Fasteners SUZUKI SWIFT 2008 2.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-16
Removal1) Remove fuel pump assembly from fuel tank referring to “Fuel Pump Assembly Removal and Installation”.
2) Disconnect main fuel level sensor connector (3).
3) With pressing snap-fit part (2), remove main fuel level sensor (1) by sliding it in the arrow direction as
shown in figure.
Installation
Reverse removal procedure for installation.Fuel Pump InspectionS7RS0B1706019
• Check fuel pump assembly for damage.
• Check fuel suction filter for evidence of dirt and contamination. If present, replace or clean and check
for presence of dirt in fuel tank.
• For electrical circuit, refer to “Fuel Pressure Check in Section 1A”.
• For inspection of main fuel level sensor (1), refer to “Fuel Level Sensor Inspection in Section 9C”.
Specifications
Tightening Torque SpecificationsS7RS0B1707001
NOTE
The specified tightening torque is also described in the following.
“Fuel System Components”
“Fuel Hose Disconnecting and Reconnecting”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
1
21
3
I5RS0D170006-031
I5RS0D170008-01
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
Fuel delivery pipe bolt 25 2.5 18.0 )
Ground wire bolt 11 1.1 8.0 )
Fuel tank bolt 45 4.5 33.0 )
Fuel filler hose clamp 2 0.2 1.5 )
Fuel pump assembly bolt 11 1.1 8.0 )

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-9
6) Set timing light (1) to high-tension cord for No.1 cylinder and check that ignition timing is within
specification.
Initial ignition timing
Fixed with SUZUKI scan tool: 5 ± 3° BTDC (at
specified idle speed)
Ignition order
1 – 3 – 4 – 2
Special tool
(A): 09930–76420 7) If ignition timing is out
of specification, check the
followings.
• CKP sensor
• CKP sensor plate
• CMP sensor
• CMP sensor rotor tooth of camshaft
• VSS
• Timing chain cover installation
8) After checking initial igniti on timing, release ignition
timing fixation by using scan tool.
9) With engine idling (throttl e opening at closed position
and vehicle stopped), check that ignition timing is
about 3 ° – 13° BTDC. (Constant variation within a
few degrees from 3 ° – 13° BTDC indicates no
abnormality but proves operation of electronic timing
control system.) Also, check that increasing engine
speed advances ignition timing.
If the check results are not satisfactory, check CKP
sensor and ECM.
Specifications
Tightening Torque SpecificationsS7RS0B1807001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Special ToolS7RS0B1808001
1, (A)10
0I3RB0A180004-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Spark plug 25 2.5 18.0 )
Ignition coil bolt 10 1.0 7.5 )
09930–76420SUZUKI scan tool
Timing-light (dry cell type) —
) This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12. )

Downloaded from www.Manualslib.com manuals search engine 1I-9 Starting System:
Specifications
Cranking System SpecificationsS7RS0B1907001
Tightening Torque SpecificationsS7RS0B1907002
NOTE
The specified tightening torque is also described in the following.
“Starting Motor Dismounting and Remounting”
“Starting Motor Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS7RS0B1908001
NOTE
Required service material is also described in the following.
“Starting Motor Components”

Voltage 12 volts
Output 1.2 kW
Rating 30 seconds
Direction of rotation Clockwise as viewed from pinion side
Brush length Standard: 12.3 mm (0.48 in.) Limit: 7.0 mm (0.28 in.)
Number of pinion teeth 8
Performance Condition Guarantee
Around at 20 °C
(68 °F) No load characteristic 11.0 V
90 A maximum
2370 r/min minimum
Load characteristic 7.5 V
300 A 10.65 N
⋅m (1.065 kgf-m, 7.70 lb-ft) minimum
840 r/min minimum
Locked characteristic 4.0 V 780 A maximum
20 N
⋅m (2.0 kgf-m, 14.5 lb-ft) minimum
Magnetic switch operating voltage 8 volts maximum
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Starting motor battery cable nut 9.8 0.98 7.0 )

Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-13
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.
)

Downloaded from www.Manualslib.com manuals search engine Exhaust System: 1K-4
2) Install new seal ring and connect exhaust No.1 pipe (1) to exhaust manifold.
Tighten pipe fasteners to specified torque.
Tightening torque
Exhaust No.1 pipe bolt (a): 50 N·m (5.0 kgf-m,
36.5 lb-ft)
3) Install exhaust manifold stiffener (2). Tighten exhaust manifold stiffener bolts to specified
torque.
Tightening torque
Exhaust manifold stiffener bolt (b): 50 N·m (5.0
kgf-m, 36.5 lb-ft)
4) Install new seal ring and connect exhaust No.1 pipe (1) to exhaust No.2 pipe. Tighten pipe fasteners to
specified torque.
Tightening torque
Exhaust No.2 pipe bolt (c): 43 N·m (4.3 kgf-m,
31.0 lb-ft)
5) Install heated oxygen sensors (3) referring to “HO2S-1 and HO2S-2 Removal and Installation in
Section 1C”, if removed.
NOTE
Be sure to identify heated oxygen sensor
No.1 and No.2 by its connector color.

6) Connect heated oxygen sensor No.2 connector (1)
(connector color: green) and heated oxygen sensor
No.1 connector (2) (connector color: black), and then
fit coupler to br acket securely. 7) Install exhaust manifold cover to exhaust manifold.
8) Install A/C condenser to vehicle body for equipped
with A/C.
9) Install radiator referrin g to “Radiator Removal and
Installation in Section 1F” for equipped with A/C.
10) Install front bumper with fr ont grille by referring to
“Front Bumper and Rear Bumper Components in
Section 9K”.
11) Install engine cover.
12) Connect negative cable at battery.
13) Check exhaust system for exhaust gas leakage.
Exhaust Pipe and Muffler Removal and
Installation
S7RS0B1B06003
For replacement of exhaust pipe, be sure to hoist vehicle
and observe WARNING under “Exhaust System
Components” and the following.
CAUTION!
Exhaust manifold have three way catalytic
converter in it, it should not be exposed to
any impulse.
Be careful not to drop it or hit it against
something.

• Tighten bolts and nuts to specified torque when reassembling. Refer to “Exhaust System
Components”.
• After installation, start engine and check each joint of exhaust system for leakage.
2
(b)
(a)
1(C)
3
I4RS0A1B0005-01
1
2
I6RS0C1B0002-01

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 Precautions: 2-1
Suspension
Precautions
Precautions
Precautions on SuspensionS7RS0B2000001
Emergency Flat Tire Repair Kit handle Warning
Refer to “Warning for Handling Emergency Flat Tire Repair Kit in Section 00”.
Suspension Caution
Refer to “Suspension Caution in Section 00”.
Wheels and Tires Caution
Refer to “Wheels and Tires Caution in Section 00”.
General Precautions
Refer to “General Precautions in Section 00”.
Vehicle Lifting Points
Refer to “Vehicle Lifting Points in Section 0A”.
Fastener Caution
Refer to “Fastener Caution in Section 00”.
Fastener Information
Refer to “Fasteners Information in Section 0A”.
Brake Caution
Refer to “Brake Caution in Section 00”.

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 2B-19 Front Suspension:
13) Install suspension control arm referring to
“Suspension Control Arm / Bushing Removal and
Installation”.
14) Connect couplers of torque sensor and P/S motor.
15) Connect tie-rod ends to knuckles (right & left) and then install cotter pins referring to “Tie-Rod End
Removal and Installa tion in Section 6C”.
16) Be sure that steering wheel and brake discs (right & left) are all straight-ahead position and then insert
steering lower shaft (5) into steering pinion shaft (3)
with matching marks (4).
17) Tighten steering shaft joint lower bolt (1) and upper bolt (2) to specified torque (Lower side first and then
upper side).
Tightening torque
Steering shaft joint bolt (a): 25 N·m (2.5 kgf-m,
18.5 lb-ft)
18) Install both wheels and tighten wheel bolts to specified torque.
Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
19) Lower hoist.
20) Check toe setting. Adjust as required refer to “Front Wheel Alignment Inspection and Adjustment”.
Front Suspension Frame CheckS7RS0B2206016
Inspect for cracks, deformation or damage.
If defective, replace.
Front Stabilizer Bar, Bushing and/or Joint
Check
S7RS0B2206017
Stabilizer Bar
Inspect for damage or deformation.
If defective, replace.
Stabilizer Bushing
Inspect for damage, wear or deterioration.
If defective, replace.
Stabilizer Joint
1) Check for smooth rotation.
2) Check damages of ball stud.
3) Check damages of dust cover.
NOTE
Stabilizer joint (1) cannot be disassembled.

If there is any damage to either parts, stabilizer joint
assembly must be replaced as a complete unit.
Front Suspension Fasteners CheckS7RS0B2206018
Check each bolt and nut fastening suspension parts for
tightness. Tighten loose one, if any, to specified torque,
referring to “Front Suspension Construction”.
5
4
1, (a)
3
2, (a)
1, (a)
5
I4RS0B630016-01
I4RS0A220054-01
I4RS0A220052-01
I4RS0A220056-01
1
I4RH01220007-01