main SUZUKI SWIFT 2008 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words , and NOTE have special meanings. Pay specia l attention to the messages high-
lighted by these signal words.
The circle with a slash in this manual me ans “Don’t do this” or “Don’t let this happen”.
WARNING!CAUTION!
Indicates a potential hazard that could result in death or injury.
WARNING!
Indicates a potential hazard that could result in vehicle damage.
CAUTION!
NOTE:
Indicates special information to make main tenance easier or instructions clearer.
This service manual is intended for authorized Su zuki dealers and qualified service technicians only.
Inexperienced technicians or technicians without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the technician and may render the vehicle unsafe for the driver
and passengers.
WARNING!
For vehicles equipped with a 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-Vehicl e 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 re nder the system inoperative. Either of these two
conditions may result in severe injury.
 If the air bag system and another vehicle system both need repair, Suzuki recommends that the air
bag system be repaired first, to help av oid unintended air bag system activation.
 Do not modify the steering wheel, instrument pa nel or any other air bag system component on or
around air bag system components or wiring. Modi fications 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
process, remove the air bag system components, th at is air bag (inflator) modules, SDM and/or seat
belt with pretensioner, beforehand to avoid component damage or unintended activation.
WARNING!

Downloaded from www.Manualslib.com manuals search engine FOREWORD
This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service
operations, replacement of components (Service) and for disassembly and reassembly of major components
(Unit Repair-Overhaul).
Applicable Model:
SWIFT (RS416) produced at KOSAI plant in Japan wi th the following vehicle identification numbers
(VINs).

JSAEZC31S############


The contents are classified into sectio ns each of which is given a section number as indicated in the Table of
Contents on following page. And on the first page of ea ch individual section is an index of that section.
This manual should be kept in a handy place for ready reference of the service work.
Strict observance of the so specif ied items will enable one to obtain the full performance of the vehicle.
When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials as specif ied in each description.
All information, illustrations and specif ications contained in this literature are based on the late st product infor-
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specificatio ns among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
JSAEZC31S########

Downloaded from www.Manualslib.com manuals search engine 00
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Vo l u m e 1
Precautions............................................................... 00-iPrecautions ............................................................ 00-1
General Information ................ ................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubricatio n ................................. 0B-1
Engine ......................................................................... 1-i Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1
Aux. Emission Control Devices .............................. 1B-1
Engine Electrical Devices....................................... 1C-1
Engine Mechanical ................................................. 1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System .......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System....................................................... 1H-1
Starting System ....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System ..................................................... 1K-1
Suspension ................................................................. 2-i Precautions .............................................................. 2-1
Suspension General Diagnosis .............................. 2A-1
Front Suspension ................................................... 2B-1
Rear Suspension................ .................................... 2C-1
Wheels and Tires ................................................... 2D-1
Driveline / Axle ........................................................... 3-i Precautions .............................................................. 3-1
Drive Shaft / Axle ................................................... 3A-1
Brakes ......................................................................... 4-i Precautions .............................................................. 4-1
Brake Control System and Diagnosis .................... 4A-1
Front Brakes........................................................... 4B-1
Rear Brakes ........................................................... 4C-1
Parking Brake......................................................... 4D-1
ABS ........................................................................ 4E-1
Electronic Stability Program ................................... 4F-1
Vo l u m e 2
Precautions ............................................................... 00-iPrecautions ............................................................ 00-1
Transmission / Transaxle .... ...................................... 5-i
Precautions .............................................................. 5-1
Automatic Transmission/Transaxle ........................ 5A-1
Manual Transmission/Transaxle ............................ 5B-1
Clutch .....................................................................5C-1
Steering ....................................................................... 6-i Precautions .............................................................. 6-1
Steering General Diagnosis ................................... 6A-1
Steering Wheel and Column .................................. 6B-1
Power Assisted Steering System ...........................6C-1
HVAC ........................................................................... 7-i Precautions .............................................................. 7-1
Heater and Ventilation............................................ 7A-1
Air Conditioning System ......................................... 7B-1
Restraint ...................................................................... 8-i Precautions .............................................................. 8-1
Seat Belts ............................................................... 8A-1
Air Bag System ...................................................... 8B-1
Body, Cab and Accessories .... .................................. 9-i
Precautions .............................................................. 9-1
Wiring Systems ...................................................... 9A-1
Lighting Systems .................................................... 9B-1
Instrumentation / Driver Info. / Horn .......................9C-1
Wipers / Washers ...................................................9D-1
Glass / Windows / Mirrors ...................................... 9E-1
Security and Locks ................................................. 9F-1
Seats ..................................................................... 9G-1
Interior Trim ............................................................9H-1
Hood / Fenders / Doors .......................................... 9J-1
Body Structure ....................................................... 9K-1
Paint / Coatings ...................................................... 9L-1
Exterior Trim .......................................................... 9M-1
Control Systems ....................................................... 10-i Precautions ............................................................ 10-1
Body Electrical Control Sy stem ............................ 10B-1
Immobilizer Control System .................................10C-1
Keyless Start System ........................................... 10E-1
TABLE OF CONTENTS

Downloaded from www.Manualslib.com manuals search engine 00-1 Precautions:
Precautions
Precautions
Precautions
Precautions for Vehicles Equipped with a
Supplemental Restraint (Air Bag) System
S7RS0B0000001
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 Air Bag System
section. Failure to follow proper
procedures could result in possible air bag
system activation, personal injury, damage
to parts or air bag system being unable to
activate when necessary.
• If the air bag system and another vehicle system both need repair, SUZUKI
recommends that the air bag system 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 process),
remove the air bag system components
beforehand to avoid component damage
or unintended air bag system activation.

Diagnosis
• When troubleshooting air bag system, be sure to follow “Diagnosis” in Air Bag System section.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacement.
• Never use electrical test equipment other than that specified.
WARNING!
Never attempt to measure the resistance of
the air bag (inflator) modules (driver,
passenger, side and curtain) and seat belt
pretensioners (driver and passenger). It is
very dangerous as the electric current from
the tester may deploy the air bag or activate
the pretensioner.

1. Air bag wire harness (in floor, main and instrument panel harness) 6. Driver air bag (inflator) module
2. Passenger air bag (inflator) module 7. Side air bag (inflator) module (if equipped)
3. SDM 8. Curtain air bag (inflator) module (if equipped)
4. Seat belt pretensioner 9. Forward sensor
5. Contact coil 10. Side sensor (if equipped)
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I4RS0B000001-02
I4RS0A000002-02

Downloaded from www.Manualslib.com manuals search engine 00-7 Precautions:
Warning for Wheel (with tire) RemovalS7RS0B0000003
WARNING!
When removing any of these wheels installed
with wheel bolts, never remove all wheel
bolts at the same time. Leave at least 1 bolt
for each wheel as it is to prevent wheel from
dropping. When removing this remaining 1
bolt, hold wheel and tire so as not to allow
them to come off.

Warning for Handling Emergency Flat Tire
Repair Kit
S7RS0B0000004
WARNING!
If vehicle is equipped with Emergency Flat
Tire Repair Kit instead of spare tire, be sure
to observe “Precaution for Emergency Flat
Tire Repair Kit in Section 2D” when handling
Emergency Flat Tire Repair Kit and repairing
flat tire.
Otherwise, your health may be ruined or it
will be impossible to repair flat tire.

Precautions for Catalytic ConverterS7RS0B0000005
For vehicles equipped with a catalytic converter, use
only unleaded gasoline and be careful not to let a large
amount of unburned gasoline enter the converter or it
can be damaged.
• Conduct a spark jump test only when necessary, make it as short as possible, and do not open the
throttle.
• Conduct engine compression checks within the shortest possible time.
• Avoid situations which can result in engine misfire (e.g. starting the engine when the fuel tank is nearly
empty.)
Precautions for Installing Mobile
Communication Equipment
S7RS0B0000006
When installing mobile communication equipment such
as CB (Citizens-Band)-radi o or cellular-telephone, be
sure to observe the following precautions.
Failure to follow cautions may adversely affect electronic
control system.
• Keep the antenna as far away as possible from the vehicle’s electronic control unit.
• Keep the antenna feeder more than 20 cm (7.9 in.) away from electronic control unit and its wire
harnesses.
• Do not run the antenna feeder parallel with other wire harnesses.
• Confirm that the antenna and feeder are correctly adjusted.
Precaution for CAN Communication SystemS7RS0B0000007
• The loose (1) in the wire harnesses twist of the CAN lines except around the connector (3) should be within
100 mm (3.9 in.). Refer to the wiring diagram for the
CAN lines discrimination. Excessively-loosed lines
may be influenced by the electric noise.
• Do not connect terminals of the CAN line using a bypass wire (1). Otherwise, the CAN line may be
influenced by the electric noise.
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1
I4JA01000002-01
1
I4JA01000003-01

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
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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-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-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.
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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