AIR CON SUZUKI SWIFT 2008 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 1H-8 Ignition System:
Ignition Coil Assembly (Including ignitor)
Removal and Installation
S7RS0B1806005
Removal1) Disconnect negative (–) cable at battery.
2) Remove air cleaner assembly with air intake pipe and cylinder head upper cover.
3) Disconnect ignition coil coupler.
4) Disconnect high-tension cord (3) from ignition coil assembly (2).
5) Remove ignition coil bolts (1) and then pull out ignition coil assembly.
Installation 1) Install ignition coil assembly (2).
2) Tighten ignition coil bolts (1) to specified torque, and then connect igni tion coil coupler.
Tightening torque
Ignition coil bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
3) Install high-tension cord (3) to ignition coil assembly while gripping its cap.
4) Install cylinder head upper cover and air cleaner assembly with air intake pipe.
5) Connect negative (–) cable to battery.
Ignition Coil Assembly (Including ignitor)
Inspection
S7RS0B1806006
Measure secondary coil for resistance.
If resistance is out of specification, replace ignition coil
assembly.
Secondary coil resistance
7.5 – 10.3 k Ω at 20 °C, 68 ° F
Ignition Timing InspectionS7RS0B1806007
NOTE
• Ignition timing is not adjustable. If ignition
timing is out of specification, check
system related parts.
• Before starting engine, place transmission gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T model), and set
parking brake.

1) Connect scan tool to DLC (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
2) Start engine and warm it up to normal operating temperature.
3) Make sure that all of electrical loads except ignition are switched off.
4) Check to be sure that idle speed is within specification referring to “Idle Speed and IAC
Throttle Valve Opening Inspection in Section 1A”
5) Fix ignition timing by using “Fixed Spark” of “Misc Test” mode on scan tool.
I2RH0B180006-01
I3RM0A180004-01
I2RH0B180007-01
(A)
1
I4RS0B180003-01

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-2
ConditionPossible cause Correction / Reference Item
Motor not running (No
operating sound of
magnetic switch) Shift lever switch is not in P or N, or not
adjusted (A/T)
Shift in P or N, or
adjust switch. (A/T)
Battery run down Recharge battery.
Battery voltage too low due to battery
deterioration Replace battery.
Poor contact in battery terminal
connection Retighten or replace.
Loose grounding cable connection Retighten.
Fuse set loose or blown off Tighten or replace.
Poor contacting action of ignition switch
and magnetic switch Replace.
Lead wire coupler loose in place Retighten.
Open-circuit between ignition switch and
magnetic switch Repair.
Open-circuit in pull-in coil Replace magnetic switch.
Brushes are seating poorly or worn
down Repair or replace.
Poor sliding of plunger and/or pinion Repair.
Faulty starting motor control relay “Main Relay, Fuel Pump Relay and Starting
Motor Control Relay Inspection in Section 1C”.
Faulty ECM and its circuit “Inspection of ECM and Its Circuits in Section
1A”.
Motor not running
(Operating sound of
magnetic switch heard) Battery run down
Recharge battery.
Battery voltage too low due to battery
deterioration Replace battery.
Loose battery cable connections Retighten.
Burnt main contact point, or poor
contacting action of magnetic switch Replace magnetic switch.
Brushes are seating poorly or worn
down Repair or replace.
Weakened brush spring Replace.
Burnt commutator Replace armature.
Layer short-circuit of armature Replace.
Crankshaft rotation obstructed Repair.
Starting motor running
but too slow (small
torque) (If battery and
wiring are satisfactory,
inspect starting motor) Insufficient contact
of magnetic switch
main contacts Replace magnetic switch.
Layer short-circuit of armature Replace.
Disconnected, burnt or worn
commutator Repair commutator or replace armature.
Worn brushes Replace brush.
Weakened brush springs Replace spring.
Burnt or abnormally worn end bush Replace bush.
Starting motor running,
but not cranking engine Worn pinion tip
Replace over-running clutch.
Poor sliding of over-running clutch Repair.
Over-running clutch slipping Replace over-running clutch.
Worn teeth of ring gear Replace flywheel (M/T) or drive plate (A/T).
Noise Abnormally worn bush Replace bush.
Worn pinion or worn teeth of ring gear Replace over-running clutch, flywheel (M/T) or
drive plate (A/T).
Poor sliding of pinion (failure in return
movement) Repair or replace.
Worn internal or planetary gear teeth Replace.
Lack of oil in each part Lubricate.
Starting motor does not
stop running Fused contact points of magnetic switch
Replace magnetic switch.
Short-circuit between turns of magnetic
switch coil (layer short-circuit) Replace magnetic switch.
Failure of returning action in ignition
switch Replace.

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-4
Repair Instructions
Starting Motor Dismounting and RemountingS7RS0B1906001
Dismounting1) Disconnect negative (–) battery lead at battery.
2) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals.
3) Detach shift & select control cable bracket from transaxle. (M/T model only)
4) Remove starting motor mount bolt (3) and nut (4).
5) Remove starting motor (5).
Remounting
Reverse the dismounting procedure noting the following.
• Tighten battery cable nut (6) to specified torque.
Tightening torque
Starting motor battery cable nut (a): 9.8 N·m (0.98 kgf-m, 7.0 lb-ft)
I4RS0A190002-01
: 9.8 N ⋅m (0.98 kgf-m, 7.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 1I-7 Starting System:
Spring
Inspect brush springs for wear, damage or other
abnormal conditions. Replace if necessary.
Brush spring tension
Standard: 2.2 kg (4.85 lb)
Limit: 0.6 kg (1.33 lb)
Brush Holder
• Check movement of brush in brush holder. If brush movement within brush holder is sluggish, check
brush holder for distortion and sliding faces for
contamination.
Clean or correct as necessary.
• Check for continuity across insulated brush (positive side) and grounded brush (negative side).
If continuity exists, brus h holder is grounded due to
defective insulation and should be replaced.
Armature
• Inspect commutator for dirt or burn. Correct with sandpaper or lathe, if necessary.
• Check commutator for uneven wear with armature (1) supported on V-blocks (2). If deflection of dial gauge
(4) pointer exceeds limit, repair or replace.
NOTE
The following specification presupposes that
the armature is free from bend. Bent
armature must be replaced.

Commutator out of round
Standard: 0.05 mm (0.002 in.) or less
Limit: 0.4 mm (0.016 in.) • Inspect the commutator for wear. If diameter is below
limit, replace the armature.
Commutator outside diameter
Standard: 29.4 mm (1.16 in.)
Limit: 28.8 mm (1.14 in.)
• Inspect the commutator (1) for insulator (2) depth. Correct or replace if below limit.
Commutator insulator depth “a”
Standard: 0.4 – 0.6 mm (0.016 – 0.023 in.)
Limit: 0.2 mm (0.008 in.)
I4RS0A190004-01
I2RH01190015-01
3. Magnetic stand
[A]: Correct
[B]: Incorrect
I2RH01190016-01
I2RH01190017-01
I3RH0A190005-01

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 Charging System: 1J-5
Generator Test (Undercharged Battery Check)S7RS0B1A04003
This condition, as evidenced by slow cranking or
indicator clear with dark or light yellow dot can be
caused by one or more of the following conditions even
though indicator lamp may be operating normal.
The following procedure also applies to cars with
voltmeter and ammeter.1) Make sure that undercharged condition has not been caused by accessories left on for extended period of
time.
2) Check drive belt for proper tension.
3) If battery defect is suspected, refer to “Battery Description”.
4) Inspect wiring for defects. Check all connections for tightness and cleanliness, battery cable connections
at battery, starting motor, ignition ground cable and
no “C” terminal circuit at ground.
5) Connect switch (6), load (5), battery (4), voltmeter (3) and ammeter (2) to generator (1) as shown in
figure.
Voltmeter: Set between generator “B” terminal
and ground.
Ammeter: Set between generator “B” terminal
and battery (+) terminal.
NOTE
Use fully charged battery.

6) Measure current and voltage.
No-Load Check 1) Run engine from idling up to 2000 rpm and read meters.
NOTE
Turn off switches of all accessories (wiper,
heater etc.).

Specification for undercharged battery (No-load
check)
Current: 10 A
Voltage: 14.2 – 14.8 V (at 20 °C, 68 °F)
NOTE
Consideration should be taken that voltage
will differ somewhat with regulator case
temperature as shown in figure.

2) Using service wire, ground “C” terminal (1) of
generator.
3) Measure voltage between “B” terminal of generator and body ground.
Voltage: 12.5 – 13.1 V (at 20 °C, 68 °F)
• If voltage is higher than standard value
If voltage is higher than standard value, check ground
of brushes.
If brushes are not grounded, replace IC regulator.
If voltage is lower than standard value, proceed to the
following check.
Load Check 1) Run engine at 2000 rpm and turn on head light and blower motor.
2) Measure current. If measure current is less than 30 A, repair or
replace generator.
IYSQ011A0007-01
[A]: Regulated voltage (V)
[B]: Heat sink temperature ( °C)
16.0
15.5
15.0
14.5
14.0
13.5
13.0
-30 0 20
[A]
[B]
68
22120 (˚C)
248 (˚F)
(V)
I6RS0B1A1002-01
I5JB0A1A0011-01

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

Downloaded from www.Manualslib.com manuals search engine Exhaust System: 1K-2
Repair Instructions
Exhaust System ComponentsS7RS0B1B06001
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.

I7RS0B1B0001-01
[A]: MT model14. Exhaust manifold bolt 29. To vehicle body
[B]: AT model 15. Exhaust manifold nut 30. Damper
1. Exhaust manifold gasket 16. Exhaust No.1 pipe bolt 31. Damper nut
2. Exhaust manifold 17. Exhaust manifold stiffener bolt 32. To exhaust pipe No.1
3. Exhaust manifold stiffener 18. Exhaust No.2 pipe bolt 33. To exhaust manifold stiffener
4. Heated oxygen sensor No.2 (connector color: green) 19. Exhaust center pipe bolt 34. To oil pan
5. Exhaust pipe No.1 gasket 20. Exhaust pipe No.2 gasket : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft)
6. No.1 seal ring 21. Muffler nut : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft)
7. No.2 seal ring 22. Muffler tail pipe : 43 N⋅m (4.3 kgf-m, 31.0 lb-ft)
8. Exhaust No.1 pipe 23. Engine hook : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)
9. Exhaust No.2 pipe 24. Heated oxygen sensor No.1 (connector color: gray) : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
10. Exhaust center pipe 25. Heat insulator : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
11. Muffler 26. Heat insulator bolt : Do not reuse.
12. Center pipe mounting 27. Exhaust manifold cover
13. Muffler mounting 28. To cylinder block

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 2-ii Table of Contents
Balancing Wheels Description ............................ 2D-5
Repair Instructions ..............................................2D-6 General Balance Procedures ..............................2D-6
Tire Rotation........................................................2D-6
Wheel Removal and Installation..........................2D-7
Tire Mounting and Dismounting ..........................2D-8 Tire Repair ..........................................................2D-8
Tire Repair for Emergency Repaired-Tire with
Sealant ..............................................................2D-8
Specifications ..................... ..................................2D-9
Wheels and Tires Specifications .........................2D-9
Tightening Torque Specifications ........................2D-9