2004-2008 Suzuki Swift Sport RS416 Service Repair Workshop Manual (2004 2005 2006 2007 2008)
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🏷️ Basic Information Identification Make: Suzuki Model: Swift Sport Internal Model Code: RS416 Generation: Second Generation (ZC21S/ZC31S/ZC71S) Model Years Covered: 2004, 2005, 2006, 2007, 2008 👋 Introduction Market Position Segment: Sporty Subcompact Hatchback Target Audience: Enthusiasts seeking a spirited driving experience in a compact and affordable package. Competitive Analysis Competitors: Honda Civic Si, Volkswagen Golf GTI, Ford Fiesta ST (in some markets), Mini Cooper S. Key Features Performance Orientation: Tuned engine, sport-tuned suspension, revised body styling, and sport seats differentiate it from standard Swift models. Handling: Known for agile handling and a fun-to-drive character, making it a popular choice for spirited driving. 📋 Manual Details Coverage Manual Type: Service Repair Workshop Manual Language: English Format File Format: PDF Compatibility: All Versions of Windows & Mac Requirements: Adobe PDF Reader Printability: All pages are printable 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, disassembly, assembly, inspection, repair, and overhaul procedures for the M16A engine. Suspension: Front and rear suspension systems, including struts, springs, control arms, bushings, and alignment specifications. Driveline Axle: Front-wheel drive system, including CV joints, drive shafts, differential, and gearbox lubrication. Brakes: Front and rear brake systems (disc/disc or disc/drum depending on market/spec), including hydraulic components, ABS, and parking brake. Transmission Transaxle: Manual transmission (e.g., M16A engine with 5-speed manual) and automatic transmission (if applicable), including clutch, gearbox components, and fluid specifications. Steering: Power steering system, steering column, rack and pinion, and wheel alignment. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, including refrigerant charging, component replacement, and troubleshooting. Restraint: Airbag system, seat belts, and related SRS components. Body Cab Accessories: Exterior body panels, doors, hood, trunk, interior trim, seats, glass, mirrors, and accessories. Control Systems: Electrical system overview, wiring diagrams, fuses, relays, ECUs, and various electronic control modules. Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspections, and brake pad replacement. Troubleshooting: Diagnostic procedures for common problems, fault code interpretation, and symptom-based troubleshooting guides. Repair: Step-by-step repair instructions for virtually all mechanical and electrical components of the vehicle. Diagnostics: Detailed diagnostic procedures for engine performance, emissions, ABS, SRS, and other electronic systems. Installation: Instructions for replacing major components and accessories. Technical Depth Depth: Comprehensive coverage from basic maintenance and fluid checks to complete engine and transmission rebuilds, including detailed specifications and torque values. 📊 Manual Specifications File Details File Quality: High-quality scanned pages with clear text and diagrams. Searchability: Likely text-searchable due to PDF format, allowing quick access to specific information. Physical Attributes Binding Type: Digital (PDF) Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Code: M16A Engine Type: Naturally Aspirated Inline 4-Cylinder Displacement: 1.6 Liters (1586 cc) Bore X Stroke: 78.0 mm x 83.0 mm Compression Ratio: 11.0:1 (approx.) Performance Horsepower: 125 PS (approx. 123 bhp) @ 6700 rpm (EU/JDM spec) Torque: 148 Nm (approx. 109 lb-ft) @ 4800 rpm (EU/JDM spec) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (95 RON recommended) Engine Management Ignition System: Electronic Ignition (Distributorless Coil-on-Plug) Emission Control: Catalytic Converter, Oxygen Sensors, EGR (depending on market) 🔧 Transmission Standard Type: 5-Speed Manual Transmission Gear Ratios: Specific ratios detailed in the manual (e.g., 1st: 3.454, 2nd: 1.894, 3rd: 1.310, 4th: 1.032, 5th: 0.815, Reverse: 3.250, Final Drive: 4.389) Optional Type: 4-Speed Automatic Transmission (available on some variants) Features Clutch: Hydraulically actuated, single dry plate clutch. Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 (or as specified in the manual) Automatic Transmission Fluid: Suzuki ATF 3317 or equivalent DEXRON-III/MERCON 📐 Dimensions Exterior Length: Approx. 3715 mm (146.3 in) Width: Approx. 1680 mm (66.1 in) Height: Approx. 1535 mm (60.4 in) Wheelbase: Approx. 2370 mm (93.3 in) Weights Curb Weight: Approx. 1060 kg (2337 lbs) for manual transmission Cargo Rear Seat Folded: Moderate cargo space, expandable with folding rear seats. 🛡️ Safety Features Ratings Euro Ncap: 4-star rating for adult occupant protection (for some variants of this generation). Active Features ABS: Anti-lock Braking System (ABS) standard on Sport models. E Brake Force Distribution: Electronic Brake-force Distribution (EBD) often included with ABS. Passive Features Airbags: Front airbags for driver and passenger, side airbags and curtain airbags available on higher trims or as options. Seat Belts: 3-point seat belts with pre-tensioners and force limiters. Child Seat Anchors: ISOFIX/LATCH child seat mounting points. 💡 Technology Features Infotainment Audio System: Factory fitted radio with CD player, AM/FM. Some markets may have upgraded audio systems or MP3 compatibility. Navigation: Optional satellite navigation systems may have been available on higher trim levels or as dealer fitment. Driver Assistance Cruise Control: Available on some higher specification models. Connectivity Auxiliary Input: Auxiliary audio input jack may be present for connecting external devices. 🔧 Maintenance Service Intervals Oil Change: Every 7,500 miles (12,000 km) or 6 months, whichever comes first. Air Filter Replacement: Every 15,000 miles (24,000...
Enthusiasts seeking a spirited driving experience in a compact and affordable package.
Competitive Analysis
Competitors:
Honda Civic Si, Volkswagen Golf GTI, Ford Fiesta ST (in some markets), Mini Cooper S.
Key Features
Performance Orientation:
Tuned engine, sport-tuned suspension, revised body styling, and sport seats differentiate it from standard Swift models.
Handling:
Known for agile handling and a fun-to-drive character, making it a popular choice for spirited driving.
📋 Manual Details
Coverage
Manual Type:
Service Repair Workshop Manual
Language:
English
Format
File Format:
PDF
Compatibility:
All Versions of Windows & Mac
Requirements:
Adobe PDF Reader
Printability:
All pages are printable
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, disassembly, assembly, inspection, repair, and overhaul procedures for the M16A engine.
Suspension:
Front and rear suspension systems, including struts, springs, control arms, bushings, and alignment specifications.
Driveline Axle:
Front-wheel drive system, including CV joints, drive shafts, differential, and gearbox lubrication.
Brakes:
Front and rear brake systems (disc/disc or disc/drum depending on market/spec), including hydraulic components, ABS, and parking brake.
Transmission Transaxle:
Manual transmission (e.g., M16A engine with 5-speed manual) and automatic transmission (if applicable), including clutch, gearbox components, and fluid specifications.
Steering:
Power steering system, steering column, rack and pinion, and wheel alignment.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, including refrigerant charging, component replacement, and troubleshooting.
Restraint:
Airbag system, seat belts, and related SRS components.
Body Cab Accessories:
Exterior body panels, doors, hood, trunk, interior trim, seats, glass, mirrors, and accessories.
Control Systems:
Electrical system overview, wiring diagrams, fuses, relays, ECUs, and various electronic control modules.
Procedures Included
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspections, and brake pad replacement.
Troubleshooting:
Diagnostic procedures for common problems, fault code interpretation, and symptom-based troubleshooting guides.
Repair:
Step-by-step repair instructions for virtually all mechanical and electrical components of the vehicle.
Diagnostics:
Detailed diagnostic procedures for engine performance, emissions, ABS, SRS, and other electronic systems.
Installation:
Instructions for replacing major components and accessories.
Technical Depth
Depth:
Comprehensive coverage from basic maintenance and fluid checks to complete engine and transmission rebuilds, including detailed specifications and torque values.
📊 Manual Specifications
File Details
File Quality:
High-quality scanned pages with clear text and diagrams.
Searchability:
Likely text-searchable due to PDF format, allowing quick access to specific information.
Catalytic Converter, Oxygen Sensors, EGR (depending on market)
🔧 Transmission
Standard
Type:
5-Speed Manual Transmission
Gear Ratios:
Specific ratios detailed in the manual (e.g., 1st: 3.454, 2nd: 1.894, 3rd: 1.310, 4th: 1.032, 5th: 0.815, Reverse: 3.250, Final Drive: 4.389)
Optional
Type:
4-Speed Automatic Transmission (available on some variants)
Features
Clutch:
Hydraulically actuated, single dry plate clutch.
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (or as specified in the manual)
Automatic Transmission Fluid:
Suzuki ATF 3317 or equivalent DEXRON-III/MERCON
📐 Dimensions
Exterior
Length:
Approx. 3715 mm (146.3 in)
Width:
Approx. 1680 mm (66.1 in)
Height:
Approx. 1535 mm (60.4 in)
Wheelbase:
Approx. 2370 mm (93.3 in)
Weights
Curb Weight:
Approx. 1060 kg (2337 lbs) for manual transmission
Cargo
Rear Seat Folded:
Moderate cargo space, expandable with folding rear seats.
🛡️ Safety Features
Ratings
Euro Ncap:
4-star rating for adult occupant protection (for some variants of this generation).
Active Features
ABS:
Anti-lock Braking System (ABS) standard on Sport models.
E Brake Force Distribution:
Electronic Brake-force Distribution (EBD) often included with ABS.
Passive Features
Airbags:
Front airbags for driver and passenger, side airbags and curtain airbags available on higher trims or as options.
Seat Belts:
3-point seat belts with pre-tensioners and force limiters.
Child Seat Anchors:
ISOFIX/LATCH child seat mounting points.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio with CD player, AM/FM. Some markets may have upgraded audio systems or MP3 compatibility.
Navigation:
Optional satellite navigation systems may have been available on higher trim levels or as dealer fitment.
Driver Assistance
Cruise Control:
Available on some higher specification models.
Connectivity
Auxiliary Input:
Auxiliary audio input jack may be present for connecting external devices.
🔧 Maintenance
Service Intervals
Oil Change:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Cabin Air Filter Replacement:
Every 12,000 miles (19,000 km) or 12 months.
Spark Plug Replacement:
Every 60,000 miles (96,000 km) for iridium-tipped plugs.
Coolant Flush:
Every 30,000 miles (48,000 km) or 2 years.
Fluid Specifications
Engine Oil:
API SN/SP, ILSAC GF-5/GF-6, SAE 0W-20 synthetic (check manual for exact specs)
Engine Oil Capacity:
Approx. 3.4 Liters (3.6 Quarts) with filter change.
Coolant:
Suzuki Super Long Life Coolant (Blue) or equivalent HOAT coolant (50/50 mix with distilled water).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Clutch Wear:
Some early models might experience clutch wear, particularly with spirited driving.
Suspension Bushings:
Rear suspension bushings can wear over time, leading to a less precise feel.
Engine Misfires:
Occasional misfires can be attributed to ignition coil or spark plug issues, which this manual helps diagnose.
Rust:
As with many cars of this era, especially in regions with harsh winters, rust can be a concern on the underbody and wheel arches.
📚 Vehicle History
Brand Heritage
Suzuki Automotive:
Suzuki has a long history of producing compact and lightweight vehicles known for their practicality and value.
Model Evolution
Swift History:
The Swift nameplate has been used globally for decades, with various iterations and market-specific models. The 'Sport' variant emerged as a performance-oriented version to cater to driving enthusiasts.
Production
Manufacturing Locations:
Primarily manufactured in Japan, with some production potentially occurring in other Suzuki global facilities.
🏆 Awards & Recognition
Recognitions
General Reputation:
The Swift Sport is generally praised for its engaging driving dynamics, value for money, and sporty character within its class.
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