2008 SUZUKI SWIFT Brake system

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-95
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

NOTE
Check to make sure that following conditions ar e satisfied when using this “DTC Confirmation
Procedure”.
• Intake air temperature at engine start: –10 °C (14 ° F) to 80 °C (176 °F)
• Intake air temperature: –10 °C (14 °F) to 70 °C (158 °F)
• Engine Coolant temperature: 70 °C (158 °F) to 150 °C (302 °F)
• Altitude (barometric pressure): 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)

1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and warm up to normal operating temperature.
4) Increase vehicle speed to 70 – 80 km/h (43 – 50 mile/h) at 5th gear or D range.
5) Release accelerator pedal and with engine brake applied, ke ep vehicle coasting (with fuel cut for 4 sec. or more),
then stop vehicle and run engine at idle speed for 60 sec. or more.
6) Repeat Step 4).
7) Keep above vehicle speed for 8 min. or more. (Throt tle valve opening is kept constant in this step.)
8) Repeat Step 5).
9) Check DTC and pending DTC.
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/ or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 Is there DTC(s) other than fuel system (DTC P0171 / P0172)
and HO2S-2 (DTC P0140)? Go to applicable DTC
diag. flow.Go to Step 3.
3 HO2S-2 and its circuit check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Warm up engine to normal operating temperature and keep it at 2000 r/min. for 60 sec.
3) Repeat racing engine (Repeat depressing accelerator pedal 5 to 6 times continuous ly to enrich A/F mixture and
take foot off from pedal to enlean it).
Does HO2S-2 output voltage indicate deflection between
over 0.35 V and below 0.25 V? Go to “DTC P0171 /
P0172: Fuel System
Too Lean / Rich”.
Go to Step 4.

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DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2)S7RS0B1104035
Wiring Diagram
Refer to “DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)”
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and warm up to normal operating temperature.
4) Increase vehicle speed to 60 – 80 km/h (37 – 50 mile/h) at 5th gear or D range.
5) Release accelerator pedal and with engine brake applied, ke ep vehicle coasting (with fuel cut for 4 sec. or more),
then stop vehicle and run engine at idle speed for 60 sec. or more.
6) Check DTC and pending DTC.
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/ or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

DTC detecting condition Trouble area
HO2S-2 voltage is higher than specified value after warming up engine
(circuit open).
(2 driving cycle detection logic) •HO2S-2
• HO2S-2 circuit
•ECM
• Exhaust gas leakage
• Air intake system
Step
Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 HO2S-2 ground check
1) Disconnect connector from HO 2S-2 with ignition switch
turned OFF.
2) Check for proper connection to HO2S-2 connector at “RED/BLU”, “BRN”, “YEL” and “BLK/WHT” wire
terminals.
3) If connections are OK, m easure resistance between
“YEL” wire terminal of HO2S-2 connector and engine
ground.
Is resistance less than 5
Ω? Go to Step 3. “YEL” wire is open or
high resistance circuit.
Poor “C37-57” terminal
connection. Faulty ECM
ground.
If they are OK,
substitute a known-
good ECM and recheck.

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-117
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

NOTE
Check to make sure that following conditions ar e satisfied when using this “DTC confirmation
procedure”.
• Intake air temperature at engine start: –10 °C (14 ° F) to 80 °C (176 °F)
• Intake air temperature: –10 °C (14 °F) to 70 °C (158 °F)
• Engine coolant temperature: 70 °C (158 °F) to 150 °C (302 °F)
• Altitude (barometric pressure): 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)

1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and warm up to normal operating temperature.
4) Run engine at idle for 10 min.
5) Drive vehicle and increase engine speed 3000 rpm in 3rd gear.
6) Release accelerator pedal and with engine brake applied, keep vehicle coasting for 5 sec. or more. (Keep fuel cut condition for 5 sec. or more) If fuel cut condition is not ke pt for 5 sec. or more, coast down a slope in engine speed
1000 – 3000 rpm for 5 sec. or more.
7) Stop vehicle and run engine at idle.
8) Check DTC and pending DTC by using scan tool.
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/ or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

DTC detecting condition Trouble area
DTC P0401:
Difference in intake manifold absolute pressure between opened EGR valve
and closed EGR valve is smaller than specified value.
(*2 driving cycle detection logic, monitoring once per driving cycle)
DTC P0402:
Difference in intake manifold absolute pressure between opened EGR valve
and closed EGR valve is la rger than specified value.
(*2 driving cycle detection logic, monitoring once per driving cycle) •EGR valve
• EGR passage
• MAP sensor
•ECM
Step
Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 Do you have SUZUKI scan tool? Go to Step 3.Go to Step 5.

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-129
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester.

1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Warm up engine to normal operating temperature.
4) M/T model
a) Drive vehicle at 4000 rpm (e ngine speed) with 3rd gear.
b) Release accelerator pedal and with engine brake applied, keep vehicle coasting for 6 sec. or more (fuel cut condition for 5 sec. or more) and stop vehicle.
A/T model
a) Drive vehicle at more than 3000 rpm for 10 sec.
5) Check pending DTC and DTC.
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/ or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

DTC detecting condition Trouble area
• Vehicle speed signal is not input while fuel is cut at deceleration for 4 seconds continuously at 3600 rpm or
less.
• Vehicle speed signal is not input even if engine is running with more than 3000 rpm at D-Range for 4 sec. (A/T model).
(2 driving cycle detection logic) • Wheel speed sensor and/or its circuit
• ABS/ESP®
control module
•ECM
Step Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 Vehicle speed signal check
Is vehicle speed displayed on scan tool in Step 4) and 5) of
“DTC Confirmation Procedure”? Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.Go to Step 3.
3 DTC check in ABS/ESP ® control module
1) Check ABS/ESP ® control module for DTC.
Is there any DTC of wheel speed sensor or CAN
communication system? Go to applicable DTC
diag. flow.
Substitute a know-good
ECM and recheck.

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)
1
I4RS0B110093-01

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 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.

1
I6RS0B141014-01

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-3
6) Start engine and warm engine up to normal operating temperature.
NOTE
Be sure to shift transaxle gear shift lever in
“Neutral” (shift select lever in “P” range for
A/T vehicle), set parking brake and block
drive wheels.

7) After warming up, raise engine speed to 4,000 r/min. and measure oil pressure.
Oil pressure specification
More than 270 kPa (2.7 kg/cm2, 39.8 psi) at 4,000
r/min. (rpm)
8) After checking oil pressure, stop engine and remove oil pressure gauge and attachment.
9) Before reinstalling oil pressure switch (2), be sure to
wrap its screw threads with sealing tape (1) and
tighten switch to specified torque.
NOTE
If sealing tape edge is bulged out from screw
threads of switch, cut it off.

Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft) 10) Start engine and check oil pressure switch for oil
leakage. If oil leakage is found, repair it.
11) Connect oil pressure switch coupler (1).
Repair Instructions
Heat Exchanger ComponentsS7RS0B1506001
I2RH0B150005-01
I2RH0B150006-01
3
4
5
7
6
(a)
2
1
I6RS0B151001-02
1. Heat exchanger inlet No. 1 hose 4. Gasket7. O-ring
: Apply engine oil.
2. Heat exchanger outlet No. 1 hose 5. Heat exchanger stand bolt : 22 N⋅m (2.2 kgf-m, 16.0 lb-ft)
3. Heat exchanger 6. Oil filter adapter case : Do not reuse.