📚 Vehicle Manual Information

2004-2008 Suzuki Swift Sport RS416 Workshop Manual

🏷️ Basic Information

Make:

Suzuki

Model:

Swift Sport

Model Code:

RS416

Year:

2004-2008

👋 Introduction

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:

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:

Lightweight chassis, sporty suspension tuning, distinctive body kit, performance-oriented interior, and a free-revving M-series engine.

📋 Manual Details

Coverage Areas:

Engine, Suspension, Driveline/Axle, Brakes, Transmission/Transaxle, Steering, HVAC, Restraint Systems, Body/Cab/Accessories, Control Systems

Page Count:

1496

Manual Type:

Workshop Manual / Repair Manual

Language:

English

Format:

PDF Download

Compatibility:

Mac/Windows

📖 Manual Coverage

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:

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:

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:

Portable Document Format (PDF)

Print Quality:

Optimized for digital viewing and printing, featuring clear diagrams, legible text, and high-resolution images for ease of use.

Binding Type:

Digital Download (N/A for print)

Paper Type:

Digital (N/A for print)

⚙️ Engine Specifications

Primary Engine:

M16A

Engine Type:

Inline 4-cylinder, DOHC, VVT

Displacement:

1.6 Liters (1586 cc)

Bore X Stroke:

78.0 mm x 83.0 mm

Compression Ratio:

10.5:1

Power Output:

125 PS (123 hp; 92 kW) at 6800 rpm (Europe/Australia specification)

Torque Output:

147 Nm (108 lb-ft) at 4800 rpm

Fuel System:

Multi-point Fuel Injection (MPI)

Ignition System:

Electronic ignition with coil-on-plug

Cooling System:

Pressurized liquid cooling system

Lubrication System:

Forced lubrication with wet sump

Engine Mounts:

Hydraulic engine mounts for vibration damping

Timing Drive:

Timing Chain

Engine Code Notes:

RS416 refers to the chassis/model code, typically housing the M16A engine in Sport trim.

Ec Certification:

Euro 4 compliant

🔧 Transmission

Standard Transmission:

5-speed Manual

Optional Transmission:

4-speed Automatic (may be available in certain markets/trims, though less common for Sport models)

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:

Suzuki Genuine Manual Transmission Gear Oil 75W-90 (API GL-4 or GL-5)

Clutch Type:

Hydraulic dry single-plate clutch

Differential Type:

Open Differential

📐 Dimensions

Exterior Length:

3770 mm (148.4 in)

Exterior Width:

1680 mm (66.1 in)

Exterior Height:

1545 mm (60.8 in)

Wheelbase:

2370 mm

Ground Clearance:

130 mm (5.1 in) (approx.)

Curb Weight:

1070 kg (2359 lbs) (Manual Transmission)

Cargo Volume:

213 Liters (7.5 cu ft) (rear seats up)

Track Width Front:

1470 mm

Track Width Rear:

1475 mm

Fuel Tank Capacity:

45 Liters (11.9 US Gallons)

Tire Size Standard:

195/50R16

Wheel Size Standard:

16 x 6.0J Alloy

Wheel Bolt Pattern:

4 x 100 mm

Wheel Offset:

+45 mm

🛡️ Safety Features

Ratings:

Euro NCAP: 4 Stars (for the general Swift model generation, Sport specific ratings may vary or not be individually published).

Active Features:

Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), Brake Assist (BA)

Passive Features:

Front airbags, side airbags, curtain airbags (market dependent), seatbelt pretensioners, whiplash protection seats.

💡 Technology Features

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:

Basic driver assistance systems including ABS, EBD, and Brake Assist. Cruise control available on some higher-spec models.

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:

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.

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:

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.

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:

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:

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:

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:

Front-Wheel Drive (FWD)

📄 Suspension

Front Suspension Type:

MacPherson strut with coil springs and stabilizer bar

Rear Suspension Type:

Torsion beam axle with trailing arms and coil springs

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:

Ventilated Discs

Rear Brake Type:

Solid Discs

Front Brake Rotor Diameter:

270 mm (approx.)

Rear Brake Rotor Diameter:

250 mm (approx.)

📄 Steering

Steering Type:

Electric Power Steering (EPS)

Steering Ratio:

13.8:1 (approx.)

Turns Lock To Lock:

2.7 turns

📄 Hvac

Climate Control:

Manual air conditioning and heating system standard. Automatic climate control may be available on top trims.

📄 Restraint

Airbag Systems:

Front dual-stage airbags, front side airbags, front and rear curtain airbags (optional/market dependent).

📄 Body

Body Style:

5-door Hatchback

Aerodynamics:

Sport-specific front bumper, rear spoiler, side skirts, and rear diffuser for enhanced aerodynamics and aggressive styling.

📄 Control Systems

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.

Diagnostic Interface:

OBD-II (On-Board Diagnostics II) compliant