2004-2008 Suzuki Swift Sport RS416 Workshop Manual
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🏷️ Basic Information Identification Make: Suzuki Model: Swift Sport Model Code: RS416 Year: 2004-2008 👋 Introduction Market Position Market Position: The Suzuki Swift Sport (RS416) represented a significant step in Suzuki's sport compact offerings, targeting enthusiasts who sought a potent, agile, and fun-to-drive hatchback. Positioned against competitors like the Mini Cooper, Ford Fiesta ST, and Volkswagen Polo GTI, the Swift Sport emphasized nimble handling and a responsive powertrain. Competitive Analysis Competitive Analysis: The RS416 Swift Sport distinguished itself with its naturally aspirated, high-revving engine and a focus on chassis dynamics, offering a more analogue driving experience compared to some turbocharged rivals. Its compact size and lightweight construction contributed to its lauded agility. Key Features Key Features: Lightweight chassis, sporty suspension tuning, distinctive body kit, performance-oriented interior, and a free-revving M-series engine. 📋 Manual Details Coverage Areas Coverage Areas: Engine, Suspension, Driveline/Axle, Brakes, Transmission/Transaxle, Steering, HVAC, Restraint Systems, Body/Cab/Accessories, Control Systems Page Count Page Count: 1496 Manual Type Manual Type: Workshop Manual / Repair Manual Language Language: English Format Format: PDF Download Compatibility Compatibility: Mac/Windows 📖 Manual Coverage Systems Covered Systems Covered: Comprehensive coverage including engine mechanicals, fuel, ignition, cooling, lubrication, exhaust, transmission (manual and automatic where applicable), clutch, drivetrain components (CV joints, driveshafts), differential, braking system (ABS, EBD), steering system (power steering), suspension (front and rear, including specific performance tuning for Sport models), HVAC system, SRS (airbag) systems, body panels, interior trim, doors, windows, lighting, wipers, and electronic control units (ECU) and related systems. Procedures Included Procedures Included: Detailed diagnostic procedures, troubleshooting guides, step-by-step repair instructions, component removal and installation, replacement procedures, adjustment specifications, torque values, wiring diagrams, and maintenance schedules. Technical Depth Technical Depth: Extensive technical depth suitable for professional technicians and experienced DIY enthusiasts. Includes in-depth explanations of system operations, component functions, diagnostic trouble codes (DTCs), and advanced repair techniques for complete vehicle overhaul and maintenance. 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Print Quality Print Quality: Optimized for digital viewing and printing, featuring clear diagrams, legible text, and high-resolution images for ease of use. Binding Type Binding Type: Digital Download (N/A for print) Paper Type Paper Type: Digital (N/A for print) ⚙️ Engine Specifications Primary Engine Primary Engine: M16A Engine Type Engine Type: Inline 4-cylinder, DOHC, VVT Displacement Displacement: 1.6 Liters (1586 cc) Bore X Stroke Bore X Stroke: 78.0 mm x 83.0 mm Compression Ratio Compression Ratio: 10.5:1 Power Output Power Output: 125 PS (123 hp; 92 kW) at 6800 rpm (Europe/Australia specification) Torque Output Torque Output: 147 Nm (108 lb-ft) at 4800 rpm Fuel System Fuel System: Multi-point Fuel Injection (MPI) Ignition System Ignition System: Electronic ignition with coil-on-plug Cooling System Cooling System: Pressurized liquid cooling system Lubrication System Lubrication System: Forced lubrication with wet sump Engine Mounts Engine Mounts: Hydraulic engine mounts for vibration damping Timing Drive Timing Drive: Timing Chain Engine Code Notes Engine Code Notes: RS416 refers to the chassis/model code, typically housing the M16A engine in Sport trim. Ec Certification Ec Certification: Euro 4 compliant 🔧 Transmission Standard Standard Transmission: 5-speed Manual Optional Optional Transmission: 4-speed Automatic (may be available in certain markets/trims, though less common for Sport models) Manual Gear Ratios Manual Gear Ratios: 1st: 3.600, 2nd: 1.947, 3rd: 1.323, 4th: 1.032, 5th: 0.844, Reverse: 3.333, Final Drive: 4.176 Transmission Fluid Type Transmission Fluid Type: Suzuki Genuine Manual Transmission Gear Oil 75W-90 (API GL-4 or GL-5) Clutch Type Clutch Type: Hydraulic dry single-plate clutch Differential Type Differential Type: Open Differential 📐 Dimensions Exterior Length Exterior Length: 3770 mm (148.4 in) Exterior Width Exterior Width: 1680 mm (66.1 in) Exterior Height Exterior Height: 1545 mm (60.8 in) Wheelbase Wheelbase: 2370 mm Ground Clearance Ground Clearance: 130 mm (5.1 in) (approx.) Curb Weight Curb Weight: 1070 kg (2359 lbs) (Manual Transmission) Cargo Volume Cargo Volume: 213 Liters (7.5 cu ft) (rear seats up) Track Width Front Track Width Front: 1470 mm Track Width Rear Track Width Rear: 1475 mm Fuel Tank Capacity Fuel Tank Capacity: 45 Liters (11.9 US Gallons) Tire Size Standard Tire Size Standard: 195/50R16 Wheel Size Standard Wheel Size Standard: 16 x 6.0J Alloy Wheel Bolt Pattern Wheel Bolt Pattern: 4 x 100 mm Wheel Offset Wheel Offset: +45 mm 🛡️ Safety Features Ratings Ratings: Euro NCAP: 4 Stars (for the general Swift model generation, Sport specific ratings may vary or not be individually published). Active Features Active Features: Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), Brake Assist (BA) Passive Features Passive Features: Front airbags, side airbags, curtain airbags (market dependent), seatbelt pretensioners, whiplash protection seats. 💡 Technology Features Infotainment Infotainment: Base models typically featured a simple CD player with radio and auxiliary input. Higher trims may have offered optional upgraded audio systems with CD changer capability. Limited integrated Bluetooth or navigation in early models. Driver Assistance Driver Assistance: Basic driver assistance systems including...
The Suzuki Swift Sport (RS416) represented a significant step in Suzuki's sport compact offerings, targeting enthusiasts who sought a potent, agile, and fun-to-drive hatchback. Positioned against competitors like the Mini Cooper, Ford Fiesta ST, and Volkswagen Polo GTI, the Swift Sport emphasized nimble handling and a responsive powertrain.
Competitive Analysis
Competitive Analysis:
The RS416 Swift Sport distinguished itself with its naturally aspirated, high-revving engine and a focus on chassis dynamics, offering a more analogue driving experience compared to some turbocharged rivals. Its compact size and lightweight construction contributed to its lauded agility.
Key Features
Key Features:
Lightweight chassis, sporty suspension tuning, distinctive body kit, performance-oriented interior, and a free-revving M-series engine.
📋 Manual Details
Coverage Areas
Coverage Areas:
Engine, Suspension, Driveline/Axle, Brakes, Transmission/Transaxle, Steering, HVAC, Restraint Systems, Body/Cab/Accessories, Control Systems
Page Count
Page Count:
1496
Manual Type
Manual Type:
Workshop Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
Compatibility
Compatibility:
Mac/Windows
📖 Manual Coverage
Systems Covered
Systems Covered:
Comprehensive coverage including engine mechanicals, fuel, ignition, cooling, lubrication, exhaust, transmission (manual and automatic where applicable), clutch, drivetrain components (CV joints, driveshafts), differential, braking system (ABS, EBD), steering system (power steering), suspension (front and rear, including specific performance tuning for Sport models), HVAC system, SRS (airbag) systems, body panels, interior trim, doors, windows, lighting, wipers, and electronic control units (ECU) and related systems.
Extensive technical depth suitable for professional technicians and experienced DIY enthusiasts. Includes in-depth explanations of system operations, component functions, diagnostic trouble codes (DTCs), and advanced repair techniques for complete vehicle overhaul and maintenance.
📊 Manual Specifications
File Format
File Format:
Portable Document Format (PDF)
Print Quality
Print Quality:
Optimized for digital viewing and printing, featuring clear diagrams, legible text, and high-resolution images for ease of use.
Euro NCAP: 4 Stars (for the general Swift model generation, Sport specific ratings may vary or not be individually published).
Active Features
Active Features:
Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), Brake Assist (BA)
Passive Features
Passive Features:
Front airbags, side airbags, curtain airbags (market dependent), seatbelt pretensioners, whiplash protection seats.
💡 Technology Features
Infotainment
Infotainment:
Base models typically featured a simple CD player with radio and auxiliary input. Higher trims may have offered optional upgraded audio systems with CD changer capability. Limited integrated Bluetooth or navigation in early models.
Driver Assistance
Driver Assistance:
Basic driver assistance systems including ABS, EBD, and Brake Assist. Cruise control available on some higher-spec models.
Connectivity
Connectivity:
Auxiliary input jack for audio devices was common. USB or Bluetooth connectivity was not standard and less common in this generation.
🔧 Maintenance
Service Intervals
Service Intervals:
Typical oil change: 10,000 - 15,000 km (6,000 - 9,000 miles) or 12 months. Air filter: 30,000 - 40,000 km. Spark plugs: 100,000 km. Coolant: Every 2 years or 40,000 km. Brake fluid: Every 2 years. Transmission fluid: 60,000 - 80,000 km. Timing chain inspection: As needed per manual, but generally designed for the life of the engine.
Fluid Specifications
Engine Oil Specification:
Suzuki recommends 0W-20 or 5W-30 synthetic engine oil meeting API SN or ILSAC GF-5 standards. Consult manual for specific viscosity depending on climate.
Coolant Specification:
Suzuki Super Long Life Coolant (50/50 mix with distilled water) or equivalent G12/G12+ rated ethylene glycol-based coolant.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid.
Known Issues
Known Issues:
Common reported issues include clutch wear (especially in spirited driving), minor interior rattles, and occasional electrical gremlins. The M16A engine is generally reliable but requires regular maintenance. Some owners report premature wear on suspension components due to sporty driving.
Filter Part Numbers
Oil Filter Part Number:
Suzuki OEM: 16510-61A00 (example, verify for specific VIN)
Air Filter Part Number:
Suzuki OEM: 13780-63J00 (example, verify for specific VIN)
📚 Vehicle History
Brand Heritage
Brand Heritage:
Suzuki, a Japanese multinational corporation, has a long history in automotive manufacturing, known for its small, fuel-efficient cars and reliable motorcycles. The Swift nameplate has been a global success, evolving over several generations to cater to diverse market needs.
Model Evolution
Model Evolution:
The third generation (ZC21S/ZC31S) Swift, launched globally from 2004, introduced the 'Sport' variant as a performance-focused model. This generation marked a significant improvement in styling, handling, and interior quality compared to its predecessors, with the RS416 designation specifically referring to the 1.6L M16A engine equipped Swift Sport.
Production
Production:
Produced in Japan, Hungary (Magyar Suzuki), and India (Maruti Suzuki) for various global markets. The RS416 Swift Sport was primarily targeted at performance enthusiasts in Europe, Australia, and Japan.
📄 Driveline
Drive Type
Drive Type:
Front-Wheel Drive (FWD)
📄 Suspension
Front Suspension Type
Front Suspension Type:
MacPherson strut with coil springs and stabilizer bar
Rear Suspension Type
Rear Suspension Type:
Torsion beam axle with trailing arms and coil springs
Sport Tuning
Sport Tuning:
Sport suspension package with stiffer springs, re-tuned dampers, and thicker front anti-roll bar for enhanced handling characteristics.
📄 Brakes
Front Brake Type
Front Brake Type:
Ventilated Discs
Rear Brake Type
Rear Brake Type:
Solid Discs
Front Brake Rotor Diameter
Front Brake Rotor Diameter:
270 mm (approx.)
Rear Brake Rotor Diameter
Rear Brake Rotor Diameter:
250 mm (approx.)
📄 Steering
Steering Type
Steering Type:
Electric Power Steering (EPS)
Steering Ratio
Steering Ratio:
13.8:1 (approx.)
Turns Lock To Lock
Turns Lock To Lock:
2.7 turns
📄 Hvac
Climate Control
Climate Control:
Manual air conditioning and heating system standard. Automatic climate control may be available on top trims.
📄 Restraint
Airbag Systems
Airbag Systems:
Front dual-stage airbags, front side airbags, front and rear curtain airbags (optional/market dependent).
📄 Body
Body Style
Body Style:
5-door Hatchback
Aerodynamics
Aerodynamics:
Sport-specific front bumper, rear spoiler, side skirts, and rear diffuser for enhanced aerodynamics and aggressive styling.
📄 Control Systems
Ecu Type
ECU Type:
Engine Control Unit (ECU) managing fuel injection, ignition timing, and other engine parameters. Body Control Module (BCM) for lighting, power windows, and other body electronics. ABS Control Module.