Components SUZUKI SWIFT 2008 2.G Service Service 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-5 Engine Cooling System:
Repair Instructions
Cooling System ComponentsS7RS0B1606001
I7RS0B160004-01
F: Vehicle forward10. Water outlet cap gasket 20. Heater outlet No.2 hose 30. Heat exchanger water pipe
1. Radiator 11. O-ring 21. Heater union 31. To cylinder head
2. Reservoir 12. Thermostat case water outlet pipe 22. Heater inlet No.1 hose 32. To water pump
3. Engine cooling fan assembly 13. Thermostat case 23. Heater outlet No.1 hose33. To heater core
4. Radiator cap 14. Thermostat 24. Water bypass No.2 hose 34. To throttle body
5. Drain plug 15. Thermostat cap 25. Heat exchanger 35. Heater inlet No.2 hose
6. Radiator outlet hose 16. Water bypass No.1 hose 26.Heat exchanger inlet No.1 hose 36. Heater inlet pipe
7. Radiator inlet hose 17. Water inlet No.1 pipe 27. Heat exchanger inlet No.2 hose : 15 N⋅m (1.5 kgf-m, 11.0 lb-ft)
8. Water outlet cap 18. Water inlet hose 28. Heat exchanger outlet No.1 hose : Do not reuse.
9. ECT sensor 19. Water inlet No.2 pipe 29. Heat exchanger outlet No.2 hose

Downloaded from www.Manualslib.com manuals search engine 1F-7 Engine Cooling System:
Cooling System Flush and RefillS7RS0B1606005
WARNING!
To help avoid danger of being burned, do not
remove radiator cap while engine and
radiator are still hot. Scalding fluid and steam
can be blown out under pressure if cap is
taken off too soon.

NOTE
For detail of coolant specification, refer to
“Coolant Description”.

1) Remove radiator cap when engine is cool as follows.a) Turn cap counterclockwise slowly until it reaches a “stop” (Do not press down while turning it).
b) Wait until pressure is relieved (indicated by a hissing sound) then press down on cap and
continue to turn it counterclockwise.
2) With radiator cap removed, run engine until upper radiator hose is hot (this shows that thermostat is
open and coolant is flowing through system).
3) Stop engine and drain coolant from radiator drain plug (1).
4) Close radiator drain plug. Add water until system is filled and run engine until up per radiator hose is hot
again.
5) Repeat Steps 3) and 4) several times until drained liquid is nearly colorless.
6) Close radiator drain plug (1) tightly. 7) Remove reservoir (1) and remove cap (2) from
reservoir (1).
8) Pour out any fluid, scrub and clean inside of reservoir with soap and water.
Flush it well with clean water and drain, Reinstall
reservoir.
9) Fill reservoir with coolant up to “Full” level mark (3).
10) Install reservoir cap (2) on reservoir. 11) Fill radiator with coolant up to bottom of radiator filler neck and install radiator cap, making sure that the
ear of cap lines is parallel to radiator.
12) Run engine at idle speed.
13) Run engine until radiator fan motor is operated.
14) Stop engine and wait until engine comes cooled down to help avoid danger of being burned.
15) Add coolant to radiator up to bottom of radiator filler
neck, and install radiator ca p, making sure that the
ear of cap lines is parallel to radiator.
16) Repeat Step 12) through 15).
17) Confirm that reservoir cool ant level is “Full” level
mark (3). If coolant is insu fficient, repeat Step 9) and
10).
Cooling Water Pipes or Hoses Removal and
Installation
S7RS0B1606006
Removal
1) Drain coolant referring to “Cooling System Draining”.
2) To remove these pipes or hoses, loosen clamp on each hose and pull hose end off.
Installation
Install removed parts in reverse order of removal
procedure, noting the following.
• Tighten each clamp securely referring to “Cooling System Components”.
• Refill cooling system referrin g to Step 7) to 22) of
“Cooling System Flush and Refill”.
1I4RS0A160003-01
1
2
1
3
2
I7RS0B160005-01

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-1 Fuel System:
Engine
Fuel System
Precautions
Precautions on Fuel System ServiceS7RS0B1700001
WARNING!
Before attempting service of any type on fuel system, the following should be always observed in
order to reduce the risk of fire and personal injury.
• Disconnect negative cable at battery.
• Do not smoke, and place no smoking signs near work area.
• Be sure to have CO
2 fire extinguisher handy.
• Be sure to perform work in a well-ventilated area and away from any open flames (such as gas hot heater).
• Wear safety glasses.
• To relieve fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then
reinstall it.
• As fuel feed line is still under high fuel pr essure even after stopping engine, loosening or
disconnecting fuel feed line directly may cause dangerous spout of fuel. Before loosening or
disconnecting fuel feed line, make sure to relieve fuel pressure referring to “Fuel Pressure Relief
Procedure”.
• A small amount of fuel may be released when the fuel line is disconnected. In order to reduce the risk of personal injury, cover a shop cloth to the fitting to be disconnected. Be sure to put that cloth
in an approved container after disconnecting.
• Never run engine with fuel pump relay disconnected when engine and exhaust system are hot.
• Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each hose correctly referring to “Fuel Hose Disconnecting and Reconnecting”.
After connecting, make sure that it has no twist or kink.
• When installing inje ctor or fuel feed pipe, lubr icate its O-ring with gasoline.

General Description
Fuel System DescriptionS7RS0B1701001
CAUTION!
This engine requires the unleaded fuel only.
The leaded and/or low lead fuel can result in
engine damage and reduce the effectiveness
of the emission control system.

The main components of the fuel system are fuel tank,
fuel pump assembly (with fuel filter, fuel level gauge, fuel
pressure regulator, fuel feed line and fuel vapor line.
For the details of fuel flow, refer to “Fuel Delivery System
Diagram”.
Fuel Delivery System DescriptionS7RS0B1701002
The fuel delivery system consists of the fuel tank, fuel
pump assembly (with built-in f uel filter and fuel pressure
regulator), delivery pipe, injectors and fuel feed line.
The fuel in the fuel tank is pumped up by the fuel pump,
sent into delivery pipe and injected by the injectors.
As the fuel pump assembly is equipped with built-in fuel
filter and fuel pressure regulator, the fuel is filtered and
its pressure is regulated before being sent to the feed
pipe.
The excess fuel at fuel pressure regulation process is
returned back into the fuel tank.
Also, fuel vapor generated in fuel tank is led through the
fuel vapor line into the EVAP canister.
For system diagram, refer to “Fuel Delivery System
Diagram”.

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-4
Repair Instructions
Fuel System ComponentsS7RS0B1706001
5
14
4
24
8
3
13
23
1
25
21
112
22 10
6
16
26
18
17
19
10
12
9
(b)
(a)
15
(c)
20 27
7
I6RS0C170003-01
1. Fuel tank 12. Fuel tank bolt 23. Main fuel level sensor
2. Fuel pump assembly 13. Fuel pump assembly bolt 24. To fuel vapor line
3. Breather hose 14. Fuel filler neck 25. Fuel feed hose
4. Fuel tank filler hose 15. Fuel delivery pipe 26. Grommet
5. Fuel filler cap 16. Fuel delivery pipe bolt 27. To fuel tank
6. Fuel feed line 17. Fuel injector : Do not reuse.
7. Fuel vapor line 18. Injector cushion : 45 N⋅m (4.5 kgf-m, 33.0 lb-ft)
8. Fuel tank inlet valve 19. Fuel delivery pipe insulator : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
9. Fuel tank protector 20. O-ring : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
10. Fuel tank belt 21. To canister
11. Fuel pump gasket 22. Fuel tank cover

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-16
Removal1) Remove fuel pump assembly from fuel tank referring to “Fuel Pump Assembly Removal and Installation”.
2) Disconnect main fuel level sensor connector (3).
3) With pressing snap-fit part (2), remove main fuel level sensor (1) by sliding it in the arrow direction as
shown in figure.
Installation
Reverse removal procedure for installation.Fuel Pump InspectionS7RS0B1706019
• Check fuel pump assembly for damage.
• Check fuel suction filter for evidence of dirt and contamination. If present, replace or clean and check
for presence of dirt in fuel tank.
• For electrical circuit, refer to “Fuel Pressure Check in Section 1A”.
• For inspection of main fuel level sensor (1), refer to “Fuel Level Sensor Inspection in Section 9C”.
Specifications
Tightening Torque SpecificationsS7RS0B1707001
NOTE
The specified tightening torque is also described in the following.
“Fuel System Components”
“Fuel Hose Disconnecting and Reconnecting”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
1
21
3
I5RS0D170006-031
I5RS0D170008-01
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
Fuel delivery pipe bolt 25 2.5 18.0 )
Ground wire bolt 11 1.1 8.0 )
Fuel tank bolt 45 4.5 33.0 )
Fuel filler hose clamp 2 0.2 1.5 )
Fuel pump assembly bolt 11 1.1 8.0 )

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-3
Component Location
Ignition System Components LocationS7RS0B1803001
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

16*
1
2
14
7
5 12 11
410
6
89
3 13*
15
17
I6RS0C180001-01
1. ECM 7. ECT sensor13. Data link connector
2. Ignition coil assembly for No.1 and No.4 spark plugs 8. MAF and IAT sensor 14. Battery fuse box
3. Ignition coil assembly for No.2 and No.3 spark plugs 9. Electric throttle body 15. Relay box
4. CMP sensor 10. Wheel speed sensor (VSS) 16. Junction block assembly
5. CKP sensor 11. High-tension cords
6. MAP sensor 12. Knock sensor

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 )