1000 SUZUKI SWIFT 2005 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 00-7 Precautions:
Warning for Wheel (with tire) RemovalS7RS0B0000003
WARNING!
When removing any of these wheels installed
with wheel bolts, never remove all wheel
bolts at the same time. Leave at least 1 bolt
for each wheel as it is to prevent wheel from
dropping. When removing this remaining 1
bolt, hold wheel and tire so as not to allow
them to come off.

Warning for Handling Emergency Flat Tire
Repair Kit
S7RS0B0000004
WARNING!
If vehicle is equipped with Emergency Flat
Tire Repair Kit instead of spare tire, be sure
to observe “Precaution for Emergency Flat
Tire Repair Kit in Section 2D” when handling
Emergency Flat Tire Repair Kit and repairing
flat tire.
Otherwise, your health may be ruined or it
will be impossible to repair flat tire.

Precautions for Catalytic ConverterS7RS0B0000005
For vehicles equipped with a catalytic converter, use
only unleaded gasoline and be careful not to let a large
amount of unburned gasoline enter the converter or it
can be damaged.
• Conduct a spark jump test only when necessary, make it as short as possible, and do not open the
throttle.
• Conduct engine compression checks within the shortest possible time.
• Avoid situations which can result in engine misfire (e.g. starting the engine when the fuel tank is nearly
empty.)
Precautions for Installing Mobile
Communication Equipment
S7RS0B0000006
When installing mobile communication equipment such
as CB (Citizens-Band)-radi o or cellular-telephone, be
sure to observe the following precautions.
Failure to follow cautions may adversely affect electronic
control system.
• Keep the antenna as far away as possible from the vehicle’s electronic control unit.
• Keep the antenna feeder more than 20 cm (7.9 in.) away from electronic control unit and its wire
harnesses.
• Do not run the antenna feeder parallel with other wire harnesses.
• Confirm that the antenna and feeder are correctly adjusted.
Precaution for CAN Communication SystemS7RS0B0000007
• The loose (1) in the wire harnesses twist of the CAN lines except around the connector (3) should be within
100 mm (3.9 in.). Refer to the wiring diagram for the
CAN lines discrimination. Excessively-loosed lines
may be influenced by the electric noise.
• Do not connect terminals of the CAN line using a bypass wire (1). Otherwise, the CAN line may be
influenced by the electric noise.
33
2
2
1
I4JA01000002-01
1
I4JA01000003-01

Downloaded from www.Manualslib.com manuals search engine Precautions: 00-12
4) Using continuity check or voltage check the following procedure, check the wire harness for open circuit
and poor connection with its terminals. Locate
abnormality, if any.
Continuity Check 1) Measure resistance between connector terminals at both ends of the circuit being checked (between “A-
1” and “C-1” in the figure). If no continuity is indicated
(infinity or over limit), that means that the circuit is
open between terminals “A-1” and “C-1”.
2) Disconnect the connector included in the circuit (connector-B in the figure) and measure resistance
between terminals “A-1” and “B-1”.
If no continuity is indica ted, that means that the
circuit is open between terminals “A-1” and “B-1”. If
continuity is indicated, there is an open circuit
between terminals “B-1” and “C-1” or an abnormality
in connector-B. Voltage Check
If voltage is supplied to the circuit being checked, voltage
check can be used as circuit check.
1) With all connectors connected and voltage applied to the circuit being checked, measure voltage between
each terminal and body ground.
a) If measurements were taken as shown in the figure and results were as listed in the following,
it means that the circuit is open between
terminals “B-1” and “A-1”.
Voltage between
“C-1” and body ground: Approx. 5 V
“B-1” and body ground: Approx. 5 V
“A-1” and body ground: 0 V
b) Also, if measured values were as listed in the following, it means that there is a resistance
(abnormality) of such le vel that corresponds to
the voltage drop in the circuit between terminals
“A-1” and “B-1”.
Voltage between
“C-1” and body ground: Approx. 5 V
“B-1” and body ground: Approx. 5 V
“A-1” and body ground: Approx. 3 V
1. Looseness of crimping
2. Open
3. Thin wire (single strand of wire)
I2RH01010051-01
I2RH01010052-01
I2RH01010053-01
I5RH01000005-01

Downloaded from www.Manualslib.com manuals search engine 00-13 Precautions:
Short Circuit Check (Wire Harness to Ground)1) Disconnect negative (–) cable at battery.
2) Disconnect connectors at bot h ends of the circuit to
be checked.
NOTE
If the circuit to be checked is connected to
other parts (1), disconnect all connectors of
those parts.
Otherwise, diagnosis will be misled.

3) Measure resistance between terminal at one end of circuit (“A-1” terminal in the figure) and body ground.
If continuity is indicated, it means that there is a short
to ground between terminals “A-1” and “C-1” of the
circuit. 4) Disconnect the connector included in circuit
(connector-B) and measure resistance between “A-
1” and body ground. If continuity is indicated, it
means that the circuit is shorted to the ground
between terminals “A-1” and “B-1”.
Intermittent and Poor Connection InspectionS7RS0B0006002
Most intermittent are caused by faulty electrical
connections or wiring, although a sticking relay or
solenoid can occasionally be at fault. When checking it
for proper connection, perfor m careful check of suspect
circuits for:
• Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
• Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could
impede proper terminal contact. However, cleaning
the terminal with a sand paper or the like is prohibited.
• Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper
terminal orientation with the component or mating
connector.
I5RH01000006-01
1. To other parts
I2RH01010056-01
I2RH01010057-01

Downloaded from www.Manualslib.com manuals search engine Precautions: 00-14
• Improperly formed or damaged terminals.Check each connector terminal in problem circuits
carefully to ensure good contact tension by using the
corresponding mating terminal.
If contact tension is not enough, reform it to increase
contact tension or replace.
• Poor terminal-to -wire connection.
Check each wire harness in problem circuits for poor
connection by shaking it by hand lightly. If any
abnormal condition is found, repair or replace. • Wire insulation which is rubbed through, causing an
intermittent short as the bare area touches other
wiring or parts of the vehicle.
• Wiring broken inside the insulation. This condition
could cause continuity check to show a good circuit,
but if only 1 or 2 strands of a multi-strand-type wire
are intact, resistance could be far too high.
If any abnormality is found, repair or replace.
1. Check contact tension by inserting and removing just once.
2. Check each terminal for bend and proper alignment.
I5RH01000007-01
I2RH01010059-01
I2RH01010060-01

Downloaded from www.Manualslib.com manuals search engine 0A-3 General Information:
There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored
(striped) wire.
The single-colored wire uses only one color symbol (i.e. “GRN”).
The dual-colored wire uses two color sy mbols (i.e. “GRN/YEL”). The first symbo l represents the base color of the wire
(“GRN” in the figure) and the second symbol represents the color of the stripe (“YEL” in the figure).
Fasteners InformationS7RS0B0101004
Metric Fasteners
Most of the fasteners used for this vehicle are JIS-
defined and ISO-defined metric fasteners. When
replacing any fasteners, it is most important that
replacement fasteners be the correct diameter, thread
pitch and strength.
CAUTION!
Even when the nominal diameter (1) of thread
is the same, the thread pitch (2) or the width
across flats (3) may vary between ISO and
JIS. Refer to JIS-TO-ISO Main Fasteners
Comparison Table below for the difference.
Installing a mismatched bolt or nut will cause
damage to the thread.
Before installing, check the thread pitch for
correct matching and then tighten it by hand
temporarily. If it is tight, recheck the thread
pitch.

JIS-TO-ISO Main Fasteners Comparison Table Fastener Strength Identification
Most commonly used metric fastener strength property
classes are 4T, 6.8, 7T, 8.8 and radial line with the class
identification embossed on the head of each bolt. Some
metric nuts will be marked with punch, 6 or 8 mark
strength identification on the nut face. Figure shows the
different strength markings.
When replacing metric fasteners, be careful to use bolts
and nuts of the same strength or greater than the original
fasteners (the same number marking or higher). It is
likewise important to select replacement fasteners of the
correct diameter and thread
pitch. Correct replacement
bolts and nuts are available through the parts division.
Metric bolts: Identification class numbers or marks
correspond to bolt strength (increasing numbers
represent increasing strength).
I2RH01010010-01
Nominal diameter
M6 M8 M10 M12 M14
JIS Thread pitch 1.0 1.25 1.25 1.25 1.5
Width across flats 10 12 14 17 19
ISO Thread pitch 1.0 1.25 1.5 1.5 1.5
Width across flats 10 13 16 18 21
I4RH0A010005-01
1. Nut strength identification
I5RH01010001-01

Downloaded from www.Manualslib.com manuals search engine 0A-5 General Information:
Vehicle Lifting PointsS7RS0B0101005
WARNING!
• Before applying hoist to underbody, always take vehicle balance throughout service into
consideration. Vehicle balance on hoist may change depending on 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 Frame Contact Hoist
1
:2
:3
4
4
I4RS0A010001-01
1. Vehicle front
3. Floor jack position
2. Support position for frame contact hoist and safety stand 4. Body mounting stay

Downloaded from www.Manualslib.com manuals search engine General Information: 0A-6
When Using Floor Jack
WARNING!
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.

CAUTION!
• Never apply jack against rear suspension parts (i.e., stabilizer, etc.) or vehicle floor,
or it may get deformed.
• When jacking up the front end, be sure to use an air type floor jack with the following
specified height or a manual type floor jack
of the following size. Otherwise, the jack
may cause the bumper or vehicle body
panel a damage.

Jack size
Height “h”: under 145 mm (under 5.71 in.)
Length “l”: above 900 mm (above 35.4 in.) In raising front or rear vehicl
e end off the floor by jacking,
be sure to put the jack a gainst front suspension frame
(1) or rear jacking bracket (2).
To perform service with either front or rear vehicle end
jacked up, be sure to place safety stands (1) under body
mounting stay (2) so that vehicle body is securely
supported. And then check to ensure that body mounting
stay (2) does not slide on safety stands (1) and the
vehicle is held stable for safety’s sake.
“h”
“l”
I4RS0A010002-01
[A]: Front
[B]: Rear
2
1
I4RS0A010003-01
1
1
2
2
[B] [A]
I4RS0A010004-01

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 General Information: 0A-8
Component Location
Warning, Caution and Information Labels LocationS7RS0B0103001
The figure 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
2
3
4
6
5
I5RS0C010001-02
1. Air bag label on sun visor (if equipped) 4.Steering shaft joint cover label (if equipped)
2. Radiator cap label 5. Jack label
3. Engine cooling fan label 6. Rear beam label

Downloaded from www.Manualslib.com manuals search engine 0A-9 General Information:
[A]
12
4 5
6
7 8
9
3
I4RS0B010002-03
1. Air bag label on driver air bag (inflator) module 6. Air bag label on SDM
2. Air bag label on combination switch and contact coil assembly7. Pretensioner label on seat belt retractor
3. Air bag label on passenger air bag (inflator) module 8. Child seat label (if equipped)
4. Air bag label on side air bag (inflator) module (if equipped) 9. Side/Curtain air bag label on pillar (both right and left sides) (if equipped)
5. Air bag label on curtain air bag (inflator) module (if equipped) [A]: These labels are attached on vehicle equipped with air ba g system only.