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2004-2008 Suzuki Swift Sport RS416 Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: Swift Sport Chassis Code: RS416 Vin Prefix Engine Code: JSAEZC31S Generation Generation Codes: ZC21S, ZC31S (Third Generation) Year Range Covered Years: 2004, 2005, 2006, 2007, 2008 👋 Introduction Market Position Vehicle Segment: Subcompact performance hatchback. Competitive Analysis Key Competitors: Mini Cooper S, Volkswagen Golf GTI, Ford Fiesta ST, Honda Civic Si (in certain markets). Key Features Performance Focus: Sport-tuned suspension, enhanced engine output, and sporty exterior styling. Target Audience Enthusiast Appeal: Drivers seeking an affordable and engaging performance-oriented small car. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive service and repair for all systems. Manual Type Manual Format: Service Repair Manual (Volumes 1 & 2) Language Language: English Format Availability Digital Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Diagnosis, maintenance, adjustments, minor service, component replacement, unit repair (overhaul). Suspension: Inspection, repair, adjustment procedures. Driveline Axle: Component replacement and repair of drive axles and related components. Brakes: System diagnosis, maintenance, caliper, rotor, and hydraulic component service. Transmission Transaxle: Service and overhaul procedures for manual and automatic transmissions. Steering: System maintenance, component replacement, and alignment. HVAC: Air conditioning and heating system diagnosis and repair. Restraint: Airbag system diagnosis and service procedures. Body Cab Accessories: Body panel repair, trim, interior components, and accessories. Control Systems: Electronic control unit (ECU) diagnosis and related system management. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, tune-ups. Diagnosis: Systematic troubleshooting and fault identification. Repair: Component replacement, minor adjustments, and complex repairs. Overhaul: Disassembly and reassembly of major mechanical components. Torque Specifications: Detailed torque values for critical fasteners across all systems. Diagnostic Trouble Codes: Information on common DTCs and troubleshooting steps for engine and other electronic systems. Technical Depth Depth Of Information: Detailed diagnostic procedures, repair instructions, and unit overhaul specifications. Electrical Systems: Covers wiring diagrams, component testing, diagnosis of lighting, ignition, charging, and ECU systems. Chassis And Body: Detailed procedures for body panel repair, frame straightening basics, interior trim removal, and glass replacement. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: All pages printable at high quality. Binding Type Binding: Digital (No physical binding) Paper Type Paper Quality: N/A (Digital) Software Requirements Reader Requirement: Adobe PDF Reader Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Code: M16A Engine Type: Inline 4-cylinder, DOHC, VVT Displacement: 1.6 Liters (1586 cc) Performance Horsepower: Approximately 125 PS (123 hp / 92 kW) at 6800 rpm (JDM specification, may vary by market). Torque: Approximately 153 Nm (113 lb-ft) at 4800 rpm (JDM specification, may vary by market). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Engine Management Ignition System: Electronic ignition 🔧 Transmission Standard Transmission Standard Type: 5-Speed Manual Transmission Optional Transmission Optional Type: 4-Speed Automatic Transmission Features Manual Gear Ratios: Specific ratios detailed within the manual. Fluid Specifications Manual Transmission Fluid: API GL-4, viscosity SAE 75W-90 (refer to manual for exact Suzuki specification). Automatic Transmission Fluid: Suzuki ATF 5D06 or equivalent (refer to manual for exact specification). 📐 Dimensions Exterior Length: Approximately 3765 mm (148.2 in) - varies slightly by market. Width: Approximately 1680 mm (66.1 in). Height: Approximately 1540 mm (60.6 in). Wheelbase Wheelbase: Approximately 2430 mm (95.7 in). Weights Curb Weight: Approximately 1090 kg (2403 lbs) for manual transmission. 🛡️ Safety Features Ratings Crash Test Ratings: Varies by market and testing agency (e.g., Euro NCAP, JNCAP). Refer to specific market data and manual for system details. Passive Features Airbags: Front airbags standard; side and curtain airbags may be optional or market-dependent. Seatbelts: Pretensioner and force limiter equipped seatbelts. Active Features ABS: Anti-lock Braking System (ABS) typically standard on Sport models. Ebs Ebv: Electronic Brake-force Distribution (EBD) often coupled with ABS. Esp Vsc: Electronic Stability Program (ESP) or Vehicle Stability Control (VSC) may be available on higher trims or as an option. 💡 Technology Features Infotainment Audio System: Factory fitted audio system with CD player and radio; MP3 playback and auxiliary input may be standard or optional. Driver Assistance Cruise Control: Available on certain trim levels or as an option. Connectivity Power Windows Locks: Standard feature on the Sport trim. Lighting Headlights: Halogen headlights, potentially with projector beams on higher trims. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 10,000 km (6,000 miles) or 6 months, whichever comes first (refer to manual for exact Suzuki recommendation). Air Filter Replacement: Recommended every 20,000 km (12,000 miles) or as needed based on driving conditions. Spark Plug Replacement: Refer to manual, typically around 80,000 - 100,000 km (50,000 - 60,000 miles) for iridium plugs. Fluid Specifications Engine Oil Type: Suzuki recommends 0W-20 or 5W-30 synthetic engine oil (API SN or ILSAC GF-5 compliant). Always verify with the manual. Engine Oil Capacity: Approximately 3.4 Liters (3.6 US Quarts) with filter change. Coolant Type: Suzuki Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based...
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2004-2008 Suzuki Swift Sport RS416 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
Swift Sport
Chassis Code:
RS416
Vin Prefix Engine Code:
JSAEZC31S
Generation
Generation Codes:
ZC21S, ZC31S (Third Generation)
Year Range
Covered Years:
2004, 2005, 2006, 2007, 2008
👋 Introduction
Market Position
Vehicle Segment:
Subcompact performance hatchback.
Competitive Analysis
Key Competitors:
Mini Cooper S, Volkswagen Golf GTI, Ford Fiesta ST, Honda Civic Si (in certain markets).
Key Features
Performance Focus:
Sport-tuned suspension, enhanced engine output, and sporty exterior styling.
Target Audience
Enthusiast Appeal:
Drivers seeking an affordable and engaging performance-oriented small car.
📋 Manual Details
Coverage Areas
Manual Coverage Scope:
Comprehensive service and repair for all systems.
Manual Type
Manual Format:
Service Repair Manual (Volumes 1 & 2)
Language
Language:
English
Format Availability
Digital Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Diagnosis, maintenance, adjustments, minor service, component replacement, unit repair (overhaul).
Suspension:
Inspection, repair, adjustment procedures.
Driveline Axle:
Component replacement and repair of drive axles and related components.
Brakes:
System diagnosis, maintenance, caliper, rotor, and hydraulic component service.
Transmission Transaxle:
Service and overhaul procedures for manual and automatic transmissions.
Steering:
System maintenance, component replacement, and alignment.
HVAC:
Air conditioning and heating system diagnosis and repair.
Restraint:
Airbag system diagnosis and service procedures.
Body Cab Accessories:
Body panel repair, trim, interior components, and accessories.
Control Systems:
Electronic control unit (ECU) diagnosis and related system management.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, tune-ups.
Diagnosis:
Systematic troubleshooting and fault identification.
Repair:
Component replacement, minor adjustments, and complex repairs.
Overhaul:
Disassembly and reassembly of major mechanical components.
Torque Specifications:
Detailed torque values for critical fasteners across all systems.
Diagnostic Trouble Codes:
Information on common DTCs and troubleshooting steps for engine and other electronic systems.
Technical Depth
Depth Of Information:
Detailed diagnostic procedures, repair instructions, and unit overhaul specifications.
Electrical Systems:
Covers wiring diagrams, component testing, diagnosis of lighting, ignition, charging, and ECU systems.
Chassis And Body:
Detailed procedures for body panel repair, frame straightening basics, interior trim removal, and glass replacement.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
All pages printable at high quality.
Binding Type
Binding:
Digital (No physical binding)
Paper Type
Paper Quality:
N/A (Digital)
Software Requirements
Reader Requirement:
Adobe PDF Reader
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Code:
M16A
Engine Type:
Inline 4-cylinder, DOHC, VVT
Displacement:
1.6 Liters (1586 cc)
Performance
Horsepower:
Approximately 125 PS (123 hp / 92 kW) at 6800 rpm (JDM specification, may vary by market).
Torque:
Approximately 153 Nm (113 lb-ft) at 4800 rpm (JDM specification, may vary by market).
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Engine Management
Ignition System:
Electronic ignition
🔧 Transmission
Standard Transmission
Standard Type:
5-Speed Manual Transmission
Optional Transmission
Optional Type:
4-Speed Automatic Transmission
Features
Manual Gear Ratios:
Specific ratios detailed within the manual.
Fluid Specifications
Manual Transmission Fluid:
API GL-4, viscosity SAE 75W-90 (refer to manual for exact Suzuki specification).
Automatic Transmission Fluid:
Suzuki ATF 5D06 or equivalent (refer to manual for exact specification).
📐 Dimensions
Exterior
Length:
Approximately 3765 mm (148.2 in) - varies slightly by market.
Width:
Approximately 1680 mm (66.1 in).
Height:
Approximately 1540 mm (60.6 in).
Wheelbase
Wheelbase:
Approximately 2430 mm (95.7 in).
Weights
Curb Weight:
Approximately 1090 kg (2403 lbs) for manual transmission.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies by market and testing agency (e.g., Euro NCAP, JNCAP). Refer to specific market data and manual for system details.
Passive Features
Airbags:
Front airbags standard; side and curtain airbags may be optional or market-dependent.
Seatbelts:
Pretensioner and force limiter equipped seatbelts.
Active Features
ABS:
Anti-lock Braking System (ABS) typically standard on Sport models.
Ebs Ebv:
Electronic Brake-force Distribution (EBD) often coupled with ABS.
Esp Vsc:
Electronic Stability Program (ESP) or Vehicle Stability Control (VSC) may be available on higher trims or as an option.
💡 Technology Features
Infotainment
Audio System:
Factory fitted audio system with CD player and radio; MP3 playback and auxiliary input may be standard or optional.
Driver Assistance
Cruise Control:
Available on certain trim levels or as an option.
Connectivity
Power Windows Locks:
Standard feature on the Sport trim.
Lighting
Headlights:
Halogen headlights, potentially with projector beams on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000 km (6,000 miles) or 6 months, whichever comes first (refer to manual for exact Suzuki recommendation).
Air Filter Replacement:
Recommended every 20,000 km (12,000 miles) or as needed based on driving conditions.
Spark Plug Replacement:
Refer to manual, typically around 80,000 - 100,000 km (50,000 - 60,000 miles) for iridium plugs.
Fluid Specifications
Engine Oil Type:
Suzuki recommends 0W-20 or 5W-30 synthetic engine oil (API SN or ILSAC GF-5 compliant). Always verify with the manual.
Engine Oil Capacity:
Approximately 3.4 Liters (3.6 US Quarts) with filter change.
Coolant Type:
Suzuki Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant with anti-corrosive additives (pink or red).
Known Issues
Common Wear Items:
Clutch wear (especially in spirited driving), suspension bushings, wheel bearings, and potential catalytic converter issues on high-mileage examples.
Engine Performance Notes:
M16A engine is generally reliable but can benefit from regular maintenance to preserve performance. Carbon buildup on intake valves can occur in some cases.
📚 Vehicle History
Brand Heritage
Suzuki Motorsport Legacy:
Suzuki has a strong heritage in motorsport, particularly in rallying and motorcycle racing, which influenced the Swift Sport's development.
Model Evolution
Third Generation Launch:
The third generation (ZC21S/ZC31S) was launched in 2004, with the performance-oriented Sport variant debuting shortly after, focusing on a balance of agility and power.
Production
Manufacturing Locations:
Primarily manufactured in Japan (Kosai Plant) and subsequently in other Suzuki global facilities depending on market.
🏆 Awards & Recognition
Recognitions
Performance Car Awards:
The Swift Sport consistently received praise in automotive media for its handling, agility, and value for money in the hot hatch segment.
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