2006 SUZUKI SWIFT oil plug

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-3
Diagnostic Information and Procedures
Manual Transaxle Symptom DiagnosisS7RS0B5204001
Repair Instructions
Manual Transaxle Oil ChangeS7RS0B5206001
1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage exists, correct it.
NOTE
Whenever vehicle is hoisted for any other
service work than oil change, also be sure to
check for oil leakage.

3) Remove oil filler plug (2).
4) Remove drain plug (1), and drain old oil. 5) Apply sealant to thread of drain plug (1), and tighten
it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil drain plug (a): 21 N·m (2.1 kgf-m,
15.5 lb-ft)
6) Pour new specified oil unt il oil level reaches bottom
of oil filler plug hole (3) as shown in figure.NOTE
It is highly recommended to use API GL-4
75W-90 gear oil.

Transaxle oil specification
: API GL-4 (For SAE classification, refer to
viscosity chart [A] in figure.)
Manual transaxle oil capacity
Reference: 2.0 liters (4.2/3.5 US/Imp. pt)
Condition Possible cause Correction / Reference Item
Gears slipping out of
mesh Worn shift fork shaft
Replace.
Worn shift fork or synchronizer sleeve Replace.
Weak or damaged locating springs Replace.
Worn bearings on input shaft or
countershaft Replace.
Worn chamfered tooth on sleeve and
gear Replace sleeve and gear.
Hard shifting Maladjusted gear select control cable Adjust.
Inadequate or insufficient lubricant Replenish.
Improper clutch pedal free travel Replace clutch master cylinder or clutch pedal
arm.
Distorted or broken clutch disc Replace.
Damaged clutch pressure plate Replace clutch cover.
Worn synchronizer ring Replace.
Worn chamfered tooth on sleeve or gear Replace sleeve or gear.
Worn gear shift / select control cables
joint Replace.
Distorted shift shaft Replace.
Worn gear shift / select control cables Replace.
Noise Inadequate or insufficient lubricant Replenish.
Damaged or worn bearing(s) Replace.
Damaged or worn gear(s) Replace.
Damaged or worn synchronizer parts Replace.

Downloaded from www.Manualslib.com manuals search engine 5B-4 Manual Transmission/Transaxle:
7) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil level / filler plug (b): 21 N·m (2.1
kgf-m, 15.5 lb-ft)Differential Side Oil Seal ReplacementS7RS0B5206002
1) Lift up vehicle and drain transaxle oil.
2) Remove front drive shaft and/or center shaft referring to “Front Driv e Shaft Assembly Removal
and Installation in Section 3A”.
3) Remove oil seal (1) using special tool.
Special tool
(A): 09913–50121
4) Install oil seal (1) facing its spring side inward. Use special tool and hammer for installation.
Special tool
(A): 09913–85210
5) Apply grease to oil seal lip and at the same time check drive shaft where oil seal contacts and make
sure of its smoothness.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
6) Insert front drive shaft and/or center shaft referring to “Front Drive Shaft A ssembly Removal and
Installation in Section 3A”.
7) Fill transaxle oil as specified referring to “Manual Transaxle Oil Change”, and make sure that oil has
been sealed with oil seal.
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Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-13
Manual Transaxle Assembly ComponentsS7RS0B5206013
I6RS0C520005-01
1. Transaxle right case 24. Shift fork bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
2. Transaxle left case : Apply sealant 99000-31260 to mating surface of left case and right
case. 25. 5th gear shift fork
3. Gear shift and select shaft assembly 26. Needle bearing
4. Transaxle left case plate 27. Input shaft 5th gear
5. Transaxle side cover : Apply sealant 99000-31260 to mating surface of side cover and left
case. 28. Reverse gear shift lever
6. Back up light switch 29. Reverse gear shift lever bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
7. O-ring 30. Reverse gear shaft
8. Differential assembly 31. Washer
9. Oil level/filler plug : Apply sealant 99000-31260 to all around thread part of plug. 32. Reverse idler gear
10. Oil drain plug : Apply sealant 99000-31260 to all around thread part of plug. 33. Reverse shaft bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.

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 7B-2 Air Conditioning System: Manual Type
Refrigerant Line
• Never use heat for bending pipes. When bending a pipe , try to make its bending angle as smooth as possible.
• Keep internal parts of air conditioning free from moistu re and dirt. When disconnecting any line from system, install
a blind plug or cap to the fitting immediately.
• When connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to O-ring.
• When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.
• When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.
• Check local governmental regulations regarding working with refrigerator systems and its tooling.
• Route drain hose so that drained water does not make any contact to vehicle components.
• If pipes or hoses are replaced, replenish specified amount of compressor oil to compre ssor suction side referring to
“Replenishing Compressor Oil” in “Operation Procedure for Refrigerant Charge”.
Refrigerant Recovery
When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling
equipment because discharging refrigerant HFC-134a (R-1 34a) into atmosphere would cause adverse effect to
environments.
NOTE
When handling recovery and recycling equipment, be sure to follow the instruction manual for the
equipment.

Refrigerant Charge
After performing compressor oil replenishment and evacuat ion, charge a proper amount of refrigerant to A/C system
referring to “Charge” in “Operation Procedure for Refrigerant Charge”.
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1. Suction hose : Apply compressor oil (refrigerant oil) to O-ring. 4. Expansion valve
: Apply compressor oil (refrigerant oil) to O-ring.
2. Discharge hose : Apply compressor oil (refrigerant oil) to O-ring. 5. A/C refrigerant pressure sensor
: Apply compressor oil (refrigerant oil) to O-ring.
3. Liquid pipe : Apply compressor oil (refrigerant oil) to O-ring.

Downloaded from www.Manualslib.com manuals search engine 7B-22 Air Conditioning System: Manual Type
5) Remove condenser assembly (1) as shown.
Installation
Reverse the removal procedure to install condenser
noting the following instructions.
• Replenish specified amount of compressor oil to compressor suction side referring to “Replenishing
Compressor Oil” in “Operation Procedure for
Refrigerant Charge”.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
Receiver/Dryer Removal and InstallationS7RS0B7216031
Removal
1) Remove front bumper referring to “Front Bumper and Rear Bumper Components in Section 9K”.
2) Remove receiver/dryer bolt (1), and then remove receiver/dryer (2) from condenser.
3) Remove joints (3) and O-rings (4). Installation
Reverse the removal procedure noting the following
instructions.
• Replenish specified amount of compressor oil to
compressor suction side referring to “When replacing
other parts” in “Operation Procedure for Refrigerant
Charge”.
• Use new receiver/dryer and O-ring.
• Do not remove plug from receiver/dryer until just before installin g it condenser.
• Apply compressor oil to O-ring.
: Compressor oil 99000–99015–00A
(MATSUSHITADENKI GU10)
• Tighten receiver/dryer bolts to the specified torque. Tightening torque
Receiver/dryer bolt: 10 N· m (1.0 kgf-m, 7.5 lb-ft)
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
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Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-123
8) Route deployment harness (1) out of vehicle.
9) Check that inside of vehicle and area surrounding vehicle are clear of all people and loose or
flammable objects.
10) Stretch deployment harness (1) to its full length 10 m (33 ft).
11) Place 12 volts vehicle battery (2) near shorted end of deployment harness (1).
12) Completely cover windshield area and front door window openings with drop cloth, a blanket or any
similar item. This reduces possibility of injury due to
possible fragmentation of vehicle’s glass or interior.
13) Notify all people in immediate area that you intend to deploy air bag (inflator) module or activate seat belt
pretensioners.
NOTE
• When air bag (inflator) module deploys or seat belt pretensioners activate, rapid gas
expansion will create substantial report.
Wear suitable ear protection. Notify all
people in immediate area that you intend
to deploy air bag (inflator) module or to
activate seat belt pretensioner and suitable
ear protection should be worn.
• After air bag (inflator) module has been deployed, surface of air bag may contain
powdery residue. This powder consists
primarily of cornstarch (used to lubricate
air bag (inflator) module as it inflates) and
by-products of chemical reaction.

WARNING!
• Do not place deployed air bag (inflator) module and activated seat belt
pretensioners near any flammable objects.
• Do not apply water, oil, etc. to deployed air bag (inflator) module and activated seat
belt pretensioners.
• Wait for about 30 minutes before touching any metal surface of air bag (inflater)
module or seat belt pretensioner modules.
Disregarding these precautions may cause
fire or personal injury.
Failure to follow procedures may result in fire
or personal injury.

14) Separate two banana plugs (1) on deployment harness (2).
15) Connect deployment harness (2) to 12 volts vehicle battery (3). This will immedi ately deploy or activate
air bag (inflator) module or seat belt pretensioners.
16) Disconnect deployment harness (2) from 12 volts vehicle battery (3) and short two deployment
harness leads together by fully seating one banana
plug into the other.
17) Repeat Steps 3) through 16) to deploy / activate air bag (inflator) modules and seat belt pretensioners
which has not been deployed / activated, if any.
18) In the unlikely event that air bag (inflator) module and seat belt pretensioners after following these
procedures, proceed immediately with Step 24)
through 26). If air bag (inflator) module and seat belt
pretensioners did deploy / activate, proceed with
Steps 19) through 23).
19) Carefully remove drop cloth from vehicle and clean off any fragments or discard it entirely.
20) Put on pair of shop gloves to protect your hands from
possible irritation and heat when handling deployed
air bag (inflator) module and activated seat belt
pretensioners.
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