Air bag SUZUKI SWIFT 2005 2.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-1
General Information
Maintenance and Lubrication
Precautions
Precautions for Maintenance and LubricationS7RS0B0200001
Air Bag Warning
Refer to “Air Bag Warning in Section 00”.
Scheduled Maintenance
Maintenance Schedule under Normal Driving ConditionsS7RS0B0205001
NOTE
• This interval should be judged by odometer reading or months, whichever comes first.
• This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km
(54,000 miles), carry out the same services at the same intervals respectively.

Interval Km (x 1,000) 15 30 45 60 75 90
Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
Engine
Accessory drive belt (I: ), R: ))——I——R
Valve lash (clearance) (I: )) —I—I—I
Engine oil and oil filter (R: )) RRRRRR
Engine coolant (R: ))— —R— — R
Exhaust system (I: )) —I—I—I
Ignition system
Spark plugs (R: ) )When unleaded fuel is used Iridium Plug
Replace every 60,000 km (36,000
miles) or 48 months
When leaded fuel is used, refer to “Maintenance Recommended under Severe Driving
Conditions”.
Fuel system
Air cleaner filter (R: ), I: )) Paved-road
I I R I I R
Dusty conditions Refer to “Maintenance Recommended
under Severe Driv
ing Conditions”.
Fuel lines and connections (I: )) —I—I—I
Fuel filter (R: )) (See NOTE below) Replace every 105,000 km (63,000
miles)
Fuel tank (I: ))— —I— — I
Emission control system
PCV valve (I: )) ————— I
Fuel evaporative emission control system (I: )) ————— I
Brake
Brake discs and pads (thickness, wear, damage) (I: )) IIIIII
Brake hoses and pipes (leakage, damage, clamp) (I: )) —I—I—I
Brake fluid (R: )) —R—R—R
Brake lever and cable (damage, stroke, operation) (I: )) Inspect at first 15,000 km (9,000 miles
only)
Chassis and body
Clutch (fluid leakage, level) (I: )) —I—I—I
Tires (wear, damage, rotation) / wheels (damage) (I: ) / ) ) IIIIII
Suspension system (tightness, damage, rattle, breakage) (I: )) —I—I—I
Steering system (tightness, damage, breakage, rattle) (I: )) —I—I—I
Drive shaft (axle) boots (I: ))— —I— — I
Manual transaxle oil (leakage, level) (I: ) 1st 15,000 km only) (R: ))I—R——R

Downloaded from www.Manualslib.com manuals search engine 1-1 Precautions:
Engine
Precautions
Precautions
Precautions for EngineS7RS0B1000001
Air Bag Warning
Refer to “Air Bag Warning in Section 00”.
Precautions on Engine Service
Refer to “Precautions on Engine Service in Section 1A”.
Precautions in Diagnosing Trouble
Refer to “Precautions in Diagnosing Trouble in Section 1A”.
Precautions of ECM Circuit Inspection
Refer to “Precautions of ECM Circuit Inspection in Section 1A”.
Precautions on Fuel System Service
Refer to “Precautions on Fuel System Service in Section 1G”.
Precaution for CAN Communication System
Refer to “Precaution for CAN Communication System in Section 00”.
Precautions for Catalytic Converter
Refer to “Precautions for Catalytic Converter in Section 00”.
Precautions for Electrical Circuit Service
Refer to “Precautions for Electric al Circuit Service in Section 00”.
Precautions of Electric Throttle Body System Calibration
Refer to “Precautions of El ectric Throttle Body System Calibration in Section 1A”.

Downloaded from www.Manualslib.com manuals search engine 1A-6 Engine General Information and Diagnosis:
For information about the following items, refer to “Euro
OBD Model: ”.
• Warm-up cycle
• Driving cycle
• 2 driving cycle detection logic
• Pending DTC
Data Link Connector (DLC)S7RS0B1101013
DLC (1) is in compliance with SAE J1962 in the shape of
connector and pin assignment.
OBD serial data line (3) (K line of ISO 9141) is used for
SUZUKI scan tool or OBD generic scan tool to
communicate with ECM, Air bag SDM, HVAC control
module (auto A/C model), immobilizer control module (in
ECM), BCM (Body electrical Control Module), TCM
(Transmission Cont rol Module (A/T model)) and ABS/
ESP ® control module.
Engine and Emission Control System
Description
S7RS0B1101004
The engine and emission control system is divided into 4
major sub-systems: air in take system, fuel delivery
system, electronic control sy stem and emission control
system.
Air intake system includes air cleaner, throttle body, IAC
valve and intake manifold.
Fuel delivery system includes fuel pump, delivery pipe,
etc.
Electronic control system incl udes ECM, various sensors
and controlled devices.
Emission control system includes EGR, EVAP and PCV
system.
2. B + (Unswitched vehicle battery positive)
4. ECM ground (Signal ground)
5. Vehicle body ground (Chassis ground)
2
345
1
910111213141516
12345678
1I4RS0B110002-01

Downloaded from www.Manualslib.com manuals search engine 2B-15 Front Suspension:
Front Suspension Frame, Stabilizer Bar and/or Bushings ComponentsS7RS0B2206014
Front Suspension Frame, Stabilizer Bar and/or
Bushings Removal and Installation
S7RS0B2206015
WARNING!
Do not touch exhaust system to avoid danger
of being burned when it is still hot.
Any service on exhaust system should be
performed when it is cool.
When removing front suspension frame, be
sure to apply some supporting equipment
(such as mission jack) under it at well-
balanced position in the center section so as
to prevent from its drop.

Removal
CAUTION!
Be sure to set front wheels (tires) in straight
direction and remove ignition key from key
cylinder before performing the following
steps; otherwise, contact coil of air bag
system may get damaged.

1) Remove steering joint cover.
2) Make alignment marks (1) on pinion shaft (2) and joint of steering lower shaft (3) for a guide during
reinstallation.
3) Loosen joint bolt (steering column side) (4) and remove joint bolt (pin ion shaft side) (5) and
disconnect steering lower shaft (3) from pinion shaft
(2).
I6RS0C220016-01
A: View A 4. Stabilizer bar mounting
bracket bolt 8. Suspension control arm mounting bolt : 50 N
⋅m (5.0 kgf-m, 36.5 lb-ft)
1. Stabilizer bar 5. Stabilizer joint 9. Front suspension frame : 150 N⋅m (15.0 kgf-m, 108.5 lb-ft)
2. Stabilizer bushing 6. Stabilizer joint nut10. Front suspension frame mounting bolt : 95 N ⋅m (9.5 kgf-m, 68.0 lb-ft)
3. Stabilizer mounting bracket 7. Suspension control arm : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft) : Do not reuse.
5
2
1
5
34
3
I4RS0B630013-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-1
Brakes
Brake Control System and Diagnosis
Precautions
Precautions on BrakeS7RS0B4100001
Air Bag Warning
Refer to “Air Bag System Service Warning in Section 00”.
Brakes Diagnosis Note
Refer to “Brakes Diagnosis Note”.
General Description
Brakes ConstructionS7RS0B4101001
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two
in front and two in rear).
The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make two
independent circuits. One connects front right & rear left brakes and the other connects front left & rear right brakes.
In this brake system, the disc brake type is used for the front wheel brake and the rear wheel brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and
mechanical linkage system. The same brake shoes or pads are used for both parking and foot brakes.
A
5
3
2
1
4
8
8
6
7
I6RS0C410001-01
1. Brake booster 4. Primary side 7. Parking brake lever
2. Master cylinder 5. 4 way joint 8. Parking brake cable
3. Secondary side 6. ABS or ESP® hydraulic unit / control module assembly A: Forward

Downloaded from www.Manualslib.com manuals search engine 5-1 Precautions:
Transmission / Transaxle
Precautions
Precautions
Precautions on Transmission / TransaxleS7RS0B5000001
Air Bag Warning
Refer to “Air Bag System Service Warning in Section 00”.
Precautions in Diagnosing Trouble
Refer to “Precautions in Diagnosing Trouble in Section 5A”.
Precautions for Disassembly and Reassembly
Refer to “Precautions for Disassembly and Reassembly in Section 5A”.
Precaution for CAN Communication System
Refer to “Precaution for CAN Communication System in Section 00”.
Precautions for Electrical Circuit Service
Refer to “Precautions for Electric al Circuit Service in Section 00”.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-93
Select Cable AdjustmentS7RS0B5106013
1) Shift manual shift lever to “N” range (transmission range sensor “N” range).
2) Remove adjuster (cable end) from select lever pin of select lever assembly.
3) Release lock plate (1) which restrict moving of cable end holder (2).
4) Push cable end holder (1) out from eye-end (2) using an appropriate tool (3) to disengage cable.
5) Shift select lever to “N” position.
6) Apply grease to select lever pin and install adjuster (cable end) to it.
: Grease 99000–25011 (SUZUKI Super Grease
A)
7) With both select lever and transmission range sensor kept each “N” position, drive cable end holder
(1) in until it locks cable.
8) Slide lock plate (2) to secure cable end holder in position. 9) After select cable was
installed, check for the
following.
• Push vehicle with select lever shifted to “P” range. Vehicle should not move.
• Vehicle can not be driven in “N” range.
• Vehicle can be driven in “D”, “3”, “2” and “L” ranges.
• Vehicle can be backed in “R” range.
Key Interlock Cable Removal and InstallationS7RS0B5106014
NOTE
Don’t bend interlock cable excessively when
removing and installing it, or system will not
operate correctly.

Removal
1) If the vehicle is equipped with air bag system, disconnect negative cable at battery and disable air
bag system, referring to “Disabling Air Bag System in
Section 8B”.
2) Remove steering column cover.
3) Turn ignition switch to ACC position.
4) Pull out key interlock cable (1) from key cylinder cover (2) while pressing check hook with slotted
screwdriver (3) or the like.
“P” “R”
“N”
“D”
“2”
“L”
I3RM0B510036-01
I2RH01510046-01
I2RH01510047-01
I3RM0B510037-01
1
2 3
I2RH01510083-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-95
5) Shift select lever to “N” position.
NOTE
If select lever is in “P” position, shift select
lever referring to “Select Lever Inspection”.

6) Install cable casing cap (3) to selector bracket (4).
7) Connect cable end (1) to interlock cam (2) with ignition switch turned to ACC position.
8) Drive lock button (5) in cable end until it locks cable expansion and contraction.
9) With select lever set at “P ” position, turn ignition key
to ACC position and then check for the following
conditions.
• With knob button released, ignition key can be turned from ACC position to LOCK position.
• With knob button pressed, ignition key cannot be
turned from ACC position to LOCK position.
10) Install steering column cover. 11) If the vehicle is equipped with air bag system, connect negative cable at battery and enable air bag
system, referring to “Enabling Air Bag System in
Section 8B”.
Transmission Range Sensor (Shift Switch)
Inspection and Adjustment
S7RS0B5106015
1) Shift manual select lever (4) to “N” range.
2) Check that needle direction shaped on lock washer (2) and “N” reference line (1) on transmission range
sensor are aligned. If not, loosen sensor bolts (3)
and align them.
Tightening torque
Transmission range sensor bolt (a): 5.5 N·m (
0.55 kgf-m, 4.0 lb-ft)
3) Check that engine starts in “N” and “P” ranges but it doesn’t start in “D”, “2”, “L” or “R” range. Also, check
that back-up lamp lights in “R” range.
If faulty condition cannot be corrected by adjustment,
disconnect transmission range sensor connector
and check that continuity ex ists as shown by moving
manual select lever.
3
4 1
2
3 5
I4RS0A510055-01
I3RM0B510038-01
4
3
2
1
98 76 5
12 345
6789
P
R N
D 2
L
I3RM0B510039-01

Downloaded from www.Manualslib.com manuals search engine 5A-102 Automatic Transmission/Transaxle:
Operation Check
Check pressure control solenoid valves (Pressure
control solenoid and TCC pressure control solenoid)
operation in the either manner of the following.
Using regulated DC power supply
1) Connect pressure contro l solenoid valve (1) with
regulated DC power supply (2) as shown in figure.
2) Turn regulated DC power supply switch ON and increase voltage of power supply keeping current
within 1.0 A.
3) Check for gradual movement of valve (3) in the direction of arrow “A” as voltage is increased.
4) Check movement of valve (3) in the direction of arrow “B” as voltage is decreased.
5) Turn power supply switch OFF.
CAUTION!
Do not pass current 1.0 A or more, or
pressure control solenoid is burned out.

Not using regulated DC power supply 1) Connect pressure control solenoid valve (1) to battery (2) setting 21 W bulb (4) on the way as
shown in figure.
2) Check for movement of valve (3) in the direction of arrow “A”.
3) Disconnect pressure control solenoid valve (1) from battery (2) and check movement of valve (3) in the
direction of arrow “B” as shown in figure.
CAUTION!
Set 21 W bulb on the way, or pressure control
solenoid valve is burned out.

Transmission Control Module (TCM) Removal
and Installation
S7RS0B5106026
CAUTION!
• TCM and ECM consists of highly precise
parts, therefore when handling it, be
careful not to expose to excessive shock.
• When replacing TCM with used one, all learned contents, which have been stored
in TCM memory by executing learning
control, should be initialized after
replacement.

Removal
1) Disconnect negative cable at battery.
2) If the vehicle is equipped with air bag system, disable air bag system. Refer to “Disabling Air Bag
System in Section 8B”.
3) Disconnect connectors from TCM (1).
4) Remove TCM by removing its bolts.
I2RH0B510064-01
I4RS0A510031-01
1
I4RS0B510007-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-103
Installation
Reverse removal procedure noting the following.
• Connect TCM connectors securely.
• If the vehicle is equipped with air bag system, be sure to enable air bag system after TCM is back in place.
Refer to “Enabling Air Bag System in Section 8B”.
A/T Relay InspectionS7RS0B5106027
1) Disconnect negative cable at battery.
2) Remove A/T relay (2) from fuse and relay box (1).
3) Check that there is no continuity between terminal “C” and “D”.
If continuity is indicated, replace A/T relay.
4) Connect battery positive (+ ) terminal to terminal “A”
of A/T relay and battery negative (–) terminal to
terminal “B” of A/T relay.
Check continuity between terminal “C” and “D” of A/T
relay.
If continuity does not indicated, replace A/T relay.
Differential Side Oil Seal ReplacementS7RS0B5106028
1) Lift up vehicle and drain automatic transaxle fluid.
2) Remove drive shaft joints from differential gear of transaxle. Refer to “Front Drive Shaft Assembly
Removal and Installation in Section 3A” for
procedure to disconnect drive shaft joints.
For differential side oil seal removal, it is not
necessary to remove drive shafts from steering
knuckle.
3) Remove differential side oil seal (1) by using screwdriver or the like.
"D"
"B" "A"
"C"
1
2
I6RS0C510012-01
I2RH0B510067-01