2008 SUZUKI SWIFT 100

Downloaded from www.Manualslib.com manuals search engine 1B-1 Aux. Emission Control Devices:
Engine
Aux. Emission Control Devices
Diagnostic Information and Procedures
EGR System InspectionS7RS0B1204001
1) Connect SUZUKI scan tool to data link connector (DLC) with ignition switch turned OFF.
2) Turn ON ignition switch and erase DTC using “CLEAR DTC” in “TROUBLE CODES” menu.
3) Start engine and warm it up to normal operating temperature, then select “DATA LIST” mode on scan
tool.
4) Make sure that vehicle condition is as follows.
• Vehicle speed = 0 km/h (0 KPH)
• Engine speed ≤ 900 rpm
• Engine coolant temp. ≥ 90 °C, 164 °F
5) With engine idling (without depressing accelerator pedal), open EGR valve by using “STEP EGR” mode
in “MISC TEST” menu. In this state, as EGR valve
opening increases engine idle speed drops. If not,
possible cause is clogged EGR gas passage, stuck
or faulty EGR valve.
Repair Instructions
EVAP Canister Purge InspectionS7RS0B1206001
NOTE
Before inspection, check to make sure that gear shift lever is in neutral position (with A/T model,
selector lever in “P” range) and that parking brake lever is pulled all the way up.

1) Disconnect purge hose (1) from EVAP canister (2).
2) Place finger against the end of disconne cted hose and check that vacuum is not felt there when engine is cool and
running at idle speed. If check result is not satisfacto ry, check EVAP canister purge valve, wire harness and ECM.
1. SUZUKI scan tool display
2. EGR valve opening (0: Close, 100: Full open)
Step EGR
Step EGR Flow Duty 21 %
Step EGR (con) 23%
Engine Speed 771 RPM
Desired Idle 698 RPM
IAC Flow Duty 20.0 %
Ignition Advance 11.5 BTDC
Closed Throttle Pos ON
1 2
I4RS0B120001-01
1
2
I6RS0C120001-01

Downloaded from www.Manualslib.com manuals search engine 1C-2 Engine Electrical Devices:
MAP Sensor InspectionS7RS0B1306002
1) Remove air cleaner assembly.
2) Disconnect connector from MAP sensor.
3) Remove MAP sensor.
4) Arrange 3 new 1.5 V batteries (2) in series (check that total voltage is 4.5 – 5.0 V) and connect its
positive terminal to “Vin ” terminal of sensor and
negative terminal to “Ground” terminal. Then check
voltage between “Vout” and “Ground”. Also, check if
voltage reduces when vacuum is applied up to 400
mmHg by using vacuum pump (3).
If check result is not satisfactory, replace MAP
sensor (1).
Output voltage (When input voltage is 4.5 – 5.5 V,
ambient temp. 20 – 30 °C, 68 – 86 °F)
5) Install MAP sensor securely.
6) Connect MAP sensor connector securely.
7) Install air cleaner assembly.
Electric Throttle Body Assembly On-Vehicle
Inspection
S7RS0B1306003
WARNING!
Never touch throttle valve with finger while
ignition switch is turned ON and accelerator
pedal is depressed. Otherwise, injury may
result by pinching the finger between throttle
valve and throttle body housing.

CAUTION!
• Do not disassemble electric throttle body assembly.
• Do not expose electric throttle body assembly to excessive shock like a
dropping it. If electric throttle body
assembly has been exposed to excessive
shock, it should be replaced.
• Be careful not to accurate a foreign material (like dust and/ or metallic particle)
to the throttle body housing and/or throttle
valve.
Otherwise, the throttle body assembly is
breaking down by throttle valve accretion.
• Do not apply excessive moving force to throttle valve for thro ttle valve operation
check and/or TP sensor performance
check.
Otherwise, the throttle body assembly is
breaking down by damaging the internal
resinous gear of throttle valve actuator.

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

Throttle Valve Visual Check
1) Remove air cleaner outlet hose.
2) Check that there isn’t any foreign matter caught between throttle valve and throttle body housing. If
there is, take it out after removing throttle body
referring to “Electric Th rottle Body Assembly
Removal and Installation in Section 1D” and clean
inside of throttle body thoroughly.
Altitude (Reference) Barometric pressure
Output
voltage
(ft) (m) (mmHg) (kPa) (V)
0 – 2000 0 – 610 760 – 707 100 – 94 3.3 – 4.3 2001 – 5000 611 –
1524 Under 707
over 634 94 – 85 3.0 – 4.1
5001 – 8000 1525 –
2438 Under 634
over 567 85 – 76 2.7 – 3.7
8001 – 10000 2439 –
3048 Under 567
over 526 76 – 70 2.5 – 3.3
I3RM0A130005-01

Downloaded from www.Manualslib.com manuals search engine Engine Electrical Devices: 1C-3
Throttle Valve Operation Check1) Remove air cleaner outlet hose.
2) Turn OFF ignition switch.
3) Move throttle valve with finger to its full open position and check that it moves smoothly.
4) Move throttle valve with fi nger to its completely
closed position and check that it moves smoothly.
5) Take off finger from throttle valve (1) which is at full open position and check that it moves smoothly by
its return spring and open spring force back to
default position (2) (positio n where throttle valve is
open by 6 ° from completely closed position).
6) Take off finger from throttle valve (1) which is at completely closed position and check that it moves
smoothly by its return spring and open spring force
back to default position.
If check result is not satisfactory, replace electric
throttle body assembly. Electric Throttle Body
Assembly Operation Check
1) Remove air cleaner outlet hose.
2) Turn ON ignition switch.
3) Depress accelerator pedal gradually and check that throttle valve moves smoo thly until it opens fully.
4) Release accelerator pedal depressed in Step 3) and check that throttle valve (1) moves back to default
position (2) (position where throttle valve is open by
6° from its completely closed position).
If check result is satisfactory, electric throttle body
system is in good condition. If check result is not
satisfactory, proceed to next step.
5) Perform “Accelerator Pe dal Position (APP) Sensor
Assembly On-Vehicle Inspection (Electric throttle
body model)”, “Throttle Actuator (Motor) Check” and
if check results are not satisfactory, replace electric
throttle body assembly.
If check results are satisfactory, wire circuit and/or
ECM are faulty.
Throttle Actuator (Motor) Check 1) Turn OFF ignition switch.
2) Disconnect connector from electric throttle body assembly.
3) Measure resistance between “M1” terminal (1) and “M2” terminal (2) of electric throttle body assembly.
If measured resistance is out of specified value,
replace electric throttle body assembly.
Throttle actuator (motor) resistance
0.3 – 100 Ω at 20 °C, 68 °F
I4RS0B130004-01
1
2
I4RS0B130005-01
1
2
I4RS0B130005-01
2 1
I4RS0B130023-01

Downloaded from www.Manualslib.com manuals search engine 1C-12 Engine Electrical Devices:
MAF and IAT Sensor InspectionS7RS0B1306020
CAUTION!
Do not heat up MAF and IAT sensor more
than 100 °C (212 °F). Otherwise, MAF and IAT
sensor will be damaged.

• Check sensor O-ring (1) for damage and deterioration. Replace as necessary.
• Blow hot air to temperature sensing part (2) of MAF and IAT sensor (3) using hot air drier (4) and measure
resistance between sensor terminals while heating air
gradually.
If measured resistance does not show such
characteristic as shown, replace MAF and IAT sensor.
IAT sensor resistance
–20 °C (–4 °F): 13.6 – 18.4 k Ω
20 °C (68 °F): 2.21 – 2.69 k Ω
60 °C (140 °F): 0.493 – 0.667 k Ω
Electric Load Current Sensor On-Vehicle
Inspection
S7RS0B1306021
Using SUZUKI Scan Tool
1) Connect scan tool to DLC with ignition switch turned OFF.
2) Check “Battery Current” displayed on scan tool at following condition.
Battery current
Ignition switch ON: 6.5 – 7.5 A
Ignition switch ON, headlight ON: 18.6 – 19.1 A
Ignition switch ON, headlight ON and blower
motor switch is HI position: 27.1 – 27.6 A
Engine running at idle speed, headlight ON,
blower motor switch is HI position and rear
defogger switch ON: 38.1 – 41.7 A
If check result is satisfactory, electric load current sensor
is in good condition.
If check result is not satisf actory, 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 ci rcuit (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.
[A]: Lower limit [D]: Resistance
[B]: Nominal [E]: Temperature
[C]: Upper limit 5. Temperature gauge
200
6832104 140 17640 60 80
(2.45)
(0.58)
1
2
3
4 5
[A] [B]
[E]
[C]
[D]
I4RS0A130012-01
2. Main fuse box
2
1
I5RS0C130001-01

Downloaded from www.Manualslib.com manuals search engine 1D-1 Engine Mechanical:
Engine
Engine Mechanical
General Description
Engine Construction DescriptionS7RS0B1401001
The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft)
valve mechanism arranged for “V” type valve configurat ion and 16 valves (4 valves/one cylinder). The double
overhead camshaft is mounted over the cy linder head; it is driven from crankshaft through timing chain, and no push
rods are provided in the valve train system.
I6RS0C140001-02

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-2
Camshaft Position Control (VVT Variable Valve Timing) System DescriptionS7RS0B1401002
System Description
The VVT system is an electronic control system which continuously vary and optimize the intake valve timing in
response to the engine operating condition.
The optimized intake valve timing produce such an air intake with high efficiency that both the higher power generation
and lower fuel consumption can be attained in the whole engine speed range from low to high. In the area of the
average engine load, low emission of nitrogen oxides (NOx) and high fuel efficiency can also be attained by making
the valve opening overlap between the intake and exhaust valves longer.
For the brief of the system operation, the intake valve timing is varied by the cam timing sprocket (1) which varies the
rotational phase between the intake camshaft (3) and sprocket . The rotor (2) in the cam timing sprocket is actuated by
switching or adjusting the hydraulic pressure applied to the chambers for the timing advancing (7) and/or retarding (6).
To switch or adjust the hydraulic pressure appropriately, ECM operates the oil control valve (12) with detecting the
engine speed, intake air value, throttle opening, engine coolant temperature and camshaft position (angle).
1
4
5
13
10
89
2
7
6
12
11
3
14
60 (variable angle)
Most retarded timing
Most advanced timing
Exhaust valve Intake valve
Crank angle
Overlap of valves
Valve lift
I3RH0B140002-01
4. Oil passage to chamber for timing retarding 8. Oil filter10. Oil pan 13. Oil return
5. Oil passage to chamber for timing advancing 9. Oil pump11. Control signal from ECM 14. Oil flow

Downloaded from www.Manualslib.com manuals search engine 1D-5 Engine Mechanical:
11) Connect negative cable at battery.
12) Install special tools (Compression gauge) into spark plug hole.
Special tool
(A): 09915–64512
(B): 09915–64530
(C): 09915–67010
13) Disengage clutch (1) (to lighten starting load on engine) for M/T vehicle, and depress accelerator
pedal (2) all the way to make throttle fully open.
14) Crank engine with fully charged battery, and read the highest pressure on compression gauge.
NOTE
• For measuring compression pressure, crank engine at least 250 r/min. by using
fully charged battery.
• If measured compression pressure is lower than limit value, check installation
condition of special tool. If it is properly
installed, possibility is compression
pressure leakage from where piston ring
and valve contact.

Compression pressure
Standard: 1400 kPa (14.0 kg/cm2, 199.0 psi)
Limit: 1100 kPa (11.0 kg/cm2, 156.0 psi)
Max. difference between any two cylinders: 100
kPa (1.0 kg/cm
2, 14.2 psi) 15) Carry out Steps 12) through 14) on each cylinder to
obtain 4 readings.
16) Disconnect negative cable at battery.
17) After checking, install spark plugs and ignition coil assemblies (2) with high-tension cord (3).
18) Connect ignition coil couplers (1).
19) Connect fuel injector wires (4) at the coupler.
20) Install cylinder head upper cover.
21) Install air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
22) Install engine cover.
23) Connect negative cable at battery.
Engine Vacuum CheckS7RS0B1404002
The engine vacuum that develops in the intake line is a
good indicator of the condition of the engine. The
vacuum checking procedure is as follows:
1) Warm up engine to normal operating temperature.
NOTE
After warming up engine, be sure to place
transaxle gear shift lever in “Neutral”, and set
parking brake and block drive wheels.

2) Stop engine and turn off the all electric switches.
3) Remove engine cover.
4) Remove air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
5) Remove PCV hose (1) from PCV valve (2).
(A)
(C)
(B)
I3RH0B140009-01
I2RH0B140005-01
I2RH0B140003-01
2
1
I6RS0B141001-01

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