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Swift SF413
Suzuki Swift SF413 Manuals
Manuals and User Guides for Suzuki Swift SF413. We have
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Suzuki Swift SF413 manuals available for free PDF download: Service Manual, User Manual
Suzuki Swift SF413 Service Manual (675 pages)
Brand:
Suzuki
| Category:
Automobile
| Size: 49.47 MB
Table of Contents
Table of Contents
2
Table of Contents: General Information
4
Vehicle Identification
4
Engine and Transmission Identification
5
Metric Fasteners
6
Fastener Strength Identification
6
Bolt Strength Markings
6
Standard Tightening Torque
7
Vehicle Lifting Points
8
Precaution against Tipping
8
Front/Rear Support Locations
8
Table of Contents: Maintenance and Lubrication
10
Maintenance Schedule: Normal Condition
11
Maintenance Recommended under Severe Driving Conditions
13
Water Pump Belt Inspection and Replacement
14
Engine Oil and Filter Change
14
Engine Maintenance Service
14
Engine Oil Capacity
15
Cooling System, Hoses and Connections Inspection
16
Engine Coolant Change
16
Exhaust Pipes and Mountings Inspection
17
Wiring Harness and Connections Inspection
17
Ignition System Maintenance
18
Spark Plugs Inspection and Replacement
18
Plug Specification
18
Distributor Cap and Rotor Inspection
18
Ignition Wiring Inspection and Replacement
19
Carburetor Choke System Inspection
19
Air Cleaner Element Replacement
19
Air Cleaner Element Inspection
19
Engine Idle Speed and Idle Mixture Inspection
20
Fuel Tank, Cap Gasket and Fuel Lines Inspection
20
Fuel Filter Replacement
20
Emission Control System Maintenance
21
Brake Maintenance
21
Brake Hoses and Pipes Inspection
22
Brake Fluid Inspection and Change
22
Brake Lever and Cable Inspection
22
Brake Pedal Inspection
22
Chassis and Body Maintenance
23
Clutch Pedal Free Travel Inspection
23
Tire and Wheel Disc Inspection
23
Drive Axle Boot, Suspension System Inspection
23
Steering System Inspection
24
Transmission Oil Inspection and Change
24
Automatic Transmission Inspection
25
Door Hinges, Gear Shift Control Lever and Shaft Lubrication
25
Final Inspection: Body Parts Operation
25
Owner Inspections and Services: before Operating Your Car - Outside
26
Owner Inspections and Services: before Operating Your Car - Inside
26
Owner Inspections and Services: before Operating Your Car - under Hood
27
Owner Inspections and Services: While Operating Your Car
28
Recommended Fluids and Lubricants
29
Table of Contents: Heater and Ventilation
30
Heater Overview
31
Heater Control Operation
32
Heater Diagnosis
33
On Car Service: Heater Blower Motor Overview
33
On Car Service: Heater Blower Motor Removal, Installation
34
On Car Service: Heater Blower Motor Resistor Removal, Inspection, Installation
34
On Car Service: Heater Blower Motor Switch Removal, Inspection, Installation
35
On Car Service: Heater Control Cables Removal, Installation
36
On Car Service: Heater Unit Overview
37
On Car Service: Heater Unit Removal, Installation
38
Table of Contents: Bumpers and Sheet Metal
39
Front Bumper Removal, Installation
40
Rear Bumper Removal, Installation
41
Hood Removal, Adjustment
42
Front Fender Removal, Installation
43
Removing Small Light
43
Replacement Fender
43
Steering, Suspension, Wheel and Tires: Table of Contents
44
Steering, Suspension, Wheel and Tires: General Diagnosis
45
Tire Diagnosis
49
Irregular And/Or Premature Wear
49
Wear Indicators
49
Radial Tire Waddle
49
Lead Diagnosis
50
Radial Tire Lead
51
Vibration Diagnosis
51
Front End Alignment: Table of Contents
52
Preliminary Checks Prior to Adjusting Front Alignment
53
Toe Adjustment
53
Camber and Caster Adjustment
53
Steering Angle
54
Manual Rack and Pinion: Table of Contents
55
General Description of Steering System
56
Exploded View of Manual Rack and Pinion
57
On-Car Service: Lubrication
57
Remove and Install Tie Rod End
58
Remove and Install Manual Rack and Pinion Assembly (Steering Gear Case)
59
Remove and Install Rack Boot/Tie Rod
61
Remove and Install Steering Rack Plunger
63
Remove and Install Steering Pinion
64
Remove and Install Steering Rack
65
Remove and Install Pinion Bearing
66
Remove and Install Rack Bushing
67
Rack and Pinion Inspection: Steering Rack Boots
68
Rack and Pinion Inspection: Steering Shaft Joint
68
Rack and Pinion Inspection: Tire Rod End/Boots
68
Rack and Pinion Inspection: Rack Plunger
68
Rack and Pinion Inspection: Steering Pinion/ Bearing
69
Rack and Pinion Inspection: Steering Rack/Bushing
69
Rack and Pinion Inspection: Steering Wheel
69
Recommended Torque Specifications
70
Required Service Materials
70
Manual Rack and Pinion: Special Tools
71
Steering Wheel and Column: Table of Contents
72
Steering Wheel and Column Overview
73
Remove and Install Sterring Wheel
74
Remove and Install Combination Switch
75
Remove and Install Steering Column
76
Steering Column Assembly
76
Remove and Install Steering Lock
78
Remove and Install Steering Shaft Lower Joint
79
Checking Steering Column for Accident Damage
80
Checking Tilt Steering Column
81
Recommended Torque Specifications: Tilt Steering Column
81
Front Suspension: Table of Contents
82
Front Suspension General Description and Overview
83
Remove and Install Stabilizer Bar And/Or Bushings
85
Remove and Install Strut Damper Assembly
86
Disassembly and Assembly Strut Damper
87
Remove and Install Wheel Hub, Wheel Stud/Wheel Bearing Outside Inner Race
89
Remove and Install Suspension Arm/Bushing
91
Remove and Install Knuckle/Bearing
93
Remove Oil Seals, Snap Ring and Wheel Bearing
95
Install Oil Seals, Snap Ring and Wheel Bearing
95
Front Suspension Inspection: Stabilizer Bar And/Or Bushing
96
Front Suspension Inspection: Strut Damper
96
Front Suspension Inspection: Suspension Arm/Arm Bracket/Knuckle Arm
97
Front Suspension Inspection: Suspension Arm Joint
97
Front Suspension Inspection: Suspension Arm Bushing
97
Front Suspension Inspection: Wheel Disc, Nut and Bearing
97
Front Suspension Inspection: Recommended Torque Specifications
98
Front Suspension Inspection: Required Service Materials
98
Rear Suspension: Table of Contents
100
Rear Suspension: General Description
101
Remove and Install Control Rod
102
Remove and Install Coil Spring and Suspension
104
Rear Strut Assembly Remove and Install
107
Rear Suspension Knuckle Remove and Install
109
Wheel Bearing Remove and Install
112
Rear Suspension Inspection
113
Strut Damper
113
Suspension Control Arm, Coil Spring and Knuckle Arm
113
Control Rod
113
Rear Suspension Fasteners
114
Wheel Disc, Nut and Bearing
114
Rear Wheel Alignment
115
Toe Setting
115
Toe Inspection and Adjustment
115
Wheels and Tires: Table of Contents
118
Wheels and Tires: General Description
118
Wheel Maintenance
119
Matched Tires and Wheels
120
Inflation of Tires
120
Tire Placard
120
Tire Rotation
121
Metric Lug Nuts and Wheel Studs
121
Wheel Removal
121
Tire Mounting and Demounting
122
Tire Repair
122
Balancing Wheels
122
Static Unbalance/Dynamic Unbalance Correction
122
General Balance Procedures
123
Wheels and Tires Recommended Torque Specifications
123
Front Drive Shaft: Table of Contents
124
Front Drive Shaft: General Description
124
Left Side Shaft Removal on Floor
125
Left Side Shaft Removal on Lift
125
Removing Drive Shaft Nut
125
Detaching Suspension Arm from Knuckle/Snap Ring from Differential
125
Right Side Shaft Removal on Floor
126
Right Side Shaft Removal on Lift
126
Drive Shaft Disassembly
127
Drive Shaft Inspection
128
Center Shaft and Center Bearing Support Disassembly
128
Drive Shaft Reassembly
128
Center Shaft and Center Bearing Support Reassembly
131
Center Shaft and Center Bearing Support Installation
132
Center Shaft and Center Recommended Torque Specifications
132
Front Drive Shaft (Tripod Joint Type): Table of Contents
134
Front Drive Shaft (Tripod Joint Type): General Description
134
Front Drive Shaft (Tripod Joint Type): Removal
135
Front Drive Shaft Disassembly
135
Front Drive Shaft Inspection
135
Brakes: Table of Contents
138
Brakes: General Description
139
Disc Brake Caliper Assembly
140
Front Caliper Assembly
140
Caliper Operation
141
Clearance Correction
141
Drum Brake Assembly: General Description
142
Rear Brake Operation
143
Rear Brake Clearance Correction
143
Master Cylinder Assembly: General Description
145
Master Cylinder Assembly: Operation
145
Booster Assembly General Description and Overview
147
Booster Operation
148
Vacuum Booster Assembly
148
When Foot Brake Pedal Is Not Depressed
148
When Foot Brake Pedal Is Depressed
149
When Foot Brake Pedal Is Released
149
Diagnosis
150
Road Testing Brakes
150
Substandard or Contaminated Brake Fluid
150
Break Fluid Leaks
150
Brake Diagnosis Chart
151
Break Pedal Free Height Adjustment
153
Excessive Pedal Travel Check
153
Stop Light Switch Adjustment
153
Rear Brake Shoe Inspection
154
Brake Pedal Play Inspection
154
Rear Drum Brake Shoe Adjustment
154
Master Cylinder Inspection
154
Disc Inspection
155
Pad Lining Inspection
155
Parking Brake Inspection and Adjustment
155
Flushing Brake Hydraulic System
156
Bleeding Brakes
156
Brake Hose and Pipe Inspection
158
Brake Fluid Level Inspection
158
Remove and Install Front Brake Hose/Pipe
159
Remove and Install Rear Brake Hose/Pipe
160
Precaution for Installation: Rear Brake Hose/Pipe
160
Remove and Install Parking Brake Lever
161
Remove and Install Parking Brake Cable
162
Remove and Install Pad (Shoe and Lining)
165
Remove and Install Caliper Assembly
166
Remove and Install Seal, Piston, Dust Boot and Bleeder Screw
167
Remove and Install Disc
169
Disc Brake Inspection
170
Inspect Brake Pad Lining
170
Inspect Brake Caliper Inner Parts
170
Inspect Brake Disc
171
Remove and Install Brake Drum
172
Remove and Install Brake Shoe
176
Remove and Install Wheel Cylinder
177
Remove and Install Brake Back Plate
178
Brake Drum and Components Inspection
180
Inspect Brake Drum
180
Inspect Brake Shoe and Lining
180
Inspect Wheel Cylinder
181
Inspect Springs
181
Inspect Brake Strut
181
Inspect Parking Shoe Lever
181
Master Cylinder Repair
182
Remove and Install Master Cylinder Reservoir
182
Remove and Install Master Cylinder Assembly
183
Disassembly and Assembly of Master Cylinder
184
Inspect Master Cylinder
185
Master Cylinder: Fill Reservoir
185
Remove and Install Booster
186
Disassemble and Assemble Booster
187
Brake Booster Inspection and Adjustment
193
Inspect Booster Inner Parts
193
Inspect/Adjust Clearance between Booster Piston Rod and Master Cylinder Piston
193
Inspect Booster Operation
194
Inspection Without Tester
194
Check Operation
195
Check Air Tightness under Load
195
Booster Inspection Table
196
Booster Recommended Torque Specifications
197
Booster: Requires Service Materials
198
Booster: Special Tools
199
Engine: Table of Contents
200
Engine: Statement on Cleanliness and Care
200
General Information on Engine Service
201
Engine: Hose Connection
202
Engine Diagnosis
203
Engine Mechanical: Table of Contents
210
Engine Construction: General Description
211
Engine Lubrication
212
Cylinder Head and Valve Train
213
Cylinder Block
213
Crankshaft and Main Bearings
213
Piston, Rings, Piston Pins and Connecting Rods
213
Compression Check
214
Engine Vacuum Check
214
Oil Pressure Check
215
Valve Lash Specifications
216
Valve Lash Checking and Adjusting Procedures
216
Air Cleaner Element
217
Air Cleaner Assembly
218
Cylinder Head Cover: Remove or Disconnect
219
Cylinder Head Cover: Install or Connect
219
Carburetor and Intake Manifold: Remove or Disconnect
220
Carburetor and Intake Manifold: Install or Connect
221
Exhaust Manifold Remove or Disconnect
222
Exhaust Manifold Install or Connect
222
Remove or Disconnect Timing Belt and Belt Tensioner
223
Removing Fender Apron Extension
223
Crankshaft Pulley and Pulley Bolts
223
Timing Belt and Belt Tensioner Inspection, Installation, Connection
224
Locking Crankshaft for M/T and A/T Models
224
Removing the Timing Belt
224
Loosening Timing Belt Pulley Bolt
224
Tensioner Installation
225
Valve Adjusting Screw and Lock Nut
225
Timing Marks
225
Installing Timing Belt
226
Tensioner Bolt and Stud
226
Tightening Pulley Bolt
227
Oil Pan and Oil Pump Strainer: Remove and Disconnect
227
Oil Pan and Oil Pump Strainer: Clean
227
Oil Pan and Oil Pump Strainer: Install or Connect
227
Applying Sealant to Oil Pan
228
Oil Pump: Remove or Disconnect
228
Oil Pump: Disassemble
229
Oil Pump: Measure
230
Oil Pump: Inspect
230
Oil Pump: Install or Connect
230
Oil Pump: Assemble
230
Oil Seal Guide Installation
231
Installing Rubber Seal
231
Cutting Edge of Gasket
231
Oil Pump Bolts
231
Installing Guide, Key and Pulley
232
Rocker Arms, Rocker Arm Shafts and Camshaft Overview
233
Rocker Arms, Rocker Arm Shafts and Camshaft Remove and Disconnect
233
Rocker Arm Shaft Screws Removal
233
Adjusting Screw and Lock Nut
233
Rocker Arm Shaft Removal
234
Camshaft Removal
234
Adjusting Screw and Rocker Arm
234
Locking Camshaft
234
Rocker Arm Shaft Runout
235
Measuring Runout
235
Measuring Cam Height
235
Measuring Shaft Dia. and Arm I.D.
235
Camshaft Runout
236
Camshaft Runout Measurement
236
Camshaft Journal Wear
236
Camshaft Journal Dia. Measurement
236
Journal Bore Dia. Measurement
237
Pulley Pin, Slot and Pulley Bolt
237
Camshaft Installation
237
Rocker Arm Shafts Installation
237
Rocker Arms, Springs, Rocker Arm Shafts and Screws Installation
238
Valves and Cylinder Head: Remove or Disconnect
239
Valve
239
Special Tool (Valve Lifter) Installation
240
Special Tool (Forceps) and Valve Cotters
240
Valve Stem Oil Seal Removal
240
Valve Guide Removal
240
Valve Stem End Deflection Measurement
241
Valve Head Thickness
241
Radial Runout Measurement
242
Valve Seating Contact Width
242
Valve Seat Cutting
243
Valve Seat Angles for Exhaust Valve
243
Measuring Surface of Intake Manifold Seating Face
244
Surface Measurement
244
Measuring Surface of Exhaust Manifold Seating Face
244
Valve Springs
244
Measuring Free Length of Spring
245
Measuring Spring Squareness
245
Measuring Spring Preload
245
Valve Guide Assembly
245
Reaming Valve Guide Bore
246
Valve Seal Installation
246
Valve Installation
246
Installing Valve Spring
247
Valve Cotters Installation
247
Cylinder Head Gasket Installation
247
Tightening Sequence of Cylinder Head Bolts
247
Pistons, Piston Rings, Connecting Rods and Cylinders: Remove or Disconnect
248
Pistons, Piston Rings, Connecting Rods and Cylinders: Clean
249
Pistons, Piston Rings, Connecting Rods and Cylinders: Disassembly
249
Pistons, Piston Rings, Connecting Rods and Cylinders: Inspect
249
Pistons to be Measured
249
Measuring Cylinder Bore with Cylinder Gauge
250
Measuring Piston Diameter with Micrometer
250
Measuring Ring Groove Clearance
250
Piston Pin, Piston Rings
251
Connecting Rod
251
Crank Pin and Connecting Rod Bearings
251
Measuring Piston Ring End Gap
251
Rod Bearing Clearance
252
Piston, Piston Rings, Connecting Rods and Cylinders: Assembly
253
Piston-To-Cylinder Orientation
253
Fitting Connecting Rod to Piston
253
Fitting Piston to Special Tool
254
Installing Piston Pin
254
Installing Piston Rings
254
Line Marked on Driver Handle
254
Piston Ring End Gaps Positions
255
Piston, Piston Rings, Connecting Rods and Cylinders: Install or Connect
255
Direction of Arrow Mark on Piston Head
255
Installing Bearing Cap
255
Unit Repair Overhaul
257
Engine Assembly Dismounting
257
Engine Assembly Remounting
258
Main Bearings, Crankshaft and Cylinder Block Overview
260
Main Bearings, Crankshaft and Cylinder Block Remove and Disconnect
261
Inspecting Crankshaft Runout
261
Out-Of-Round and Taper of Journals
262
Main Bearings General Information
262
Inspecting Main Bearing Clearance
262
Selection of Main Bearings
263
Stamped Alphabets on Cylinder Block
264
Paint on Standard Bearing
264
Paints on Undersize Bearing
265
Rear Oil Seal
266
Flywheel (M/T Model Only)
266
Distortion of Gasket Surface
266
Honing or Reboring Cylinders
266
Installing Thrust Bearings
267
Installing Main Bearing Caps
268
Engine Cooling: Table of Contents
273
Engine Cooling System Circulation
274
Radiator Cap
275
Water Reservoir Tank
275
Water Pump
276
Thermostat
276
Cooling Fan
277
Water Temp Gauge
277
Thermo Switch
277
Engine Cooling Diagnosis
278
Engine Cooling Maintenance
278
Coolant
278
Anti-Freeze Proportioning Chart
278
Coolant Capacity
279
Coolant Level
279
Cooling System Service
280
Cooling System Flush and Refill
280
Installation of Radiator Cap
280
Radiator Drain Plug
280
Water Pump Belt Tension
281
Coolant Draining
282
Cooling Water Pipes or Hoses Removal
282
Thermostat Removal
282
Cooling Water Pipes or Hoses Installation
282
Air Bleed Valve of Thermostat
283
Checking Thermostat Valve Operation
283
Thermostat Installation
283
Water Pump Belt Removal
284
Water Pump Belt Installation
284
Fan Thermo Switch Removal, Installation, Inspection
284
Checking Fan Thermo Switch
284
Radiator Removal, Clean
285
Radiator Installation, Inspection
285
Water Pump Inspection, Installation
286
Engine Fuel: Table of Contents
288
Fuel System Overview and General Description
288
Fuel Tank and Fuel Pump
289
Fuel Filter
289
Fuel Filler Cap
289
Fuel Filter Cap Cross-Section
289
Fuel Lines Inspection
290
Fuel Pipe Remove or Disconnect
291
Fuel Pipe Install or Connect
291
Installing, Removing Clamp
291
Detaching Clamp with Pipes
291
Fuel Filler Cap Removal and Replacement
292
Fuel Filter: Remove or Disconnect
292
Fuel Filter: Install or Connect
292
Fuel Tank Remove or Disconnect
293
Disconnecting Couplers
293
Breather and Filler Hoses
293
Disconnecting Hoses
293
Fuel Tank Purging Procedure
294
Fuel Tank Install or Connect
294
Fuel Level Gauge Remove or Install
294
Fuel Pump Remove or Install
295
Carburetor: Table of Contents
296
Carburetor: General Description
297
Carburetor Scheme
298
Float System
299
Primary Slow System
299
Primary Main System
299
Secondary Main System
300
Secondary Slow System
300
Acceleration Pump System
301
Choke System
301
At Cold Engine Start
302
Immediately after Engine Start
303
Fast Idle Cam Opener Operation
303
Release of Choke
303
Summary of Choke System Operation
304
Idle up System
305
Accelerator Cable Play
306
Float Level Inspection, Adjustment
306
Idle Speed and Idle Mixture
307
Idle up (for Manual Transmission) Inspection
309
Idle up (for Manual Transmission) Adjustment
309
Idle up (for Automatic Transmission) Inspection
310
Idle up (for Automatic Transmission) Adjustment
311
Choke System Inspection
311
Fast Idle
314
Secondary Diaphragm Inspection
315
Unloader System Inspection
315
Fuel Cut System Inspection
315
Accelerator Pump Inspection
316
Throttle Sensor (for Automatic Transmission) Inspection
317
Throttle Sensor (for Automatic Transmission) Removal
318
Throttle Sensor (for Automatic Transmission) Installation
318
Carburetor Removal and Installation
320
Carburetor Disassembly
321
Carburetor Cleaning
322
Carburetor Inspection
323
Carburetor Assembly
323
Float Chamber Cover
323
Bimetal Case
323
Ignition System: Table of Contents
328
Ignition System: General Description
328
Ignition Circuit Diagram
329
Ignition Diagnosis
329
Power Supply for Ignition Coil
330
High Tension Cords
330
Checking Power Supply to Distributor
330
Measuring High Tension Cord Resistance
330
Spark Plugs
331
Ignition Coil
331
Checking Spark Plug Gap
331
Measuring Ignition Coil Resistance
331
Distributor: Centrifugal Advancer
332
Distributor: Vacuum Advancer
332
Ignition Timing
332
Distributor Components
333
Distributor Removal
334
Distributor Disassembly
334
Distributor Inspection
335
Checking Centrifugal Advancer
335
Distributor Reassembly
336
Distributor Installation
336
Aligning Camshaft to TDC Compression
336
Aligning Distributor Coupling
337
Cranking System (0.8, 0.9, 1.0 Kw Type): Table of Contents
338
Cranking System (0.8, 0.9, 1.0 Kw Type): Circuit
338
Cranking System (0.8, 0.9, 1.0 Kw Type): Starting Motor
338
Basic Cranking Circuit
339
Cranking System Specifications
339
Convertional Type Starting Motor
340
Reduction Type Starting Motor
341
Starting System Diagnosis
342
Cranking System (0.8, 0.9, 1.0 Kw Type) Dismounting and Remounting
343
Conventional Type Starting Motor
344
Magnetic Switch Assembly
344
Removing Magnetic Switch
344
Installing Magnetic Switch
344
Motor Assembly: Disassembly, Reassembly
345
Installing Overrunning Clutch
346
Installing Brush Holder
346
Installing Armature
346
Installing Commutator End Cap
346
Reduction Type Starting Motor Overview
347
Reduction System Disassembly Procedure
347
Reduction System Reassembly
348
Assembling Internal Gear
348
Inspection and Correction of Armature
348
Checking Coil Ground
348
Checking Open Circuit
349
Checking Commutator Diameter
349
Checking Commutator Run-Out
349
Checking Mica Depth
349
Checking Yoke, Brush, Brush Holder
350
Checking Overrunning Clutch, Shaft and Bush
350
Cranking System (0.8, 0.9, 1.0 Kw Type) Performance Test
351
Cranking System (1.2 Kw Type): Table of Contents
352
Cranking System (1.2 Kw Type) General Description
352
Cranking System (1.2 Kw Type) Diagnosis
353
Starter Motor Overview
353
Magnetic Switch Assembly: Removal and Installation
354
Motor Brush Removal
354
Armature Removal
355
Over-Running Clutch Removal
355
Armature Inspection and Correction
358
Ground Inspection and Correction
359
Plunger Inspection and Correction
359
Open Circuit Inspection and Correction
359
Brush Inspection and Correction
359
Brush Holder and Spring Inspection and Correction
360
Pinion and Over-Running Clutch Inspection and Correction
360
Armature Shaft Bearing Inspection and Correction
360
Magnetic Switch Inspection and Correction
361
Gears Inspection and Correction
361
Pull-In Coil Open Circuit Test
361
Pull-In/Hold-In Tests
362
Check Plunger Return
362
Charging System: Table of Contents
363
Battery General Description
363
Electrolyte Freezing
364
Carrier and Hold-Down
364
Visual Inspection of Battery
364
Care of the Battery
364
Jump Starting in Case of Emergency
366
Remove and Replace Battery
367
Battery Cables
367
Generator General Description and Overview
368
Generator Schematic
369
Generator Specifications
369
Generator Diagnosis
370
Faulty Indicator Lamp Operation
370
Undercharged Battery
370
Overcharged Battery
371
Generator Exploded View
372
Dismounting and Remounting Generator
373
Generator Disassembly
373
Removing Rectifier
373
Removing Pulley Nut
373
Generator Reassembly
374
Inspection and Correction: Rotor, Fan, Bearing, Starter, Rotor
375
Inspection and Correction: Rectifier
376
Inspection and Correction: Brush
376
Inspection and Correction: Condenser
376
Emission Controls: Table of Contents
377
Emission Controls: General Description
377
Emission Controls for Vehicle with Manual Transmission: Scheme
378
Emission Controls for Vehicle with Automatic Transmission: Scheme
379
Positive Crankcase Ventilation PCV System
380
Throttle Positioner System
381
Intake Air Temperature Control System
382
Exhaust Gas Recirculation (EGR with EGR Modulator) System
383
Pulse Air Control System
384
Fuel Cut System
385
Evaporative Emission Control System
386
Hot Idle Compensator (HIC)
387
Catalyst
387
Emission Controls Diagnosis
388
PCV Hose Inspection
389
Checking PCV Valve for Sticking
389
Checking Throttle Positioner System
390
Intake Air Temperature Control System Checking Procedure
391
Checking Hot Idle Compensator (HIC)
392
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Suzuki Swift SF413 User Manual (558 pages)
Swift Suzuki
Brand:
Suzuki
| Category:
Automobile
| Size: 15.04 MB
Table of Contents
Related Manuals
3
Table of Contents
4
General Information
5
How to Use this Manual
6
Diagnosis
7
Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System
7
Handling and Servicing
8
General Precautions
10
Precautions for Catalytic Converter
13
Precautions for Electrical Circuit Service
13
Electrical Circuit Inspection Procedure
16
Open Circuit Check
16
Continuity Check
17
Voltage Check
17
Short Circuit Check (Wire Harness to Ground)
18
Voltage between
18
Intermittent and Poor Connection
19
Precaution for Installing Mobile Communication Equipment
20
Precaution in Servicing Full-Time 4Wd Vehicle
21
Switching from 4Wd to 2Wd
21
Identification Information
22
Vehicle Identification Number
22
Engine Identification Number
22
Transmission Identification Number
22
Identification Whether Vehicle Equipped with WU-TWC or Not
22
Warning, Caution and Information Labels
23
Vehicle Lifting Points
24
Abbreviations and Symbols May be Used in this Manual
26
Symbols
28
Wire Color Symbols
28
Fastener Strength Identification
29
Metric Fasteners
29
Fastener Information 0A-25
29
Standard Tightening Torque
30
Tightening Torque Chart
30
General Information
31
Maintenance and Lubrication
31
Maintenance Schedule
32
Normal Condition Schedule
32
Maintenance Recommended under Severe Driving Conditions
34
Severe Condition Code
34
Maintenance Service
35
Drive Belt Inspection and Replacement
35
A/C Compressor And/Or Power Steering Pump Drive Belt Inspection (if Equipped)
35
A/C Compressor And/Or Power Steering Pump Drive Belt Replacement
35
Water Pump Belt Replacement
36
Camshaft Timing Belt Replacement
36
Valve Lash Inspection (1.3 Liter Engine Only)
36
Engine Oil and Filter Change
37
Engine Oil Capacity
38
Engine Coolant Change
38
Exhaust System Inspection
39
Ignition System
40
Spark Plugs Replacement
40
Distributor Cap and Rotor Inspection (if Equipped)
40
Air Cleaner Filter Inspection
40
Fuel System
40
Air Cleaner Filter Replacement
41
Fuel Lines Inspection
41
Fuel Tank Inspection
41
Emission Control System
42
Brake
42
PCV (Positive Crankcase Ventilation) Valve Inspection
42
Fuel Evaporative Emission Control System Inspection
42
Brake Hoses and Pipes Inspection
43
Brake Fluid Change
43
Brake Lever and Cable Inspection
44
Parking Brake Lever
44
Parking Brake Cable
44
Clutch Pedal Free Travel Inspection
44
Wheel Bearing Inspection
45
Propeller Shaft Inspection (4WD Vehicle Only)
45
Drive Shaft Boot Inspction
45
Suspension System Inspection
45
Steering System Inspection
46
Power Steering (P/S) System Inspection (if Equipped)
46
Manual Transmission Oil Inspection and Change
47
Rear Differential Oil Inspection and Change
47
Automatic Transmission
48
All Latches, Hinges and Locks Inspection
49
Doors
49
Engine Hood
49
Final Inspection
50
Seats
50
Seat Belt
50
Battery Electrolyte Level Check
50
Recommended Fluids and Lubricants
51
Body, Wheels and Power Transmitting System
51
Meters and Gauge
51
Windshield Defroster
51
Engine General Information and Diagnosis (Tbi for G10)
52
Statement on Cleanliness and Care
54
General Information on Engine Service
54
Precaution on Fuel System Service
55
Hose Connection
55
Fuel Pressure Relief Procedure
56
Fuel Leakage Check Procedure
56
Engine Diagnosis
57
General Description
57
On-Board Diagnostic System
57
Warm-Up Cycle
58
Driving Cycle
58
2 Driving Cycles Detection Logic
58
Pending DTC
58
Freeze Frame Data Clearance
59
Data Link Connector (DLC)
59
Precaution in Diagnosing Trouble
60
Engine Diagnostic Flow Table
61
Customer Complaint Analysis
62
Visual Inspection
62
Trouble Symptom Confirmation
62
Engine Basic Inspection and Engine Diagnosis Table
62
Customer Problem Inspection Form (Example)
63
Vehicle/Environmental Condition When Problem Occurs
63
Malfunction Indicator Lamp (MIL) Check
64
Diagnostic Trouble Code (DTC) Check
64
Diagnostic Trouble Code (DTC) Clearance
65
Diagnostic Trouble Code (DTC) Table
66
Fail-Safe Table
69
Engine Basic Inspection
71
Engine Diagnosis Table
73
Scan Tool Data
80
Scan Tool Data Definitions
83
Calc Load (Calculated Load Value, %)
83
Short Ft B1 (Short Term Fuel Trim, %)
83
Long Ft B1 (Long Term Fuel Trim, %)
83
Closed Throttle Position (On/Off)
84
Fuel Cut (On/Off)
84
Electric Load (On/Off)
84
Fuel Tank Level (%)
84
Inspection of Ecm (Pcm) and Its Circuits
85
Resistance Check
89
Component Location
90
Malfunction Indicator Lamp Circuit Check – Lamp Does Not Come “On” at Ignition Switch on (but Engine at Stop)
91
Malfunction Indicator Lamp Circuit Check – Lamp Remains “On” after Engine Starts
92
Ecm (Pcm) Power and Ground Circuit Check – Mil Doesn’t Light at Ignition Switch on and Engine Doesn’t Start Though It Is Cranked up
93
Manifold Absolute Pressure (Map) Circuit Malfunction
95
Intake Air Temp. (IAT) Circuit Malfunction
97
Engine Coolant Temperature (ECT) Circuit Malfunction
99
Throttle Position Circuit Malfunction
101
Throttle Position Circuit Range/Performance Problem
103
Heated Oxygen Sensor (Ho2S) Circuit Malfunction (Sensor-1)
105
Heated Oxygen Sensor (Ho2S) Circuit Slow Response (Sensor-1)
106
Heated Oxygen Sensor (Ho2S) Circuit no Activity Detected (Sensor-1)
107
Heated Oxygen Sensor (Ho2S) Heater Circuit Malfunction (Sensor-1)
108
Heated Oxygen Sensor (Ho2S) Circuit Malfunction (Sensor-2)
110
Heated Oxygen Sensor (Ho2S) Heater Circuit Malfunction (Sensor-2)
113
DTC P0171 Fuel System too Lean
115
DTC P0172 Fuel System too Rich
115
DTC P0300 Random Misfire Detected (Misfire Detected at 2 or more Cylinders)
119
DTC P0301 Cylinder 1 Misfire Detected
119
DTC P0302 Cylinder 2 Misfire Detected
119
DTC P0303 Cylinder 3 Misfire Detected
119
DTC P0335 Crankshaft Position (Ckp) Sensor Circuit Malfunction
123
DTC P0340 Camshaft Position (Cmp) Sensor Circuit Malfunction
125
DTC P0420 Catalyst System Efficiency below Threshold
127
DTC P0443 Purge Control Valve Circuit Malfunction
130
DTC P0480 Radiator Fan Control System Malfunction
131
DTC P0500 Vehicle Speed Sensor (Vss) Malfunction (M/T)
133
DTC P0500 Vehicle Speed Sensor (Vss) Malfunction for A/T Vehicle (A/T)
135
DTC P0505 Idle Control System Malfunction
137
DTC P0510 Closed Throttle Position (Ctp) Switch Malfunction
139
DTC P0601 Internal Control Module Memory Check Sum Error
140
DTC P1250 Early Fuel Evaporation (Efe) Heater Circuit Malfunction
141
DTC P1450 Barometric Pressure Sensor Low/High Input
143
DTC P1451 Barometric Pressure Sensor Performance Problem
143
DTC P1500 Engine Starter Signal Circuit Malfunction
144
DTC P1510 ECM (PCM) Back-Up Power Supply Malfunction
145
Table B-1 Fuel Injector Circuit Check
147
Table B-2 Fuel Pump and Its Circuit Check
149
Table B-3 Fuel Pressure Check
151
Table B-4 A/C Signal Circuits Check (Vehicle with A/C)
153
Table B-5 Power Steering Pressure (PSP) Switch Signal Circuit Check (if Equipped)
154
Special Tool
155
Engine General Information and Diagnosis (TBI for G13)
156
Engine General Information and Diagnosis (SFI for G13)
157
MAP Sensor Individual Check
200
DTC P0110 Intake Air Temp. (IAT) Circuit Malfunction
202
DTC P0115 Engine Coolant Temperature (Ect) Circuit Malfunction
204
DTC P0120 Throttle Position Circuit Malfunction
206
DTC P0121 Throttle Position Circuit Range/Performance Problem
208
DTC P0130 Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-1)
210
DTC P0133 Heated Oxygen Sensor (Ho2S) Circuit Slow Response (Sensor-1)
212
DTC P0135 Heated Oxygen Sensor (Ho2S) Heater Circuit Malfunction (Sensor-1)
214
DTC P0136 Heated Oxygen Sensor (Ho2S) Circuit Malfunction (Sensor-2)
216
DTC P0141 Heated Oxygen Sensor (Ho2S) Heater Circuit Malfunction (Sensor-2)
219
DTC P0443 Evap Purge Control Valve Circuit Malfunction
240
DTC P0480 Radiator Cooling Fan Control System Malfunction
241
DTC P0500 Vehicle Speed Sensor (Vss) Malfunction for M/T Vehicle
243
DTC P0500 Vehicle Speed Sensor (Vss) Malfunction for A/T Vehicle
245
Special Tools
264
Engine Mechanical
265
Oil Pressure Check
266
Cylinder Head Cover
268
Exhaust Manifold
272
Unit Repair Overhaul
288
Engine Assembly
288
Special Tools
294
Engine Mechanical (G13B, 1-CAM 16-VALVES ENGINE)
296
General Description
298
Engine Lubrication
298
Cylinder Block
299
Crankshaft and Main Bearings
299
Pistons, Rings, Piston Pins and Connecting Rods
299
Cylinder Head and Valve Train
299
On Vehicle Service
300
On-Vehicle Service
300
Compression Check
300
Engine Vacuum Check
301
Oil Pressure Check
302
Valve Lash (Clearance)
304
Air Cleaner Element Removal
306
Air Cleaner Element Inspection
306
Air Cleaner Element Clean
306
Air Cleaner Element Installation
306
Air Cleaner Outlet Hose Removal
307
Air Cleaner Outlet Hose Installation
307
Cylinder Head Cover Removal
308
Cylinder Head Cover Installation
308
Throttle Body and Intake Manifold
309
Exhaust Manifold Removal
312
Exhaust Manifold Installation
313
Timing Belt and Belt Tensioner Removal
314
Timing Belt and Belt Tensioner Inspection
316
Timing Belt and Belt Tensioner Installation
316
Oil Pan and Oil Pump Strainer Removal
320
Oil Pan and Oil Pump Strainer Cleaning
321
Oil Pan and Oil Pump Strainer Installation
321
Oil Pump Removal
323
Oil Pump Disassembly
324
Oil Pump Measurement
325
Oil Pump Assembly
325
Oil Pump Installation
326
Rocker Arms, Rocker Arm Shaft and Camshaft Removal
328
Rocker Arms, Rocker Arm Shaft and Camshaft Inspection
330
Adjusting Screw and Rocker Arm
330
Rocker Arm Shaft Runout
330
Rocker Arm-To-Rocker Arm Shaft Clearance
331
Cam Wear
331
Camshaft Runout
331
Camshaft Journal Wear
331
Rocker Arms, Rocker Arm Shaft and Camshaft Installation
333
Valves and Cylinder Head Removal
336
Valves and Cylinder Head Disassembly
339
Valves and Cylinder Head Inspection
340
Valve Guides
340
Valve Springs
344
Valves and Cylinder Head Assembly
345
Valves and Cylinder Head Installation
347
Piston, Piston Rings, Connecting Rods and Cylinders
349
Piston Pin
352
Ring Groove Clearance
352
Piston Rings
353
Connecting Rod
353
Crank Pin and Connecting Rod Bearings
354
Flywheel
371
Distortion of Gasketed Surface
371
Honing or Reboring Cylinders
371
Engine Cooling
378
Cooling System Circulation
379
Thermostat
380
Cooling Fan
380
Coolant (Water) Temp. Gauge
381
Coolant Maintenance
382
Anti-Freeze Proportioning Table
382
Cooling System Flush and Refill
383
Cooling Water Pipes or Hoses Removal/Installation
384
Thermostat Removal
384
Thermostat Inspection
385
Thermostat Installation
385
Water Pump Inspection
386
Water Pump Installation
386
Engine Fuel
388
Fuel System
388
Fuel Pump Assembly (with Fuel Level Gauge)
388
Fuel Tank Removal
389
Fuel Lines
389
Fuel Tank Installation
390
Fuel Pump Assembly Removal
391
Fuel Pump Assembly Inspection
391
Fuel Pump Assembly Installation
391
Engine and Emission Control System (TBI for G10)
392
Air and Fuel Delivery System
395
Electronic Control System
396
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