bolt torque SUZUKI SWIFT 2006 2.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 1K-5 Exhaust System:
Specifications
Tightening Torque SpecificationsS7RS0B1B07001
NOTE
The specified tightening torque is also described in the following.
“Exhaust System Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
Exhaust manifold bolt 505.0 36.5 )
Exhaust manifold nut 505.0 36.5 )
Exhaust No.1 pipe bolt 505.0 36.5 )
Exhaust manifold stiffener bolt 505.0 36.5 )
Exhaust No.2 pipe bolt 434.3 31.0 )

Downloaded from www.Manualslib.com manuals search engine Table of Contents 2- i
2
Section 2
CONTENTS
Suspension
Precautions ................................................. 2-1
Precautions............................................................. 2-1
Precautions on Suspension .................................. 2-1
Suspension General Dia gnosis.............. 2A-1
Diagnostic Information and Procedures ............ 2A-1
Suspension, Wheels and Tires Symptom Diagnosis .......................................................... 2A-1
Front Suspension ........... ......................... 2B-1
General Description ............................................. 2B-1
Front Suspension Construction ........................... 2B-1
Front Wheel Alignment Cons truction .................. 2B-2
Repair Instructions .............................................. 2B-2 Front Wheel Alignment Inspection and Adjustment ........................................................ 2B-2
Front Strut Assembly Comp onents ..................... 2B-4
Front Strut Assembly Removal and Installation ......................................................... 2B-4
Front Strut Assembly Disassembly and Assembly .......................................................... 2B-6
Front Strut Assembly Chec k ............................... 2B-7
Front Wheel Hub and Steering Knuckle Components...................................................... 2B-8
Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation .......... 2B-8
Front Wheel Hub, Disc, Nut and Bearing Check .............................................................. 2B-12
Suspension Control Arm / Bushing Removal and Installation ................................................ 2B-12
Suspension Control Arm / Bushing Disassembly and Assembly ............................ 2B-13
Suspension Control Arm / Steering Knuckle Check .............................................................. 2B-14
Suspension Control Arm Bushing Check .......... 2B-14
Suspension Control Arm Joint Check ............... 2B-14
Front Suspension Fram e, Stabilizer Bar and/
or Bushings Components................................ 2B-15
Front Suspension Fram e, Stabilizer Bar and/
or Bushings Removal and Installation ............. 2B-15
Front Suspension Frame Ch eck ....................... 2B-19
Front Stabilizer Bar, Bushing and/or Joint Check .............................................................. 2B-19
Front Suspension Fastener s Check .................. 2B-19
Specifications ..................................................... 2B-20 Tightening Torque Specifications ...................... 2B-20
Special Tools and Equipmen t ...........................2B-21
Special Tool ...................................................... 2B-21
Rear Suspension ............ ......................... 2C-1
General Description .............................................2C-1
Rear Suspension Construction ...........................2C-1
Repair Instructions ........... ...................................2C-2
Rear Wheel Alignment Inspection .......................2C-2
Rear Shock Absorber Removal and Installation .........................................................2C-2
Rear Shock Absorber Ins pection ........................2C-3
Rear Shock Absorber Bush Removal and Installation .........................................................2C-4
Rear Shock Absorber Bush Inspection ...............2C-4
Rear Coil Spring Removal and Installation .........2C-4
Spring Upper Seat / Spring Lower Seat Inspection ..........................................................2C-5
Spring Upper Seat and Lower Seat Removal and Installation ..................................................2C-6
Rear Axle Removal and Inst allation ....................2C-6
Trailing Arm, Rear Axle and Coil Spring Inspection ..........................................................2C-9
Rear Axle Bush Inspection ..................................2C-9
Rear Wheel Hub Components ..........................2C-10
Rear Wheel Hub Removal an d Installation .......2C-10
Rear Wheel Disc, bolt and Bearing Inspection ..2C-11
Spindle Removal and Installation ......................2C-12
Spindle Inspection .............................................2C-13
Rear Suspension Fasteners Inspection ............2C-13
Specifications .................... .................................2C-13
Tightening Torque Specifications ......................2C-13
Special Tools and Equipmen t ...........................2C-13
Special Tool ......................................................2C-13
Wheels and Tires ............ ......................... 2D-1
Precautions...........................................................2D-1
Precaution for Emergency Flat Tire Repair Kit ....2D-1
General Description .............................................2D-1 Tires Description .................................................2D-1
Wheels Description .............................................2D-2
Irregular and/or Premature Wear Description .....2D-3
Wear Indicators Description ................................2D-3
Radial Tire Waddle Description...........................2D-4
Radial Tire Lead / Pull Description ......................2D-5

Downloaded from www.Manualslib.com manuals search engine 2B-5 Front Suspension:
5) Remove brake hose mounting bolt (1) and remove brake hose (2) from bracket and then wheel speed
sensor harness (3) from strut bracket as shown in
figure.
6) Remove strut bracket bolts and nuts (4).
7) Remove strut rod cap.
8) Remove strut nut (1), and remove rebound stopper (2).
NOTE
Hold strut by hand so th at it will not fall off.

9) Remove strut assembly.
Installation
Install strut assembly by reversing removal procedure,
noting the following instructions.
CAUTION!
Never reuse strut bracket nuts.
Nuts are pre-coated with friction stabilizer.
Be sure to replace pre-coated nut with a new
one, or nut may loosen.

• Insert bolts in such direction as shown in figure.
• Tighten all fasteners to specified torque. Tightening torque
Strut bracket nut (a): 90 N·m (9.0 kgf-m, 65.5 lb-ft)
Brake hose mounting bolt (c): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Stabilizer joint nut (d): 50 N·m (5.0 kgf-m, 36.5 lb-
ft)
• Lower hoist and vehicle in unloaded condition, tighten strut nut (b) to specified torque.
Tightening torque
Strut nut (b): 50 N·m (5.0 kgf-m, 36.5 lb-ft)
• Install windshield wiper arms with blades referring to
“Windshield Wiper Removal and Installation in
Section 9D”.
NOTE
• Don’t twist brake hose and wheel speed sensor harness when installing them.
• Install wheel speed sensor harness (1) which marking (2) in figure is placed to
open hook side of the bracket.

1 3
2
2
1
4
4
3
I4RS0A220005-01
2
1
I4RS0A220006-01
(d) (a)
(b)
(c)
1
2
I4RS0B220012-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-6
• Tighten wheel nuts to specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
• After installation, confirm front wheel alignment.
Front Strut Assembly Disassembly and
Assembly
S7RS0B2206004
WARNING!
Use a regular coil spring compressor and
follow the operation procedure described in
the Instruction Manual.

Disassembly 1) Attach special tool (A) to coil spring as shown. Turn special tool bolts alternat ely until coil spring tension
is released. Rotate the strut around its axis to
confirm that the coil spring is released or not.
Special tool
(A): 09940-71431
2) While keeping coil spring compressed with special
tools as shown, remove strut support lower nut.
Special tool
(B): 09900-00411 socket
(C): 09900-00414 6 mm
3) Disassemble strut assembly. Assembly
For assembly, reverse disassembly procedure, noting
the following instructions.
1) Compress coil spring with special tool (A) until total
length becomes about 280 mm (11.0 in.) as shown.
Special tool
(A): 09940–71431
Length
“a”: 280 mm (11.0 in.)
2) Install compressed coil spring to strut, and place coil
spring end (2) onto spring lower seat (1) as shown.
NOTE
End of coil spring must not interfere with
step of spring lower seat.

I4RS0A220009-01
(B)
(C)
I4RS0A220007-01
U: Upper side (small dia.) L: Lower side (large dia.)
I4RS0A220010-01
I4RS0A220011-01

Downloaded from www.Manualslib.com manuals search engine 2B-11 Front Suspension:
7) Install ball joint bolt (1) and nut (2) from the direction
as shown in figure.
8) Tighten new suspension co ntrol arm ball joint nut (2)
to specified torque.
Tightening torque
Suspension control arm ball joint nut (a): 60
N·m (6.0 kgf-m, 43.5 lb-ft)
CAUTION!
Never reuse the removed suspension control
arm ball joint nut.

9) Tighten strut bracket new nuts (3) to specified torque.
Tightening torque
Strut bracket nut (b): 90 N·m (9.0 kgf-m, 65.5 lb-
ft)
CAUTION!
Never reuse strut bracket nuts.
Nuts are pre-coated with friction stabilizer.
Be use to replace pre-coated nut with a new
one, or may loosen.

10) Install wheel speed sensor (1).
Tightening torque
Wheel speed sensor mounting bolt (a): 11 N·m (
1.1 kgf-m, 8.0 lb-ft) 11) Connect tie-rod end to steering knuckle and then
install cotter pin referrin g to “Tie-Rod End Removal
and Installation in Section 6C”.
12) Install brake disc (2) and brake caliper (3).
13) Tighten caliper carrier bolt to specified torque.
Tightening torque
Caliper carrier bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
14) Depress foot brake pedal and hold it there. Tighten new drive shaft nut (1) to specified torque.
Tightening torque
Drive shaft nut (b): 200 N·m (20.0 kgf-m, 145.0
lb-ft)
CAUTION!
Never reuse drive shaft nut (1).

15) Caulk drive shaft nut (1) as shown.
CAUTION!
Be careful not to damage the drive shaft nut
while caulking it. If it is damaged, replace it
with new one.

16) Tighten wheel nuts to specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
17) After installing, confirm front wheel alignment.F: Vehicle front
I4RS0B220015-01
1 (a)
I4RS0B220006-01
I6RS0C220005-01

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 2B-13 Front Suspension:
Installation1) Install suspension control arm as shown but tighten new suspension contro l arm bolts (1) only
temporarily.
2) Install suspensi on control arm ball joint to steering
knuckle. Align ball stud gr oove with steering knuckle
bolt hole. Then install su spension control arm ball
joint bolt (1) from the direction as shown in figure.
Tighten new suspension cont rol arm ball joint nut (2)
to specified torque.
Tightening torque
Suspension control arm ball joint nut (a): 60
N·m (6.0 kgf-m, 43.5 lb-ft)
3) Lower hoist and vehicle in unloaded condition, tighten new suspension control arm front bolt and
suspension control arm rear bolt to specified torque.
CAUTION!
Never reuse suspension control arm front
and rear mounting bolts.
Bolts are pre-coated with friction stabilizer.
Be sure to replace pre-coated bolt with a new
one, or bolt may loosen.

Tightening torque
Suspension control arm front bolt (a): 95 N·m (
9.5 kgf-m, 68.0 lb-ft)
Suspension control arm re ar bolt (b): 95 N·m (
9.5 kgf-m, 68.0 lb-ft)
4) Confirm front wheel alignment referring to “Front Wheel Alignment Inspection and Adjustment”.
Suspension Control Arm / Bushing
Disassembly and Assembly
S7RS0B2206010
Disassembly
1) Cut off bushing flange (rubber) (1) with knife.
2) Push out bushing by using hydraulic press (2) and special tools.
Special tool
(A): 09943–76310
(B): 09913–75821
F: Vehicle front
1
1
I6RS0C220011-01
I2RH01220054-01
(a)(b)
I6RS0C220012-01
I4RS0B220019-01
2
(A)
(B)
I6RS0C220013-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-16
4) Hoist vehicle and remove both wheels referring to “Wheel Removal and Installation in Section 2D”.
5) Remove cotter pins and tie-rod end nuts, and then disconnect both tie-rod ends from steering knuckles
referring to “Tie-Rod End Re moval and Installation in
Section 6C”.
6) Disconnect couplers of torque sensor and P/S motor.
7) Remove suspension control arm referring to “Suspension Control Arm / Bushing Removal and
Installation”.
8) Remove stabilizer joints (1). When loosening joint nu t, hold stud with special
tools.
Special tool
(A): 09900–00411 socket
(B): 09900–00413 5 mm
9) Support engine assemble by using supporting device referring to “Engine Supporting Points in
Section 0A”.
10) Disconnect muffler No.1 mounting (1) from suspension frame (2). 11) Remove engine rear mounting bolts (1) from engine
rear mounting (2).
12) Support front suspension frame (2) by using mission jack (1).
13) Remove front suspension frame mounting bolts (1), and then lower mission jack and remove front
suspension frame (2) with st abilizer bar and steering
gear case.
14) Remove steering gear case mounting No.1 bolts (1) and No.2 bolts (2), then remove gear case (3) from
front suspensio n frame (4).
11
(A)
(A)
(B)
(B)
I4RS0A220038-01
1
2
I4RS0A220040-01
3. Suspension frame
2
3 1
I4RS0A220041-01
2
1
I4RS0A220042-01
1
2 1
I4RS0A220043-01
1
3
4 2
I4RS0B220010-02

Downloaded from www.Manualslib.com manuals search engine 2B-17 Front Suspension:
15) Remove stabilizer bar (1) and bushing from front
suspension frame (2).
Installation 1) When installing stabilizer, loosely assemble all components while insuring that stabilizer is centered,
side-to-side.
2) Install stabilizer bar (1), stabilizer bushing (2) and
stabilizer mounting bracket (3) to front suspension
frame as shown in figure.
NOTE
For correct installation of stabilizer bar, side-
to-side, be sure that stopper ring (4) on
stabilizer bar aligns with mount bush, both
right and left, as shown in figure.

3) Tighten stabilizer bar mounting bracket bolts to specified torque.
Tightening torque
Stabilizer bar mounting bracket bolt (a): 23 N·m (
2.3 kgf-m, 17.0 lb-ft) 4) Mount steering gear case
(1) to front suspension
frame (2) and tighten gear case mounting No.1 bolts
(3) and No.2 bolts (4) to specified torque.
Tightening torque
Steering gear case mounting No.1 bolt (a): 55
N·m (5.5 kgf-m, 40.0 lb-ft)
Steering gear case mounting No.2 bolt (b): 55
N·m (5.5 kgf-m, 40.0 lb-ft)
5) Support front suspension frame (2) with stabilizer bar by using mission jack (1), and jack up it.
6) Align lugs (1) (right and left) of front suspension frame with holes (2) in vehicle body respectively.
F: Forward
1
2I4RS0A220044-01
I4RS0A220055-01
3, (a)
1
2 4, (b)
I4RS0B220011-02
2
1
I4RS0A220046-01
1
2
I4RS0A220047-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-18
7) Tighten front suspension frame mounting bolts (a) to specified torque.
Tightening torque
Front suspension frame mounting bolt (a): 150
N·m (15.0 kgf-m, 108.5 lb-ft)
8) Lower mission jack.
9) Tighten engine rear mounting bolts (a) to specified torque.
Tightening torque
Engine rear mounting bolt (a): 55 N·m (5.5 kgf-
m, 40.0 lb-ft)
10) Connect muffler No.1 mounting (1) to front suspension frame (2). 11) Remove supporting device from engine.
12) Install stabilizer joints (1), and tighten nuts to
specified torque.
When tightening, hold stud with special tools.
Special tool
(A): 09900–00411 socket
(B): 09900–00413 5 mm
Tightening torque
Stabilizer joint nut (a): 50 N·m (5.0 kgf-m, 36.5
lb-ft)
2. Engine rear mounting 3. Suspension frame
(a)
(a)
I4RS0A220048-01
2
3 (a)
I4RS0A220049-01
1
2
I4RS0A220040-01
1 1
(A)
(A)
(a) (a)
(B)
(B)
I4RS0A220051-01