Engine parts SUZUKI SWIFT 2006 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Security and Locks: 9F-7
8) Remove key cylinder mounting bolt (1), and then remove key cylinder (2).
9) Disconnect door opening control rod (1) from outside handle.
10) Disconnect door lock motor lead wire at coupler. 11) Remove door latch screws (2) and remove door lock assembly (3).
Installation
Reverse removal procedure to install front door lock
assembly noting the following instructions.
• Apply grease to sliding parts of door latch assembly.
: Grease 99000–25010 (SUZUKI Super Grease A)
• Tighten door latch screws to specified torque.
Tightening torque
Door latch screw (a): 5.0 N·m (0.5 kgf-m, 4.0 lb-ft) • Move door latch striker (2) up or down so its center
aligns with the center of groove “A” on the door lock
assembly (1) as shown.
Striker should be moved vertically and placed level.
Do not adjust door lock.
Tightening torque
Door latch striker screw (a): 10 N·m (1.0 kgf-m, 7.5
lb-ft)
• Move door latch striker (1) sideways to adjust door outer panel surface (2) flush with rear door outer
panel or body outer panel surface (3) as shown.
In order to correctly obtain door lock operation
increase or decrease number of shims inserted
between body and striker (1) to adjust it.
1 2
I4RS0B960005-01
1
2
3
I4RS0A960006-01
(a)
I4RS0A960008-01
3. Shaft
[A]: Front door
[B]: Rear door
I4RS0A960029-01
I3RM0A960013-01

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 10-ii Table of Contents
DTC P1615: ID Code Does Not Registered (Vehicle equipped with keyless start system
only) ................................................................10C-9
DTC P1616: Different Registration ID Codes (Vehicle equipped with keyless start system
only) ..............................................................10C-10
DTC P1618: CAN Communication Error (Reception Error for Keyless Start Control
Module) (Vehicle equipped with keyless
start system only) ..........................................10C-11
DTC P1621: Immobilizer Communication Line Error ......................................................10C-12
DTC P1622: EEPROM Reading / Writing Error ..............................................................10C-13
DTC P1623: Unregistered Transponder .........10C-13
DTC P1625: Immobilizer An tenna Error..........10C-14
DTC P1636: Immobilizer Information Registration Failure .......................................10C-14
DTC P1638: Immobilizer Information Mismatched ...................................................10C-15
Inspection of Immobilizer Control Module (ICM) and Its Circuit ....... ...............................10C-16
Repair Instructions ........... ...............................10C-18
Immobilizer Control Mo dule (ICM) Removal
and Installation ..............................................10C-18
Registration of the Ignition Key .......................10C-18
Procedure after ECM Replacement ................10C-18
Special Tools and Equipmen t .........................10C-19
Special Tool ....................................................10C-19
Keyless Start System ....... ......................10E-1
General Description ........................................... 10E-1
Keyless Start System Description ..................... 10E-1
Parts and Functions .......................................... 10E-2
Keyless Engine Start Function .......................... 10E-3
Door Lock Function of Keyless Start System .... 10E-4
Operation Area of Remote Controller................ 10E-5
Alarm Function .................................................. 10E-6
CAN Communication System Description......... 10E-6
Schematic and Routing Diagram ...................... 10E-7 Keyless Start System El ectric Wiring Circuit
Diagram .......................................................... 10E-7
Diagnostic Information and Procedures .......... 10E-8 Precautions in Diagnosing Troubles ................. 10E-8
Self-Diagnosis Function .................................... 10E-8
Keyless Start System Diagn osis Introduction ... 10E-8 Keyless Start System Chec
k ............................. 10E-8
Customer Questionnaire (E xample) .................. 10E-9
Key Indicator Lamp Check .............................. 10E-10
DTC Check...................................................... 10E-10
DTC Table ....................................................... 10E-11
DTC Clearance ............................................... 10E-12
Keyless Start System Symp tom Diagnosis ..... 10E-12
Keyless Start System Operation Inspection .... 10E-13
Door Lock Operation (Keyless Start System) . 10E-14
Inspection of Keyless Start Control Module and Its Circuits .............................................. 10E-14
No DTC Detection After Performing DTC Check ............................................................ 10E-18
Key Indicator Lamp Circuit Check (Key indicator lamp doesn’t light when ignition
knob switch is pushed.) ................................. 10E-20
Keyless Start Control Module Power and Ground Circuit Check .................................... 10E-22
DTC No. 11: Communi cation Error with
Steering Lock Unit ......................................... 10E-23
DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit
Malfunction .................................................... 10E-24
DTC No. 21 / No. 22: Internal Error of Keyless Start Control Module (EEPROM reading
error) / (EEPROM writing error) ............ ........ 10E-24
DTC No. 31: Lost Commun ication with BCM .. 10E-25
DTC No. 33: Control Module Communication
Bus Off .......................................................... 10E-27
DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door Request
Switch Failure................................................ 10E-28
Repair Instructions ............ .............................. 10E-30
Antennas and Request Switches Removal and Installation .............................................. 10E-30
Front Door (Driver and Passenger Side), Rear End Door Request Switch Inspection............ 10E-31
Steering Lock Unit Removal and Installation .. 10E-31
Steering Lock Unit Inspection ......................... 10E-31
Front Door Lock Switch In spection ................. 10E-31
Keyless Start Control Module Removal and Installation ..................................................... 10E-32
Remote Controller Inspection.......................... 10E-32
Replacement of Remote Controller Battery .... 10E-32
Registration Procedure for Remote Controller
ID Code ......................................................... 10E-33

Downloaded from www.Manualslib.com manuals search engine 10B-11 Body Electrical Control System:
Customer Complaint Analysis
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a questionnaire form as shown in figure will facilitate collectin g information to the point
required for proper analysis and diagnosis. Customer questionnaire (example)
Problem Symptom Confirmation
Check if what the custom er claimed in “Customer
Questionnaire” is accurately f ound in the vehicle. If that
symptom is found, check whether the symptom is
identified as a failure. (This step should be shared with
the customer if possible.)
DTC Check
Check DTC stored in BCM me mory referring to “DTC
Check”, record it and then clear it referring to “DTC
Clearance”. DTC indicates malfunction that occurred in
the system but does not indicate whether it exists now or
it occurred in the past and the normal condition has been
restored now. To check which case applies, clear DTC
once and check whether or not any fault exists.
Troubleshooting for DTC
Based on the DTC indicated in Step 3 and referring to
applicable DTC flow, locate the cause of the trouble,
namely in a sensor, wire harness, connector, BCM or
other part and repair or replace faulty parts. Body Electrical Control System Symptom Diagnosis
Check the parts or system
suspected as a possible
cause referring to symptom diagnosis of each system.
Check for Intermi ttent Problem
Check parts where an intermit tent trouble is easy to
occur (e.g., wire harness, connector, etc.), referring to
“Intermittent and Poor Connec tion Inspection in Section
00”.
Final Confirmation Test
Confirm that the problem symptom has gone and the
body electrical control system is free from any abnormal
conditions. If what has been repaired is related to the
malfunction DTC, check DTC again and confirm that no
DTC is indicated.
Customers name:
Model:
VIN:

Date of issue:
Date Reg:
Date of problem:
Mileage:

Problem Symptoms
Power door lock system does not operate
Keyless entry system does not operate
Rear end door window defogger does not operate
Rear wiper does not operate
Rear end door opener does not operate
Other
Frequency of Occurrence
Continuous / Intermittent ( times a day, a month)
/ Other

Environmental Condition
Weather:
Fine / Cloudy / Rain / Snow / Other

Temperature: (F )
Diagnostic Trouble Code Normal code / Malfunction code ( )

Warning buzzer does not sound
Interior light does not light
Theft deterrent light does not flush
I5RS0DA20006-01

Downloaded from www.Manualslib.com manuals search engine 10B-13 Body Electrical Control System:
Scan Tool Data Definitions
Vehicle Speed (km/h, mph): It is computed based on pulse signals from vehicle speed sensor on transmission.
Outside air Temp ( °C, °F): It is detected by outside air temperature sensor.
Battery Voltage (V): This parameter indicates battery po sitive voltage inputted to BCM.
Coolant Temp (Engine coolant temperature) ( °C, °F): It is detected by engine coolant temperature sensor.
Engine Speed (RPM): It is computed by reference pulse signals from CMP sensor.
Fuel Consumption (km/l): This parameter indicates the fuel consumption computed by ECM.
Key Reminder Sw (Key reminder switch) (Pulled / Key in): This parameter indicates the state of the key reminder
switch.
Rear Wiper Sw (Rear wiper switch) (ON / INT / OFF): This parameter indicates the state of the rear wiper switch.
Door key Sw (Door key cylinder switch) (Lock / Neutral / Unlock): This parameter indicates the state of the door
key cylinder switch.
Door lock Sw (Manual door lock switch) (Lock / Neutral / Unlock): This parameter indicates the state of the
manual door lock switch.
Driv Door Sw (Driver side d oor switch) (Open / Close): This parameter indicates the state of the driver side door
switch.
Pass Door Sw (Other than driver side door switch) (Open / Close): This parameter indicates the state of the door
switches other than driver side door switch.
Brake Fluid Level (Low / Normal): Low: Brake fluid level is lower than specified level.
Normal: Brake fluid level is higher than MIN level.
Parking Brake Sw (Parking brake switch) (ON / OFF): ON: Parking brake lever is pulled up.
OFF: Parking brake lever is released.
Rear Defogger Sw (Rear end door window defogger switch) (ON / OFF): This parameter indicates the state of
the rear end door window defogger switch.
Tail Light Sw (Lighting switch) (ON / OFF): This parameter indicates the state of the lighting switch.
Driv Seatbelt Sw (Driver seat belt switch) (Fasten / Unfasten): This parameter indicates the state of the driver
side seat belt buckle switch.
Rear end Door Opener (Rear end door opener switch) (ON / OFF): This parameter indicates the state of the rear
end door opener switch.
“3” position Sw (ON/OFF): This parameter indicates the state of the “3 ” position switch included in A/T manual
selector assembly.
Charge lamp (ON / OFF): This parameter indicates the state of the charge system monitor switch.
Oil pressure switch (ON / OFF): This parameter indicates the state of the oil pressure switch.
A/C Switch (ON / OFF): This parameter indicates the state of the air conditioning switch.
Diagnosis Using Output Test Function of SUZUKI Scan Tool
SUZUKI scan tool has the output test function which can force operation of following actuators and relays of the
system controlled by BCM. When a malf unction is found in the system controlled by BCM, execute the output test
which enables easy judgment whether the malfunction is on the input side or output side of BCM. For detailed
information on operation of SUZUKI scan tool, refer to “SUZUKI Scan Tool Operator’s Manual”.
Output Teat Item Controlled Parts
Hazard Warning Light Turn signal and hazard warning relay
Interior (Dome) Light Interior (Dome) light (wh en interior light switch is at DOOR position)
Door Each door lock actuator
Rear end door open Rear end door opener relay
Warning buzzer Warning buzzer (in BCM)
Rear wiper Rear wiper relay
Alarm indicator Theft deterrent light (in information display or clock)
Rear defogger Rear end door window defogger relay

Downloaded from www.Manualslib.com manuals search engine Body Electrical Control System: 10B-20
DTC Troubleshooting
DTC B1157 (No. 1157): Air Bag Deployment Signal InputS7RS0BA204011
Wiring Diagram
Refer to “DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction”.
DTC Detecting Conditi on and Possible Cause
Flow Test Description
Step 1: Check DTC for SDM.
DTC Troubleshooting Step Action Yes No
1 Check air bag communication circuit
1) Turn ignition switch to OFF position.
2) Disconnect connector from SDM referring to “SDM
Removal and Installation in Section 8B”.
3) Disconnect connector from junction block assembly.
4) Turn ignition switch to ON position.
5) Measure voltage between “L29-37” terminal of SDM connector and vehicle body ground.
Is voltage 0 V? Go to Step 2. Short to power supply in
air bag communication
circuit.
2 Check air bag communication circuit
1) Turn ignition switch to OFF position.
2) Connect connectors to junction block assembly.
3) Turn ignition switch to ON position.
4) Measure voltage between “L04-2” terminal of junction
block assembly connector and vehicle body ground.
Is voltage 4 – 6 V? Go to Step 3.
Short to ground in air
bag communication
circuit. If OK, substitute
a known-good BCM
(included in junction
block assembly) and
recheck.
3 Check air bag communication circuit
1) Measure voltage between “L29-37” terminal of SDM
connector and vehicle body ground.
Is voltage 4 – 6 V? Substitute a known-
good SDM and recheck.
Open or high resistance
in air bag
communication circuit.
DTC detecting condition
Possible cause
Air bag deployment signal is fed from SDM to BCM. • Air bag component parts
• BCM malfunction
StepAction YesNo
1 DTC check of SDM
1) Check DTC stored in SDM re ferring to “DTC Check in
Section 8B”.
Is DTC B1021 detected? Go to “DTC B1021:
Front Air Bag Module
Deployed in Section
8B”.
Substitute a known-
good BCM (included in
junction block
assembly) and recheck.

Downloaded from www.Manualslib.com manuals search engine Keyless Start System: 10E-1
Control Systems
Keyless Start System
General Description
Keyless Start System DescriptionS7RS0BA501001
Keyless start system consisting of the parts shown below has three functions as described below.
• Keyless engine start function:With the remote controller which has been registered in the keyless start control module carried with oneself, the
engine can be started without using the ignition key.
• Door lock function: Pushing the request switch incorporated in the outside handl e of the driver side door, passenger side door or rear
end door while carrying the remote controller which has been registered in the keyless start control module, doors
can be locked or unlocked.
• Keyless entry system function: It is possible to lock or unlock doors by push ing the lock or unlock button of remote controller.
The keyless start control module can accept regi stration of up to four remote controllers.
5
12
13
9
14
1
2
6
3
748
3
11
10
I4RS0BA50001-02
1. Keyless start control module 5. Luggage room antenna 9. Steering lock unit13. Key indicator lamp
2. Remote controller 6. Driver side door antenna10. Lock button14. ECM
3. Request switch 7. Passenger side door antenna11. Unlock button
4. Center antenna 8. Rear end door antenna12. BCM

Downloaded from www.Manualslib.com manuals search engine 10E-2 Keyless Start System:
Parts and FunctionsS7RS0BA501002
PartsFunction
Keyless start control module • Activates each antenna
• Verifies ID code of remote controller
• Requests steering lock unit to release steering lock
• Requests BCM to lock or unlock doors
• Controls key indicator la
mp in combination meter
• Transmits its ID code to ECM
Remote controller • Receives request signal from each antenna
• Transmits ID code and request signal to keyless start control module
• Request keyless start control module to lock or unlock doors (keyless entry
system function)
Request switch • Requests keyless start control module to activate each antenna
Center antenna • Transmits request signal to remote controller
Luggage room antenna • Transmits request signal to remote controller
Driver side door antenna • Transmits request signal to remote controller
Passenger side door antenna • Transmits request signal to remote controller
Rear end door antenna • Transmits request signal to remote controller
Steering lock unit • Releases steering lock
Unlock button • Transmits door unlock request signal (keyless entry system function)
Lock button • Transmits door lock request signal (keyless entry system function)
BCM • Controls each door lock actuator
• Controls warning buzzer
• Lights hazard warning lamp and interior (DOME) light (answer back)
Key indicator lamp • Indicates operation state of keyless start system (indicates check result of
remote controller ID code)
ECM • Checks keyless start control module ID code
• Transmits its ID code to keyless start control module
• Starts engine

Downloaded from www.Manualslib.com manuals search engine Keyless Start System: 10E-9
Customer Questionnaire (Example)S7RS0BA504005
3 1) Inspect and repair basic parts referring to “Keyless Start System Symptom Diagnosis”.
Is there faulty condition? Repair or replace
malfunction part(s), and
go to Step 5.
Go to Step 4.
4 1) Check for intermittent problems referring to “Intermittent and Poor Connection Inspection in Section 00”.
Is there any faulty condition? Repair or replace
malfunction part(s), and
go to Step 5.
Go to Step 5.
5 1) Confirm if the problem is solved and the keyless start system is free from any abnormal conditions. If what has
been repaired is related to the DTC, clear the DTC once
and then confirm that no DTC is indicated.
Is there any problem symptom, DTC or abnormal condition? Go to 2) of Step 1 and
perform trouble
diagnosis again.
End.
Step Action Yes No
Customers name:
Model:
VIN:

Date of issue:
Date Reg:
Date of problem:
Mileage:

Problem Symptoms
Engine can not be started by turning Ignition knob
switch
All doors can not be locked / unlocked by all of
request switches
Other
Frequency of Occurrence Continuous / Intermittent ( times a day, a month)
/ Other

Environmental Condition
Weather:
Fine / Cloudy / Rain / Snow / Other

Temperature: (F )
Stopping near area where intense radio waves are
emitted such as TV station, radio station, etc.
Yes / No
Diagnostic Trouble Code
First check:
Normal code / malfunction code ( )
Second check:
Normal code / malfunction code ( )
I4RS0BA50007-03