SUZUKI SWIFT 2005 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Body Structure: 9K-4
Rear end Door
Hole to hole distance
I4RS0A9B0004-01
a (a’). Roof back member bolt installation holec (c’). Back panel bolt installation hole
b (b’). Jig hole d. Rear end door striker installation left side hole
a-a’: 759 mm (29.88 in.) a’-b: 1037 mm (40.83 in.) b-c’: 985 mm (38.78 in.)
a-c: 762 mm (30.00 in.) a’-d: 904 mm (35.59 in.) c-c’: 850 mm (33.46 in.)
a-d: 887 mm (34.92 in.) a’-b’: 528 mm (20.79 in.)
a-c’: 1107 mm (43.58 in.) b-b’: 1051 mm (41.38 in.)

Downloaded from www.Manualslib.com manuals search engine 9K-5 Body Structure:
Side Body
Hole to hole distance
Hole to hole distance
I4RS0A9B0005-02
a (a’). Jig hole (φ 8 mm) e (e’). Rear door lower hinge installation rear hole i (i’). Jig hole ( φ 10 mm)
b (b’). Front door upper hinge installation upper hole f (f’). Rear door upper hinge installation upper hole j (j’). Rear door switc h installation hole (large hole)
c (c’). Front door lower hinge installation lower hole g (g’). Jig hole ( φ 10 mm) k (k’). Rear side sill scuff installation hole
d (d’). Bleeding hole h (h’). Curtain air bag clip installation hole
a-d: 1055 mm (41.54 in.) c-e: 1021 mm (40.20 in.) f-j: 835 mm (32.87 in.) a-f: 747 mm (29.41 in.) c-f: 1123 mm (44.21 in.) h-i: 601 mm (23.66 in.)
a-g: 378 mm (14.88 in.) d-g: 1129 mm (44.45 in.) h-j: 817 mm (32.17 in.)
b-c: 383 mm (15.08 in.) e-f: 354 mm (13.94 in.) h-k: 1097 mm (43.19 in.)
b-e: 1085 mm (42.72 in.) e-j: 946 mm (37.24 in.) i-k: 1153 mm (45.39 in.) b-f: 1061 mm (41.77 in.) f-i: 926 mm (36.46 in.)
a-a’: 1039 mm (40.91 in.) e-e’: 1474 mm (58.03 in.) i-i’: 1009 mm (39.72 in.)
b-b’: 1461 mm (57.52 in.) f-f’: 1468 mm (57.80 in.) j-j’: 1327 mm (52.24 in.) c-c’: 1489 mm (58.62 in.) g-g’: 1018 mm (40.08 in.) k-k’: 1472 mm (57.95 in.)
d-d’: 1472 mm (57.95 in.) h-h’: 1022 mm (40.24 in.)

Downloaded from www.Manualslib.com manuals search engine Body Structure: 9K-6
Hole to hole distance
a
cb
a’
a
bc
b’
I4RS0B9B0004-02
a (a’). Jig hole (φ 6.5 mm) b (b’). Panel cross point c. Parking brake cable bracket installation front hole
a-b: 638 mm (25.12 in.) a-b’: 1194 mm (47.01 in.)
a-c: 1293 mm (50.91 in.) b-c: 1422 mm (55.98 in.)
a-a’: 800 mm (31.50 in.) b-b’: 1272 mm (50.08 in.)

Downloaded from www.Manualslib.com manuals search engine 9K-7 Body Structure:
Under Body
Hole to hole distance
Hole to hole distance
ab
c d e fg
h i
j
a' b'c'
d'
e' f'
g' i'
j'
a b
c d e fg
hi
j
a' b'c'
d'
e' f'
g'h'
i' j'
h'
I4RS0A9B0007-01
a (a’). Jig hole (
φ 20 mm) e (e’). Jig hole ( φ 15 mm) i (i’). Drain hole ( φ 10 mm)
b (b’). Front suspension frame installation hole f (f’). Jig hole ( φ 15 mm) j (j’). Jig hole ( φ 16 mm)
c (c’). Front suspension frame installation hole g (g’). Jig hole (φ 25 mm)
d (d’). Jig hole ( φ 10 mm) h (h’). Rear axle housing installation inside hole
a-b: 674 mm (26.54 in.) c-d’: 836 mm (32.91 in.) g’-h: 1135 mm (44.69 in.)
a-b’: 1018 mm (40.08 in.) c’-d’: 288 mm (11.34 in.) g’-i: 1229 mm (48.39 in.) a-c’: 1163 mm (45.79 in.) d-e’: 911 mm (35.87 in.) g’-i’: 612 mm (24.09 in.)
a’-d: 1391 mm (54.76 in.) d-f’: 1205 mm (47.44 in.) g’-j: 1433 mm (65.42 in.)
a’-c’: 908 mm (35.75 in.) d’-e’: 488 mm (1 9.21 in.) g’-j’: 971 mm (38.23 in.)
b-c: 335 mm (13.19 in.) e-f’: 887 mm (34.92 in.) h-i: 324 mm (12.76 in.)
b-c’: 904 mm (35.59 in.) e’-f’: 440 mm (17.32 in.) h-i’: 1070 mm (42.13 in.)
b-d’: 1016 mm (40.00 in.) f-g: 240 mm (9.45 in.)
b’-d’: 594 mm (23.39 in.) f-g’: 969 mm (38.15 in.)
a-a’: 660 mm (25.98 in.) e-e’: 770 mm (30.31 in.) i-i’: 992 mm (39.06 in.)
b-b’: 881 mm (34.69 in.) f-f’: 770 mm (30.31 in.) j-j’: 970 mm (38.19 in.) c-c’: 800 mm (31.50 in.) g-g’: 1144 mm (45.04 in.)
d-d’: 770 mm (30.31 in.) h-h’: 1048 mm (41.26 in.)

Downloaded from www.Manualslib.com manuals search engine Body Structure: 9K-8
Hole to hole distance
Projection dimension from standard line “A”
Front Suspension Frame
Hole to hole distance
i
g
f
e
d
c
ab
"A"j
h
I4RS0A9B0008-01
a. Jig hole ( φ 20 mm) e. Jig hole ( φ 15 mm) i. Drain hole ( φ 10 mm)
b. Front suspension frame installation hole f. Jig hole (φ 15 mm) j. Jig hole (φ 16 mm)
c. Front suspension frame installation hole g. Jig hole ( φ 25 mm)
d. Jig hole ( φ 10 mm) h. Rear axle housing installation inside hole
a-b: 644 mm (25.35 in.) d-e: 488 mm (19.21 in.) g-h: 293 mm (11.54 in.)
b-c: 260 mm (10.24 in.) e-f: 440 mm (17.32 in.) g-i: 597 mm (23.50 in.)
c-d: 288 mm (11.34 in.) f-g: 138 mm (5.43 in.) g-j: 956 mm (37.64 in.)
a: 73 mm (2.87 in.) e: 10 mm (0.39 in.) i: 181 mm (7.13 in.)
b: 236 mm (9.29 in.) f: 10 mm (0.39 in.) j: 221 mm (8.70 in.) c: 29 mm (1.14 in.) g: 68 mm (2.68 in.)
d: 12 mm (0.47 in.) h: 72 mm (2.83 in.)
a b c
d
e
a'
b'
c' d'
e'
I4RS0A9B0009-01
a (a’). Stud
d (d’). Front suspension frame installation hole
b (b’). Front suspension frame installation hole e (e’). Front suspension control arm installation hole
c (c’). Front suspension control arm installation hole
a-a’: 896 mm (35.28 in.) d-d’: 881.5 mm (34.70 in.)
b-b’: 800 mm (31.50 in.) e-e’: 765 mm (30.12 in.) c-c’: 666 mm (26.22 in.)

Downloaded from www.Manualslib.com manuals search engine 9K-9 Body Structure:
Hole to hole distance
Projection dimension from standard line “A”
I4RS0A9B0010-01
a. Studd. Front suspension frame installation hole
b. Front suspension frame installation hole e. Front suspension control arm installation hole
c. Front suspension control arm installation hole
a-b: 10 mm (0.39 in.) a-d: 270 mm (10.63 in.)
a-c: 108 mm (4.25 in.) a-e: 309 mm (12.17 in.)
a: 50 mm (1.97 in.) d: 258 mm (10.16 in.)
b: 50 mm (1.97 in.) e: 66 mm (2.60 in.)
c: 97 mm (3.82 in.)

Downloaded from www.Manualslib.com manuals search engine Body Structure: 9K-10
Panel ClearanceS7RS0B9B07002
Panel to panel distance
o
bc
e h
f
j
i l
m
k n
r
u
s
t
o
q
o
g
a
d
p
v
I7RS0B9B0002-01
a: 0-1 mm (0-0.039 in.) i: 4.7-6.7 mm (0.185-0.263 in.) q: 1.5-3.0 mm (0.059-0.118 in.)
b: 2.3-4.3 mm (0.091-0.169 in.) j: 15.4-18.4 mm (0.606-0.724 in.) r: 6.8-8.3 mm (0.268-0.327 in.) c: 3.1-5.1 mm (0.122-0.201 in.) k: 3.0-5.0 mm (0.118-0.197 in.) s: 4.1 mm (0.161 in.)
d: 1.1-3.1 mm (0.043-0.122 in.) l: 3.1-5.1 mm (0.122-0.201 in.) t: 3.8-5.8 mm (0.150-0.228 in.) e: 4.7-6.7 mm (0.185-0.263 in.) m: 3.6-5.6 mm (0.142-0.220 in.) u: 5.8-7.8 mm (0.228-0.307 in.) f: 14.7-17.7 mm (0.579-0.697 in.) n: 0-1.0 mm (0-0.039 in.) v: 3.6-5.6 mm (0.142-0.220 in.)
g: 3.1-5.1 mm (0.122-0.201 in.) o: 8.1 mm (0.319 in.)
h: 3.1-5.1 mm (0.122-0.201 in.) p: 6.1-8.1 mm (0.240-0.319 in.)

Downloaded from www.Manualslib.com manuals search engine 9L-1 Paint / Coatings:
Body, Cab and Accessories
Paint / Coatings
General Description
Anti-Corrosion Treatment ConstructionS7RS0B9C01001
WARNING!
Standard shop practices, particularly eye protection, should be followed during the performance of the
following operations to avoid personal injury.

As rust proof treatment, steel sheets are given corrosion resistance on the interior and/or exterior.
These corrosion resistance steel sheet materials ar e called one of two-side galvanized steel sheets.
It is for the sake of rust protection that these materials are selected and given a variety of treatments as described
blow.
• Steel sheets are treated with cathodic electro primer which is excellent in corrosion resistance.
• Rust proof wax coatings are applied to door and side sill insides where mois ture is liable to stay.
• Vinyl coating is applied to body underside and wheel housing inside.
• Sealer is applied to door hem, engine compartment steel sheet-to-steel sheet joint, and the like portions to prevent water penetration and resulting in rust occurrence.
In panel replacement or collision damage repair, leaving the relevant area untreated as it is in any operation which
does disturb the rust proof treatment will cause corrosion to th at area. Therefore, it is the essential function of any
repair operation to correctly recoat t he related surfaces of the relevant area.
All the metal panels are coated with metal conditioners an d primer coating during vehicle production. Following the
repair and/or replacement parts installation, every access ible bare metal surface should be cleaned and coated with
rust proof primer. Perform this operation prior to the application of sealer and rust proof wax coating.
Sealer is applied to the spec ific joints of a vehicle during production. The sealer is intended to prevent dust from
entering the vehicle and serves also as an anti corrosion barrier. The sealer is applied to the door and hood hem areas
and between panels. Correct and reseal the originally sealed joints if damaged. Reseal the attaching joints of a new
replacement panel and reseal the hem area of a replacement door or hood.
Use a quality sealer to seal the flanged joints, overlap joints and seams. The sealer must have flexible characteristics
and paint ability after it’s applied to repair areas.
For the sealer to fill open joints, use caulking material. Select a sealer in conf ormance with the place and purpose of a
specific use. Observe the ma nufacturer’s label-stand instructions when using the sealer.
In many cases, repaired places require color painting. When this is required, follow the ordinary techniques specified
for the finish preparation, color painting and undercoating build-up.
Rust proof wax, a penetrative compound, is applied to the metal-to-metal surfaces (door and side sill insides) where it
is difficult to use ordinary undercoating material for coating. Therefore, when selecting the rust proof wax, it may be the
penetrative type.
During the undercoating (vinyl coating) application, care should be taken that sealer is not applied to the engine-
related parts and shock absorber mounting or rotating parts. Following the under coating, make sure that body drain
holes are kept open.
The sequence of the application steps of the anti-corrosion materials are as follows:
1) Clean and prepare the metal surface.
2) Apply primer.
3) Apply sealer (all joints sealed originally).
4) Apply color in areas where color is required such as hem flanges, exposed joints and under body components.
5) Apply anti corrosion compound (penetrative wax).
6) Apply undercoating (rust proof material).

Downloaded from www.Manualslib.com manuals search engine Paint / Coatings: 9L-2
Plastic Parts FinishingS7RS0B9C01002
Paintable plastic parts are ABS plastic parts.
Painting
Rigid or hand ABS plastic needs no primer coating.
General acrylic lacquers can be painted properly over hard ABS plastic in terms of adherence.
1) Use cleaning solvent for paint finish to wash each part.
2) Apply conventional acrylic color lacquer to part surface.
3) Follow lacquer directions for required drying time. (Proper drying temperature range is 60 – 70 °C (140 – 158 ° F)).
Reference
Plastic parts employ not only ABS (Acrylonitrile Butadiene Styrene) plastic but also polypro pylene, vinyl, or the like
plastic. Burning test method to iden tify ABS plastic is described below.
1) Use a sharp blade to cut off a plastic sliver from the part at its hidden backside.
2) Hold sliver with pincer s and set it on fire.
3) Carefully observe condition of the burning plastic.
4) ABS plastic must raise readily dist inguishable back smoke while burning with its residue suspended in air
temporarily.
5) Polypropylene must raise no readily distinguishable smoke while burning.

Downloaded from www.Manualslib.com manuals search engine 9L-3 Paint / Coatings:
Component Location
Sealant Application AreasS7RS0B9C03001
I7RS0A9C0001-01
“A”: Apply sealant.“C”: Smooth out sealant with a brush.
“B”: Wipe off excess sealant after application. “D”: Do not apply sealant