bolt SUZUKI SWIFT 2008 2.G Service Manual Online

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 1K-3 Exhaust System:
Exhaust Manifold Removal and InstallationS7RS0B1B06002
Removal
WARNING!
To avoid danger of being burned, do not
service exhaust system while it is still hot.
Service should be performed after system
cools down.

1) Disconnect negative cable at battery.
2) Remove engine cover.
3) Remove front bumper with front grille referring to
“Front Bumper and Rear Bumper Components in
Section 9K”.
4) Remove radiator referring to “Radiator Removal and Installation in Section 1F ” for equipped with A/C.
5) With hose connected, detach A/C condenser from vehicle body for equipped with A/C.
6) Remove exhaust manifold cover from exhaust manifold.
7) Disconnect heated oxygen sensor No.2 connector (1) (connector color: green) and heated oxygen
sensor No.1 connector (2) (connector color: black),
and then detach it from its stay.
8) Remove exhaust manifold stiffener (1).
9) Remove heated oxygen sensors (3) from exhaust manifold and exhaust No.1 pipe, if necessary.
10) Disconnect exhaust No.1 pipe (2) from exhaust manifold. 11) Remove exhaust manifold (1) and its gasket from
cylinder head.
Installation 1) Install new gasket to cylinder head. Then install exhaust manifold (3).
Tighten manifold bolts (1) and nuts (2) to specified
torque.
Tightening torque
Exhaust manifold bolt (a): 50 N·m (5.0 kgf-m,
36.5 lb-ft)
Exhaust manifold nut (b): 50 N·m (5.0 kgf-m,
36.5 lb-ft)
NOTE
Be sure to install exhaust manifold bolts and
nuts to proper location referring to “Exhaust
System Components”.

1
2
I6RS0C1B0002-01
1
2
3
I4RS0A1B0002-01
1
I6RS0C1B0003-01
2, (b) 2, (b)
3
1, (a)
I6RS0C1B0004-01

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 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 Suspension General Diagnosis: 2A-2
NOTE
*1: Right-to-left trim height (“H”) difference should be within 15 mm (0.6 in.) with curb weight. (same
with rear side.)

Body leans or sways in
corners Loose stabilizer bar
Tighten stabilizer bar bolts or nuts, or replace
bushes.
Faulty strut (shock absorber) or
mounting Replace strut (shock absorber) or tighten
mounting.
Broken or sagging coil springs Replace coil springs.
Overloaded Check loading.
Cupped tires Front struts defective Replace struts.
Worn wheel bearings Replace wheel bearings.
Excessive tire or wheel run-out Replace tire and/or wheel.
Worn ball joints Replace front suspension control arm.
Tire out of balance Adjust tire balance.
Condition Possible cause Correction / Reference Item
“H”
I2RH01210001-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-4
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

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 Front Suspension: 2B-6
• Tighten wheel nuts to specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
• After installation, confirm front wheel alignment.
Front Strut Assembly Disassembly and
Assembly
S7RS0B2206004
WARNING!
Use a regular coil spring compressor and
follow the operation procedure described in
the Instruction Manual.

Disassembly 1) Attach special tool (A) to coil spring as shown. Turn special tool bolts alternat ely until coil spring tension
is released. Rotate the strut around its axis to
confirm that the coil spring is released or not.
Special tool
(A): 09940-71431
2) While keeping coil spring compressed with special
tools as shown, remove strut support lower nut.
Special tool
(B): 09900-00411 socket
(C): 09900-00414 6 mm
3) Disassemble strut assembly. Assembly
For assembly, reverse disassembly procedure, noting
the following instructions.
1) Compress coil spring with special tool (A) until total
length becomes about 280 mm (11.0 in.) as shown.
Special tool
(A): 09940–71431
Length
“a”: 280 mm (11.0 in.)
2) Install compressed coil spring to strut, and place coil
spring end (2) onto spring lower seat (1) as shown.
NOTE
End of coil spring must not interfere with
step of spring lower seat.

I4RS0A220009-01
(B)
(C)
I4RS0A220007-01
U: Upper side (small dia.) L: Lower side (large dia.)
I4RS0A220010-01
I4RS0A220011-01