rack SUZUKI SWIFT 2008 2.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine 1E-6 Engine Lubrication System:
Installation1) Install new O-rings (2) in the position as shown in figure and install o il pump strainer (1).
Tighten strainer bolt (3) first and then bracket bolt (4)
to specified torque.
Tightening torque
Oil pump strainer bolt (a): 11 N·m (1.1 kgf-m, 8.0
lb-ft)
Oil pump strainer bracket bolt (b): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
2) Install dowel pin (1) to oil pan. 3) Apply sealant continuously to oil pan mating surface
as shown in figure.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Sealant amount for oil pan
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
4) Install oil pan to cy linder block temporarily.
5) Insert dowel pin (1) in hole (2) of oil pan in order to
locate oil pan precisely.
NOTE
Dowel pin is available as a spare part (part
number: 04211–13189).

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Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-11
Specifications
Tightening Torque SpecificationsS7RS0B1507001
NOTE
The specified tightening torque is also described in the following.
“Heat Exchanger Components”
“Oil Pan and Oil Pump Strainer Components”
“Oil Pump 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 MaterialS7RS0B1508001
NOTE
Required service material is also described in the following.
“Heat Exchanger Components”
“Oil Pan and Oil Pump Strainer Components”
“Oil Pump Components”

Special ToolS7RS0B1508002
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Oil pressure switch 13 1.3 9.5 )
Heat exchanger stand bolt 22 2.2 16.0 )
Oil pump strainer bolt 11 1.1 8.0 )
Oil pump strainer bracket bolt 11 1.1 8.0 )
Oil pan bolt (M6) 11 1.1 8.0 )
Oil pan bolt (M10) 55 5.5 40.0 )
Oil pan nut 11 1.1 8.0 )
Oil pan drain plug 35 3.5 25.5 )
Transaxle stiffener bolt 55 5.5 40.0 )
Oil pump rotor plate bolt 11 1.1 8.0 )
MaterialSUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260)
09915–77310 09915–78211
Oil pressure gauge (0-10kg/
cm2) Oil pressure gauge
attachment
))

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-6
Coolant Level CheckS7RS0B1606002
WARNING!
To help avoid danger of being burned, do not
remove radiator cap while engine and
radiator are still hot. Scalding fluid and steam
can be blown out under pressure if radiator
cap is taken off too soon.

To check level, lift hood and look at “see-through”
coolant reservoir.
It is not necessary to remove radiator cap to check
coolant level.
When engine is cool, check coolant level in reservoir (1).
A normal coolant level should be between FULL mark
(2) and LOW mark (3) on reservoir (1).
If coolant level is below LOW mark (3), remove reservoir
cap (4) and add proper coolant to reservoir to bring
coolant level up to FULL mark (2).
NOTE
If proper quality antifreeze is used, there is
no need to add extra inhibitors or additives
that claim to improve system. They may be
harmful to proper operation of system, and
are unnecessary expense.

Engine Cooling System Inspection and
Cleaning
S7RS0B1606003
WARNING!
To help avoid danger of being burned, do not
remove radiator cap while engine and
radiator are still hot. Scalding fluid and steam
can be blown out under pressure if cap is
taken off too soon.

1) Check cooling system for leakage or damage.
2) Wash radiator cap and fille r neck with clean water by
removing radiator cap when engine is cold.
3) Check coolant for proper level and freeze protection.
4) Using a pressure tester (1), check system and radiator cap (2) for proper pressure holding capacity.
If replacement of cap is required, use a proper cap
for this vehicle.
NOTE
After installing radiator cap to radiator, make
sure that the ear of cap lines is parallel to
radiator.

Cooling system and radiator cap holding
pressure (for inspection)
110 kPa (1.1 kg/cm2, 15.6 psi)
5) Tighten hose clamps and inspect all hoses. Replace hoses whenever cracked, swollen or otherwise
deteriorated.
6) Clean frontal area of radiator core.
Cooling System DrainingS7RS0B1606004
1) Remove radiator cap.
2) Drain coolant from radiator drain plug (1).
3) After draining coolant, be sure to tighten drain plug (1) securely.
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Downloaded from www.Manualslib.com manuals search engine 1G-7 Fuel System:
Fuel Pressure Relief ProcedureS7RS0B1706003
CAUTION!
This work must not be done when engine is
hot. If done so, it may cause adverse effect to
catalyst.

NOTE
If ECM detects DTC(s) after servicing, clear
DTC(s) referring to “DTC Clearance in
Section 1A”.

1) Make sure that engine is cold.
2) Shift transaxle gear shift lever in “Neutral” (shift select lever in “P” range for A/T model), set parking
brake and block drive wheels.
3) Remove relay / fuse box cover.
4) Disconnect fuel pump relay (1) from relay / fuse box (2).
5) Remove fuel filter cap in order to release fuel vapor pressure in fuel tank, and then reinstall it.
6) Start engine and run it until engine stops for lack of fuel. Repeat cranking engine 2 – 3 times for about 3
seconds each time in order to dissipate fuel pressure
in lines. Fuel connections are now safe for servicing.
7) After servicing, connect fuel pump relay (1) to relay / fuse box and install re lay / fuse box cover.
Fuel Leakage Check ProcedureS7RS0B1706004
After performing any service on fuel system, check to
make sure that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump) and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply
fuel pressure to fuel line until fuel pressure is felt by
hand placed on fuel feed hose.
2) In this state, check to see that there are no fuel leakages from any part of fuel system.
Fuel Lines On-Vehicle InspectionS7RS0B1706005
CAUTION!
Due to the fact that fuel feed line (1) is under
high pressure, use special care when
servicing it.

Visually inspect fuel lines for evidence of fuel leakage,
hose crack and deterioration or damage.
Make sure all cl amps are secure.
Replace parts as needed.
Fuel Pipe Removal and InstallationS7RS0B1706006
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal
1) Relieve fuel pressure in fuel feed line according to “Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Disconnect fuel pipe joint and fuel hose (3) from fuel pipe (2) at the front and rear of each fuel pipe
referring to “Fuel Hose Disconnecting and
Reconnecting”.
4) Mark the location of clamps (1) on fuel pipes (2), so that the clamps can be reinstalled to where they
were.
5) Remove pipes (2) with clamp (1) from vehicle.
6) Remove clamp (1) from pipes (2).
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Downloaded from www.Manualslib.com manuals search engine 1G-15 Fuel System:
3) Remove fuel pump assembly (1) from fuel tank (2).
Installation
CAUTION!
When connecting joint, clean outside surface
of pipe where joint is to be inserted, push
joint into pipe till jo int lock clicks and check
to ensure that pipes are connected securely,
or fuel leak may occur.

1) Clean mating surfaces of fuel pump assembly (1) and fuel tank.
2) Put plate (2) on fuel pump assembly (1) by matching the protrusion of fuel pump assembly (3) to plate
hole (4) as shown.
3) Install new gasket (2) and fuel pump assembly (1) earth bracket (5) with plate (3) to fuel tank (4).
Tightening torque
Fuel pump assembly bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft) 4) Connect fuel feed line (1) (pipe joint) to fuel pump
assembly (2).
5) Install fuel tank to vehi cle. Refer to “Fuel Tank
Removal and Installation”.
Main Fuel Level Sensor Removal and
Installation
S7RS0B1706018
CAUTION!
• Do not touch resister plate (1) and deform arm (2). It may cause main fuel level sensor
to fail.
• Be very careful not to cause damage to fuel tube installed section (sealed section
in bore). If it be damaged, replace it with
new one, or fuel will leak from the part.

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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)
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: 9.8 N ⋅m (0.98 kgf-m, 7.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 1I-5 Starting System:
Starting Motor ComponentsS7RS0B1906002
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1. Front housing 7. Plate 13. Planetary gear 19. Rear bush
2. Bush 8. Seal rubber 14. Packing 20. Starting motor battery cable nut
3. Pinion stop ring 9. Magnetic switch 15. Yoke :9.8 N
⋅m (0.98 kgf-m, 7.0 lb-ft)
4. Over-running clutch 10. Ball 16. Armature: Do not reuse.
5. Lever 11. Internal gear 17. Brush assembly : Apply grease 99000-25010 to sliding surface of each part.
6. Plunger 12. Planetary carrier shaft 18. Rear bracket

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-6
Starting Motor InspectionS7RS0B1906003
Plunger
Inspect plunger for wear. Replace if necessary.
Magnetic Switch
Push in plunger and release it. The plunger should
return quickly to its original position. Replace if
necessary.
Pull-in coil open circuit test
Check for continuity across magnetic switch “S” terminal
(1) and “M” terminal (2). If no continuity, coil is open and
should be replaced. Hold-in coil open circuit test
Check for continuity across ma
gnetic switch “S” terminal
(1) and coil case. If no continuity, coil is open and should
be replaced.
Rear Bracket Bush
Inspect bush for wear or damage. Replace if necessary.
Brush
• Check brushes for wear. Measure length of brushes and if below the limit,
replace the brush.
Brush length
Standard: 12.3 mm (0.48 in.)
Limit: 7.0 mm (0.28 in.)
• Install brushes to each brush holder and check for smooth movement.
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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-8 Charging System:
3) After loosening generator bracket bolts (2) and pivot bolt (3), adjust belt tensio n to specification described
at step 2) by loosening / tightening generator adjust
bolt (1).
4) Tighten generator bracket bolts and pivot bolt as specified torque.
Tightening torque
Generator bracket bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Generator pivot bolt (b): 50 N·m (5.0 kgf-m, 36.0
lb-ft)
5) Check belt tension for specification after turning crankshaft two rotations clockwise.
6) Tighten generator adjusting bolt (1) as specified torque.
Tightening torque
Generator adjusting bolt (c): 7 N·m (0.7 kgf-m,
5.0 lb-ft) by the specified procedure.
7) Connect negative cable at battery.Water Pump / Generator Drive Belt Removal and
Installation
S7RS0B1A06004
Removal 1) Disconnect negative cable at battery.
2) If vehicle equipped with A/C, remove compressor drive belt before removing water pump belt (1). Refer
to “Compressor Drive Belt Removal and Installation
in Section 7B” or “Compr essor Drive Belt Removal
and Installation in Section 7B”.
3) Loosen drive belt adjusting bolt (2) and generator pivot bolt (3).
4) Loosen generator adjusting bolt (4), and then remove water pump belt.
Installation
Reverse removal procedure for installation noting the
following.
• Adjust belt tension referring to “Water Pump / Generator Drive Belt Tension Inspection and
Adjustment” and “Compressor Drive Belt Inspection
and Adjustment in Section 7B” or “Compressor Drive
Belt Inspection and Adjustment in Section 7B”.
1, (c)
2, (a)
3, (b)
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