Downloaded from www.Manualslib.com manuals search engine Suzuki Swift Sport (RS416) 2004-2008 Service/Repair Manual This Service Manual has been prepared with the latest service information available at the time of publication. It is subdivided into various group categories and each section contains diagnostic, disassembly, repair and installation procedures along with complete specifications and tightening references. Please read this manual carefully before proceeding, as incorrect service procedures may result in injury or death to service personnel or to the operator’s of the vehicle. Downloaded from www.Manualslib.com manuals search engine IMPORTANT WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the words, and NOTE have special meanings. Pay specia l attention to the messages high- lighted by these signal words. The circle with a slash in this manual me ans “Don’t do this” or “Don’t let this happen”.

• 2000 Suzuki Swift Service Manual
• 2008 Suzuki Swift Owners Manual

Indicates a potential hazard that could result in death or injury. Indicates a potential hazard that could result in vehicle damage. NOTE: Indicates special information to make main tenance easier or instructions clearer.

This service manual is intended for authorized Su zuki dealers and qualified service technicians only. Inexperienced technicians or technicians without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the technician and may render the vehicle unsafe for the driver and passengers. For vehicles equipped with a Supplemental Restraint (Air Bag) System:. Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer.

Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser- vice Precautions” under “On-Vehicl e Service” in air bag system section before performing service on or around the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional activation of the system or could re nder the system inoperative. Either of these two conditions may result in severe injury.  If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help av oid unintended air bag system activation.

 Do not modify the steering wheel, instrument pa nel or any other air bag system component on or around air bag system components or wiring. Modi fications can adversely affect air bag system performance and lead to injury.  If the vehicle will be exposed to temperatures over 93 °C (200 °F), for example, during a paint baking process, remove the air bag system components, th at is air bag (inflator) modules, SDM and/or seat belt with pretensioner, beforehand to avoid component damage or unintended activation. Downloaded from www.Manualslib.com manuals search engine FOREWORD This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and reassembly of major components (Unit Repair-Overhaul).

Applicable Model: SWIFT (RS416) produced at KOSAI plant in Japan wi th the following vehicle identification numbers (VINs). JSAEZC31S############ The contents are classified into sectio ns each of which is given a section number as indicated in the Table of Contents on following page. And on the first page of ea ch individual section is an index of that section.

This manual should be kept in a handy place for ready reference of the service work. Strict observance of the so specif ied items will enable one to obtain the full performance of the vehicle. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specif ied in each description. All information, illustrations and specif ications contained in this literature are based on the late st product infor- mation available at the time of publication approval. And used as the main subject of description is the vehicle of standard specificatio ns among others. Therefore, note that illustrations may differ from the vehicle being actually serviced.

The right is reserved to make changes at any time without notice. Downloaded from www.Manualslib.com manuals search engine 00 0 1 2 3 4 5 6 7 8 9 10 11 Vo l u m e 1 Precautions. 00-1 General Information. 0-i General Information.

0A-1 Maintenance and Lubricatio n. 0B-1 Engine. 1-i Precautions. 1-1 Engine General Information and Diagnosis. Emission Control Devices.

1B-1 Engine Electrical Devices. 1C-1 Engine Mechanical. 1D-1 Engine Lubrication System. 1E-1 Engine Cooling System. 1F-1 Fuel System.1G-1 Ignition System. 1H-1 Starting System.

1I-1 Charging System.1J-1 Exhaust System. 1K-1 Suspension.

2-i Precautions. 2-1 Suspension General Diagnosis. 2A-1 Front Suspension. 2B-1 Rear Suspension. 2C-1 Wheels and Tires.

2D-1 Driveline / Axle. 3-i Precautions. 3-1 Drive Shaft / Axle. 3A-1 Brakes. 4-i Precautions. 4-1 Brake Control System and Diagnosis.

4A-1 Front Brakes. 4B-1 Rear Brakes. 4C-1 Parking Brake.

4D-1 ABS. 4E-1 Electronic Stability Program.

4F-1 Vo l u m e 2 Precautions. 00-1 Transmission / Transaxle. 5-i Precautions. 5-1 Automatic Transmission/Transaxle.

5A-1 Manual Transmission/Transaxle. 5B-1 Clutch.5C-1 Steering. 6-i Precautions. 6-1 Steering General Diagnosis. 6A-1 Steering Wheel and Column.

6B-1 Power Assisted Steering System.6C-1 HVAC. 7-i Precautions.

7-1 Heater and Ventilation. 7A-1 Air Conditioning System. 7B-1 Restraint.

8-i Precautions. 8-1 Seat Belts.

8A-1 Air Bag System. 8B-1 Body, Cab and Accessories.

9-i Precautions. 9-1 Wiring Systems.

9A-1 Lighting Systems. 9B-1 Instrumentation / Driver Info.

/ Horn.9C-1 Wipers / Washers.9D-1 Glass / Windows / Mirrors. 9E-1 Security and Locks. 9F-1 Seats. 9G-1 Interior Trim.9H-1 Hood / Fenders / Doors. 9J-1 Body Structure. 9K-1 Paint / Coatings.

9L-1 Exterior Trim. 9M-1 Control Systems. 10-i Precautions. 10-1 Body Electrical Control Sy stem. 10B-1 Immobilizer Control System.10C-1 Keyless Start System. 10E-1 TABLE OF CONTENTS. Downloaded from www.Manualslib.com manuals search engine Table of Contents 00- i 00 Section 00 CONTENTS Precautions Precautions.

00-1 Precautions. 00-1 Precautions for Vehicles Equipped with a Supplemental Restraint (A ir Bag) System. 00-1 General Precautions.

00-4 Warning for Wheel (with tire) Removal. 00-7 Warning for Handling Emergency Flat Tire Repair Kit. 00-7 Precautions for Catalytic Converter. 00-7 Precautions for Installing Mobile Communication Equipment. 00-7 Precaution for CAN Communication System. 00-7 Precautions for Electrical Circuit Service. 00-8 Air Bag Warning.

2000 Suzuki Swift Service Manual

00-10 Air Bag System Service Warning. 00-10 Fastener Caution. 00-10 Suspension Caution. 00-10 Wheels and Tires Caution. 00-10 Precaution for Vehicle Equipped with ESP ® System.

00-11 Brake Caution. 00-11 Repair Instructions. 00-11 Electrical Circuit Inspection Procedure. 00-11 Intermittent and Poor Co nnection Inspection.

Downloaded from www.Manualslib.com manuals search engine 00-1 Precautions: Precautions Precautions Precautions Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System S7RS0B0000001 WARNING!. The configuration of air bag system parts are as shown in the figure. When it is necessary to service (remove, reinstall and inspect) these parts, be sure to follow procedures described in Air Bag System section.

Failure to follow proper procedures could result in possible air bag system activation, personal injury, damage to parts or air bag system being unable to activate when necessary. If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air bag system be repaired first, to help avoid unintended air bag system activation. Do not modify the steering wheel, dashboard, or any other air bag system components. Modifications can adversely affect air bag system performance and lead to injury. If the vehicle will be exposed to temperatures over 93 °C (200 °F) (for example, during a paint baking process), remove the air bag system components beforehand to avoid component damage or unintended air bag system activation. Diagnosis.

When troubleshooting air bag system, be sure to follow “Diagnosis” in Air Bag System section. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect parts replacement. Never use electrical test equipment other than that specified. Never attempt to measure the resistance of the air bag (inflator) modules (driver, passenger, side and curtain) and seat belt pretensioners (driver and passenger). It is very dangerous as the electric current from the tester may deploy the air bag or activate the pretensioner.

Air bag wire harness (in floor, main and instrument panel harness) 6. Driver air bag (inflator) module 2. Passenger air bag (inflator) module 7. Side air bag (inflator) module (if equipped) 3. Curtain air bag (inflator) module (if equipped) 4. Seat belt pretensioner 9. Forward sensor 5.

Contact coil 10. Side sensor (if equipped) 1 2 3 4 4 5 6 7 7 8 9 10 10 I4RS0B000001-02 I4RS0A000002-02.

Downloaded from www.Manualslib.com manuals search engine Precautions: 00-2 Servicing and Handling WARNING! Many of service procedures require disconnection of “A/BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver, Passenger, Side and Curtain Air Bag (Inflator) Modules. For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65 °C (150 ° F), without high humidity and away from electric noise. When carrying a live air bag (inflator) module, make sure the bag opening is pointed away from you. In case of an accidental deployment, the bag will then deploy with minimal chance of injury.

Never carry the air bag (inflator) module by the wires or connector on the underside of the module. When placing a live air bag (inflator) module on a bench or other surface, always face the bag up, away from the surface. As the live passenger air bag (inflator) module must be placed with its bag (trim cover) facing up, place it on the workbench with a slit (1) or use the workbench vise (2) to hold it securely at its lower mounting bracket (3). It is also prohibited to place anything on top of the trim cover and stack air bag (inflator) modules. This is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental deployment.

Otherwise, personal injury may result. Never dispose of live (undeployed) air bag (inflator) modules (driver, passenger, side and curtain). If disposal is necessary, be sure to deploy them according to deployment procedures described in “Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal in Section 8B” before disposal. The air bag (inflator) module immediately after deployment is very hot. Wait for at least half an hour to cool it off before proceeding the work. After an air bag (inflator) module has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by- products of the chemical reaction.

As with many service procedures, gloves and safety glasses should be worn. A: Always carry air bag (inflator) module with trim cover (air bag opening) away from body. B: Always place air bag (inflator) module on workbench with trim cover (air bag opening) up, away from loose objects. 1 2 3 A B I4RS0A000003-02. Downloaded from www.Manualslib.com manuals search engine 00-3 Precautions: WARNING! SDM.

For handling and storage of a SDM, select a place where the ambient temperature below 65 °C (150 °F), without high humidity and away from electric noise. During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system.

The SDM could be activated when powered while not rigidly att ached to the vehicle which could cause deployment and result in personal injury. Driver and Passenger Seat Belt Pretensioners. For handling and storage of a live seat belt pretensioner, select a place where the ambient temperature below 65 °C (150 ° F), without high humidity and away from electric noise. Never carry seat belt pretensioner by wire or connector of pretensioner. When placing a live seat belt pretensioner on the workbench or some place like that, never put something on seat belt pretensioner.

Otherwise, personal injury may result. Never dispose of live (inactivated) seat belt pretensioners (drive and passenger). If disposal is necessary, be sure to activate them according to activation procedures described in “Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal in Section 8B” before disposal. The seat belt pretensioner immediately after activation is very hot. Wait for at least half an hour to cool it off before proceeding the work. With many service procedures, gloves and safety glasses should be worn to prevent any possible irritation of the skin or eyes. Even when the accident was light enough not to cause air bags to activate, be sure to inspect system parts and other related parts according to instructions under “Repair and Inspection Required after Accident in Section 8B”.

When servicing parts other than air bag system, if shocks may be applied to air bag system component parts, remove those parts beforehand. When handling the air bag (inflator) modules (driver, passenger, side and curtain), seat belt pretensioners (driver and passenger), forward sensor, side sensors or SDM, be careful not to drop it or apply an impact to it. If an excessive impact was applied, never attempt disassembly or repair but replace it with a new one. When grease, cleaning agent, oil, water, etc. Has got onto air bag (inflator) modules (driver, passenger, side and curtain) or seat belt pretensioners (drive and passenger), wipe off immediately with a dry cloth. Air bag wire harness is included in floor and instrument panel wire harnesses. Air bag wire harness branched off from floor and instrument panel wire harnesses can be identifie d easily as it is covered with a yellow protection tube and it has yellow connectors.

Be very ca reful when handling it. When an open in air bag wire harness, damaged wire harness, connector or terminal is found, replace wire harness, connectors and terminals as an assembly. Do not apply power to the air bag system unless all components are connected or a diagnostic flow requests it, as this will set a DTC. Never use air bag system component parts from another vehicle.

When using electric welding, be sure to disconnect all air bag (inflator) module connectors and pretensioner connectors from air bag wire harness respectively. Never expose air bag system component parts directly to hot air (drying or baking the vehicle after painting) or flames. WARNING / CAUTION labels are attached on each part of air bag system components. Be sure to follow the instructions.

After vehicle is completely repaired, perform “Air Bag Diagnostic System Check in Section 8B”. Downloaded from www.Manualslib.com manuals search engine Precautions: 00-4 General PrecautionsS7RS0B0000002 The WARNING and CAUTION describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures, and they will not necessarily be repeated with each procedure to which they apply.

Whenever raising a vehicle for service, be sure to follow the instructions under “Vehicle Lifting Points in Section 0A”. When it is necessary to do service work with the engine running, make sure that the parking brake is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for automatic transmission vehicles), Keep hands, hair, clothing, tools, etc. Away from the fan and belts when the engine is running. When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.

Do not perform service work in areas where combustible materials can come in contact with a hot exhaust system. When working with toxic or flammable materials (such as gasoline and refrigerant), make sure that the area you work in is well- ventilated. To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail pipe, muffler, etc.

New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or used oil. Keep new and used oil and used engine oil filters away from children and pets. Continuous contact with used engine oil has been found to cause skin cancer in laboratory animals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a long- sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing engine oil. If engine oil contacts your skin, wash thoroughly with soap and water.

Launder any clothing or rags if wet with oil, recycle or properly dispose of used oil and filters. Be sure to observe following instructions when handling service materials such as fuel, oil, fluid, coolant, grease, sealant, thread lock cement, etc. Otherwise, your health may be ruined. – Whenever handling any of these service materials, wear safety glasses to protect your eyes. If it gets into your eye, it may cause inflammation. – Whenever handling any of these service materials, wear moistu re-proof gloves to protect your skin.

Ga7ff manual. If it adheres to your skin, it may cause inflammation. – Do not swallow any of these service materials. It would cause diarrhea or nausea. – Keep all these materials out of children’s reach. Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly during driving, obstructing your view and resulting in an accident.

Before starting any service work, cover fenders, seats and any other parts that are likely to get scratched or stained during servicing. Also, be aware that what you wear (e.g., buttons) ma y cause damage to the vehicle’s finish. Downloaded from www.Manualslib.com manuals search engine 00-5 Precautions:. When performing service to electrical parts that does not require use of battery power, disconnect the negative cable of the battery. When disconnecting the negative cable from the battery, be careful to the following. – Check and record DTCs in ECM and HVAC control module if necessary before disconnecting. – Record displayed contents of the clock and/or audio system, etc.

Before disconnecting and reset it as before after connecting. – For vehicle equipped with electric throttle body system, perform electric throttle body system calibration referring to “Electric Throttle Body System Calibration in Section 1C” after reconnecting the negative cable to the battery. – For vehicle equipped with ESP ®, calibrate steering angle sensor referring to “Sensor Calibration in Section 4F” after reconnecting the negative cable to the battery. When removing the battery, be sure to disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover.

When removing parts that are to be reused, be sure to keep them arranged in an orderly manner so that they may be reinstalled in the proper order and position. Whenever you use oil seals, gaskets, packing, O- rings, locking washers, split pins, self-locking nuts, and certain other parts as specified, be sure to use new ones. Also, before installing new gaskets, packing, etc., be sure to remove any residual material from the mating surfaces. Make sure that all parts used in reassembly are perfectly clean.

When use of a certain type of lubricant, bond or sealant is specified, be sure to use the specified type. “A”: Water tight sealant 0 (SUZUKI Bond No.1207F) I2RH01010026-01 I2RH01010027-01 I2RH01010028-01 I2RH01010029-01 I2RH01010030-01.

2008 Suzuki Swift Owners Manual

. General Information. Engine. Precautions. Engine General Information and Diagnosis. Aux.