Engine Controls - Remove/install/overhaul Suzuki Swift II

INTRODUCTION

Removal, overhaul and installation procedures (when given by manufacturer) are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

Removal

Remove spark plug wires and distributor cap. Disconnect distributor harness connector. Mark rotor-to-distributor housing reference for reinstallation. Remove distributor hold-down bolt and lift out distributor.

(Scheme 1)& 2.

Note. Ensure magnet is free of any metal particles.

Scheme 1

Scheme 2

Note. Distributor drive coupling and camshaft slot are offset. Distributor cannot be installed backward.

Installation

1. Before installing distributor, ensure "O" ring is in good condition. Replace as required. If new "O" ring is installed, lubricate with engine oil.
2. Install distributor while aligning distributor drive coupling into slot of camshaft. Distributor drive coupling and camshaft slot are offset. If distributor coupling does not fit into slot, turn distributor shaft 180 degrees.
3. Ensure distributor is fully seated. Install distributor hold-down bolt. Adjust ignition timing. See ADJUSTMENTS article in this section.

FUEL SYSTEM PRESSURE RELEASE

1. Place transmission in Neutral (M/T) or Park (A/T). Set parking brake and block drive wheels. Remove coolant reservoir from bracket. Remove main fuse box cover.
2. Main fuse box is located near battery. Disconnect main fuse box from body. Disconnect fuel pump relay connector. (Scheme 3) Remove fuel filler cap to release fuel vapor pressure in fuel tank. Reinstall fuel filler cap.
3. Start engine and run until engine runs out of fuel. Crank engine 2-3 times for about 3 seconds to dissipate fuel pressure in lines.

Scheme 3

Removal (DOHC)

1. Relieve fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/suzuki/swift/ii-1989-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Remove idle speed control solenoid valve. Remove EGR modulator bracket from intake manifold (if equipped). Disconnect fuel delivery and return hoses from fuel rail. Disconnect vacuum hose from fuel pressure regulator.
2. Disconnect couplers from each injector. Remove mounting bolts and lift off fuel rail with injectors. Remove injectors from fuel rail.

1. Coat new "O" rings with thin coat of fuel. Install new grommets and "O" rings on injectors. (Scheme 4) Install injectors on fuel rail. Ensure injectors rotate smoothly on fuel rail. If not, check for binding "O" ring.
2. Install insulators in cylinder head. Install fuel rail with injectors. Install and tighten fuel rail mounting bolts to 13-20 ft. lbs. (18-28 N.m). To complete installation, reverse removal procedure.
3. Check for fuel leaks. With fuel pump relay (SOHC) connected, install a jumper wire between fuel pump relay Pink and White/Blue wires (SOHC) or control relay Pink/Black. Fuel pump relay is located in main fuse box, near battery. (Scheme 3) On all models, turn ignition on (engine off) to activate fuel pump.

Scheme 4

INJECTOR (TBI)

Removal (SOHC)

1. Relieve fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/suzuki/swift/ii-1989-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) under FUEL SYSTEM. Disconnect negative battery cable. Remove air cleaner assembly.
2. Remove air cleaner mounting bracket from throttle body. Remove injector cover and upper insulator. Disconnect fuel injector connector. Remove fuel injector.

1. Apply thin coat of fuel to new upper and lower fuel injector "O" rings. Install lower "O" ring to fuel injector cavity and upper "O" ring to injector. (Scheme 5)
2. Install new lower insulator to injector cavity. Install injector by pushing straight into fuel injector cavity. DO NOT turn injector while pushing. Install new upper insulator and injector cover.
3. Tighten injector cover screws to 25-35 INCH lbs. (2.8-3.9 N.m). Reconnect fuel injector connector with lug side facing upward. Install connector cover. Connect negative battery cable. Check for fuel leaks.
4. With fuel pump relay connected, install a jumper wire between fuel pump relay Pink and White/Blue wires. Fuel pump relay is located in main fuse box, near battery. (Scheme 3) Turn ignition on (engine off) to activate fuel pump.

Scheme 5

Removal & Installation

1. Ensure engine is cool before removing O2 sensor. Disconnect negative battery cable and then the O2 sensor connector.
2. On all models, remove O2 sensor from manifold. To install O2 sensor, coat threads with anti-seize compound. Tighten O2 sensor to specification. See «TORQUE SPECIFICATIONS»(/suzuki/swift/ii-1989-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) table at end of article. Connect negative battery cable. After installing O2 sensor start engine and check for exhaust leaks.

Removal & Installation (DOHC)

1. Disconnect negative battery cable. Drain engine coolant so level is below throttle body. Disconnect accelerator cable from throttle lever and cable bracket.
2. Disconnect airflow meter outlet hose. Disconnect throttle position sensor connector. Label and disconnect all vacuum hoses from throttle body. Disconnect engine coolant hoses from throttle body. Remove throttle body from intake manifold.
3. To install, reverse removal procedure. Using new gasket, install throttle body on intake manifold. Tighten throttle body mounting bolts and nuts to 13-20 ft. lbs. (18-27 N.m). After installing accelerator cable, ensure cable has.12-.20" (3.0-5.0 mm) play.
4. Hold exposed portion of cable at center and move cable up and down to measure play. (Scheme 6) Use lock nuts on cable bracket to adjust play. Refill cooling system.

Scheme 6

1. Relieve fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/suzuki/swift/ii-1989-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) under FUEL SYSTEM. Disconnect negative battery cable. Drain engine coolant so level is below throttle body. Remove air intake case from throttle body and air cleaner. NOTE: DO NOT remove either the fuel pressure regulator or the air valve from throttle body. They are factory installed and adjusted.
2. Disconnect throttle position sensor, fuel injector, and water temperature sensor connectors. Disconnect and mark fuel, engine, cooling, and vacuum hoses to throttle body. Disconnect accelerator cable from throttle valve lever and cable bracket. Remove throttle body from intake manifold.

Note. DO NOT soak injector or any electrical device in any type of solvent or cleaner

Scheme 7

1. Remove fuel injector from throttle body. See «INJECTOR (TBI)»(/suzuki/swift/ii-1989-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul__injector-tbi) under FUEL SYSTEM.
2. Remove throttle position sensor, throttle switch (SOHC M/T), coolant (water) and temperature sensor (SOHC) from throttle body. (Scheme 9) Remove attaching screws and separate upper and lower bodies.
3. DO NOT soak any electrical device or air valve in solvent or other cleaner. DO NOT put drills or wires into passages. Clean upper and lower passages with compressed air only. Reassembly components with new gaskets and "O" rings.
4. Assemble upper and lower bodies with new gasket. On SOHC, tighten upper-to-lower body attaching screws to 25-35 INCH lbs. (2.8-3.9 N.m).
5. On SOHC, install coolant (water) temperature sensor. Tighten sensor to 15-22 ft. lbs (20-30 N.m). On all models, install fuel injector. See «INJECTOR (TBI)»(/suzuki/swift/ii-1989-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul__injector-tbi). Apply thread locking compound to injector cover mounting screws and install cover.
6. On all models except SOHC, tighten injector cover screws to 17 INCH lbs. (1.9 N.m). On SOHC, tighten injector cover screws to 25-35 INCH lbs. (2.8-3.9 N.m).
7. On (SOHC A/T), install throttle position sensor so adjusting holes slightly cover mounting bolt holes. (Scheme 7) Turn sensor so mounting holes align.
8. On SOHC M/T, install throttle switch to throttle shaft by aligning flat part of throttle switch rotor with cut part of throttle shaft. (Scheme 8) Push throttle switch in until it makes full contact with throttle body.
9. On all models, install sensor mounting bolts (finger tighten only). Clamp wiring harness securely to side of throttle body.

Scheme 8

Scheme 9

1. Install new throttle body base gasket on intake manifold. Install throttle body. Tighten throttle body mounting bolts to 13-20 ft. lbs. (18-27 N.m).
2. Connect fuel feed pipe with new "O" ring. Tighten fuel feed pipe bolts to 72-102 INCH lbs. (8.0-11.9 N.m).
3. To complete installation, reverse removal procedure. Refill cooling system. Connect negative battery cable.
4. On all models, turn ignition on, engine off. This will activate fuel pump. Check for fuel leaks. Adjust accelerator cable, A/T kickdown cable (if equipped), throttle position sensor (SOHC A/T) and throttle switch (SOHC M/T). See ADJUSTMENTS article in this section.

THROTTLE POSITION SENSOR (TPS)

Note. If TPS is being replaced, wiring may have to be removed from connector. Note wire colors and placement before removal.

1. Disconnect negative battery cable. Unplug TPS harness connector. Remove TPS from throttle body.
2. To install TPS, reverse removal procedure. Adjust TPS. See ADJUSTMENTS article in this section. Tighten TPS mounting screws to 31 INCH lbs. (3.5 N.m) for DOHC.

Note. Throttle switch is used on SOHC M/T. See THROTTLE SWITCH.

Removal & Installation (SOHC A/T)

1. Disconnect negative battery cable. Unplug TPS wiring harness connector. Remove mounting bolts and remove TPS from throttle body.
2. Install throttle position sensor so its adjusting holes slightly cover mounting bolt holes. (Scheme 7) Turn sensor so mounting holes align. Install sensor mounting bolts and finger tighten only.
3. Clamp wiring harness securely to side of throttle body. Connect negative battery cable. Adjust TPS. See ADJUSTMENTS article in this section. Tighten TPS mounting bolts to 14-20 INCH lbs. (1.5-2.2 N.m).

THROTTLE SWITCH

Note. Throttle position sensor is used on SOHC A/T. See THROTTLE POSITION SENSOR (TPS) .

Removal & Installation (SOHC M/T)

1. Disconnect negative battery cable. Unplug throttle switch harness connector. Remove throttle switch from throttle body.
2. Install throttle switch to throttle shaft by aligning flat part of throttle switch rotor with cut part of throttle shaft. (Scheme 8) Push throttle switch in until it is making full contact with throttle body.
3. Install sensor mounting bolts and finger tighten only. Adjust throttle switch. See ADJUSTMENTS article in this section. Tighten throttle switch mounting bolts to 14-20 INCH lbs. (1.5-2.2 N.m).

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• FUEL SYSTEM PRESSURE RELEASE
• TORQUE SPECIFICATIONS
• INJECTOR (TBI)
• THROTTLE POSITION SENSOR (TPS)