Rear seat SUZUKI SWIFT 2006 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 00
0
1
2
3
4
5
6
7
8
9
10
11
Vo l u m e 1
Precautions............................................................... 00-iPrecautions ............................................................ 00-1
General Information ................ ................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubricatio n ................................. 0B-1
Engine ......................................................................... 1-i Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1
Aux. Emission Control Devices .............................. 1B-1
Engine Electrical Devices....................................... 1C-1
Engine Mechanical ................................................. 1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System .......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System....................................................... 1H-1
Starting System ....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System ..................................................... 1K-1
Suspension ................................................................. 2-i Precautions .............................................................. 2-1
Suspension General Diagnosis .............................. 2A-1
Front Suspension ................................................... 2B-1
Rear Suspension................ .................................... 2C-1
Wheels and Tires ................................................... 2D-1
Driveline / Axle ........................................................... 3-i Precautions .............................................................. 3-1
Drive Shaft / Axle ................................................... 3A-1
Brakes ......................................................................... 4-i Precautions .............................................................. 4-1
Brake Control System and Diagnosis .................... 4A-1
Front Brakes........................................................... 4B-1
Rear Brakes ........................................................... 4C-1
Parking Brake......................................................... 4D-1
ABS ........................................................................ 4E-1
Electronic Stability Program ................................... 4F-1
Vo l u m e 2
Precautions ............................................................... 00-iPrecautions ............................................................ 00-1
Transmission / Transaxle .... ...................................... 5-i
Precautions .............................................................. 5-1
Automatic Transmission/Transaxle ........................ 5A-1
Manual Transmission/Transaxle ............................ 5B-1
Clutch .....................................................................5C-1
Steering ....................................................................... 6-i Precautions .............................................................. 6-1
Steering General Diagnosis ................................... 6A-1
Steering Wheel and Column .................................. 6B-1
Power Assisted Steering System ...........................6C-1
HVAC ........................................................................... 7-i Precautions .............................................................. 7-1
Heater and Ventilation............................................ 7A-1
Air Conditioning System ......................................... 7B-1
Restraint ...................................................................... 8-i Precautions .............................................................. 8-1
Seat Belts ............................................................... 8A-1
Air Bag System ...................................................... 8B-1
Body, Cab and Accessories .... .................................. 9-i
Precautions .............................................................. 9-1
Wiring Systems ...................................................... 9A-1
Lighting Systems .................................................... 9B-1
Instrumentation / Driver Info. / Horn .......................9C-1
Wipers / Washers ...................................................9D-1
Glass / Windows / Mirrors ...................................... 9E-1
Security and Locks ................................................. 9F-1
Seats ..................................................................... 9G-1
Interior Trim ............................................................9H-1
Hood / Fenders / Doors .......................................... 9J-1
Body Structure ....................................................... 9K-1
Paint / Coatings ...................................................... 9L-1
Exterior Trim .......................................................... 9M-1
Control Systems ....................................................... 10-i Precautions ............................................................ 10-1
Body Electrical Control Sy stem ............................ 10B-1
Immobilizer Control System .................................10C-1
Keyless Start System ........................................... 10E-1
TABLE OF CONTENTS

Downloaded from www.Manualslib.com manuals search engine 1D-63 Engine Mechanical:
Main Bearing Cap No.1 Bolt
Measure each thread diameter main bearing cap No.1
bolts (1) at “A” on 60 mm (2.36 in.) from seat side of
flange bolt and “B” on 90 mm (3.54 in.) from seat side of
flange bolt by using a micrometer (2).
Calculate difference in diameters (“A” – “B”).
If it exceeds limit, replace with new one.
Main bearing cap No.1 bolt diameter measurement
points
“a”: 60 mm (2.36 in.)
“b”: 90 mm (3.54 in.)
Main bearing cap No.1 bolt diameter difference
Limit (“A” – “B”): 0.2 mm (0.008 in.)
Sensor Plate InspectionS7RS0B1406039
Check sensor plate for crack damage.
If malcondition is found, replace it.
Rear Oil Seal InspectionS7RS0B1406040
Carefully inspect oil seal (1) for wear or damage. If its lip
is worn or damaged, replace it.
Flywheel InspectionS7RS0B1406041
Visual Inspection
• If ring gear is damaged, cracked or worn, replace flywheel.
• If the surface contacting cl utch disc is damaged, or
excessively worn, replace flywheel.
Flywheel Face Runout
Check flywheel face runout with a dial gauge.
If runout exceeds its limit, replace flywheel.
Flywheel face runout
Limit: 0.2 mm (0.0079 in.)
Cylinder Block InspectionS7RS0B1406042
Distortion of Gasketed Surface
Using straightedge and thickness gauge, check
gasketed surface for distortion and, if flatness exceeds
its limit, correct It.
Cylinder block flatness
Limit: 0.03 mm (0.0012 in.)

“A”
“a” “b” “B”

1
1
2
I2RH0B140145-01
I2RH0B140151-01
I4RS0A140020-01
I2RH01140198-01
I2RH01140199-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 2- i
2
Section 2
CONTENTS
Suspension
Precautions ................................................. 2-1
Precautions............................................................. 2-1
Precautions on Suspension .................................. 2-1
Suspension General Dia gnosis.............. 2A-1
Diagnostic Information and Procedures ............ 2A-1
Suspension, Wheels and Tires Symptom Diagnosis .......................................................... 2A-1
Front Suspension ........... ......................... 2B-1
General Description ............................................. 2B-1
Front Suspension Construction ........................... 2B-1
Front Wheel Alignment Cons truction .................. 2B-2
Repair Instructions .............................................. 2B-2 Front Wheel Alignment Inspection and Adjustment ........................................................ 2B-2
Front Strut Assembly Comp onents ..................... 2B-4
Front Strut Assembly Removal and Installation ......................................................... 2B-4
Front Strut Assembly Disassembly and Assembly .......................................................... 2B-6
Front Strut Assembly Chec k ............................... 2B-7
Front Wheel Hub and Steering Knuckle Components...................................................... 2B-8
Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation .......... 2B-8
Front Wheel Hub, Disc, Nut and Bearing Check .............................................................. 2B-12
Suspension Control Arm / Bushing Removal and Installation ................................................ 2B-12
Suspension Control Arm / Bushing Disassembly and Assembly ............................ 2B-13
Suspension Control Arm / Steering Knuckle Check .............................................................. 2B-14
Suspension Control Arm Bushing Check .......... 2B-14
Suspension Control Arm Joint Check ............... 2B-14
Front Suspension Fram e, Stabilizer Bar and/
or Bushings Components................................ 2B-15
Front Suspension Fram e, Stabilizer Bar and/
or Bushings Removal and Installation ............. 2B-15
Front Suspension Frame Ch eck ....................... 2B-19
Front Stabilizer Bar, Bushing and/or Joint Check .............................................................. 2B-19
Front Suspension Fastener s Check .................. 2B-19
Specifications ..................................................... 2B-20 Tightening Torque Specifications ...................... 2B-20
Special Tools and Equipmen t ...........................2B-21
Special Tool ...................................................... 2B-21
Rear Suspension ............ ......................... 2C-1
General Description .............................................2C-1
Rear Suspension Construction ...........................2C-1
Repair Instructions ........... ...................................2C-2
Rear Wheel Alignment Inspection .......................2C-2
Rear Shock Absorber Removal and Installation .........................................................2C-2
Rear Shock Absorber Ins pection ........................2C-3
Rear Shock Absorber Bush Removal and Installation .........................................................2C-4
Rear Shock Absorber Bush Inspection ...............2C-4
Rear Coil Spring Removal and Installation .........2C-4
Spring Upper Seat / Spring Lower Seat Inspection ..........................................................2C-5
Spring Upper Seat and Lower Seat Removal and Installation ..................................................2C-6
Rear Axle Removal and Inst allation ....................2C-6
Trailing Arm, Rear Axle and Coil Spring Inspection ..........................................................2C-9
Rear Axle Bush Inspection ..................................2C-9
Rear Wheel Hub Components ..........................2C-10
Rear Wheel Hub Removal an d Installation .......2C-10
Rear Wheel Disc, bolt and Bearing Inspection ..2C-11
Spindle Removal and Installation ......................2C-12
Spindle Inspection .............................................2C-13
Rear Suspension Fasteners Inspection ............2C-13
Specifications .................... .................................2C-13
Tightening Torque Specifications ......................2C-13
Special Tools and Equipmen t ...........................2C-13
Special Tool ......................................................2C-13
Wheels and Tires ............ ......................... 2D-1
Precautions...........................................................2D-1
Precaution for Emergency Flat Tire Repair Kit ....2D-1
General Description .............................................2D-1 Tires Description .................................................2D-1
Wheels Description .............................................2D-2
Irregular and/or Premature Wear Description .....2D-3
Wear Indicators Description ................................2D-3
Radial Tire Waddle Description...........................2D-4
Radial Tire Lead / Pull Description ......................2D-5

Downloaded from www.Manualslib.com manuals search engine Rear Suspension: 2C-1
Suspension
Rear Suspension
General Description
Rear Suspension ConstructionS7RS0B2301001
I6RS0C230001-03
A: View A7. Circlip 14. Spindle cap : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft)
1. Rear coil spring 8. Rear trailing arm bolt 15. Wheel hub : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)
2. Rear spring upper seat 9. Rear shock absorber upper
nut 16. Washer
: 175 N⋅m (17.5 kgf-m, 126.5 lb-ft)
3. Rear shock absorber 10. Rear shock absorber lower nut “F”: Vehicle front : 88 N⋅m (8.8 kgf-m, 64.0 lb-ft)
4. Rear axle 11. Rear spindle bolt “I”: Body inside : Do not reuse.
5. Wheel bearing : Seal side of bearing comes
brake back plate side. 12. Wheel nut
: 73 N⋅m (7.3 kgf-m, 53.0 lb-ft)
6. Brake disc 13. Rear spindle nut
: Caulk spindle nut as shown
“a”. :28 N
⋅m (2.8 kgf-m, 20.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Rear Suspension: 2C-5
Installation1) Install coil spring (1) on spring seat (2) of rear axle and mate spring open end with stepped part (3) of
spring lower seat and raise rear axle.
2) Install shock absorbers (1) lower side (right & left) to rear axle.
Install washers and tighten shock absorber lower
nuts (2) temporarily by hand at this step. 3) Remove floor jacks from rear axle.
4) Install wheels and tighten wheel nuts to specified
torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
5) Lower hoist and vehicle in unloaded condition, tighten shock absorber lower nuts (a) to specified
torque.
Tightening torque
Rear shock absorber lower nut (a): 90 N·m (9.0
kgf-m, 65.0 lb-ft)
Spring Upper Seat / Spring Lower Seat
Inspection
S7RS0B2306006
Inspect for cracks, deformation or damage.
Replace any defective part.
F: Vehicle front
I4RS0A230011-01
1
2
I4RS0A230012-01
(a)
I4RS0A230013-01
I4RS0A230015-01

Downloaded from www.Manualslib.com manuals search engine 2C-6 Rear Suspension:
Spring Upper Seat and Lower Seat Removal and
Installation
S7RS0B2306007
Removal1) Remove coil spring referring to “Rear Coil Spring Removal and Installation”.
2) Remove spring upper seat (1) and lower seat (2).
Installation 1) Install spring upper seat (1) and lower seat (2).
NOTE
For proper installing direction of spring
upper seat (1) and lower seat (2), refer to the
figure.

2) Install coil spring referr ing to “Rear Coil Spring
Removal and Installation”.
Rear Axle Removal and InstallationS7RS0B2306008
Removal
1) Hoist vehicle and remove rear wheels (right & left).
2) Disconnect rear brake caliper flexible hoses (1) (right & left) from brake pipes (2) and put bleeder plug cap
(3) onto pipe (2) prevent fluid from spilling.
CAUTION!
Do not drop brake fluid onto painted surface.

1
2
I4RS0A230016-01
I3RM0A230021-01
A: Vehicle body side (Upper side)
F: Vehicle front3. Stepped part
I4RS0A230017-01
1
2
2 3
I6RS0B230002-01

Downloaded from www.Manualslib.com manuals search engine 2C-8 Rear Suspension:
3) Install coil springs (right & left) on spring seats of rear
axle referring to “Spring Upper Seat and Lower Seat
Removal and Installation” and “Rear Coil Spring
Removal and Installation”.
4) Install shock absorbers lower side (right & left) and washers referring to “Rear Shock Absorber Removal
and Installation”.
5) Install brake dust covers, spindles and wheel speed sensors (right and left) referring to “Spindle Removal
and Installation”.
6) Connect wheel speed sensors (1) and lead wire clamps (2) (right & left).
Tightening torque
Wheel speed sensor bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)
7) Connect brake flexible hoses (1) to bracket on rear axle with E-rings (3) (right & left) and tighten brake
pipe flare nuts (a) to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft) 8) Install wheel speed sensor clamp and parking brake
clamp and tighten parking brake clamp bolts (1) to
specified torque.
Tightening torque
Parking brake cable clamp bolt (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
9) Install rear wheel hubs (right & left) referring to “Rear Wheel Hub Removal and Installation”.
10) Install brake discs (right & left) and rear brake caliper assemblies (right & left) referring to “Rear Brake Disc
Removal and Installati on in Section 4C”.
11) Connect rear brake caliper flexible hoses (1) to brake pipes (2) with E-rings (3) (right & left).
Tighten brake pipe flare nuts to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft)
1 2
(a)
3
I6RS0B230005-01
I4RS0A230028-01
1, (a)I6RS0B230006-01
3
2 1
(a)
I6RS0B230007-01

Downloaded from www.Manualslib.com manuals search engine 2C-10 Rear Suspension:
Rear Wheel Hub ComponentsS7RS0B2306011
Rear Wheel Hub Removal and InstallationS7RS0B2306012
Removal1) Hoist vehicle and remove wheel.
2) Remove rear brake caliper assembly and rear brake disc referring to “Rear Brake Disc Removal and
Installation in Section 4C”.
3) Remove spindle cap (1) by hammering lightly at 3 locations around it so as not to deform or cause
damage to seating part of cap.
4) Uncaulk and remove rear axle nut (2). 5) Using special tools, draw out wheel hub (1).
Special tool
(A): 09943–17912
(B): 09942–15511
6) Remove wheel stud bolt (1) from wheel hub (2) by using hydraulic press (3).
(b)5
4
3
(a)2
1
6
I6RS0C230002-03
1. Spindle cap 4. Spindle: 175 N⋅m (17.5 kgf-m, 126.5 lb-ft)
2. Rear axle nut :Calk, after Tightening 5. Disc dust cover
: 88 N⋅m (8.8 kgf-m, 64.0 lb-ft)
3. Rear wheel hub :Never disassemble wheel hub assembly 6. Hub bolt
: Do not reuse.
2
1
I6RS0B230010-01
1
(A) (B)
I6RS0B230011-01
1
3
2
I6RS0C230003-01

Downloaded from www.Manualslib.com manuals search engine Wheels and Tires: 2D-4
Radial Tire Waddle DescriptionS7RS0B2401005
Waddle is side to side movement at the front and/or rear
of the vehicle. It is caused by the steel belt not being
straight within the tire. It is most noticeable at a low
speed, 8 to 48 kph (5 to 30 mph).
It is possible to locate the f aulty tire by road testing the
vehicle. If it is on the rear , the rear end of the vehicle
shakes from side to side or “waddles”. To the driver in
the seat, it feels as though someone is pushing on the
side of vehicle.
If the faulty tire is on the front, waddling is more visual.
The front sheet metal appears to be moving back and
forth and the driver feels as though he is at the pivot
point in vehicle.
Waddle can be quickly diagnosed by using Tire Problem
Detector (TPD) and following the equipment
manufacture’s recommendations.
If TPD is not available, an alternative method of
substituting known-good tire / wheel assemblies can be
used as follows, although it takes a longer time. 1) Ride vehicle to determine whether the front or rear
waddles.
2) Install tires and wheels that are known to be good (on similar vehicle) in place of those on waddling end
of vehicle. If waddling end cannot be identified,
substitute rear ones.
3) Road test again. If improvement is noted, reinstall originals one at a time till w addle causal tire is found.
If no improvement is noted, install known-good tires
in place of all four. Then reinstall originals in the
same manner.
Equipment manufacture’s recommendations
I2RH01240006-01
Inflate tires to recommended pressure
Road test vehicle on level unrouned road in both directions
Switch front tires side to side and road test again
Lead corrected,
if roughness results, replace tiresLeads in same directionLeads reverses direction
Put tires back in original position
and check alignmentInstall a known-good tire on one front side
Lead remains install a known-good
tire in place of other front tire
Lead remains known-good tires are not goodLead corrected replace tire
Lead corrected replace tire
I2RH01240007-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 8- i
8
Section 8
CONTENTS
Restraint
Precautions ................................................. 8-1
Precautions............................................................. 8-1
Precautions on Restraint ....................................... 8-1
Seat Belts .......... ............................... ........ 8A-1
Precautions........................................................... 8A-1
Precautions on Service a nd Diagnosis of Seat
Belt .................................................................... 8A-1
General Description ............................................. 8A-1 Seat Belt Construction ........................................ 8A-1
Diagnostic Information and Procedures ............ 8A-2 Repair and Inspection Required after Accident ............................................................ 8A-2
Repair Instructions .............................................. 8A-3 Front Seat Belt Components ............................... 8A-3
Front Seat Belt Removal and Installation ............ 8A-4
Front Seat Belt Inspection ................................... 8A-4
Rear Seat Belt Components ............................... 8A-6
Rear Seat Belt Removal and Installation ............ 8A-7
Rear Seat Belt Inspection ................................... 8A-7
Specifications ....................................................... 8A-7
Tightening Torque Specifications ........................ 8A-7
Air Bag System ............... ......................... 8B-1
Precautions........................................................... 8B-1
Precautions on Service and Diagnosis of Air Bag System....................................................... 8B-1
Precautions on Handling and Storage of Air Bag System Components . ................................ 8B-2
Precautions on Disposal of Air Bag and Seat
Belt Pretensioner .............................................. 8B-5
General Description ............................................. 8B-5 Air Bag System Construction .............................. 8B-5
Air Bag System Input / Output Table .................. 8B-6
Schematic and Routing Diagram ........................ 8B-7 Air Bag System Wiring Circuit Diagram .............. 8B-7
Component Locatio n ........................................... 8B-9
Air Bag System Components, Wiring and Connectors Location ......................................... 8B-9
Diagnostic Information and Procedures .......... 8B-10 Air Bag Diagnostic System Check .................... 8B-10
Air Bag Diagnostic System Check Flow ............ 8B-10
DTC Table ......................................................... 8B-11
DTC Check ....................................................... 8B-12 DTC Clearance ................................................. 8B-12
Scan Tool Data ................................................. 8B-13
“AIR BAG” Warning Right Comes ON Steady .. 8B-13
“AIR BAG” Warning Right Does Not Come
ON ................................................................... 8B-15
“AIR BAG” Warning Right Flashes .................... 8B-16
DTC B1013: SDM fault...................................... 8B-17
DTC B1014: “AIR BAG” Warning Right Circuit Failure ............................................................. 8B-17
DTC B1016: Power Source Voltage High ......... 8B-18
DTC B1017: Power Source Voltage Low .......... 8B-20
DTC B1021: Front Air Bag Module Deployed ... 8B-22
DTC B1024 / B1025: Side-Air Bag (Driver / Passenger) Deployed...................................... 8B-22
DTC B1026: Pretensioner Activated ................. 8B-23
DTC B1027: Reusable Number Exceeded ....... 8B-24
DTC B1031: Driver Air Bag Initiator Circuit
Resistance High .............................................. 8B-24
DTC B1032: Driver Air Bag Initiator Circuit
Resistance Low ............................................... 8B-29
DTC B1033: Driver Air Bag Initiator Circuit
Short to Ground............................................... 8B-34
DTC B1034: Driver Air Bag Initiator Circuit
Short to Power Circuit .... ................................. 8B-39
DTC B1041: Passenger Air Bag Initiator Circuit Resistance High ................................... 8B-44
DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low.................................... 8B-47
DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground ................................... 8B-50
DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circ uit .......................... 8B-53
DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance
High ................................................................. 8B-56
DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circu it Resistance Low .. 8B-58
DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground .. 8B-60
DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power
Circuit .............................................................. 8B-62
DTC B1061 / B1065: Driver / Passenger Side- Air Bag Initiator Circuit Resistance High ......... 8B-64