2005 SUZUKI SWIFT Rear

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-64
Honing or Reboring Cylinders1) When any cylinder needs reboring, all other cylinders must also be rebored at the same time.
2) Select oversized piston according to amount of cylinder wear.
Oversize piston specification
Oversize 0.50: 78.453 – 78.468 mm (3.0887 –
3.0893 in.)
3) Using micrometer, measure piston diameter. Measurement position for piston diameter
“a”: 7.0 mm (0.28 in.) 4) Rebore and hone cylinder to the following
dimension.
NOTE
Before reboring, install all main bearing caps
in place and tighten to specification to avoid
distortion of bearing bores.

Cylinder bore diameter to be rebored
Oversize 0.50: 78.500 – 78.514 mm (3.0906 –
3.0911 in.)
5) Measure piston clearance after honing. Piston clearance
0.032 – 0.061 mm (0.0013 – 0.0024 in.)
Specifications
Tightening Torque SpecificationsS7RS0B1407001
I2RH01140157-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Camshaft housing bolt 11 1.1 8.0 )
Cylinder head cover bolt Tighten 3 N ⋅m (0.3 kgf-m, 2.5 lb-ft), 5 N ⋅m
(0.5 kgf-m, 4.0 lb-ft) and 8 N ⋅m (0.8 kgf-m,
6.0 lb-ft) by the specified procedure )
Intake manifold bolt 23 2.3 17.0 )
Intake manifold nut 23 2.3 17.0 )
Intake manifold ground terminal bolt 11 1.1 8.0 )
Engine left mounting bracket nut 55 5.5 40.0 )
Engine right mounting nut 65 6.5 47.0 )
Engine rear mounting bush bolt 55 5.5 40.0 )
Starting motor terminal nut 11 1.1 8.0 )
Generator terminal nut 6 0.6 4.5 )
Intake manifold ground terminal bolt 11 1.1 18.0 )
Timing chain cover bolt 25 2.5 18.0 )
Timing chain cover nut 25 2.5 18.0 )
Cap bolt 25 2.5 18.0 )
Oil gallery pipe No.2 and No.3 bolt 11 1.1 8.0 )
Crankshaft pulley bolt 150 15.0 108.5 )
Oil control valve mounting nut 11 1.1 8.0 )
Oil gallery pipe No.1 bolt 30 3.0 21.5 )
Timing chain No.1 guide bolt 9 0.9 6.5 )
Timing chain tensioner bolt 25 2.5 18.0 )
Timing chain tensioner adjuster bolt 11 1.1 8.0 )
Camshaft housing bolt 5 N ⋅m (0.5 kgf-m, 4.0 lb-ft) and 11 N ⋅m (1.1
kgf-m, 8.0 lb-ft) by the specified procedure )
/ )
Intake cam timing sprocket bolt 60 6.0 43.5 )
Venturi plug 3.5 0.35 3.0 )
Cylinder head bolt for M8 25 2.5 18.0 )
Cylinder head bolt for M10 20 N ⋅m (2.0 kgf-m, 14.5 lb-ft), 40 N ⋅m (4.0
kgf-m, 29.0 lb-ft) and then retighten by
turning through to 60 ° twice )

Downloaded from www.Manualslib.com manuals search engine 1D-65 Engine Mechanical:
NOTE
The specified tightening torque is also described in the following.
“Air Cleaner Components”
“Throttle Body and Intake Manifold Components”
“Engine Mountings Components”
“Timing Chain Cover Components”
“Timing Chain and Chain Tensioner Components”
“Camshaft, Tappet and Shim Components”
“Valves and Cylinder Head Components”
“Pistons, Piston Rings, Connecting Rods and Cylinders Components”
“Main Bearings, Crankshaft and Cylinder Block Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Connecting rod bearing cap bolt
15 N⋅m (1.5 kgf-m, 11.0 lb-ft) and then
retighten by turning through 45 ° twice )
/ )
Sensor plate bolt 111.1 8.0 )
Piston cooling valve 111.1 8.0 )
Main bearing cap No.1 bolt (a) 30 N⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N ⋅m (5.0
kgf-m, 36.5 lb-ft) and then retighten by
turning through 60 ° )
Main bearing cap No.2 bolt (b) 252.5 18.0 )
Rear oil seal housing bolt 111.1 8.0 )
Flywheel or drive plate bolt 707.0 51.0 )
Main bearing cap No.1 bolt 30 N⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N ⋅m (5.0
kgf-m, 36.5 lb-ft) and then retighten by
turning through 60 ° )
Main bearing cap No.2 bolt 252.5 18.0 ) / )
Main bearing cap No.1 bolt 30 Nm (3.0 kgf-m, 22.0 lb-ft), 50 Nm (5.0
kgf-m, 36.5 lb-ft) and then retighten by
turning through 60 ° )
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft

Downloaded from www.Manualslib.com manuals search engine 1E-2 Engine Lubrication System:
Diagnostic Information and Procedures
Oil Pressure CheckS7RS0B1504001
WARNING!
To avoid danger of being burned, do not
touch exhaust system when it is still hot.

NOTE
Prior to checking oil pressure, check the
following.
• Oil level in oil pan
If oil level is low, add oil up to Full level
mark (hole) (1) on oil level gauge referring
to “Engine Oil and Filter Change in Section
0B”.
• Oil quality If oil is discolored or deteriorated, change
it. For particular oil to be used, refer to
“Engine Oil and Filter Change in Section
0B”.
• Oil leaks If leak is found, repair it.

1) Remove front bumper referring to “Front Bumper and Rear Bumper Components in Section 9K”.
2) Remove engine front cover (1).
3) Disconnect oil pressure switch coupler (1).
4) Remove oil pressure swit ch (2) from cylinder block.
5) Install special tools (oil pressure gauge) to vacated threaded hole of oil pressure switch.
Special tool
(A): 09915–77310
(B): 09915–78211
2. Low level mark (hole)
I2RH0B150002-01
1
I4RS0A150001-01
I2RH0B150003-01
I2RH0B150004-01

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-10
Radiator Cooling Fan Removal and InstallationS7RS0B1606011
Removal1) Disconnect negative (–) cable at battery.
2) Disconnect connector (1) of cooling fan motor.
3) Drain coolant.
4) Remove front bumper, front bumper upper absorber and upper member referring to “Front Bumper and
Rear Bumper Componen ts in Section 9K”.
5) Remove radiator inlet hose and reservoir hose.
6) Remove cooling fan mounting bolts (1).
7) Slide condenser with radiator, and then remove radiator cooling fan.
CAUTION!
Be sure not to damage condenser outlet pipe.

Installation
Reverse removal procedure for installation noting the
following.
• Refill cooling system referring to Step 7) to 22) of “Cooling System Fl ush and Refill”.
• After installation, verify there is no coolant leakage at each connection.
Radiator On-Vehicle Inspection and CleaningS7RS0B1606012
Inspection
Check radiator for leakage or damage. Straighten bent
fins, if any.
Cleaning
Clean frontal area of radiator cores.
Radiator Removal and InstallationS7RS0B1606013
Removal
1) Disconnect negative cable at battery.
2) Drain A/T fluid.
3) Drain coolant.
4) Remove cooling fan assemb ly referring to “Radiator
Cooling Fan Removal and Installation”.
5) Remove A/T fluid cooler inlet and outlet hoses.
6) Remove radiator outlet hose from radiator.
7) Remove radiator from vehicle.
Installation
Reverse removal procedures, noting the following.
• Refill cooling system referrin g to Step 7) to 22) of
“Cooling System Flush and Refill”.
• After installation, verify there is no coolant leakage each connection.
• Refill A/T fluid referring to “A/T Fluid Change in
Section 5A”.
1
I7RS0A160004-01
I4RS0A160009-01
I2RH01160014-01

Downloaded from www.Manualslib.com manuals search engine 1G-7 Fuel System:
Fuel Pressure Relief ProcedureS7RS0B1706003
CAUTION!
This work must not be done when engine is
hot. If done so, it may cause adverse effect to
catalyst.

NOTE
If ECM detects DTC(s) after servicing, clear
DTC(s) referring to “DTC Clearance in
Section 1A”.

1) Make sure that engine is cold.
2) Shift transaxle gear shift lever in “Neutral” (shift select lever in “P” range for A/T model), set parking
brake and block drive wheels.
3) Remove relay / fuse box cover.
4) Disconnect fuel pump relay (1) from relay / fuse box (2).
5) Remove fuel filter cap in order to release fuel vapor pressure in fuel tank, and then reinstall it.
6) Start engine and run it until engine stops for lack of fuel. Repeat cranking engine 2 – 3 times for about 3
seconds each time in order to dissipate fuel pressure
in lines. Fuel connections are now safe for servicing.
7) After servicing, connect fuel pump relay (1) to relay / fuse box and install re lay / fuse box cover.
Fuel Leakage Check ProcedureS7RS0B1706004
After performing any service on fuel system, check to
make sure that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump) and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply
fuel pressure to fuel line until fuel pressure is felt by
hand placed on fuel feed hose.
2) In this state, check to see that there are no fuel leakages from any part of fuel system.
Fuel Lines On-Vehicle InspectionS7RS0B1706005
CAUTION!
Due to the fact that fuel feed line (1) is under
high pressure, use special care when
servicing it.

Visually inspect fuel lines for evidence of fuel leakage,
hose crack and deterioration or damage.
Make sure all cl amps are secure.
Replace parts as needed.
Fuel Pipe Removal and InstallationS7RS0B1706006
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal
1) Relieve fuel pressure in fuel feed line according to “Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Disconnect fuel pipe joint and fuel hose (3) from fuel pipe (2) at the front and rear of each fuel pipe
referring to “Fuel Hose Disconnecting and
Reconnecting”.
4) Mark the location of clamps (1) on fuel pipes (2), so that the clamps can be reinstalled to where they
were.
5) Remove pipes (2) with clamp (1) from vehicle.
6) Remove clamp (1) from pipes (2).
1
I4RS0A170004-01
1
I4RS0A170005-01
2
13
I4RS0A170020-01

Downloaded from www.Manualslib.com manuals search engine 1I-5 Starting System:
Starting Motor ComponentsS7RS0B1906002
I4RS0A190003-01
1. Front housing 7. Plate 13. Planetary gear 19. Rear bush
2. Bush 8. Seal rubber 14. Packing 20. Starting motor battery cable nut
3. Pinion stop ring 9. Magnetic switch 15. Yoke :9.8 N
⋅m (0.98 kgf-m, 7.0 lb-ft)
4. Over-running clutch 10. Ball 16. Armature: Do not reuse.
5. Lever 11. Internal gear 17. Brush assembly : Apply grease 99000-25010 to sliding surface of each part.
6. Plunger 12. Planetary carrier shaft 18. Rear bracket

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-6
Starting Motor InspectionS7RS0B1906003
Plunger
Inspect plunger for wear. Replace if necessary.
Magnetic Switch
Push in plunger and release it. The plunger should
return quickly to its original position. Replace if
necessary.
Pull-in coil open circuit test
Check for continuity across magnetic switch “S” terminal
(1) and “M” terminal (2). If no continuity, coil is open and
should be replaced. Hold-in coil open circuit test
Check for continuity across ma
gnetic switch “S” terminal
(1) and coil case. If no continuity, coil is open and should
be replaced.
Rear Bracket Bush
Inspect bush for wear or damage. Replace if necessary.
Brush
• Check brushes for wear. Measure length of brushes and if below the limit,
replace the brush.
Brush length
Standard: 12.3 mm (0.48 in.)
Limit: 7.0 mm (0.28 in.)
• Install brushes to each brush holder and check for smooth movement.
I2RH01190008-01
I2RH01190009-01
I2RH01190010-01
I2RH01190011-01
I2RH01190012-01
I2RH01190013-01

Downloaded from www.Manualslib.com manuals search engine 1J-2 Charging System:
Generator DescriptionS7RS0B1A01002
The basic charging system is the IC integral regulator charging system. The internal co mponents are connected
electrically as shown below.
I5JB0A1A0004-01
1. Pulley 6. Field coil11. Rear housing IG: Ignition terminal
2. Pulley nut 7. RectifierB: Generator output (Battery terminal) L: Lamp terminal
3. Rotor fan 8. BrushC: Generator cut terminal
4. Stator coil 9. RegulatorE: Ground
5. Stator core 10. Front housing FR: Field duty monitor terminal