Head Bolt SUZUKI SWIFT 2006 2.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-21
Removal of Manifold Gauge Set
WARNING!
High pressure side is under high pressure.
Therefore, be careful not to get injured
especially on your eyes and skin.

For the A/C system charged with the specified amount of
refrigerant, remove manifold gauge set as follows:
1) Close low pressure side valve of manifold gauge set. (The high pressure side valve is closed continuously
during the process of charging.)
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service valves. This operation must be performed quickly.
5) Put caps on service valves.
Check A/C System for Refrigerant Leaks
Whenever a refrigerant leak is suspected in the system
or any service operation has been performed which may
result in malfunction of lines and connections, it is
advisable to check for leaks.
Common sense should be used during refrigerant leak
test, since the need and extent of any such test will, in
general, depend upon the nature of a complaint and the
type of a service performed on the system.
Liquid leak detector
WARNING!
• To prevent explosions and fires, make sure that there are no flammables in the vicinity.
• When the refrigerant exposed to fire, it turns into a poisonous gas (phosgene). Do
not inhale this gas.

There is a number of fittings and places throughout the
A/C system where a liquid leak detector solution may be
used to pinpoint refrigerant leaks.
By merely applying the solution to the area in question
with a swab, such as attached to the cap of a vial,
bubbles will form within seconds if there is a leak.
For confined areas, such as sections of the evaporator
and condenser, an electronic (refrigerant) leak detector
is more practical fo r determining leaks.
Special tool
(A): 09990–86012
Condenser Assembly On-Vehicle InspectionS7RS0B7216002
Check the followings.
• Clog of condenser fins If any clog is found, cond enser fins should be washed
with water and should be dried with compressed air.
• Condenser fins for leakage and breakage If any defects are found, repair or replace condenser.
• Condenser fittings for leakage. If any defects are found, repair or replace condenser.
Condenser Assembly Removal and InstallationS7RS0B7216003
CAUTION!
Do not damage condenser fins. If condenser
fin is bent, straighten it by using flat head
screwdriver or pair of pliers.

Removal
1) Recover refrigerant from A/C system referring to “Operation Procedure for Refrigerant Charge”.
NOTE
The amount of removed compressor oil must
be measured for replenishing compressor
oil.

2) Remove front bumper referring to “Front Bumper and Rear Bumper Components in Section 9K”.
3) Disconnect discharge hose (1) and liquid pipe (2) from condenser assembly (3).
4) Remove condenser assembly mounting bolts (4).
(A)
I5RS0C721006-01
4
1
3
2
I4RS0A720017-01

Downloaded from www.Manualslib.com manuals search engine 8B-108 Air Bag System:
4) Remove side curtain-air bag (inflator) module fixing bolts (1) and clips (2).
5) Remove side curtain-air bag (inflator) module.
WARNING!
• When carrying a live air bag (inflator) module, make sure the bag opening is
pointed away from you.
Never carry air bag (inflator) module by
wires or connector on the side of the
module. In case of an accidental
deployment, the bag will then deploy with
minimal chance of injury.
• As the live curtain air bag (inflator) module must be kept with it s bag facing up while
being stored or left standing. This is
necessary so that a free space is provided
to allow the air bag to expand in the
unlikely event of accidental deployment.
• Observe “Precautions on Handling and Storage of Air Bag System Components”
for handling and storing it.
Otherwise, personal injury may result.

Installation
WARNING!
Do not install side curtain-air bag (inflator)
module while twisted or bended. Otherwise,
side curtain-air bag (inflator) module may not
deploy and injury may result.

1) Install side curtain-air bag (inflator) module (1) with
clips and new bolts.
2) Tighten side curtain-air bag (inflator) module attaching bolts (1) to specified torque.
Tightening torque
Side curtain-air bag (inflator) module attaching
bolts (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Connect side curtain-air bag (inflator) module connector (1) securely as shown in figure.
a) Connect connector.
b) Lock connector wi th lock button (2).
4) Install head lining referring to “Head Lining Removal and Installation in Section 9H”.
5) Enable air bag system. Refer to “Enabling Air Bag System”.1 2
2
22
1
I4RS0A820076-01
1,(a) 1,(a)
I4RS0A820110-01
1
2
a)
b)
I4RS0A820055-01

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-125
Specifications
Tightening Torque SpecificationsS7RS0B8207001
NOTE
The specified tightening torque is also described in the following.
“Air Bag System Components, Wiring and Connectors Location”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Use of Special ToolsS7RS0B8208001
WARNING!
To avoid deployment when troubleshooting
the air bag system, do not use electrical test
equipment such as a battery powered or AC
powered voltmeter, ohmmeter, etc., or any
type of electrical equipment other than that
specified. Do not use a non-powered probe
type tester.
Instructions must be followed carefully,
otherwise personal injury may result.

You should be familiar with the tools listed under the
heading “Special Tool”. You should be able to measure
voltage and resistance. You should be familiar with
proper use of a scan tool such as Air Bag Driver /
Passenger Load Tool, Connector Test Adapter Kit and
the Digital Multimeter.
Special tool
(A): 09932–76010 Connector Test Adapter Kit
This must be used whenever a diagnostic procedure
requests checking or probing a terminal.
Using the appropriate adapter in the special tool will
ensure that no damage to the terminal will occur from the
multimeter probe, such as spreading or bending.
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
SDM bolt 9 0.9 6.5 )
Driver air bag (inflator) module mounting bolt 9 0.9 6.5 )
Passenger air bag (inflator) module attaching
bolt 23 2.3 16.5)
Sleeve lock nut 2.5 0.25 2.0 )
Side curtain-air bag (inflator) module attaching
bolts 11 1.1 8.0)
Forward-sensor mounting bolt 9 0.9 6.5 )
Side-sensor bolt 9 0.9 6.5 )
I3JA01820041-01

Downloaded from www.Manualslib.com manuals search engine Lighting Systems: 9B-5
Interior Light Symptom DiagnosisS7RS0B9204008
NOTE
• Use of SUZUKI scan tool makes it easy to check whether a faulty condition is on the input side or
output side of BCM. For checking procedure, re fer to “Diagnosis Using Output Test Function of
SUZUKI Scan Tool” under “Scan Tool Data in Section 10B”.
• Check each part in the order from the top of the following list.

Repair Instructions
Headlight Housing Removal and InstallationS7RS0B9206001
Removal 1) Disconnect negative (–) cable at battery.
2) Remove front bumper. Refer to “Front Bumper and Rear Bumper Componen ts in Section 9K”.
3) Remove headlight mounting bolts.
4) Detach headlight housing (1) from vehicle.
5) Disconnect couplers (2) from headlight housing (1). Installation
Reverse removal procedure noting the following.
• Install headlight mounting bolts, and then tighten
headlight mounting bolts (“1” – “3”) according to
numerical order as shown in figure.
• After installation, be sure to inspect and adjust aiming referring to “Headlight Aiming Adjustment with
Screen”.
Condition Possible cause Correction / Reference Item
Dome light does not light
up Bulb blown
Replace bulb.
Circuit fuse blown Replace fuse and check for short circuit.
Dome light switch faulty Check dome light switch.
Door switch faulty Check door switch referring to “Door Switch
(Front / Rear Door) Inspection in Section 9C”.
Wiring or grounding faulty Repair circuit.
BCM faulty Replace after making sure that none of above
parts is faulty.
Luggage compartment
light does not light up (if
equipped) Bulb blown
Replace bulb.
Rear end door switch faulty Check switch referring to “Rear End Door
Switch Inspection in Section 9C”.
Wiring or grounding faulty Repair circuit.
2 1
I4RS0A920003-01
2
1 3
I4RS0A920004-01

Downloaded from www.Manualslib.com manuals search engine Security and Locks: 9F-11
Rear End Door Lock Assembly ComponentsS7RS0B9606010
Rear End Door Lock Assembly Removal and
Installation
S7RS0B9606011
Removal1) Remove door trim (1) from rear end door panel (2). 2) Disconnect door lock motor lead wire.
3) Loosen door latch bolts (1) and remove door latch
assembly (2).
1
7
3 4 5
2
(a)
(b)
6
I4RS0B960009-01
1. Rear end door latch assembly
(rear end door switch is built in this assembly) 4. Shim 7. Rear end door request switch
(if equipped)
2. Rear end door opener switch 5. Door handle : 10 N⋅ m (1.0 kgf-m, 7.5 lb-ft)
3. Latch striker 6. Emergency lever : Rear end door is unlocked by pushing emergency lever
with flat head driver if rear end door lock can not be
released by door opener switch. :23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
“A”
“B”
“B”
“A”“B”“A”“A”“A”
“A”“A”“A”
“A”
2
1
I4RS0A960016-01
1
2
I4RS0A960017-01

Downloaded from www.Manualslib.com manuals search engine Seats: 9G-3
Rear Seat ComponentsS7RS0B9706003
1
5
(b)
(b)
(b)
8
7
9
2
4
4
3
(b)
6
6(c)
2
3
10
6
(a)
10
11
12
“1”
“2”
“3”
I7RS0A970001-01
1. Rear seat cushion
6. Rear seat center hinge11. Seat cushion hook
2. Rear seat back right 7. Seat hinge bracket12. Seat back striker mounting bolt
:Tightening order (Right side): “1” →“2” →“3”
:Tightening order (Left side): “2 →“1” →“3”
3. Rear seat back left 8. Rear seat belt buckle : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Head rest 9. Seat back striker : 43 N⋅m (4.3 kgf-m, 31.5 lb-ft)
5. Child anchorage bracket 10. Seat cushion insert wire : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Interior Trim: 9H-1
Body, Cab and Accessories
Interior Trim
Repair Instructions
Floor Carpet Removal and InstallationS7RS0B9806001
WARNING!
Refer to “Air Bag Warning in Section 00”
before starting service work.

Removal1) Remove front seats and rear seats referring to “Front Seat Removal and Installa tion in Section 9G” and
“Rear Seat Removal and Installation in Section 9G”.
2) Remove seat belt lower anchor bolt.
3) Remove dash side trims, fr ont side sill scuffs, center
pillar inner lower trims, qu arter inner front trims and
rear side sill scuffs.
4) Remove console box.
5) Remove floor carpet.
Installation
Reverse removal sequence to install floor carpet, noting
the following instruction.
• For tightening torque of rear seat mounting bolt, refer to “Rear Seat Components in Section 9G”.
• For tightening torque of front seat mounting bolt, refer to “Front Seat Components in Section 9G”.
Head Lining Removal and InstallationS7RS0B9806002
WARNING!
Refer to “Air Bag Warning in Section 00”
before starting service work.

Removal
1) Remove sun visor (1), room mirror (2), dome light (3), assistant grip (4) and head lining clips (5). 2) Remove front pillar trim (1
), front side sill scuff (2)
and dash side trim (3).
3) Remove front seat belt u pper anchor (1), center pillar
inner trim (2), center pillar inner upper trim (3) and
rear side sill scuff (4).
4) Remove tail end member trim (1).
I6RS0C980001-02
[A]: With curtain air bag 4. Forward
[B]: Without curtain air bag
“A”“A”
“A”
2
4
1
3
“A”
“A”
1
[B]
[A]
“B”“B”
“C”“C”
I6RS0C980002-01
“A”
“B”
“A”
“B”
1
3
2
4
I4RS0A980002-01
“A”
“A”
“A”
“A”“A”1
I4RS0A980003-01

Downloaded from www.Manualslib.com manuals search engine Hood / Fenders / Doors: 9J-2
Front Fender ComponentsS7RS0B9A06003
Front Fender Removal and InstallationS7RS0B9A06004
Removal1) Remove splash guard (if equipped) referring to “Splash Guard (If Equipped) Components in Section 9M”.
2) Remove front fender lining.
3) Remove front bumper referring to “Front Bumper and Rear Bumper Components in Section 9K”.
4) Remove headlight assembly referring to “Headlig ht Housing Removal and Installation in Section 9B”.
5) Disconnect connector from side turn signal lamp.
6) Remove front fender cover.
7) Remove front fender.
Installation
Reverse removal procedure to install fron t fender noting the following instruction.
• If paint on fender bolt is peeled off, be sure to apply paint again.
• Adjust panel clearance referring to “Panel Clearance in Section 9K”.
1 2
3
I4RS0A9A0003-01
1. Front fender lining
2. Front fender3. Front fender cover