instrument panel SUZUKI SWIFT 2008 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 00-1 Precautions:
Precautions
Precautions
Precautions
Precautions for Vehicles Equipped with a
Supplemental Restraint (Air Bag) System
S7RS0B0000001
WARNING!
• The configuration of air bag system parts are as shown in the figure. When it is
necessary to service (remove, reinstall and
inspect) these parts, be sure to follow
procedures described in Air Bag System
section. Failure to follow proper
procedures could result in possible air bag
system activation, personal injury, damage
to parts or air bag system being unable to
activate when necessary.
• If the air bag system and another vehicle system both need repair, SUZUKI
recommends that the air bag system be
repaired first, to help avoid unintended air
bag system activation.
• Do not modify the steering wheel, dashboard, or any other air bag system
components. Modifications can adversely
affect air bag system performance and
lead to injury.
• If the vehicle will be exposed to temperatures over 93 °C (200 °F) (for
example, during a paint baking process),
remove the air bag system components
beforehand to avoid component damage
or unintended air bag system activation.

Diagnosis
• When troubleshooting air bag system, be sure to follow “Diagnosis” in Air Bag System section.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacement.
• Never use electrical test equipment other than that specified.
WARNING!
Never attempt to measure the resistance of
the air bag (inflator) modules (driver,
passenger, side and curtain) and seat belt
pretensioners (driver and passenger). It is
very dangerous as the electric current from
the tester may deploy the air bag or activate
the pretensioner.

1. Air bag wire harness (in floor, main and instrument panel harness) 6. Driver air bag (inflator) module
2. Passenger air bag (inflator) module 7. Side air bag (inflator) module (if equipped)
3. SDM 8. Curtain air bag (inflator) module (if equipped)
4. Seat belt pretensioner 9. Forward sensor
5. Contact coil 10. Side sensor (if equipped)
1 2
3
4
4
5
6
7 7
8
9
10 10
I4RS0B000001-02
I4RS0A000002-02

Downloaded from www.Manualslib.com manuals search engine 00-3 Precautions:
WARNING!
SDM
• For handling and storage of a SDM, select a place where the ambient temperature
below 65 °C (150 °F), without high humidity
and away from electric noise.
• During service procedures, be very careful when handling a Sensing and Diagnostic
Module (SDM). Never strike or jar the SDM.
• Never power up the air bag system when the SDM is not rigidly attached to the
vehicle. All SDM and mounting bracket
fasteners must be carefully torqued and
the arrow must be pointing toward the
front of the vehicle to ensure proper
operation of the air bag system.
The SDM could be activated when powered
while not rigidly att ached to the vehicle
which could cause deployment and result
in personal injury.

WARNING!
Driver and Passenger Seat Belt
Pretensioners
• For handling and storage of a live seat belt pretensioner, select a place where the
ambient temperature below 65 °C (150 ° F),
without high humidity and away from
electric noise.
• Never carry seat belt pretensioner by wire or connector of pretensioner. When
placing a live seat belt pretensioner on the
workbench or some place like that, never
put something on seat belt pretensioner.
Otherwise, personal injury may result.
• Never dispose of live (inactivated) seat belt pretensioners (drive and passenger). If
disposal is necessary, be sure to activate
them according to activation procedures
described in “Air Bag (Inflator) Module and
Seat Belt Pretensioner Disposal in Section
8B” before disposal.
• The seat belt pretensioner immediately after activation is very hot. Wait for at least
half an hour to cool it off before
proceeding the work.
• With many service procedures, gloves and safety glasses should be worn to prevent
any possible irritation of the skin or eyes.

• Even when the accident was light enough not to cause air bags to activate, be sure to inspect system
parts and other related parts according to instructions
under “Repair and Inspection Required after Accident
in Section 8B”.
• When servicing parts other than air bag system, if shocks may be applied to air bag system component
parts, remove those parts beforehand.
• When handling the air bag (inflator) modules (driver, passenger, side and curtain), seat belt pretensioners
(driver and passenger), forward sensor, side sensors
or SDM, be careful not to drop it or apply an impact to
it. If an excessive impact was applied, never attempt
disassembly or repair but replace it with a new one.
• When grease, cleaning agent, oil, water, etc. has got onto air bag (inflator) modules (driver, passenger, side
and curtain) or seat belt pretensioners (drive and
passenger), wipe off immediately with a dry cloth.
• Air bag wire harness is included in floor and instrument panel wire harnesses. Air bag wire
harness branched off from floor and instrument panel
wire harnesses can be identifie d easily as it is covered
with a yellow protection tube and it has yellow
connectors. Be very ca reful when handling it.
• When an open in air bag wire harness, damaged wire harness, connector or terminal is found, replace wire
harness, connectors and terminals as an assembly.
• Do not apply power to the air bag system unless all components are connected or a diagnostic flow
requests it, as this will set a DTC.
• Never use air bag system component parts from another vehicle.
• When using electric welding, be sure to disconnect all air bag (inflator) module connectors and pretensioner
connectors from air bag wire harness respectively.
• Never expose air bag system component parts directly to hot air (drying or baking the vehicle after
painting) or flames.
• WARNING / CAUTION labels are attached on each
part of air bag system components. Be sure to follow
the instructions.
• After vehicle is completely repaired, perform “Air Bag Diagnostic System Check in Section 8B”.

Downloaded from www.Manualslib.com manuals search engine 0A-7 General Information:
Engine Supporting PointsS7RS0B0101006
WARNING!
When using engine supporting device (1), be
sure to observe the followings.
Otherwise, not only deformation of vehicle
body but also personal injury may result.
• Apply supporting device at the specified positions (2) indicated in figure
• Install supporting device taking a well- balanced posture.
• Do not contact supporting device with other parts than engine room body panel
and engine hooks.

Vehicle Identification NumberS7RS0B0101007
The number is punched close by the right side strut
support in engine room and it is also attached on the left
side of instrument panel depending on the vehicle
specification.
Engine Identification NumberS7RS0B0101008
The number is punched on cylinder block.
Transmission Identification NumberS7RS0B0101009
The automatic transmission identification number is
located on transmission case.
2
2
2
1
I4RS0A010005-01
I4RS0B010003-01
I3RM0A010005-01
I4RS0A010008-01

Downloaded from www.Manualslib.com manuals search engine 1A-26 Engine General Information and Diagnosis:
DTC CheckS7RS0B1104003
NOTE
• There are two types of OBD system depending on the vehicle specification.
For details, refer to “Precaution on On-
Board Diagnostic (OBD) System”.
• The MIL is turned on when the ECM and/or TCM detect malfunction(s). Each ECM and
TCM stores diagnostic information as the
diagnostic trouble code (DTC) in its
memory and outputs th e DTC to the scan
tool.
Therefore, check both of the ECM and TCM
for any DTC with the SUZUKI scan tool
because the DTC stored in ECM and TCM
is not read and displayed at a time.
However, each of the ECM and TCM needs
not to be checked with the generic scan
tool because the DTC stored in ECM and
TCM is read and displayed at a time.

Using Scan Tool
1) Prepare OBD generic scan tool or SUZUKI scan tool.
2) With ignition switch turned OFF, connect it to DLC (1) located on underside of instrument panel at
driver’s seat side.
Special tool
(A): SUZUKI scan tool
3) Turn ignition switch ON and confirm that MIL lights.
4) Read DTC, pending DTC and freeze frame data according to instructions displayed on scan tool and
print them or write them down. Refer to scan tool
operator’s manual for further details.
If communication between scan tool and ECM is not
possible, check if scan tool is communicable by
connecting it to ECM in another vehicle. If
communication is possible in this case, scan tool is
in good condition. Then check data link connector
and serial data line (circuit) in the vehicle with which
communication was not possible. If connector and
circuit are OK, check that power supply and ground
circuits of ECM and DLC are in good condition
referring to “ECM Power and Ground Circuit Check”. 5) After completing the check,
turn ignition switch OFF
and disconnect scan tool from data link connector.
Without Using Scan Tool (Hong Kong Model) 1) Turn ignition switch to OFF position.
2) Using service wire, ground diagnosis switch terminal (1) of diagnosis connector (2).
3) Turn ON ignition switch and check DTC displayed on
odometer (3) of combination meter.
When more than 2 DTCs are stored in memory,
blinking for each DTC star ts with the smallest DTC
number in increasing order. Also, DTC is indicated
repeatedly until the ignition switch is turned OFF or
disconnect service wire.
NOTE
When no DTC is detected, display on
odometer of combinatio n meter is “0000”.

4) After completing the check, turn ignition switch to
OFF position and disconnect service wire from
diagnosis connector.
(A)
1
I4RS0B110026-01
21
3
I5RS0C110009-01

Downloaded from www.Manualslib.com manuals search engine 6B-7 Steering Wheel and Column:
Steering Column Removal and InstallationS7RS0B6206006
CAUTION!
Once the steering column is removed from
the vehicle, the column is extremely
susceptible to damage.
• Dropping the column assembly on its end could collapse the steering shaft or loosen
the plastic shear pins which maintain
column length.
• Leaning on the column assembly could cause it to bend or deform.
Any of the damage could impair the column’s
collapsible design.
Steering column mounting nuts should not
be loosened with steering shaft joint upper
side bolt tightened as this could cause
damage to shaft joint bearing.

NOTE
When servicing steering column or any
column-mounted component, remove
steering wheel. But when removing steering
column simply to gain access to instrument
panel components, leave steering wheel
installed on steering column.

Removal
WARNING!
Never rest a steering column assembly on
the steering wheel with the air bag (inflator)
module face down and column vertical.
Otherwise, personal injury may result.

1) Disconnect negative (–) cable at battery.
2) Disable air bag system. Re fer to “Disabling Air Bag
System in Section 8B”.
3) Remove steering wheel and contact coil cable assembly referring to “S teering Wheel Removal and
Installation” and “Contact Coil Cable Assembly
Removal and Installation”.
4) Detach lighting switch and wiper switch from steering column.
5) Remove immobilizer cont rol module from steering
column, referring to “Immo bilizer Control Module
(ICM) Removal and Installation in Section 10C”.
6) Remove steering column hole cover.
7) Remove steering joint cover.
8) Make alignment marks (4) on lower shaft (1) and shaft joint of steering column (2) and lower shaft (1)
and pinion shaft (3) for a guide during reinstallation.
9) Remove lower shaf t joint bolts (5).
10) Remove steering lower shaft (1).
11) Remove steering column mounting nuts (1).
12) Remove steering column from vehicle.
I4RS0A620016-01
1
1
I4RS0A620017-01

Downloaded from www.Manualslib.com manuals search engine 6C-8 Power Assisted Steering System:
Step 2: DTC Check, Record and Clearance
First, check DTC, referring to “DTC Check”. If DTC is
indicated, print it or write them down and then clear them
by referring to “DTC Clearance”. DTC indicates
malfunction that occurred in the system but does not
indicate whether it exists now or it occurred in the past
and the normal condition has been restored now. To
check which case applies, check the symptom in
question according to Step 5 and recheck DTC
according to Step 6 and 7.
Attempt to diagnose a trouble based on DTC in this step
only or failure to clear the DTC in this step will lead to
incorrect diagnosis, trouble diagnosis of a normal circuit
or difficulty in troubleshooting.
Step 3 and 4: Visual Inspection
As a preliminary step, be sure to perform visual check of
the items that support proper function of the P/S system
referring to “Visual Inspection”.
Step 5: Trouble Symptom Confirmation
Based on information obtained in “Step 1: Customer
Complaint Analysis: ” and “S tep 2: DTC Check, Record
and Clearance: ”, confirm trouble symptoms. Also,
reconfirm trouble symptom by performing test drive and
turning steering wheel fully to right and left at stopped
vehicle.
Step 6 and 7: Rechecking and Record of DTC
Refer to “DTC Check” for checking procedure.
Step 8: Steering Symptom Diagnosis and P/S
System Symptom Diagnosis
Perform basic steering system check according to
“Steering Symptom Diagnosis in Section 6A” first. When
the end of the flow has been reached, check the parts of
the system suspected as a possible cause referring to
“P/S System Symptom Diagnosis” and based on
symptoms appearing on the vehicle (symptoms obtained
through steps of customer complaint analysis, trouble
symptom confirmation and/or basic P/S system check)
and repair or replace faulty parts, if any.
Step 9: Troubleshooting for DTC (See each DTC
Diag. Flow)
Based on the DTC indicated in Step 6 or 7 and referring
to the applicable DTC diag. flow, locate the cause of the
trouble, namely in a sensor, switch, wire harness,
connector, actuator, P/S control module or other part and
repair or replace faulty parts.
Step 10: Intermittent Problems Check
Check parts where an intermittent trouble is easy to
occur (e.g., wire harness, connector, etc.), referring to
“Intermittent and Poor Connection Inspection in Section
00” and related circuit of DTC recorded in Step 2. Step 11: Final Confirmation Test
Confirm that the problem symptom has gone and the P/
S system is free from any abnormal conditions. If what
has been repaired is related to the DTC, clear the DTC
once, perform DTC confirmation procedure and confirm
that no DTC is indicated.
“EPS” Warning Light CheckS7RS0B6304002
1) Turn ignition switch to ON position (without engine
running) and chec k if the “EPS” warning light (1)
lights up. If the light dose not light up, go to ““EPS”
Warning Light Does Not Come ON with Ignition
Switch Turned ON before Engine Starts” of the
diagnostic flows.
2) Start engine and check if the “EPS” warning light turns OFF. If light remains ON and no DTC is stored
in P/S control module, go to ““EPS” Warning Light
Remains ON Steady after Engine Starts” for
troubleshooting.
DTC CheckS7RS0B6304003
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector (DLC) (1) located on underside of instrument panel
at driver’s seat side.
Special tool
(A): SUZUKI scan tool
1
I6RS0C630002-01
(A)
1
I4RS0B450003-01

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-9
3) Start engine.
4) Read DTC according to the instructions displayed on
SUZUKI scan tool. For further details, refer to
operator’s manual for SUZUKI scan tool.
NOTE
• If communication between SUZUKI scan tool and the vehicle can not be
established, perform “Serial Data Link
Circuit Check”.
• DTC C1122 (engine speed signal failure) is indicated when ignition switch is at ON
position and engine is not running, but it
means there is nothing abnormal if
indication changes to a normal one when
engine is started.

5) After completing the check, turn ignition switch to
OFF position and disconnect SUZUKI scan tool from
DLC.
DTC ClearanceS7RS0B6304004
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector (DLC) (1) located on underside of instrument panel
at driver’s seat side.
Special tool
(A): SUZUKI scan tool
3) Turn ignition switch to ON position.
4) Erase DTC according to the instructions displayed on SUZUKI scan tool. For further details, refer to
operator’s manual for SUZUKI scan tool.
5) After completing the clearance, turn ignition switch to OFF position and disconnect SUZUKI scan tool from
DLC.
DTC TableS7RS0B6304005
CAUTION!
Be sure to perform the “EPS Syst em Check” before starting troubleshooting corresponding to each
DTC.

(A)
1
I4RS0B450003-01
DTC No. Detecting item Detecting condition
(DTC will set when detecting) Trouble area MIL
No
CODES Normal — — —
) C1113 Steering torque sensor (Main
and Sub) circuit correlation Voltage difference between torque
sensor main signal and sub signal
is more than 0.6 V for 1 second
continuously. • Torque sensor signal circuit
• Torque sensor
• P/S control module
1 driving
cycle
) C1114 Steering torque sensor
reference power supply
circuit Circuit voltage of torque sensor 5
V reference power supply voltage
is more than 5.7 V or less than 4.3
V for 1 second continuously. • Torque sensor circuit
• Torque sensor
• P/S control module
1 driving
cycle
) C1117 Steering torque sensor
failure signal circuit low Torque sensor internal failure
signal circuit voltage is less than
1.7 V when ignition switch turned
ON.
• Torque sensor signal circuit
• Torque sensor
• P/S control module1 driving
cycle
) C1118 Steering torque sensor
failure signal circuit high Torque sensor internal failure
signal circuit voltage is more than
3.7 V for 1 second continuously. 1 driving
cycle
) C1119 Steering torque sensor
power supply circuit Circuit voltage of torque sensor
main power supply
is less than
7.5 V for 1 second continuously. • Torque sensor circuit
• Torque sensor
• P/S control module
1 driving
cycle

Downloaded from www.Manualslib.com manuals search engine 7A-4 Heater and Ventilation:
Repair Instructions
HVAC Unit ComponentsS7RS0B7106001
For manual type A/C, refer to “HVAC Unit Components
in Section 7B”.
For automatic type A/C, refer to “HVAC Unit
Components in Section 7B”.
HVAC Unit Removal and InstallationS7RS0B7106002
Removal
1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove cowl top panel from vehicle body referring to “Cowl Top Components in Section 9K”.
4) Drain engine coolant, and then disconnect heater hoses (1) from HVAC unit (2).
5) Remove instrument panel from vehicle body referring to “Instrument Panel Removal and
Installation in Section 9C”.
6) Remove nuts (3).
7) Remove HVAC unit from vehicle body.
Installation
Reverse removal procedure noting the following
instructions.
• Be careful not to catch any cable and wiring harness in inappropriate position.
• Adjust control cables of HVAC control unit referring to “HVAC Control Unit Remo val and Installation”.
• Fill engine coolant to radiator.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Blower Motor Removal and InstallationS7RS0B7106003
Removal
1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Disconnect connector (1) from blower motor (2).
4) Remove blower motor from HVAC unit by removing screws (3).
Installation
Reverse removal procedure noting the following
instruction.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Blower Motor InspectionS7RS0B7106004
• Check for continuity between two terminals as shown. If there is no continuity, replace blower motor.
3
2
3
1
3I4RS0B710004-01
3
1
2
3
3
I4RS0B710005-01
I4RS0A710006-01

Downloaded from www.Manualslib.com manuals search engine Heater and Ventilation: 7A-5
• Check for operation and current.a. Put blower motor (1) in a soft-jawed vise.
b. Connect battery to blower motor as shown.
c. Check if blower motor operates smoothly without noise.
d. Check if ammeter indicates the specified current. If measured current is out of specification, replace
blower motor.
Blower motor specified current at 12 V
16 A maximum
Blower Motor Resistor Removal and InstallationS7RS0B7106005
Removal
1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove glove box from instrument panel.
4) Remove bolts (1) from instrument panel.
5) Remove foot duct (1) from HVAC unit by removing screw (2). 6) Remove connector (1) from blower motor resistor
(2), and then remove blower motor resistor from
HVAC unit by removing screws (3).
Installation
Reverse removal procedure noting the following
instruction.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Blower Motor Resistor InspectionS7RS0B7106006
Measure each terminal-to-terminal resistance. If
measured resistance is out of specification, replace
blower motor resistor.
Blower motor resistor resistance
“H” – “MH”: Approximately 0.6 Ω at 20 – 25 °C (68 –
77 °F)
“MH” – “ML”: Approximately 1.6 Ω at 20 – 25 °C (68 –
77 °F)
“ML” – “L”: Approximately 3.4 Ω at 20 – 25 °C (68 –
77 °F)
1
I4RS0A710007-01
11I4RS0B710006-01
12I4RS0B710007-01
1
3
23
I4RS0A710010-01
MHL
HMLI4RS0B710024-01

Downloaded from www.Manualslib.com manuals search engine Heater and Ventilation: 7A-7
HVAC Control Unit Removal and InstallationS7RS0B7106009
Removal1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove passenger air bag module from instrument panel referring to “Passenger Air Bag (Inflator)
Module Removal and Installation in Section 8B”.
4) Remove radio assembly from instrument panel referring to “Audio Unit Re moval and Installation in
Section 9C”.
5) Remove driver side foot duct (1) from HVAC unit by removing screw (2).
6) Disconnect temperature control cable (1) and air flow control cable (2) from HVAC unit. 7) Remove two connectors from HVAC control unit.
8) Remove HVAC control unit (1) from instrument
panel.
NOTE
Be careful not to damage HVAC control unit
and instrument panel by using rag.

Installation
Reverse removal procedure noting the following
instructions.
• Connect temperature control cable and air flow control
cable of HVAC control unit to links of HVAC unit.
a. For LH steering vehicle, set air flow selector (1) to “DEF” position and temperature selector (2) to
“MAX HOT” position.
For RH steering vehicle, set air flow selector (1) to
“VENT” position and temperature selector (2) to
“MAX COOL” position.
[A]: LH steering vehicle [B]: RH steering vehicle
2
1
I4RS0B710010-01
2
1
1
2
[B] [A]
I4RS0B710011-01
1
I4RS0B710012-01
12I4RS0B710013-01
12I4RS0A710016-01