boot SUZUKI SWIFT 2005 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Table of Contents 0- i
0
Section 0
CONTENTS
General Information
General Information ................................ 0A-1
General Description ............................................. 0A-1
Abbreviations ...................................................... 0A-1
Symbols .............................................................. 0A-2
Wire Color Symbols ............................................ 0A-2
Fasteners Information ......................................... 0A-3
Vehicle Lifting Points ........................................... 0A-5
Engine Supporting Points ................................... 0A-7
Vehicle Identification Number ............................. 0A-7
Engine Identification Number .............................. 0A-7
Transmission Identification Number .................... 0A-7
Component Locatio n ........................................... 0A-8
Warning, Caution and Information Labels Location ............................................................ 0A-8
Maintenance and Lubricat ion ................. 0B-1
Precautions........................................................... 0B-1
Precautions for Maintenance and Lubrication ..... 0B-1
Scheduled Maintenance ...................................... 0B-1 Maintenance Schedule under Normal Driving Conditions ......................................................... 0B-1
Maintenance Recommended under Severe Driving Conditions ............................................. 0B-2
Repair Instructions .............................................. 0B-3 Accessory Drive Belt Inspection.......................... 0B-3
Accessory Drive Belt Repl acement ..................... 0B-4
Valve Lash (Clearance) Inspection ..................... 0B-4
Engine Oil and Filter Change .............................. 0B-4
Engine Coolant Change ...... ................................ 0B-5
Exhaust System Inspection ................................. 0B-6
Spark Plug Replacement .................................... 0B-6
Air Cleaner Filter Inspection ................................ 0B-6
Air Cleaner Filter Replac ement ........................... 0B-6 Fuel Lines and Connections Inspection .............. 0B-6
Fuel Filter Replacement ...................................... 0B-7
Fuel Tank Inspection ........................................... 0B-7
PCV Valve Inspection ......................................... 0B-7
Fuel Evaporative Emission Control System
Inspection .......................................................... 0B-7
Brake Discs and Pads Inspection ....................... 0B-7
Brake Hoses and Pipes Inspection ..................... 0B-7
Brake Fluid Inspection......................................... 0B-8
Brake Fluid Replacement .................................... 0B-8
Brake Lever and Cable Inspection ...................... 0B-8
Clutch Fluid Inspection ........................................ 0B-8
Tires Inspection ................................................... 0B-9
Wheel Discs Inspection ....................................... 0B-9
Wheel Bearing Inspection ................................... 0B-9
Suspension System Inspection ........................... 0B-9
Steering System Inspection .............................. 0B-10
Drive Shaft (Axle) Boots Inspection .................. 0B-10
Manual Transaxle Oil Inspection ....................... 0B-10
Manual Transaxle Oil Replacement .................. 0B-10
Automatic Transaxle Fluid Level Inspection...... 0B-11
Automatic Transaxle Fluid Replacement .......... 0B-11
Automatic Transaxle Fluid Cooler Hose Inspection ........................................................ 0B-11
All Latches, Hinges and Locks Inspection......... 0B-11
HVAC Air Filter (If Equipped) Inspection ........... 0B-12
HVAC Air Filter (If Equipped) Replacement ...... 0B-12
Final Inspection for Maint enance Service ......... 0B-12
Specifications .................... .................................0B-13
Tightening Torque Specifications ...................... 0B-13
Special Tools and Equipmen t ...........................0B-13
Recommended Fluids and Lubricants............... 0B-13
Special Tool ...................................................... 0B-14

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-1
General Information
Maintenance and Lubrication
Precautions
Precautions for Maintenance and LubricationS7RS0B0200001
Air Bag Warning
Refer to “Air Bag Warning in Section 00”.
Scheduled Maintenance
Maintenance Schedule under Normal Driving ConditionsS7RS0B0205001
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.

Interval Km (x 1,000) 15 30 45 60 75 90
Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
Engine
Accessory drive belt (I: ), R: ))——I——R
Valve lash (clearance) (I: )) —I—I—I
Engine oil and oil filter (R: )) RRRRRR
Engine coolant (R: ))— —R— — R
Exhaust system (I: )) —I—I—I
Ignition system
Spark plugs (R: ) )When unleaded fuel is used Iridium Plug
Replace every 60,000 km (36,000
miles) or 48 months
When leaded fuel is used, refer to “Maintenance Recommended under Severe Driving
Conditions”.
Fuel system
Air cleaner filter (R: ), I: )) Paved-road
I I R I I R
Dusty conditions Refer to “Maintenance Recommended
under Severe Driv
ing Conditions”.
Fuel lines and connections (I: )) —I—I—I
Fuel filter (R: )) (See NOTE below) Replace every 105,000 km (63,000
miles)
Fuel tank (I: ))— —I— — I
Emission control system
PCV valve (I: )) ————— I
Fuel evaporative emission control system (I: )) ————— I
Brake
Brake discs and pads (thickness, wear, damage) (I: )) IIIIII
Brake hoses and pipes (leakage, damage, clamp) (I: )) —I—I—I
Brake fluid (R: )) —R—R—R
Brake lever and cable (damage, stroke, operation) (I: )) Inspect at first 15,000 km (9,000 miles
only)
Chassis and body
Clutch (fluid leakage, level) (I: )) —I—I—I
Tires (wear, damage, rotation) / wheels (damage) (I: ) / ) ) IIIIII
Suspension system (tightness, damage, rattle, breakage) (I: )) —I—I—I
Steering system (tightness, damage, breakage, rattle) (I: )) —I—I—I
Drive shaft (axle) boots (I: ))— —I— — I
Manual transaxle oil (leakage, level) (I: ) 1st 15,000 km only) (R: ))I—R——R

Downloaded from www.Manualslib.com manuals search engine 0B-2 Maintenance and Lubrication:
NOTE
• “R”: Replace or change
• “I”: Inspect and correct, replace or lubricate if necessary
• For spark plugs, replace every 50,000 km if the local law requires.
• Periodic replacement of fuel filter is not necessary if it is not instructed in “Periodic Maintenance Schedule” section of the Owner’s manual. The scheduled maintenance varies depending on the
vehicle specification.

Maintenance Recommended under Severe Driving ConditionsS7RS0B0205002
If the vehicle is usually used under the conditions corres ponding to any severe condition code given below, IT IS
RECOMMENDED that applicable maintenance operation be per formed at the particular interval as shown in the
following table.
Severe condition code:
A: Repeated short trips
B: Driving on rough and/or muddy roads
C: Driving on dusty roads
D: Driving in extremely cold weather and/or salted roads
E: Repeated short trips in extremely cold weather
F: Leaded fuel use
G: – – – – –
H: Towing a trailer (if admitted) Automatic transaxle fluid
Fluid level (I:
)) —I—I—I
Fluid change (R: )) Replace every 165,000 km (99,000
miles)
Fluid hose (I: ))———I——
All latches, hinges and locks (I: )) —I—I—I
HVAC air filter (if equipped) (I: ) ) (R: ))— IR — IR
Interval
Km (x 1,000)
15 30 45 60 75 90
Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
Severe
condition code MaintenanceMaintenance
operation Maintenance interval
– B C D – – – – Accessory drive belt )
I Every 15,000 km
(9,000 miles) or 12 months
) R Every 45,000 km
(27,000 miles) or 36 months
A – C D E F – H Engine oil and oil filter ) R Every 7,500 km
(4,500 miles) or 6 months
– – C – – – – – Air cleaner filter *1 )
I Every 2,500 km
(1,500 miles)
) R Every 30,000 km
(18,000 miles) or 24 months
A B C – E F – H Spark plugs Iridium plug ) R Every 30,000 km (18,000 miles) or
24 months
– B C D – – – H Wheel bearings ) I Every 15,000 km
(9,000 miles) or 12 months
– B – D E – – H Drive shaft (axle) boots ) I Every 15,000 km
(9,000 miles) or 12 months
– B – – E – – H Manual transaxle oil ) R First time only:
15,000 km (9,000 miles) or 12
months
Second time and after:
Every 30,000 km (18,000 miles) or
24 months reckoning from 0 km (0
mile) or 0 month

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-9
Tires InspectionS7RS0B0206020
1) Check tires for uneven or excessive wear, or damage. If defective, replace.
Refer to “Irregular and/or Premature Wear
Description in Section 2D” and “Wear Indicators
Description in Section 2D” for details.
2) Check inflating pressure of each tire and adjust pressure to specification as necessary.
NOTE
• Tire inflation pressure should be checked when tires are cool.
• Specified tire inflation pressure should be found on tire placard or in owner’s manual
which came with the vehicle.

3) Rotate tires. For details, refer to “Tire Rotation in Section 2D”.
Wheel Discs InspectionS7RS0B0206021
Inspect each wheel disc for de nts, distortion and cracks.
A disc in badly damaged condition must be replaced.
Wheel Bearing InspectionS7RS0B0206022
1) Check front wheel bearing for wear, damage, abnormal noise or rattles. For details, refer to “Front
Wheel Hub, Disc, Nut and Bearing Check in Section
2B”.
2) Check rear wheel bearing for wear, damage, abnormal noise or rattles. For details, refer to“Rear
Wheel Disc, bolt and Bearing Inspection in Section
2C”.
Suspension System InspectionS7RS0B0206023
• Inspect front struts and rear shock absorbers for evidence of oil leakage, dents or any other damage on
sleeves; and inspect anchor ends for deterioration.
Replace defective parts, if any.
• Check front and rear suspension systems for damaged, loose or missing parts; also for parts
showing signs of wear or lack of lubrication.
Repair or replace defective parts, if any.
• Check front suspension arm ball joint stud dust seals for leakage, detachment, tear or any other damage.
Replace defective boot, if any.
1. Wear indicator
I2RH01020022-01
I2RH01020023-01
I4RS0A020011-01
I4RS0A020012-01

Downloaded from www.Manualslib.com manuals search engine 0B-10 Maintenance and Lubrication:
Steering System InspectionS7RS0B0206024
1) Check steering wheel for play and rattle, holding vehicle straight on ground.
Steering wheel play
“a”: 0 – 30 mm (0 – 1.1 in.)
2) Check bolts and nuts for tightness and retighten them as necessary. Repair or replace defective
parts, if any.
3) Check steering linkage for looseness and damage. Repair or replace defective parts, if any.
4) Check boots (1) and (2) of steering linkage and steering gear case for damage (leak, detachment,
tear, etc.). If damage is fo und, replace defective boot
with new one.
If any dent is found on steering gear case boots,
correct it to original shape by turning steering wheel
to the right or left as far as it stops and holding it for a
few seconds.
5) Check universal joints (3) of steering shaft for rattle and damage. If rattle or damage is found, replace
defective part with a new one.
6) Check that steering wheel can be turned fully to the
right and left. Repair or replace defective parts, if
any.
7) If equipped with power steering system, check also, in addition to check items, that steering wheel can be
turned fully to the right and left more lightly when
engine is running at idle speed than when it is
stopped. Repair, if found faulty.
8) Check wheel alignment referring to “Front Wheel Alignment Inspection and Adjustment in Section 2B”.
Drive Shaft (Axle) Boots InspectionS7RS0B0206025
Check drive shaft boots (wheel side and differential side)
for leaks, detachment, tear or other damage.
Replace defective parts as necessary.
Manual Transaxle Oil InspectionS7RS0B0206026
1) Inspect transaxle case for evidence of oil leakage. Repair leaky point if any.
2) Make sure that vehicle is placed level for oil level
check.
3) Remove oil filler/leve l plug (1) of transaxle.
4) Check oil level. Oil level can be checked roughly by means of filler/
level plug hole. That is, if oil flows out of level plug
hole or if oil level is found up to hole when level plug
is removed, oil is properly filled.
If oil is found insufficient, po ur specified oil up to level
hole. For specified oil, refe r to “Manual Transaxle Oil
Change in Section 5B”.
5) Apply sealant to filler/leve l plug and tighten it to
specified torque.
Manual Transaxle Oil ReplacementS7RS0B0206027
Change transaxle oil with new specified oil referring to
“Manual Transaxle Oil Change in Section 5B”.
I2RH01020026-01
2
3
2
1
1
I4RS0B020007-01
I2RH01310001-01
I6RS0C020001-01

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-8
Front Wheel Hub and Steering Knuckle ComponentsS7RS0B2206006
Front Wheel Hub, Steering Knuckle and Wheel
Bearing Removal and Installation
S7RS0B2206007
CAUTION!
When removing and installing steering
knuckle assembly, be careful not to damage
dust boots of suspension control arm joint
by drive shaft dust cover and brake dust
cover.

Removal1) Hoist vehicle and remove wheel.
2) Uncaulk drive shaft nut.
3) Depress foot brake pedal and hold it. Remove drive shaft nut.
4) Remove brake disc referring to “Front Brake Disc Removal and Installa tion in Section 4B”.
5) Pull out wheel hub (1) with special tools.
Special tool
(A): 09943-17912
(B): 09942-15511
CAUTION!
When wheel hub is removed, replace wheel
bearing with new one.

6) Remove cotter pin and tie-rod end nut, and then disconnect tie-rod end from steering knuckle
referring to “Tie-Rod End Removal and Installation in
Section 6C”.
7) Remove wheel speed sensor (1) from steering knuckle.
I7RS0B220005-03
1. Front wheel hub 3. Wheel bearing
: Face grooved rubber seal side to wheel hub. 5. Drive shaft nut
: Calk, after tightening. : 200 N
⋅m (20.0 kgf-m, 145 lb-ft)
2. Circlip 4. Steering knuckle 6. Hub bolt: Do not reuse.
I3RM0A220023-01
1
I4RS0B220005-01

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 3A-4 Drive Shaft / Axle:
Front Drive Shaft Assembly On-Vehicle
Inspection
S7RS0B3106002
• Check boots for breakage or deterioration.
• Check wheel side joint for rattle or smooth rotation.
• Check differential side (or center shaft side) joint for smooth rotation.
If any abnormality is found, replace.
Front Drive Shaft Assembly Removal and
Installation
S7RS0B3106003
Removal
1) Hoist vehicle and remove wheel.
2) Undo caulking (1) and remove drive shaft nut (2). 3) Drain transaxle oil.
4) Disconnect tie-rod end (1) from steering knuckle (2)
using puller (3).
5) Remove stabilizer join t referring to “Front
Suspension Frame, Stabiliz er Bar and/or Bushings
Removal and Installati on in Section 2B”.
6) Remove brake hose mounting bolt (1) and break hose (2) from bracket and then detach wheel speed
sensor harness (3) from strut bracket.
7) Remove suspension contro l arm ball joint bolt (4).
[A]: Right side drive shaft assembly (M/T model) 8. Wheel side joint (Constant velocity ball joint)
: Apply black grease included in spare part to joint.
[B]: Left side drive shaft assembly (M/T model) 9. Center shaft side joint (Constant velocity tripod joint)
: Apply dark gray grease included in spare part to joint.
[C]: Right side drive shaft assembly (A/T model) 10. Oil seal
: Apply grease 99000-25011 to oil seal lip.
[D]: Left side drive shaft assembly (A/T model) 11. Center bearing support circlip
[E]: Center shaft assembly (A/T model) 12. Center bearing support
[F]: Center shaft assembly (M/T model) 13. Center bearing
1. Circlip 14. Center shaft
2. Differential side joint (Constant velocity tripod joint) : Apply dark gray grease included in spare part to joint. 15. Cage
3. Snap ring 16. Tripod joint spider
: Never disassemble.
4. Boot band (Large) 17. O-ring
: Apply grease 99000-25011 to all round of O-ring.
5. Boot (Differential or center shaft side) 18. Differential side joint (Constant velocity tripod joint)
: Apply dark gray grease included in spare part to joint.
6. Boot band (Small) 19. Center shaft side joint (Constant velocity tripod joint)
: Apply dark gray grease included is spare part to joint.
7. Boot (Wheel side) : Do not reuse.
I6RS0C310004-01
F: Vehicle front
I3RM0A310003-01
I6RS0C310005-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: 3A-5
8) Disconnect front suspension control arm ball joint
stud from steering knuckle.
9) Pull out drive shaft joint as follows. • For differential sideUsing tire lever (1), pull out drive shaft joint (2) so
as to release snap ring fitting of joint spline at
differential side.
• For center shaft side Using plastic hammer (3), drive out drive shaft
joint (2) so as to release snap ring fitting of joint
spline at center shaft.
10) Remove drive shaft assembly. 11) Remove center bearing support bolts (3) and remove center bearing support (2) with center shaft (1) from
differential side gear. Installation
CAUTION!
• Be careful not to damage oil seals and
boots when installing drive shaft.
• Do not hit joint boot with hammer. Inserting joint only by hands is allowed.
• Make sure that differential side joint is inserted fully and its snap ring is seated as
it was.

Install drive shaft assemb ly by reversing removal
procedure and noting the following points.
• Tighten each bolt and nut to the specified torque referring to “Front Drive Shaft Assembly Components
Location”.
• Tighten brake hose mounting bolt to specified torque.
Tightening torque
Brake hose mounting bolt: 25 N·m (2.5 kgf-m,
18.0 lb-ft)
• Fill transaxle with oil as sp ecified referring to “A/T
Fluid Change in Section 5A” or “Manual Transaxle Oil
Change in Section 5B”.
• Check toe setting referring to “Front Wheel Alignment Inspection and Adjustment in Section 2B” and adjust
as required.
[A]: Differential side
[B]: Center shaft side
I6RS0C310006-01
3
2
1I2RH01310007-01