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SUZUKI SWIFT REPAIR MANUAL PDF

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Suzuki Swift Service Repair Manual - Suzuki Swift PDF The Swift was powered by a new generation of Suzuki inline-four gasoline engines, the M family. This manual is a PDF file. Suzuki Repair Manual | eBay. View and Download Suzuki Swift user manual online. Swift Suzuki. Swift Automobile pdf manual. This manual contains procedures for diagnosis, maintenance, adjustments, minor service operations, Suzuki Swift (RS Series) Service Manual PDF. Home».


Suzuki Swift Repair Manual Pdf

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File: PDF Size: Mb Free download Suzuki Swift (RS, RS, RS) Factory Service Repair Manual PDF The password for archive: resourceone.info 4 days ago Suzuki Swift Service Manual - [Free] Suzuki Swift Service Manual [ PDF] [EPUB]. Samurai / Sidekick Basics. Suzuki Samurai History. Suzuki Swift Maintenance Manual - [Free] Suzuki Swift Maintenance Manual [ PDF] [EPUB] No. Comments on “Suzuki Samurai Repair/.

Be very ca reful when handling it. Be sure to follow the instructions. Page 9 of Downloaded from www. These general precautions apply to many of the service procedures, and they will not necessarily be repeated with each procedure to which they apply. When working with toxic or flammable materials such as gasoline and refrigerant , make sure that the area you work in is well- ventilated.

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. Otherwise, your health may be ruined. If it gets into your eye, it may cause inflammation. If it adheres to your skin, it may cause inflammation. It would cause diarrhea or nausea. If it is not, it can fly up unexpectedly during driving, obstructing your view and resulting in an accident. Also, be aware that what you wear e. Page 10 of Downloaded from www. When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover.

Radiator inlet hose Heater inlet hose IAC valve outlet 9. Timing belt Cylinder head bolts in reverse order of tightening. Once each bolt is loose, remove the bolts from the cylinder head.

Check to be sure all components are removed or disconnected before removing the cylinder head. Remove the cylinder head with the intake manifold, exhaust manifold and distributor as an assembly.

Install a new cylinder head gasket and the cylinder head, with the distributor case, onto the cylinder block. Tighten the cylinder head bolts, in sequence, using the following 3 Steps: Timing belt Engine cooling water hoses 4. Cylinder head cover Fuel feed and return hoses to each pipe Vacuum hoses All remaining electrical components All remaining components in the reverse order of removal 6.

Fill the engine coolant and check all fluids. Connect the negative battery cable to the battery. Start the engine and check for leaks. Air cleaner outlet hose Intake manifold rear stiffener bolt, alternator adjustment arm reinforcement bolt and right mounting bracket stiffener from the intake manifold Heated Oxygen HO 2 S sensor connector and release its clamps Exhaust from the manifold 5.

Distributor, if equipped Ignition coils, if equipped. Timing belt Engine cooling water hoses. Remove air cleaner case with air cleaner outlet hose. Disconnect accelerator cable from throttle body. Remove accelerator cable from bracket. Brake booster hose from intake manifold Coolant hose from throttle body Fuel feed hose from delivery pipe Fuel return hose from fuel return pipe Heater hose from water outlet cap Radiator inlet hose from water outlet cap Vacuum hose from EVAP canister purge valve Disconnect the following electric lead wires: Remove intake manifold rear stiffener.

Disconnect coolant pipe from intake manifold.

SUZUKI SWIFT 2006 2.G Service Workshop Manual

Remove 1st timing chain. Remove camshafts and valve lash adjuster. Remove engine RH mounting bracket.

Disconnect power steering pump and alternator from power steering pump bracket. That may cause damage to engine, transmission, etc. Cylinder head bolt loosening sequence: Install engine rear mounting No.

Loosen cylinder head bolts in such order as numbered in the figure and remove them. Don-t forget to remove bolt M6 as shown in the figure. Check all around cylinder head for any other parts required to be removed or disconnected and remove or disconnect whatever necessary. Remove cylinder head with intake manifold, exhaust manifold and water outlet cap.

Be careful not to damage fins of radiator. Clean mating surface of cylinder head and cylinder block. Remove oil, old gasket and dust from mating surface. Install knock pins to cylinder block. Install new cylinder head gasket to cylinder block. Top mark provided on gasket comes to crankshaft pulley side, facing up toward cylinder head side. Cylinder head bolt tightening sequence: Install cylinder head to cylinder block.

Apply engine oil to cylinder head bolts and tighten them gradually as follows: Tighten all bolts to 39 ft. In the same manner as in the first step, retighten them to 61 ft. Loosen all bolts according to the bolt loosening sequence until tightening torque is reduced to 0 according to numerical order in the figure.

Tighten all bolts to 27 ft. In the same manner as in the previous step, retighten them to 76 ft. After securing the other bolts, be sure to tighten the M6 bolt to 8 ft. Install engine RH mounting bracket and tighten bracket bolts to 40 ft. Install power steering pump bracket. Install power steering pump and alternator-to-power steering pump bracket. Install camshafts and valve lash adjuster.

Install 1st timing chain. Reverse removal procedure for installation. Adjust accelerator cable play as follows: Warm up engine to normal operating temperature. And check to make sure that fast idle control cam is off cam follower lever.

With throttle valve closed, check accelerator pedal play which should measure 0. If measured value is out of. Back to Top specification, adjust it to specification with cable adjusting nut.

With accelerator pedal depressed fully, check clearance between throttle lever and lever stopper throttle body which should measure 0.

If measured value is out of specification, adjust it to specification by changing height of pedal stopper bolt. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled. Refill engine with engine oil. Refill cooling system. Connect negative cable at battery.

Verify that there is no fuel leakage, coolant leakage, oil leakage and exhaust gas leakage at each connection. Properly relieve the fuel system pressure. Battery and tray Windshield washer hose from the hood 4. Using a grease pencil or marker, mark the hood hinge to hood outline. With the aid of an assistant, remove the hood.

Disconnect the following electrical wires and release the wiring harness from the clamps: Evaporative EVAP emission canister purge valve, if equipped 8. Disconnect the following vacuum hoses: Brake booster hose from the intake manifold Canister purge hose Air conditioning valve hose 9. Fuel return hose and the fuel feed hose from the throttle body Heater inlet and outlet hoses Disconnect the following cables: Accelerator cable from the throttle body Clutch cable from the transaxle, if equipped Speedometer cable from the transaxle, if equipped Shift switch, if equipped with an automatic transaxle VSS, if equipped EVAP canister from the vehicle Fender apron extensions Exhaust pipe from the exhaust manifold Control shaft and extension rod from the transaxle Drain the engine and transaxle oil.

NOTE For engine and transaxle removal, it is not necessary to remove the halfshafts from the steering knuckles. Left and right halfshafts NOTE Suspend the compressor where no damage will occur during engine removal and installation. Air conditioning compressor from its mounting bracket with the hoses still attached, if equipped with air conditioning NOTE Plug the power steering hose, pipe and pump ports to minimize fluid loss. Power steering hoses from the power steering pump, if equipped Rear torque rod bracket from the transaxle, if equipped with an automatic transaxle Rear mount from the body, if equipped with a manual transaxle If equipped with an automatic transaxle, remove the rear mounting nut.

Install an engine lifting device. Rear mount from the body Left side engine mounting bracket bolts and bracket Right side engine mount from its bracket Before lifting the engine and assembly check to be sure that all the hoses, electric wires and cables are disconnected. Remove the engine with the transaxle from the vehicle.

Lower the engine and transaxle into the engine compartment but do not remove the lifting device. Rear mount to the body Left side engine mounting bracket and bolts Right side engine mount to its bracket Rear mounting nut, if equipped with an automatic transaxle 3.

Tighten the engine mounting nuts and bolts to specification. Tighten the mounting bolts to ft. Power steering hose and pipe to the power steering pump, if equipped Left and right halfshafts Control shaft and the extension rod to the transaxle. Tighten the control shaft nuts and bolts to ft.

Exhaust pipe to the exhaust manifold. Tighten the bolts to ft. Fill the transaxle with gear oil. Install the remaining components in the reverse order of removal. Adjust the clutch pedal free-play. Adjust the accelerator cable free-play. Fill the engine with engine oil and the cooling system with coolant. Fill the power steering reservoir and bleed the power steering system. Run the engine and verify that there are no fuel, coolant, transmission or exhaust leaks.

Rear mount from the body Left side engine mounting bracket bolts and bracket Right side engine mount from its bracket. Mark the position of the hood on the hinges for installation reference, then remove the hood with the aid of an assistant. Radiator and cooling fan Air cleaner outlet hose Air cleaner case bolts and case 6.

Accelerator cable from the throttle body Clutch cable from the transaxle, if equipped with manual transmission Gear select cable from the transaxle, if equipped with automatic transmission 7. Disconnect the following electrical connectors: Fuel feed hose from the feed pipe Return hose from the fuel pressure regulator Heater inlet and outlet hoses Right and left engine undercovers Front exhaust pipe from the exhaust manifold and center exhaust pipe Gear shift control shaft from the transaxle and the extension rod, if equipped with a manual transaxle Position the air conditioning out of the way from the engine.

If equipped with power steering, drain the power steering pump of fluid. Power steering hose from the power steering pump, if equipped Install a lifting device on the engine. Center member from the vehicle by unfastening the 7 nuts and 4 bolts Left engine mount Right engine mount and bracket Check to be sure all cooling hoses, vacuum hoses and electrical wires are disconnected from the engine.

Lower the engine with the transaxle from the vehicle. Raise the engine and transaxle into the engine compartment. Right engine mount with the bolts and nuts. Tighten the bolts and nuts to 40 ft. Left engine mount and install the bolts and nuts. Install the center member using the 7 nuts and 4 bolts.

Tighten the bolts and nuts as follows: Center member to the radiator support: Center member to crossmember: Engine mounts to center member nuts: Remove the lifting device.

Gear shift control shaft on the transaxle and the extension rod, if equipped with a manual transaxle Front exhaust pipe on the center exhaust pipe and exhaust manifold Remaining components in the reverse order of removal 6. Fill the cooling system, engine, transaxle and power steering pump. Adjust all cables and check all connections.

Start the vehicle and check for leaks. Fuel feed hose from the feed pipe Return hose from the fuel pressure regulator Heater inlet and outlet hoses Right and left engine undercovers Front exhaust pipe from the exhaust manifold and center exhaust pipe. Gear shift control shaft from the transaxle and the extension rod, if equipped with a manual transaxle Remove radiator with cooling fan.

Remove air cleaner outlet hose. Remove air cleaner case by removing its fastening bolts. Disconnect the following cables:. Brake booster hose from intake manifold Coolant hoses from throttle body Fuel feed hose from delivery pipe Fuel return hose from return pipe Heater hose from water outlet cap Radiator inlet hose from water outlet cap Vacuum hose from EVAP canister purge valve Disconnect the following electric wires: Release above wire harness from clamps.

Suspend removed clutch operating cylinder at a place free from any possible damage during removal and installation of engine assembly. Remove right and left engine under covers. Remove exhaust No. Drain engine and transmission oil. Remove halfshafts. For engine and transmission removal, it is not necessary to remove drive shafts from steering knuckle.

Suspend removed compressor at a place free from any possible damage during removal and installation of engine assembly. Install lifting device. Remove mounting member from front member and suspension frame. Remove engine left mounting from body. Remove engine right mounting from right mounting bracket. Before removing engine with transmission from body, recheck to make sure all hoses, electric wires and cables are disconnected from engine and transmission.

Lower engine with transaxle from body. At this time, use care so that no excessive force is applied to hoses. Disconnect transaxle from the engine. Remove clutch cover and clutch disc. Install clutch cover and clutch disc. Connect transaxle assembly to engine. Lift engine with transaxle into engine compartment, but do not remove lifting device.

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Install engine right mounting to right mounting bracket and stiffener. Install engine left mounting to body. Install mounting member to front member and suspension frame. Tighten bolts and nuts of all parts installed in the previous three steps to specified torque: Mounting member, mounting and bracket bolt and nut a ft.

Remove lifting device. Reverse removal procedures for installation of remainder. Install the halfshaft assemblies. Clamp electric wires securely. With shift lever in NEUTRAL position, adjust shift cable adjusting nut so that distance between edge of instrument panel and center of shift knob measures 5. After shift cable adjustment, tighten lock nut securely to 4.

Make sure that boots are installed correctly. After select cable adjustment, tighten lock nut securely to 4. Upon completion of installation, Check to make sure that there is no fuel leakage, coolant leakage, transmission oil leakage or exhaust gas leakage at each connection.

Inspect and adjust ignition timing. Service should be performed only after the system cools down.

Negative battery cable Heated oxygen HO 2 S sensor electrical coupler and release the wire from its clamps Exhaust manifold cover Exhaust manifold stiffener bolt 2 bolts attaching the exhaust pipe to the exhaust manifold Exhaust manifold mounting nuts and bolts Exhaust manifold and the gasket.

Before installing any components check the exhaust manifold and the engine for deterioration or damage and replace as necessary. Manifold gasket and the exhaust manifold on the engine. Tighten the nuts and bolts to ft. Exhaust pipe gasket on the exhaust pipe and position the exhaust pipe 2 bolts that attach the exhaust pipe on the exhaust manifold and tighten the bolts to ft.

Run the engine and check for exhaust leaks.

Negative battery cable Heated oxygen HO 2 S sensor electrical connector and release the wire from its clamps Exhaust manifold cover Exhaust manifold stiffener bolt 2 bolts attaching the exhaust pipe to the exhaust manifold Exhaust manifold mounting nuts and bolts Exhaust manifold and the gasket To install: Negative cable 2 exhaust pipe bolts connecting the exhaust pipe to the exhaust manifold Oxygen O 2 S sensor lead wire at the coupler Exhaust manifold heat shield from the manifold by unfastening the nut and bolt Exhaust manifold mounting bolts and nuts Exhaust manifold To install: Clean and inspect the sealing surfaces of the exhaust manifold and the cylinder head.

New gaskets Exhaust manifold and tighten the mounting bolts and nuts to 17 ft. Check for exhaust leaks when finished. Exhaust manifold and related components Negative cable 2 exhaust pipe bolts connecting the exhaust pipe to the exhaust manifold Oxygen O 2 S sensor lead wire at the connector Exhaust manifold heat shield from the manifold by unfastening the nut and bolt Exhaust manifold mounting bolts and nuts Exhaust manifold To install: Disconnect heated oxygen sensor connector and release it from bracket.

Remove exhaust manifold upper cover and lower cover. Remove heated oxygen sensor-1 from exhaust manifold. Remove engine under cover Right side. Remove heated oxygen sensor-2 from exhaust No.

Remove exhaust pipe front No. Support engine with engine support jack and remove engine RH mounting. Engine RH mounting bracket 1 Exhaust manifold 1 and gasket 2 Remove exhaust manifold and its gasket from cylinder head.

Install new gasket to cylinder head. Install exhaust manifold. Tighten manifold bolt and nuts to 37 ft. Install engine RH mounting bracket. Tighten bracket bolts to 40 ft. Install engine RH mounting. Tighten bolts, and nut to 40 ft.

Install air cleaner case with air cleaner outlet hose. Install pipe gasket and exhaust No. Before installing pipe gasket, check it for deterioration or damage, and replace as necessary. Tighten exhaust pipe nuts and bolts to 32 ft. Install exhaust pipe front No.

Install heated oxygen sensor-2 to exhaust No. Install engine under cover Right side. Install heated oxygen sensor-1 and tighten to 33 ft. Install exhaust manifold upper cover and lower cover. Back to Top Connect heated oxygen sensor connector and clamp its wire securely.

Check exhaust system for exhaust gas leakage. Remove the engine or transaxle assembly. Using a special holding tool, hold the crankshaft. Clean the bolts and bolt holes. Install and uniformly tighten the 6 bolts in several passes, to the following torque values: NOTE Do not start the engine within an hour after installing.

Install the engine or transaxle assembly.

SUZUKI Manuals

Oil seal guide tool NOTE Be careful not to damage the crankshaft or the oil pump sealing surfaces when removing or installing the seal. Negative battery cable Timing belt Crankshaft sprocket bolt using a suitable gear stopper to hold the flywheel Sprocket bolt, sprocket and key Seal from the oil pump housing, using a suitable tool 2.

Clean and inspect the surfaces of the crankshaft and the oil pump assembly. Lubricate the new seal with clean engine oil. New seal over the crankshaft and into the oil pump, making sure the oil seal lip is not turned up. Use an oil seal guide tool.

Crankshaft sprocket and timing belt Negative battery cable. Crankshaft sprocket and timing belt Negative battery cable 1. Negative battery cable Timing belt Crankshaft timing belt sprocket 3. Using a knife, cut off the oil seal lip. Tape the end of a flat bladed tool to avoid damaging the crankshaft. Pry out the oil seal using the taped end of the tool. Inspect the oil seal contact surface on the crankshaft for signs of wear or damage.

Wipe the seal bore with a clean rag. Apply multipurpose grease to the lip of a new oil seal. Oil seal into place using a seal installer tool. Be sure the seal surface is flush with the edge of the oil pump case. Work from the front of the cover.

Be extremely careful not to damage the seal. Crankshaft sprocket Timing belt Negative battery cable to the battery 4.

Front crankshaft oil seal location Remove the accessory drive belt. Remove the front timing chain cover. Remove the seal from the timing chain cover using a suitable prying tool. NOTE Be careful not to damage the crankshaft or front timing chain cover sealing surface when removing or installing the seal. Clean and inspect the surface of the crankshaft and the front timing chain cover.

Front timing chain cover 1 , crankshaft front seal 2 and seal installer tool A When installing new oil seal, drive it in until its surface is flush with edge of timing chain cover. To install oil seal, use special tool bearing installer.

Install the front timing chain cover. Install the crankshaft pulley. Install the accessory drive belt. Intake manifold and related components Drain the coolant from the vehicle. Scalding fluid and steam can be blown out under pressure if the plug and cap are taken off too soon.

Negative battery cable Air cleaner assembly 5. Disconnect the following electrical wires: Fuel return and feed hoses from the fuel pipes Coolant hoses from the throttle body and the intake manifold 7. Intake manifold attaching nuts and bolts Intake manifold and throttle body To install: Before installing the gasket, make sure that the mating surfaces of the intake manifold and the cylinder head are clean and undamaged.

New intake manifold gasket on the cylinder head Intake manifold and throttle body on the cylinder head Intake manifold mounting nuts and bolts. Be sure that the clamps are properly installed on the lower intake manifold bolts. Remaining components in the reverse order of removal 3. Refill the cooling system. Start the engine and check for fuel and cooling system leaks. Remove the throttle body assembly from intake manifold.

Brake booster hose from intake manifold. Remove intake manifold front stiffener and rear stiffener. Remove EGR pipe. Remove intake manifold from cylinder head, and then its gasket.

Intake manifold gasket 1 , intake manifold 2 and fasteners a Install new intake manifold gasket to cylinder head. Install intake manifold.

Tighten bolts and nuts to 17 ft. Connect coolant pipe to intake manifold. Install EGR pipe. Install intake manifold front stiffener and rear stiffener. Tighten the front stiffener bolts to 18 ft. Tighten the rear stiffener bolts to 37 ft. Connect the following hoses: Connect the following electric lead wires: Install accelerator cable to bracket. Install the throttle body assembly onto the intake manifold with a new gasket and tighten bolts and nuts.

Finally, start engine and check for engine coolant leaks. Suzuki Esteem, Swift Negative battery cable Engine undercovers on 1. Drain the engine oil into a suitable container.

Lower plate on 1. Front exhaust pipe from the vehicle Transaxle stiffener plate from the engine and transaxle 5. Support the transmission and engine. Vehicle center member by removing the 7 nuts and 4 bolts from the center member, on 1. Clean the mating surfaces of the oil pan and the engine block. Oil pump strainer.

Tighten the strainer bolt first at the bracket. Tighten the bolts to 96 inch lbs. Apply silicon sealant to the oil pan mating surface in one continuous bead.

SUZUKI SWIFT 2006 2.G Service Workshop Manual

Oil pan to the engine block and install the bolts. Start tightening the bolts at the center and move outward. CKP sensor on the oil pan Drain plug and drain plug gasket on the oil pan Lower plate on the clutch housing, on 1. Center member on the vehicle. Tighten the bolts and nuts at the engine mounts to 40 ft. Transaxle stiffener plate and tighten the bolts to 37 ft. Refill the engine with oil.

Oil pan mounting Raise vehicle. Drain engine oil by removing drain plug.

Suzuki Swift Workshop Manual PDF

Remove engine under covers. Support engine and transmission with engine support jack. Remove mounting member. Remove oil pan and then oil pump strainer. Correct sealant application A on oil pan 1 Apply sealant to oil pan mating surface in a continuous bead. Install O-rings to oil pump strainer securely. Tighten strainer bolts to 8 ft. After fitting oil pan to cylinder block, run in securing bolts and start tightening at the center: Tighten bolts and nuts to 8 ft.

Install gasket and drain plug to oil pan. Tighten drain plug to 26 ft. Mounting member 1 , engine front torque bush 2 , engine rear mounting 3 and suspension frame 4 Install mounting member. Tighten bolts and nuts to specified torque: Mounting member bolt and nut a ft. Remove engine support jack.

Install exhaust No. NOTE Tighten bolts and nuts marked first. Use new gasket for exhaust No.Check the crankshaft alignment by verifying that the punch mark on the timing belt pulley is aligned with the arrow on the oil pump case. Brake booster hose from intake manifold. Follow the tightening sequence in 3 to 4 even stages, finishing with a final torque of 96 inch lbs.

After select cable adjustment, tighten lock nut securely to 4. Page 9 of Downloaded from www.