2008 SUZUKI SWIFT Direction

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-58
2) Tighten main bearing cap No.1 bolts (a) and main bearing cap No.2 bolts (b ) gradually as follows.
a) Tighten bolts (“1” through “10”) to 30 N ⋅m (3.0
kgf-m, 22.0 lb-ft) according to numerical order in
the figure.
b) In the same manner as in Step a), tighten them to 50 N ⋅m (5.0 kgf-m, 36.5 lb-ft).
c) In the same manner as in Step a), retighten them to 60 °.
d) Tighten bolts (“11” through “18”) to 25 N ⋅m (2.5
kgf-m, 18.0 lb-ft) according to numerical order in
figure.
Tightening torque
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): 25 N·m (2.5
kgf-m, 18.0 lb-ft) 3) Use a dial gauge to read displacement in axial
(thrust) direction of crankshaft.
If its limit is exceeded, replace thrust bearing with
new standard one or oversize one to obtain standard
thrust play.
Crankshaft thrust play
Standard: 0.11 – 0.31 mm (0.0043 – 0.0122 in.)
Limit: 0.35 mm (0.0138 in.)
NOTE
After checking the thrust play, make sure that
thread deformation of each bearing cap No.1
bolt referring to “Main Bearing Cap No.1
Bolt” in “Main Bear ings Inspection”.

Out-of-Round and Taper (Uneven Wear) of Journals
An unevenly worn crankshaft journal shows up as a
difference in diameter at a cross section or along its
length (or both). This difference, if any, is determined by
taking micrometer readings. If any one of journals is
badly damaged or if amount of uneven wear in the sense
exceeds its limit, regrind or replace crankshaft.
Crankshaft out-of-round and taper
Limit: 0.01 mm (0.0004 in.)
Out-of-round
A – B
Ta p e r
a – b
I6RS0C140027-01
I2RH01140183-01
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-62
Undersize bearing (0.25 mm (0.0098 in.))
• 0.25 mm (0.0098 in.) undersize bearing is available, in five kinds varying in thickness.
To distinguish them, each bearing is painted in the following colors at such position as indicated in the figure.
Each color represents the following thickness at the center of bearing.
Undersize of crankshaft main bearing thickness
• If necessary, regrind crankshaft journal and sele ct undersize bearing to use with it as follows.
a. Regrind journal to the following finished diameter.
Finished journal diameter
51.7320 – 51.7500 mm (2.0367 – 2.0374 in.)
b. Using micrometer, measure regrind journal diameter. Measurement should be taken in two directions perpendicular to each other in order to check for out-of-round.
c. Using journal diameter measured above and alphabets stamped on cylinder block, select an undersize bearing
by referring to the following table.
Check bearing clearance with ne wly selected undersize bearing.
New undersize crankshaft main bearing specification
Color painted Bearing thickness
Red and Purple 2.117 – 2.121 mm (0.08335 – 0.08350 in.)
Red and Brown 2.120 – 2.124 mm (0.08347 – 0.08362 in.) Red and Green 2.123 – 2.127 mm (0.08359 – 0.08374 in.) Red and Black 2.126 – 2.130 mm (0.08371 – 0.08385 in.) Red only 2.129 – 2.133 mm (0.08382 – 0.08397 in.)
1. Paint
Measured journal diameter
51.7320 – 51.7379 mm (2.0367 – 2.0369 in.) 51.7380 – 51.7439 mm
(2.0370 – 2.0371 in.) 51.7440 – 51.7500 mm
(2.0372 – 2.0373 in.)
Alphabets stamped on cylinder block A (1) Red and Green Red and Brown Red and Purple
B (2) Red and Black Red and Green Red and Brown
C (3) Red only Red and Black Red and Green
Undersize bearing to be installed
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Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-16
Removal1) Remove fuel pump assembly from fuel tank referring to “Fuel Pump Assembly Removal and Installation”.
2) Disconnect main fuel level sensor connector (3).
3) With pressing snap-fit part (2), remove main fuel level sensor (1) by sliding it in the arrow direction as
shown in figure.
Installation
Reverse removal procedure for installation.Fuel Pump InspectionS7RS0B1706019
• Check fuel pump assembly for damage.
• Check fuel suction filter for evidence of dirt and contamination. If present, replace or clean and check
for presence of dirt in fuel tank.
• For electrical circuit, refer to “Fuel Pressure Check in Section 1A”.
• For inspection of main fuel level sensor (1), refer to “Fuel Level Sensor Inspection in Section 9C”.
Specifications
Tightening Torque SpecificationsS7RS0B1707001
NOTE
The specified tightening torque is also described in the following.
“Fuel System Components”
“Fuel Hose Disconnecting and Reconnecting”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
1
21
3
I5RS0D170006-031
I5RS0D170008-01
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
Fuel delivery pipe bolt 25 2.5 18.0 )
Ground wire bolt 11 1.1 8.0 )
Fuel tank bolt 45 4.5 33.0 )
Fuel filler hose clamp 2 0.2 1.5 )
Fuel pump assembly bolt 11 1.1 8.0 )

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-8
• Check the commutator and armature core. If there is
continuity, the armature is grounded and must be
replaced.
• Check for continuity between segments. If there is no continuity at any test point , there is an open circuit
and the armature must be replaced.
Gears
Inspect the internal gear and the planetary gears for
wear, damage or other abnorma l conditions. Replace if
necessary. Pinion and Over-Running Clutch
• Inspect the pinion for wear, damage or other abnormal
conditions.
Check that clutch locks up when turned in direction of
drive and rotates smoothly in reverse direction.
Replace if necessary.
• Inspect the spline teeth for wear or damage. Replace if necessary.
Inspect the pinion for smooth movement.
Front Housing Bush
Inspect the bush for wear or damage. Replace if
necessary.
I2RH01190019-01
I2RH01190020-01
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I2RH01190022-01
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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 )

Downloaded from www.Manualslib.com manuals search engine 1J-12 Charging System:
• Using an ohmmeter (1), check that there is no continuity between slip ring (2) and rotor core (3). If there is
continuity, replace the rotor.
• Check slip rings for roughness or scoring. If rough or scored, replace the rotor.
Stator
• Using an ohmmeter (1), check all leads (2) for continuity. If there is no co ntinuity, replace the stator.
• Using an ohmmeter (1), check that there is no continuity between coil leads (2) and stator core (3). If
there is continuity, replace the stator. Brush and Brush Holder
Check each brush (1) for wear by measuring its length
as shown. If brush is found worn down to service limit,
replace brush.
Exposed brush length “a”
Standard: 16 mm (0.63 in.)
: Limit: 5.0 mm (0.20 in.)
Rectifier
Using ohmmeter, check continuity between “B” terminal
(1) or “E” terminal (2) and each diode lead (3).
Check both directions by reversing probes of ohmmeter
and there should be only one-way continuity in each
case. If check result is not satisfactory, replace rectifier
(4).
I4RS0B1A0008-01
I4RS0B1A0009-01
I4RS0B1A0010-01
I4RS0B1A0011-01
1
1
3 3
2
2
4
I6RS0B1A1010-01

Downloaded from www.Manualslib.com manuals search engine 2B-5 Front Suspension:
5) Remove brake hose mounting bolt (1) and remove brake hose (2) from bracket and then wheel speed
sensor harness (3) from strut bracket as shown in
figure.
6) Remove strut bracket bolts and nuts (4).
7) Remove strut rod cap.
8) Remove strut nut (1), and remove rebound stopper (2).
NOTE
Hold strut by hand so th at it will not fall off.

9) Remove strut assembly.
Installation
Install strut assembly by reversing removal procedure,
noting the following instructions.
CAUTION!
Never reuse strut bracket nuts.
Nuts are pre-coated with friction stabilizer.
Be sure to replace pre-coated nut with a new
one, or nut may loosen.

• Insert bolts in such direction as shown in figure.
• Tighten all fasteners to specified torque. Tightening torque
Strut bracket nut (a): 90 N·m (9.0 kgf-m, 65.5 lb-ft)
Brake hose mounting bolt (c): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Stabilizer joint nut (d): 50 N·m (5.0 kgf-m, 36.5 lb-
ft)
• Lower hoist and vehicle in unloaded condition, tighten strut nut (b) to specified torque.
Tightening torque
Strut nut (b): 50 N·m (5.0 kgf-m, 36.5 lb-ft)
• Install windshield wiper arms with blades referring to
“Windshield Wiper Removal and Installation in
Section 9D”.
NOTE
• Don’t twist brake hose and wheel speed sensor harness when installing them.
• Install wheel speed sensor harness (1) which marking (2) in figure is placed to
open hook side of the bracket.

1 3
2
2
1
4
4
3
I4RS0A220005-01
2
1
I4RS0A220006-01
(d) (a)
(b)
(c)
1
2
I4RS0B220012-01

Downloaded from www.Manualslib.com manuals search engine 2B-7 Front Suspension:
3) Install bump stopper onto strut rod. For installing
direction, refer to the figure in “Front Suspension
Construction”.
4) Pull strut rod as far up as possible and use care not to allow it to re tract into strut.
5) Install spring seat on coil spring and then spring upper seat (1) aligning “OUT” mark (3) on spring
upper seat and center of strut bracket (2).
6) Install strut bearing (3), strut support (2) and strut
support lower nut (1) in this sequence.
Tighten strut support lower nut (1) to specified
torque.
When tightening strut support lower nut, hold stud
with special tools.
Special tool
(A): 09900–00411 socket
(B): 09900–00414 6 mm
Tightening torque
Strut support lower nut (a): 50 N·m (5.0 kgf-m,
36.5 lb-ft)Front Strut Assembly CheckS7RS0B2206005
• Inspect strut for oil leakage, damage or deformation.
• If defect is found, replace strut as an assembly unit, because it can not be disassembled.
• Inspect strut function re ferring to the following
procedures:
1) Check and adjust tire pressures as specified.
2) Bounce vehicle body up and down 3 or 4 times continuously by pushing front end of the vehicle side
body to check strut.
Also, note how many times vehicle body rebounds to
stop after force application.
3) Repeat the same procedure to the other strut to confirm that the both side struts equally respond.
If conditions of struts are in doubt, compare them with
known-good vehicle or strut.
• Inspect bearing for wear, abnormal noise or gripping. If defective, replace.
• Inspect coil spring seat for cracks or deformation.
If defective, replace.
• Inspect bump stopper for deterioration. If defective, replace.
• Inspect rebound stopper and strut mount for wear, cracks or deformation.
If defective, replace.
I4RS0A220012-01
I6RS0B220006-01
I4RS0A220014-01