2004-2008 Suzuki Swift Sport RS416 Workshop Repair Manual
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🏷️ Basic Information Identification Make: Suzuki Model: Swift Sport Model Code: RS416 Year Range: 2004-2008 👋 Introduction Market Position Target Audience: Owners of 2004-2008 Suzuki Swift Sport RS416 seeking to perform maintenance, diagnostics, and repairs. Competitive Analysis Value Proposition: Provides in-depth technical information essential for maintaining the performance and longevity of the Swift Sport RS416, saving on dealership costs. Key Features Comprehensiveness: Covers all major vehicle systems, offering a complete resource for repair and maintenance. Expertise Transfer: Empowers users with the knowledge to understand their vehicle's intricacies and perform tasks confidently. 📋 Manual Details Coverage Manual Type: Workshop Repair Manual / Service Manual Language: English File Format: PDF Compatibility: All Versions of Windows & Mac Requirements: Adobe PDF Reader 📖 Manual Coverage Systems Covered Engine: Complete Engine Overhaul, Assembly, Disassembly, Tuning, Component Specifications Suspension: Front and Rear Suspension Systems, Component Replacement, Alignment Procedures, Specifications Driveline Axle: Front Axle, Rear Axle (if applicable), CV Joints, Drive Shafts, Differential, Wheel Bearings Brakes: Front and Rear Brake Systems, Disc and Drum Brakes, ABS, Component Diagnosis and Replacement Transmission Transaxle: Manual Transmission, Clutch System, Shifting Mechanisms, Fluid Specifications, Repair Procedures Steering: Power Steering System, Steering Column, Rack and Pinion, Components and Diagnosis HVAC: Heating, Ventilation, and Air Conditioning System, Refrigerant, Component Diagnosis and Replacement Restraint: Airbag System, Seatbelts, Pre-tensioners, Safety System Components and Diagnosis Body Cab Accessories: Exterior Body Panels, Interior Trim, Doors, Windows, Locks, Seats, Bumpers Control Systems: Electronic Control Units (ECUs), Sensors, Actuators, Diagnostic Trouble Codes (DTCs) Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug Replacement, Fluid Checks Troubleshooting: Diagnostic Procedures for Common and Uncommon Issues, Symptom-Based Troubleshooting Charts Repair: Step-by-Step Repair Instructions for all Covered Systems and Components Assembly Disassembly: Detailed Procedures for Component Removal and Installation Technical Specifications: Torque Specifications, Clearances, Lubrication Requirements, Electrical Schematics Technical Depth Level Of Detail: Comprehensive Workshop Level - Suitable for Professional Technicians and Advanced DIYers 📊 Manual Specifications Format File Type: PDF Searchable Text: Likely Searchable (depending on original document scanning quality) Printable: Yes ⚙️ Engine Specifications Primary Engine Engine Code: M16A (for RS416 model variant) Engine Type: Inline 4-cylinder, DOHC, 16-valve, VVT (Variable Valve Timing) Displacement: 1.6 Liters (1586 cc) Performance Horsepower: Approximately 125 PS (92 kW) at 6700 rpm (specifications may vary by market) Torque: Approximately 150 Nm (111 lb-ft) at 4800 rpm (specifications may vary by market) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Petrol (Gasoline) Engine Management Ignition System: Electronic Ignition 🔧 Transmission Standard Type: 5-Speed Manual Transmission Optional Type: 4-Speed Automatic Transmission (availability may vary by market and trim) Features Clutch Type: Hydraulically Actuated Dry Single Plate Clutch 📐 Dimensions Exterior Length: Approx. 3,775 mm Width: Approx. 1,705 mm Height: Approx. 1,490 mm Wheelbase Distance: Approx. 2,380 mm Weights Curb Weight: Approx. 1,040 - 1,100 kg (depending on configuration) 🛡️ Safety Features Ratings Euro Ncap: Typically 4-star or 5-star for models equipped with relevant safety packages (specific ratings vary by year and region) Active Features ABS: Anti-lock Braking System Esp: Electronic Stability Program (optional or standard on certain trims/markets) Ebs: Electronic Brake-force Distribution Passive Features Airbags: Front Driver and Passenger Airbags, Side Airbags (optional/standard) Seatbelts: Pre-tensioner seatbelts with force limiters 💡 Technology Features Infotainment Audio System: Typically a CD player with radio, and speaker system. Aux input or USB may be available on later models or as an upgrade. Instrument Cluster: Analog gauges for speedometer, tachometer, fuel, and temperature. Multi-function display for trip computer. Driver Assistance Cruise Control: Available on some models/trims. Keyless Entry: Available on some models/trims. Connectivity Power Outlets: 12V power outlet in the cabin. 🔧 Maintenance Service Intervals Oil Change: Typically every 15,000 km or 12 months, whichever comes first (refer to manual for exact specification based on driving conditions). Air Filter Replacement: Inspect every 15,000 km, replace as needed or at around 30,000 km. Spark Plug Replacement: Typically around 90,000 km for iridium type spark plugs. Fluid Specifications Engine Oil: Refer to manual for exact API/ACEA specification and viscosity (e.g., 5W-30 is common). Transmission Fluid: Refer to manual for specific manual transmission fluid (MTF) type and capacity (e.g., GL-4 rated gear oil). Brake Fluid: DOT 3 or DOT 4 recommended (check manual). Coolant: Suzuki Super Long Life Coolant or equivalent (typically a pink ethylene glycol based coolant). Known Issues Clutch Wear: Can be subject to premature wear with aggressive driving. Suspension Components: Bushings and ball joints may wear over time, leading to clunks or imprecise handling. Exhaust System: Corrosion or leaks in the exhaust system can occur due to age and environmental factors. Vvt System: Rarely, issues with the VVT solenoid or phaser can arise, affecting engine performance and fuel economy. 📚 Vehicle History Brand Heritage Manufacturer: Suzuki Motor Corporation, a Japanese multinational corporation renowned for compact cars and motorcycles. Model Evolution Generation: This is the second generation...
Approximately 125 PS (92 kW) at 6700 rpm (specifications may vary by market)
Torque:
Approximately 150 Nm (111 lb-ft) at 4800 rpm (specifications may vary by market)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Petrol (Gasoline)
Engine Management
Ignition System:
Electronic Ignition
🔧 Transmission
Standard
Type:
5-Speed Manual Transmission
Optional
Type:
4-Speed Automatic Transmission (availability may vary by market and trim)
Features
Clutch Type:
Hydraulically Actuated Dry Single Plate Clutch
📐 Dimensions
Exterior
Length:
Approx. 3,775 mm
Width:
Approx. 1,705 mm
Height:
Approx. 1,490 mm
Wheelbase
Distance:
Approx. 2,380 mm
Weights
Curb Weight:
Approx. 1,040 - 1,100 kg (depending on configuration)
🛡️ Safety Features
Ratings
Euro Ncap:
Typically 4-star or 5-star for models equipped with relevant safety packages (specific ratings vary by year and region)
Active Features
ABS:
Anti-lock Braking System
Esp:
Electronic Stability Program (optional or standard on certain trims/markets)
Ebs:
Electronic Brake-force Distribution
Passive Features
Airbags:
Front Driver and Passenger Airbags, Side Airbags (optional/standard)
Seatbelts:
Pre-tensioner seatbelts with force limiters
💡 Technology Features
Infotainment
Audio System:
Typically a CD player with radio, and speaker system. Aux input or USB may be available on later models or as an upgrade.
Instrument Cluster:
Analog gauges for speedometer, tachometer, fuel, and temperature. Multi-function display for trip computer.
Driver Assistance
Cruise Control:
Available on some models/trims.
Keyless Entry:
Available on some models/trims.
Connectivity
Power Outlets:
12V power outlet in the cabin.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 15,000 km or 12 months, whichever comes first (refer to manual for exact specification based on driving conditions).
Air Filter Replacement:
Inspect every 15,000 km, replace as needed or at around 30,000 km.
Spark Plug Replacement:
Typically around 90,000 km for iridium type spark plugs.
Fluid Specifications
Engine Oil:
Refer to manual for exact API/ACEA specification and viscosity (e.g., 5W-30 is common).
Transmission Fluid:
Refer to manual for specific manual transmission fluid (MTF) type and capacity (e.g., GL-4 rated gear oil).
Brake Fluid:
DOT 3 or DOT 4 recommended (check manual).
Coolant:
Suzuki Super Long Life Coolant or equivalent (typically a pink ethylene glycol based coolant).
Known Issues
Clutch Wear:
Can be subject to premature wear with aggressive driving.
Suspension Components:
Bushings and ball joints may wear over time, leading to clunks or imprecise handling.
Exhaust System:
Corrosion or leaks in the exhaust system can occur due to age and environmental factors.
Vvt System:
Rarely, issues with the VVT solenoid or phaser can arise, affecting engine performance and fuel economy.
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation, a Japanese multinational corporation renowned for compact cars and motorcycles.
Model Evolution
Generation:
This is the second generation of the Suzuki Swift (ZC/ZD series), with the RS416 designation specifically referring to the performance-oriented Sport variant.
Production
Manufacturing Location:
Primarily manufactured in Japan, with potential assembly in other global locations.
🏆 Awards & Recognition
Recognitions
General Reputation:
Praised for its sporty handling, responsive engine, and value for money in the hot hatch segment of its era.
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