generator dismounting and remounting SUZUKI SWIFT 2008 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Table of Contents 1-v
Ignition Timing Inspection ................................... 1H-8
Specifications ....................................................... 1H-9
Tightening Torque Specifications ........................ 1H-9
Special Tools and Equipmen t ............................. 1H-9
Special Tool ........................................................ 1H-9
Starting System ................. ........................ 1I-1
Schematic and Routing Diagram ......................... 1I-1
Cranking System Circuit Diagram ........................ 1I-1
Diagnostic Information and Procedures ............. 1I-1
Cranking System Symptom Diagnosis ................. 1I-1
Cranking System Test.......................................... 1I-3
Repair Instructions ............................................... 1I-4 Starting Motor Dismounting and Remounting ...... 1I-4
Starting Motor Components ................................. 1I-5
Starting Motor Inspection ..................................... 1I-6
Specifications ........................................................ 1I-9
Cranking System Specifications........................... 1I-9
Tightening Torque Specifications ......................... 1I-9
Special Tools and Equipment .............................. 1I-9
Recommended Service Material .......................... 1I-9
Charging System ............ .......................... 1J-1
General Description ......... .................................... 1J-1
Battery Description ...............................................1J-1
Generator Descripti on ..........................................1J-2
Diagnostic Information and Procedures ............ 1J-4 Battery Inspection ................................................1J-4
Generator Symptom Diagnosis ............................1J-4 Generator Test (Undercharged Battery
Check) ............................................................... 1J-5
Generator Test (Overcharg ed Battery Check) .... 1J-6
Repair Instructions ........... ................................... 1J-6
Jump Starting in Case of Emergency.................. 1J-6
Battery Dismounting and Remounting ................ 1J-7
Water Pump / Generator Drive Belt Tension Inspection and Adjustment ................................ 1J-7
Water Pump / Generator Drive Belt Removal and Installation .................................................. 1J-8
Generator Unit Co mponents ............................... 1J-9
Generator Dismounting a nd Remounting............ 1J-9
Generator Components........ ............................. 1J-10
Generator Insp ection......................................... 1J-11
Specifications ..................................................... 1J-13 Charging System Specifications ....................... 1J-13
Tightening Torque Specifications ...................... 1J-13
Exhaust System .............. ......................... 1K-1
General Description .............................................1K-1
Exhaust System Description ............................... 1K-1
Diagnostic Information and Procedures ............1K-1 Exhaust System Check ....................................... 1K-1
Repair Instructions ........... ...................................1K-2
Exhaust System Components ............................. 1K-2
Exhaust Manifold Removal and Installation ........ 1K-3
Exhaust Pipe and Muffler Removal and Installation ......................................................... 1K-4
Specifications .................... ...................................1K-5
Tightening Torque Specifications ........................ 1K-5

Downloaded from www.Manualslib.com manuals search engine 1D-19 Engine Mechanical:
24) Before removing engine with transaxle from engine compartment, recheck to make sure all hoses,
electric wires and cables are disconnected from
engine and transaxle.
25) Lower engine with transaxle from engine compartment.
CAUTION!
Before lowering engine, to avoid damage to
A/C compressor and clutch operating
cylinder, make clearance by rising them. Be
sure not to damage suspended A/C
compressor and clutch operating cylinder.

26) Disconnect transaxle from engine, referring to “Manual Transaxle Unit Dismounting and
Remounting in Section 5B” or “Automatic Transaxle
Unit Dismounting and Re mounting in Section 5A”.
27) For M/T model, remove clutch cover and clutch disk referring to “Clutch Cover, Clutch Disc and Flywheel
Removal and Installa tion in Section 5C”.
Installation 1) For M/T model, install clutch cover and clutch disk referring to “Clutch Cover, Clutch Disc and Flywheel
Removal and Installa tion in Section 5C”.
2) Connect transaxle to engine referring to “Manual Transaxle Unit Dismounting and Remounting in
Section 5B” or “Automatic Transaxle Unit
Dismounting and Remounting in Section 5A”.
3) Lift engine and transaxle into engine compartment with jack.
4) Install engine left mounting bracket nuts (1) and engine right mounting nuts (2).Tighten these nuts to
specified torque.
Tightening torque
Engine left mounting bracket nut (a): 55 N·m (5.5
kgf-m, 40.0 lb-ft)
Engine right mounting nut (b): 65 N·m (6.5 kgf-
m, 47.0 lb-ft) 5) Support engine assemble by using chain hoist.
6) Install engine rear mounting to engine rear
mountingNo.1 bracket.
Tightening torque
Engine rear mounting bush bolt: 55 N·m (5.5
kgf-m, 40.0 lb-ft)
7) Install suspension frame referring to “Front Suspension Frame, Stabiliz er Bar and/or Bushings
Removal and Installati on in Section 2B”.
8) Remove chain hoist.
9) Install exhaust No.1, No.2 and center pipes referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
10) Connect drive shaft joints referring to “Front Drive Shaft Assembly Removal and Installation in Section
3A”.
11) Reverse disconnected hoses, cables and electric wires for connection noting the followings.
• Tighten nuts to specified torque.
Tightening torque
Starting motor terminal nut: 11 N·m (1.1 kgf-m,
8.0 lb-ft)
Generator terminal nut: 6 N·m (0.6 kgf-m, 4.5 lb-
ft)
Intake manifold ground terminal bolt: 11 N·m (
1.1 kgf-m, 18.0 lb-ft)
12) Install intake manifold rear stiffener to intake
manifold and cylinder block.
13) Install air cleaner assembly referring to “Air Cleaner Components”.
14) Install cowl top referring to “Cowl Top Components in
Section 9K”.
I4RS0A140009-01
1, (a)
2, (b)
I4RS0A140010-01

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Thermostat Removal and InstallationS7RS0B1606007
Removal1) Drain coolant referring to “Cooling System Draining”.
2) Remove intake manifold referring to “Intake Manifold Removal and Installa tion in Section 1D”.
3) Remove generator referring to “Generator Dismounting and Remounting in Section 1J”.
4) Disconnect water hose (1) and heater hose (2) from each pipe.
5) Remove thermostat case (3) with thermostat cap (4)
and water inlet pipe (5).
6) Remove water inlet pipe with thermostat cap from thermostat case.
7) Remove thermostat from thermostat case (3).
Installation
Reverse removal procedure for installation noting the
following points.
• Install thermostat cap (1) to thermostat case (2) by aligning match mark (3) of thermostat case with air
bleed valve (4) of the thermostat (5).
• Use new O-rings when installing.
• Adjust water pump belt tension referring to “Water Pump / Generator Drive Belt Tension Inspection and
Adjustment in Section 1J”.
• Adjust A/C compressor belt tension referring to “Compressor Drive Belt Inspection and Adjustment in
Section 7B” or “Compressor Drive Belt Inspection and
Adjustment in Section 7B”. • Refill cooling system referrin
g to Step 7) to 22) of
“Cooling System Flush and Refill”.
• Verify that there is no coolant leakage at each connection.
Thermostat InspectionS7RS0B1606008
• Make sure that air bleed valve (1) of thermostat is clean.
• Check to make sure that va lve seat (2) is free from
foreign matters which would prevent valve from
seating tight.
• Check thermostat seal (3) for breakage, deterioration or any other damage.
• Check thermostatic movement of wax pellet as follows:
a. Immerse thermostat (1) in water, and heat water gradually.
b. Check that valve starts to open at specific temperature.
Temperature at which valve begins to open
80 – 84 °C (176 – 183 °F)
Temperature at which valve become fully open
95 – 97 °C (203 °F)
Va l v e l i ft
More than 8 mm at 95 °C (203 ° F)
If valve starts to open at a temperature substantially
below or above specific temperature, thermostat unit
should be replaced with a new one. Such a unit, if
reused, will bring about ov ercooling or overheating
tendency.
I3RM0A160007-01
4
5 3
1 2
I7RS0B160006-01
2. Thermometer
3. Heater
I3RM0A160008-01
I2RH01160012-01

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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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Generator Unit ComponentsS7RS0B1A06005
Generator Dismounting and RemountingS7RS0B1A06006
Dismounting1) Disconnect negative (–) cable at battery.
2) Remove right side drive shaft referring to “Front Drive Shaft Assembly Removal and Installation in
Section 3A”.
3) Disconnect generator lead wire (“B” terminal wire) and coupler from generator.
4) Remove generator belt. Refer to “Water Pump / Generator Drive Belt Re moval and Installation”.
5) Remove generator bracket bolts and generator pivot bolt.
6) Remove generator. Remounting
Reverse dismounting procedure for remounting noting
the followings.
• Tighten each bolt and nut to specified torque referring
to “Generator Unit Components”.
• Adjust belt tension referring to “Water Pump / Generator Drive Belt Tension Inspection and
Adjustment”.
(a)
(b)
(c)
1
2 8
3 7 5 49 6(c)
(c)
I6RS0C1A0003-02
1. “B” terminal nut
5. Generator pivot bolt : 5 N⋅m (0.5 kgf-m, 3.5 lb-ft)
2. “B” terminal wire 6. Generator belt : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft)
3. Connector 7. Generator : 25 N⋅m (2.5 kgf-m, 18.5 lb-ft)
4. Generator adjusting bolt 8. Generator bracket bolt