2006 SUZUKI SWIFT engine cover

Downloaded from www.Manualslib.com manuals search engine Precautions: 00-2
Servicing and Handling
WARNING!
Many of service procedures require
disconnection of “A/BAG” fuse and all air
bag (inflator) module(s) from initiator circuit
to avoid an accidental deployment.
Driver, Passenger, Side and Curtain Air Bag
(Inflator) Modules
• For handling and storage of a live air bag (inflator) module, select a place where the
ambient temperature below 65 °C (150 ° F),
without high humidity and away from
electric noise.
• When carrying a live air bag (inflator) module, make sure the bag opening is
pointed away from you. In case of an
accidental deployment, the bag will then
deploy with minimal chance of injury.
Never carry the air bag (inflator) module by
the wires or connector on the underside of
the module. When placing a live air bag
(inflator) module on a bench or other
surface, always face the bag up, away from
the surface. As the live passenger air bag
(inflator) module must be placed with its
bag (trim cover) facing up, place it on the
workbench with a slit (1) or use the
workbench vise (2) to hold it securely at its
lower mounting bracket (3). It is also
prohibited to place anything on top of the
trim cover and stack air bag (inflator)
modules. This is necessary so that a free
space is provided to allow the air bag to
expand in the unlikely event of accidental
deployment. Otherwise, personal injury
may result.
• Never dispose of live (undeployed) air bag (inflator) modules (driver, passenger, side
and curtain). If disposal is necessary, be
sure to deploy them according to
deployment procedures described in “Air
Bag (Inflator) Module and Seat Belt
Pretensioner Disposal in Section 8B”
before disposal.
• The air bag (inflator) module immediately
after deployment is very hot. Wait for at
least half an hour to cool it off before
proceeding the work.
• After an air bag (inflator) module has been deployed, the surface of the air bag may
contain a powdery residue. This powder
consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by-
products of the chemical reaction. As with
many service procedures, gloves and
safety glasses should be worn.

[A]: Always carry air bag (inflator) module with trim cover (air bag opening) away from body.
[B]: Always place air bag (inflator) module on workbench with trim cover (air bag opening) up, away from loose objects.
1
2
3
[A]
[B]
I4RS0A000003-02

Downloaded from www.Manualslib.com manuals search engine 00-3 Precautions:
WARNING!
SDM
• For handling and storage of a SDM, select a place where the ambient temperature
below 65 °C (150 °F), without high humidity
and away from electric noise.
• During service procedures, be very careful when handling a Sensing and Diagnostic
Module (SDM). Never strike or jar the SDM.
• Never power up the air bag system when the SDM is not rigidly attached to the
vehicle. All SDM and mounting bracket
fasteners must be carefully torqued and
the arrow must be pointing toward the
front of the vehicle to ensure proper
operation of the air bag system.
The SDM could be activated when powered
while not rigidly att ached to the vehicle
which could cause deployment and result
in personal injury.

WARNING!
Driver and Passenger Seat Belt
Pretensioners
• For handling and storage of a live seat belt pretensioner, select a place where the
ambient temperature below 65 °C (150 ° F),
without high humidity and away from
electric noise.
• Never carry seat belt pretensioner by wire or connector of pretensioner. When
placing a live seat belt pretensioner on the
workbench or some place like that, never
put something on seat belt pretensioner.
Otherwise, personal injury may result.
• Never dispose of live (inactivated) seat belt pretensioners (drive and passenger). If
disposal is necessary, be sure to activate
them according to activation procedures
described in “Air Bag (Inflator) Module and
Seat Belt Pretensioner Disposal in Section
8B” before disposal.
• The seat belt pretensioner immediately after activation is very hot. Wait for at least
half an hour to cool it off before
proceeding the work.
• With many service procedures, gloves and safety glasses should be worn to prevent
any possible irritation of the skin or eyes.

• Even when the accident was light enough not to cause air bags to activate, be sure to inspect system
parts and other related parts according to instructions
under “Repair and Inspection Required after Accident
in Section 8B”.
• When servicing parts other than air bag system, if shocks may be applied to air bag system component
parts, remove those parts beforehand.
• When handling the air bag (inflator) modules (driver, passenger, side and curtain), seat belt pretensioners
(driver and passenger), forward sensor, side sensors
or SDM, be careful not to drop it or apply an impact to
it. If an excessive impact was applied, never attempt
disassembly or repair but replace it with a new one.
• When grease, cleaning agent, oil, water, etc. has got onto air bag (inflator) modules (driver, passenger, side
and curtain) or seat belt pretensioners (drive and
passenger), wipe off immediately with a dry cloth.
• Air bag wire harness is included in floor and instrument panel wire harnesses. Air bag wire
harness branched off from floor and instrument panel
wire harnesses can be identifie d easily as it is covered
with a yellow protection tube and it has yellow
connectors. Be very ca reful when handling it.
• When an open in air bag wire harness, damaged wire harness, connector or terminal is found, replace wire
harness, connectors and terminals as an assembly.
• Do not apply power to the air bag system unless all components are connected or a diagnostic flow
requests it, as this will set a DTC.
• Never use air bag system component parts from another vehicle.
• When using electric welding, be sure to disconnect all air bag (inflator) module connectors and pretensioner
connectors from air bag wire harness respectively.
• Never expose air bag system component parts directly to hot air (drying or baking the vehicle after
painting) or flames.
• WARNING / CAUTION labels are attached on each
part of air bag system components. Be sure to follow
the instructions.
• After vehicle is completely repaired, perform “Air Bag Diagnostic System Check in Section 8B”.

Downloaded from www.Manualslib.com manuals search engine Precautions: 00-4
General PrecautionsS7RS0B0000002
The WARNING and CAUTION describe some general
precautions that you should observe when servicing a
vehicle. These general precautions apply to many of the
service procedures, and they will not necessarily be
repeated with each procedure to which they apply.
WARNING!
• Whenever raising a vehicle for service, be sure to follow the instructions under
“Vehicle Lifting Points in Section 0A”.
• When it is necessary to do service work with the engine running, make sure that
the parking brake is set fully and the
transmission is in Neutral (for manual
transmission vehicles) or Park (for
automatic transmission vehicles), Keep
hands, hair, clothing, tools, etc. away from
the fan and belts when the engine is
running.
• When it is necessary to run the engine indoors, make sure that the exhaust gas is
forced outdoors.
• Do not perform service work in areas where combustible materials can come in
contact with a hot exhaust system. When
working with toxic or flammable materials
(such as gasoline and refrigerant), make
sure that the area you work in is well-
ventilated.
• To avoid getting burned, keep away from hot metal parts such as the radiator,
exhaust manifold, tail pipe, muffler, etc.
• New and used engine oil can be hazardous. Children and pets may be
harmed by swallowing new or used oil.
Keep new and used oil and used engine oil
filters away from children and pets.
Continuous contact with used engine oil
has been found to cause [skin] cancer in
laboratory animals. Brief contact with used
oil may irritate skin. To minimize your
exposure to used engine oil, wear a long-
sleeve shirt and moisture-proof gloves
(such as dish washing gloves) when
changing engine oil. If engine oil contacts
your skin, wash thoroughly with soap and
water. Launder any clothing or rags if wet
with oil, recycle or properly dispose of
used oil and filters. • Be sure to observe following instructions
when handling service materials such as
fuel, oil, fluid, coolant, grease, sealant,
thread lock cement, etc. Otherwise, your
health may be ruined.
– Whenever handling any of these service materials, wear safety glasses to protect
your eyes. If it gets into your eye, it may
cause inflammation.
– Whenever handling any of these service materials, wear moistu re-proof gloves to
protect your skin. If it adheres to your
skin, it may cause inflammation.
– Do not swallow any of these service materials. It would cause diarrhea or
nausea.
– Keep all these materials out of children’s reach.
• Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly
up unexpectedly during driving,
obstructing your view and resulting in an
accident.

• Before starting any service work, cover fenders, seats and any other parts that are likely to get scratched or
stained during servicing. Also, be aware that what you
wear (e.g., buttons) ma y cause damage to the
vehicle’s finish.
I2RH01010025-01

Downloaded from www.Manualslib.com manuals search engine 00-5 Precautions:
• When performing service to electrical parts that does not require use of battery power, disconnect the
negative cable of the battery.
• When disconnecting the negative cable from the battery, be careful to the following.
– Check and record DTCs in ECM and HVAC control module if necessary before disconnecting.
– Record displayed contents of the clock and/or audio system, etc. before disconnecting and reset it
as before after connecting.
– For vehicle equipped with electric throttle body system, perform electric throttle body system
calibration referring to “Electric Throttle Body
System Calibration in Section 1C” after
reconnecting the negative cable to the battery.
– For vehicle equipped with ESP ®, calibrate steering
angle sensor referring to “Sensor Calibration in
Section 4F” after reconnecting the negative cable
to the battery.
• When removing the battery, be sure to disconnect the negative cable first and then the positive cable. When
reconnecting the battery, connect the positive cable
first and then the negative cable, and replace the
terminal cover. • When removing parts that are to be reused, be sure to
keep them arranged in an orderly manner so that they
may be reinstalled in the proper order and position.
• Whenever you use oil seals, gaskets, packing, O- rings, locking washers, split pins, self-locking nuts,
and certain other parts as specified, be sure to use
new ones. Also, before installing new gaskets,
packing, etc., be sure to remove any residual material
from the mating surfaces.
• Make sure that all parts used in reassembly are perfectly clean.
When use of a certain type of lubricant, bond or
sealant is specified, be sure to use the specified type.
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
I2RH01010026-01
I2RH01010027-01
I2RH01010028-01
I2RH01010029-01
I2RH01010030-01

Downloaded from www.Manualslib.com manuals search engine General Information: 0A-8
Component Location
Warning, Caution and Information Labels LocationS7RS0B0103001
The figure shows main labels among others that are attached to vehicle component parts.
When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels.
If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.
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2
3
4
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5
I5RS0C010001-02
1. Air bag label on sun visor (if equipped) 4.Steering shaft joint cover label (if equipped)
2. Radiator cap label 5. Jack label
3. Engine cooling fan label 6. Rear beam label

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-5
4) Screw new filter on oil filter stand by hand until the filter O-ring contacts mounting surface.
CAUTION!
To tighten oil filter prop erly, it is important to
accurately identify the position at which filter
O-ring first contacts mounting surface.

5) Tighten the filter (1) 3/4 tu rn from the point of contact
with the mounting surface using an oil filter wrench
(2).
Tightening torque
Oil filter (b): 14 N·m (1 .4 kgf-m, 10.5 lb-ft) for
reference
6) Replenish oil until oil leve l is brought to FULL level
mark on dipstick (oil pan and oil filter capacity). The
filler inlet is at the top of the cylinder head cover. It is
recommended to use engine oil of SG, SH, SJ, SL or
SM grade. Select the appropriate oil viscosity
according to the proper engine oil viscosity chart [A].
NOTE
Engine oil capacity is specified as the
following.
However, note that the amount of oil required
when actually changing oil may somewhat
differ from the data depending on various
conditions (temperature, viscosity, etc.).

Engine oil specification
Oil pan capacity: About 3.7 liters (7.8 / 6.5 US /
lmp pt.)
Oil filter capacity: About 0.2 liter (0.4 / 0.3 US /
lmp pt.)
Others: About 0.3 liter (0 .6 / 0.5 US / lmp pt.)
Total: About 4.2 liters (8.9 / 7.4 US / lmp pt.) 7) Check oil filter and drain plug for oil leakage.
8) Start engine and run it for 3 minutes. Stop it and wait
another 5 minutes before checking oil level. Add oil,
as necessary, to bring oil le vel to FULL level mark (1)
on dipstick.
Engine Coolant ChangeS7RS0B0206005
WARNING!
To help avoid danger of being burned, do not
remove radiator cap while engine and
radiator are still hot. Scalding fluid and steam
can be blown out under pressure if cap is
taken off too soon.

CAUTION!
When changing engine coolant, use mixture
of 50% specified water and 50% ANTIFREEZE
/ ANTICORROSION COOLANT for the
purpose of corrosion protection and
lubrication.

Change engine coolant with new one referring to
“Cooling System Flush and Refill in Section 1F”.
IYSQ01020010-01
Co
Fo-30
-22 -20
-4 -10
14 32 50 68 86 104 010203040
5W-30
20W-40
15W-40
10W-30, 10W-40
[A]
I7RS0B020001-02
2. Low level mark (hole)
IYSQ01020012-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 1-iii
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

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-1
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