2006 SUZUKI SWIFT IGN

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.
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Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-4
Diagnostic Information and Procedures
Engine Cooling Symptom DiagnosisS7RS0B1604001
ConditionPossible cause Correction / Reference Item
Engine overheats
(Radiator fan operates) Loose or broken water pump belt
Adjust or replace.
Not enough coolant Check coolant level and add as necessary.
Faulty thermostat Replace.
Faulty water pump Replace.
Dirty or bent radiator fins Clean or remedy.
Coolant leakage on cooling system Repair.
Clogged radiator Check and replace radiator as necessary.
Faulty radiator cap Replace.
Improper ignition timing Adjust.
Dragging brakes Adjust brake.
Slipping clutch Adjust or replace.
Poor charge battery Check and replace as necessary.
Poor generation generator Check and repair.
ECT sensor faulty Check and replace as necessary.
Radiator cooling fan relay No.2 and/or
No.3 faulty Check and replace as necessary.
Radiator fan motor faulty Check and replace as necessary.
ECM faulty Check and replace as necessary.
Wiring or grounding faulty Repair as necessary.
Equipped with too much electric load
part(s) Dismount.
Engine overheats
(Radiator fan does not
operate) Fuse blown
Check 30 A fuse of relay/fuse box and check
for short circuit to ground.
Radiator cooling fan relay No.1 faulty Check and replace as necessary.
ECT sensor faulty Check and replace as necessary.
Radiator cooling fan motor faulty Check and replace as necessary.
Wiring or grounding faulty Repair as necessary.
ECM faulty Check and replace as necessary.

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-8
Thermostat Removal and InstallationS7RS0B1606007
Removal1) Drain coolant referring to “Cooling System Draining”.
2) Remove intake manifold referring to “Intake Manifold Removal and Installa tion in Section 1D”.
3) Remove generator referring to “Generator Dismounting and Remounting in Section 1J”.
4) Disconnect water hose (1) and heater hose (2) from each pipe.
5) Remove thermostat case (3) with thermostat cap (4)
and water inlet pipe (5).
6) Remove water inlet pipe with thermostat cap from thermostat case.
7) Remove thermostat from thermostat case (3).
Installation
Reverse removal procedure for installation noting the
following points.
• Install thermostat cap (1) to thermostat case (2) by aligning match mark (3) of thermostat case with air
bleed valve (4) of the thermostat (5).
• Use new O-rings when installing.
• Adjust water pump belt tension referring to “Water Pump / Generator Drive Belt Tension Inspection and
Adjustment in Section 1J”.
• Adjust A/C compressor belt tension referring to “Compressor Drive Belt Inspection and Adjustment in
Section 7B” or “Compressor Drive Belt Inspection and
Adjustment in Section 7B”. • Refill cooling system referrin
g to Step 7) to 22) of
“Cooling System Flush and Refill”.
• Verify that there is no coolant leakage at each connection.
Thermostat InspectionS7RS0B1606008
• Make sure that air bleed valve (1) of thermostat is clean.
• Check to make sure that va lve seat (2) is free from
foreign matters which would prevent valve from
seating tight.
• Check thermostat seal (3) for breakage, deterioration or any other damage.
• Check thermostatic movement of wax pellet as follows:
a. Immerse thermostat (1) in water, and heat water gradually.
b. Check that valve starts to open at specific temperature.
Temperature at which valve begins to open
80 – 84 °C (176 – 183 °F)
Temperature at which valve become fully open
95 – 97 °C (203 °F)
Va l v e l i ft
More than 8 mm at 95 °C (203 ° F)
If valve starts to open at a temperature substantially
below or above specific temperature, thermostat unit
should be replaced with a new one. Such a unit, if
reused, will bring about ov ercooling or overheating
tendency.
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5 3
1 2
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2. Thermometer
3. Heater
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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”.

Downloaded from www.Manualslib.com manuals search engine 1G-3 Fuel System:
4) Check that battery voltage is 11 V or more.
5) Measure fuel pressure at each condition.If measured pressure is out of specification, refer to
“Fuel Pressure Check in Section 1A” and check each
possibly defective part. Replace if found defective.
a) Turn ignition switch ON to operate fuel pump and after 2 seconds turn it OFF. Repeat this 3 or 4
times and then check fuel pressure.
Fuel pressure specification
With fuel pump operating and engine
stopped: 270 – 310 kPa (2.7 – 3.1 kg/cm2, 38.4
– 44.0 psi)
b) Start engine and warm it up to normal operating temperature, and measure fuel pressure at
idling.
Fuel pressure specification
At specified idle speed: 270 – 310 kPa (2.7 –
3.1 kg/cm2, 38.4 – 44.0 psi)
c) Stop engine, and measure fuel pressure at one minute after stopping.
Fuel pressure specification
With 1 min. after engine (fuel pump) stop
(Pressure reduces as time passes): Over 300
kPa (3.0 kg/cm
2, 42.7 psi)
6) After checking fuel pressure, remove fuel pressure gauge.
WARNING!
As fuel feed line is still under high fuel
pressure, make sure to release fuel pressure
according to the following procedures.
• Place fuel container under joint.
• Cover joint with rag and loosen joint nut slowly in order to release fuel pressure
gradually.

7) Remove special tools from fuel delivery pipe and fuel feed hose.
8) Connect fuel feed hose to fuel delivery pipe and clamp it securely.
9) With engine OFF and ignition switch ON, check for fuel leaks.
Fuel Cut Operation InspectionS7RS0B1704002
NOTE
Before inspection, make sure that gear shift
lever is in neutral positi on (shift select lever
is “P” range for A/T vehicle), A/C is OFF and
parking brake lever is pulled all the way up.

1) Warm engine up to normal operating temperature.
2) While listening to sound of injector (2) by using sound scope (1) or such, increase engine speed to
higher than 3,000 r/min.
3) Check to make sure that injector operation sound is stop when throttle valve is closed instantly and it is
heard again when engine speed is reduced to
approx. 2,000 r/min or less.
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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.
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[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
1
2 1
2
(A)
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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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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).
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1
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