2007 SUZUKI SWIFT hoses

Downloaded from www.Manualslib.com manuals search engine 1A-216 Engine General Information and Diagnosis:
Repair Instructions
Idle Speed and IAC Throttle Valve Opening
Inspection
S7RS0B1106001
Before idle speed check, make sure of the following.
• Lead wires and hoses of electronic fuel injection and engine and emission control systems are connected
securely.
• Valve lash is checked according to maintenance schedule.
• Ignition timing is within specification.
• All accessories (wipers, heater, lights, A/C, etc.) are out of service.
• Air cleaner has been properly installed and is in good condition.
• No abnormal air drawn in from air intake system.
After all items are confirmed, check idle speed and IAC
duty as follows.
NOTE
Before starting engine, place transmission
gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T vehicle), and set
parking brake and block drive wheels.

1) Connect SUZUKI scan tool to DLC (1) with ignition
switch turned OFF.
Special tool
(A): SUZUKI scan tool 2) Warm up engine to normal operating temperature.
3) Check engine idle speed and “IAC throttle opening”
by using “Data List” mode on scan tool to check “IAC
throttle opening”.
4) If check result is out of sp ecification, inspect electric
throttle body assembly referring to “Electric Throttle
Body Assembly On-Vehicle Inspection in Section
1C”.
Engine idle speed
A/C OFF: 700 ± 50 rpm (IAC duty: 5 – 55%)
A/C ON: 850 ± 50 rpm
5) Check that specified engine idle speed is obtained with A/C turned ON if vehi cle is equipped with A/C.
If not, check A/C system.
(A)
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I4RS0B110093-01

Downloaded from www.Manualslib.com manuals search engine Aux. Emission Control Devices: 1B-2
EVAP Canister Purge Valve and Its Circuit
Inspection
S7RS0B1206002
WARNING!
Do not apply vacuum by mouth; otherwise
harmful fuel vapor can be breathed in.

CAUTION!
Do not apply vacuum more than –86 kPa (–
12.47 psi); otherwise EVAP canister purge
valve could be damaged.

1) Prepare to operate EVAP canister purge valve as follows.
a) When using SUZUKI scan tool:
i) Connect SUZUKI scan tool to DLC (1) with ignition switch turned OFF and disconnect
purge valve vacuum hoses from intake
manifold and EVAP canister.
ii) Turn ON ignition switch, clear DTC and select “MISC TEST” mode on SUZUKI scan
tool.
Special tool
(A): SUZUKI scan tool b) When not using SUZUKI scan tool:
NOTE
Before performed this check, be sure to read
the “Precautions of ECM Circuit Inspection in
Section 1A”.

i) Disconnect purge valve vacuum hoses from
intake manifold and EVAP canister.
ii) Remove ECM from it s bracket referring to
“ECM Removal and Inst allation in Section
1C”.
iii) Connect special tool between ECM and ECM connector referring to “Inspection of ECM
and Its Circuits in Section 1A”
iv) Turn ON ignition switch. Using service wire, ground “C37-29” terminal
circuit of special tool (valve ON: “B”) and
unground it (valve OFF: “A”).
2) Check purge valve for operation and vacuum passage for clog when valve is switched ON and
OFF by using SUZUKI scan tool or service wire.
If check result is not satisfactory, check vacuum
hoses, EVAP canister purge valve, wire harness and
connections.
EVAP canister purge valve specification
[A] Valve OFF: When vacuum (–60 kPa (–8.7 psi))
is applied to hose (1), vacuum can be applied.
[B] Valve ON: When vacuum is applied to hose
(1), vacuum can not be applied.
Special tool
(A): 09917–47011
(A)
1
I4RS0B120003-03
“C37-29”“A”
“B”
I4RS0B120006-02
[A] [B]
1
(A)1
(A)
I3RB0A120005-02

Downloaded from www.Manualslib.com manuals search engine 1B-3 Aux. Emission Control Devices:
Vacuum Passage InspectionS7RS0B1206003
Start engine and run it at idle speed. Disconnect vacuum
hose (1) from EVAP canister purge valve (2). With finger
placed against disconnected hose, check that vacuum is
applied.
If it is not applied, clean vacuum passage by blowing
compressed air.
Vacuum Hose and Purge Valve Chamber
Inspection
S7RS0B1206004
Check hoses and purge valv e chamber for connection,
leakage, clog and deterioration.
Replace as necessary.
EVAP Canister Purge Valve InspectionS7RS0B1206005
WARNING!
Do not apply vacuum by mouth; otherwise
harmful fuel vapor can be breathed in.

CAUTION!
Do not apply vacuum more than –86 kPa (–
12.47 psi); otherwise EVAP canister purge
valve could be damaged.

1) With ignition switch turned OFF, disconnect coupler and vacuum hoses from canister purge valve.
2) Remove EVAP canister purge valve from air cleaner assembly.
3) Check resistance between two terminals of EVAP canister purge valve.
If resistance is not as specified, replace EVAP
canister purge valve.
EVAP canister purge valve resistance
30 – 34 Ω at 20 °C (68 °F) 4) With coupler disconnected, apply vacuum (–60 kPa
(–8.7 psi)) to pipe (1). If vacuum can be applied, go
to next step. If vacuum can not be applied, replace
EVAP canister purge valve.
5) In this state, connect 12 V-battery to EVAP canister purge valve terminals. If vacuum can not be applied,
EVAP canister purge valve is in good condition.
If applied, replace EVAP canister purge valve.
WARNING!
Do not suck the air through valve. Fuel vapor
inside valve is harmful.

Special tool
(A): 09917–47011
6) Install EVAP canister purge valve to air cleaner assembly.
I3RM0A120006-01
I3RM0A120008-01
1
1 (A)
(A)
I3RB0A120007-01

Downloaded from www.Manualslib.com manuals search engine Aux. Emission Control Devices: 1B-4
EVAP Canister InspectionS7RS0B1206006
WARNING!
DO NOT SUCK nozzles on EVAP canister.
Fuel vapor inside EVAP canister is harmful.

1) Check outside of EVAP canister visually.
2) Disconnect vacuum hoses from EVAP canister.
3) Check that there is no restriction of flow through purge pipe (1) and air pipe (2) when air is blown (4)
into tank pipe (3).
If any faulty condition is found in this inspection,
replace EVAP canister.
EGR Valve Removal and InstallationS7RS0B1206007
Removal
1) Disconnect negative (–) cable at battery.
2) Remove air intake pipe.
3) Remove EGR pipe.
4) Disconnect EGR valve connector.
5) Remove EGR valve and gasket from cylinder head.
Installation
Reverse removal procedure noting the following.
• Clean mating surface of valve and cylinder head.
• Use new gaskets.
EGR Valve InspectionS7RS0B1206008
1) Check resistance between following terminals of EGR valve (1) in each pair.
If found faulty, replace EGR valve assembly.
EGR valve resistance (A – B, C – B, F – E, D – E
terminal)
20 – 24 Ω
2) Remove carbon from EGR valve gas passage.
CAUTION!
Do not use any sharp-edged tool to remove
carbon.
Be careful not to damage or bend EGR valve
(1), valve seat (3) and rod.

3) Inspect valve (2), valve seat and rod for fault, cracks, bend or other damage.
If found faulty, replace EGR valve assembly.
PCV Hose InspectionS7RS0B1206009
NOTE
Be sure to check that there is no obstruction
in PCV valve or its hoses before checking
IAC duty, for obstructed PCV valve or hose
hampers its accurate adjustment.

Check hoses for connection, leakage, clog and
deterioration.
Replace as necessary.
I4RS0A120006-01
I2RH0B120005-01
I2RH0B120006-01

Downloaded from www.Manualslib.com manuals search engine 1B-5 Aux. Emission Control Devices:
PCV Valve InspectionS7RS0B1206010
NOTE
Be sure to check that there is no obstruction
in PCV valve or its hoses before checking
IAC duty, for obstructed PCV valve or hose
hampers its accurate adjustment.

1) Detach air cleaner assembly.
2) Disconnect PCV valve from cylinder head cover and install plug to head cover hole.
3) Install air cleaner assembly temporarily.
4) Run engine at idle.
5) Place your finger over end of PCV valve (1) to check for vacuum.
If there is no vacuum, ch eck for clogged valve.
Replace as necessary. 6) After checking vacuum, stop engine and remove
PCV valve (1).
Shake valve and listen for rattle of check needle
inside the valve. If valve does not rattle, replace PCV
valve.
7) After checking, remove plug and install PCV valve.
8) Install air cleaner assembly securely.
Special Tools and Equipment
Special ToolS7RS0B1208001
I2RH0B120007-01
I2RH0B120008-01
09917–47011 SUZUKI scan tool
Vacuum pump gauge —
) / ) 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. )

Downloaded from www.Manualslib.com manuals search engine 1D-13 Engine Mechanical:
Throttle Body On-Vehicle InspectionS7RS0B1406006
Check electric throttle body assembly referring to
“Throttle Valve Operation Check” and “Electric Throttle
Body Assembly Operation Check” under “Electric
Throttle Body Assembly On-Vehicle Inspection in
Section 1C”.
Electric Throttle Body Assembly Removal and
Installation
S7RS0B1406007
CAUTION!
Never disassemble electric throttle body.
Disassembly will spoil its original
performance. If faulty condition is found,
replace it with new one.

NOTE
After replacing electric throttle body
assembly, perform calibration of throttle
valve referring to “Electric Throttle Body
System Calibration in Section 1C”.

Removal
1) Disconnect negative cable at battery.
2) Drain coolant referring to “Cooling System Draining in Section 1F”.
3) Remove air cleaner assembly referring to “Air Cleaner Components”.
4) Detach EVAP canister and purge valve chamber, and remove air cleaner outlet hose.
5) Disconnect engine coolant hoses (1) and breather hose (2) from electric throttle body assembly (3).
6) Disconnect connector (4) from electric throttle body assembly.
7) Remove electric throttle body assembly from intake
manifold. Installation
1) Clean mating surfaces and install new throttle body gasket (1) to intake manifold.
2) Install electric throttle bo dy assembly (1) to intake
manifold.
3) Connect connector (2) to electric throttle body assembly securely.
4) Connect engine coolant hoses (3) and breather hose (4) to electric thrott le body assembly (1).
5) Install air cleaner assembly referring to “Air Cleaner
Components”.
6) Install EVAP canister and purge valve chamber and air cleaner outlet hose.
7) Refill coolant referring to “Cooling System Flush and
Refill in Section 1F”.
8) Connect negative cable at battery.
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4
3
1I4RS0B140004-02
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I6RS0C140013-02
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2
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3I4RS0B140006-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-14
Throttle Body CleaningS7RS0B1406008
Clean electric throttle body assembly referring to
“Throttle Valve Visual Check” under “Electric Throttle
Body Assembly On-Vehicle Inspection in Section 1C”.
Intake Manifold Removal and InstallationS7RS0B1406009
Removal1) Remove cowl top plate referring to “Cowl Top Components in Section 9K”.
2) Remove throttle body referring to “Electric Throttle Body Assembly Removal and Installation”.
3) Disconnect MAP sensor coupler (1).
4) Disconnect the following hoses: • Brake booster hose (2) from cylinder head cover
• Breather hose (3) from cylinder head cover
• PCV hose (4) from intake manifold
• EVAP canister purge valve hose (5) from intake manifold
5) Remove hose clamp (6) from intake manifold.
6) Remove EGR pipe bolt (7) from EGR valve. 7) Remove stiffener (1) and ground terminal (2) from
intake manifold.
8) Remove intake manifold (1) with EGR pipe (2) from
cylinder head, and then remove their gaskets (3).
9) Remove EGR pipe from intake manifold, if necessary.
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2 1
3
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7I6RS0B141008-01
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2
I6RS0B141010-01
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2
1
I6RS0B141009-01

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.

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I6RS0B141014-01