warning SUZUKI SWIFT 2000 1.G SF310 Service Workshop Manual

IMPORTANT
WARNING / CAUTION / NOTE
Please read this manual and follow its instructions
carefully. To emphasize special information, the
words WARNING, CAUTION and NOTE have spe-
cial meanings. Pay special attention to the messages
highlighted by these signal words.
NOTE:
Indicates special information to make mainte-
nance easier or instructions clearer.
WARNING:
Indicates a potential hazard that could result
in death or injury.
CAUTION:
Indicates a potential hazard that could result
in vehicle damage.
WARNING:
This service manual is intended for authorized
SUZUKI dealers and qualified service me-
chanics only. Inexperienced mechanics or
mechanics without the proper tools and
equipment may not be able to properly per-
form the services described in this manual.
Improper repair may result in injury to the me-
chanic and may render the vehicle unsafe for
the driver and passengers.

GENERAL INFORMATION 0A-1
0ASECTION 0A
GENERAL INFORMATION
CONTENTS
HOW TO USE THIS MANUAL0A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS0A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System 0A- 3. . . . . . . . . . . . . . . .
General Precautions0A- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Catalytic Converter 0A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Electrical Circuit Service 0A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Circuit Inspection Procedure 0A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermittent and Poor Connection 0A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precaution for Installing Mobile Communication Equipment 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precaution in Servicing Full-Time 4WD Vehicle 0A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDENTIFICATION INFORMATION0A-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Identification Number0A-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Whether Vehicle Equipped with WU-TWC or Not 0A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Identification Number0A-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Identification Number 0A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING, CAUTION AND INFORMATION LABELS0A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE LIFTING POINTS0A-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL0A-22 . . . . . . . . . . . . . . . . . . . . . . . . . . .
FASTENER INFORMATION0A-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric Fasteners0A-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fasteners Strength Identification 0A-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tightening Torque0A-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Air bag wire harness
2. Driver air bag (inflator) module
3. Passenger air bag (inflator) module
4. SDM
GENERAL INFORMATION 0A-3
PRECAUTIONS
PRECAUTION FOR VEHICLES EQUIPPED
WITH A SUPPLEMENTAL RESTRAINT (AIR
BAG) SYSTEM
WARNING:

The configuration of air bag system parts are as shown in
the figure. When it is necessary to service (remove, rein-
stall and inspect) these parts, be sure to follow proce-
dures described in Section 9J. Failure to follow proper
procedures could result in possible air bag deployment,
personal injury, damage to parts or air bag being unable
to deploy 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 deploy-
ment.

Do not modify the steering wheel, dashboard, or any other
air bag system component. Modifications can adversely
affect air bag system performance and lead to injury.

If the vehicle will be exposed to temperatures over 93C,
200F (for example, during a paint baking process), re-
move the air bag system components (air bag (inflator)
modules, sensing and diagnostic module) beforehand to
avoid component damage or unintended deployment.
DIAGNOSIS

When troubleshooting air bag system, be sure to follow
“DIAGNOSIS” in Section 9J. Bypassing these procedures
may result in extended diagnostic time, incorrect diagnosis,
and incorrect parts replacement.

Never use electrical test equipment other than that specified
in this manual.
WARNING:
Never attempt to measure the resistance of the air bag (in-
flator) modules (driver and passenger). It is very dangerous
as the electric current from the tester may deploy the air
bag.

1. Slit on workbench
2. Workbench vise
3. Lower mounting bracket
ALWAYS CARRY AIR BAG (INFLATOR) MODULE
WITH TRIM COVER (AIR BAG OPENING) AWAY
FROM BODY.
ALWAYS PLACE AIR BAG (INFLATOR) MODULE
ON WORKBENCH WITH TRIM COVER (AIR BAG
OPENING) UP, AWAY FROM LOOSE OBJECTS.
0A-4 GENERAL INFORMATION
HANDLING AND SERVICING
WARNING:

Many of service procedures require disconnection of
“AIR BAG” fuse and air bag (inflator) modules (driver and
passenger) from deployment loop to avoid an accidental
deployment.
Driver and Passenger Air Bag (Inflator) Modules

For handling and storage of a live air bag (inflator) module,
select a place where the ambient temperature below 65C
(150F), without high humidity and away from electric
noise.

When carrying a live air bag (inflator) module, make sure
the bag opening is pointed away from you. In case of an
accidental deployment, the bag will then deploy with mini-
mal chance of injury. Never carry the air bag (inflator)
module by the wires or connector on the underside of the
module. When placing a live air bag (inflator) module on
a bench or other surface, always face the bag up, away
from the surface. As the live passenger air bag (inflator)
module must be placed with its bag (trim cover) facing up,
place it on the workbench with a slit or use the workbench
vise to hold it securely at its lower mounting bracket. This
is necessary so that a free space is provided to allow the
air bag to expand in the unlikely event of accidental de-
ployment. Otherwise, personal injury may result.

Never dispose of live (undeployed) air bag (inflator) mod-
ules (driver and passenger). If disposal is necessary, be
sure to deploy them according to deployment procedures
described in Section 9J before disposal.

The air bag (inflator) module immediately after deploy-
ment is very hot. Wait for at least half an hour to cool it off
before proceeding the work.

After an air bag (inflator) module has been deployed, the
surface of the air bag may contain a powdery residue.
This powder consists primarily of cornstarch (used to lu-
bricate the bag as it inflates) and by-products of the chem-
ical reaction. As with many service procedures, gloves
and safety glasses should be worn.
SDM

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 ve-
hicle to ensure proper operation of the air bag system. The
SDM could be activated when powered while not rigidly at-
tached to the vehicle which could cause deployment and
result in personal injury.

GENERAL INFORMATION 0A-5
CAUTION:

Even when the accident was light enough not to cause air
bags to deploy, be sure to inspect system parts and other
related parts according to instructions under “Repair and
Inspection Required after an Accident” in Section 9J.

When servicing parts other than air bag system, if shocks
may be applied to air bag system component parts, re-
move those parts beforehand.

When handling the air bag (inflator) modules (driver and
passenger) or SDM, be careful not to drop it or apply an im-
pact to it. If an excessive impact was applied (e.g.,
dropped from a height of 91.4 cm (3 feet) or more), 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 and passenger), wipe off
immediately with a dry cloth.

Air bag wire harness can be identified easily as it is cov-
ered with a yellow protection tube. Be very careful when
handling it.

When an open in air bag wire harness, damaged wire har-
ness, connector or terminal is found, replace wire har-
ness, connectors and terminals as an assembly.

Do not apply power to the air bag system unless all com-
ponents are connected or a diagnostic chart requests it,
as this will set a diagnostic trouble code.

Never use air bag system component parts from another
vehicle.

When using electric welding, be sure to temporarily dis-
able air bag system referring to “Disabling Air Bag Sys-
tem” under “Service Precaution” in Section 9J.

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 instruc-
tions.

After vehicle is completely repaired, perform “Air Bag
Diagnostic System Check” described in “Diagnosis” in
Section 9J.

0A-6 GENERAL INFORMATION
GENERAL PRECAUTIONS
The WARNING and CAUTION below describe some general precautions that you should observe when servicing
a vehicle. These general precautions apply to many of the service procedures described in this manual, and they
will not necessarily be repeated with each procedure to which they apply.
WARNING:

Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING
POINTS” on SECTION 0A.

When it is necessary to do service work with the engine running, make sure that the parking brake
is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for automatic
transmission vehicles). Keep hands, hair, clothing, tools, etc. away from the fan and belts when the
engine is running.

When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.

Do not perform service work in areas where combustible materials can come in contact with a hot
exhaust system. When working with toxic or flammable materials (such as gasoline and refrigerant),
make sure that the area you work in is well-ventilated.

To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail-
pipe, muffler, etc.

New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or
used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory animals.
Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a
long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing engine
oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or
rags if wet with oil, recycle or properly dispose of used oil and filters.

Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly
during driving, obstructing your view and resulting in an accident.
CAUTION:

Before staring any service work, cover fenders, seats and
any other parts that are likely to get scratched or stained dur-
ing servicing. Also, be aware that what you wear (e.g. but-
tons) may cause damage to the vehicle’s finish.

When performing service to electrical parts that does not re-
quire use of battery power, disconnect the negative cable of
the battery.

NOTE:
Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only.
Air bag
caution
labelTire information
placard
Child lock caution label
Fuel limitation
Emission control
information label
(if equipped)
A / C warning label
(if equipped with A / C)
Engine cooling fan
warning label
Air bag warning label on driver air bag
(inflator) module
Air bag warning label on combination
switch / contact coil assembly
Air bag caution label
on steering columnAir bag warning
label on passenger
air bag (inflator)
module
Air bag warning
label on SDMRadiator cap
warning label
GENERAL INFORMATION 0A-19
WARNING, CAUTION AND INFORMATION LABELS
The figure below shows main labels among others that are attached to vehicle component parts.
When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels.
If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.

1. Front left tire
2. Rear left tire
3. Front
4. Front fender left panel
5. Rear left panel
6. Embossed-mark
When using frame contact hoist:
Front Support Location Rear Support Location
11 0 m m
(4.3 in.)
SUPPORT LOCATION
Forward of embossed-mark120 mm
(4.7 in.)
SUPPORT LOCATION
Rearward of embossed-mark
: Support position for frame contact hoist and safety stand
: Floor jack position Bolt
0A-20 GENERAL INFORMATION
VEHICLE LIFTING POINTS
WARNING:

Before applying hoist to underbody, always take vehicle balance throughout service into consider-
ation. Vehicle balance on hoist may change depending of what part to be removed.

Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe,
fuel pipe, bracket or any other part.

When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up the
vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by trying to
move vehicle body in both ways. Work can be started only after this confirmation.

Make absolutely sure to lock hoist after vehicle is hoisted up.

When using floor jack:
GENERAL INFORMATION 0A-21
In raising front or rear vehicle end off the floor by jacking, be sure
to put the jack against the center portion of front cross member (1)
or rear cross member (2).
WARNING:

Never apply jack against suspension parts (i.e., stabilizer,
etc.) or vehicle floor, or it may get deformed.

If the vehicle to be jacked up only at the front or rear end,
be sure to block the wheels on ground in order to ensure
safety.
After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on the
vehicle raised on jack alone.
To perform service with either front or rear vehicle end jacked up,
be sure to place safety stands under body so that body is securely
supported. And then check to ensure that body does not slide on
safety stands and the vehicle is held stable for safety’s sake.

0B
MAINTENANCE AND LUBRICATION 0B-1
SECTION 0B
MAINTENANCE AND LUBRICATION
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 autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” 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).
CONTENTS
MAINTENANCE SCHEDULE0B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Condition Schedule0B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Recommended Under Severe Driving Conditions 0B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SERVICE0B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine0B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System0B-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System0B-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emission Control System0B-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake0B-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis and Body0B-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Inspection0B-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECOMMENDED FLUIDS AND LUBRICANTS0B-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .