oil SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

GENERAL INFORMATION 0A-3
PRECAUTIONS
PRECAUTION FOR VEHICLES EQUIPPED
WITH A SUPPLEMENTAL RESTRAINT
(AIR BAG) SYSTEM
DIAGNOSIS
 When troubleshooting air bag system, be sure to follow
“DIAGNOSIS” in SECTION 10B. Bypassing these proce-
dures may result in extended diagnostic time, incorrect diag-
nosis, and incorrect parts replacement.
 Never use electrical test equipment other than that specified
in this manual. WARNING:
 The configuration of air bag system parts are as shown
in the figure. When it is necessary to service (remove,
reinstall and inspect) these parts, be sure to follow
procedures described in SECTION 10B. Failure to fol-
low proper procedures could result in possible air bag
system activation, personal injury, damage to parts or
air bag system being unable to activate when neces-
sary.
 If the air bag system and another vehicle system both
need repair, SUZUKI recommends that the air bag sys-
tem be repaired first, to help avoid unintended air bag
system activation.
 Do not modify the steering wheel, dashboard, or any
other air bag system components. Modifications can
adversely affect air bag system performance and lead
to injury.
 If the vehicle will be exposed to temperatures over
93°C (200°F) (for example, during a paint baking pro-
cess), remove the air bag system components before-
hand to avoid component damage or unintended air
bag system activation.
1. Air bag wire harness 4. Seat belt pretensioner
2. Passenger air bag (inflator) module 5. Contact coil
3. SDM 6. Driver air bag (inflator) module
3
4
4
6
1
52
WARNING:
Never attempt to measure the resistance of the air bag
(inflator) modules (driver and passenger) and seat belt
pretensioners (driver and passenger). It is very danger-
ous as the electric current from the tester may deploy the
air bag or activate the pretensioner.

GENERAL INFORMATION 0A-5
 Even when the accident was light enough not to cause air bags to activate, be sure to inspect sys-
tem parts and other related parts according to instructions under “REPAIR AND INSPECTION
REQUIRED AFTER AN ACCIDENT” in SECTION 10B.
 When servicing parts other than air bag system, if shocks may be applied to air bag system compo-
nent parts, remove those parts beforehand.
 When handling the air bag (inflator) modules (driver and passenger), seat belt pretensioners (driver
and passenger) or SDM, be careful not to drop it or apply an impact to it. If an excessive impact was
applied, never attempt disassembly or repair but replace it with a new one.
 When grease, cleaning agent, oil, water, etc. has got onto air bag (inflator) modules (driver and pas-
senger) or seat belt pretensioners (drive and passenger), wipe off immediately with a dry cloth. WARNING:
SDM
 For handling and storage of a SDM, select a place where the ambient temperature below 65°C
(150°F), without high humidity and away from electric noise.
 During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM).
Never strike or jar the SDM.
 Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and
mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the
front of the vehicle to ensure proper operation of the air bag system.
The SDM could be activated when powered while not rigidly attached to the vehicle which could
cause deployment and result in personal injury.
WARNING:
Driver and Passenger Seat Belt Pretensioners
(If equipped)
 For handling and storage of a live seat belt preten-
sioner, select a place where the ambient temperature
below 65°C (150°F), without high humidity and away
from electric noise.
 Never carry seat belt pretensioner by wire or connec-
tor of pretensioner. When placing a live seat belt pre-
tensioner on the workbench or some place like that, be
sure not to lay it with its exhaust hole (1) provided side
facing down. It is also prohibited to put something on
its face with an exhaust hole or to put a seat belt pre-
tensioner on top of another. Otherwise, personal injury
may result.
 Never dispose of live (inactivated) seat belt pretension-
ers (drive and passenger). If disposal is necessary, be
sure to activate them according to activation proce-
dures described in SECTION 10B before disposal.
 The seat belt pretensioner immediately after activation
is very hot. Wait for at least half an hour to cool it off
before proceeding the work.
 With many service procedures, gloves and safety
glasses should be worn to prevent any possible irrita-
tion of the skin or eyes.

0A-6 GENERAL INFORMATION
 Air bag wire harness can be identified easily as it is covered with a yellow protection tube. Be very
careful when handling it.
 When an open in air bag wire harness, damaged wire harness, connector or terminal is found,
replace wire harness, connectors and terminals as an assembly.
 Do not apply power to the air bag system unless all components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble code.
 Never use air bag system component parts from another vehicle.
 When using electric welding, be sure to temporarily disable air bag system referring to “DISABLING
AIR BAG SYSTEM” in Section 10B.
 Never expose air bag system component parts directly to hot air (drying or baking the vehicle after
painting) or flames.
 WARNING/CAUTION labels are attached on each part of air bag system components. Be sure to fol-
low the instructions.
 After vehicle is completely repaired, perform “AIR BAG DIAGNOSTIC SYSTEM CHECK” in SECTION
10B.
GENERAL PRECAUTIONS
The WARNING and CAUTION below describe some general precautions that you should observe when servic-
ing a vehicle. These general precautions apply to many of the service procedures described in this manual, and
they will not necessarily be repeated with each procedure to which they apply.
WARNING:
 Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING
POINTS” in this section.
 When it is necessary to do service work with the engine running, make sure that the parking brake
is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for auto-
matic transmission vehicles), Keep hands, hair, clothing, tools, etc. away from the fan and belts
when the engine is running.
 When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.
 Do not perform service work in areas where combustible materials can come in contact with a hot
exhaust system. When working with toxic or flammable materials (such as gasoline and refriger-
ant), make sure that the area you work in is well-ventilated.
 To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail
pipe, muffler, etc.
 New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or
used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory ani-
mals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil,
wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing
engine oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any
clothing or rags if wet with oil, recycle or properly dispose of used oil and filters.
 Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpect-
edly during driving, obstructing your view and resulting in an accident.

GENERAL INFORMATION 0A-7
 Before starting any service work, cover fenders, seats
and any other parts that are likely to get scratched or
stained during servicing. Also, be aware that what you
wear (e.g, buttons) may cause damage to the vehicle’s
finish.
 When performing service to electrical parts that does
not require use of battery power, disconnect the nega-
tive cable of the battery.
 When removing the battery, be sure to disconnect the
negative cable first and then the positive cable. When
reconnecting the battery, connect the positive cable first
and then the negative cable, and replace the terminal
cover.
 When removing parts that are to be reused, be sure to
keep them arranged in an orderly manner so that they
may be reinstalled in the proper order and position.
 Whenever you use oil seals, gaskets, packing, O-rings,
locking washers, split pins, self-locking nuts, and cer-
tain other parts as specified, be sure to use new ones.
Also, before installing new gaskets, packing, etc., be
sure to remove any residual material from the mating
surfaces.

0A-8 GENERAL INFORMATION
 Make sure that all parts used in reassembly are perfectly
clean.
When use of a certain type of lubricant, bond or sealant
is specified, be sure to use the specified type.
“A” : Sealant 99000-31150
 Be sure to use special tools when instructed.
Special Tool
(A) : 09917-98221
(B) : 09916-58210
 When disconnecting vacuum hoses, attach a tag
describing the correct installation positions so that the
hoses can be reinstalled correctly.
 After servicing fuel, oil, coolant, vacuum, exhaust or
brake systems, check all lines related to the system for
leaks.
 For vehicles equipped with fuel injection systems, never
disconnect the fuel line between the fuel pump and
injector without first releasing the fuel pressure, or fuel
can be sprayed out under pressure.
 When performing a work that produces a heat exceeding
80°C (176°F) in the vicinity of the electrical parts, remove
the heat sensitive electrical part(s) beforehand.

GENERAL INFORMATION 0A-19
WARNING, CAUTION AND INFORMATION LABELS
The figure below shows main labels among others that are attached to vehicle component parts.
When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels.
If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary.
1. Air bag label on back side of engine hood (if equipped)
2. Air bag label on sun visor (if equipped)
3. Radiator cap label
4. Engine cooling fan label
1. Air bag label on driver air bag (inflator) module 4. Air bag label on SDM
2. Air bag label on combination switch and contact coil assembly 5. Pretensioner label on seat belt retractor
3. Air bag label on passenger air bag (inflator) module [A] : These labels are attached on vehicle equipped with air bag system only.
5

0A-24 GENERAL INFORMATION
SYMBOLS
WIRE COLOR SYMBOLS
There are two kinds of colored wire used in this vehicle. One is
single-colored wire and the other is dual-colored (striped) wire.
The single-colored wire uses only one color symbol (i.e. “GRN”).
The dual-colored wire uses two color symbols (i.e. “GRN/YEL”).
The first symbol represents the base color of the wire (“GRN” in
the figure) and the second symbol represents the color of the
stripe (“YEL” in the figure). SYMBOL DEFINITION SYMBOL DEFINITION
Tightening torque Apply SUZUKI BOND NO. 1216
99000-31160
Apply oil (engine, transmission, trans-
fer, differential)Apply SILICONE SEALANT
99000-31120
Apply fluid (brake, power steering or
automatic transmission fluid)Apply SEALING COMPOUND 366E
99000-31090
Apply SUZUKI SUPER GREASE A
99000-25010
Apply SUZUKI SUPER GREASE C
99000-25030Apply THREAD LOCK 1322
99000-32110
Apply SUZUKI SUPER GREASE E
99000-25050Apply THREAD LOCK 1333B
99000-32020
Apply SUZUKI SUPER GREASE H
99000-25120Apply THREAD LOCK 1342
99000-32050
Apply SUZUKI SUPER GREASE I
99000-25210
Apply SUZUKI BOND NO. 1215
99000-31110Do not reuse
Apply SUZUKI BOND NO. 1207C
99000-31150Note on reassembly
Symbol Wire Color Symbol Wire Color
B BLK Black O, Or ORN Orange
Bl BLU Blue R RED Red
Br BRN Brown W WHT White
GGRN Green Y YEL Yellow
Gr GRY Gray P PNK Pink
Lbl LT BLU Light blue V PPL Violet
Lg LT GRN Light green

MAINTENANCE AND LUBRICATION 0B-1
0A 6F1
0B
0B
6G
1A 6H
1B 6K
37A
3A 7A1
3B1 7B1
3C1 7C1
3D 7D
3E 7E
3F 7F
4A2 8A
4B 8B
8C
58D
5A 8E
5B
5C 9
5E
5E1 10
10A
610B
6-1
6A1
6A2
6A4
6B
6C
6E1
6E2
SECTION 0B
MAINTENANCE AND LUBRICATION
CONTENTS
MAINTENANCE SCHEDULE .......................... 0B-2
MAINTENANCE SCHEDULE UNDER
NORMAL DRIVING CONDITIONS .............. 0B-2
MAINTENANCE RECOMMENDED UNDER
SEVERE DRIVING CONDITIONS ............... 0B-4
MAINTENANCE SERVICE .............................. 0B-5
ENGINE ....................................................... 0B-5
DRIVE BELT ............................................ 0B-5
VALVE LASH (CLEARANCE) .................. 0B-6
ENGINE OIL AND OIL FILTER ................ 0B-6
ENGINE COOLANT ................................. 0B-8
EXHAUST SYSTEM............................... 0B-10
IGNITION SYSTEM ................................... 0B-10
SPARK PLUGS ...................................... 0B-10
FUEL SYSTEM .......................................... 0B-10
AIR CLEANER FILTER .......................... 0B-10
FUEL LINES AND CONNECTIONS....... 0B-11
FUEL FILTER ......................................... 0B-11
FUEL TANK............................................ 0B-12
EMISSION CONTROL SYSTEM ............... 0B-12
PCV VALVE ........................................... 0B-12
FUEL EVAPORATIVE EMISSION
CONTROL SYSTEM .............................. 0B-12BRAKE ....................................................... 0B-12
BRAKE DISCS AND PADS (FRONT) .... 0B-12
BRAKE DRUMS AND SHOES
(REAR) ................................................... 0B-13
BRAKE HOSES AND PIPES ................. 0B-13
BRAKE FLUID........................................ 0B-13
BRAKE LEVER AND CABLE ................. 0B-13
CHASSIS AND BODY ............................... 0B-14
CLUTCH................................................. 0B-14
TIRES / WHEELS .................................. 0B-14
SUSPENSION SYSTEM ........................ 0B-15
STEERING SYSTEM ............................. 0B-15
DRIVE SHAFT (AXLE) BOOTS /
PROPELLER SHAFTS (4WD) ............... 0B-16
MANUAL TRANSMISSION OIL ............. 0B-17
AUTOMATIC TRANSMISSION FLUID .. 0B-17
TRANSFER OIL (4WD) AND REAR
DIFFERENTIAL OIL (4WD) ................... 0B-18
ALL LATCHES, HINGES AND
LOCKS ................................................... 0B-19
FINAL INSPECTION ..................................... 0B-19
RECOMMENDED FLUIDS AND
LUBRICANTS................................................ 0B-21

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
 Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
 Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

0B-2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE UNDER NORMAL DRIVING CONDITIONS
NOTE:
 This interval should be judged by odometer reading or months, whichever comes first.
 This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km
(54,000 miles), carry out the same services at the same intervals respectively.
IntervalKm (x 1,000) 15 30 45 60 75 90
Miles (x 1,000) 9 1827364554
Months 12 24 36 48 60 72
ENGINE
Drive belt––I––R
Valve lash (clearance) –I–I–I
Engine oil and oil filter R R R R R R
Engine coolant––R––R
Exhaust system–I–I–I
IGNITION SYSTEM
✱Spark plugs When
unleaded
fuel is usedVehicle without
HO2SNickel plug–R–R–R
Iridium plug–––R––
Vehicle with
HO2SNickel plug––R––R
Iridium plug Replace every 105,000 km (63,000 miles) or
84 months
When leaded fuel is used, refer to “MAINTENANCE RECOMMENDED UNDER SEVERE
DRIVING CONDTION” in this section.
FUEL SYSTEM
Air cleaner filter Paved-road I I R I I R
Dusty conditions Refer to “MAINTENANCE RECOM-
MENDED UNDER SEVERE DRIVING CON-
DITIONS” in this section.
Fuel lines and connections–I–I–I
Fuel filter Replace every 105,000 km (63,000 miles)
Fuel tank––I––I
EMISSION CONTROL SYSTEM
✱PCV valve Vehicle without HO2S––I––I
Vehicle with HO2S–––––I
✱Fuel evaporative emission control system–––––I
NOTE:
 “R” : Replace or change
 “I” : Inspect and correct, replace or lubricate if necessary
 For Sweden, items with
✱
✱✱ ✱ (asterisk) should be performed by odometer reading only.
 For spark plugs, replace every 50,000 km if the local law requires.
 Nickel spark plug : BKR6E-11 (NGK) or K20PR-U11 (DENSO)
 Iridium spark plug : IFR5E11 (NGK)

MAINTENANCE AND LUBRICATION 0B-3
IntervalKm (x 1,000) 153045607590
Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
BRAKE
Brake discs and pads (thickness, wear, damage) I I I I I I
Brake drums and shoes (wear, damage)–I–I–I
Brake hoses and pipes (leakage, damage, clamp)–I–I–I
Brake fluid–R–R–R
Brake lever and cable (damage, stroke, operation) Inspect at first 15,000 km (9,000 miles only)
CHASSIS AND BODY
Clutch (pedal height and travel)–I–I–I
Tires (wear, damage, rotation) /wheels (damage) I I I I I I
Suspension system (tightness, damage, rattle, breakage)–I–I–I
Steering system (tightness, damage, breakage, rattle)–I–I–I
Drive shaft (axle) boots/Propeller shafts (4WD)––I––I
Manual transmission oil (leakage, level) (I : 1st 15,000 km only) I–R––R
Automatic transmission
fluidFluid level–I–I–I
Fluid change Replace every 165,000 km (99,000 miles)
Transfer oil (4WD) (leakage, level) I–I–I–
Rear differential oil (4WD) (leakage, level) (R : 1st 15,000 km
only)R or I–I–I–
All latches, hinges and locks–I–I–I
NOTE:
 “R” : Replace or change
 “I” : Inspect and correct or replace if necessary