2008 SUZUKI SWIFT precaution

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 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 Engine Electrical Devices: 1C-11
MAF and IAT Sensor On-Vehicle InspectionS7RS0B1306018
NOTE
Before performed this inspection, be sure to
read the “Precautions of ECM Circuit
Inspection in Section 1A”.

1) Disconnect negative (–) cable at battery.
2) Disconnect MAF and IAT sensor connector.
3) Connect voltmeter to “BLK/RED” wire terminal (2) of
MAF and IAT sensor connector (1) disconnected and
ground.
4) Turn ON ignition switch position and check that voltage is battery voltage.
If not, check if wire harness is open or connection is
poor.
5) Turn OFF ignition switch position and connect connector to MAF and IAT sensor.
6) Remove ECM from its bracket referring to “ECM Removal and Installation”.
7) Connect special tool between ECM and ECM connector referring to “Inspection of ECM and Its
Circuits in Section 1A”.
8) Turn ON ignition switch position and check MAF signal voltage between “C37-26” terminal circuit and
“C37-27” terminal circuit of special tool.
MAF signal voltage between “C37-26” terminal
circuit and “C37-27” termi nal circuit of special
tool
MAF signal voltage of MAF and IAT sensor with
ignition switch turned ON: 0.5 – 1.0 V
9) Start engine and check that voltage is lower than 5 V and it rises as engine speed increases.
MAF signal voltage between “C37-26” terminal
circuit and “C37-27” termi nal circuit of special
tool
MAF signal reference voltage of MAF and IAT
sensor at specified Idle speed: 1.3 – 1.8 V 10) If check result is not as
specified above, cause may
lie in wire harness, connec tor connection, MAF and
IAT sensor or ECM.
MAF and IAT Sensor Removal and InstallationS7RS0B1306019
CAUTION!
• Do not disassemble MAF and IAT sensor.
• Do not expose MAF and IAT sensor to any shock.
• Do not clean MAF and IAT sensor.
• If MAF and IAT sensor has been dropped, it should be replaced.
• Do not blow compressed air by using air gun or the like.
• Do not put finger or any other object into MAF and IAT sensor. Malfunction may
occur.

Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect MAF and IAT sensor connector.
3) Remove air cleaner case (1).
4) Remove MAF and IAT sensor (2) from air cleaner case.
Installation
Reverse removal procedure noting the followings.
• Tighten MAF and IAT sensor screws to specified torque.
Tightening torque
MAF and IAT sensor screw (a): 1.5 N·m (0.15 kgf-
m, 1.1 lb-ft)
• Connect MAF and IAT sensor connector securely.
1. ECM
I3RB0A130009-01
“C37-27” “C37-26” 1
I4RS0A130009-01
1
2
I4RS0A130010-01
(a)
I4RS0A130011-01

Downloaded from www.Manualslib.com manuals search engine 1G-1 Fuel System:
Engine
Fuel System
Precautions
Precautions on Fuel System ServiceS7RS0B1700001
WARNING!
Before attempting service of any type on fuel system, the following should be always observed in
order to reduce the risk of fire and personal injury.
• Disconnect negative cable at battery.
• Do not smoke, and place no smoking signs near work area.
• Be sure to have CO
2 fire extinguisher handy.
• Be sure to perform work in a well-ventilated area and away from any open flames (such as gas hot heater).
• Wear safety glasses.
• To relieve fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then
reinstall it.
• As fuel feed line is still under high fuel pr essure even after stopping engine, loosening or
disconnecting fuel feed line directly may cause dangerous spout of fuel. Before loosening or
disconnecting fuel feed line, make sure to relieve fuel pressure referring to “Fuel Pressure Relief
Procedure”.
• A small amount of fuel may be released when the fuel line is disconnected. In order to reduce the risk of personal injury, cover a shop cloth to the fitting to be disconnected. Be sure to put that cloth
in an approved container after disconnecting.
• Never run engine with fuel pump relay disconnected when engine and exhaust system are hot.
• Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each hose correctly referring to “Fuel Hose Disconnecting and Reconnecting”.
After connecting, make sure that it has no twist or kink.
• When installing inje ctor or fuel feed pipe, lubr icate its O-ring with gasoline.

General Description
Fuel System DescriptionS7RS0B1701001
CAUTION!
This engine requires the unleaded fuel only.
The leaded and/or low lead fuel can result in
engine damage and reduce the effectiveness
of the emission control system.

The main components of the fuel system are fuel tank,
fuel pump assembly (with fuel filter, fuel level gauge, fuel
pressure regulator, fuel feed line and fuel vapor line.
For the details of fuel flow, refer to “Fuel Delivery System
Diagram”.
Fuel Delivery System DescriptionS7RS0B1701002
The fuel delivery system consists of the fuel tank, fuel
pump assembly (with built-in f uel filter and fuel pressure
regulator), delivery pipe, injectors and fuel feed line.
The fuel in the fuel tank is pumped up by the fuel pump,
sent into delivery pipe and injected by the injectors.
As the fuel pump assembly is equipped with built-in fuel
filter and fuel pressure regulator, the fuel is filtered and
its pressure is regulated before being sent to the feed
pipe.
The excess fuel at fuel pressure regulation process is
returned back into the fuel tank.
Also, fuel vapor generated in fuel tank is led through the
fuel vapor line into the EVAP canister.
For system diagram, refer to “Fuel Delivery System
Diagram”.

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-2
Fuel Pump DescriptionS7RS0B1701003
The fuel pump (1) is an in-tank type electric pump.
Incorporated in the pump assembly are;
a fuel filter (2) and a fuel pressure regulator (3) are
included and a fuel level gauge (4) is attached.
Addition of the fuel pressure regulator to the fuel pump
makes it possible to mainta in the fuel pressure at
constant level and ECM controls compensation for
variation in the intake manifold pressure.
Schematic and Routing Diagram
Fuel Delivery System DiagramS7RS0B1702001
Diagnostic Information and Procedures
Fuel Pressure InspectionS7RS0B1704001
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

1) Relieve fuel pressure in fuel feed line referring to
“Fuel Pressure Relief Procedure”.
2) Disconnect fuel feed hose from fuel delivery pipe.
3) Connect special tools and hose between fuel feed hose (1) and fuel delivery pipe as shown in figure,
and clamp hoses securely in order to ensure that no
leaks occur during checking.
Special tool
(A): 09912–58442
(B): 09912–58432
(C): 09912–58490
1
3
2
4
I6RS0C170001-01
4
6 7
8
12
2 3
11
10
5
1
9
I6RS0C170002-01
1. Fuel tank
5. Fuel injector9. EVAP canister
2. Fuel pump 6. Fuel feed line10. Fuel filter
3. Fuel pressure regulator 7. Fuel vapor line 11. Main fuel level sensor
4. Delivery pipe 8. Intake manifold12. EVAP canister purge valve
1
(C) (B)
(A)
I3RM0A170004-01

Downloaded from www.Manualslib.com manuals search engine 1G-5 Fuel System:
Fuel Hose Disconnecting and ReconnectingS7RS0B1706002
WARNING!
Before starting the following procedure, be sure to observe “Precautions on Fuel System Service” in
order to reduce the risk or fire and personal injury.

Be sure to connect and clamp each hose correctly as shown in figure.
For Connection Other Than Quick Joint
Clamp around fuel tank
NOTE
Be sure to install hose to spool of pipe surely.

I6RS0C170004-01
1. Pipe “a” 3 – 7 mm (0.12 – 0.28 in.)“e” 38 mm (1.50 in.)
2. Hose “b” 5 – 12 mm (0.20 – 0.48 in.): 2 N⋅m (0.2 kgf-m, 1.5 lb-ft)
3. Clamp “c” 33 mm (1.30 in.)
4. Fuel filler hose clamp screw “d” 30 mm (1.18 in.)

Downloaded from www.Manualslib.com manuals search engine 1G-7 Fuel System:
Fuel Pressure Relief ProcedureS7RS0B1706003
CAUTION!
This work must not be done when engine is
hot. If done so, it may cause adverse effect to
catalyst.

NOTE
If ECM detects DTC(s) after servicing, clear
DTC(s) referring to “DTC Clearance in
Section 1A”.

1) Make sure that engine is cold.
2) Shift transaxle gear shift lever in “Neutral” (shift select lever in “P” range for A/T model), set parking
brake and block drive wheels.
3) Remove relay / fuse box cover.
4) Disconnect fuel pump relay (1) from relay / fuse box (2).
5) Remove fuel filter cap in order to release fuel vapor pressure in fuel tank, and then reinstall it.
6) Start engine and run it until engine stops for lack of fuel. Repeat cranking engine 2 – 3 times for about 3
seconds each time in order to dissipate fuel pressure
in lines. Fuel connections are now safe for servicing.
7) After servicing, connect fuel pump relay (1) to relay / fuse box and install re lay / fuse box cover.
Fuel Leakage Check ProcedureS7RS0B1706004
After performing any service on fuel system, check to
make sure that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump) and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply
fuel pressure to fuel line until fuel pressure is felt by
hand placed on fuel feed hose.
2) In this state, check to see that there are no fuel leakages from any part of fuel system.
Fuel Lines On-Vehicle InspectionS7RS0B1706005
CAUTION!
Due to the fact that fuel feed line (1) is under
high pressure, use special care when
servicing it.

Visually inspect fuel lines for evidence of fuel leakage,
hose crack and deterioration or damage.
Make sure all cl amps are secure.
Replace parts as needed.
Fuel Pipe Removal and InstallationS7RS0B1706006
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal
1) Relieve fuel pressure in fuel feed line according to “Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Disconnect fuel pipe joint and fuel hose (3) from fuel pipe (2) at the front and rear of each fuel pipe
referring to “Fuel Hose Disconnecting and
Reconnecting”.
4) Mark the location of clamps (1) on fuel pipes (2), so that the clamps can be reinstalled to where they
were.
5) Remove pipes (2) with clamp (1) from vehicle.
6) Remove clamp (1) from pipes (2).
1
I4RS0A170004-01
1
I4RS0A170005-01
2
13
I4RS0A170020-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-8
Installation1) Install clamps to marked location on pipes. If clamp is deformed, its claw is bent or broken, replace it with
new one.
2) Install pipes with pipe clamps to vehicle.
3) Connect fuel hoses and pipes to each pipe referring to “Fuel Hose Disconnecting and Reconnecting”.
4) Connect negative cable at battery.
5) With engine OFF, turn igniti on switch to ON position
and check for fuel leaks.
Fuel Injector On-Vehicle InspectionS7RS0B1706007
1) Using sound scope (1) or such, check operating sound of injector (2) when engine is running or
cranking.
Cycle of operating sound should vary according to
engine speed.
If no sound or an unusual sound is heard, check
injector circuit (wire or coupler) or injector.
2) Disconnect connector (1) from injector, connect ohmmeter between terminals of injector and check
resistance.
If resistance is out of specification, replace.
Resistance of fuel injector
11.3 – 13.8 Ω at 20 °C, 68 °F
3) Connect connector to injector securely.
Fuel Injector Removal and InstallationS7RS0B1706008
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal 1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Disconnect MAF sensor connector, and detach EVAP canister purge valve.
4) Remove air cleaner assembly with air intake pipe.
5) Disconnect fuel injector couplers.
6) Disconnect fuel feed hose from fuel delivery pipe (1).
7) Remove fuel delivery pipe bolts (2).
8) Remove fuel injector(s) (3).
I2RH0B170007-01
I2RH0B170008-01
2
1
3
3
I3RM0A170010-01