2005 SUZUKI SWIFT spec

Downloaded from www.Manualslib.com manuals search engine 1J-6 Charging System:
Generator Test (Overcharged Battery Check)S7RS0B1A04004
1) To determine battery condition, refer to “Battery Description”.
2) If obvious overcharge condition exists as evidenced by excessive spewing of electrolyte, measure
generator “B” terminal voltage at engine 2000 rpm. 3) If measured voltage is higher than upper limit value,
proceed to disassemble generator.
4) Check ground of brushes. If brushes are not grounded, replace IC regulator. Then check field coil
for grounds and shorts, referring to “Generator
Inspection”.
Repair Instructions
Jump Starting in Case of EmergencyS7RS0B1A06001
CAUTION!
If vehicle is manual transaxle model and has
a catalytic converter, do not push or tow it to
start. Damage to its emission system and/or
to other parts may result.

Both booster and discharged battery should be treated
carefully when using ju mper cables. Follow the
procedure outlined as follows, being careful not to cause
sparks.
WARNING!
• Departure from these conditions or procedure described as follows could
result in:
– Serious personal injury (particularly to eyes) or property damage from such
causes as battery explosion, battery
acid, or electrical burns.
– Damage to electronic components of either vehicle.
• Remove rings, watches, and other jewelry. Wear approved eye protection.
• Be careful so that metal tools or jumper cables do not contact positive battery
terminal (or metal in contact with it) and
any other metal on vehicle, because a
short circuit could occur. • Never expose battery to open flame or
electric spark. Batteries generate gas
which is flammable and explosive.
• Do not allow battery fluid to contact eyes, skin, fabrics, or painted surface as fluid is
a corrosive acid. Flush any contacted area
with water immediately and thoroughly.
• Batteries should always be kept out of reach of children.
• Do not connect negative cable directly to negative terminal of dead battery.

1) Set parking brake and place automatic transaxle in PARK (NEUTRAL on manual transaxle). Turn off
ignition, turn off lights and all other electrical loads.
2) Check electrolyte level. If it is below low level line, add distilled water.
3) Attach end of one jumper cable to positive terminal of booster battery and the other end of the same
cable to positive terminal of discharged battery. (Use
12-volt battery only to jump start engine).
4) Attach one end of the remaining negative cable to negative terminal of booster battery, and the other
end to a solid engine ground (such as exhaust
manifold) at least 45 cm (18 in.) away from battery of
vehicle being started.
5) Start engine of vehicle with booster battery and turn off electrical accessories. Then start engine of the
vehicle with discharged battery.
16.0
15.5
15.0
14.5
14.0
13.5
13.0 -30 0 20
[C]
[D]
68
22120 (˚C)
248 (˚F)
(V)
I6RS0C1A0001-02

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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

Downloaded from www.Manualslib.com manuals search engine 1J-8 Charging System:
3) After loosening generator bracket bolts (2) and pivot bolt (3), adjust belt tensio n to specification described
at step 2) by loosening / tightening generator adjust
bolt (1).
4) Tighten generator bracket bolts and pivot bolt as specified torque.
Tightening torque
Generator bracket bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Generator pivot bolt (b): 50 N·m (5.0 kgf-m, 36.0
lb-ft)
5) Check belt tension for specification after turning crankshaft two rotations clockwise.
6) Tighten generator adjusting bolt (1) as specified torque.
Tightening torque
Generator adjusting bolt (c): 7 N·m (0.7 kgf-m,
5.0 lb-ft) by the specified procedure.
7) Connect negative cable at battery.Water Pump / Generator Drive Belt Removal and
Installation
S7RS0B1A06004
Removal 1) Disconnect negative cable at battery.
2) If vehicle equipped with A/C, remove compressor drive belt before removing water pump belt (1). Refer
to “Compressor Drive Belt Removal and Installation
in Section 7B” or “Compr essor Drive Belt Removal
and Installation in Section 7B”.
3) Loosen drive belt adjusting bolt (2) and generator pivot bolt (3).
4) Loosen generator adjusting bolt (4), and then remove water pump belt.
Installation
Reverse removal procedure for installation noting the
following.
• Adjust belt tension referring to “Water Pump / Generator Drive Belt Tension Inspection and
Adjustment” and “Compressor Drive Belt Inspection
and Adjustment in Section 7B” or “Compressor Drive
Belt Inspection and Adjustment in Section 7B”.
1, (c)
2, (a)
3, (b)
I5RW0C160007-01
4
23
1
I6RS0C1A0002-01

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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

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Generator InspectionS7RS0B1A06008
Rotor
• Using ohmmeter, connect positive terminal to “FR” terminal and connect negative terminal to “B” terminal of generator, check that continuity between “B” terminal and “FR” terminal. If there is no continuity, replace rotor or
regulator.
• Using an ohmmeter (1), check for continuity between slip ring s (2) of rotor. If there is no continuity, replace the rotor.
Standard resistance between slip rings of rotor
: 1.7 – 2.0 Ω
I5JB0A1A0012-01
I4RS0B1A0005-01

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Specifications
Charging System SpecificationsS7RS0B1A07001
Battery
Battery
: 48AH/20H, 40.6AH/5H 12 V
Generator
Tightening Torque SpecificationsS7RS0B1A07002
NOTE
The specified tightening torque is also described in the following.
“Generator Unit Components”
“Generator Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Nominal output
12 V
Rated capacity 48 Ah/20 h
40.6 Ah/5 h
Cold cranking amperes 300 A (DIN)
Ty p e 80A type
Rated voltage 12 V
Nominal output 80A
Permissible max. speed 18,000 r/min.
No-load speed 1200 r/min. (rpm)
Regulated voltage 14.2 – 14.8 V at 25 ° C (77 °F)
Exposed brush length Standard: 16 mm (0.63 in.)
Limit: 5.0 mm (0.02 in.)
Permissible ambient temperature –30 to 100 °C (–22 to 212 °F)
Polarity Negative ground
Rotation Clockwise viewed from pulley side
Fastening partTightening torque
Note
N ⋅mkgf-mlb-ft
Generator bracket bolt 25 2.5 18.0 )
Generator pivot bolt 50 5.0 36.0 )
Generator adjusting bolt 70.7 5.0by the specified
procedure.
)

Downloaded from www.Manualslib.com manuals search engine 1K-1 Exhaust System:
Engine
Exhaust System
General Description
Exhaust System DescriptionS7RS0B1B01001
The exhaust system consists of an exhaust manifold, three-way catalytic converter (TWC) in catalyst case, exhaust
pipes, a muffler and seals, gasket and etc.
The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of
Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
Diagnostic Information and Procedures
Exhaust System CheckS7RS0B1B04001
WARNING!
To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any
service on the exhaust system should be performed when the system is cool.

At every interval of periodic maintenance service, and when vehicle is raised for other service, check exhaust system
as follows:
• Check rubber mountings for damage, deterioration, and out of position.
• Check exhaust system for leakage, loose connection, dent and damage.
• If bolts or nuts are loosened, tighten them to specified torque referring to “Exhaust System Components”.
• Check nearby body areas damaged, missing, or mispositio ned part, open seam, hole connection or any other
defect which could permit exhaust fumes to seep into vehicle.
• Make sure that exhaust system components have enough clearance from underbody to avoid overheating and
possible damage to passenger compartment carpet.
• Any defect should be fixed at once.
IYSY011B0003-01

Downloaded from www.Manualslib.com manuals search engine 1K-3 Exhaust System:
Exhaust Manifold Removal and InstallationS7RS0B1B06002
Removal
WARNING!
To avoid danger of being burned, do not
service exhaust system while it is still hot.
Service should be performed after system
cools down.

1) Disconnect negative cable at battery.
2) Remove engine cover.
3) Remove front bumper with front grille referring to
“Front Bumper and Rear Bumper Components in
Section 9K”.
4) Remove radiator referring to “Radiator Removal and Installation in Section 1F ” for equipped with A/C.
5) With hose connected, detach A/C condenser from vehicle body for equipped with A/C.
6) Remove exhaust manifold cover from exhaust manifold.
7) Disconnect heated oxygen sensor No.2 connector (1) (connector color: green) and heated oxygen
sensor No.1 connector (2) (connector color: black),
and then detach it from its stay.
8) Remove exhaust manifold stiffener (1).
9) Remove heated oxygen sensors (3) from exhaust manifold and exhaust No.1 pipe, if necessary.
10) Disconnect exhaust No.1 pipe (2) from exhaust manifold. 11) Remove exhaust manifold (1) and its gasket from
cylinder head.
Installation 1) Install new gasket to cylinder head. Then install exhaust manifold (3).
Tighten manifold bolts (1) and nuts (2) to specified
torque.
Tightening torque
Exhaust manifold bolt (a): 50 N·m (5.0 kgf-m,
36.5 lb-ft)
Exhaust manifold nut (b): 50 N·m (5.0 kgf-m,
36.5 lb-ft)
NOTE
Be sure to install exhaust manifold bolts and
nuts to proper location referring to “Exhaust
System Components”.

1
2
I6RS0C1B0002-01
1
2
3
I4RS0A1B0002-01
1
I6RS0C1B0003-01
2, (b) 2, (b)
3
1, (a)
I6RS0C1B0004-01