check engine SUZUKI SWIFT 2005 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Exhaust System: 1K-4
2) Install new seal ring and connect exhaust No.1 pipe (1) to exhaust manifold.
Tighten pipe fasteners to specified torque.
Tightening torque
Exhaust No.1 pipe bolt (a): 50 N·m (5.0 kgf-m,
36.5 lb-ft)
3) Install exhaust manifold stiffener (2). Tighten exhaust manifold stiffener bolts to specified
torque.
Tightening torque
Exhaust manifold stiffener bolt (b): 50 N·m (5.0
kgf-m, 36.5 lb-ft)
4) Install new seal ring and connect exhaust No.1 pipe (1) to exhaust No.2 pipe. Tighten pipe fasteners to
specified torque.
Tightening torque
Exhaust No.2 pipe bolt (c): 43 N·m (4.3 kgf-m,
31.0 lb-ft)
5) Install heated oxygen sensors (3) referring to “HO2S-1 and HO2S-2 Removal and Installation in
Section 1C”, if removed.
NOTE
Be sure to identify heated oxygen sensor
No.1 and No.2 by its connector color.

6) Connect heated oxygen sensor No.2 connector (1)
(connector color: green) and heated oxygen sensor
No.1 connector (2) (connector color: black), and then
fit coupler to br acket securely. 7) Install exhaust manifold cover to exhaust manifold.
8) Install A/C condenser to vehicle body for equipped
with A/C.
9) Install radiator referrin g to “Radiator Removal and
Installation in Section 1F” for equipped with A/C.
10) Install front bumper with fr ont grille by referring to
“Front Bumper and Rear Bumper Components in
Section 9K”.
11) Install engine cover.
12) Connect negative cable at battery.
13) Check exhaust system for exhaust gas leakage.
Exhaust Pipe and Muffler Removal and
Installation
S7RS0B1B06003
For replacement of exhaust pipe, be sure to hoist vehicle
and observe WARNING under “Exhaust System
Components” and the following.
CAUTION!
Exhaust manifold have three way catalytic
converter in it, it should not be exposed to
any impulse.
Be careful not to drop it or hit it against
something.

• Tighten bolts and nuts to specified torque when reassembling. Refer to “Exhaust System
Components”.
• After installation, start engine and check each joint of exhaust system for leakage.
2
(b)
(a)
1(C)
3
I4RS0A1B0005-01
1
2
I6RS0C1B0002-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 2- i
2
Section 2
CONTENTS
Suspension
Precautions ................................................. 2-1
Precautions............................................................. 2-1
Precautions on Suspension .................................. 2-1
Suspension General Dia gnosis.............. 2A-1
Diagnostic Information and Procedures ............ 2A-1
Suspension, Wheels and Tires Symptom Diagnosis .......................................................... 2A-1
Front Suspension ........... ......................... 2B-1
General Description ............................................. 2B-1
Front Suspension Construction ........................... 2B-1
Front Wheel Alignment Cons truction .................. 2B-2
Repair Instructions .............................................. 2B-2 Front Wheel Alignment Inspection and Adjustment ........................................................ 2B-2
Front Strut Assembly Comp onents ..................... 2B-4
Front Strut Assembly Removal and Installation ......................................................... 2B-4
Front Strut Assembly Disassembly and Assembly .......................................................... 2B-6
Front Strut Assembly Chec k ............................... 2B-7
Front Wheel Hub and Steering Knuckle Components...................................................... 2B-8
Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation .......... 2B-8
Front Wheel Hub, Disc, Nut and Bearing Check .............................................................. 2B-12
Suspension Control Arm / Bushing Removal and Installation ................................................ 2B-12
Suspension Control Arm / Bushing Disassembly and Assembly ............................ 2B-13
Suspension Control Arm / Steering Knuckle Check .............................................................. 2B-14
Suspension Control Arm Bushing Check .......... 2B-14
Suspension Control Arm Joint Check ............... 2B-14
Front Suspension Fram e, Stabilizer Bar and/
or Bushings Components................................ 2B-15
Front Suspension Fram e, Stabilizer Bar and/
or Bushings Removal and Installation ............. 2B-15
Front Suspension Frame Ch eck ....................... 2B-19
Front Stabilizer Bar, Bushing and/or Joint Check .............................................................. 2B-19
Front Suspension Fastener s Check .................. 2B-19
Specifications ..................................................... 2B-20 Tightening Torque Specifications ...................... 2B-20
Special Tools and Equipmen t ...........................2B-21
Special Tool ...................................................... 2B-21
Rear Suspension ............ ......................... 2C-1
General Description .............................................2C-1
Rear Suspension Construction ...........................2C-1
Repair Instructions ........... ...................................2C-2
Rear Wheel Alignment Inspection .......................2C-2
Rear Shock Absorber Removal and Installation .........................................................2C-2
Rear Shock Absorber Ins pection ........................2C-3
Rear Shock Absorber Bush Removal and Installation .........................................................2C-4
Rear Shock Absorber Bush Inspection ...............2C-4
Rear Coil Spring Removal and Installation .........2C-4
Spring Upper Seat / Spring Lower Seat Inspection ..........................................................2C-5
Spring Upper Seat and Lower Seat Removal and Installation ..................................................2C-6
Rear Axle Removal and Inst allation ....................2C-6
Trailing Arm, Rear Axle and Coil Spring Inspection ..........................................................2C-9
Rear Axle Bush Inspection ..................................2C-9
Rear Wheel Hub Components ..........................2C-10
Rear Wheel Hub Removal an d Installation .......2C-10
Rear Wheel Disc, bolt and Bearing Inspection ..2C-11
Spindle Removal and Installation ......................2C-12
Spindle Inspection .............................................2C-13
Rear Suspension Fasteners Inspection ............2C-13
Specifications .................... .................................2C-13
Tightening Torque Specifications ......................2C-13
Special Tools and Equipmen t ...........................2C-13
Special Tool ......................................................2C-13
Wheels and Tires ............ ......................... 2D-1
Precautions...........................................................2D-1
Precaution for Emergency Flat Tire Repair Kit ....2D-1
General Description .............................................2D-1 Tires Description .................................................2D-1
Wheels Description .............................................2D-2
Irregular and/or Premature Wear Description .....2D-3
Wear Indicators Description ................................2D-3
Radial Tire Waddle Description...........................2D-4
Radial Tire Lead / Pull Description ......................2D-5

Downloaded from www.Manualslib.com manuals search engine 2A-1 Suspension General Diagnosis:
Suspension
Suspension General Diagnosis
Diagnostic Information and Procedures
Suspension, Wheels and Tires Symptom DiagnosisS7RS0B2104001
ConditionPossible cause Correction / Reference Item
Vehicle pulls (Leads) Mismatched or uneven tires Replace tires.
Tires not adequately inflated Adjust tire pressure.
Broken or sagging coil springs Replace coil springs.
Radial tire lateral force Replace tire.
Disturbed wheel alignment Check and adjust wheel alignment.
Brake dragging in one road wheel Repair brake.
Loose, bent or broken front or rear
suspension parts Tighten or replace related suspension parts.
Abnormal or excessive
tire wear Sagging or broken coil spring
Replace coil spring.
Tire out of balance Adjust balance or replace tire.
Disturbed wheel alignment Check and adjust wheel alignment.
Faulty strut (shock absorber) Replace strut (shock absorber).
Hard driving Replace tires.
Overloaded vehicle Replace tires and check suspension parts.
Not rotated tires Replace or rotate tires.
Worn or loose wheel bearing Replace wheel bearing.
Wobbly wheel or tire Replace wheel or tire.
Tires not adequately inflated Adjust tire pressure.
Wheel tramp Blister or bump on tire Replace tire.
Improper strut (shock absorber) action Replace strut (shock absorber).
Shimmy, shake or
vibration Tire or wheel out of balance
Balance wheel or replace tire and/or wheel.
Loosen wheel bearings Replace wheel bearings.
Worn tie-rod ends Replace tie-rod ends.
Worn lower ball joints Replace front suspension control arm.
Excessive wheel runout Repair or replace wheel and/or tire.
Blister or bump on tire Replace tire.
Excessively loaded radial runout of tire /
wheel assembly Replace tire or wheel.
Disturbed wheel alignment Check and adjust wheel alignment.
Loose or worn steering linkage Tighten or replace steering linkage.
Loose steering gear case bolts Tighten steering gear case bolts.
Abnormal noise, front end Worn, sticky or loose tie-rod ends, lower
ball joints, tie-rod in side ball joints or
drive shaft joints Replace tie-rod end, su
spension arm, tie-rod
or drive shaft joint.
Damaged struts or mountings Repair or replace struts or mountings.
Worn suspension arm bushings Replace suspension arm bushings.
Loose stabilizer bar Tighten bolts or nuts and/or replace bushes.
Loose wheel nuts Tighten wheel nuts.
Loose suspension bolts or nuts Tighten suspension bolts or nuts.
Broken or damaged wheel bearings Replace wheel bearings.
Broken suspension springs Replace suspension springs.
Poorly lubricated or worn strut bearings Replace strut bearing.
Malfunction of Power Steering System Check and correct malfunction.
Low or uneven trim height
NOTE
See NOTE *1.

Broken or sagging coil springs Replace coil springs.
Over loaded Check loading.
Incorrect coil springs Replace coil spring.
Tires not adequately inflated Adjust tire pressure.
Ride too soft Faulty strut (shock absorber) Replace strut (shock absorber).
Suspension bottoms Overloaded Check loading.
Faulty strut (shock absorber) Replace strut (shock absorber).
Incorrect, broken or sagging coil springs Replace coil spring.

Downloaded from www.Manualslib.com manuals search engine Suspension General Diagnosis: 2A-2
NOTE
*1: Right-to-left trim height (“H”) difference should be within 15 mm (0.6 in.) with curb weight. (same
with rear side.)

Body leans or sways in
corners Loose stabilizer bar
Tighten stabilizer bar bolts or nuts, or replace
bushes.
Faulty strut (shock absorber) or
mounting Replace strut (shock absorber) or tighten
mounting.
Broken or sagging coil springs Replace coil springs.
Overloaded Check loading.
Cupped tires Front struts defective Replace struts.
Worn wheel bearings Replace wheel bearings.
Excessive tire or wheel run-out Replace tire and/or wheel.
Worn ball joints Replace front suspension control arm.
Tire out of balance Adjust tire balance.
Condition Possible cause Correction / Reference Item
“H”
I2RH01210001-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-2
Front Wheel Alignment ConstructionS7RS0B2201002
Among factors for front wheel alignment, only toe setting
can be adjusted. Camber and caster are not adjustable.
Therefore, should camber or caster be out of
specification due to the damage caused by hazardous
road conditions or collision, whether the damage is in
body or in suspension should be determined and
damaged body should be repaired or damaged
suspension should be replaced.
Preliminary Checks Prior to Adjustment Front Wheel
Alignment
Steering and vibration complaints are not always the
result of improper wheel alignment. An additional item to
be checked is the possibility of tire lead due to worn or
improperly manufactured tires. “Lead” is the vehicle
deviation from a straight path on a level road without
hand pressure on the steering wheel. Refer to “Radial
Tire Lead / Pull Description in Section 2D” in order to
determine if the vehicle has a tire lead problem. Before
making any adjustment affecting wheel alignment, the
following checks and inspections should be made to
ensure correctness of alignment readings and alignment
adjustments:
• Check all tires for proper inflation pressures and approximately the same tread wear. • Check for loose of ball join
ts. Check tie-rod ends; if
excessive looseness is noted, it must be corrected
before adjusting.
• Check for run-out of wheels and tires.
• Check vehicle trim heights; if it is out of limit and a
correction is needed, it must be done before adjusting
toe.
• Check for loose of suspension control arms.
• Check for loose or missin g stabilizer bar attachments.
• Consideration must be given to excess loads, such as
tool boxes. If this excess load is normally carried in
vehicle, it should remain in vehicle during alignment
checks.
• Consider condition of equipment being used to check alignment and follow manufa cturer’s instructions.
• Regardless of equipment used to check alignment, vehicle must be placed on a level surface.
NOTE
To prevent possible incorrect reading of toe,
camber or caster, vehicle front and rear end
must be moved up and down a few times
before inspection.

Repair Instructions
Front Wheel Alignment Inspection and
Adjustment
S7RS0B2206001
Toe Inspection and Adjustment
Preparation for toe inspection and adjustment.
• Place vehicle in unloaded state on level surface.
• Set steering wheel in straight state.
• Check that inflation pressure of each tire is adjusted properly and wheel is free from deflection.
• Check that each suspension part is free from bend, dent, wear or damage in any other form.
• Check that ground clearance at the right and left is just about the same.
Inspection
Measure toe using toe-in gauge (1).
If toe is out of specified value, adjust it at the tie-rod. Front toe (total) “b”-“a”
: 0 + 1.0 / – 0.5 mm (0 + 0.0394 / – 0.0197 in.)
I6RS0C220007-01
F: Forward
“a”
“c”
“b” F
I7RS0A220002-02

Downloaded from www.Manualslib.com manuals search engine 2B-3 Front Suspension:
Adjustment1) Loosen right and left tie-rod end lock nuts (1) first.
2) Rotate right and left tie-rods (2) by the same amount to align toe to specification. In this adjustment, the
lengths “A” of both right and left tie-rod should be
equal.
NOTE
Before rotating tie-rods (2), apply grease
between tie-rods and rack boots so that
boots won’t be twisted.

3) After adjustment, tighten lock nuts (1) to specified torque.
Tightening torque
Tie-rod end lock nut (a): 45 N·m (4.5 kgf-m, 32.5 lb-
ft)
NOTE
Make sure that rack boots are not twisted.

Camber and Caster Check
Check camber and caster by camber caster kingpin
gauge (1) and turning radius gauge (2).
If measured value is out of specified value, check
following items for damage, deformation and crack.
• Strut and component
• Suspension control arm and bush
• Suspension frame
• Wheel hub, steering knuckle or wheel bearing
• Vehicle body Front camber “a”
: 0
± 1°
Front caster “b”
: 5 °12’ ± 2°
NOTE
Front camber and caster are not adjustable.

Steering Angle Check and Adjustment
When tie-rod or tie-rod end was replaced, check toe and
then also steering angle with turning radius gauge.
If measured value is out of specified value, perform
inspection and adjustment of toe.
Steering angle
Inside: 33.8 ° ± 3 °
Outside: 29.8 ° (Reference)
I3RH0A220002-01
[A]: Camber (Front view) S: Body center
[B]: Caster (Side view) T: Center line of wheel
F: Forward
2
1
I7RS0B220003-01
[B]
S T
90°
“a”
[A]
F
90°
“b”
I7RS0B220004-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-4
Reference Information
Side slip
When checked with side slip tester, side slip should
satisfy following specification.Side slip
0 to IN 3.0 mm/m (0 to IN 0.118 in/3.3 ft)
If side slip is greatly di
fferent, toe or front wheel
alignment may not be correct.
Front Strut Assembly ComponentsS7RS0B2206002
Front Strut Assembly Removal and InstallationS7RS0B2206003
Removal
1) Remove windshield wipe r arms with wiper blades.
2) Remove cowl top covers referring to “Cowl Top
Components in Section 9K”.
NOTE
When servicing component parts of strut
assembly, remove stru t rod cap and then
loosen strut nut a little before removing strut
assembly. This will make service work easier.
Note that the nut must not be removed at this
point.

3) Hoist vehicle, allowing front suspension to hang free.
4) Remove wheel and disconn ect stabilizer joint (1)
from strut bracket.
When loosening joint nu t, hold stud with special
tools.
Special tool
(A): 09900–00411 socket
(B): 09900–00413 5 mm
11 3
2 1
12
13
4
5
6
7
10
8(a)
(b)
9
(a)
14
15(a)
16
I6RS0C220006-02
1. Strut assembly
6. Strut bearing 11. Strut rod cap16. Bump stopper
2. Coil spring 7. Strut support 12. Strut bracket nut : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft)
3. Dust cover 8. Strut support lower nut 13. Strut bracket bolt
:Insert from vehicle front side. : 90 N
⋅m (9.0 kgf-m, 65.5 lb-ft)
4. Coil spring seat 9. Strut nut 14. Stabilizer joint nut : Do not reuse.
5. Coil spring upper seat 10. Rebound stopper 15. Stabilizer joint
1
(A)
(B)
I4RS0A220004-01

Downloaded from www.Manualslib.com manuals search engine 2B-7 Front Suspension:
3) Install bump stopper onto strut rod. For installing
direction, refer to the figure in “Front Suspension
Construction”.
4) Pull strut rod as far up as possible and use care not to allow it to re tract into strut.
5) Install spring seat on coil spring and then spring upper seat (1) aligning “OUT” mark (3) on spring
upper seat and center of strut bracket (2).
6) Install strut bearing (3), strut support (2) and strut
support lower nut (1) in this sequence.
Tighten strut support lower nut (1) to specified
torque.
When tightening strut support lower nut, hold stud
with special tools.
Special tool
(A): 09900–00411 socket
(B): 09900–00414 6 mm
Tightening torque
Strut support lower nut (a): 50 N·m (5.0 kgf-m,
36.5 lb-ft)Front Strut Assembly CheckS7RS0B2206005
• Inspect strut for oil leakage, damage or deformation.
• If defect is found, replace strut as an assembly unit, because it can not be disassembled.
• Inspect strut function re ferring to the following
procedures:
1) Check and adjust tire pressures as specified.
2) Bounce vehicle body up and down 3 or 4 times continuously by pushing front end of the vehicle side
body to check strut.
Also, note how many times vehicle body rebounds to
stop after force application.
3) Repeat the same procedure to the other strut to confirm that the both side struts equally respond.
If conditions of struts are in doubt, compare them with
known-good vehicle or strut.
• Inspect bearing for wear, abnormal noise or gripping. If defective, replace.
• Inspect coil spring seat for cracks or deformation.
If defective, replace.
• Inspect bump stopper for deterioration. If defective, replace.
• Inspect rebound stopper and strut mount for wear, cracks or deformation.
If defective, replace.
I4RS0A220012-01
I6RS0B220006-01
I4RS0A220014-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-12
Front Wheel Hub, Disc, Nut and Bearing CheckS7RS0B2206008
• Inspect each wheel disc for dents, distortion and cracks.
A disc in badly damaged condition must be replaced.
• Check rust of installation face inside of wheel disc.
As rust affects adversely, remove it thoroughly.
• Check wheel nuts for tightness and, as necessary, retighten them to specification.
• Check wheel bolt press-fitted into wheel hub for wear, damage, poor thread condition, and looseness.
Replace defective bolt with a new one.
When bolt installation is found loose, replace both bolt
and wheel hub with new ones.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
• Check wear of wheel bearing. When measuring thrust play, apply a dial gauge to wheel hub as shown in
figure.
Front wheel bearing thrust play limit
“a”: 0.1 mm (0.004 in.)
• Check wheel bearing noise and smooth wheel rotation by rotating wheel in figure.
If defective, replace bearing.
Suspension Control Arm / Bushing Removal
and Installation
S7RS0B2206009
CAUTION!
When removing and installing steering
knuckle assembly, be ca reful not to damage
dust boots of suspension control arm joint
by drive shaft dust cover and brake dust
cover.

Removal
1) Remove suspension contro l arm ball joint bolt (1)
and nut (2).
2) Remove suspension control arm bolts (1).
3) Remove suspension control arm (2).
I7RS0A220010-02
I2RH01220011-01
F: Vehicle front
I2RH01220046-01
1
2
I6RS0C220010-02

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-14
Assembly1) Front bushing Press-fit front bushing (1) by using special tools and
press (2).
Special tool
(A): 09943–76310
(B): 09913–75821
CAUTION!
Be sure to use new bushing.

NOTE
• Before installing bushing, apply soap water on its circumference to facilitate
bushing installation.

2) Press-fit bushing (1) so that dimensions “A” and “B” in figure become equal.
Suspension Control Arm / Steering Knuckle
Check
S7RS0B2206011
Inspect for cracks, deformation or damage.
If defective, replace.
Suspension Control Arm Bushing CheckS7RS0B2206012
Inspect for damage, wear or deterioration.
If defective, replace.
Suspension Control Arm Joint CheckS7RS0B2206013
• Check smooth rotation of ball stud.
• Check damages of ball stud.
• Check damages of dust cover.
NOTE
Suspension control a rm and arm joint cannot
be separated.

If there is any damage to either parts, control arm
assembly must be replaced as a complete unit.
1 2
(A)
(B)
I6RS0C220014-01
I4RS0A220033-01
I6RS0C220015-01
I4RS0B220023-01