ECU SUZUKI SWIFT 2000 1.G Transmission Service User Guide

7D-4 TRANSFER
UNIT REPAIR OVERHAUL
1. Transfer left case 11. Bevel gear shim 21. Driven gear bearing
2. Transfer right case 12. Bevel gear (Hypoid gear) 22. Reduction drive gear bearing
3. Transfer output retainer 13. Bevel pinion shaft (Hypoid gear) 23. Flange nut
: After tightening nut so as rotation torque
of bevel pinion shaft to be in specified
value, caulk nut securely.
4. O-ring
: Apply grease 99000-25010 to all
around surface14. Reduction driven gear 24. Stiffener
5. Bevel pinion shim 15. Flange 25. Intermediate right bearing
6. Drain plug
: Apply sealant 99000-31230 to all
around thread part of drain plug16. Pinion shaft spacer Do not reuse.
7. Level plug
: Apply sealant 99000-31230 to all
around thread part of level plug17. Reduction drive gear Tightening torque
8. Intermediate shaft 18. Circlip Apply transfer oil.
9. Oil seal
: Apply SUZUKI SUPER GREASE A
99000-25010 to oil seal lip.19. Snap ring
10. Pinion shaft bearing 20. Bevel gear nut
: After tightening nut to specified
torque, caulk nut securely

REAR DIFFERENTIAL 7F-3
DIAGNOSIS
Condition Possible Cause Correction
Gear noise
Deteriorated or water mixed lubricant Repair and replenish.
Inadequate or insufficient lubricant Repair and replenish.
Maladjusted backlash between bevel pinion
and gearAdjust and prescribed.
Improper tooth contact in the mesh between
bevel pinion and gearAdjust or replace.
Loose bevel gear securing bolts Replace or retighten.
Damaged side gear(s) or side pinion(s) Replace.
Bearing noise
(Constant noise) Deteriorated or water mixed
lubricantRepair or replenish.
(Constant noise) Inadequate or insufficient
lubricantRepair or replenish.
(Noise while coasting) Damaged bearing(s) of
bevel pinionReplace.
(Noise while turning) Damaged differential side
bearing(s)Replace.
Oil leakage
Clogged breather plug Clean.
Worn or damaged oil seal Replace.
Excessive oil Adjust oil level.

REAR DIFFERENTIAL 7F-5
UNIT REPAIR OVERHAUL
22 80 Nm (8.2 kg-m) 1513
17 16
15 12
14 7
22
22 2121
2020
1918 18
16 3 10 70-250 Nm (7.0-25.0 kg-m)
23 Nm (2.3kg-m)
23 Nm (2.3kg-m)
8
5
10
2611
23 Nm (2.3kg-m)
9
4
1 130 Nm(13.0 kg-m)
3
1. Companion flange nut
: After tightening nut to specified torque,
caulk nut securely.10. Drive bevel pinion nut
: After tightening nut to specified torque,
caulk nut securely.19. Differential pinion shaft
2. Companion flange 11. Viscous coupling 20. Differential pinion
3. Oil seal
: Apply grease 99000-25010 to oil seal
lip.12. Drive bevel gear (hypoid gear) 21. Differential pinion washer
4. Coupling case 13. Drive bevel pinion gear (hypoid gear) 22. Bevel gear bolt
: Apply thread lock cement 99000-
32110 to thread part of bolt.
5. Differential input hub 14. Differential case Do not reuse.
6. Bearing 15. Differential side bearing Tightening torque
7. Spacer 16. Pinion shaft bearing Apply differential oil
8. Differential carrier 17. Bevel pinion shim
9. Rear differential input flange 18. Differential gear

IMMOBILIZER CONTROL SYSTEM 8G-23
HOW TO REGISTER IGNITION KEY
Register the ignition key with a built-in transponder in Immobilizer
Control Module by using the following procedure.
1) Prepare SUZUKI scan tool and cartridge for immobilizer con-
trol system.
2) With ignition switch OFF, connect SUZUKI scan tool to data
link connector (DLC) (1) located on underside of instrument
panel at driver’s seat side.
(A) : 09931-76011 (SUZUKI scan tool)
(B) : Immobilizer cartridge
(C) : 09931-76030 (16/14 pin DLC cable)
3) Prepare ignition key with a built-in transponder (1). And then
turn ignition switch ON by using it.
4) Number of Transponder codes for ignition key with a built-in
transponder that can be registered in Immobilizer Control
Module is limited to 4. If needed, clear all Transponder
codes for ignition key with a built-in transponder that have
been registered in Immobilizer Control Module by executing
the “CLR. TRANS COD (CLEAR TP CODE)” command in
the SELECT MODE menu by using SUZUKI scan tool. CAUTION:
When registering the ignition key including a transpon-
der into the immobilizer control module by using Suzuki
scan tool, confirm that the knob color of the ignition key
to be registered for the vehicle is dark gray. The ignition
key with wrong knob color cannot be registered.
NOTE:
For operation procedure of SUZUKI scan tool, refer to
SUZUKI scan tool operator’s manual.
1
(C)(A)
(B)
NOTE:
When “CLR. TRANS COD (CLEAR TP CODE)” command
is executed with the immobilizer indicator lamp ON, it
remains ON even after execution of that command is
over. It will start flashing when the ignition switch is
turned OFF once and then turned ON after some sec-
onds.

8G-24 IMMOBILIZER CONTROL SYSTEM
5) Using SUZUKI scan tool, register Transponder code in
Immobilizer Control Module by executing “ENT. TRANS
COD (ENT. TP CODE)” command in SELECT MODE menu.
6) Make sure that immobilizer indicator lamp lights when igni-
tion switch is turned OFF once and then ON.
7) If any other Transponder code for ignition key with a built-in
transponder needs to be registered, repeat above steps 3),
5) and 6).
PROCEDURE AFTER IMMOBILIZER CONTROL MODULE
REPLACEMENT
When Immobilizer Control Module was replaced, including when replaced because rechecking by using a
known-good Immobilizer Control Module was necessary during trouble diagnosis, register Transponder code
and ECM/Immobilizer Control Module code in Immobilizer Control Module and ECM/Immobilizer Control Module
code in ECM by performing following procedure.
1) Perform steps 1) and 2) described in “How To Register Ignition Key”.
2) Prepare ignition key with a built-in transponder. And then turn ignition switch ON by using it.
3) Using SUZUKI scan tool, clear all transponder codes registered in Immobilizer Control Module by executing
“CLR. TRANS COD (CLEAR TP CODE)” command in SELECT MODE menu.
4) Using SUZUKI scan tool, register Transponder code in Immobilizer Control Module by executing “ENT.
TRANS COD (ENT. TP CODE)” command in SELECT MODE menu.
5) Using SUZUKI scan tool, register ECM/Immobilizer Control Module code in both Immobilizer Control Module
and ECM by executing “RECORD ECU (RECORD ECM/PCM/ICM)” command in SELECT MODE menu.
6) Make sure that immobilizer indicator lamp lights when ignition switch is turned OFF once and then ON.
7) If any other Transponder code for ignition key with a built-in transponder needs to be registered, repeat
above steps 2), 4) and 6).NOTE:
Up to 4 Transponder codes for ignition key with a built-
in transponder can be registered.
It is not possible to register the same Transponder
code for ignition key with a built-in transponder as the
one already registered in Immobilizer Control Module.
CAUTION:
When registering the ignition key including a transponder into the immobilizer control module by
using Suzuki scan tool, confirm that the knob color of the ignition key to be registered for the vehicle
is dark gray. The ignition key with wrong knob color cannot be registered.
NOTE:
When “CLR. TRANS COD (CLEAR TP CODE)” command is executed with the immobilizer indicator
lamp ON, it remains ON even after execution of that command is over. It will start flashing when the
ignition switch is turned OFF once and then turned ON after some seconds.

IMMOBILIZER CONTROL SYSTEM 8G-25
PROCEDURE AFTER ECM REPLACEMENT
When ECM was replaced, including when replaced because rechecking by using a known-good ECM was nec-
essary during trouble diagnosis, register ECM/Immobilizer Control Module code in ECM by performing following
procedure.
1) Perform steps 1) and 2) described in “How To Register Ignition Key”. And then turn ignition switch ON.
2) Using SUZUKI scan tool, register ECM/Immobilizer Control Module code in ECM by executing “RECORD
ECU (RECORD ECM/lCM)” command in SELECT MODE menu.
3) Make sure that malfunction indicator lamp lights when ignition switch is turned OFF once and then ON.
SPECIAL TOOL
NOTE:
Up to 4 Transponder codes for ignition key with a built-in transponder can be registered.
It is not possible to register the same Transponder code for ignition key with a built-in transponder
as the one already registered in Immobilizer Control Module.
NOTE:
For operation procedure of SUZUKI scan tool, refer to SUZUKI scan tool operator’s manual.
09931-76011 09931-76030
Tech 1A kit
See NOTE below.Immobilizer cartridge of
version 1.1 or more16/14 pin DLC cable Mass storage cartridge of
version 1.5 or more
NOTE:
This kit includs the following items.
1. Storage case, 2. Operator’s manual, 3. Tech 1A, 4. DLC cable, 5. Test lead/probe,
6. Power source cable, 7. DLC cable adaptor, 8. Self-test adaptor

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.

BODY SERVICE 9-5
Adjust equalizer (1) of window regular so that measurement
“a” and “b” are equal.
Secure door sealing cover (1) with adhesive (2).
Install door window regulator handle (1) so that it has a 45°
±12.5° angle when glass is fully closed as shown in figure
1 “a”“b”
1
2
A : Front

9-10 BODY SERVICE
8) Remove rear door outer garnish (1).
9) Remove outer weather-strip (2).
Lower window all the way down. Then, use a tape-wrapped
putty knife (or screwdriver) to pry off outer weather-strip.
10) Detach rear part of glass run (1) from sash (2) and remove
sash (2) by removing 2 screws (3).
11) Loosen window regulator mounting screws (5).
12) When removing door glass (4), turn door glass 90° counter-
clockwise to remove it.
INSTALLATION
Reverse removal procedure to install door glass noting the follow-
ing instructions.
If there is deformity for glass run, replace new one.
Tighten bottom channel attaching screws. Tighten rear
screw first, and then tighten front screw.
Glass fitted position of bottom channel (1) is as shown in fig-
ure.
Glass fitted position of bottom channel
“a” : 201.9 - 204.9 mm (7.95 - 8.07 in.)
Secure door sealing cover (1) with adhesive (2). NOTE:
When removed outer weather-strip (2) from door panel
(3), be careful not to deformation for outer weather-strip
(2).
2 3
1
4
1
23
5
4
1
2

BODY SERVICE 9-17
QUARTER WINDOW
REMOVAL AND INSTALLATION
Refer to “WINDSHIELD” in this section as removal and installa-
tion procedures are basically the same. However, note the follow-
ing.
Observe the following precautions when applying adhesive
(1) along glass (2) edge.
Adhesive (1) should be applied evenly especially in height.
Be careful not to damage primer (3).
Press glass against body quickly after adhesive (1) is
applied.
Adhesive amount specification and position for quarter
window
Height “a” : 13 mm (0.51 in.)
Width “b” : 6 mm (0.24 in.)
Width “c” : 14 mm (0.55 in.)
Position “d” : 5 mm (0.20 in.) for glass front section.
Position “e” : 11 mm (0.43 in.) for glass rear and upper
sections
Position “e” : 8 mm (0.31 in.) for 3 door model glass bot-
tom section
Position “e” : 10 mm (0.39 in.) for 5 door model glass bot-
tom section CAUTION:
Upon completion of installation, note the following.
Sudden closing of door before adhesive is completely
set may cause glass to become loose or to come off.
Therefore, if door is opened or closed before adhesive
is completely set, make sure to open all door glasses
and use proper care.
If molding is not securely in place, hold it down with a
tape until adhesive is completely set.
Each adhesive has its own setting time.
Be sure to refer to its maker’s instruction, check set-
ting time of adhesive to be used and observe precau-
tions to be taken before adhesive is set.
Refrain from driving till adhesive is completely set so
as to ensure proper and sufficient adhesion.
[A] : 3-door model
[B] : 5-door model
“A”
“A”“B”
“B”
“B”
“B”
“B”“B”
11
22
2
33 “d”
“c”“c”“e”
“a”“a”
“b”“b”
11
2 “A”“B”
[A]
[B]