cat SUZUKI SWIFT 2007 2.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine 00-13 Precautions:
Short Circuit Check (Wire Harness to Ground)1) Disconnect negative (–) cable at battery.
2) Disconnect connectors at bot h ends of the circuit to
be checked.
NOTE
If the circuit to be checked is connected to
other parts (1), disconnect all connectors of
those parts.
Otherwise, diagnosis will be misled.

3) Measure resistance between terminal at one end of circuit (“A-1” terminal in the figure) and body ground.
If continuity is indicated, it means that there is a short
to ground between terminals “A-1” and “C-1” of the
circuit. 4) Disconnect the connector included in circuit
(connector-B) and measure resistance between “A-
1” and body ground. If continuity is indicated, it
means that the circuit is shorted to the ground
between terminals “A-1” and “B-1”.
Intermittent and Poor Connection InspectionS7RS0B0006002
Most intermittent are caused by faulty electrical
connections or wiring, although a sticking relay or
solenoid can occasionally be at fault. When checking it
for proper connection, perfor m careful check of suspect
circuits for:
• Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
• Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could
impede proper terminal contact. However, cleaning
the terminal with a sand paper or the like is prohibited.
• Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper
terminal orientation with the component or mating
connector.
I5RH01000006-01
1. To other parts
I2RH01010056-01
I2RH01010057-01

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 0A-1 General Information:
General Information
General Information
General Description
AbbreviationsS7RS0B0101001
A:
ABDC: After Bottom Dead Center
ABS: Anti-lock Brake System
AC: Alternating Current
A/C: Air Conditioning
A-ELR: Automatic-Emergency Locking Retractor
A/F: Air Fuel Mixture Ratio
ALR: Automatic Locking Retractor
API: American Petroleum Institute
APP sensor: Accelerator Pedal Position Sensor
A/T: Automatic Transmission , Automatic Transaxle
AT D C : After Top Dead Center
ATF: Automatic Transmission Fluid, Automatic
Transaxle Fluid
B:
B+: Battery Positive Voltage
BBDC: Before Bottom Dead Center
BCM: Body Electrical Control Module
BDC: Bottom Dead Center
BTDC: Before Top Dead Center
C:
CAN: Controller Area Network
CKT: Circuit
CKP Sensor: Crankshaft Position Sensor
CMP Sensor: Camshaft Position Sensor
CO: Carbon Monoxide
CPP Switch: Clutch Pedal Position Switch (Clutch
Switch, Clutch Start Switch)
CPU: Central Processing Unit
CRS: Child Restraint System
D:
DC: Direct Current
DLC: Data Link Connector (Assembly Line Diag. Link,
ALDL, Serial Data Link, SDL)
DOHC: Double Over Head Camshaft
DOJ: Double Offset Joint
DRL: Daytime Running Light
DTC: Diagnostic Trouble Code (Diagnostic Code)
E:
EBCM: Electronic Brake Cont rol Module, ABS Control
Module
EBD: Electronic Brake Force Distribution
ECM: Engine Control Module
ECT Sensor: Engine Coolant Temperature Sensor (Water Temp. Sensor, WTS)
EFE Heater: Early Fuel Evaporation Heater (Positive
Temperature Coefficient, PTC Heater)
EGR: Exhaust Gas Recirculation
EGRT Sensor: EGR Temperature Sensor (Recirculated
Exhaust Gas Temp. Sensor, REGTS)
ELR: Emergency Locking Retractor
ESP ®: Electronic Stability Program
EPS: Electronic Power Steering
EVAP: Evaporative Emission EVAP Canister:
Evaporative Emission Canister
(Charcoal Canister)
F:
4WD: 4 Wheel
Drive
G:
GEN: Generator
GND: Ground
GPS: Global Positioning System
H:
HVAC: Heating, Ventilating and Air Conditioning
HC: Hydrocarbons
HO2S: Heated Oxygen Sensor
I:
IAC Valve: Idle Air Control Valve (Idle Speed Control
Solenoid Valve, ISC Solenoid Valve)
IAT Sensor: Intake Air Temperature Sensor (Air
temperature Sensor, ATS)
ICM: Immobilizer Control Module
IG: Ignition
ISC Actuator: Idle Speed Control Actuator
L:
LH: Left Hand
LHD: Left Hand Drive Vehicle
LSPV: Load Sensing Proportioning Valve
M:
MAF Sensor: Mass Air Flow Sensor (Air Flow Sensor, AFS, Air Flow Meter, AFM)
MAP Sensor: Manifold Absolute Pressure Sensor
(Pressure Sensor, PS)
Max: Maximum
MFI: Multiport Fuel Injection (Mu ltipoint Fuel Injection)
Min: Minimum
MIL: Malfunction Indicator Lamp (“SERVICE ENGINE
SOON” Light)
M/T: Manual Transmission, Manual Transaxle
N:
NOx: Nitrogen Oxides
O:
OBD: On-Board Diagnostic System (Self-Diagnosis
Function)
O/D: Overdrive
OHC: Over Head Camshaft
O2S: Oxygen Sensor
P:
PCM: Powertrain Control Module
PCV: Positive Crankcase Ventilation
PNP: Park / Neutral Position
P/S: Power Steering
PSP Switch: Power Steering Pressure Switch (P/S
Pressure Switch)
R:
RH: Right Hand
RHD: Right Hand Drive Vehicle
S:
SAE: Society of Automotive Engineers

Downloaded from www.Manualslib.com manuals search engine General Information: 0A-2
SAS: Steering Angle Sensor
SDM: Sensing and Diagnostic Module (Air Bag Controller, Air bag Control Module)
SDT: Smart Diagnostic Tester
SFI: Sequential Multipor t Fuel Injection
SOHC: Single Over Head Camshaft
T:
TBI: Throttle Body Fuel Injection (Single-Point Fuel
Injection, SPI)
TCC: Torque Converter Clutch
TCM: Transmission Control Module (A/T Controller, A/T
Control Module)
TDC: Top Dead Center
TP Sensor: Throttle Position Sensor TVV:
Thermal Vacuum Valve (Thermal Vacuum
Switching Valve, TVSV, Bi metal Vacuum Switching
Valve, BVSV)
TWC: Three Way Catalytic Converter (Three Way
Catalyst)
2WD: 2 Wheel Drive
U:
USB: Universal Serial Bus
V:
VIN: Vehicle Identification Number
VSS: Vehicle Speed Sensor
VVT: Variable Valve Timing (Camshaft Position Control)
W:
WU-OC: Warm Up Oxidation Catalytic Converter
WU-TWC: Warm Up Three Way Catalytic Converter
SymbolsS7RS0B0101002
Wire Color SymbolsS7RS0B0101003
Symbol Definition SymbolDefinition
Tightening torque Apply SUZUKI BOND NO. 1216B
99000-31230
Apply oil (engine, transmission, transfer,
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
99000-25011
Apply SUZUKI SUPER GREASE C
99000-25030 Apply THREAD LOCK 1322
99000-32110
Apply SUZUKI SUPER GREASE E
99000-25050 Apply THREAD LOCK 1333B
99000-32020
Apply SUZUKI SUPER GREASE H
99000-25121 Apply THREAD LOCK 1342
99000-32050
Apply SUZUKI SUPER GREASE I
99000-25210
Apply SUZUKI BOND NO. 1215
99000-31110 Do not reuse
Apply SUZUKI BO ND NO. 1207F
99000-31250 Note on reassembly
Apply SUZUKI BO ND NO. 1217G
99000-31260
Symbol Wire Color SymbolWire Color
B BLK Black O, Or ORN Orange
Bl BLU Blue RRED Red
Br BRN Brown WWHT White
G GRN Green YYEL Yellow
Gr GRY Gray PPNK Pink
Lbl LT BLU Light blueVPPL Violet
Lg LT GRN Light green

Downloaded from www.Manualslib.com manuals search engine 0A-3 General Information:
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 sy mbols (i.e. “GRN/YEL”). The first symbo l 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).
Fasteners InformationS7RS0B0101004
Metric Fasteners
Most of the fasteners used for this vehicle are JIS-
defined and ISO-defined metric fasteners. When
replacing any fasteners, it is most important that
replacement fasteners be the correct diameter, thread
pitch and strength.
CAUTION!
Even when the nominal diameter (1) of thread
is the same, the thread pitch (2) or the width
across flats (3) may vary between ISO and
JIS. Refer to JIS-TO-ISO Main Fasteners
Comparison Table below for the difference.
Installing a mismatched bolt or nut will cause
damage to the thread.
Before installing, check the thread pitch for
correct matching and then tighten it by hand
temporarily. If it is tight, recheck the thread
pitch.

JIS-TO-ISO Main Fasteners Comparison Table Fastener Strength Identification
Most commonly used metric fastener strength property
classes are 4T, 6.8, 7T, 8.8 and radial line with the class
identification embossed on the head of each bolt. Some
metric nuts will be marked with punch, 6 or 8 mark
strength identification on the nut face. Figure shows the
different strength markings.
When replacing metric fasteners, be careful to use bolts
and nuts of the same strength or greater than the original
fasteners (the same number marking or higher). It is
likewise important to select replacement fasteners of the
correct diameter and thread
pitch. Correct replacement
bolts and nuts are available through the parts division.
Metric bolts: Identification class numbers or marks
correspond to bolt strength (increasing numbers
represent increasing strength).
I2RH01010010-01
Nominal diameter
M6 M8 M10 M12 M14
JIS Thread pitch 1.0 1.25 1.25 1.25 1.5
Width across flats 10 12 14 17 19
ISO Thread pitch 1.0 1.25 1.5 1.5 1.5
Width across flats 10 13 16 18 21
I4RH0A010005-01
1. Nut strength identification
I5RH01010001-01

Downloaded from www.Manualslib.com manuals search engine General Information: 0A-4
Standard Tightening Torque
Each fastener should be tightened to the torque specified in each section. If no description or specification is provided,
refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater
strength than the original one is used, however, use the torque specified for the original fastener.
NOTE
• For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening torque given in the following chart.
• The following chart is applicable only where the fastened parts are made of steel light alloy.

Tightening torque chart
*:Self-lock nut Strength Unit
Thread diameter (Nominal diameter) (mm)
4 5 6 8 10 12 14 16 18
A equivalent of 4T strength fastener N⋅ m 1.5 3.0 5.5 13 29 45 65 105 160
kgf-m 0.15 0.30 0.55 1.3 2.9 4.5 6.5 10.5 16 lb-ft 1.0 2.5 4.0 9.5 21.0 32.5 47.0 76.0 116.0
A equivalent of 6.8 strength fastener
without flange N
⋅m 2.4 4.7 8.4 20 42 80 125 193 280
kgf-m 0.24 0.47 0.84 2.0 4.2 8.0 12.5 19.3 28 lb-ft 2.0 3.5 6.0 14.5 30.5 58.0 90.5 139.5 202.5
A equivalent of 6.8 strength fastener
with flange
*: Self-lock nut (6 strength) N
⋅m 2.4 4.9 8.8 21 44 84 133 203 298
kgf-m 0.24 0.49 0.88 2.1 4.4 8.4 13.3 20.3 29.8 lb-ft 2.0 3.5 6.5 15.5 32.0 61.0 96.5 147.0 215.5
A equivalent of 7T strength fastener N⋅ m 2.3 4.5 10 23 50 85 135 210 240
kgf-m 0.23 0.45 1.0 2.3 5.0 8.5 13.5 21 24 lb-ft 2.0 3.5 7.5 17.0 36.5 61.5 98.0 152.0 174.0
A equivalent of 8.8 strength bolt (8
strength nut) without flange N
⋅m 3.1 6.3 11 27 56 105 168 258 373
kgf-m 0.31 0.63 1.1 2.7 5.6 10.5 16.8 25.8 37.3 lb-ft 2.5 4.5 8.0 19.5 40.5 76.0 121.5 187.0 270.0
A equivalent of 8.8 strength bolt (8
strength nut) with flange N
⋅m 3.2 6.5 12 29 59 113 175 270 395
kgf-m 0.32 0.65 1.2 2.9 5.9 11.3 17.5 27 39.5 lb-ft 2.5 5.0 9.0 21.0 43.0 82.0 126.5 195.5 286.0
I2RH01010012-01
I2RH01010013-01
I2RH01010014-01
I2RH01010015-01
I2RH01010016-01
I2RH01010017-01

Downloaded from www.Manualslib.com manuals search engine 0A-7 General Information:
Engine Supporting PointsS7RS0B0101006
WARNING!
When using engine supporting device (1), be
sure to observe the followings.
Otherwise, not only deformation of vehicle
body but also personal injury may result.
• Apply supporting device at the specified positions (2) indicated in figure
• Install supporting device taking a well- balanced posture.
• Do not contact supporting device with other parts than engine room body panel
and engine hooks.

Vehicle Identification NumberS7RS0B0101007
The number is punched close by the right side strut
support in engine room and it is also attached on the left
side of instrument panel depending on the vehicle
specification.
Engine Identification NumberS7RS0B0101008
The number is punched on cylinder block.
Transmission Identification NumberS7RS0B0101009
The automatic transmission identification number is
located on transmission case.
2
2
2
1
I4RS0A010005-01
I4RS0B010003-01
I3RM0A010005-01
I4RS0A010008-01

Downloaded from www.Manualslib.com manuals search engine General Information: 0A-8
Component Location
Warning, Caution and Information Labels LocationS7RS0B0103001
The figure 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
2
3
4
6
5
I5RS0C010001-02
1. Air bag label on sun visor (if equipped) 4.Steering shaft joint cover label (if equipped)
2. Radiator cap label 5. Jack label
3. Engine cooling fan label 6. Rear beam label

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