warning SUZUKI SWIFT 2000 1.G Transmission Service Owner's Manual

BODY SERVICE 9-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 9
BODY SERVICE
CONTENTS
GLASS, WINDOWS AND MIRRORS ................. 9-2
FRONT DOOR GLASS ................................... 9-2
FRONT DOOR WINDOW REGULATOR ........ 9-6
DOOR MIRROR .......................................... 9-7
REAR DOOR GLASS (IF EQUIPPED) ....... 9-8
REAR DOOR WINDOW REGULATOR ........ 9-11
WINDOW SHIELD ........................................ 9-12
QUARTER WINDOW .................................... 9-17
BACK DOOR GLASS .................................... 9-18
BODY STRUCTURE......................................... 9-19
FRONT DOOR ASSEMBLY .......................... 9-19
REAR DOOR ASSEMBLY ............................ 9-22
BACK DOOR ASSEMBLY ............................ 9-23
HOOD ........................................................... 9-25
FRONT FENDER .......................................... 9-26
FRONT BUMPER AND REAR BUMPER...... 9-27
ROOF RAIL (IF EQUIPPED) ......................... 9-28
BODY DIMENSIONS .................................... 9-29
ENGINE ROOM ........................................ 9-29
BACK DOOR ............................................. 9-30
SIDE BODY ............................................... 9-31UNDER BODY .......................................... 9-34
PANEL CLEARANCE ................................... 9-36
INSTRUMENTATION AND DRIVER
INFORMATION................................................. 9-38
INSTRUMENT PANEL .................................. 9-38
SEATS .............................................................. 9-40
FRONT SEAT ............................................... 9-40
REAR SEAT.................................................. 9-41
SECURITY AND LOCKS ................................. 9-42
FRONT DOOR LOCK ASSEMBLY............... 9-42
REAR DOOR LOCK ASSEMBLY (IF
EQUIPPED) .................................................. 9-44
BACK DOOR LOCK ASSEMBLY ................. 9-45
KEY CODING ............................................... 9-46
KEY USAGE AND IDENTIFICATION ....... 9-46
IGNITION SWITCH LOCK CYLINDER ..... 9-47
EXTERIOR AND INTERIOR TRIM ................... 9-47
FLOOR CARPET .......................................... 9-47
HEAD LINING ............................................... 9-48
PAINT AND COATINGS .................................. 9-50 WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
When body servicing, if shock may be applied to air bag system component parts, remove those
parts beforehand. (Refer to Section 10B.)
NOTE:
Fasteners are important attaching parts in that they could affect the performance of vital components
and systems, and / or could result in major repair expense. They must be replaced with one of the
same part number of with an equivalent part if replacement becomes necessary.
Do not use a replacement part of lesser quality or substitute a design. Torque values must be used as
specified during reassembly to assure proper retention of these parts.

9-24 BODY SERVICE
INSTALLATION
Reverse removal procedure to install back door noting the follow-
ing instructions.
Secure wiring harness.
Adjust door latch striker position by referring “BACK DOOR
LOCK ASSEMBLY” in this section.
Adjust door cushion so that door contacts body when closed.
Adjust door clearance by loosening door hinge mounting
bolts and nuts referring to “PANEL CLEARANCE” in this sec-
tion.
Apply sealant to contact face “A” of door hinge (1) and apply
grease to rotating part “B” of hinge (1).
“A” : Sealant 99000-31110
“B” : Lithium grease 99000-25010 WARNING:
Handling of Back Door Balancer (Damper)
Do not disassemble balancer (1) because its cylinder is
filled with gas.
Handle balancer carefully. Do not scar or scratch
exposed surface of its piston rod, and never allow any
paint or oil to stick to its surface.
Do not turn piston rod with balancer fully extended.
When discarding removed back door balancer
(damper), use a 2 – 3 mm (0.08 – 0.12 in.) drill (2) to
make a hole as shown.
The gas itself is harmless but it may issue out of the
hole together with chips generated by the drill (2).
Therefore, be sure to wear goggle.

9-38 BODY SERVICE
INSTRUMENTATION AND DRIVER INFORMATION
INSTRUMENT PANEL
REMOVAL
1) Disconnect negative cable at battery.
2) Disable air bag system, if equipped. Refer to “DISABLE AIR
BAG SYSTEM” in Section 10B.
3) Remove steering column hole cover (1).
4) Remove glove box (1) and food latch release lever (2).
5) Disconnect instrument panel harness connectors, antenna
and heater control cables which need to be disconnected for
removal for instrument panel.
6) Remove instrument panel ground wire.
7) Remove steering column assembly referring to “STEERING
COLUMN ASSEMBLY” in Section 3C.
8) Remove front pillar trims (1) and dash side trims (2).
9) Remove speaker covers (3).WARNING:
See WARNING at the beginning of this section.
“A”
“A”“A”
“A”
“A”
1
2“A” 1
3
“A”

9-50 BODY SERVICE
PAINT AND COATINGS
ANTI-CORROSION TREATMENT
As rust proof treatment, steel sheets are given corrosion resistance on the interior and/or exterior.
These corrosion resistance steel sheet materials are called one of two-side galvanized steel sheets.
It is for the sake of rust protection that these materials are selected and given a variety of treatments as
described blow.
Steel sheets are treated with cathodic electroprimer which is excellent in corrosion resistance.
Rust proof wax coatings are applied to door and side sill insides where moisture is liable to stay.
Vinyl coating is applied to body underside and wheel housing inside.
Sealer is applied to door hem, engine compartment steel sheet-to-steel sheet joint, and the like portions to
prevent water penetration and resulting in rust occurrence.
In panel replacement or collision damage repair, leaving the relevant area untreated as it is in any operation
which does disturb the above-mentioned rust proof treatment will cause corrosion to that area. Therefore, it is
the essential function of any repair operation to correctly recoat the related surfaces of the relevant area.
All the metal panels are coated with metal conditioners and primer coating during vehicle production. Following
the repair and/or replacement parts installation, every accessible bare metal surface should be cleaned and
coated with rust proof primer. Perform this operation prior to the application of sealer and rust proof wax coating.
Sealer is applied to the specific joints of a vehicle during production. The sealer is intended to prevent dust from
entering the vehicle and serves also as an anticorrosion barrier. The sealer is applied to the door and hood hem
areas and between panels. Correct and reseal the originally sealed joints if damaged. Reseal the attaching
joints of a new replacement panel and reseal the hem area of a replacement door or hood.
Use a quality sealer to seal the flanged joints, overlap joints and seams. The sealer must have flexible character-
istics and paint ability after it’s applied to repair areas.
For the sealer to fill open joints, use caulking material. Select a sealer in conformance with the place and pur-
pose of a specific use. Observe the manufacturer’s label-stand instructions when using the sealer.
In many cases, repaired places require color painting. When this is required, follow the ordinary techniques
specified for the finish preparation, color painting and undercoating build-up.
Rust proof wax, a penetrative compound, is applied to the metal-to-metal surfaces (door and side sill insides)
where it is difficult to use ordinary undercoating material for coating. Therefore, when selecting the rust proof
wax, it may be the penetrative type.
During the undercoating (vinyl coating) application, care should be taken that sealer is not applied to the engine-
related parts and shock absorber mounting or rotating parts. Following the under coating, make sure that body
drain holes are kept open.
The sequence of the application steps of the anti-corrosion materials are as follows:
1) Clean and prepare the metal surface.
2) Apply primer.
3) Apply sealer (all joints sealed originally).
4) Apply color in areas where color is required such as hem flanges, exposed joints and under body compo-
nents.
5) Apply anticorrosion compound (penetrative wax).
6) Apply undercoating (rust proof material).WARNING:
Standard shop practices, particularly eye protection, should be followed during the performance of the
below-itemized operations to avoid personal injury.

RESTRAINT SYSTEM 10-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 10
RESTRAINT SYSTEM
CONTENTS
GENERAL DESCRIPTION .............................. 10-2
SYSTEM SPECIFICATION .......................... 10-3
SEAT BELT PRETENSIONER
(IF EQUIPPED) ............................................ 10-3
DIAGNOSIS ..................................................... 10-3
INSPECTION AND REPAIR REQUIRED
AFTER ACCIDENT ...................................... 10-3
ON-VEHICLE SERVICE .................................. 10-4SERVICE PRECAUTIONS .......................... 10-4
SERVICE AND DIAGNOSIS .................... 10-4
DISABLING AIR BAG SYSTEM............... 10-4
ENABLING AIR BAG SYSTEM................ 10-4
HANDLING AND STORAGE ................... 10-4
DISPOSAL ............................................... 10-4
FRONT SEAT BELT .................................... 10-5
REAR SEAT BELT....................................... 10-8

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System with seat belt pretensioner:
Service on or around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-
Vehicle Service” in air bag system section before performing service on or around the air bag sys-
tem components or wiring. Failure to follow WARNINGS could result in unintentional activation of
the system or could render the system inoperative. Either of these two conditions may result in
severe injury.
The procedures in this section must be followed in the order listed to disable the air bag system
temporarily and prevent false diagnostic trouble codes from setting. Failure to follow procedures
could result in possible activation of the air bag system, personal injury or otherwise unneeded air
bag system repairs.
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application.
If the correct part number fastener is not available, a fastener of equal size and strength (or stronger)
may be used. Fasteners that are not reused, and those requiring thread-locking compound, will be
called out. The correct torque value must be used when installing fasteners that require it. If the above
procedures are not followed, parts or system damage could result.

RESTRAINT SYSTEM 10-3
Driver and Front Passenger Air Bags and Seat Belt Pretensioners
With the air bag system which includes air bags for both the driver’s and passenger’s sides as well as the seat
belt pretensioners, the pretensioner takes up the sag of the seat belt, the driver air bag (inflator) module is
deployed from the center of the steering column and the passenger air bag (inflator) module from the top of the
instrument panel in front of the front passenger seat in occurrence of a front collision with an impact larger than
a certain set value to supplement protection offered by the driver and front passenger seat belts.
SYSTEM SPECIFICATION
SEAT BELT PRETENSIONER (IF EQUIPPED)
Some seat belts of the driver and front passenger seats are provided with a pretensioner as an optional function
unit. The pretensioner is incorporated in retractor assembly and controlled by SDM as one of air bag system
components. It will be activated at the same time as the air bag when an impact at the front of vehicle exceeds
the specified value.
When servicing seat belt (retractor assembly) with pretensioner, be sure to observe all WARNINGS and CAU-
TIONS in this section and “SERVICE PRECAUTIONS” of “ON-VEHICLE SERVICE” in Section 10B
DIAGNOSIS
For diagnosis of air bag system (including in seat belt pretensioner), refer to Section 10B.
INSPECTION AND REPAIR REQUIRED AFTER ACCIDENT
After an accident, whether the seat belt pretensioner has been activated or not, be sure to perform checks and
repairs described on “REPAIRS AND INSPECTIONS REQUIRED AFTER ACCIDENT” under “DIAGNOSIS” in
Section 10B.Type 1 Type 2 Type 3
Front
seatSeat belt with ELRDriver air bag
Seat belt with ELR and
pretensionerDriver and front passenger air bags
Seat belt wit ELR and pretensioner
Rear
seatSeat belt with A-ELR
(right and left)
Seat belt (center)Seat belt with A-ELR
(right and left)
Seat belt (center)Seat belt with A-ELR (right and left)
Seat belt (center)
CAUTION:
Do not reuse the seat belt pretensioner (retractor assembly) that has operated but replace it with a
new one as an assembly. For checking procedure of its operation, refer to “SERVICE PRECAUTIONS”
of “ON-VEHICLE SERVICE” in Section 10B.

10-4 RESTRAINT SYSTEM
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
SERVICE AND DIAGNOSIS
Before servicing or replacing seat belts, refer to following precautionary items.
Seat belts should be normal relative to strap retractor and buckle portions.
Keep sharp edges and damaging objects away from belts.
Avoid bending or damaging any portion of belt buckle or latch plate.
Do not bleach or dye belt webbing. (Use only mild soap and lukewarm water to clean it.)
When installing a seat belt anchor bolt, it should be tightened by hand at first to prevent cross-threading and
then to specified torque.
Do not attempt any repairs on retractor mechanisms or retractor covers. Replace defective assemblies with
new replacement parts.
Keep belts dry and clean at all times.
If there exist any parts in question, replace such parts.
Replace belts whose webbing is cut or otherwise damaged.
Do not put anything into trim panel opening which seat belt webbing passes through.
For Seat Belt with Pretensioner
Refer to “SERVICE AND DIAGNOSIS” of “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in Sec-
tion 10B.
DISABLING AIR BAG SYSTEM
Refer to “DISABLING AIR BAG SYSTEM” of “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in
Section 10B.
ENABLING AIR BAG SYSTEM
Refer to “ENABLING AIR BAG SYSTEM” of “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in
Section 10B.
HANDLING AND STORAGE
Refer to “HANDLING AND STORAGE” of “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in Sec-
tion 10B.
DISPOSAL
Refer to “DISPOSAL” of “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in Section 10B. WARNING:
If replacing seat belt is necessary, replace buckle and ELR (or webbing) together as a set. This is for
the reason of ensuring locking of tongue plate with buckle.
If these parts are replaced individually, such a locking condition may become unreliable. For this rea-
son, SUZUKI will supply only the spare buckle and ELR (or webbing) in a set part.
WARNING:
When performing service on or around air bag system components or air bag system wiring, disable
the air bag system. Refer to “DISABLING AIR BAG SYSTEM” of “SERVICE PRECAUTIONS” under
“ON-VEHICLE SERVICE” in Section 10B.
Failure to follow procedures could result in possible air bag activation, personal injury or unneeded
air bag system repairs.

RESTRAINT SYSTEM 10-5
FRONT SEAT BELT
WARNING:
Never attempt to disassemble or repair the seat belt pretensioner (retractor assembly). If any abnor-
mality is found, be sure to replace it with new one as an assembly.
Be sure to read “SERVICE PRECAUTIONS”, before starting to work and observe every precaution
during work. Neglecting them may result in personal injury or unactivation of the seat belt preten-
sioner when necessary.
1. Upper anchor 4. BuckleTightening torque
2. Lower anchor 5. Yellow connector (for seat belt pretensioner) (if equipped)
3. Retractor assembly 6. Retractor assembly upper mounting bolt
: After tightening lower bolt, tightening upper bolt

10-6 RESTRAINT SYSTEM
REMOVAL
1) Disconnect negative battery cable at battery.
2) Disable air bag system. Refer to “DISABLING AIR BAG SYSTEM” of “SERVICE PRECAUTIONS” under
“ON-VEHICLE SERVICE” in Section 10B.
3) Remove center pillar lower trim.
4) Disconnect Yellow connector for seat belt pretensioner.
a) Release locking of lock lever.
b) After unlocked, disconnect to connector.
5) Remove front seat belts from the vehicle.
INSPECTION
Seat belts and attaching parts can affect the vital components
and systems of a vehicle.
Therefore, they should be inspected carefully and replaced with
genuine parts only.
Seat belt
Its webbing or strap should be free from damage.
Retractor assembly
It should lock webbing when pulled quickly.
The front seat belt retractor assembly (1) should pass the
above inspection and should lock webbing even when tilted
(approx. 15°) toward the fore and aft or right and left direc-
tions.
Check retractor assembly (1) with seat belt pretensioner
appearance visually for following symptoms and if any one of
them is applicable, replace it with a new one as an assem-
bly.
Pretensioner has activated.
There is a crack in seat belt pretensioner (retractor assem-
bly).
Wire harness or connector (2) is damaged.
Seat belt pretensioner (retractor assembly) is damaged or a
strong impact (e.g., dropping) was applied to it.
Anchor bolt
Anchor bolts should be torqued to specification.
Belt latch
It should be secure when latched. WARNING:
Never measure resistance of pretensioner or disassem-
ble it. Otherwise, personal injury may result.
CAUTION:
If seat belt pretensioner (retractor assembly) was
dropped from a height of 30 cm (1 ft) or more, it should
be replaced.

10-8 RESTRAINT SYSTEM
REAR SEAT BELT
REMOVAL
Remove rear seat belts as shown in figure.
INSPECTION
Check the rear seat belt in the same way as “INSPECTION” of “FRONT SEAT BELT”.
INSTALLATION
Install the rear seat belt observing the same precautions as “INSTALLATION” of “FRONT SEAT BELT”. WARNING:
Be sure to read “SERVICE PRECAUTIONS” before starting to work and observe every precaution dur-
ing work.
1. Upper anchor 4. Buckle
2. Lower anchor Tightening torque
3. Retractor assembly