low SUZUKI SWIFT 2007 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 9J-7 Hood / Fenders / Doors:
WARNING!
Handling of Rear End Door Balancer
(Damper)
• Handle balancer carefully. Do not scar or scratch exposed surface of its piston rod,
and never allow any paint or oil to stick to
its surface.
• Do not turn piston rod with balancer fully extended.
• Do not disassemble balancer (1) because its cylinder is filled with gas.
Discarding of Rear End Door Balancer
(Damper)
• The gas itself in balancer is harmless but it may issue out of the hole together with
chips generated by th e drill (2). Therefore,
be sure to wear goggle when drilling.
• Using a 2 to 3 mm (0.08 to 0.12 in.) drill (2),
make a hole to remove gas inside as
shown before discarding.

Installation
Reverse removal procedure noting the following.
• Tighten rear end door balancer bolt to specified torque.
Tightening torque
Rear end door balancer bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lb-ft) • Secure wiring harness (1).
• Adjust door latch striker position by referring to “Rear
Door Lock Assembly Removal and Installation in
Section 9F”.
• Adjust door cushion so that door contacts body when closed.
• Apply sealant to contact face “A” of door hinge (1) and apply grease to rotating part “B” of hinge (1).
Specified sealant and grease.
“A”: Sealant 99000–31110 (SUZUKI Bond
No.1215)
“B”: Grease 99000–25010 (SUZUKI Super Grease
A)
I2RH019A0010-01
(a)
(a)
I4RS0A9A0013-01
1
I4RS0A9A0012-01
I2RH019A1012-01

Downloaded from www.Manualslib.com manuals search engine Hood / Fenders / Doors: 9J-8
Specifications
Tightening Torque SpecificationsS7RS0B9A07001
NOTE
The specified tightening torque is also described in the following.
“Front Door Assembly Components”
“Rear Door Assembly Components”
“Rear End Door Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS7RS0B9A08001
NOTE
Required service material is also described in the following.
“Front Door Assembly Components”
“Rear Door Assembly Components”
“Rear End Door Assembly Components”

Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Hood latch bolt 10 1.0 7.5 )
Door hinge mounting bolt (body side) 27 2.7 19.5 )
Door hinge mounting bolt (door side) 23 2.3 17.0 )
Door open stopper bolt 21 2.1 15.5 )
Rear end door balancer bolt 23 2.3 17.0 )
MaterialSUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25010) / )
Sealant SUZUKI Bond No.1215 P/No.: 99000–31110) / ) / )

Downloaded from www.Manualslib.com manuals search engine 9K-1 Body Structure:
Body, Cab and Accessories
Body Structure
Repair Instructions
Front Bumper and Rear Bumper ComponentsS7RS0B9B06001
10
6
79
8
32
1
5
4 1117
175
1315
14
12
16
18
14
13
I7RS0B9B0001-01
1. Front bumper
6. Front bumper upper absorber 11. License plate nut16. Front bumper guard
2. Radiator upper grill 7. Front bumper lower absorber 12. Rear bumper17. Rear bumper guard cap
3. Radiator lower grill 8. Front bumper upper member 13. Rear bumper holder
4. Front air dam skirt 9. Front bumper lower member 14. Plastic nut
5. Front fog lamp cap 10. Front bumper holder 15. Rear bumper guard

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 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 10B-1 Body Electrical Control System:
Control Systems
Body Electrical Control System
Precautions
Precautions in Diagnosing TroubleS7RS0BA200001
• Diagnostic information stored in BCM memory can be cleared as well as checked by using SUZUKI scan tool.
Before using scan tool, read its Operator ’s (Instruction) Manual carefully to have good understanding as to what
functions are available and how to use it.
• Be sure to read “Precautions for Electrical Circuit Serv ice in Section 00” before inspection and observe what is
written there.
• Communication of ECM, TCM (if equipped), ABS/ESP ® control module, steering angle sensor (ESP ® model),
keyless start control module (if equipped), combinatio n meter and BCM is established by CAN (Controller Area
Network). For detail of CAN communication for BCM, refer to “CAN Communication System Description”.
Therefore, handle CAN communication line with care referr ing to “Precaution for CAN Communication System in
Section 00”.
General Description
BCM General DescriptionS7RS0BA201001
The Body electrical Control Module (BCM) is incorporated in junction block assembly. Do not attempt removal of BCM
from junction block assembly as it may cause contact failure.
The BCM incorporates relays and controllers which are used for the following systems and controls them.
• Power door lock
• Keyless entry (if equipped)
• Door lock function of keyle ss start system (if equipped)
• Rear wiper
• Combination meter
• Interior light
• Warning buzzer
• Rear end door window defogger and door mirror heater (if equipped)
• Rear end door opener
• Theft deterrent light
Also, the BCM has a function to cause the interior light and open door warning lamp in the combination meter to turn
off when any door is left open for longer than 15 minutes to reduce wasteful battery consumption.
In addition, it is possible to check operation of actuator whic h is controlled by BCM by using the output test function of
SUZUKI scan tool to operate actuator simulatively.

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CAN Communication System DescriptionS7RS0BA201002
Refer to “CAN Communication System Description in Section 1A” for CAN communication system description. BCM
communication control data with ea ch control module as follows.
BCM Transmission Data
BCM Reception Data
A/C switch ON signal
Electric load signal
"3" position switch signal
Illumination ON signal
Brake fluid level switch signal
Parking brake switch signal
Seat belt buckle switch signal
Charging system signal
Engine oil pressure switch signal
Diagnostic trouble code (DTC)
Door switch status
Door lock status ECM
TCM
(A/T model) Combination
Meter Keyless Start
Control Module
(if equipped)
Transmit DATA
BCM
ESP
Control Module
(if equipped)
I7RS0BA20002-01
Engine speed signal
Vehicle speed signal Engine coolant temperature signal
A/C refrigerant pressure signal
Fuel consumption signal A/C compressor clutch signal
Transmission range sensor signal
Fuel level signal
Ignition knob switch signal
Door lock/unlock request signal
Buzzer request signal
Answer back request signal
DATA
BCM
Receive
Combination
Meter
TCM
(A/T model) Keyless Start
Control Module (if equipped)
ECM
I7RS0AA20001-01

Downloaded from www.Manualslib.com manuals search engine 10B-3 Body Electrical Control System:
Theft Deterrent LightS7RS0BA201003
The information display or clock (1) of this vehicle includes a theft deterrent light (2) for the theft preventive purpose.
The BCM makes the theft deterrent light flash at certain interval s after the ignition switch is turned off until it is turned
on again. Also, to check DTCs stored in BCM without usin g a SUZUKI scan tool when diagnosing troubles, it is
possible to identify them by flashing patterns of the theft deterrent light.
Security Alarm Description (If Equipped)S7RS0BA201004
Operation
The security alarm system provides a warning of an abnormal condition to those who are around. Its operation is as
follows. While the system is in the stand- by mode (when 20 seconds or more elapsed after the door is locked using a
keyless entry transmitter or door request switch), BCM monitors door lock status, door switch status and battery power
supply voltage. When it detects an abnormal condition (door is unlocked by some way other than using keyless entry
transmitter or door request switch and opened or cut off BCM power supply voltage temporarily), it activates the
warning buzzer (located in BCM), theft deterr ent light, hazard warning relay and horn relay.
The security alarm system has 2 selectable modes.
• A mode: No operation
• B mode: Theft deterrent light blinks, hazard warning lights blink, warning buzzer (located in BCM) sounds and horn
sounds
When B mode is selected and the door is locked using keyl ess entry transmitter or door request switch, the theft
deterrent light (1) flashes at 0.1 second interval for 20 seconds and the se curity alarm system is set to the stand-by
mode (2). Once it is se t to the stand-by mode, the theft deterrent light blinks at 2 second intervals.
When the system is set to stand-by mode and the door is unlocked by some way other than using keyless entry
transmitter or door request switch and opened or cut off BCM power supply voltage temporarily, the alarm devices
operate according to the selected mode as described above.
The alarm stops under either of the following conditions.
• Ignition switch is turned ON
• A certain time has elapsed since the alarm started
For selection of the mode of the security alarm system , refer to “Security Alarm Mode Selection Procedure (If
Equipped)”.
1 2I4RS0AA20031-01
B A1T3
T1
T2 2
C
I5RS0DA20003-01
A: Indicator lamp turned ON
T1: 0.1 seconds
B: Indicator lamp turned OFF T2: 20 seconds
C: When door is locked using keyless entry tr ansmitter or door request switch T3: 2 seconds

Downloaded from www.Manualslib.com manuals search engine Body Electrical Control System: 10B-4
Input / Output Table
Schematic and Routing Diagram
Body Electrical Control System Wiring Circuit DiagramS7RS0BA202001
NOTE
This wiring diagram shows circuits related to only BCM, not the entire circuits of BCM and junction
block. Refer to “Power Supply Diagram in Section 9A” for wiring circuits other than the figure below.

Input Output
Keyless entry transmitter
Door switch status
Door lock status BCMHorn relay
Theft deterrent light
(in information display)
Warning buzzer
(located in BCM)
Hazard warning relay
Door request switch signal
Ignition switch
I5RS0CA20003-01