Operating cylinder SUZUKI SWIFT 2008 2.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine 1D-17 Engine Mechanical:
Engine Assembly Removal and InstallationS7RS0B1406011
NOTE
After replacing electric throttle body
assembly, perform calibration of throttle
valve referring to “Electric Throttle Body
System Calibration in Section 1C”.

Removal1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure in Section 1G”.
2) Disconnect negative and pos itive cable at battery.
3) Remove battery and tray.
4) Remove engine hood after disconnecting windshield washer hose.
5) Remove right and left side engine under covers.
6) Remove A/C compressor belt by referring to “Compressor Drive Belt Remo val and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
7) Drain engine oil, transaxle oil and coolant.
8) Remove cowl top plate referring to “Cowl Top Components in Section 9K”.
9) Remove air cleaner assembly referring to “Air Cleaner Components”.
10) With hose connected, detach A/C compressor from its bracket (A/C model) referring to “Compressor
Assembly Removal and Installation in Section 7B” or
“Compressor Assembly Removal and Installation in
Section 7B”.
CAUTION!
Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

11) Remove intake manifold rear stiffener (1) from intake manifold and cylinder block. 12) Disconnect the following electric wires:
• MAP sensor (1)
• ECT sensor (2)
•EGR valve (3)
• CMP sensor (4)
• Electric throttle body assembly (5)
• Ignition coil assembly (6)
• Injectors (7)
• Heated oxygen sensor No. 2 (8) and No. 1 (9)
• Oil control valve (10)
• Engine oil pressure switch (11)
• CKP sensor (12)
• Knock sensor (13)
• Back up light switch (14)
• Generator (15)
• Starting motor (16)
• Ground terminal (17) from intake manifold
• Battery ground terminal (18) from exhaust manifold
• Battery ground cable (19) from transaxle
• Magnet clutch switch of A/C compressor (A/C model)
• Each wire harness clamps
• Output shaft speed sensor (VSS) (34) (A/T model)
• Solenoid valve (33) (A/T model)
• Transmission range sensor (32) (A/T model)
• Input shaft speed sensor (31) (A/T model)
13) Remove fuse box from its bracket.
14) Disconnect the following cables: • Gear select control cable (23) (M/T model)
• Gear shift control cable (24) (M/T model)
• A/T select cable (A/T model)
15) Disconnect the following hoses: • Brake booster hose (26) from intake manifold
• Radiator inlet and outlet hoses (20) from each pipe
• Heater inlet and outlet hoses (21) from each pipe
• Fuel feed hoses (22) from fuel feed pipe
• EVAP canister purge valve hose (30) from purge pipe
• A/T fluid cooler hoses (A/T model)
16) With hose connected, detach clutch operating cylinder (25). (M/T model)
CAUTION!
Suspend removed clutch operating cylinder
at a place where no damage will be caused
during removal and installation of engine
assembly.

1
I6RS0B141014-01

Downloaded from www.Manualslib.com manuals search engine 1D-19 Engine Mechanical:
24) Before removing engine with transaxle from engine compartment, recheck to make sure all hoses,
electric wires and cables are disconnected from
engine and transaxle.
25) Lower engine with transaxle from engine compartment.
CAUTION!
Before lowering engine, to avoid damage to
A/C compressor and clutch operating
cylinder, make clearance by rising them. Be
sure not to damage suspended A/C
compressor and clutch operating cylinder.

26) Disconnect transaxle from engine, referring to “Manual Transaxle Unit Dismounting and
Remounting in Section 5B” or “Automatic Transaxle
Unit Dismounting and Re mounting in Section 5A”.
27) For M/T model, remove clutch cover and clutch disk referring to “Clutch Cover, Clutch Disc and Flywheel
Removal and Installa tion in Section 5C”.
Installation 1) For M/T model, install clutch cover and clutch disk referring to “Clutch Cover, Clutch Disc and Flywheel
Removal and Installa tion in Section 5C”.
2) Connect transaxle to engine referring to “Manual Transaxle Unit Dismounting and Remounting in
Section 5B” or “Automatic Transaxle Unit
Dismounting and Remounting in Section 5A”.
3) Lift engine and transaxle into engine compartment with jack.
4) Install engine left mounting bracket nuts (1) and engine right mounting nuts (2).Tighten these nuts to
specified torque.
Tightening torque
Engine left mounting bracket nut (a): 55 N·m (5.5
kgf-m, 40.0 lb-ft)
Engine right mounting nut (b): 65 N·m (6.5 kgf-
m, 47.0 lb-ft) 5) Support engine assemble by using chain hoist.
6) Install engine rear mounting to engine rear
mountingNo.1 bracket.
Tightening torque
Engine rear mounting bush bolt: 55 N·m (5.5
kgf-m, 40.0 lb-ft)
7) Install suspension frame referring to “Front Suspension Frame, Stabiliz er Bar and/or Bushings
Removal and Installati on in Section 2B”.
8) Remove chain hoist.
9) Install exhaust No.1, No.2 and center pipes referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
10) Connect drive shaft joints referring to “Front Drive Shaft Assembly Removal and Installation in Section
3A”.
11) Reverse disconnected hoses, cables and electric wires for connection noting the followings.
• Tighten nuts to specified torque.
Tightening torque
Starting motor terminal nut: 11 N·m (1.1 kgf-m,
8.0 lb-ft)
Generator terminal nut: 6 N·m (0.6 kgf-m, 4.5 lb-
ft)
Intake manifold ground terminal bolt: 11 N·m (
1.1 kgf-m, 18.0 lb-ft)
12) Install intake manifold rear stiffener to intake
manifold and cylinder block.
13) Install air cleaner assembly referring to “Air Cleaner Components”.
14) Install cowl top referring to “Cowl Top Components in
Section 9K”.
I4RS0A140009-01
1, (a)
2, (b)
I4RS0A140010-01

Downloaded from www.Manualslib.com manuals search engine 1H-8 Ignition System:
Ignition Coil Assembly (Including ignitor)
Removal and Installation
S7RS0B1806005
Removal1) Disconnect negative (–) cable at battery.
2) Remove air cleaner assembly with air intake pipe and cylinder head upper cover.
3) Disconnect ignition coil coupler.
4) Disconnect high-tension cord (3) from ignition coil assembly (2).
5) Remove ignition coil bolts (1) and then pull out ignition coil assembly.
Installation 1) Install ignition coil assembly (2).
2) Tighten ignition coil bolts (1) to specified torque, and then connect igni tion coil coupler.
Tightening torque
Ignition coil bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
3) Install high-tension cord (3) to ignition coil assembly while gripping its cap.
4) Install cylinder head upper cover and air cleaner assembly with air intake pipe.
5) Connect negative (–) cable to battery.
Ignition Coil Assembly (Including ignitor)
Inspection
S7RS0B1806006
Measure secondary coil for resistance.
If resistance is out of specification, replace ignition coil
assembly.
Secondary coil resistance
7.5 – 10.3 k Ω at 20 °C, 68 ° F
Ignition Timing InspectionS7RS0B1806007
NOTE
• Ignition timing is not adjustable. If ignition
timing is out of specification, check
system related parts.
• Before starting engine, place transmission gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T model), and set
parking brake.

1) Connect scan tool to DLC (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
2) Start engine and warm it up to normal operating temperature.
3) Make sure that all of electrical loads except ignition are switched off.
4) Check to be sure that idle speed is within specification referring to “Idle Speed and IAC
Throttle Valve Opening Inspection in Section 1A”
5) Fix ignition timing by using “Fixed Spark” of “Misc Test” mode on scan tool.
I2RH0B180006-01
I3RM0A180004-01
I2RH0B180007-01
(A)
1
I4RS0B180003-01

Downloaded from www.Manualslib.com manuals search engine 4F-20 Electronic Stability Program:
NOTE
•{: Activated
• X: Deactivated
• *1: If two or more wheel speed sensor are defective, ABS warning lamp, EBD warning lamp and ESP ® warning lamp are lit and all the control functions are deactivated. If one wheel speed sensor is
defective, ABS warning lamp and ESP ® warning lamp are lit and ABS and TCS / stability control are
deactivated.
• *2: ESP ® OFF mode is cancelled and all control functions are activated.
• *3: EBD control function is activated only if po wer supply circuit is little low voltage malfunction.

Scan Tool DataS7RS0B4604024
The parameter data below are values measured with the scan tool when the normally operating vehicle is under the
following conditions. When taking measurements for comparis on by using the scan tool, be sure to check that the
vehicle is under the following conditions.
• Apply parking brake and block wheels.
• Ignition switch ON.
• Turn OFF air conditioning (if equipped).
• Set the wheel in straight-ahead position and hands off steering wheel.
• Turn OFF all electric loads (except ignition).
• Check that there is no DTC.
Scan Tool Data Definition
Battery Volt (V): Battery Voltage is an analog input
signal read by the ESP ® control module. Certain
ESP ® control module functions will be modified if the
battery voltage falls below or rises above
programmed thresholds.
Pump Motor Driver (V): This parameter indicates the
operational condition of the pump motor driver
(transistor).
RF Wheel Speed, LF Wheel Speed, RR Wheel Speed and LR Wheel Speed (km/h, MPH): Wheel speed
is ESP ® control module internal parameter. It is
computed by reference puls es from the wheel speed
sensor. Brake Switch (ON, OFF):
This switch signal informs
the ESP ® control module whether the brake is active
or not.
Master Cyl Press (MPa): Brake fluid pressure from
brake master cylinder.
G Sensor (lateral) (G): Lateral acceleration is
measured by yaw rate / G sensor assembly and
output to ESP ® control module by pulse signal.
Yaw rate sensor (Deg/s): Yaw rate sensor is measured
by yaw rate / G sensor assembly and output to
ESP® control module by pulse signal.
Steering angle Sen ( °): Steering wheel rotation angle
is measured by steering angle sensor and output to
ESP® control module by pulse signal.
Scan Tool Data Standards Condition
Battery Voltage 10.0 – 16.0 V —
Pump Motor Driver 0.0 V —
RF Wheel Speed 0 km/h, 0.0 MPH Veh icle is in stationary condition.
LF Wheel Speed 0 km/h, 0.0 MPH Veh icle is in stationary condition.
RR Wheel Speed 0 km/h, 0.0 MPH Vehic le is in stationary condition.
LR Wheel Speed 0 km/h, 0.0 MPH Veh icle is in stationary condition.
Brake Switch ON Brake pedal is depressed
OFF Brake pedal is released
Master Cyl Press 0 ± 0.8 MPa Brake pedal is released
G Sensor (lateral) 0 ± 0.1 G Vehicle is on the level
Yaw rate sensor 0 ± 4 deg/s Vehicle is on the level
Steering angle Sen 0 ± 3 ° Front wheels are in straight-ahead
position
Stability control INACTIVE Stability control system is not working
TCS control (brake) INACTIVE Brake function by TCS is not working
TCS control (engine) INACTIVE Torque control by TCS is not working
ESP ® off state (cont) ESP®
ON ESP
® OF
F switch is OFF condition
ESP® OFF ESP ® OFF switch is ON condition
Steering angle Sen Neutral Front wheels are in straight-ahead
position

Downloaded from www.Manualslib.com manuals search engine Table of Contents 5-iii
Gear Shift Control Lever and Cable Components...................................................... 5B-5
Gear Shift Control Le ver and Cable Removal
and Installation .................................................. 5B-6
Gear Select Control Cable Adjustment ............... 5B-6
Back Up Light Switch Removal and Installation ......................................................... 5B-7
Back Up Light Switch Inspection ......................... 5B-7
Manual Transaxle Unit Components ................... 5B-8
Manual Transaxle Unit Dismounting and Remounting....................................................... 5B-9
Gear Shift and Sele ct Shaft Assembly
Components.................................................... 5B-11
Gear Shift and Sele ct Shaft Assembly
Removal and Installation................................. 5B-11
Gear Shift and Select Shaft Disassembly and Assembly ........................................................ 5B-12
Manual Transaxle Assembly Components........ 5B-13
Fifth Gear Disassembly and Assembly ............. 5B-14
Manual Transaxle Assembly Disassembly and Reassembly ............................................. 5B-16
Transaxle Right Case Disassembly and Assembly ........................................................ 5B-23
Transaxle Left Case Disassembly and Assembly ........................................................ 5B-24
Input Shaft and Countershaft Components....... 5B-25
Input Shaft Assembly Disassembly and Reassembly .................................................... 5B-26
Countershaft Assembly Disassembly and Reassembly .................................................... 5B-28
Synchronizer Parts Inspec tion .......................... 5B-31
Gear Shift Shaft Components ........................... 5B-31
5th and Reverse Gear Shift Shafts Disassembly and Assembly ............................ 5B-32
Gear Shift Shaft and Fork Inspection ................ 5B-32
Differential Components ................................... 5B-33
Differential Disassembly and Assembly ............ 5B-33
Specifications ..................................................... 5B-35
Tightening Torque Specifications ...................... 5B-35
Special Tools and Equipmen t ........................... 5B-36
Recommended Service Material ....................... 5B-36 Special Tool ...................................................... 5B-36
Clutch ................
.............................. ......... 5C-1
General Description .............................................5C-1
Clutch Construction .............................................5C-1
Diagnostic Information and Procedures ............5C-2 Clutch System Symptom Diagnosis ....................5C-2
Repair Instructions ........... ...................................5C-2
Clutch Pedal Inspection ......................................5C-2
Clutch Fluid Level Inspection ..............................5C-3
Air Bleeding of Clutch System.............................5C-3
Clutch Pedal Position (CPP) Switch Removal and Installation ..................................................5C-4
Clutch Pedal Position (CPP) Switch Inspection and Adjustment ................................5C-5
Clutch Fluid Pipe and Hose Components ...........5C-5
Clutch Fluid Pipe Removal and Installation.........5C-6
Clutch Fluid Pipe Inspection................................5C-6
Clutch Master Cylinder Removal and Installation .........................................................5C-6
Clutch Operating Cylinder Removal and Installation .........................................................5C-7
Clutch Operating Cylinder Inspection..................5C-7
Clutch Pedal and Clutch Pedal Bracket Components ......................................................5C-7
Clutch Cover, Clutch Disc and Flywheel Components ......................................................5C-8
Clutch Cover, Clutch Disc and Flywheel Removal and Installation ...................................5C-8
Clutch Cover, Clutch Disc and Flywheel Inspection ........................................................5C-10
Clutch Release Syst em Removal and
Installation .......................................................5C-11
Clutch Release System Inspection ...................5C-13
Specifications .................... .................................5C-13
Tightening Torque Specifications ......................5C-13
Special Tools and Equipmen t ...........................5C-14
Recommended Service Material .......................5C-14
Special Tool ......................................................5C-14

Downloaded from www.Manualslib.com manuals search engine 5B-8 Manual Transmission/Transaxle:
Manual Transaxle Unit ComponentsS7RS0B5206008
13
6(a)
5
14(c)
114 7
(b)
12
7(b)
8
2
5 [A]
1
10
6
(a)
(a)
(b)3
9
9
(b)
(d)
I6RS0C520004-03
[A]: Forward
7. Engine left mounting bracket bolt and nuts 14. Clutch operating cylinder bolt
1. Engine 8. Clutch housing lower plate : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)
2. Transaxle 9. Engine rear mounting bracket bolts : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
3. Engine rear mounting and bracket 10. Transaxle to engine nut : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Back up light switch connector 11. Ground cable : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
5. Clutch operating cylinder 12. Engine left mounting bracket
6. Transaxle to engine bolt 13. Gear shift & select control cables

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-9
Manual Transaxle Unit Dismounting and
Remounting
S7RS0B5206009
Dismounting1) Drain coolant and transaxle oil.
2) Remove coolant reservoir with reservoir hose.
3) Remove battery and tray.
4) Remove air cleaner case and resonator.
5) Disconnect gear shift and gear select control cables (1) while pressing claws (2) of clip (3).
6) Disconnect back up light switch coupler and undo wiring harness clamps.
7) Remove ground cable from transaxle.
8) Remove clutch operating cylinder with fluid hose from transaxle.
9) Remove water inlet No.2 pipe from transaxle.
10) Remove starting motor re ferring to “Starting Motor
Dismounting and Remounting in Section 1I”.
11) Remove transaxle to engine bolts (1) of upper side. 12) Support engine using supporting device (1).
CAUTION!
Do not apply supporting device to projection
part A. If do so, it may be deformed.

13) Remove front drive shafts and center shaft referring
to “Front Drive Shaft Assembly Removal and
Installation in Section 3A”.
14) Remove exhaust No.2 pipe referring to “Exhaust Pipe and Muffler Removal a nd Installation in Section
1K”.
15) Remove clutch housing lower plate (1).
1
2
3
I7RS0A521003-01
1
1
I4RS0A520018-01
1
A
I4RS0A520019-01
1I4RS0A520020-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-3
Clutch Release Margin “C”1) Pull up parking brake fully and block wheels.
2) Start engine and keep engine at idle with neutral gear position.
3) Without clutch pedal (1) dep ressed, slightly push the
shift lever to re verse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress clutch pedal (1), and at gear contact noise died
position (release point) stop depressing.
5) Measure distance between release point (4) and full stroke point (5) on clutch pedal (1) which is shown by
“C” in figure.
Clutch release margin
“C”: 25 – 55 mm (0.98 – 2.17 in.)
6) If “C” is not within specificat ion, it is possible that air
is trapped in this system. If suspected so, bleed air
referring to “Air Bleeding of Clutch System”. Upon
completion of above inspection, start engine and
check clutch for proper operation.
Clutch Fluid Level InspectionS7RS0B5306002
Refer to “Brake Fluid Level Inspection in Section 4A”.
Clutch fluid specification
: Refer to reservoir cap.
Air Bleeding of Clutch SystemS7RS0B5306003
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

Bleeding operation is necessary to remove air whenever
it entered hydraulic clutch system.
1) Fill master cylinder reservoir with brake fluid and keep at least one-half full of fluid during bleeding
operation.
Brake Fluid
Refer to reservoir cap
2) Remove bleeder plug cap from clutch operating cylinder (3). Attach a vinyl tube (1) to bleeder plug
(4), and insert the other end into container (2).
2
1
“A”
3
2
1
3
“B”
“C”
4
5
I4RS0B530001-01
I4RS0A530023-01
3 4 1
2
3
I4RS0A530003-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-5
Clutch Pedal Position (CPP) Switch Inspection
and Adjustment
S7RS0B5306005
Inspection
Check for resistance between terminals under each
condition below. If check result is not satisfactory,
replace.
CPP switch resistance
When switch shaft is pushed (1): Continuity
When switch shaft is free (2): No continuityAdjustment
With clutch pedal depressed,
adjust switch (1) position
so that clearance between end of thread and clutch
pedal arm is within specification, and then tighten lock
nut to specified torque.
Clearance between end of thread and clutch pedal
arm
“a”: 3.5 – 4.0 mm (0.14 – 0.16 in.)
Tightening torque
CPP switch lock nut (a): 7.5 N·m (0.75 kgf-m, 5.5 lb-
ft)
Clutch Fluid Pipe and Hose ComponentsS7RS0B5306006
I5JB0A530006-01
(a)
1
“a”
I6RS0C530002-01
6
1
5
2 5
4(a)
3
I6RS0C530003-01
1. Master cylinder
: Apply grease 99000-25100 to push rod end. 5. Clamp
2. Pipe 6. Clutch reservoir hose
3. Operating cylinder : Apply grease 99000-25100 to rod tip. : 23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Operating cylinder bolt

Downloaded from www.Manualslib.com manuals search engine 5C-6 Clutch:
Clutch Fluid Pipe Removal and InstallationS7RS0B5306007
Removal
CAUTION!
Do not allow fluid to get on painted surface. It
may cause painted surface damage.

1) Remove dust and dirt from each joint of pipe to be disconnected and clean around brake master
cylinder reservoir cap.
2) Take out fluid with syringe or such from brake master cylinder reservoir.
3) Pull clamp (1) of clutch master cylinder (3) and push clamp (5) of clutch operating cylinder (4) and then
disconnect clutch fluid pipe (2).
Installation
Reverse removal procedure for installation noting the
following.
CAUTION!
• Do not allow fluid to get on painted surface.
• Do not allow pipe to contact hard against vehicle body or other parts.

• Install each clamp securely.
• After installation, check clutch pedal free travel and bleed air from system referring to “Clutch Pedal
Inspection” and “Air Blee ding of Clutch System”.
• Check fluid leakage.
• Add fluid to MAX level of reservoir.
Clutch Fluid Pipe InspectionS7RS0B5306008
Check pipe (1) for dent, kink, crack, dirt and dust.
Replace if check result is not satisfactory.
Clutch Master Cylinder Removal and
Installation
S7RS0B5306009
Removal 1) Clean around brake master cylinder reservoir cap and take out fluid with syringe or such from brake
master cylinder reservoir.
2) Disconnect clutch fluid pipe from clutch master cylinder (1) referring to “C lutch Fluid Pipe Removal
and Installation”.
3) Disconnect clutch reservoir hose (2).
4) Remove push rod from clutch pedal.
5) Turn clutch master cylinder (1) clockwise as shown in figure, and then remove it.
Installation
Reverse removal procedure for installation noting the
following.
• Apply grease to push rod tip.
“A”: Grease 99000–25100 (SUZUKI Silicone
Grease)
31
2
5
4
I4RS0B530003-01
3. Brake booster
1
I6RS0C530004-01
1
2
3
I4RS0B530005-01
“A”
I4RS0B530006-01