Lever SUZUKI SWIFT 2006 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-8
Installation
CAUTION!
After tightening steering column mounting
nuts, shaft joint bolts should be tightened.
Wrong tightening order could cause a
damage to shaft joint.

1) Be sure that front wheels are in straight.
2) Install steering column assembly to lower and upper brackets. Tighten steering column lower nuts (1) first
and then upper nuts (2) to specifications as given
below.
Tightening torque
Steering column nut (a): 14 N·m (1.4 kgf-m, 10.5
lb-ft)
NOTE
After installing tilt steering column, make
sure that steering column moves backwards
and forwards smoothly and stops when tilt
lever is fixed.

3) Align flat part “A” of stee ring lower shaft (1) with bolt
hole “B” of shaft joint (2) of column as shown. Then
insert lower shaft into shaf t joint of steering column
with matching marks (4).
4) Insert lower shaft (1) into pinion shaft (3) with matching marks (4).
5) Tighten joint bolt (pinion shaft side) (6) to specified torque first and then joint bolt (steering column side)
(5) to specified torque.
CAUTION!
After tightening column nuts, tighten steering
shaft upper joint bolt. Otherwise shaft joint
bearing is damaged.

Tightening torque
Steering shaft joint bolt (a): 25 N·m (2.5 kgf-m,
18.5 lb-ft) 6) Install steering joint cover.
7) Install immobilizer cont
rol module from steering
column, referring to “Immo bilizer Control Module
(ICM) Removal and Installation in Section 10C”.
8) Install lighting switch and wiper switch to steering column.
9) Install contact coil cable assembly and steering wheel referring to “Conta ct Coil Cable Assembly
Removal and Installation” and “Steering Wheel
Removal and Installation”.
10) Install steering column hole cover. 11) Connect negative (–) battery to cable.
12) Enable air bag system refe rring to “Enabling Air Bag
System in Section 8B”.
Steering Column InspectionS7RS0B6206007
Check steering column for damage and operation
referring to “Checking Steering Column for Accident
Damage”.
2,(a)
1,(a)
1,(a)
2,(a)
I4RS0B620009-02
I6RS0C620003-01

Downloaded from www.Manualslib.com manuals search engine Heater and Ventilation: 7A-3
Diagnostic Information and Procedures
Heater and Ventilation Symptom DiagnosisS7RS0B7104001
ConditionPossible cause Correction / Reference Item
Blower motor does not
operate with blower
speed selector ON Fuse blown
Check related fuses, and then check for short
circuit to ground.
Blower motor relay faulty Check blower motor relay referring to “Blower
Motor Relay Inspection”.
Blower motor resistor faulty Check blower motor resistor referring to
“Blower Motor Resistor Inspection”.
Blower speed selector faulty Check blower speed selector referring to
“Blower Speed Selector Inspection”.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection”.
Wiring or grounding faulty Repair as necessary.
Incorrect temperature
output Temperature control cable broken or
bent (manual A/C) Check temperature control cable.
Temperature control lever faulty (manual
A/C) Check temperature control lever.
Incorrect installation of temperature
control cable (manual A/C) Check position and adjust it as necessary.
Temperature control door assembly
broken Repair temperature control door assembly.
Air ducts clogged Repair air ducts.
Heater core leaked or clogged Replace heater core.
Heater hoses leaked or clogged Replace heater hoses.
Thermostat faulty Check thermostat referring to “Thermostat
Inspection in Section 1F”.
Temperature control actuator faulty
(automatic A/C) Check temperature control actuator referring to
“Temperature Control Actuator Inspection in
Section 7B”.
HVAC control module faulty (automatic
A/C) Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit in Section 7B”.
Wiring or grounding faulty (automatic A/
C) Repair as necessary.
Air outlet port does not
change or does not agree
with air flow selector’s
position even if air flow
selector is changed Air flow control cable broken or bent
(manual A/C)
Check air flow control cable.
Air flow control lever faulty (manual A/C) Check air flow control lever.
Incorrect installation of air flow control
cable (manual A/C) Check position and adjust it as necessary.
Air flow control door assembly broken Repair air flow control door assembly.
Air ducts leaked or clogged Repair air ducts.
Air flow control actuator faulty
(automatic A/C) Check air flow control actuator referring to “Air
Flow Control Actuator
Inspection in Section
7B”.
HVAC control module faulty (automatic
A/C) Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit in Section 7B”.
Wiring or grounding faulty (automatic A/
C) Repair as necessary.
Air intake door does not
change even if air intake
mode is changed Air intake door broken
Repair air intake door.
Air intake control actuator faulty Check air intake control actuator referring to
“Air Intake Control Actuator Inspection”.
Air intake selector faulty Check air intake selector referring to “Air Intake
Selector Inspection”.
Wiring or grounding faulty Repair as necessary.

Downloaded from www.Manualslib.com manuals search engine 7A-8 Heater and Ventilation:
b. Move temperature control lever (1) and air flow control plate (2) fully to the arrow direction. c. Fix temperature control inner cable (1) to pin of
temperature control lever and air flow control inner
cable (2) to pin of air fl ow control plate, and then
fix each outer cable (3) to each cable lock clamp.
NOTE
After installing control cables, make sure that
control lever and plate move smoothly and
stop at proper position.

• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
• Make sure that air flow outlet changes correctly as air flow selector is changed.
[A]: LH steering vehicle [B]: RH steering vehicle
1
2
[A]
[B]
1
2
I4RS0B710014-01
[A]: LH steering vehicle [B]: RH steering vehicle
1
2
[B] [A] 3
3
1
3
23
I4RS0B710015-01

Downloaded from www.Manualslib.com manuals search engine 7B-24 Air Conditioning System: Manual Type
HVAC Unit Removal and InstallationS7RS0B7216006
Removal1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Recover refrigerant from A/C system with recovery and recycling equipment referring to “Recovery” in
“Operation Procedure for Refrigerant Charge”.
4) Remove cowl top panel referring to “Cowl Top Components in Section 9K”.
5) Drain engine coolant, and then disconnect heater hoses (1) from HVAC unit (2).
6) Remove instrument panel from vehicle body referring to “Audio Unit Re moval and Installation in
Section 9C”.
7) Loosen suction hose and liquid pipe bolt (4).
8) Remove nuts (3).
9) Remove HVAC unit from vehicle body. Installation
Reverse removal procedure noting the following
instructions.
• Replenish specified amount of compressor oil to
compressor suction side referring to “Replenishing
Compressor Oil” in “Operation Procedure for
Refrigerant Charge”.
• Install the padding (1) to the installation hole uniformly.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
• Adjust control cables referr ing to “HVAC Control Unit
Removal and Installati on in Section 7A”.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Evaporator InspectionS7RS0B7216007
Check the followings.
• Clog of A/C evaporator fins.If any clogs are found, A/C evaporator fins should be
washed with water, and then should be dried with
compressed air.
• A/C evaporator fins for leakage and breakage. If any defects are found, repair or replace A/C
evaporator.
• A/C evaporator fittings for leakage. If any defects are found, repair or replace A/C
evaporator.
2. Blower upper case 8. Temperature control door assembly 14. Temperature control lever 20. Packing
3. Air intake control actuator 9. Blower motor resistor 15. Airflow control lever21. Filter cover (if equipped)
4. HVAC Air filter (if equipped) 10. Blower lower case 16. Evaporator22. Drain hose
5. Heater unit upper case 11. Blower motor 17. O-ring23. Cable lock clamp
6. Foot duct 12. Heater unit lower case 18. Expansion valve: Do not reuse.
3
2
3
3
1
4
I4RS0B720009-01
1
I4RS0B720010-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-73
HVAC Unit Removal and InstallationS7RS0B7226003
Refer to “HVAC Unit Removal and Installation”.
Temperature Control Actuator Removal and
Installation
S7RS0B7226004
Removal1) Disconnect negative (–) cable at battery.
2) Remove steering column hol e cover from instrument
panel.
3) Remove foot duct from HVAC unit.
4) Disconnect temperature control actuator connector (1).
5) Detach temperature control actuator rods (2) from linkage (3).
6) Remove temperature control actuator (4) from HVAC unit.
Installation
Reverse removal procedure.
Temperature Control Actuator InspectionS7RS0B7226005
1) Remove temperature control actuator from HVAC unit referring to “Temperature Control Actuator
Removal and Installation”.
2) Connect connector to temperature control actuator.
3) Set temperature selector of HVAC control module to MAX HOT position with ignition switch ON, and
make sure if the position of actuator lever is MAX
HOT position (A).
4) Turn ignition switch OFF, and then disconnect connector from temperature control actuator.
5) Measure resistance between terminal “3” and “5”.
Temperature control actuator resistance between
terminal “3” and “5” (MAX HOT position)
Approximately 2.5 k Ω at 25 °C (77 °F) 6) Connect connector to tem
perature control actuator.
7) Set temperature selector of HVAC control module to MAX COOL position with ignition switch ON, and
make sure if the position of actuator lever is MAX
COOL position (B).
8) Turn ignition switch OFF, and then disconnect connector from temperature control actuator.
9) Measure resistance between terminal “3” and “5”
Temperature control actuator resistance between
terminal “3” and “5” (MAX COOL position)
Approximately 4.8 k Ω at 25 °C (77 °F)
If check result is not satisfactory, replace the actuator
with new one.
2. Blower upper case 9. Blower motor controller 16. Evaporator 23. Temperature control actuator
3. Air intake control actuator 10. Blower lower case 17. O-ring24. Air flow control actuator
4. Air filter (if equipped) 11. Blower motor 18. Expansion valve25. Inside air temperature sensor
5. Heater unit upper case 12. Heater unit lower case 19. Evaporator temperature sensor 26. Aspirator hose
6. Foot duct 13. Heater core 20. Packing : Do not reuse.
7. Air flow control door assembly 14. Temperature control links 21. Filter cover
1
2
2
3
4
I5RS0A722020-02
I5RS0A722021-03
I5RS0A722022-03

Downloaded from www.Manualslib.com manuals search engine 7B-74 Air Conditioning System: Automatic Type
Air Flow Control Actuator Removal and
Installation
S7RS0B7226006
Removal1) Disconnect negative (–) cable at battery.
2) Remove steering column hol e cover from instrument
panel.
3) Remove foot duct from HVAC unit.
4) Disconnect air flow contro l actuator connector (2).
5) Remove air flow control actuator (1) from HVAC unit, and then detach air flow actuator rod from linkage.
Installation
Reverse removal procedure.
Air Flow Control Actuator InspectionS7RS0B7226007
1) Remove air flow control actuator from HVAC unit referring to “Air Flow C ontrol Actuator Removal and
Installation”.
2) Connect actuator connector to the actuator.
3) Set air flow selector of HVAC control module to DEF position with ignition switch ON, and make sure if the
position of actuator lever is DEF position (8).
4) Turn ignition switch OFF, and then disconnect connector from air flow control actuator.
5) Measure resistance between terminal “3” and “5”
Air flow control actuator resistance between
terminal “3” and “5” (DEF position)
Approximately 4.8 k Ω at 25 °C (77 °F)
I5RS0A722023-03
[A]: LH steering vehicle [B]: RH steering vehicle
8
[A]
[B]
8
7654 321
I5RS0C722004-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-75
6) Connect connector to air flow control actuator.
7) Set air flow selector of HVAC control module to VENT position with ignition switch ON, and make
sure if the position of act uator lever is VENT position
(8).
8) Turn ignition switch OFF, and then disconnect connector from air flow control actuator.
9) Measure resistance between terminal “3” and “5”.
Air flow control actuator resistance between
terminal “3” and “5” (VENT position)
Approximately 2.0 k Ω at 25 °C (77 °F)
If check result is not satisfactory, replace the actuator
with new one.
Air Intake Control Actuator Removal and
Installation
S7RS0B7226008
Refer to “Air Intake Control Actuator Removal and
Installation in Section 7A”.
Air Intake Control Actuator InspectionS7RS0B7226009
Check air intake contro l actuator as follows:
1) Using service wire, connect battery positive terminal
to terminal “7” and battery negative terminal to
terminal “1”. And, check if air intake selector link
operates smoothly and it stops at “REC” position (A).
2) Using service wire, connect battery positive terminal
to terminal “7” and battery negative terminal to
terminal “5”. And, check if air intake selector link
operates smoothly and it stops at “MIX” position (B).
3) For auto A/C model, using service wire, connect battery positive terminal to terminal “7” and battery
negative terminal to “3” terminal. And, check air
intake selector link operates smoothly and it stops at
“FRE” position (C).
If malfunction is found, replace air intake control
actuator.
[A]: LH steering vehicl e [B]: RH steering vehicle
[A]
[B]
8
8765 4 3 21
I5RS0C722005-02
A
C
B“a”
“a”“a”
-
+
A
C
B “1” “3” “5” “7”
“1”
“3”
“5”
“7”
120
°
120° 120
°
I7RS0A722002-01

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-119
11) Connect adapter cable (B) to deployment harness (A) connector and lock connectors with lock lever. 12) Notify all people in immediate area that you intend to
deploy / activate air bag (inflator) module or seat belt
pretensioner.
NOTE
• When air bag (inflator) module deploys and seat belt pretensioner activates, rapid gas
expansion will create substantial report.
Wear suitable ear protection. Notify all
people in immediate area that you intend
to deploy air bag (inflator) module or
activate seat belt pretensioner and suitable
ear protection should be worn.
• When driver air bag (inflator) module deploys, driver air bag (inflator) module
may jump about 30 cm (1 ft) vertically. This
is normal reaction to force of rapid gas
expansion inside of drive air bag (inflator)
module.
• After air bag (inflator) module has been deployed, surface of air bag (inflator) may
contain powdery residue. This powder
consists primarily of cornstarch (used to
lubricate bag (inflator) as it inflates) and
byproducts of chemical reaction.

WARNING!
• Do not place deployed air bag (inflator) module and activated seat belt
pretensioner near any flammable objects.
• Do not apply water, oil, etc. to deployed air bag (inflator) module and activated seat
belt pretensioner.
• Wait for about 30 minutes before touching any metal surface of air bag (inflater)
module or seat belt pretensioner module.
Disregarding these precautions may cause
fire or personal injury.
Failure to follow procedures may result in fire
or personal injury.

[A]
10 m (33 ft)
(A)
(B)
1
10 m (33 ft)
(A)
(B) 1
5
3 2
4
(A)
[B]
[C]
[D]
[E]
7
3
6 5
(A) (B)
1
10 m (33 ft)
10 m (33 ft)
(A)
(B)
1
1
10 m (33 ft)
I4RS0A820092-02

Downloaded from www.Manualslib.com manuals search engine Wiring Systems: 9A-24
L: Floor harness
L: ACC socket wire
L: License plate wire
R: Fuel pump wireNo./Color Connective position No./Color Connective position
L01/BLU BCM L27/BLK Parking brake switch L02/N Main harness (To E44) L28/BLU ACC socket wire (To L44)
L03/YEL Main harness (To E45) L29/PNK A/B SDM
L04/YEL J/B L29/BRN (With
Side A/B,
Curtain A/B System) A/B SDM
L05/N J/B L30/YEL (IF
EQPD) Side air-bag inflator (Passenger side)
L06/N J/B L31/N Front door wire (Passenger side) (To J09)
L07/N Front door wire (Driver side) (To J01) L32/YEL Instrument panel harness (To G04)
L10/BLK Pretensioner (Driver side) L33/N Instrument panel harness (To G03)
L11/N (IF EQPD) Driver side-sensor L34/N Front door switch (Passenger side)
L12/N Front door switch (Driver side) L35/N Passenger side-sensor
L13/N Rear door wire (R) (To J16) L 36/BLK Pretensioner (Passenger side)
L14/N Wheel speed sensor (RR) L37/N Rear door wire (L) (To J21)
L15/GRY Fuel pump wire (To R01) L38/N Wheel speed sensor (RL)
L16/N Rear door switch (R) L39/N Antenna amplifier
L17/N High mounted stop light L40/N Rear door switch (L)
L18/BLK (IF EQPD) Side curtain air-bag (R) L41/BLK (IF
EQPD) Side curtain air-bag (L)
L19/GRY Luggage compartment light L42/N Rear end door wire (To O01) L20/N Rear combination light (R) L43/BLK Rear combination light (L)
L21/N License plate wire (To L22) L51/ GRY Instrument panel harness (To G43)
L23/N (A/T) A/T shift lever L59/GRY (IF
EQPD) Rear end antenna
L24/GRY J/C L65/BRN (IF
EQPD) Inside antenna
L25/YEL (IF EQPD) Side air-bag inflator (Driver side) L66/BRN (IF
EQPD) Luggage antenna
L26/N Seat belt switch L74/BLU J/C
No./Color Connective position No./Color Connective position
L44/BLU Floor harness (To L28) L46/BLK ACC socket
No./ColorConnective position No./Color Connective position
L22/N Floor harness (To L21) L48/N License plate light #2
L47/N License plate light #1
No./Color Connective position No./Color Connective position
R01/GRY Floor harness (To L15) R03/N (IF
EQPD) Sub fuel level sensor
R02/BLK Fuel pump and gauge

Downloaded from www.Manualslib.com manuals search engine Wiring Systems: 9A-26
L: Floor harness
L: ACC socket wire
L: License plate wire
R: Fuel pump wireNo./Color Connective position No./Color Connective position
L01/BLU BCM L29/BRN (With
Side A/B,
Curtain A/B System) A/B SDM
L02/N Main harness (To E44) L30/YEL (IF
EQPD) Side air-bag inflator (Passenger side)
L03/YEL Main harness (To E45) L31/N Front door wire (Passenger side) (To J09)
L04/YEL J/B L32/YEL Instrument panel harness (To G04) L05/N J/B L33/N Instrument panel harness (To G03)
L06/N J/B L34/N Front door switch (Passenger side)
L07/N Front door wire (Driver side) (To J01) L35/N (IF
EQPD) Passenger side-sensor
L10/BLK Pretensioner (Driver side) L36/ BLK Pretensioner (Passenger side)
L11/N (IF EQPD) Driver side-sensor L37/N Rear door wire (L) (To J21)
L12/N Front door switch (Driver side) L38/N Wheel speed sensor (RL)
L13/N Rear door wire (R) (To J16) L39/N Antenna amplifier
L14/N Wheel speed sensor (RR) L40/N Rear door switch (L)
L15/GRY Fuel pump wire (To R01) L41/BLK (IF
EQPD) Side curtain air-bag (L)
L16/N Rear door switch (R) L42/N Rear end door wire (To O01)
L17/N High mounted stop light L43/BLK Rear combination light (L)
L18/BLK Side curtain air-bag (R) L51/GRY Instrument panel harness (To G43)
L19/GRY Luggage compartment light L53/N Diagnosis connector #3
L20/N Rear combin ation light (R) L59/GRY (IF
EQPD) Rear end antenna
L21/N License plate wire (To L22) L60/BLK (IF
EQPD) Rear fog light
L23/N (A/T) A/T shift lever L61/N (IF
EQPD) Seat heater (Driver side) and seat belt
switch
L24/GRY J/C L62/N (IF
EQPD) Seat heater (Passenger side)
L25/YEL Side air-bag inflator (Driver side) L63/YEL (IF
EQPD) Seat heater switch (Driver side)
L26/N Seat belt switch L64/GRN (IF
EQPD) Seat heater switch (Passenger side)
L27/BLK Parking brake switch L65/BRN (IF
EQPD) Inside antenna
L28/BLU ACC socket wire (To L44) L66/BRN (IF
EQPD) Luggage antenna
L29/PNK A/B SDM L74/BLU J/C
No./Color Connective position No./Color Connective position
L44/BLU Floor harness (To L28) L46/BLK ACC socket
No./ColorConnective position No./Color Connective position
L22/N Floor harness (To L21) L48/N License plate light #2
L47/N License plate light #1
No./Color Connective position No./Color Connective position
R01/GRY Floor harness (To L15) R03/N (IF
EQPD) Sub fuel level sensor
R02/BLK Fuel pump and gauge