2008 SUZUKI SWIFT Head lamp

Downloaded from www.Manualslib.com manuals search engine 0A-1 General Information:
General Information
General Information
General Description
AbbreviationsS7RS0B0101001
A:
ABDC: After Bottom Dead Center
ABS: Anti-lock Brake System
AC: Alternating Current
A/C: Air Conditioning
A-ELR: Automatic-Emergency Locking Retractor
A/F: Air Fuel Mixture Ratio
ALR: Automatic Locking Retractor
API: American Petroleum Institute
APP sensor: Accelerator Pedal Position Sensor
A/T: Automatic Transmission , Automatic Transaxle
AT D C : After Top Dead Center
ATF: Automatic Transmission Fluid, Automatic
Transaxle Fluid
B:
B+: Battery Positive Voltage
BBDC: Before Bottom Dead Center
BCM: Body Electrical Control Module
BDC: Bottom Dead Center
BTDC: Before Top Dead Center
C:
CAN: Controller Area Network
CKT: Circuit
CKP Sensor: Crankshaft Position Sensor
CMP Sensor: Camshaft Position Sensor
CO: Carbon Monoxide
CPP Switch: Clutch Pedal Position Switch (Clutch
Switch, Clutch Start Switch)
CPU: Central Processing Unit
CRS: Child Restraint System
D:
DC: Direct Current
DLC: Data Link Connector (Assembly Line Diag. Link,
ALDL, Serial Data Link, SDL)
DOHC: Double Over Head Camshaft
DOJ: Double Offset Joint
DRL: Daytime Running Light
DTC: Diagnostic Trouble Code (Diagnostic Code)
E:
EBCM: Electronic Brake Cont rol Module, ABS Control
Module
EBD: Electronic Brake Force Distribution
ECM: Engine Control Module
ECT Sensor: Engine Coolant Temperature Sensor (Water Temp. Sensor, WTS)
EFE Heater: Early Fuel Evaporation Heater (Positive
Temperature Coefficient, PTC Heater)
EGR: Exhaust Gas Recirculation
EGRT Sensor: EGR Temperature Sensor (Recirculated
Exhaust Gas Temp. Sensor, REGTS)
ELR: Emergency Locking Retractor
ESP ®: Electronic Stability Program
EPS: Electronic Power Steering
EVAP: Evaporative Emission EVAP Canister:
Evaporative Emission Canister
(Charcoal Canister)
F:
4WD: 4 Wheel
Drive
G:
GEN: Generator
GND: Ground
GPS: Global Positioning System
H:
HVAC: Heating, Ventilating and Air Conditioning
HC: Hydrocarbons
HO2S: Heated Oxygen Sensor
I:
IAC Valve: Idle Air Control Valve (Idle Speed Control
Solenoid Valve, ISC Solenoid Valve)
IAT Sensor: Intake Air Temperature Sensor (Air
temperature Sensor, ATS)
ICM: Immobilizer Control Module
IG: Ignition
ISC Actuator: Idle Speed Control Actuator
L:
LH: Left Hand
LHD: Left Hand Drive Vehicle
LSPV: Load Sensing Proportioning Valve
M:
MAF Sensor: Mass Air Flow Sensor (Air Flow Sensor, AFS, Air Flow Meter, AFM)
MAP Sensor: Manifold Absolute Pressure Sensor
(Pressure Sensor, PS)
Max: Maximum
MFI: Multiport Fuel Injection (Mu ltipoint Fuel Injection)
Min: Minimum
MIL: Malfunction Indicator Lamp (“SERVICE ENGINE
SOON” Light)
M/T: Manual Transmission, Manual Transaxle
N:
NOx: Nitrogen Oxides
O:
OBD: On-Board Diagnostic System (Self-Diagnosis
Function)
O/D: Overdrive
OHC: Over Head Camshaft
O2S: Oxygen Sensor
P:
PCM: Powertrain Control Module
PCV: Positive Crankcase Ventilation
PNP: Park / Neutral Position
P/S: Power Steering
PSP Switch: Power Steering Pressure Switch (P/S
Pressure Switch)
R:
RH: Right Hand
RHD: Right Hand Drive Vehicle
S:
SAE: Society of Automotive Engineers

Downloaded from www.Manualslib.com manuals search engine 1C-8 Engine Electrical Devices:
Installation
Reverse removal procedure noting the following.
• Tighten heated oxygen sensor to specified torque.Tightening torque
Heated oxygen sensor (a): 45 N·m (4.5 kgf-m,
32.5 lb-ft)
• Install exhaust manifold referring to “Exhaust Manifold Removal and Installation in Section 1K”, if removed.
• Connect connector of heated oxygen sensor and clamp wire harness securely.
• After installing heated oxygen sensor, start engine and check that no exhaust gas leakage exists.
CMP Sensor Removal and InstallationS7RS0B1306012
Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect connector from CMP sensor.
3) Remove CMP sensor from cylinder head.
Installation 1) Install CMP sensor to cylinder head.
Tightening torque
CMP sensor bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
2) Connect connector to CMP sensor securely.
3) Connect negative (–) cable to battery.
Camshaft Position (CMP) Sensor InspectionS7RS0B1306013
Visual check
• Check that O-ring is free from damage.
• Check that end face of sensor and signal rotor tooth are free from any metal particles and damage.
Performance check 1) Remove metal particles on end face of CMP sensor, if any.
2) Arrange 12 V battery (1) and connect its positive terminal to “Vin” terminal (2) and negative terminal to
“Ground” terminal (3) of sensor. Then using
ohmmeter, measure resistance between “Vout”
terminal (4) of sensor and negative terminal of
battery by passing magnetic substance (iron) (5)
while keeping approximately 1 mm (0.03 in.) gap
with respect to end face of CMP sensor.
If resistance does not vary as specified below,
replace CMP sensor.
CMP sensor resistance
Resistance varies from less than 220 Ω (ON) to
infinity (OFF) or from infinity (OFF) to less than 220
Ω (ON)
1. EGR valve
(a)
(a)
I6RS0C130003-02
I6RS0C130004-01
I4RS0B130015-01
I6RS0C130005-01

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 1D-11 Engine Mechanical:
2) Remove oil, old sealant, and dust from sealing surfaces on cylinder head and cover. After cleaning,
apply sealant “A” to the following point.
• Cylinder head cover gasket (1) sealing surface area (2) as shown.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F)
• Timing chain cover (1) and cylinder head (2) mating surface as shown.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F) 3) Install cylinder head cover to cylinder head.
NOTE
When installing cylinder head cover, use care
so that cylinder head cover gasket or spark
plug hole gaskets will not get out of place or
fall off.

4) Tighten cylinder head cover bolts as follows.
a) Tighten cylinder head cover bolts to 3 N ⋅m (0.3
kgf-m, 2.5 lb-ft) according to numerical order (“1”
through “7”) as shown in figure.
b) In the same manner as in Step, a) tighten them
to 5 N ⋅m (0.5 kgf-m, 4.0 lb-ft).
c) Retighten them by turning through 8 N ⋅m (0.8
kgf-m, 6.0 lb-ft) in same manner as Step a).
Tightening torque
Cylinder head cover bolt (a): Tighten 3 N ⋅m (0.3
kgf-m, 2.5 lb-ft), 5 N ⋅m (0.5 kgf-m, 4.0 lb-ft) and 8
N ⋅m (0.8 kgf-m, 6.0 lb-ft) by the specified
procedure
5) Connect PCV hose (2) to PCV valve (3).
6) Connect breather hose (4).
7) Install oil level gauge (1).
8) Install wire harness clamp to cylinder head cover.
9) Install ignition coil assemb lies with high-tension cord
referring to “Ignit ion Coil Assembly (Including ignitor)
Removal and Installati on in Section 1H”.
10) Connect ignition coil couplers and clamp harness securely.
11) Install cylinder head upper cover.
12) Install air cleaner case and resonator.
13) Connect negative cable at battery.
I2RH0B140036-01
I2RH0B140037-01
I3RH0B140016-01

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.
6
2 1
3
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7I6RS0B141008-01
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2
I6RS0B141010-01
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2
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I6RS0B141009-01

Downloaded from www.Manualslib.com manuals search engine 1G-11 Fuel System:
Fuel Tank Inlet Valve Removal and InstallationS7RS0B1706011
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.

Removal1) Remove fuel filler cap.
2) Insert hose of a hand oper ated pump into fuel filler
hose (1) and drain fuel in space “A” as shown in
figure.
CAUTION!
Do not force pump hose into fuel tank, or
pump hose may damage to fuel tank inlet
valve (2).

3) Hoist vehicle, and remove clamp (2) and fuel filler
hose (1) from fuel tank. 4) Remove fuel tank inlet valve (1) using flat head rod
(2) or the like.
CAUTION!
Be careful not to damage fuel tank inlet valve
(1) with flat head rod (2) or the like.

Installation
1) Install fuel tank inlet valve (1) to fuel tank.
2) Install fuel filler hose (1) to fuel tank and secure it
with clamp (2).
For proper installation, refer to “Fuel Hose
Disconnecting and Reconnecting”.
3) Lower vehicle and install fuel filler cap.
IYSQ01170010-01
1
2
I4RS0A170007-01
I6RS0C170007-01
I2RH0B170018-01
1
2
I4RS0A170007-01

Downloaded from www.Manualslib.com manuals search engine 1H-6 Ignition System:
Ignition Spark TestS7RS0B1804004
1) Remove air cleaner assembly with air intake pipe.
2) Disconnect all injector couplers from injectors.
WARNING!
Without disconnection of injector couplers,
combustible gas may come out from spark
plug holes during this test and may get
ignited in engine room.

3) Remove spark plug and check it for condition and
type referring to “Spark Plug Inspection”.
4) If OK, connect ignition coil coupler to ignition coil assembly and connect spark plug to ignition coil
assembly or high-tension cord. Ground spark plug. 5) Crank engine and check if each spark plug sparks.
6) If no spark is emitted, inspect the related parts as
described in “Ignition System Symptom Diagnosis”.
Repair Instructions
High-Tension Cord Removal and InstallationS7RS0B1806001
Removal
1) Remove air cleaner assembly with air intake pipe and cylinder head upper cover.
2) Disconnect No.1 cylinder (2) and No.3 cylinder (3)
high-tension cords from ignition coil assemblies (1)
while gripping each cap.
3) Pull out high-tension cords from spark plugs while gripping each cap.
CAUTION!
• Removal of high-tension cords together with clamps will be recommended so as
not to damage their inside wire (resistive
conductor).
• For the same reason, pull out each connection by gripping cap portion.

Installation
1) Install No.1 cylinder (2) and No.3 cylinder (3) high-
tension cords to spark plugs and ignition coil
assemblies (1) while gripping each cap.
CAUTION!
• Never attempt to use metal conductor high-tension cords as replacing parts.
• Insert each cap portion fully when installing high-tension cords.

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