2008 SUZUKI SWIFT refill

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-7
6) After fitting oil pan to cylinder block, run in securing bolts and start tightening at the center: move wrench
outward, tightening one bolt at a time. Tighten bolts
and nuts to specified torque.
Tightening torque
Oil pan bolt (M6) (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Oil pan bolt (M10) (c): 55 N·m (5.5 kgf-m, 40.0 lb-
ft)
Oil pan nut (e): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
7) Install new gasket and drain plug to oil pan. Tighten drain plug to specified torque.
Tightening torque
Oil pan drain plug (b): 35 N·m (3.5 kgf-m, 25.5 lb-
ft)
8) Tighten transaxle stiffener bolts to specified torque. Tightening torque
Transaxle stiffener bolt (d): 55 N·m (5.5 kgf-m,
40.0 lb-ft)
9) Install exhaust manifold stiffener (2) and exhaust No.1 pipe (1) and heated oxygen sensor No.2
(connector color: green) (3) referring to “Exhaust
System Components in Section 1K”. 10) Install clutch housing lower plate (1).
11) Install oil level gauge.
12) Refill engine with engine oil referring to “Engine Oil
and Filter Change in Section 0B”.
13) Verify that there is no en gine oil leakage and exhaust
gas leakage at each connection.
Oil Pan and Oil Pump Strainer CleaningS7RS0B1506006
• Clean sealing surface between oil pan and cylinder block.
Remove oil, old sealant, and dust from sealing
surface.
• Clean oil pump strainer screen (1).(a)
(b)
(c)(e)
(d)I4RS0A150008-01
2
1
3
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Downloaded from www.Manualslib.com manuals search engine 1F-7 Engine Cooling System:
Cooling System Flush and RefillS7RS0B1606005
WARNING!
To help avoid danger of being burned, do not
remove radiator cap while engine and
radiator are still hot. Scalding fluid and steam
can be blown out under pressure if cap is
taken off too soon.

NOTE
For detail of coolant specification, refer to
“Coolant Description”.

1) Remove radiator cap when engine is cool as follows.a) Turn cap counterclockwise slowly until it reaches a “stop” (Do not press down while turning it).
b) Wait until pressure is relieved (indicated by a hissing sound) then press down on cap and
continue to turn it counterclockwise.
2) With radiator cap removed, run engine until upper radiator hose is hot (this shows that thermostat is
open and coolant is flowing through system).
3) Stop engine and drain coolant from radiator drain plug (1).
4) Close radiator drain plug. Add water until system is filled and run engine until up per radiator hose is hot
again.
5) Repeat Steps 3) and 4) several times until drained liquid is nearly colorless.
6) Close radiator drain plug (1) tightly. 7) Remove reservoir (1) and remove cap (2) from
reservoir (1).
8) Pour out any fluid, scrub and clean inside of reservoir with soap and water.
Flush it well with clean water and drain, Reinstall
reservoir.
9) Fill reservoir with coolant up to “Full” level mark (3).
10) Install reservoir cap (2) on reservoir. 11) Fill radiator with coolant up to bottom of radiator filler neck and install radiator cap, making sure that the
ear of cap lines is parallel to radiator.
12) Run engine at idle speed.
13) Run engine until radiator fan motor is operated.
14) Stop engine and wait until engine comes cooled down to help avoid danger of being burned.
15) Add coolant to radiator up to bottom of radiator filler
neck, and install radiator ca p, making sure that the
ear of cap lines is parallel to radiator.
16) Repeat Step 12) through 15).
17) Confirm that reservoir cool ant level is “Full” level
mark (3). If coolant is insu fficient, repeat Step 9) and
10).
Cooling Water Pipes or Hoses Removal and
Installation
S7RS0B1606006
Removal
1) Drain coolant referring to “Cooling System Draining”.
2) To remove these pipes or hoses, loosen clamp on each hose and pull hose end off.
Installation
Install removed parts in reverse order of removal
procedure, noting the following.
• Tighten each clamp securely referring to “Cooling System Components”.
• Refill cooling system referrin g to Step 7) to 22) of
“Cooling System Flush and Refill”.
1I4RS0A160003-01
1
2
1
3
2
I7RS0B160005-01

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-8
Thermostat Removal and InstallationS7RS0B1606007
Removal1) Drain coolant referring to “Cooling System Draining”.
2) Remove intake manifold referring to “Intake Manifold Removal and Installa tion in Section 1D”.
3) Remove generator referring to “Generator Dismounting and Remounting in Section 1J”.
4) Disconnect water hose (1) and heater hose (2) from each pipe.
5) Remove thermostat case (3) with thermostat cap (4)
and water inlet pipe (5).
6) Remove water inlet pipe with thermostat cap from thermostat case.
7) Remove thermostat from thermostat case (3).
Installation
Reverse removal procedure for installation noting the
following points.
• Install thermostat cap (1) to thermostat case (2) by aligning match mark (3) of thermostat case with air
bleed valve (4) of the thermostat (5).
• Use new O-rings when installing.
• Adjust water pump belt tension referring to “Water Pump / Generator Drive Belt Tension Inspection and
Adjustment in Section 1J”.
• Adjust A/C compressor belt tension referring to “Compressor Drive Belt Inspection and Adjustment in
Section 7B” or “Compressor Drive Belt Inspection and
Adjustment in Section 7B”. • Refill cooling system referrin
g to Step 7) to 22) of
“Cooling System Flush and Refill”.
• Verify that there is no coolant leakage at each connection.
Thermostat InspectionS7RS0B1606008
• Make sure that air bleed valve (1) of thermostat is clean.
• Check to make sure that va lve seat (2) is free from
foreign matters which would prevent valve from
seating tight.
• Check thermostat seal (3) for breakage, deterioration or any other damage.
• Check thermostatic movement of wax pellet as follows:
a. Immerse thermostat (1) in water, and heat water gradually.
b. Check that valve starts to open at specific temperature.
Temperature at which valve begins to open
80 – 84 °C (176 – 183 °F)
Temperature at which valve become fully open
95 – 97 °C (203 °F)
Va l v e l i ft
More than 8 mm at 95 °C (203 ° F)
If valve starts to open at a temperature substantially
below or above specific temperature, thermostat unit
should be replaced with a new one. Such a unit, if
reused, will bring about ov ercooling or overheating
tendency.
I3RM0A160007-01
4
5 3
1 2
I7RS0B160006-01
2. Thermometer
3. Heater
I3RM0A160008-01
I2RH01160012-01

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 1F-11 Engine Cooling System:
Water Pump Removal and InstallationS7RS0B1606014
Removal1) Disconnect negative cable at battery.
2) Drain coolant.
3) Remove water pump / generator drive belt referring to “Water Pump / Generator Drive Belt Removal and
Installation in Section 1J”.
4) Remove water pump assembly (1).
Installation 1) Apply sealant to mating surface of water pump (1) as shown in the figure.
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
Sealant quantity (to mating surface of water
pump)
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.) 2) Install water pump assemb
ly (1) to cylinder block
and tighten bolts and nut to specified torque.
Tightening torque
Water pump bolt and nut (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
3) Install water pump pulley.
4) Install water pump / generator drive belt referring to “Water Pump / Generator Drive Belt Tension
Inspection and Adjustment in Section 1J”.
5) Install A/C compressor belt (if equipped) referring to “Compressor Drive Belt Inspection and Adjustment
in Section 7B” or “Compressor Drive Belt Inspection
and Adjustment in Section 7B”.
6) Refill cooling system referri ng to Step 7) to 22) of
“Cooling System Flush and Refill”.
7) Connect negative cable at battery.
8) Check each part for leakage.
Water Pump InspectionS7RS0B1606015
CAUTION!
Do not disassemble water pump.
If any repair is requir ed on pump, replace it
as assembly.

Rotate water pump by hand to check for smooth
operation. If pump does not rotate smoothly or makes
abnormal noise, replace it.
I2RH0B160016-01
I3RM0A160016-01
I2RH0B160018-01
I2RH0B160019-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-5
If deterioration of rubber is evident, disassemble all
hydraulic parts and wash with alcohol. Dry these parts
with compressed air before assembly to keep alcohol out
of the system. Replace all rubber parts in the system,
including hoses. Also, when working on the brake
mechanisms, check for fluid on the linings.
If excessive fluid is found, replace the pads. If master cylinder piston seals
are satisfactory, check for
leakage or excessive heat co nditions. If leakage is not
found, drain fluid, flush with brake fluid, refill and bleed
system.
The system must be flushed if there is any doubt as to
the grade of fluid in the system or if fluid has been used
which contained parts that have been subjected to
contaminated fluid.
Brakes Symptom DiagnosisS7RS0B4104002
Condition Possible cause Correction / Reference Item
Not enough braking force Brake oil leakage from brake lines Locate leaking point and repair.
Brake disc or brake pad stained with oil Clean or replace.
Overheated brakes Determine cause and repair.
Badly worn brake pad Replace.
Malfunctioning caliper assembly Repair or replace.
Malfunctioning brake booster Check system and replace assembly.
Malfunctioning brake master cylinder Check system and replace as necessary.
Air in system Bleed system.
Malfunctioning ABS (ESP ®). Check system and replace as necessary.
Brake pull (Brakes not
working in unison) Brake pad and disc are wet with water or
stained with oil in some brakes Clean or replace.
Disc is out of round in some brakes Replace.
Tires are inflated unequally Inflate equally.
Disturbed front wheel alignment Adjust as prescribed.
Unmatched tires on same axle Tires with approximately the same amount of
tread should be used on the same axle.
Restricted brake pipes or hoses Check for soft hoses and damaged lines.
Replace with new hoses and new double-
walled steel brake tubing.
Malfunctioning caliper assembly Caliper should slide.
Check for stuck or sluggish pistons and proper
lubrication of caliper slide pin.
Loose suspension parts Check all suspension mountings.
Loose calipers Check and torque bolts to specifications.
Noise (High pitched
squeak without brake
applied) Contact wear indicator to brake disc
Replace brake pads.
Worn brake pad Replace brake pads.
Excessive pedal travel
(Pedal stroke too large) Partial brake system failure
Check brake systems and repair as necessary.
Brake fluid leaking Repair the leaking point and bleed air.
Air in system (soft / spongy pedal) Bleed system.
Brake locked Malfunctioning ABS (ESP®) Check system referri ng to “ABS Check in
Section 4E” or “Electronic Stability Program
System Check in Section 4F”.
Dragging brakes (A very
light drag is present in all
brakes immediately after
pedal is released.) Master cylinder pistons not returning
correctly
Replace master cylinder.
Restricted brake pipes or hoses Check for soft hoses or damaged pipes and
replace with new hoses and/or new brake
piping.
Incorrect parking brake adjustment on
rear brakes Check and adjust to correct specifications.
Weakened or broken return springs in
rear brakes. Replace.
Sluggish parking brake cables or linkage Repair or replace.
Brake caliper piston sticking Repair as necessary.
Badly worn piston seal in caliper Replace piston seal.
Improper brake pedal free height Check brake pedal free height.

Downloaded from www.Manualslib.com manuals search engine 4A-8 Brake Control System and Diagnosis:
Excessive Pedal Travel InspectionS7RS0B4106003
1) Start engine.
2) Depress brake pedal a few times.
3) With brake pedal depressed with approximately 300 N (30 kg, 66 lbs) load, measure brake pedal to wall
(dash panel silencer) clearance “a”. If clearance “a”
is less than specification, the most possible cause is
air in lines. Should clearance “a” remain less than
specification even after bleeding of system, other
possible infrequent cause is booster push rod length
out of adjustment.
• Bleed brake system. Refer to “Air Bleeding of Brake System”.
Brake arm pedal to wall clearance “a”
When pedal depressed at 300 N (30 kg, 66 lbs):
over 75 mm (2.95 in.)
Brake Fluid Level InspectionS7RS0B4106004
1) Check master cylinder, reservoir and reservoir hose (if equipped) for crack, damage and brake fluid
leakage. If any faulty condition exists, correct or
replace.
2) Check that brake fluid level is between MAX and MIN marks on reservoir.
NOTE
Be sure to use particular brake fluid either as
indicated on reservoir cap of that vehicle or
recommended in owner’s manual which
comes along with that vehicle. Use of any
other fluid is strictly prohibited.
Fluid level should be between MIN and MAX
lines marked on reservoir.
When brake warning lamp lights sometimes
during driving, replenis h fluid to MAX level.
When fluid decreases quickly, inspect brake
system for leakage. Correct leaky points and
then refill to specified level.

CAUTION!
Do not use shock absorber fluid or any other
fluid which contains mineral oil. Do not use a
container which has been used for mineral oil
or a container which is wet from water.
Mineral oil will cause swelling and distortion
of rubber parts in hydraulic brake system and
water mixed into brake fluid will lower fluid
boiling point. Keep all fluid containers
capped to prevent contamination.

Stop Light Switch AdjustmentS7RS0B4106005
Adjustment should be made as follows. Pull up brake
pedal toward you and while holding it there, adjust
switch position so that clea rance between end of thread
and brake pedal is as specified. Then lock it by turning
clockwise.
Clearance between brake pedal and stop light switch
“a”: 1.2 – 2.2 mm (0.05 – 0.08 in.)
I6RS0C410005-02
I4RS0B410006-01
I4RS0A410007-01

Downloaded from www.Manualslib.com manuals search engine 5B-10 Manual Transmission/Transaxle:
16) Remove engine under covers.
17) Support transaxle with transmission jack.
18) Remove transaxle to engine bolts and nut of lower side.
19) Remove engine left mounting (1) with bracket (2).
20) Remove engine rear mounting bracket bolts (1).
21) Remove other attached parts from transaxle, if any.
22) Pull transaxle so as to disconnect input shaft from clutch disc, and then lower it. Remounting
CAUTION!
• Care should be taken not to scratch oil
seal lip with drive shaft while raising
transaxle.
• Do not hit drive shaft joint with hammer when installing it into differential gear.

Reverse dismounting procedure for remounting noting
the following.
• Tighten each bolts and nuts to specified torque referring to “Manual Transaxle Unit Components”.
• Set each clamp for wiring securely.
• Fill transaxle oil referring to “Manual Transaxle Oil
Change”.
• Fill coolant referring to “Cooling System Flush and
Refill in Section 1F”.
• Install hook (1) and ground cable (2) at specified position as shown in figure.
• Connect battery and check function of engine, clutch
and transaxle.
1
2
I4RS0A520021-01
1
I4RS0A520022-01
3. Transaxle side cover 4. Transaxle left case
90
1
2 3
4
I4RS0A520023-01