2007 SUZUKI SWIFT 600

Downloaded from www.Manualslib.com manuals search engine Engine Electrical Devices: 1C-5
Electric Throttle Body System CalibrationS7RS0B1306004
NOTE
If working the service described under the
“Precautions of Electric Throttle Body
System Calibration in Section 1A” perform
following steps for electric throttle body
system calibration.

1) If electric throttle body assembly and/or APP sensor
assembly are replaced, perform following steps.
a) Disconnect negative cable at battery for 20 seconds or more for the purpose of clearing
calibration data of closed throttle position from
memory in ECM.
b) Connect negative cable to battery.
2) Keep ignition switch at ON position for 5 seconds or more without running engine.
APP Sensor Assembly On-Vehicle InspectionS7RS0B1306005
1) Check that APP sensor a ssembly has been mounted
to vehicle body properly (no pinched floor carpet,
etc.).
If mounting is not pro perly, reinstall APP sensor
assembly properly refe rring to “APP Sensor
Assembly Removal and Installation”.
2) Connect scan tool to DLC with ignition switch turned OFF.
3) Turn ON ignition switch and select “Data List” mode on scan tool.
4) Check that APP sensor voltage varies as the following graph.
If sensor voltage is out of specified value or does not
vary linearly as the fo llowing graph, check APP
sensor assembly referring to “APP Sensor Assembly
Inspection”.
APP Sensor Assembly Removal and InstallationS7RS0B1306006
CAUTION!
• Do not expose APP sensor assembly to
excessive shock like a dropping it. If APP
sensor assembly has been exposed to
excessive shock, it should be replaced.
• Be careful not to expose sensor section of APP sensor assembly to water.

NOTE
After replacing APP sensor assembly,
perform calibration of th rottle valve referring
to “Electric Throttle Body System
Calibration”.

Removal
1) Disconnect negative cable at battery.
2) Disconnect connector from APP sensor assembly.
3) Remove APP sensor asse mbly from its bracket.
Installation
Reverse removal procedure for installation noting the
following.
• Tighten APP sensor assembly upper nut (1) first and then lower nut (2) to specified torque.
Tightening torque
APP sensor assembly nut (a): 5.5 N·m (0.55 kgf-m,
4.0 lb-ft)
• Connect connector to APP sensor assembly securely.
[A]: APP sensor (main) voltage [D]: Idle position of accelerator pedal
[B]: APP sensor (sub) voltage [E]: Full depressed position of
accelerator pedal
[C]: Voltage
[C]
[B]
[D] [E] [A]
4.65 V
3.85 V
1.55 - 1.65 V
0.75 - 0.85 V
I4RS0B130010-02
1, (a)
2, (a)
I4RS0B130011-01

Downloaded from www.Manualslib.com manuals search engine 1C-6 Engine Electrical Devices:
APP Sensor Assembly InspectionS7RS0B1306007
Check APP sensor (main and sub) output voltage as
following steps.
1) For APP sensor (main) , arrange 3 new 1.5 V
batteries (1) in series (check that total voltage is 4.5 -
5.0 V) and connect its positive terminal to “Vin 1”
terminal (2) and negative terminal to “Ground 1”
terminal (3) of sensor. Then using voltmeter, connect
positive terminal to “Vout 1” terminal (4) of sensor
and negative terminal to battery.
2) For APP sensor (s ub), arrange 3 new 1.5 V batteries
(1) in series (check that total voltage is 4.5 - 5.0 V)
and connect its positive terminal to “Vin 2” terminal
(2) and negative terminal to “Ground 2” terminal (3)
of sensor. Then using volt meter, connect positive
terminal to “Vout 2” terminal (4) of sensor and
negative termin al to battery.
3) Measure output voltage variation while accelerator pedal is no depressed and fully depressed as
following specification.
If sensor voltage is out of specified value or does not
vary linearly as the followin g graph, replace APP sensor
assembly.
APP sensor output voltage
APP sensor (main) output voltage [A]: 0.75 – 3.85 V,
varying according to depressed extent of
accelerator pedal
APP sensor (sub) output voltage [B]: 1.55 – 4.65 V,
varying according to depressed extent of
accelerator pedal.
ECT Sensor Removal and InstallationS7RS0B1306008
Removal
1) Disconnect negative (–) cable at battery.
2) Drain coolant referring to “Cooling System Draining in Section 1F”.
WARNING!
To 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.

3) Remove air intake pipe.
4) Disconnect connector from ECT sensor (1).
5) Remove ECT sensor from thermostat case.
1
234I4RS0B130012-01
1
234I4RS0B130013-01
[C]: Voltage
[D]: Idle position of accelerator pedal
[E]: Fully depressed position of accelerator pedal
[C]
[B]
[D] [E] [A]
4.65 V
3.85 V
1.55 - 1.65 V
0.75 - 0.85 V
I4RS0B130010-02
1
I2RH0B130008-01

Downloaded from www.Manualslib.com manuals search engine Engine Electrical Devices: 1C-7
Installation
Reverse removal procedure noting the following.
• Clean mating surfaces of ECT sensor and thermostat case.
• Check O-ring for damage and replace, if necessary.
• Tighten ECT sensor (1) to specified torque.
Tightening torque
ECT sensor (a): 15 N·m (1.5 kgf-m, 11.0 lb-ft)
• Connect connector to ECT sensor securely.
• Refill coolant referring to “Cooling System Flush and
Refill in Section 1F”.
ECT Sensor InspectionS7RS0B1306009
Immerse temperature sensing part of ECT sensor (1) in
water (or ice) and measure resistance between sensor
terminals while heating water gradually.
If measured resistance doesn’t show such characteristic
as shown, replace ECT sensor.
HO2S-1 and HO2S-2 Heater On-Vehicle
Inspection
S7RS0B1306010
1) Disconnect sensor connector.
2) Using ohmmeter, measure resistance between terminals “V
B” and “GND” of sensor connector.
If found faulty, replace oxygen sensor.
NOTE
Temperature of sensor affects resistance
value largely. Make sure that sensor heater is
at correct temperature.

Resistance of oxygen sensor heater
HO2S-1: 5.0 – 6.4 Ω at 20 °C (68 °F)
HO2S-2: 11.7 – 14.5 Ω at 20 °C (68 °F)
Viewed from terminal side
3) Connect sensor co nnector securely.
HO2S-1 and HO2S-2 Removal and InstallationS7RS0B1306011
Removal
WARNING!
To avoid danger of being burned, do not
touch exhaust system when system is hot.
Oxygen sensor removal should be performed
when system is cool.

1) Disconnect negative (–) cable at battery.
2) Disconnect connector of heated oxygen sensor and
release its wire harness from clamps.
3) Perform following items before removing heated oxygen sensor.
a) For HO2S-1, remove exhaust manifold referring to “Exhaust Manifold Remo val and Installation in
Section 1K”, if necessary.
b) For HO2S-2, hoist vehicle.
4) Remove heated oxygen sensor from exhaust pipe or exhaust manifold.
[A]: Lower limit [D]: Resistance
[B]: Normal [E]: Temperature
[C]: Upper limit
1,(a)
I2RH0B130009-01
20
0
68
32 104 140 176 40 60 80
[E]
2.29 - 2.62
0.309 - 0.331
[A]
[B]
[C][D]
I5JB0A130037-01
[A]: HO2S-1 [B]: HO2S-2
I4RS0A130006-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-8
For example of intake side:
When thickness of removed shim is 2.40 mm (0.094
in.), and measured valve clearance is 0.45 mm
(0.018 in.).
A = 2.40 mm (0.094 in.) + 0.45 mm (0.018 in.) – 0.20
mm (0.008 in.) = 2.65 mm (0.104 in.)
Calculated thickness of new shim = 2.65 mm (0.104
in.)
6) Select new shim No. (1) with a thickness as close as possible to calculated value.
Available new shims No.
7) Install new shim facing shim No. side with tappet. 8) Lift valve by turning crankshaft counterclockwise (in
opposite direction against above Step 4)) and
remove special tool.
Special tool
(A): 09916–67020
(A): 09916–67021
9) Install camshaft housing (1) and tighten bolts to specified torque.
Tightening torque
Camshaft housing bolt (a ): 11 N·m (1.1 kgf-m,
8.0 lb-ft)
10) Check valve clearance again after adjusting it. 11) After checking and adjusting all valves.
12) Install cylinder head cover referring to “Cylinder Head Cover Removal and Installation”.
Thickness
mm (in.) Shim No.Thickness
mm (in.) Shim No.
2.175 (0.0856) 218 2.600 (0.1024) 260
2.200 (0.0866) 220 2.625 (0.1033) 263
2.225 (0.0876) 223 2.650 (0.1043) 265
2.250 (0.0886) 225 2.675 (0.1053) 268
2.275 (0.0896) 228 2.700 (0.1063) 270
2.300 (0.0906) 230 2.725 (0.1073) 273
2.325 (0.0915) 233 2.750 (0.1083) 275
2.350 (0.0925) 235 2.775 (0.1093) 278
2.375 (0.0935) 238 2.800 (0.1102) 280
2.400 (0.0945) 240 2.825 (0.1112) 283
2.425 (0.0955) 243 2.850 (0.1122) 285
2.450 (0.0965) 245 2.875 (0.1132) 288
2.475 (0.0974) 248 2.900 (0.1142) 290
2.500 (0.0984) 250 2.925 (0.1152) 293
2.525 (0.0994) 253 2.950 (0.1161) 295
2.550 (0.1004) 255 2.975 (0.1171) 298
2.575 (0.1014) 258 3.000 (0.1181) 300
I2RH0B140015-01
1. Tappet
2. Camshaft
(A)2
1
I3RM0A140006-01
I2RH0B140149-01

Downloaded from www.Manualslib.com manuals search engine 1D-9 Engine Mechanical:
Repair Instructions
Air Cleaner ComponentsS7RS0B1406001
Air Cleaner Element Removal and InstallationS7RS0B1406002
Removal1) Remove engine cover.
2) Open air cleaner case (1) by unhooking its clamps (2).
3) Remove air cleaner element from case.
Installation
Reverse removal procedure for installation.
(c)
1
2
3
4
5
6
7
8
11
910
8
(a)(a)
(b)
(c)
(e)
(d)
(b)
(b)
I7RS0B140001-01
1. Engine Cover 7. Air cleaner outlet hose : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
2. Cylinder head upper cover 8. Hose clamp : 3 N⋅m (0.3 kgf-m, 2.5 lb-ft)
3. Air cleaner assembly 9. MAF sensor : 1.5 N⋅m (0.15 kgf-m, 1.0 lb-ft)
4. Air intake pipe 10. EVAP canister purge valve : 5 N⋅m (0.5 kgf-m, 4.0 lb-ft)
5. Air suction hose 11. To throttle body
6. Air cleaner suction pipe : 8 N⋅m (0.8 kgf-m, 6.0 lb-ft)
1
2
I3RM0A140007-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-10
Air Cleaner Element Inspection and CleaningS7RS0B1406003
Inspection
Check air cleaner element for dirt. Replace excessive
dirty element.
Cleaning
Blow off dust by compressed air from air outlet side of
element.
Cylinder Head Cover Removal and InstallationS7RS0B1406004
Removal1) Disconnect negative cable at battery.
2) Remove air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
3) Remove cylinder head upper cover.
4) Disconnect ignition coil couplers (1).
5) Remove ignition coil assemblies (2) with high- tension cord (3).
6) Remove wire harness clamp from cylinder head cover.
7) Remove oil level gauge (1).
8) Disconnect PCV hose (2) from PCV valve (3) and disconnect breather hose (4) from cylinder head
cover.
9) Remove cylinder head cove r mounting bolts in such
order as indicated in the figure. 10) Remove cylinder head cover (1) with cylinder head
cover gasket (2).
Installation 1) Install new cylinder head cover gasket (2) to cylinder
head cover (1) as shown in figure.
I2RH0B140150-01
I2RH0B140032-01
I2RH0B140033-01
I6RS0B141004-01
I6RS0B141005-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-12
Throttle Body and Intake Manifold ComponentsS7RS0B1406005
45
2
15
12 11
13
14 8 10
15
6
3 9
1
(c)
(b)
(a)
(c)
(c)(d)
7
I7RS0B140002-02
1. Intake manifold 6. Breather hose11. PCV valve : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
2. Intake manifold gasket 7. EGR pipe 12. PCV valve seal : 8 N⋅m (0.8 kgf-m, 6.0 lb-ft)
3. EVAP canister purge valve hose 8. Gasket 13. PCV hose: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Throttle body 9. EVAP canister purge valve 14. To EGR valve : 5 N⋅m (0.5 kgf-m, 4.0 lb-ft)
5. Throttle body gasket 10. MAP sensor15. To cylinder head cover : Do not reuse.

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.
2
4
3
1I4RS0B140004-02
1
I6RS0C140013-02
4
2
1
3I4RS0B140006-01