Nut SUZUKI SWIFT 2006 2.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-11
Specifications
Tightening Torque SpecificationsS7RS0B1507001
NOTE
The specified tightening torque is also described in the following.
“Heat Exchanger Components”
“Oil Pan and Oil Pump Strainer Components”
“Oil Pump Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS7RS0B1508001
NOTE
Required service material is also described in the following.
“Heat Exchanger Components”
“Oil Pan and Oil Pump Strainer Components”
“Oil Pump Components”

Special ToolS7RS0B1508002
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Oil pressure switch 13 1.3 9.5 )
Heat exchanger stand bolt 22 2.2 16.0 )
Oil pump strainer bolt 11 1.1 8.0 )
Oil pump strainer bracket bolt 11 1.1 8.0 )
Oil pan bolt (M6) 11 1.1 8.0 )
Oil pan bolt (M10) 55 5.5 40.0 )
Oil pan nut 11 1.1 8.0 )
Oil pan drain plug 35 3.5 25.5 )
Transaxle stiffener bolt 55 5.5 40.0 )
Oil pump rotor plate bolt 11 1.1 8.0 )
MaterialSUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260)
09915–77310 09915–78211
Oil pressure gauge (0-10kg/
cm2) Oil pressure gauge
attachment
))

Downloaded from www.Manualslib.com manuals search engine 1F-11 Engine Cooling System:
Water Pump Removal and InstallationS7RS0B1606014
Removal1) Disconnect negative cable at battery.
2) Drain coolant.
3) Remove water pump / generator drive belt referring to “Water Pump / Generator Drive Belt Removal and
Installation in Section 1J”.
4) Remove water pump assembly (1).
Installation 1) Apply sealant to mating surface of water pump (1) as shown in the figure.
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
Sealant quantity (to mating surface of water
pump)
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.) 2) Install water pump assemb
ly (1) to cylinder block
and tighten bolts and nut to specified torque.
Tightening torque
Water pump bolt and nut (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
3) Install water pump pulley.
4) Install water pump / generator drive belt referring to “Water Pump / Generator Drive Belt Tension
Inspection and Adjustment in Section 1J”.
5) Install A/C compressor belt (if equipped) referring to “Compressor Drive Belt Inspection and Adjustment
in Section 7B” or “Compressor Drive Belt Inspection
and Adjustment in Section 7B”.
6) Refill cooling system referri ng to Step 7) to 22) of
“Cooling System Flush and Refill”.
7) Connect negative cable at battery.
8) Check each part for leakage.
Water Pump InspectionS7RS0B1606015
CAUTION!
Do not disassemble water pump.
If any repair is requir ed on pump, replace it
as assembly.

Rotate water pump by hand to check for smooth
operation. If pump does not rotate smoothly or makes
abnormal noise, replace it.
I2RH0B160016-01
I3RM0A160016-01
I2RH0B160018-01
I2RH0B160019-01

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-12
Specifications
Tightening Torque SpecificationsS7RS0B1607001
NOTE
The specified tightening torque is also described in the following.
“Cooling System Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS7RS0B1608001
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Water pump bolt and nut 25 2.5 18.0 )
MaterialSUZUKI recommended product or Specification Note
Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250)

Downloaded from www.Manualslib.com manuals search engine 1G-3 Fuel System:
4) Check that battery voltage is 11 V or more.
5) Measure fuel pressure at each condition.If measured pressure is out of specification, refer to
“Fuel Pressure Check in Section 1A” and check each
possibly defective part. Replace if found defective.
a) Turn ignition switch ON to operate fuel pump and after 2 seconds turn it OFF. Repeat this 3 or 4
times and then check fuel pressure.
Fuel pressure specification
With fuel pump operating and engine
stopped: 270 – 310 kPa (2.7 – 3.1 kg/cm2, 38.4
– 44.0 psi)
b) Start engine and warm it up to normal operating temperature, and measure fuel pressure at
idling.
Fuel pressure specification
At specified idle speed: 270 – 310 kPa (2.7 –
3.1 kg/cm2, 38.4 – 44.0 psi)
c) Stop engine, and measure fuel pressure at one minute after stopping.
Fuel pressure specification
With 1 min. after engine (fuel pump) stop
(Pressure reduces as time passes): Over 300
kPa (3.0 kg/cm
2, 42.7 psi)
6) After checking fuel pressure, remove fuel pressure gauge.
WARNING!
As fuel feed line is still under high fuel
pressure, make sure to release fuel pressure
according to the following procedures.
• Place fuel container under joint.
• Cover joint with rag and loosen joint nut slowly in order to release fuel pressure
gradually.

7) Remove special tools from fuel delivery pipe and fuel feed hose.
8) Connect fuel feed hose to fuel delivery pipe and clamp it securely.
9) With engine OFF and ignition switch ON, check for fuel leaks.
Fuel Cut Operation InspectionS7RS0B1704002
NOTE
Before inspection, make sure that gear shift
lever is in neutral positi on (shift select lever
is “P” range for A/T vehicle), A/C is OFF and
parking brake lever is pulled all the way up.

1) Warm engine up to normal operating temperature.
2) While listening to sound of injector (2) by using sound scope (1) or such, increase engine speed to
higher than 3,000 r/min.
3) Check to make sure that injector operation sound is stop when throttle valve is closed instantly and it is
heard again when engine speed is reduced to
approx. 2,000 r/min or less.
I2RH01170032-01
I2RH0B170004-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-14
Fuel Tank Purging ProcedureS7RS0B1706015
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.
• This purging procedure will not remove all fuel vapor.
Do not attempt any repair on tank using
heat of flame as an explosion resulting in
personal injury could occur.

CAUTION!
Never remain water in fu el tank after washing,
or fuel tank inside will get corrosion.

The following procedure are used for purging fuel tank.
1) After removing fuel tank, remove all hoses, pipes and fuel pump assembly from fuel tank.
2) Drain all remaining fuel from tank.
3) Place fuel tank to flushing area.
4) Fill tank with warm water or tap water, and agitate
vigorously and drain. Repeat this washing until
inside of tank is clean. Replace tank if its inside is
rusty.
5) Completely flush out rema ining water after washing.
Fuel Pump On-Vehicle InspectionS7RS0B1706016
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.

NOTE
The fuel pressure regulator is incorporated
with the fuel pump assembly so individual
inspection of it is impossible.

1) Remove filler cap and turn ON ignition switch (2).
Then fuel pump operating sound should be heard
from fuel filler (1) for about 2 seconds and stop. Be
sure to reinstall fuel filler cap after checking.
If the check result is not satisfactory, go to “Fuel
Pump and Its Circuit Check in Section 1A”. 2) Turn OFF ignition switch and leave over 10 minutes
as it is.
3) Fuel pressure should be felt at fuel feed hose (1) for about 2 seconds after ignition switch ON.
If fuel pressure is not felt, go to “Fuel Pressure
Check in Section 1A”.
Fuel Pump Assembly Removal and InstallationS7RS0B1706017
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) Remove fuel tank from vehicle. Refer to “Fuel Tank Removal and Installation”.
2) Disconnect fuel feed pipe (1) from fuel pump assembly (2) referring to “Fuel Hose Disconnecting
and Reconnecting”.
IVSY01170013-01
1I3RM0A170019-01
1
2
I6RS0C170008-02

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-4
Repair Instructions
Starting Motor Dismounting and RemountingS7RS0B1906001
Dismounting1) Disconnect negative (–) battery lead at battery.
2) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals.
3) Detach shift & select control cable bracket from transaxle. (M/T model only)
4) Remove starting motor mount bolt (3) and nut (4).
5) Remove starting motor (5).
Remounting
Reverse the dismounting procedure noting the following.
• Tighten battery cable nut (6) to specified torque.
Tightening torque
Starting motor battery cable nut (a): 9.8 N·m (0.98 kgf-m, 7.0 lb-ft)
I4RS0A190002-01
: 9.8 N ⋅m (0.98 kgf-m, 7.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 1I-5 Starting System:
Starting Motor ComponentsS7RS0B1906002
I4RS0A190003-01
1. Front housing 7. Plate 13. Planetary gear 19. Rear bush
2. Bush 8. Seal rubber 14. Packing 20. Starting motor battery cable nut
3. Pinion stop ring 9. Magnetic switch 15. Yoke :9.8 N
⋅m (0.98 kgf-m, 7.0 lb-ft)
4. Over-running clutch 10. Ball 16. Armature: Do not reuse.
5. Lever 11. Internal gear 17. Brush assembly : Apply grease 99000-25010 to sliding surface of each part.
6. Plunger 12. Planetary carrier shaft 18. Rear bracket

Downloaded from www.Manualslib.com manuals search engine 1I-9 Starting System:
Specifications
Cranking System SpecificationsS7RS0B1907001
Tightening Torque SpecificationsS7RS0B1907002
NOTE
The specified tightening torque is also described in the following.
“Starting Motor Dismounting and Remounting”
“Starting Motor Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS7RS0B1908001
NOTE
Required service material is also described in the following.
“Starting Motor Components”

Voltage 12 volts
Output 1.2 kW
Rating 30 seconds
Direction of rotation Clockwise as viewed from pinion side
Brush length Standard: 12.3 mm (0.48 in.) Limit: 7.0 mm (0.28 in.)
Number of pinion teeth 8
Performance Condition Guarantee
Around at 20 °C
(68 °F) No load characteristic 11.0 V
90 A maximum
2370 r/min minimum
Load characteristic 7.5 V
300 A 10.65 N
⋅m (1.065 kgf-m, 7.70 lb-ft) minimum
840 r/min minimum
Locked characteristic 4.0 V 780 A maximum
20 N
⋅m (2.0 kgf-m, 14.5 lb-ft) minimum
Magnetic switch operating voltage 8 volts maximum
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Starting motor battery cable nut 9.8 0.98 7.0 )

Downloaded from www.Manualslib.com manuals search engine 1J-2 Charging System:
Generator DescriptionS7RS0B1A01002
The basic charging system is the IC integral regulator charging system. The internal co mponents are connected
electrically as shown below.
I5JB0A1A0004-01
1. Pulley 6. Field coil11. Rear housing IG: Ignition terminal
2. Pulley nut 7. RectifierB: Generator output (Battery terminal) L: Lamp terminal
3. Rotor fan 8. BrushC: Generator cut terminal
4. Stator coil 9. RegulatorE: Ground
5. Stator core 10. Front housing FR: Field duty monitor terminal

Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-9
Generator Unit ComponentsS7RS0B1A06005
Generator Dismounting and RemountingS7RS0B1A06006
Dismounting1) Disconnect negative (–) cable at battery.
2) Remove right side drive shaft referring to “Front Drive Shaft Assembly Removal and Installation in
Section 3A”.
3) Disconnect generator lead wire (“B” terminal wire) and coupler from generator.
4) Remove generator belt. Refer to “Water Pump / Generator Drive Belt Re moval and Installation”.
5) Remove generator bracket bolts and generator pivot bolt.
6) Remove generator. Remounting
Reverse dismounting procedure for remounting noting
the followings.
• Tighten each bolt and nut to specified torque referring
to “Generator Unit Components”.
• Adjust belt tension referring to “Water Pump / Generator Drive Belt Tension Inspection and
Adjustment”.
(a)
(b)
(c)
1
2 8
3 7 5 49 6(c)
(c)
I6RS0C1A0003-02
1. “B” terminal nut
5. Generator pivot bolt : 5 N⋅m (0.5 kgf-m, 3.5 lb-ft)
2. “B” terminal wire 6. Generator belt : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft)
3. Connector 7. Generator : 25 N⋅m (2.5 kgf-m, 18.5 lb-ft)
4. Generator adjusting bolt 8. Generator bracket bolt