1 8.0 )
Main bearing cap No.1 bolt (a) 30 N⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N ⋅m (5.0
kgf-m, 36.5 lb-ft) and then retighten by
turning through 60 ° )
Main bearing cap No.2 bolt (b) 252.5 18.0 )
Rear oil seal housing bolt 111.1 8.0 )
Flywheel or drive plate bolt 707.0 51.0 )
Main bearing cap No.1 bolt 30 N⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N ⋅m (5.0
kgf-m, 36.5 lb-ft) and then retighten by
turning through 60 ° )
Main bearing cap No.2 bolt 252.5 18.0 ) / )
Main bearing cap No.1 bolt 30 Nm (3.0 kgf-m, 22.0 lb-ft), 50 Nm (5.0
kgf-m, 36.5 lb-ft) and then retighten by
turning through 60 ° )
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-7
6) After fitting oil pan to cylinder block, run in securing bolts and start tightening at the center: move wrench
outward, tightening one bolt at a time. Tighten bolts
and nuts to specified torque.
Tightening torque
Oil pan bolt (M6) (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Oil pan bolt (M10) (c): 55 N·m (5.5 kgf-m, 40.0 lb-
ft)
Oil pan nut (e): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
7) Install new gasket and drain plug to oil pan. Tighten drain plug to specified torque.
Tightening torque
Oil pan drain plug (b): 35 N·m (3.5 kgf-m, 25.5 lb-
ft)
8) Tighten transaxle stiffener bolts to specified torque. Tightening torque
Transaxle stiffener bolt (d): 55 N·m (5.5 kgf-m,
40.0 lb-ft)
9) Install exhaust manifold stiffener (2) and exhaust No.1 pipe (1) and heated oxygen sensor No.2
(connector color: green) (3) referring to “Exhaust
System Components in Section 1K”. 10) Install clutch housing lower plate (1).
11) Install oil level gauge.
12) Refill engine with engine oil referring to “Engine Oil
and Filter Change in Section 0B”.
13) Verify that there is no en gine oil leakage and exhaust
gas leakage at each connection.
Oil Pan and Oil Pump Strainer CleaningS7RS0B1506006
• Clean sealing surface between oil pan and cylinder block.
Remove oil, old sealant, and dust from sealing
surface.
• Clean oil pump strainer screen (1).(a)
(b)
(c)(e)
(d)I4RS0A150008-01
2
1
3
I4RS0A150003-01
1I4RS0A150004-01
I2RH0B150016-01