Part SUZUKI SWIFT 2008 2.G Service Owners Manual

Downloaded from www.Manualslib.com manuals search engine 1J-4 Charging System:
Diagnostic Information and Procedures
Battery InspectionS7RS0B1A04001
Common Causes of Failure
A battery is not designed to last indefinitely; however, with proper care, it will provide many years of service. If the
battery performs satisfactorily during te st but fails to operate properly for no apparent reason, the following are some
factors that may point to the cause of trouble:
• Accessories left on overnight or for an extended period without the generator operating.
• Slow average driving speeds for short periods.
• Electrical load exceeding generator output partic ularly with addition of aftermarket equipment.
• Defects in charging system such as high resistance, s lipping drive belt, loose generator output terminal, faulty
generator or voltage regulator, Refer to “Generator Symptom Diagnosis”.
• Battery abuse, including failure to keep battery cable terminals clean and tight or loose battery hold down.
• Mechanical problems in electrical sys tem such as shorted or pinched wires.
Visual Inspection
Check for obvious damage, such as cracked or broken case or cover, that could permit loss of electrolyte. If obvious
damage is noted, replace battery. Determine cause of damage and correct as needed.
Generator Symptom DiagnosisS7RS0B1A04002
CAUTION!
• Do not mistake polarities of “IG” terminal and “L” terminal.
• Do not create short circuit between “IG” and “L” terminals. Always connect these terminals through a lamp.
• Do not connect any load between “L” and “E” terminals.
• When connecting charger or booster battery to vehicle battery, refer to “Jump Starting in Case of Emergency”.

Trouble in charging system will show up as one or more of the following conditions:
1) Faulty indicator lamp operation.
2) An undercharged battery as evidenced by slow cranking or indicator dark.
3) An overcharged battery as evidenced by ex cessive spewing of electrolyte from vents.
Condition Possible cause Correction / Reference Item
Noisy generator Loose drive belt Adjust or replace drive belt.
Loose drive belt pulley Tighten by specified torque.
Loose mounting bolts Tighten by specified torque.
Worn or dirty bearings Replace.
Defective diode or stator Replace.
Charge light does not
light with ignition ON and
engine off Fuse blown
Replace fuse and check for shorted circuit.
Indicator lamp (LED) faulty Replace combination meter.
Wiring connection loose Tighten loose connection.
IC regulator or field coil faulty Replace.
Poor contact between brush and slip
ring Repair or replace.
Charge light does not go
out with engine running
(battery requires frequent
recharging) Drive belt loose or worn
Adjust or replace drive belt.
IC regulator or generator faulty Replace.
Wiring faulty Repair wiring.

Downloaded from www.Manualslib.com manuals search engine 1J-6 Charging System:
Generator Test (Overcharged Battery Check)S7RS0B1A04004
1) To determine battery condition, refer to “Battery Description”.
2) If obvious overcharge condition exists as evidenced by excessive spewing of electrolyte, measure
generator “B” terminal voltage at engine 2000 rpm. 3) If measured voltage is higher than upper limit value,
proceed to disassemble generator.
4) Check ground of brushes. If brushes are not grounded, replace IC regulator. Then check field coil
for grounds and shorts, referring to “Generator
Inspection”.
Repair Instructions
Jump Starting in Case of EmergencyS7RS0B1A06001
CAUTION!
If vehicle is manual transaxle model and has
a catalytic converter, do not push or tow it to
start. Damage to its emission system and/or
to other parts may result.

Both booster and discharged battery should be treated
carefully when using ju mper cables. Follow the
procedure outlined as follows, being careful not to cause
sparks.
WARNING!
• Departure from these conditions or procedure described as follows could
result in:
– Serious personal injury (particularly to eyes) or property damage from such
causes as battery explosion, battery
acid, or electrical burns.
– Damage to electronic components of either vehicle.
• Remove rings, watches, and other jewelry. Wear approved eye protection.
• Be careful so that metal tools or jumper cables do not contact positive battery
terminal (or metal in contact with it) and
any other metal on vehicle, because a
short circuit could occur. • Never expose battery to open flame or
electric spark. Batteries generate gas
which is flammable and explosive.
• Do not allow battery fluid to contact eyes, skin, fabrics, or painted surface as fluid is
a corrosive acid. Flush any contacted area
with water immediately and thoroughly.
• Batteries should always be kept out of reach of children.
• Do not connect negative cable directly to negative terminal of dead battery.

1) Set parking brake and place automatic transaxle in PARK (NEUTRAL on manual transaxle). Turn off
ignition, turn off lights and all other electrical loads.
2) Check electrolyte level. If it is below low level line, add distilled water.
3) Attach end of one jumper cable to positive terminal of booster battery and the other end of the same
cable to positive terminal of discharged battery. (Use
12-volt battery only to jump start engine).
4) Attach one end of the remaining negative cable to negative terminal of booster battery, and the other
end to a solid engine ground (such as exhaust
manifold) at least 45 cm (18 in.) away from battery of
vehicle being started.
5) Start engine of vehicle with booster battery and turn off electrical accessories. Then start engine of the
vehicle with discharged battery.
16.0
15.5
15.0
14.5
14.0
13.5
13.0 -30 0 20
[C]
[D]
68
22120 (˚C)
248 (˚F)
(V)
I6RS0C1A0001-02

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With Charging Equipment
CAUTION!
When jump starting engine with charging
equipment, be sure equipment used is 12-
volt and negative ground. Do not use 24-volt
charging equipment. Using such equipment
can cause serious damage to electrical
system or electronic parts.

Battery Dismounting and RemountingS7RS0B1A06002
WARNING!
When handling battery, following safety
precautions should be followed:
• Hydrogen gas is produced by battery. A flame or spark near battery may cause the
gas to ignite.
• Battery fluid is highly acidic. Avoid spilling on clothing or other fabric. Any spilled
electrolyte should be flushed with large
quantity of water and cleaned immediately.

Dismounting
1) Disconnect negative cable (1).
2) Disconnect positive cable (2).
3) Remove retainer (3).
4) Remove battery (4).
Remounting 1) Reverse removal procedure.
2) Tighten battery cables securely.
Water Pump / Generator Drive Belt Tension
Inspection and Adjustment
S7RS0B1A06003
WARNING!
Disconnect negative cable at battery before
checking and adjusting belt tension.

1) Inspect belt for cranks, cuts, deformation, wear and clealiness. If it is necessary to replace belt, refer to
“Water Pump / Generator Drive Belt Removal and
Installation”.
2) Check belt for tension. Belt is in proper tension when it deflects the following specification under thumb
pressure (about 10 kg or 22 lb.).
If belt tension is out of spec ification, go to next steps.
Water pump / generator drive belt tension
“a”
Existing belt: 4.5 – 5.5 mm (0.18 – 0.22 in.) as
deflection / 10 kg (22 lbs)
New belt: 3.5 – 4 mm (0.14 – 0.16 in.)as deflection
/ 10 kg (22 lbs)
5. Body ground bolt
1
3 5
2
4
I4RS0B1A0006-01
“a”
I5JB0A1A0008-01

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Specifications
Charging System SpecificationsS7RS0B1A07001
Battery
Battery
: 48AH/20H, 40.6AH/5H 12 V
Generator
Tightening Torque SpecificationsS7RS0B1A07002
NOTE
The specified tightening torque is also described in the following.
“Generator Unit Components”
“Generator Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Nominal output
12 V
Rated capacity 48 Ah/20 h
40.6 Ah/5 h
Cold cranking amperes 300 A (DIN)
Ty p e 80A type
Rated voltage 12 V
Nominal output 80A
Permissible max. speed 18,000 r/min.
No-load speed 1200 r/min. (rpm)
Regulated voltage 14.2 – 14.8 V at 25 ° C (77 °F)
Exposed brush length Standard: 16 mm (0.63 in.)
Limit: 5.0 mm (0.02 in.)
Permissible ambient temperature –30 to 100 °C (–22 to 212 °F)
Polarity Negative ground
Rotation Clockwise viewed from pulley side
Fastening partTightening torque
Note
N ⋅mkgf-mlb-ft
Generator bracket bolt 25 2.5 18.0 )
Generator pivot bolt 50 5.0 36.0 )
Generator adjusting bolt 70.7 5.0by the specified
procedure.
)

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Engine
Exhaust System
General Description
Exhaust System DescriptionS7RS0B1B01001
The exhaust system consists of an exhaust manifold, three-way catalytic converter (TWC) in catalyst case, exhaust
pipes, a muffler and seals, gasket and etc.
The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of
Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
Diagnostic Information and Procedures
Exhaust System CheckS7RS0B1B04001
WARNING!
To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any
service on the exhaust system should be performed when the system is cool.

At every interval of periodic maintenance service, and when vehicle is raised for other service, check exhaust system
as follows:
• Check rubber mountings for damage, deterioration, and out of position.
• Check exhaust system for leakage, loose connection, dent and damage.
• If bolts or nuts are loosened, tighten them to specified torque referring to “Exhaust System Components”.
• Check nearby body areas damaged, missing, or mispositio ned part, open seam, hole connection or any other
defect which could permit exhaust fumes to seep into vehicle.
• Make sure that exhaust system components have enough clearance from underbody to avoid overheating and
possible damage to passenger compartment carpet.
• Any defect should be fixed at once.
IYSY011B0003-01

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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 2A-1 Suspension General Diagnosis:
Suspension
Suspension General Diagnosis
Diagnostic Information and Procedures
Suspension, Wheels and Tires Symptom DiagnosisS7RS0B2104001
ConditionPossible cause Correction / Reference Item
Vehicle pulls (Leads) Mismatched or uneven tires Replace tires.
Tires not adequately inflated Adjust tire pressure.
Broken or sagging coil springs Replace coil springs.
Radial tire lateral force Replace tire.
Disturbed wheel alignment Check and adjust wheel alignment.
Brake dragging in one road wheel Repair brake.
Loose, bent or broken front or rear
suspension parts Tighten or replace related suspension parts.
Abnormal or excessive
tire wear Sagging or broken coil spring
Replace coil spring.
Tire out of balance Adjust balance or replace tire.
Disturbed wheel alignment Check and adjust wheel alignment.
Faulty strut (shock absorber) Replace strut (shock absorber).
Hard driving Replace tires.
Overloaded vehicle Replace tires and check suspension parts.
Not rotated tires Replace or rotate tires.
Worn or loose wheel bearing Replace wheel bearing.
Wobbly wheel or tire Replace wheel or tire.
Tires not adequately inflated Adjust tire pressure.
Wheel tramp Blister or bump on tire Replace tire.
Improper strut (shock absorber) action Replace strut (shock absorber).
Shimmy, shake or
vibration Tire or wheel out of balance
Balance wheel or replace tire and/or wheel.
Loosen wheel bearings Replace wheel bearings.
Worn tie-rod ends Replace tie-rod ends.
Worn lower ball joints Replace front suspension control arm.
Excessive wheel runout Repair or replace wheel and/or tire.
Blister or bump on tire Replace tire.
Excessively loaded radial runout of tire /
wheel assembly Replace tire or wheel.
Disturbed wheel alignment Check and adjust wheel alignment.
Loose or worn steering linkage Tighten or replace steering linkage.
Loose steering gear case bolts Tighten steering gear case bolts.
Abnormal noise, front end Worn, sticky or loose tie-rod ends, lower
ball joints, tie-rod in side ball joints or
drive shaft joints Replace tie-rod end, su
spension arm, tie-rod
or drive shaft joint.
Damaged struts or mountings Repair or replace struts or mountings.
Worn suspension arm bushings Replace suspension arm bushings.
Loose stabilizer bar Tighten bolts or nuts and/or replace bushes.
Loose wheel nuts Tighten wheel nuts.
Loose suspension bolts or nuts Tighten suspension bolts or nuts.
Broken or damaged wheel bearings Replace wheel bearings.
Broken suspension springs Replace suspension springs.
Poorly lubricated or worn strut bearings Replace strut bearing.
Malfunction of Power Steering System Check and correct malfunction.
Low or uneven trim height
NOTE
See NOTE *1.

Broken or sagging coil springs Replace coil springs.
Over loaded Check loading.
Incorrect coil springs Replace coil spring.
Tires not adequately inflated Adjust tire pressure.
Ride too soft Faulty strut (shock absorber) Replace strut (shock absorber).
Suspension bottoms Overloaded Check loading.
Faulty strut (shock absorber) Replace strut (shock absorber).
Incorrect, broken or sagging coil springs Replace coil spring.

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-2
Front Wheel Alignment ConstructionS7RS0B2201002
Among factors for front wheel alignment, only toe setting
can be adjusted. Camber and caster are not adjustable.
Therefore, should camber or caster be out of
specification due to the damage caused by hazardous
road conditions or collision, whether the damage is in
body or in suspension should be determined and
damaged body should be repaired or damaged
suspension should be replaced.
Preliminary Checks Prior to Adjustment Front Wheel
Alignment
Steering and vibration complaints are not always the
result of improper wheel alignment. An additional item to
be checked is the possibility of tire lead due to worn or
improperly manufactured tires. “Lead” is the vehicle
deviation from a straight path on a level road without
hand pressure on the steering wheel. Refer to “Radial
Tire Lead / Pull Description in Section 2D” in order to
determine if the vehicle has a tire lead problem. Before
making any adjustment affecting wheel alignment, the
following checks and inspections should be made to
ensure correctness of alignment readings and alignment
adjustments:
• Check all tires for proper inflation pressures and approximately the same tread wear. • Check for loose of ball join
ts. Check tie-rod ends; if
excessive looseness is noted, it must be corrected
before adjusting.
• Check for run-out of wheels and tires.
• Check vehicle trim heights; if it is out of limit and a
correction is needed, it must be done before adjusting
toe.
• Check for loose of suspension control arms.
• Check for loose or missin g stabilizer bar attachments.
• Consideration must be given to excess loads, such as
tool boxes. If this excess load is normally carried in
vehicle, it should remain in vehicle during alignment
checks.
• Consider condition of equipment being used to check alignment and follow manufa cturer’s instructions.
• Regardless of equipment used to check alignment, vehicle must be placed on a level surface.
NOTE
To prevent possible incorrect reading of toe,
camber or caster, vehicle front and rear end
must be moved up and down a few times
before inspection.

Repair Instructions
Front Wheel Alignment Inspection and
Adjustment
S7RS0B2206001
Toe Inspection and Adjustment
Preparation for toe inspection and adjustment.
• Place vehicle in unloaded state on level surface.
• Set steering wheel in straight state.
• Check that inflation pressure of each tire is adjusted properly and wheel is free from deflection.
• Check that each suspension part is free from bend, dent, wear or damage in any other form.
• Check that ground clearance at the right and left is just about the same.
Inspection
Measure toe using toe-in gauge (1).
If toe is out of specified value, adjust it at the tie-rod. Front toe (total) “b”-“a”
: 0 + 1.0 / – 0.5 mm (0 + 0.0394 / – 0.0197 in.)
I6RS0C220007-01
F: Forward
“a”
“c”
“b” F
I7RS0A220002-02

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Reference Information
Side slip
When checked with side slip tester, side slip should
satisfy following specification.Side slip
0 to IN 3.0 mm/m (0 to IN 0.118 in/3.3 ft)
If side slip is greatly di
fferent, toe or front wheel
alignment may not be correct.
Front Strut Assembly ComponentsS7RS0B2206002
Front Strut Assembly Removal and InstallationS7RS0B2206003
Removal
1) Remove windshield wipe r arms with wiper blades.
2) Remove cowl top covers referring to “Cowl Top
Components in Section 9K”.
NOTE
When servicing component parts of strut
assembly, remove stru t rod cap and then
loosen strut nut a little before removing strut
assembly. This will make service work easier.
Note that the nut must not be removed at this
point.

3) Hoist vehicle, allowing front suspension to hang free.
4) Remove wheel and disconn ect stabilizer joint (1)
from strut bracket.
When loosening joint nu t, hold stud with special
tools.
Special tool
(A): 09900–00411 socket
(B): 09900–00413 5 mm
11 3
2 1
12
13
4
5
6
7
10
8(a)
(b)
9
(a)
14
15(a)
16
I6RS0C220006-02
1. Strut assembly
6. Strut bearing 11. Strut rod cap16. Bump stopper
2. Coil spring 7. Strut support 12. Strut bracket nut : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft)
3. Dust cover 8. Strut support lower nut 13. Strut bracket bolt
:Insert from vehicle front side. : 90 N
⋅m (9.0 kgf-m, 65.5 lb-ft)
4. Coil spring seat 9. Strut nut 14. Stabilizer joint nut : Do not reuse.
5. Coil spring upper seat 10. Rebound stopper 15. Stabilizer joint
1
(A)
(B)
I4RS0A220004-01

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Assembly1) Front bushing Press-fit front bushing (1) by using special tools and
press (2).
Special tool
(A): 09943–76310
(B): 09913–75821
CAUTION!
Be sure to use new bushing.

NOTE
• Before installing bushing, apply soap water on its circumference to facilitate
bushing installation.

2) Press-fit bushing (1) so that dimensions “A” and “B” in figure become equal.
Suspension Control Arm / Steering Knuckle
Check
S7RS0B2206011
Inspect for cracks, deformation or damage.
If defective, replace.
Suspension Control Arm Bushing CheckS7RS0B2206012
Inspect for damage, wear or deterioration.
If defective, replace.
Suspension Control Arm Joint CheckS7RS0B2206013
• Check smooth rotation of ball stud.
• Check damages of ball stud.
• Check damages of dust cover.
NOTE
Suspension control a rm and arm joint cannot
be separated.

If there is any damage to either parts, control arm
assembly must be replaced as a complete unit.
1 2
(A)
(B)
I6RS0C220014-01
I4RS0A220033-01
I6RS0C220015-01
I4RS0B220023-01