2008 SUZUKI SWIFT lubri

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-13
Brake
Foot brake
Check the following:
• that brake pedal has proper travel,
• that brake works properly,
• that it is free from noise,
• that vehicle does not pull to one side when brake is applied.
• and that brake do not drag.
Parking brake
Check that lever has proper travel.
WARNING!
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property
damage. Be prepared to apply regular brake
quickly even if vehicle should start to move.

Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and brake
lever is pulled all the way.
Steering
• Check to ensure that steering wheel is free from instability, or abnormally heavy feeling. • Check that the vehicle does not wander or pull to one
side.
Engine
• Check that engine responds readily at all speeds.
• Check that engine is free from abnormal noise and abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting system
are free from abnormal noise and abnormal vibration or
any other abnormal condition.
Meters and Gauge
Check that speedometer, odometer, fuel meter,
temperature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that ai r comes out from defroster
outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan
switch lever to “HI” position for this check.
Specifications
Tightening Torque SpecificationsS7RS0B0207001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Fluids and LubricantsS7RS0B0208001
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Engine oil drain plug 35 3.5 25.5 )
Oil filter 14 1.4 10.5 for reference )
Engine oilSG, SH, SJ, SL or SM grade (Refer to “Engine Oil and Filter Change” for engine
oil viscosity.)
Engine coolant
(Ethylene glycol base coolant) “Antifreeze/Antico
rrosion coolant”
Brake fluid Refer to reservoir cap of brake master cylinder.
Manual transaxle oil Refer to “Manual Transaxle Oil Change in Section 5B”.
Automatic transaxle fluid Refer to “A/T Fluid Change in Section 5A”.
Door hinges Engine oil or water resistance chassis grease
Hood latch assembly Engine oil or water resistance chassis grease
Key lock cylinder Spray lubricant

Downloaded from www.Manualslib.com manuals search engine 0B-14 Maintenance and Lubrication:
Special ToolS7RS0B0208002
09915–47331
Oil filter wrench
)

Downloaded from www.Manualslib.com manuals search engine 1-iv Table of Contents
Engine Lubrication System.....................1E-1
General Description ............................................. 1E-1
Engine Lubrication Description ........................... 1E-1
Diagnostic Information and Procedures ............ 1E-2 Oil Pressure Check ............................................. 1E-2
Repair Instructions ........... ................................... 1E-3
Heat Exchanger Components ............................. 1E-3
Heat Exchanger On-Vehicle Inspection .............. 1E-4
Heat Exchanger Removal and Installation .......... 1E-4
Oil Pan and Oil Pump Strainer Components....... 1E-5
Oil Pan and Oil Pump Strainer Removal and
Installation ......................................................... 1E-5
Oil Pan and Oil Pump Stra iner Cleaning ............. 1E-7
Oil Pump Components ........................................ 1E-8
Oil Pump Removal and Installation ..................... 1E-8
Oil Pump Disassembly and Reassembly ............ 1E-8
Oil Pump Inspection ............................................ 1E-9
Specifications .... ................................................. 1E-11
Tightening Torque Specifications ...................... 1E-11
Special Tools and Equipmen t ........................... 1E-11
Recommended Service Material ....................... 1E-11
Special Tool ...................................................... 1E-11
Engine Cooling System ..... ...................... 1F-1
General Description .......... ................................... 1F-1
Cooling System Descriptio n ................................ 1F-1
Coolant Description ............................................. 1F-1
Schematic and Routing Diagram ........................ 1F-2 Coolant Circulation .............................................. 1F-2
Diagnostic Information and Procedures ............ 1F-4 Engine Cooling Symptom Diagnosis ................... 1F-4
Repair Instructions ........... ................................... 1F-5
Cooling System Components.............................. 1F-5
Coolant Level Check ........................................... 1F-6
Engine Cooling System Inspection and Cleaning ............................................................ 1F-6
Cooling System Draining.. ................................... 1F-6
Cooling System Flush and Refill ......................... 1F-7
Cooling Water Pipes or Hoses Removal and Installation ......................................................... 1F-7
Thermostat Removal and In stallation.................. 1F-8
Thermostat Inspection......................................... 1F-8
Radiator Cooling Fan Motor On-Vehicle Inspection .......................................................... 1F-9
Radiator Cooling Fan Rela y Inspection............... 1F-9
Radiator Cooling Fan Removal and Installation ....................................................... 1F-10
Radiator On-Vehicle Inspection and Cleaning .. 1F-10
Radiator Removal and Inst allation .................... 1F-10
Water Pump Removal and In stallation .............. 1F-11
Water Pump Inspection ..................................... 1F-11
Specifications .... ................................................. 1F-12
Tightening Torque Specifications ...................... 1F-12
Special Tools and Equipmen t ........................... 1F-12
Recommended Service Material ....................... 1F-12
Fuel System ................... .......................... 1G-1
Precautions.......................................................... 1G-1 Precautions on Fuel System Service ................. 1G-1
General Description ............................................ 1G-1 Fuel System Description .................................... 1G-1
Fuel Delivery System Description ...................... 1G-1
Fuel Pump Description ....................................... 1G-2
Schematic and Routing Diagram ....................... 1G-2 Fuel Delivery System Diag ram........................... 1G-2
Diagnostic Information and Procedures ........... 1G-2 Fuel Pressure Inspection ................................... 1G-2
Fuel Cut Operation Inspection ........................... 1G-3
Repair Instructions ............ ................................. 1G-4
Fuel System Components .................................. 1G-4
Fuel Hose Disconnecting and Reconnecting ..... 1G-5
Fuel Pressure Relief Procedure ......................... 1G-7
Fuel Leakage Check Procedure......................... 1G-7
Fuel Lines On-Vehicle Inspection ...................... 1G-7
Fuel Pipe Removal and Installation.................... 1G-7
Fuel Injector On-Vehicle Inspection ................... 1G-8
Fuel Injector Removal and Installation ............... 1G-8
Fuel Injector Inspection ...................................... 1G-9
Fuel Filler Cap Inspection . ............................... 1G-10
Fuel Tank Inlet Valve Removal and Installation ...................................................... 1G-11
Fuel Tank Inlet Valve Inspection ...................... 1G-12
Fuel Tank Removal and Installation ................. 1G-12
Fuel Tank Inspection ........................................ 1G-13
Fuel Tank Purging Procedure .......................... 1G-14
Fuel Pump On-Vehicle Inspection.................... 1G-14
Fuel Pump Assembly Removal and Installation ...................................................... 1G-14
Main Fuel Level Sensor Removal and Installation ...................................................... 1G-15
Fuel Pump Inspection ...................................... 1G-16
Specifications ..................... ............................... 1G-16
Tightening Torque Specifications ..................... 1G-16
Special Tools and Equipmen t .......................... 1G-17
Special Tool ..................................................... 1G-17
Ignition System .............. .......................... 1H-1
General Description .............................................1H-1
Ignition System Construction ..............................1H-1
Schematic and Routing Diagram ........................1H-2 Ignition System Wiring Circuit Diagram...............1H-2
Component Location ............ ...............................1H-3
Ignition System Components Location................1H-3
Diagnostic Information and Procedures ............1H-4 Ignition System Symptom Diagnosis...................1H-4
Reference Waveform of Ignition System.............1H-4
Ignition System Check ........................................1H-4
Ignition Spark Test ..............................................1H-6
Repair Instructions ............ ..................................1H-6
High-Tension Cord Removal and Installation......1H-6
High-Tension Cord Inspection.............................1H-7
Spark Plug Removal and Installation ..................1H-7
Spark Plug Inspection .........................................1H-7
Ignition Coil Assembly (Including ignitor)
Removal and Installation ...................................1H-8
Ignition Coil Assembly (Including ignitor)
Inspection ..........................................................1H-8

Downloaded from www.Manualslib.com manuals search engine 1A-2 Engine General Information and Diagnosis:
• Be sure to read “Precautions for Electrical Circuit Service in Section 00” befo re inspection and observe
what is written there.
• ECM replacement: When substituting a known-good ECM, check for the
following conditions. Neglec ting this check may cause
damage to a known-good ECM.
– Resistance value of all relays, actuators is as specified respectively.
– MAP sensor, A/C refrigerant pressure sensor and TP sensor are in good condition and none of power
circuits of these sensors is shorted to ground.
• Communication of ECM, BCM, ABS/ESP ® control
module, combination meter, keyless start control
module, steering angle sensor (ESP ® model) and
TCM (A/T model), is esta blished by CAN (Controller
Area Network). (For more detail of CAN
communication for ECM, refer to “CAN
Communication System Description”). Therefore,
handle CAN communication line with care referring to
“Precaution for CAN Communication System in
Section 00”.
• Immobilizer transponder code registration after
replacing ECM
When ECM is replaced with new one or with another
one, make sure to register immobilizer transponder
code to ECM correctly according to “Procedure after
ECM Replacement in Section 10C”.Precautions of ECM Circuit InspectionS7RS0B1100003
• ECM connectors are waterproofed. Each terminal of the ECM connectors is sealed up with the grommet.
Therefore, when measuring ci rcuit voltage, resistance
and/or pulse signal at ECM connector, do not insert
the tester’s probe into th e sealed terminal at the
harness side. When measuring circuit voltage,
resistance and/or pulse signal at ECM connector,
connect the special tool to the ECM connectors. And,
insert the tester’s probe into the special tool’s
connectors at the harness side, and then measure
voltage, resistance and/or pulse signal. Or, ECM and
its circuits may be damaged by water.
• Wire colors of the special tool’s connectors are different from the ones of the ECM connectors.
However, the circuit arrangement of the special tool’s
connectors is same as the one of the ECM
connectors. Therefore, measure circuit voltage and
resistance by identifying the terminal location subject
to the measurement.
Precautions of Electric Throttle Body System
Calibration
S7RS0B1100004
After performing one of works described below, it is
necessary to re-register the completely closed throttle
valve reference position stored in memory of ECM. (For
detailed information, refer to “Description of Electric
Throttle Body System Calibration”.) For the procedure to
register such data in ECM, refer to “Electric Throttle
Body System Calibration in Section 1C”.
• To shut off backup power of ECM for such purposes of battery replacement or “DOME” fuse removal
• To erase DTCs P0122, P01 23, P0222, P0223, P2101,
P2102, P2103, P2111, P2112, P2113, P2119, P2123,
P2127, P2128, P2135 and/or P2138
• To replace ECM
• To replace throttle body and/or accelerator pedal position (APP) sensor assembly
General Description
Statement on Cleanliness and CareS7RS0B1101001
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousands of an
millimeter (ten thous ands of an inch).
Accordingly, when any internal engine parts are
serviced, care and cleanliness are important.
It should be understood that proper cleaning and
protection of machined surfaces and friction areas is part
of the repair procedure. This is considered standard
shop practice even if not specifically stated.
• A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate
the surfaces on initial operation. • Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.
At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.
• Battery cables should be disconnected before any major work is performed on the engine.
Failure to disconnect cables may result in damage to
wire harness or other electrical parts.

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-1
Engine
Engine Lubrication System
General Description
Engine Lubrication DescriptionS7RS0B1501001
The oil pump is of a trochoid type, and mounted on the
crankshaft. Oil is drawn up through the oil pump strainer
and passed through the pump to the oil filter.
The filtered oil flows into two paths in cylinder block.
The filtered oil is passed to the passage in heat
exchanger and cylinder block to piston cooling valve of
oil gushed to the lower side of piston. In one path, oil reaches the crankshaft journal bearings.
Oil from the crankshaft journal bearings is supplied to
the connecting rod bearings by means of intersecting
passages drilled in the cran
kshaft, and then injected
from the big end of connecting rod to lubricate piston,
rings and cylinder wall.
In the other path oil goes up to the cylinder head and
lubricates valves and camshafts, etc., after passing
through the internal oil way of camshafts.
An oil relief valve is provided on the oil pump. This valve
starts relieving oil pressure when the pressure exceeds
about 350 kPa (3.5 kg/cm
2, 49.8 psi).
I6RS0C150001-01

Downloaded from www.Manualslib.com manuals search engine 1E-2 Engine Lubrication System:
Diagnostic Information and Procedures
Oil Pressure CheckS7RS0B1504001
WARNING!
To avoid danger of being burned, do not
touch exhaust system when it is still hot.

NOTE
Prior to checking oil pressure, check the
following.
• Oil level in oil pan
If oil level is low, add oil up to Full level
mark (hole) (1) on oil level gauge referring
to “Engine Oil and Filter Change in Section
0B”.
• Oil quality If oil is discolored or deteriorated, change
it. For particular oil to be used, refer to
“Engine Oil and Filter Change in Section
0B”.
• Oil leaks If leak is found, repair it.

1) Remove front bumper referring to “Front Bumper and Rear Bumper Components in Section 9K”.
2) Remove engine front cover (1).
3) Disconnect oil pressure switch coupler (1).
4) Remove oil pressure swit ch (2) from cylinder block.
5) Install special tools (oil pressure gauge) to vacated threaded hole of oil pressure switch.
Special tool
(A): 09915–77310
(B): 09915–78211
2. Low level mark (hole)
I2RH0B150002-01
1
I4RS0A150001-01
I2RH0B150003-01
I2RH0B150004-01

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-3
6) Start engine and warm engine up to normal operating temperature.
NOTE
Be sure to shift transaxle gear shift lever in
“Neutral” (shift select lever in “P” range for
A/T vehicle), set parking brake and block
drive wheels.

7) After warming up, raise engine speed to 4,000 r/min. and measure oil pressure.
Oil pressure specification
More than 270 kPa (2.7 kg/cm2, 39.8 psi) at 4,000
r/min. (rpm)
8) After checking oil pressure, stop engine and remove oil pressure gauge and attachment.
9) Before reinstalling oil pressure switch (2), be sure to
wrap its screw threads with sealing tape (1) and
tighten switch to specified torque.
NOTE
If sealing tape edge is bulged out from screw
threads of switch, cut it off.

Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft) 10) Start engine and check oil pressure switch for oil
leakage. If oil leakage is found, repair it.
11) Connect oil pressure switch coupler (1).
Repair Instructions
Heat Exchanger ComponentsS7RS0B1506001
I2RH0B150005-01
I2RH0B150006-01
3
4
5
7
6
(a)
2
1
I6RS0B151001-02
1. Heat exchanger inlet No. 1 hose 4. Gasket7. O-ring
: Apply engine oil.
2. Heat exchanger outlet No. 1 hose 5. Heat exchanger stand bolt : 22 N⋅m (2.2 kgf-m, 16.0 lb-ft)
3. Heat exchanger 6. Oil filter adapter case : Do not reuse.

Downloaded from www.Manualslib.com manuals search engine 1E-4 Engine Lubrication System:
Heat Exchanger On-Vehicle InspectionS7RS0B1506002
• Check heat exchanger for deformation wear or damage.
• Check heat exchanger for coolant leakage and oil leakage.
If any malcondition is found, replace O-ring, stand bolt
gasket and/or heat exchanger.
Heat Exchanger Removal and InstallationS7RS0B1506003
Removal
1) Drain engine oil by removing drain plug.
2) Drain coolant referring to “Cooling System Draining in Section 1F”.
3) Remove exhaust manifold referring to “Exhaust Manifold Removal and Inst allation in Section 1K”.
4) Remove heat exchanger inlet No. 1 hose and outlet No. 1 hose.
5) Remove heat exchanger, O-ring and gasket by removing heat exchanger stand bolt. Installation
Reverse removal procedure for installation noting the
followings.
• Use new stand bolt gasket.
• Apply engine oil to new O-ring and install it to heat
exchanger.
• Install heat exchanger (1) while matching the projection of heat exchanger (2) in rib of the cylinder
block (3) as shown in figure.
• Install heat exchanger stand bolt (4) to specified torque.
Tightening torque
Heat exchanger stand bolt (a): 22 N·m (2.2 kgf-m,
16.0 lb-ft)
• Refill cooling system with co olant referring to “Cooling
System Flush and Refill in Section 1F”.
• Refill engine with engine oil referring to “Engine Oil and Filter Change in Section 0B”.
• Upon completion of installation, check for engine coolant and oil leaks.
2
3
4, (a)
1
I6RS0B151002-01