2008 SUZUKI SWIFT check engine

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-27
3) Fit high speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as
shown in figure.
NOTE
• No specific direction is assigned to each key but it is assigned as sleeve & hub
assembly.
• Size of high speed synchronizer sleeve, hub, keys and springs is between those of
low speed and 5th speed ones.

Synchronizer key in stallation position
A = B
4) Drive in right bearing (1) to input shaft (2) using special tool and hammer.
Special tool
(A): 09951–16080
5) Install 3rd gear needle bearing, apply oil to it, then install 3rd gear (1) and synchronizer ring (2).
6) Drive in high speed synchronizer sleeve & hub assembly (3) using special tool and hammer, facing
long flange side of hub to 3rd gear.
NOTE
• While press-fitting sleeve & hub, make sure that synchronizer ring key slots are
aligned with keys in sleeve & hub
assembly.
• Check free rotation of 3rd gear after press- fitting sleeve & hub assembly.
• Synchronizer rings for 3rd and 4th are identical.

Special tool
(B): 09913–84510
7) Install circlip (1) and confirm that circlip is installed in
groove securely. Install needle bearing (2) of resin
cage type, apply oil to it and then install synchronizer
ring (3) and 4th gear (4).
[A]: 3rd gear side D: Key way
C: Long flange E: Projecting end
I3RM0B521022-01
(A)
1
2
I4RH01520031-01
[A]: 3rd gear side B: Long flange
A: Key way C: Projecting end
5. Input shaft
I3RM0B521023-01
I2RH01520052-01

Downloaded from www.Manualslib.com manuals search engine 5B-30 Manual Transmission/Transaxle:
5) Install needle bearing, apply oil to it, then install 1st gear and 1st gear synchronizer ring.
6) Drive in low speed synchronizer sleeve & hub assembly (1) using special tools and hammer.
NOTE
• Support shaft with special tool as shown in figure so that retainer of bearing cone (4)
will be free from compression.
• Make sure that synchronizer ring (2) key slots are aligned with keys while press-
fitting sleeve & hub assembly.
• Check free rotation of 1st gear (3) after press-fitting sleeve & hub assembly.

Special tool
(A): 09923–78210
(B): 09940–51710
(C): 09924–07730
(D): 09924–07710
7) Install circlip (1) and confirm that circlip is installed in groove securely.
Install needle bearing (2), apply oil to bearing.
With synchronizer outer ring (3), center cone (4) and
inner ring (5) put together and installed to 2nd gear
(6) as shown in figure. 8) Press-fit 3rd gear (2) and spacer (1) using special
tools and hydraulic press.
CAUTION!
Press-fit spacer (1) and 3rd gear (2) first, and
then 4th gear later separately so that
countershaft will not be compressed
excessively.

Special tool
(A): 09923–78210
(D): 09913–84510
9) Press-fit 4th gear (2) using the same procedure as Step 8).
10) Install left bearing cone (1) using special tools and hammer.
NOTE
For protection of right bearing cone (3),
always support shaft with special tool as
shown in figure.

Special tool
(A): 09923–78210
(E): 09913–80113
[A]: Section A – A
I4RH01520057-01
I2RH01520064-01
3. 2nd gear
I2RH01520065-01
I2RH01520066-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-31
Synchronizer Parts InspectionS7RS0B5206021
Check clearance “a” between synchronizer ring (2) and
gear (1), each chamfered tooth of gear, synchronizer
ring and sleeve, then determine parts replacement.
Clearance “a” between synchronizer ring and gear
Standard: 1.0 – 1.3 mm (0.039 – 0.051 in.)
Service limit: 0.5 mm (0.019 in.)Put the 2nd gear synchronizer outer ring (1), inner ring
(3) and the cone (2) together and then measure the step
difference between the outer ring and the inner ring. And
also check each chamfered tooth of gear and
synchronizer ring and replace with new one, if
necessary. Also, check gear tooth.
Difference “b” between synchronizer outer ring and
inner ring
Standard: 1.0 – 1.3 mm (0.039 – 0.051 in.)
Service limit: 0.5 mm (0.019 in.)
Gear Shift Shaft ComponentsS7RS0B5206022
I2RH01520048-01
I2RH01520059-01
5
3
4 6
1
2
8
7
77
(a)
(b)
(a)
(a)
I4RS0A520015-01
1. Low speed gear shift shaft
5. Reverse gear shift arm : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
2. High speed gear shift shaft 6. 5th gear shift fork : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
3. 5th & reverse gear shift shaft 7. Gear shift locating bolt
: Apply sealant 99000-31260 to bolt thread.
4. 5th & reverse gear shift guide shaft 8. Shift fork bolt
: Apply thread lock 99000-32110 to bolt thread.

Downloaded from www.Manualslib.com manuals search engine 5B-32 Manual Transmission/Transaxle:
5th and Reverse Gear Shift Shafts Disassembly
and Assembly
S7RS0B5206023
Disassembly
Disassemble component parts using special tool and
hammer.
Special tool
(A): 09922–85811
Assembly
Replace or correct parts as required and assemble
shafts making sure that component parts are in proper
order as shown.
NOTE
• Distinguish reverse gear shift arm spring (Blue) (2) from low speed locating spring
(Yellow).
• Install 2 steel balls (3) in reverse gear shift arm (1) without fail.
• Drive in spring pin for reverse gear shift arm facing slit A toward 5th gear side.

Gear Shift Shaft and Fork InspectionS7RS0B5206024
Using feeler gauge, check clearance between fork (1)
and sleeve (2) and replace those parts if it exceeds limit.
NOTE
For correct judgement of parts replacement,
carefully inspect contact portion of fork and
sleeve.

Clearance “a” between fork and sleeve
Service limit “a”: 1.0 mm (0.039 in.)
Insert each gear shift shaft into case and check that it
moves smoothly. If it doesn’t, correct using oilstone,
reamer or the like.
A: Face pin slit toward 5th gear side
4. Spring pin
5. 5th & reverse gear shift shaft
6. 5th & reverse gear shift yoke
7. 5th & reverse gear shift guide shaft
8. 5th gear side
I3RM0A520053-01
I2RH01520068-01

Downloaded from www.Manualslib.com manuals search engine 5B-34 Manual Transmission/Transaxle:
Assembly
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
after disassembly, prepare replacing parts and proceed
to reassembly. Make sure that all parts are clean.
1) Assemble differential gear and measure thrust play
of differential gear as follows.
Special tool
(A): 09900–20607
(B): 09900–20701
Differential gear thrust play
0.03 – 0.31 mm (0.001 – 0.012 in.)
Left side
1. Hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to top
surface of gear (2).
2. Using 2 screwdrivers (1), move gear up and down and read movement of dial gauge pointer.
Right side
1. Using similar procedure to the left side, set dial gauge tip to gear (2) shoulder.
2. Move gear up and down by hand and read dial gauge.
2) If thrust play is out of sp ecification, select suitable
thrust washer from among the following available
size, install it and check again that specified gear
play is obtained.
Available thrust washer thickness
3) Drive in new differential pinion shaft pin (2) till the depth from differential case (3) surface is about 1
mm (0.04 in.).
4) Press-fit left bearing (2) using special tool and copper hammer.
Special tool
(A): 09913–76010
5) Support differential assembly (1) as illustrated so as to left bearing is floating , and then press-fit right
bearing (3) using special tools.
Special tool
(A): 09913–76010
(B): 09951–16060
0.85 mm (0.033 in.) 1.05 mm (0.041 in.)
0.90 mm (0.035 in.) 1.10 mm (0.043 in.)
0.95 mm (0.037 in.) 1.15 mm (0.045 in.)
1.00 mm (0.039 in.)
[A]: Left side
[B]: Right side
I3RH0A520083-01
1
(A)
3
2 (B)
I6RS0C520008-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-1
Transmission / Transaxle
Clutch
General Description
Clutch ConstructionS7RS0B5301001
The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type,
which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward.
The disc, carrying four torsional coil springs, is positione d on the transaxle input shaft with an involute spline fit.
The clutch cover is secured to the flywheel, and carries the diaphragm spring in such a way that the peripheral edge
part of the spring pushes on the pressure plate against the flywheel (with the disc in between), when the clutch release
bearing is held back. This is the engaged condition of the clutch.
Depressing the clutch pedal c auses the release bearing to advance and pushes on the tips of the tapered fingers of
the diaphragm spring. When this happens, the diaphragm sp ring pulls the pressure plate away from the flywheel,
thereby interrupting the flow of drive from flywheel through clutch disc to transaxle input shaft. Clutch fluid is supplied
from brake fluid reservoir. Clutch fluid level can be checked by brake fluid level of brake fluid reservoir.
[A]: For petrol engine model2. Flywheel5. Clutch cover 8. Input shaft bearing
[B]: For diesel engine model 3. Clutch disc6. Diaphragm spring 9. Input shaft
1. Crankshaft 4. Pressure plate7. Release bearing 10. Release shaft
I4RS0A530001-01

Downloaded from www.Manualslib.com manuals search engine 5C-2 Clutch:
Diagnostic Information and Procedures
Clutch System Symptom DiagnosisS7RS0B5304001
Repair Instructions
Clutch Pedal InspectionS7RS0B5306001
Cylinder Push Rod Play “A”1) Press clutch pedal (1) gradually with finger, stop when slight increase of resistance is felt and
measure how much pedal has moved (push rod
play) as represented by “A” as shown.
Push rod play
“A”: Max. 3 mm (0.12 in.)
2) If “A” is not within specification, replace master cylinder (3) or pedal arm (2). Clutch Pedal Free Travel “B”
1) Depress clutch pedal (1), stop the moment clutch resistance is felt, and measure how much pedal has
moved (clutch pedal free travel) as represented by
“B” in figure.
Clutch pedal free travel
“B”
: 2 – 8 mm (0.08 – 0.31 in.)
2) If “B” is not within specification, check pedal arm (2) and master cylinder (3) and replace defective part.
Condition Possible cause Correction / Reference Item
Slipping Improper clutch pedal free travel Replace master cylinder or clutch pedal arm.
Worn or oily clutch disc facing Replace disc.
Warped disc, pressure plate or flywheel
surface Replace disc, clutch cover or flywheel.
Weakened diaphragm spring Replace clutch cover.
Master cylinder piston or seal cup not
returning Replace master cylinder.
Dragging clutch Improper clutch pedal free travel Replace master cylinder or clutch pedal arm.
Weakened diaphragm spring, or worn
spring tip Replace clutch cover.
Rusted input shaft splines Lubricate.
Damaged or worn splines of transaxle
input shaft Replace input shaft.
Excessively wobbly clutch disc Replace disc.
Clutch facings broken or dirty with oil Replace disc.
Fluid leakage Repair or replace.
Clutch vibration Glazed (glass-like) clutch facings Repair or replace disc.
Clutch facings dirty with oil Replace disc.
Release bearing slides unsmoothly on
input shaft bearing retainer Lubricate or replace input shaft bearing
retainer.
Wobbly clutch disc, or poor facing
contact Replace disc.
Weakened torsion springs in clutch disc Replace disc.
Clutch disc rivets loose Replace disc.
Distorted pressure plate or flywheel
surface Replace clutch cover or flywheel.
Weakened engine mounting Replace engine mounting.
Loosened engine mounting bolt or nut Retighten engine mounting bolt or nut.
Noisy clutch Worn or broken release bearing Replace release bearing.
Input shaft front bearing worn down Replace input shaft bearing.
Excessive rattle of clutch disc hub Replace disc.
Cracked clutch disc Replace disc.
Pressure plate and diaphragm spring
rattling Replace clutch cover.
Grabbing clutch Clutch disc facings soaked with oil Replace disc.
Clutch disc facings excessively worn Replace disc.
Rivet heads showing out of facing Replace disc.
Weakened torsion springs Replace disc.

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-3
Clutch Release Margin “C”1) Pull up parking brake fully and block wheels.
2) Start engine and keep engine at idle with neutral gear position.
3) Without clutch pedal (1) dep ressed, slightly push the
shift lever to re verse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress clutch pedal (1), and at gear contact noise died
position (release point) stop depressing.
5) Measure distance between release point (4) and full stroke point (5) on clutch pedal (1) which is shown by
“C” in figure.
Clutch release margin
“C”: 25 – 55 mm (0.98 – 2.17 in.)
6) If “C” is not within specificat ion, it is possible that air
is trapped in this system. If suspected so, bleed air
referring to “Air Bleeding of Clutch System”. Upon
completion of above inspection, start engine and
check clutch for proper operation.
Clutch Fluid Level InspectionS7RS0B5306002
Refer to “Brake Fluid Level Inspection in Section 4A”.
Clutch fluid specification
: Refer to reservoir cap.
Air Bleeding of Clutch SystemS7RS0B5306003
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

Bleeding operation is necessary to remove air whenever
it entered hydraulic clutch system.
1) Fill master cylinder reservoir with brake fluid and keep at least one-half full of fluid during bleeding
operation.
Brake Fluid
Refer to reservoir cap
2) Remove bleeder plug cap from clutch operating cylinder (3). Attach a vinyl tube (1) to bleeder plug
(4), and insert the other end into container (2).
2
1
“A”
3
2
1
3
“B”
“C”
4
5
I4RS0B530001-01
I4RS0A530023-01
3 4 1
2
3
I4RS0A530003-01