2006 SUZUKI SWIFT mounting nut

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 Starting System: 1I-4
Repair Instructions
Starting Motor Dismounting and RemountingS7RS0B1906001
Dismounting1) Disconnect negative (–) battery lead at battery.
2) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals.
3) Detach shift & select control cable bracket from transaxle. (M/T model only)
4) Remove starting motor mount bolt (3) and nut (4).
5) Remove starting motor (5).
Remounting
Reverse the dismounting procedure noting the following.
• Tighten battery cable nut (6) to specified torque.
Tightening torque
Starting motor battery cable nut (a): 9.8 N·m (0.98 kgf-m, 7.0 lb-ft)
I4RS0A190002-01
: 9.8 N ⋅m (0.98 kgf-m, 7.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 1I-9 Starting System:
Specifications
Cranking System SpecificationsS7RS0B1907001
Tightening Torque SpecificationsS7RS0B1907002
NOTE
The specified tightening torque is also described in the following.
“Starting Motor Dismounting and Remounting”
“Starting Motor Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS7RS0B1908001
NOTE
Required service material is also described in the following.
“Starting Motor Components”

Voltage 12 volts
Output 1.2 kW
Rating 30 seconds
Direction of rotation Clockwise as viewed from pinion side
Brush length Standard: 12.3 mm (0.48 in.) Limit: 7.0 mm (0.28 in.)
Number of pinion teeth 8
Performance Condition Guarantee
Around at 20 °C
(68 °F) No load characteristic 11.0 V
90 A maximum
2370 r/min minimum
Load characteristic 7.5 V
300 A 10.65 N
⋅m (1.065 kgf-m, 7.70 lb-ft) minimum
840 r/min minimum
Locked characteristic 4.0 V 780 A maximum
20 N
⋅m (2.0 kgf-m, 14.5 lb-ft) minimum
Magnetic switch operating voltage 8 volts maximum
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Starting motor battery cable nut 9.8 0.98 7.0 )

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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

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 Exhaust System: 1K-2
Repair Instructions
Exhaust System ComponentsS7RS0B1B06001
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.

I7RS0B1B0001-01
[A]: MT model14. Exhaust manifold bolt 29. To vehicle body
[B]: AT model 15. Exhaust manifold nut 30. Damper
1. Exhaust manifold gasket 16. Exhaust No.1 pipe bolt 31. Damper nut
2. Exhaust manifold 17. Exhaust manifold stiffener bolt 32. To exhaust pipe No.1
3. Exhaust manifold stiffener 18. Exhaust No.2 pipe bolt 33. To exhaust manifold stiffener
4. Heated oxygen sensor No.2 (connector color: green) 19. Exhaust center pipe bolt 34. To oil pan
5. Exhaust pipe No.1 gasket 20. Exhaust pipe No.2 gasket : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft)
6. No.1 seal ring 21. Muffler nut : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft)
7. No.2 seal ring 22. Muffler tail pipe : 43 N⋅m (4.3 kgf-m, 31.0 lb-ft)
8. Exhaust No.1 pipe 23. Engine hook : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)
9. Exhaust No.2 pipe 24. Heated oxygen sensor No.1 (connector color: gray) : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
10. Exhaust center pipe 25. Heat insulator : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
11. Muffler 26. Heat insulator bolt : Do not reuse.
12. Center pipe mounting 27. Exhaust manifold cover
13. Muffler mounting 28. To cylinder block

Downloaded from www.Manualslib.com manuals search engine 2A-1 Suspension General Diagnosis:
Suspension
Suspension General Diagnosis
Diagnostic Information and Procedures
Suspension, Wheels and Tires Symptom DiagnosisS7RS0B2104001
ConditionPossible cause Correction / Reference Item
Vehicle pulls (Leads) Mismatched or uneven tires Replace tires.
Tires not adequately inflated Adjust tire pressure.
Broken or sagging coil springs Replace coil springs.
Radial tire lateral force Replace tire.
Disturbed wheel alignment Check and adjust wheel alignment.
Brake dragging in one road wheel Repair brake.
Loose, bent or broken front or rear
suspension parts Tighten or replace related suspension parts.
Abnormal or excessive
tire wear Sagging or broken coil spring
Replace coil spring.
Tire out of balance Adjust balance or replace tire.
Disturbed wheel alignment Check and adjust wheel alignment.
Faulty strut (shock absorber) Replace strut (shock absorber).
Hard driving Replace tires.
Overloaded vehicle Replace tires and check suspension parts.
Not rotated tires Replace or rotate tires.
Worn or loose wheel bearing Replace wheel bearing.
Wobbly wheel or tire Replace wheel or tire.
Tires not adequately inflated Adjust tire pressure.
Wheel tramp Blister or bump on tire Replace tire.
Improper strut (shock absorber) action Replace strut (shock absorber).
Shimmy, shake or
vibration Tire or wheel out of balance
Balance wheel or replace tire and/or wheel.
Loosen wheel bearings Replace wheel bearings.
Worn tie-rod ends Replace tie-rod ends.
Worn lower ball joints Replace front suspension control arm.
Excessive wheel runout Repair or replace wheel and/or tire.
Blister or bump on tire Replace tire.
Excessively loaded radial runout of tire /
wheel assembly Replace tire or wheel.
Disturbed wheel alignment Check and adjust wheel alignment.
Loose or worn steering linkage Tighten or replace steering linkage.
Loose steering gear case bolts Tighten steering gear case bolts.
Abnormal noise, front end Worn, sticky or loose tie-rod ends, lower
ball joints, tie-rod in side ball joints or
drive shaft joints Replace tie-rod end, su
spension arm, tie-rod
or drive shaft joint.
Damaged struts or mountings Repair or replace struts or mountings.
Worn suspension arm bushings Replace suspension arm bushings.
Loose stabilizer bar Tighten bolts or nuts and/or replace bushes.
Loose wheel nuts Tighten wheel nuts.
Loose suspension bolts or nuts Tighten suspension bolts or nuts.
Broken or damaged wheel bearings Replace wheel bearings.
Broken suspension springs Replace suspension springs.
Poorly lubricated or worn strut bearings Replace strut bearing.
Malfunction of Power Steering System Check and correct malfunction.
Low or uneven trim height
NOTE
See NOTE *1.

Broken or sagging coil springs Replace coil springs.
Over loaded Check loading.
Incorrect coil springs Replace coil spring.
Tires not adequately inflated Adjust tire pressure.
Ride too soft Faulty strut (shock absorber) Replace strut (shock absorber).
Suspension bottoms Overloaded Check loading.
Faulty strut (shock absorber) Replace strut (shock absorber).
Incorrect, broken or sagging coil springs Replace coil spring.

Downloaded from www.Manualslib.com manuals search engine Suspension General Diagnosis: 2A-2
NOTE
*1: Right-to-left trim height (“H”) difference should be within 15 mm (0.6 in.) with curb weight. (same
with rear side.)

Body leans or sways in
corners Loose stabilizer bar
Tighten stabilizer bar bolts or nuts, or replace
bushes.
Faulty strut (shock absorber) or
mounting Replace strut (shock absorber) or tighten
mounting.
Broken or sagging coil springs Replace coil springs.
Overloaded Check loading.
Cupped tires Front struts defective Replace struts.
Worn wheel bearings Replace wheel bearings.
Excessive tire or wheel run-out Replace tire and/or wheel.
Worn ball joints Replace front suspension control arm.
Tire out of balance Adjust tire balance.
Condition Possible cause Correction / Reference Item
“H”
I2RH01210001-01