2005 SUZUKI SWIFT Engine oil nut torque

Downloaded from www.Manualslib.com manuals search engine 5B-14 Manual Transmission/Transaxle:
Fifth Gear Disassembly and AssemblyS7RS0B5206014
Disassembly1) Remove cover bolts and take off transaxle side cover (1).
CAUTION!
Care should be taken not to distort side cover
when it is removed from left case.

2) Using snap ring pliers, remove circlip (1).
3) Remove 5th shift fork bolt (2).
4) Remove gear shift fork (3), synchronizer sleeve &
hub assembly (4), synchron izer levers, synchronizer
ring and input shaft 5th gear (5) all together. Use
gear puller for removal if spline fitting of hub is tight. 5) Unfasten caulking of countershaft nut (2), install
input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut
(2).
Special tool
(A): 09927–76060
6) Remove input shaft 5th gear, needle bearing and then countershaft 5th gear (1). Gear puller (2) would
be necessary if spline fitting of countershaft 5th gear
is tight.
11. Sensor cap 34. Washer
12. Oil gutter bolt : Apply thread lock 99000-32110 to all around thread part of bolt. 35. Side bearing retainer
13. Left case plate bolts : Apply thread lock 99000-32110 to all around thread part of bolt. 36. O-ring
14. Sensor cap bolt 37. Oil seal
: Apply grease 99000-25011 to oil seal lip.
15. Side cover bolts 38. Outer race
16. Transaxle case bolts 39. Breather hose
17. 5th speed synchronizer ring 40. Side bearing retainer bolt
18. 5th speed synchronizer lever : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
19. 5th speed synchronizer sleeve & hub : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
20. Circlip :10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
21. Bearing set shim : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft)
22. Countershaft 5th gear : Do not reuse.
23. Countershaft nut : After tightening nut to specified torque, caulk nut securely. : Apply transaxle oil.
I4RS0A520027-01
342
1
5
I4RS0A520028-01
1(A)
2
I3RM0B521014-01
I4RS0A520041-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-15
Assembly1) Assemble 5th speed synchronizer sleeve (1), hub (2), 5th speed synchronizer levers (3) and
synchronizer ring (4) as follows.
a) Install hub (1) to 5th speed synchronizer sleeves (2) in specified direction as shown in figure.
b) Fit 5th speed synchronizer levers (1) to hub (2) as shown in figure.
NOTE
Align protrusion A of 5th speed synchronizer
levers (1) with groove of hub (2).

c) Install synchronizer ring (1) to hub (2) as shown in figure.
2) Install 5th gear (1) to countershaft facing machined boss A inward.
3) Install needle bearing to input shaft, apply oil then install input shaft 5th gear (1) and special tool to stop
shaft rotation.
Special tool
(A): 09927–76060
4) Tighten new countershaft nut (2) to specified torque, and caulk countershaft nut securely.
Tightening torque
Countershaft nut (a): 100 N·m (10.0 kgf-m, 72.5
lb-ft)
A: Chamfered side B: Long boss
I4RH01520054-01
1
2
B
A
I4RH01520048-01
1A
2
A
I4RH01520049-01
A: Machined boss (Inside)
B: No machining (Outside)
1
2
I4RH01520055-01
I2RH01520088-01
1
(A)
2, (a)
I3RM0B521016-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-35
6) Hold differential assembly with soft jawed vise (3),
install final gear (2) as shown in figure and then
tighten bolts (1) to specified torque.
CAUTION!
Use of any other bolts than specified ones is
prohibited.

Tightening torque
Final gear bolt (a): 90 N·m (9.0 kgf-m, 65.0 lb-ft)
Specifications
Tightening Torque SpecificationsS7RS0B5207001
NOTE
The specified tightening torque is also described in the following.
“Gear Shift Control Leve r and Cable Components”
“Manual Transaxle Unit Components”
“Gear Shift and Select Shaft Assembly Components”
“Manual Transaxle Assembly Components”
“Gear Shift Shaft Components”
“Differential Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I4RS0A520043-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Transaxle oil drain plug 21 2.1 15.5 )
Transaxle oil level / filler plug 21 2.1 15.5 )
Back up light switch 23 2.3 17.0 )
Gear shift guide case bolt 23 2.3 17.0 )
Select lever bracket bolt 23 2.3 17.0 )
Gear shift interlock bolt 23 2.3 17.0 )
5th to reverse interlock guide bolt 23 2.3 17.0 )
Countershaft nut 100 10.0 72.5 )
Shift fork bolt 10 1.0 7.5 )
Side cover bolt 10 1.0 7.5 )
Reverse gear shift lever bolt 23 2.3 17.0 )
Reverse shaft bolt 23 2.3 17.0 )
Transaxle case bolt 23 2.3 17.0 )
Side bearing retainer bolt 23 2.3 17.0 )
Gear shift locating bolt 13 1.3 9.5 )
Left case plate bolt 23 2.3 17.0 )
Oil gutter bolt 10 1.0 7.5 )
Final gear bolt 90 9.0 65.0 )

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-4
Steering Wheel Removal and InstallationS7RS0B6206002
CAUTION!
Do not turn the contact coil more than
allowable number of turns (about two and a
half turns from the center position clockwise
or counterclockwise respectively) with
steering wheel removed, or coil will break.

Removal
CAUTION!
Do not hammer the end of the shaft.
Hammering it will loosen the plastic shear
pins which maintain the column length and
impair the collapsible design of the column.

1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air
Bag System in Section 8B”.
3) Remove driver air bag (inflator) module from steering wheel. Refer to “Driver Air Bag (Inflator)
Module Removal and Installation in Section 8B”.
4) Disconnect horn connector and audio control switch connector, if equipped.
5) Remove steering shaft nut and then make alignment marks (1) on steering wheel and shaft for a guide
during reinstallation.
6) Remove steering wheel using special tool. Special tool
(A): 09944–36011 Installation
CAUTION!
Following 2 Steps (Step 1) and 2)) are
prerequisite for installation of steering wheel.
If steering wheel has
been installed without
these 2 Steps, contact coil will break when
steering wheel is turned.

1) Check that vehicle’s front tires are at straight-ahead position and contact coil is centered. If contact coil is
turned after removing steering wheel, center contact
coil referring to “Centering Contact Coil Cable
Assembly”.
2) Install steering wheel to steering shaft with 2 grooves (1) on contact coil fitted in 2 lugs (2) in the back of
steering wheel and also aligning marks (3) on
steering wheel and steering shaft.
3) Tighten steering shaft nut (4) to specified torque.
Tightening torque
Steering shaft nut (a): 33 N·m (3.3 kgf-m, 24.0 lb-
ft)
4) Connect horn connector and audio control switch connector, if necessary.
5) Install driver air bag (inflator) module to steering wheel. Refer to “Driver Air Bag (Inflator) Module
Removal and Installati on in Section 8B”.
6) Connect negative (–) battery cable.
7) Enable air bag system refe rring to “Enabling Air Bag
System in Section 8B”.
I4RS0A620005-01
(A)
I4RS0A620006-01
I4RS0A620007-01

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-8
Installation
CAUTION!
After tightening steering column mounting
nuts, shaft joint bolts should be tightened.
Wrong tightening order could cause a
damage to shaft joint.

1) Be sure that front wheels are in straight.
2) Install steering column assembly to lower and upper brackets. Tighten steering column lower nuts (1) first
and then upper nuts (2) to specifications as given
below.
Tightening torque
Steering column nut (a): 14 N·m (1.4 kgf-m, 10.5
lb-ft)
NOTE
After installing tilt steering column, make
sure that steering column moves backwards
and forwards smoothly and stops when tilt
lever is fixed.

3) Align flat part “A” of stee ring lower shaft (1) with bolt
hole “B” of shaft joint (2) of column as shown. Then
insert lower shaft into shaf t joint of steering column
with matching marks (4).
4) Insert lower shaft (1) into pinion shaft (3) with matching marks (4).
5) Tighten joint bolt (pinion shaft side) (6) to specified torque first and then joint bolt (steering column side)
(5) to specified torque.
CAUTION!
After tightening column nuts, tighten steering
shaft upper joint bolt. Otherwise shaft joint
bearing is damaged.

Tightening torque
Steering shaft joint bolt (a): 25 N·m (2.5 kgf-m,
18.5 lb-ft) 6) Install steering joint cover.
7) Install immobilizer cont
rol module from steering
column, referring to “Immo bilizer Control Module
(ICM) Removal and Installation in Section 10C”.
8) Install lighting switch and wiper switch to steering column.
9) Install contact coil cable assembly and steering wheel referring to “Conta ct Coil Cable Assembly
Removal and Installation” and “Steering Wheel
Removal and Installation”.
10) Install steering column hole cover. 11) Connect negative (–) battery to cable.
12) Enable air bag system refe rring to “Enabling Air Bag
System in Section 8B”.
Steering Column InspectionS7RS0B6206007
Check steering column for damage and operation
referring to “Checking Steering Column for Accident
Damage”.
2,(a)
1,(a)
1,(a)
2,(a)
I4RS0B620009-02
I6RS0C620003-01

Downloaded from www.Manualslib.com manuals search engine 6C-42 Power Assisted Steering System:
2) Connect tie-rod end to knuckle. Tighten tie-rod end nut (1) to spec ified torque.
3) Bend new split pin (2).
NOTE
After tightening tie-rod end nut to specified
torque, match next first slot of nut with hole
of tie-rod end for insertion of split pin
(rotation angle 60 ° max).

Tightening torque
Tie-rod end nut (a): 45 N·m (4.5 kgf-m, 32.5 lb-ft)
4) Inspect for proper toe re ferring to “Front Wheel
Alignment Inspection and Adjustment in Section 2B”.
5) After confirming proper toe, tighten tie-rod end lock nut to specified torque.
Tightening torque
Tie-rod end lock nut (a): 45 N·m (4.5 kgf-m, 32.5
lb-ft)
6) Tighten wheel nuts to specified torque and lower hoist.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
Tie-Rod End InspectionS7RS0B6306004
• Inspect for play in ball joint.
• Inspect for play in rack end ball joint. In either case, if found defective, replace.
Steering Shaft Joint On-Vehicle InspectionS7RS0B6306005
Check shaft joint for wear, breakage and any other
damage and replace if any defect exists.
Steering Gear Case Assembly Removal and
Installation
S7RS0B6306006
Removal
CAUTION!
Be sure to set front wheels (tires) in straight
direction and remove ignition key from key
cylinder before performing the following
steps; otherwise, contact coil of air bag
system may get damaged.

1) Remove front suspension frame with steering gear case assembly referrin g to “Front Suspension
Frame, Stabilizer Bar and/ or Bushings Removal and
Installation in Section 2B”.
2) Remove steering gear case mounting No.3 bolts (4), No.1 bolts (1), No.2 bolts (2) and gear case bracket,
then remove gear case (3) from front suspension
frame (5).
2 1,(a)
I7RS0A630017-01
I3RM0A630030-01
I4RS0A630043-01
I4RS0B630012-01
25
3
14
I6RS0C630018-01

Downloaded from www.Manualslib.com manuals search engine Instrumentation / Driver Info. / Horn: 9C-22
Remote Audio Control Switch Inspection (If
Equipped)
S7RS0B9306024
1) Remove driver air bag (inflator) module referring to
“Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
2) Disconnect remote audio control switch connector
from contact coil.
3) Check switch for resistance between “a” and “b” terminals under each condition below.
If check result is not satisfactory, replace remote
audio control switch.
Remote audio control switch resistance)
All switches released (OFF): 5119 – 5223 Ω
Switch “1” pushing on (ON): 55 – 57 Ω
Switch “2” pushing on (ON): 129 – 133 Ω
Switch “3” pushing on (ON): 238 – 244 Ω
Switch “4” pushing on (ON): 416 – 426 Ω
Switch “5” pushing on (ON): 743 – 759 Ω
Switch “6” pushing on (ON): 1555 – 1587 Ω
Vehicle Speed Signal Inspection (For Audio
Unit) (If Equipped)
S7RS0B9306025
Check vehicle speed pulse output signal of ECM
referring to “Reference waveform No.32” under
“Inspection of ECM and Its Circuits in Section 1A”
Specifications
Tightening Torque SpecificationsS7RS0B9307001
NOTE
The specified tightening torque is also described in the following.
“Audio System Component Location”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
“b”“a”
1
2
3 4
5
6
I5RW0A930027-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Instrument panel mounting bolt 23 2.3 17.0 )
Antenna base mounting nut 5 0.5 4.0 )