lock SUZUKI SWIFT 2000 1.G Transmission Service Repair Manual

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

REAR DIFFERENTIAL 7F-13
2) If thrust play is out of specification, select suitable side
washer from among following available size, install it and
check again that specified gear play is obtained.
Available side washer thickness
0.90, 1.00 and 1.10 mm (0.035, 0.039 and 0.043 in.)
3) Put drive bevel gear (1) on differential case (2) and fasten
them with bolts (3) by tightening them to specified torque.
Use thread lock cement for bolts (3).
“A” : Thread lock cement 99000-32110
Tightening torque
Drive bevel gear bolts (a) : 80 N·m (8.0 kg-m, 58.0 lb-ft)
4) Press-fit differential side bearings (3) to differential case (1)
by using special tools.
Special tool
(A) : 09951-76010
(B) : 09951-16060 CAUTION:
Use of any other bolts than that specified is prohibited.
2
1 3, “A”, (a)
2. Drive bevel gear

7F-16 REAR DIFFERENTIAL
8) Place zero-adjusted mounting dummy (1) and dial gauge set
on pinion dummy (2) and take measurement between zero
position and extended dial gauge measuring tip.
9) Obtain adjusting shim thickness by using measured value by
dial gauge in the following equation.
10) Select adjusting shim(s) (1) closest to calculated value from
among following available sizes and put it in place and then
press-fit rear bearing.
Special tool
(A) : 09913-80112
Available shim thickness
“a” : 0.30, 1.00, 1.03, 1.06, 1.09, 1.12, 1.15, 1.18, 1.21, 1.24,
1.27, and 1.30 mm (0.012, 0.039, 0.041, 0.042, 0.043, 0.044,
0.045, 0.046, 0.048, 0.049, 0.050 and 0.051 in.)
11) With new pinion spacer (3) inserted as shown, install front
bearing to differential carrier. NOTE:
 Repeat turning back and forth of dummy and measure
distance as far as top surface of pinion dummy accu-
rately.
 When dial gauge measuring tip extends from 0 (zero)
position, pointer turns counterclockwise.
 Measured value may exceed 1 mm. Therefore, it is also
necessary to know reading of short pointer.
Necessary shim thickness = Dial gauge measured value C
1. Drive bevel pinion mounting dummy
2. Drive bevel pinion dummy
C
1
2
NOTE:
 Make sure to use new spacer for reinstallation.
 Apply oil to bearings.
1. Drive bevel pinion
2. Rear bearing

REAR DIFFERENTIAL 7F-21
REQUIRED SERVICE MATERIAL
SPECIAL TOOL
MaterialRecommended SUZUKI product
(Part Number)Use
Thread lock cement THREAD LOCK CEMENT 1322
(99000-32110)Bevel gear bolts
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Oil seal lips
Sealant SUZUKI BOND NO. 1215
(99000-31110)Thread part of differential carrier bolt
Mating surface of differential housing
Mating surface of rear axle housing
Mating surface of viscous coupling case
09951-16060 09951-76010 09927-28010 09925-88210
Lower arm bush remover Bearing installer Bevel pinion holder Bearing puller attachment
09913-60910 09913-80112 09900-20701 09900-20606
Bearing puller Bearing installer Magnetic stand Dial gauge
09922-76140 09922-76150 09922-76330 09922-76430
Bevel pinion shaft Bevel pinion nut Rear collar Front collar

7F-22 REAR DIFFERENTIAL
09922-76350 09922-76120 09922-76250 09924-74510
Gauge block Dummy shaft Bevel gear dummy Bearing installer handle
09925-68210 09925-98210 09924-84510-002 09930-40113
Bearing installer Bearing installer Bearing installer Flange holder
09913-65135 09913-50121
Bearing puller Oil seal remover

BODY ELECTRICAL SYSTEM 8-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8
8D
8E
9
10
10A
10B
SECTION 8
BODY ELECTRICAL SYSTEM
CONTENTS
DIAGNOSIS ........................................................ 8-3
HEADLIGHT .................................................... 8-3
HEADLIGHTS WITH LEVELING SYSTEM
(IF EQUIPPED) ............................................... 8-3
TURN SIGNAL AND HAZARD WARNING
LIGHT .............................................................. 8-3
CLEARANCE, TAIL AND LICENSE
PLATE LIGHT ................................................. 8-4
BACK-UP LIGHT ............................................. 8-4
BRAKE LIGHT ................................................ 8-4
FRONT FOG LIGHT (IF EQUIPPED) ............. 8-4
REAR FOG LIGHT (IF EQUIPPED) ................ 8-4
SPEEDOMETER AND VSS ............................ 8-5
FUEL METER AND FUEL LEVEL SENSOR
(GAUGE UNIT) ............................................... 8-5
ENGINE COOLANT TEMPERATURE (ECT)
METER AND ECT SENSOR ........................... 8-5
OIL PRESSURE WARNING LIGHT ................ 8-5
BRAKE AND PARKING BRAKE WARNING
LIGHT .............................................................. 8-6
REAR WINDOW DEFOGGER ........................ 8-6
WIPERS AND WASHERS .............................. 8-6
FRONT WIPER AND WASHER .................. 8-6
REAR WIPER AND WASHER (IF
EQUIPPED)................................................. 8-6
POWER WINDOW CONTROL SYSTEM
(IF EQUIPPED) ............................................... 8-7
CIGARETTE LIGHTER ................................... 8-7
POWER DOOR LOCK CONTROL SYSTEM
(IF EQUIPPED) ............................................... 8-7
KEYLESS ENTRY SYSTEM (IF
EQUIPPED) .................................................... 8-7POWER DOOR MIRROR CONTROL
SYSTEM (IF EQUIPPED) ............................... 8-8
INTERIOR LIGHT ........................................... 8-8
HORN ............................................................. 8-8
IGNITION KEY REMAINDER (IF EQUIPPED)
AND LIGHT REMAINDER WARNING
BUZZER.......................................................... 8-8
SEAT BELT WARNING LIGHT (IF
EQUIPPED) .................................................... 8-8
FRONT SEAT HEATER (IF EQUIPPED) ....... 8-9
ON-VEHICLE SERVICE ..................................... 8-9
CAUTIONS IN SERVICING ............................ 8-9
HEADLIGHT ................................................... 8-9
HEADLIGHT SWITCH ................................ 8-9
HEADLIGHT ASSEMBLY ......................... 8-10
HEADLIGHT BULB ................................... 8-10
HEADLIGHT AIMING ADJUSTMENT
WITH SCREEN ......................................... 8-11
HEADLIGHT LEVELING SWITCH (IF
EQUIPPED) .............................................. 8-12
TURN SIGNAL AND HAZARD WARNING
LIGHTS ......................................................... 8-12
TURN SIGNAL LIGHT SWITCH ............... 8-12
REMOVAL AND INSTALLATION ............. 8-12
TURN SIGNAL AND HAZARD RELAY ..... 8-13
HAZARD SWITCH .................................... 8-13
FRONT FOG LIGHTS (IF EQUIPPED)......... 8-13
FRONT FOG LIGHT SWITCH .................. 8-13
REAR FOG LIGHT (IF EQUIPPED) ............. 8-14
REAR FOG LIGHT SWITCH..................... 8-14
IGNITION SWITCH ....................................... 8-14
COMBINATION METER ............................... 8-15 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).

8-2 BODY ELECTRICAL SYSTEM
CIRCUIT.................................................... 8-15
FUEL METER AND FUEL LEVEL
SENSOR (GAUGE UNIT) ............................. 8-16
FUEL LEVEL METER ............................... 8-16
FUEL LEVEL SENSOR (GAUGE UNIT) ... 8-17
SPEED METER AND VSS ........................... 8-17
VSS ........................................................... 8-17
ENGINE COOLANT TEMPERATURE (ECT)
METER AND SENSOR................................. 8-17
ENGINE COOLANT TEMPERATURE
(ECT) METER ........................................... 8-17
ECT SENSOR ........................................... 8-18
OIL PRESSURE WARNING LIGHT ............. 8-18
OIL PRESSURE SWITCH ........................ 8-18
BRAKE FLUID LEVEL AND PARKING
BRAKE WARNING LIGHT ............................ 8-18
BRAKE FLUID LEVEL SWITCH ............... 8-18
PARKING BRAKE SWITCH...................... 8-19
REAR WINDOW DEFOGGER...................... 8-19
DEFOGGER SWITCH .............................. 8-19
DEFOGGER WIRE ................................... 8-19
WIPERS AND WASHERS ............................ 8-21
COMPONENTS ........................................ 8-21
FRONT WIPER AND WASHER
SWITCH .................................................... 8-21
FRONT WIPER MOTOR........................... 8-23
WASHER TANK AND WASHER
PUMP ........................................................ 8-24
REAR WIPER AND WASHER SWITCH
(IF EQUIPPED) ......................................... 8-25REAR WIPER MOTOR .............................. 8-25
IGNITION KEY REMAINDER (IF EQUIPPED)
AND LIGHT REMAINDER WARNING
BUZZER ........................................................ 8-25
POWER WINDOW CONTROL SYSTEM
(IF EQUIPPED).............................................. 8-26
POWER WINDOW MAIN SWITCH ........... 8-26
POWER WINDOW SUB SWITCH ............. 8-27
DOOR SWITCH ............................................. 8-27
STOP LAMP (BRAKE) SWITCH ................... 8-27
POWER DOOR LOCK SYSTEM (IF
EQUIPPED) ................................................... 8-28
DOOR LOCK CONTROLLER .................... 8-28
DRIVER’S DOOR KNOB SWITCH ............ 8-28
DOOR LOCK ACTUATOR......................... 8-29
KEYLESS ENTRY SYSTEM (IF
EQUIPPED) ................................................... 8-29
DOOR LOCK CONTROLLER .................... 8-29
DOOR LOCK ACTUATOR......................... 8-29
RECEIVER................................................. 8-30
TRANSMITTER ......................................... 8-30
POWER DOOR MIRROR CONTROL
SYSTEM (IF EQUIPPED) .............................. 8-31
MIRROR SWITCH ..................................... 8-31
DOOR MIRROR ACTUATOR .................... 8-32
FRONT SEAT HEATER (IF EQUIPPED) ...... 8-32
SEAT HEATER SWITCH (DRIVER AND
PASSENGER SIDE) .................................. 8-32
SEAT HEATER WIRE................................ 8-33

BODY ELECTRICAL SYSTEM 8-7
POWER WINDOW CONTROL SYSTEM (IF EQUIPPED)
CIGARETTE LIGHTER
POWER DOOR LOCK CONTROL SYSTEM (IF EQUIPPED)
KEYLESS ENTRY SYSTEM (IF EQUIPPED)
Condition Possible Cause Correction
All power windows do
not operate“POWER WINDOW” fuse blown Replace fuse to check for short.
Ignition switch faulty Check ignition switch.
Power window main switch faulty Check power window main switch.
Wiring or grounding faulty Repair circuit.
Only one power win-
dow does not operateWiring and/or coupler faulty Check wiring and/or coupler.
Power window switch (main or sub) faulty Check power window switch.
Window actuator faulty Check window actuator.
Grounding faulty Repair.
Condition Possible Cause Correction
Cigarette lighter
shows no operation“CIGAR” fuse blown Replace fuse to check for short.
Ignition switch faulty Check ignition switch.
Cigarette lighter faulty Check cigarette lighter.
Wiring or grounding faulty Repair circuit.
Condition Possible Cause Correction
Power door(s) is (are)
not locked/unlocked
by driver side door
key switch“DOOR LOCK” fuse blown Replace fuse to check for short.
Ignition switch faulty Check ignition switch.
Driver’s door knob switch faulty Check driver’s door knob switch.
Door lock actuator faulty Check door lock actuator.
Wiring or grounding faulty Repair circuit.
Door lock controller faulty Check controller.
Condition Possible Cause Correction
Power door(s) is (are)
not locked/unlocked
by keyless entry trans-
mitter“DOOR LOCK” fuse blown Replace fuse to check for short.
Ignition switch faulty Check ignition switch.
Code registration error Register code.
Transmitter battery dead Replace battery.
Transmitter faulty Check transmitter.
Receiver faulty Check receiver.
Door lock controller faulty Check controller.
Wiring or grounding faulty Repair circuit.

8-14 BODY ELECTRICAL SYSTEM
REAR FOG LIGHT (IF EQUIPPED)
REAR FOG LIGHT SWITCH
INSPECTION
Check for continuity between terminals. Hold the switch button (ON or OFF) pushed in during checking switch.
IGNITION SWITCH
ON-VEHICLE INSPECTION
1) Disconnect negative cable at battery.
2) Remove steering column hole cover.
3) Remove steering column upper and lower cover.
4) Disconnect main harness couplers from ignition switch.
5) Check for continuity between terminals at each switch posi-
tion as shown below. If check result is not as specified,
replace.
REMOVAL
1) Disconnect negative cable at battery.
2) Remove steering column hole cover.
3) Remove steering column upper and lower cover.
4) Disconnect main harness couplers from ignition switch (1).
5) Remove ignition switch (1) from key cylinder (2).
INSTALLATION
Reverse removal procedure for installation.
RR
FOG SW
OFF SWTERMINAL
FREEFREE
PUSH
FREE
PUSH PUSHBE D AC F
NOTE:
Rear fog light lights up only when headlight (low or high beams) or front fog light switch (if equipped)
is ON. Rear fog lights turns OFF automatically when headlight or front fog light switch is turned OFF.
ST+B1
+B2
ACCIG2
IG1K1K2
+B1+B2
ACC IG1IG2STK1
K2
LOCK
ACC
ONSTKEY
DIRECTION
12
Position Key
OUT
LOCK
ACC
ON
START IN+B1 +B2 +ACC IG1 IG2 ST K1 K2 Terminal

8-18 BODY ELECTRICAL SYSTEM
ECT SENSOR
REMOVAL, INSTALLATION AND INSPECTION
Refer to “ECT SENSOR” in Section 6E1.
OIL PRESSURE WARNING LIGHT
OIL PRESSURE SWITCH
ON-VEHICLE INSPECTION
1) Disconnect oil pressure switch (1) lead wire.
2) Check for continuity between oil pressure switch terminal (2)
and cylinder block (3) as shown in figure.
If not, replace oil pressure switch (1).
Oil pressure switch specification
During engine running : No continuity
At engine stop : Continuity
REMOVAL AND INSTALLATION
Refer to “OIL PRESSURE CHECK” in Section 6A1.
BRAKE FLUID LEVEL AND PARKING BRAKE
WARNING LIGHT
BRAKE FLUID LEVEL SWITCH
INSPECTION
Check for continuity between terminals of brake fluid level switch
coupler.
If found defective, replace switch.
Brake fluid level switch specification
OFF position (float up) : No continuity
ON position (float down) : Continuity