start SUZUKI SWIFT 2004 2.G Service Workshop Manual

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Reference waveform No.3
Motor output signal 1(1), Motor output signal 2(2), with
engine idling
Steering Wheel Play CheckS7RS0B6304024
• Check steering wheel for looseness or rattle by moving it in its shaft direction and lateral direction.
If found defective, repair or replace.
• Check steering wheel for play, holding vehicle in straight forward condition on the ground with engine
stopped.
If steering wheel play is not within specification,
inspect as follows and replace if found defective.
• Tie-rod end ball stud for wear (Ball stud should move when more than 0.2 N ⋅m (2 kg-cm, 0.44 lb-ft) torque is
applied.)
• Lower ball joint for wear
• Steering shaft joint for wear • Steering pinion or rack gear for wear or breakage
• Each part for looseness
Steering wheel play
“a”
: 0 – 30 mm (0 – 1.18 in.)
Steering Force CheckS7RS0B6304025
1) Place vehicle on level road and set steering wheel at
straight-ahead position.
2) Check if tire inflation pressure is as specified referring to the tire placard.
3) Remove driver air bag (inflator) module referring to “Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
4) Start engine.
5) With engine idling, measure steering force by turning torque wrench.
Steering force
: Less than 6.4 N ⋅m (0.64 kgf-m, 4.6 lb-ft)
6) Install driver air bag (inflator) module referring to “Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
Measurement
terminal
CH1: “E51-1” to vehicle body ground
CH2: “E51-2” to vehicle body ground
Oscilloscope
setting CH1: 5 V/DIV, CH2: 5 V/DIV
TIME: 20
µs/DIV
Measurement
condition • Engine is idling and steering wheel
is kept fully turned to left or right
until it stops
[A]: Steering wheel is kept fully turned left until it stops
[B]: Steering wheel is kept fully turned right until it stops
[C]: 12 V ON
[D]: GND ON
I6RS0B630019-01
I3RM0A630021-01
I3RM0A630022-01

Downloaded from www.Manualslib.com manuals search engine 7B-16 Air Conditioning System: Manual Type
Repair Instructions
Operation Procedure for Refrigerant ChargeS7RS0B7216001
WARNING!
• Your eyes should not be exposed to refrigerant (liquid).Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately –
6 °C (21.2 ° F) below freezing point. Should liquid HFC-134a (R-134a) is exposed to your eyes, it may
cause a serious injury. To protect your eyes from such accident, it is necessary to always wear
goggles. Should it occur that HFC-134a (R-134a) is exposed to your eyes, consult a doctor
immediately.
– Do not use your hand to rub the affected eye(s). Instead, use fresh cold water to splash it over the affected area to gradually raise temperature of such area above freezing point.
– Obtain proper treatment as soon as possible from a doctor or eye specialist.
• Should the liquid refrigerant HFC-134a (R-134a) is exposed to your skin, the affected area should be treated in the same manner as when skin is frostbitten or frozen.
• Do not handle refrigerant near any place where welding or steam cleaning is performed.
• Refrigerant should be kept in a cold and dark pl ace. It should never be stored in any place where
temperature is high, e.g. where exposed to direct su n light, close to fire or inside vehicle (including
trunk room).
• Avoid breathing fume produced when HFC-134a (R-134a) is burned. Such fume may be hazardous to your health.

Recovery
When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling
equipment because discharging refrigerant HFC-134a (R-1 34a) into atmosphere would cause adverse effect to
environments.
Start evacuation.Start evacuation.
Stop evacuation.Stop evacuation.
Wait 10 minutesWait 10 minutes
Check A/C system forCheck A/C system for
pressure tighteness.pressure tighteness.
Recharge A/C system withRecharge A/C system withrefrigerant.refrigerant.
Check A/C system for refrigerantCheck A/C system for refrigerantleaks and amount of refrigerantleaks and amount of refrigerantcharged.charged.
Performance testPerformance test
Inspect and repair connections.Inspect and repair connections.
If gauge showsIf gauge showsabnormal conditionsabnormal conditions
Recharge 370 20 g ofRecharge 370 20 g ofrefrigerant.refrigerant.
I5RS0C721005-01

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Charge
CAUTION!
• Because the sight glass is not used for this A/C system, do not perform an additional
charge to the A/C system. To charge the
proper amount of refrigerant, recover and
evacuate the A/C system first. And then,
charge the proper amount of refrigerant
into the A/C system.
• Always charge refrigerant through low pressure side of A/C system after the initial
charge is performed from the high
pressure side with the engine stopped.
• Never charge refrigerant through high pressure side of A/C system with engine
running.
• Do not charge refrigerant while compressor is hot.
• When installing tap valve to refrigerant container to make a hole there through,
carefully follow dire ctions given by
manufacturer.
• A pressure gauge should always be used before and during refrigerant charge.
• The refrigerant container should be emptied of refrigerant when discarding it.
• The refrigerant container should not be heated up to 40 °C (104 °F) or over.
• Refrigerant container should not be reversed in direction during refrigerant
charge. Reversing in direction causes
liquid refrigerant to enter compressor,
causing troubles, such as compression of
liquid refrigerant and the like.

NOTE
The air conditioning system contains HFC-
134a (R-134a).
Described here is a method to charge the air
conditioning system with refrigerant from the
refrigerant service container.
When charging refrigerant recovered by
using the refrigerant and recycling
equipment (when recycling refrigerant),
follow the procedure described in the
equipment manufacturer’s instruction
manual.

Charge proper amount of refrigerant accurately in
accordance with the following procedure.
Specified amount of refrigerant
370 ± 20 g (13.0 ± 0.7 oz)
The initial charge of the A/C system is performed
through the high pressure side with the engine stopped.
And next, this method must be followed by charging from
the low pressure side with the engine running.
1) Check if hoses are routed properly after evacuating the system.
2) Connect low charging hose (1) and high charging hose (2) of the manifold gauge set (3) in position.
Then, open refrigerant container valve (4) to purge
the charging line.
3) Open the high pressure side valve (5) and charge refrigerant to system.
4) After a while, open the low pressure side valve (6) and close the high pressure side valve.
WARNING!
Make sure that high pressure side valve is
closed securely.

5) Start engine and keep engine speed at 1500 r/min, and then operate A/C system.
6) Charge A/C system with refrigerant in vapor state. At this time, refrigerant container should be held
upright.
1
2 6 3
5 4
I4RS0A720015-01

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Not Using SUZUKI Scan Tool
Current DTC mode1) Light over sunload sensor vertically with an incandescent lamp of approximately 100 W apart
from about 100 mm (3.94 in.).
NOTE
If sunload sensor is not lighted over with an
incandescent lamp, DTC B1504 is detected
as current DTC even though there is not any
malfunction.

2) Start engine.
3) Wait for 20 seconds or more after engine started and set temperature selector to 25 °C (77 °F).
4) Push AUTO switch (1) and defroster switch (2) at the same time.
5) Check DTC (3).
NOTE
• DTC flashes for 15 seconds. After that, the normal display is rest ored. To have DTC
displayed again, repeat the procedure from
Step 4.
• When more than two DTCs are detected, only DTC having the highest priority is
indicated. Therefore, after troubleshooting
the malfunction, DTC check has to be
performed again to see if any other DTC(s)
is detected.

History DTC mode
1) Turn ignition switch to ON position.
2) Set temperature selector to 25 °C (77 °F).
3) Push AUTO switch (1) and MODE (air flow) selector
(2) at the same time.
4) Check DTC (4).
NOTE
Each DTC item is displayed (lights up) for 4
seconds.
When HVAC control module detects 2 or
more DTC items, each one is displayed once
starting from the one of higher priority order.
After all DTC items being detected have been
displayed, “Ed” (3) appears on display of
HVAC control module and normal display is
restored. “Ed” means that all DTC items have
been displayed.

DTC ClearanceS7RS0B7224004
NOTE
Only history DTC(s) can be cleared. Current
DTC(s) can not be cleared unless the
problem(s) is fixed.

Using SUZUKI Scan tool
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 tool1
2
3
I5RS0A722006-02
1
2 34
I5RS0A722007-02
(A)
1
I5RS0A722005-01

Downloaded from www.Manualslib.com manuals search engine 7B-44 Air Conditioning System: Automatic Type
3) Light over sunload sensor vertically with an incandescent lamp approximately 100 W apart from
about 100 mm (3.94 in.).
NOTE
If sunload sensor is not lighted over with an
incandescent lamp, DTC B1504 is detected
as current DTC even though there is not any
malfunction.

4) Turn ignition switch to ON position.
5) Erase DTC according to instructions displayed on SUZUKI scan tool.
NOTE
To know how to use SUZUKI scan tool, refer
to operator’s manual for SUZUKI scan tool.

6) After completing the clearance, turn ignition switch to OFF position, and then di sconnect SUZUKI scan
tool from DLC.
Not Using SUZUKI Scan Tool 1) Turn ignition switch to ON position.
2) Set temperature selector to 25 °C (77 °F). 3) Push AUTO switch (1) and
MODE (air flow) selector
(2) at the same time to have history DTC displayed.
4) Push MODE (air flow) selector (2) and OFF switch (3) at the same time while history DTC is displayed.
5) Check that “CL” (4) appears on display. “CL” means that DTC has been cleared.
DTC TableS7RS0B7224005
CAUTION!
Be sure to perform “Air Conditioning Sy stem Check” before starting diagnosis.

1
2
3
2
4
I5RS0A722008-01
DTC No.
(displayed on
SUZUKI
scan tool) DTC
(indicated on
display of HVAC
control
module) Priority of
display
(current DTC) Priority
of
display
(history DTC) Diagnosis
“AUTO”
indicator lamp
) B1502 21 1 1 Inside air temperature sensor and/or its
circuit malfunction Open
Flashed
22 2 2 Short
) B1503 31 3 3 Evaporator temperature sensor and/or its
circuit malfunction Open
Flashed
32 4 4 Short
) B1504 41 21 — Sunload sensor and/or its circuit
malfunction Open —
42 5 5 Short Flashed
) B1511 61 6 6 Temperature control actuator (position
sensor) and/or its circuit malfunction Open
Flashed
62 7 7 Short
) B1512 71 8 8 Air flow control actuator (position sensor)
and/or its circuit malfunction Open
Flashed
72 9 9 Short
) B1513 63 10 10 Temperature control actuator and/or its circuit malfunction Flashed
) B1514 73 11 11 Air flow control actuator and/or its circuit malfunction Flashed
) B1541 E1 12 — HVAC control module back-up power supply malfunction —
) B1546 d5 22 — A/C refrigerant pressure malfunction —
) B1551 91 13 12
Serial communication circuit malfunction Open
Flashed
92 14 13 Short
) B1552 94 15 14 Serial communication signal malfunction Flashed
) B1553 A4 16 15 CAN communication signal malfunction Flashed
) B1557 b4 19 16 Vehicle speed sensor signal malfunction —
) B1561 54 17 17 Engine coolant temperature sensor signal malfunction Flashed

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DTC B1546: A/C Refrigerant Pressure MalfunctionS7RS0B7224018
DTC Detecting Condition and Trouble Area
DTC Troubleshooting
DTC B1551: Serial Communication Circuit MalfunctionS7RS0B7224019
Wiring DiagramDTC detecting condition Trouble area
A/C refrigerant pressure sensor signal voltage is lower t han specified value
even though outside air temperature is higher than specified value for
specified time continuously. • Insufficient of refrigerant
• A/C refrigerant pressure sensor
• Outside air temperature sensor
• HVAC control module
Step
Action YesNo
1 A/C refrigerant pressure and outside air temperature
check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Start engine and select “DATA LIST” mode on scan tool.
3) Check “Refrigerant Pressure” and “Outside Air Temp” varies displayed on scan tool.
Is displayed each va ries described varies in “Scan Tool
Data”? Go to Step 2.
Check the amount of
refrigerant and system
for leaks.
2 A/C system performance check
1) Check A/C system performance referring to “A/C System
Performance Inspection”.
Is check result satisfactory? Go to Step 3.
Repair or replace
defective part.
3 A/C refrigerant pressure sensor check
1) Check A/C refrigerant pressure sensor referring to “A/C
Refrigerant Pressure Sensor and Its Circuit Inspection”.
Is check result satisfactory? Go to Step 4.
A/C refrigerant pressure
sensor faulty.
4 Outside air temperature sensor check
1) Check outside air temperature sensor referring to
“Information Display (Clock) Removal and Installation in
Section 9C”.
Is check result satisfactory? HVAC control module
faulty.
Outside air temperature
sensor faulty.
YEL17812910
65 431516 14 13 12 11
G52
789101920121112
65 431718 16 15 14 13
G51
G51-7
12V
2
3
G37-11
I5RS0A722016-01
1. HVAC control module 2. BCM3. Information display

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DTC Troubleshooting
DTC B1553: CAN Communication Signal MalfunctionS7RS0B7224021
DTC Detecting Condition and Trouble Area
DTC Troubleshooting
DTC B1557: Vehicle Speed Sensor Signal MalfunctionS7RS0B7224022
DTC Detecting Condition and Trouble Area
DTC TroubleshootingStep Action Yes No
1 Serial communication signal data check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Start engine and select “DATA LIST” mode on scan tool.
3) Check “Refrigerant Pressure”, “Vehicle Speed”, “Coolant Temp” and “Outside Air Temp” varies displayed on scan
tool.
Is displayed each va ries described varies in “Scan Tool
Data”? Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.
Go to Step 2.
2 Serial communication signal check
1) Connect connectors to BCM and HVAC control module.
2) Using oscilloscope, check that serial communication
signal is outputted referring to “Reference waveform
No.8” of “Inspection of BCM and its Circuits in Section
10B”.
Is serial communication signal outputted at “G37-11”
terminal of BCM connector? HVAC control module
faulty.
BCM (included in
junction block
assembly) faulty.
DTC detecting condition
Trouble area
HVAC control module receives error code fr om BCM continuously.• CAN communication circuit
• BCM (included in junction block assembly)
•ECM
• HVAC control module
Step Action YesNo
1 DTC check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Check ECM and BCM for DTC.
Is there DTC(s)? Go to applicable DTC
diag. flow.
Substitute a known-
good HVAC control
module and recheck.
DTC detecting condition
Trouble area
HVAC control module receives error code from BCM continuously. • VSS circuit
• VSS
• HVAC control module
Step Action YesNo
1 DTC check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Check ECM for DTC.
Is there DTC P0500? Go to “DTC P0480: Fan
1 (Radiator Cooling
Fan) Control Circuit in
Section 1A”.
Substitute a known-
good HVAC control
module and recheck.

Downloaded from www.Manualslib.com manuals search engine 8A-3 Seat Belts:
Repair Instructions
Front Seat Belt ComponentsS7RS0B8106001
WARNING!
• Never attempt to disassemble or repair the seat belt pretensioner (retractor assembly). If any abnormality is found, be sure to replace it with new one as an assembly.
• Be sure to read “Precautions on Service and Diagnosis of Seat Belt” before starting to work and observe every precaution during work. Neglecting them may result in personal injury or
unactivation of the seat belt pretensioner when necessary.

(a)
(a)
(a)
1
2
3
5
a)
b)
(a)
3
7
(b)
6
2
4
(a)
7
810
9
7 2 11
9
1012
I6RS0C810001-01
1. Upper anchor
6. Shoulder adjuster mounting bolt
: Tighten upper bolt first, then tighten lower bolt. 11. Spring washer
2. Lower anchor 7. Anchor bolt
: Tighten upper bolt first, then tighten lower bolt. 12. Wave washer
3. Retractor assembly 8. Cushion : 43 N⋅m (4.3 kgf-m, 31.5 lb-ft)
4. Buckle 9. Spacer : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
5. Yellow connector (for seat belt pretensioner) 10. Washer

Downloaded from www.Manualslib.com manuals search engine Seat Belts: 8A-4
Front Seat Belt Removal and InstallationS7RS0B8106002
WARNING!
• Never attempt to disassemble or repair the seat belt pretensioner (retractor
assembly). If any abnormality is found, be
sure to replace it with new one as an
assembly.
• Be sure to read “Precautions on Service and Diagnosis of Seat Belt” before starting
to work and observe every precaution
during work. Ne glecting them may result in
personal injury or una ctivation of the seat
belt pretensioner when necessary.

Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system. Refer to “Disabling Air Bag System in Section 8B”.
3) Remove center pillar lower trim.
4) Disconnect Yellow connector (1) from seat belt pretensioner (2).
a) Release locking of lock button (3).
b) After unlocked, disconnect to connector.
5) Remove front seat belts from the vehicle.
Installation
Install in reverse order of removal, noting the following.
• Seat belt anchor bolts should have an unified fine thread (7/16-20 UNF). Under no circumstances
should any different sized or metric screw threads be
used.
• Connect Yellow connector (1) to seat belt pretensioner securely.
a. Connect connector.
b. Lock connector with lock slider (2). • Enable air bag system. Refer to “Enabling Air Bag
System in Section 8B”.
Front Seat Belt InspectionS7RS0B8106003
WARNING!
• Never attempt to disassemble or repair the seat belt pretensioner (retractor
assembly). If any abnormality is found, be
sure to replace it with new one as an
assembly.
• Be sure to read “Precautions on Service and Diagnosis of Seat Belt”, before
starting to work and observe every
precaution during work. Neglecting them
may result in personal injury or
unactivation of the seat belt pretensioner
when necessary.
• Never measure resistance of pretensioner or disassemble it. Otherwise, personal
injury may result.

CAUTION!
If seat belt pretensioner (retractor assembly)
was dropped from a height of 30 cm (1 ft) or
more, it should be replaced.

Seat belts and attaching parts can affect the vital
components and systems of a vehicle.
Therefore, they should be inspected carefully and
replaced with genuine parts only.
a
b
21 3I6RS0B810003-01
1
1
2
b)
a)
I6RS0B810004-01
I2RH01810004-01

Downloaded from www.Manualslib.com manuals search engine Seat Belts: 8A-6
Rear Seat Belt ComponentsS7RS0B8106004
WARNING!
Be sure to read “Precautions on Service and Diagnosis of Seat Belt” before starting to work and
observe every precaution during work.

(b)
(a)
(a)
(a)
(a)
14
4
5
62
1
7
(a)
(a)
3
8
1
10
3
11911(a)
12
13
12
13
15
15
I6RS0C810002-01
1. Upper anchor 7. Rear seat belt 13. Anchor bolt
: Tighten retractor mounting bolts first, then
tighten anchor bolt.
2. Lower anchor 8. Bush 14. Center retractor assembly
3. Side retractor assembly 9. Spacer 15. Center retractor mounting bolt
: Tighten lower bolt first, then tighten upper bolt.
4. Rear center seat belt (if equipped) 10. Spring washer : 43 N⋅m (4.3 kgf-m, 31.5 lb-ft)
5. Buckle for rear seat belt 11. Washer : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
6. Buckle for rear center seat belt (if equipped) 12. Side retractor mounting bolt
: Tighten upper bolt first, then tighten lower bolt.