Hood SUZUKI SWIFT 2007 2.G Service Workshop Manual

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Vo l u m e 1
Precautions............................................................... 00-iPrecautions ............................................................ 00-1
General Information ................ ................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubricatio n ................................. 0B-1
Engine ......................................................................... 1-i Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1
Aux. Emission Control Devices .............................. 1B-1
Engine Electrical Devices....................................... 1C-1
Engine Mechanical ................................................. 1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System .......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System....................................................... 1H-1
Starting System ....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System ..................................................... 1K-1
Suspension ................................................................. 2-i Precautions .............................................................. 2-1
Suspension General Diagnosis .............................. 2A-1
Front Suspension ................................................... 2B-1
Rear Suspension................ .................................... 2C-1
Wheels and Tires ................................................... 2D-1
Driveline / Axle ........................................................... 3-i Precautions .............................................................. 3-1
Drive Shaft / Axle ................................................... 3A-1
Brakes ......................................................................... 4-i Precautions .............................................................. 4-1
Brake Control System and Diagnosis .................... 4A-1
Front Brakes........................................................... 4B-1
Rear Brakes ........................................................... 4C-1
Parking Brake......................................................... 4D-1
ABS ........................................................................ 4E-1
Electronic Stability Program ................................... 4F-1
Vo l u m e 2
Precautions ............................................................... 00-iPrecautions ............................................................ 00-1
Transmission / Transaxle .... ...................................... 5-i
Precautions .............................................................. 5-1
Automatic Transmission/Transaxle ........................ 5A-1
Manual Transmission/Transaxle ............................ 5B-1
Clutch .....................................................................5C-1
Steering ....................................................................... 6-i Precautions .............................................................. 6-1
Steering General Diagnosis ................................... 6A-1
Steering Wheel and Column .................................. 6B-1
Power Assisted Steering System ...........................6C-1
HVAC ........................................................................... 7-i Precautions .............................................................. 7-1
Heater and Ventilation............................................ 7A-1
Air Conditioning System ......................................... 7B-1
Restraint ...................................................................... 8-i Precautions .............................................................. 8-1
Seat Belts ............................................................... 8A-1
Air Bag System ...................................................... 8B-1
Body, Cab and Accessories .... .................................. 9-i
Precautions .............................................................. 9-1
Wiring Systems ...................................................... 9A-1
Lighting Systems .................................................... 9B-1
Instrumentation / Driver Info. / Horn .......................9C-1
Wipers / Washers ...................................................9D-1
Glass / Windows / Mirrors ...................................... 9E-1
Security and Locks ................................................. 9F-1
Seats ..................................................................... 9G-1
Interior Trim ............................................................9H-1
Hood / Fenders / Doors .......................................... 9J-1
Body Structure ....................................................... 9K-1
Paint / Coatings ...................................................... 9L-1
Exterior Trim .......................................................... 9M-1
Control Systems ....................................................... 10-i Precautions ............................................................ 10-1
Body Electrical Control Sy stem ............................ 10B-1
Immobilizer Control System .................................10C-1
Keyless Start System ........................................... 10E-1
TABLE OF CONTENTS

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-11
Automatic Transaxle Fluid Level InspectionS7RS0B0206028
1) Inspect transaxle case for evidence of fluid leakage.Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Check fluid level under spec ified conditions referring
to “A/T Fluid Level Check in Section 5A”.
If fluid level is low, replenish specified fluid.
Automatic Transaxle Fluid ReplacementS7RS0B0206029
1) Inspect transaxle case for evidence of fluid leakage. Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Change fluid. For its procedure, refer to “A/T Fluid Change in Section 5A”.
Automatic Transaxle Fluid Cooler Hose
Inspection
S7RS0B0206030
Check automatic transaxle fluid cooler hose for fluid
leakage, cracks, damage and deterioration.
Replace hose and/or clamp if any faulty condition is
found.
All Latches, Hinges and Locks InspectionS7RS0B0206031
Doors
Check that each door of front, rear and back doors
opens and closes smoothly and locks securely when
closed.
If any malfunction is found, lubricate hinge and latch or
repair door lock system.
Engine Hood
Check that secondary latch operates properly (check
that secondary latch keeps hood from opening all the
way even when pulling hood release handle inside
vehicle.) Also check that hood opens and closes
smoothly and properly and hood locks securely when
closed.
If any malfunction is found, l ubricate hinge and latch, or
repair hood lock system.
1. Dipstick 3. FULL HOT mark
2. Clamp 4. LOW HOT mark
1. Drain plug
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Brake
Foot brake
Check the following:
• that brake pedal has proper travel,
• that brake works properly,
• that it is free from noise,
• that vehicle does not pull to one side when brake is applied.
• and that brake do not drag.
Parking brake
Check that lever has proper travel.
WARNING!
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property
damage. Be prepared to apply regular brake
quickly even if vehicle should start to move.

Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and brake
lever is pulled all the way.
Steering
• Check to ensure that steering wheel is free from instability, or abnormally heavy feeling. • Check that the vehicle does not wander or pull to one
side.
Engine
• Check that engine responds readily at all speeds.
• Check that engine is free from abnormal noise and abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting system
are free from abnormal noise and abnormal vibration or
any other abnormal condition.
Meters and Gauge
Check that speedometer, odometer, fuel meter,
temperature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that ai r comes out from defroster
outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan
switch lever to “HI” position for this check.
Specifications
Tightening Torque SpecificationsS7RS0B0207001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Fluids and LubricantsS7RS0B0208001
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Engine oil drain plug 35 3.5 25.5 )
Oil filter 14 1.4 10.5 for reference )
Engine oilSG, SH, SJ, SL or SM grade (Refer to “Engine Oil and Filter Change” for engine
oil viscosity.)
Engine coolant
(Ethylene glycol base coolant) “Antifreeze/Antico
rrosion coolant”
Brake fluid Refer to reservoir cap of brake master cylinder.
Manual transaxle oil Refer to “Manual Transaxle Oil Change in Section 5B”.
Automatic transaxle fluid Refer to “A/T Fluid Change in Section 5A”.
Door hinges Engine oil or water resistance chassis grease
Hood latch assembly Engine oil or water resistance chassis grease
Key lock cylinder Spray lubricant

Downloaded from www.Manualslib.com manuals search engine 1D-17 Engine Mechanical:
Engine Assembly Removal and InstallationS7RS0B1406011
NOTE
After replacing electric throttle body
assembly, perform calibration of throttle
valve referring to “Electric Throttle Body
System Calibration in Section 1C”.

Removal1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure in Section 1G”.
2) Disconnect negative and pos itive cable at battery.
3) Remove battery and tray.
4) Remove engine hood after disconnecting windshield washer hose.
5) Remove right and left side engine under covers.
6) Remove A/C compressor belt by referring to “Compressor Drive Belt Remo val and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
7) Drain engine oil, transaxle oil and coolant.
8) Remove cowl top plate referring to “Cowl Top Components in Section 9K”.
9) Remove air cleaner assembly referring to “Air Cleaner Components”.
10) With hose connected, detach A/C compressor from its bracket (A/C model) referring to “Compressor
Assembly Removal and Installation in Section 7B” or
“Compressor Assembly Removal and Installation in
Section 7B”.
CAUTION!
Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

11) Remove intake manifold rear stiffener (1) from intake manifold and cylinder block. 12) Disconnect the following electric wires:
• MAP sensor (1)
• ECT sensor (2)
•EGR valve (3)
• CMP sensor (4)
• Electric throttle body assembly (5)
• Ignition coil assembly (6)
• Injectors (7)
• Heated oxygen sensor No. 2 (8) and No. 1 (9)
• Oil control valve (10)
• Engine oil pressure switch (11)
• CKP sensor (12)
• Knock sensor (13)
• Back up light switch (14)
• Generator (15)
• Starting motor (16)
• Ground terminal (17) from intake manifold
• Battery ground terminal (18) from exhaust manifold
• Battery ground cable (19) from transaxle
• Magnet clutch switch of A/C compressor (A/C model)
• Each wire harness clamps
• Output shaft speed sensor (VSS) (34) (A/T model)
• Solenoid valve (33) (A/T model)
• Transmission range sensor (32) (A/T model)
• Input shaft speed sensor (31) (A/T model)
13) Remove fuse box from its bracket.
14) Disconnect the following cables: • Gear select control cable (23) (M/T model)
• Gear shift control cable (24) (M/T model)
• A/T select cable (A/T model)
15) Disconnect the following hoses: • Brake booster hose (26) from intake manifold
• Radiator inlet and outlet hoses (20) from each pipe
• Heater inlet and outlet hoses (21) from each pipe
• Fuel feed hoses (22) from fuel feed pipe
• EVAP canister purge valve hose (30) from purge pipe
• A/T fluid cooler hoses (A/T model)
16) With hose connected, detach clutch operating cylinder (25). (M/T model)
CAUTION!
Suspend removed clutch operating cylinder
at a place where no damage will be caused
during removal and installation of engine
assembly.

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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-20
15) Install A/C compressor to its bracket (if equipped) referring to “Compressor Assembly Removal and
Installation in Section 7B” or “Compressor Assembly
Removal and Installa tion in Section 7B”.
16) Adjust A/C compressor belt tension (if equipped) referring to “Compressor Drive Belt Inspection and
Adjustment in Section 7B” or “Compressor Drive Belt
Inspection and Adjustment in Section 7B”.
17) Check to ensure that a ll removed parts are back in
place.
Reinstall any necessary parts which have not been
reinstalled.
18) Refill cooling system with coolant referring to “Cooling System Flush and Refill in Section 1F”. 19) Refill engine with engine oil
referring to “Engine Oil
and Filter Change in Section 0B”.
20) Refill transaxle with transa xle oil referring to“Manual
Transaxle Oil Change in Section 5B” or “A/T Fluid
Change in Section 5A”.
21) Install battery and tray.
22) Connect positive and negative cable at battery.
23) Install engine hood and connect windshield washer hose.
24) Verify that there is no fu el leakage, coolant leakage,
oil leakage and exhaust gas leakage at each
connection.
Timing Chain Cover ComponentsS7RS0B1406012
I6RS0C140015-02
1. Crankshaft pulley bolt 13. Oil gallery pipe No.2 bolt
2. Crankshaft pulley 14. Oil gallery pipe No.3
3. Oil seal : Apply engine oil to oil seal lip. 15. Oil gallery pipe No.3 bolt
4. Timing chain cover : Apply sealant 99000-31140 to the mating surface of cylinder and cylinder head.
: Apply sealant 99000-31260 to the mating surface of timing chain cover referring to the
figure of Step 4) of “Installation” under “Timing Chain Cover Removal and Installation”. 16. O-ring
: Apply engine oil.
5. Pin 17. Oil control valve
6. Cap bolt 18. Oil control valve mounting nut
7. Timing chain cover mounting bolts 19. Cap
8. Timing chain cover mounting nut : 11 N ⋅m (1.1 kgf-m, 8.0 lb-ft)
9. Oil gallery pipe No.1 :25 N⋅m (2.5 kgf-m, 18.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-6
Coolant Level CheckS7RS0B1606002
WARNING!
To help avoid danger of being burned, do not
remove radiator cap while engine and
radiator are still hot. Scalding fluid and steam
can be blown out under pressure if radiator
cap is taken off too soon.

To check level, lift hood and look at “see-through”
coolant reservoir.
It is not necessary to remove radiator cap to check
coolant level.
When engine is cool, check coolant level in reservoir (1).
A normal coolant level should be between FULL mark
(2) and LOW mark (3) on reservoir (1).
If coolant level is below LOW mark (3), remove reservoir
cap (4) and add proper coolant to reservoir to bring
coolant level up to FULL mark (2).
NOTE
If proper quality antifreeze is used, there is
no need to add extra inhibitors or additives
that claim to improve system. They may be
harmful to proper operation of system, and
are unnecessary expense.

Engine Cooling System Inspection and
Cleaning
S7RS0B1606003
WARNING!
To help avoid danger of being burned, do not
remove radiator cap while engine and
radiator are still hot. Scalding fluid and steam
can be blown out under pressure if cap is
taken off too soon.

1) Check cooling system for leakage or damage.
2) Wash radiator cap and fille r neck with clean water by
removing radiator cap when engine is cold.
3) Check coolant for proper level and freeze protection.
4) Using a pressure tester (1), check system and radiator cap (2) for proper pressure holding capacity.
If replacement of cap is required, use a proper cap
for this vehicle.
NOTE
After installing radiator cap to radiator, make
sure that the ear of cap lines is parallel to
radiator.

Cooling system and radiator cap holding
pressure (for inspection)
110 kPa (1.1 kg/cm2, 15.6 psi)
5) Tighten hose clamps and inspect all hoses. Replace hoses whenever cracked, swollen or otherwise
deteriorated.
6) Clean frontal area of radiator core.
Cooling System DrainingS7RS0B1606004
1) Remove radiator cap.
2) Drain coolant from radiator drain plug (1).
3) After draining coolant, be sure to tighten drain plug (1) securely.
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5) Warm up engine to the normal operating temperature and keep it at the specified idle speed.
6) Turn A/C switch ON, set blower speed selector at maximum speed position, temperature selector at
maximum cold position, airflow selector at face
position, and air intake switch at recirculation
position. (Confirm that A/C compressor and
condenser fans are working.)
7) Wait for ten minutes to stabilize the A/C operation.
8) Open front windows, front doors and engine hood.
9) With about 20 mm (0.8 in.) of dry bulb thermometer
(1) put right in front of center ventilation louver and a
wet and dry bulb thermometer (2) near air inlet of
HVAC unit. 10) Check for each pressure of low side and high side if
it is within shaded range of graph. If each gauge
reading is out of specified pressure, correct defective
part referring to the following table.
NOTE
Pressure registered on gauge varies with
ambient temperature. Therefore, use the
graphs when determining if pressures are
normal or not.

Low side and high side pressure example,
Gauges should read as follows when ambient
temperature is 30 °C (86 °F)
Pressure on high pressure gauge (HI): 1590 –
1940 kPa (15.9 – 19.4 kg/cm2)
Pressure on low pressure gauge (LO): 270 – 430
kPa (2.7 – 4.3 kg/cm
2)
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[A]: Pressure of high pressure gauge
[B]: Pressure of low pressure gauge
[C]: Ambient temperature
[D]: Humidity [E]: Acceptable range
22
312.9 2200
0 1
2 3 30 70 30 70 %
4 5 6 7 8 9
10
11 12 13 14 15
16 17
18
19 21
298.7 2100
20
14.2 28.4 42.7 56.9 71.1 85.3 99.5
113.8 128.0 142.2
151.4
170.6
184.9 199.1
213.3 227.5
241.7
256.0
270.2
284.4
100 200 300 400 500 600 700 800 900
1000 1100 1200
1300
1400 1500 1600
1700 1800
1900
2000
25 30 35
77 86 95
psi kPa kg/cm
2
C
F
“A”
“B”
“C”
“D”
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2300
327.1
[A]
[B]
[C][D][E]
[E]
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Downloaded from www.Manualslib.com manuals search engine 9-iv Table of Contents
Rear End Door Opener System Symptom Diagnosis .......................................................... 9F-5
Rear End Door Opener System Operation Inspection .......................................................... 9F-5
Repair Instructions ........... ................................... 9F-6
Front Door Lock Assembly Components ............ 9F-6
Front Door Lock Assembly Removal and Installation ......................................................... 9F-6
Front Door Lock Assembly Inspection ................ 9F-8
Power Door Lock Switch In spection.................... 9F-8
Door Key Cylinder Switch Inspection .................. 9F-8
Power Door Lock Actuator Inspection ................. 9F-9
Rear Door Lock Assembly Components ........... 9F-10
Rear Door Lock Assembly Removal and Installation ....................................................... 9F-10
Rear Door Lock Assembly Inspection ............... 9F-10
Rear End Door Lock Assembly Components.... 9F-11
Rear End Door Lock Assembly Removal and Installation ....................................................... 9F-11
Rear End Door Lock Assembly Inspection........ 9F-12
Rear End Door Opener Switch Inspection ........ 9F-12
Replacement of Transmitte r Battery ................. 9F-13
Programming Transmitter Code for Keyless Entry System (Vehicle without Keyless Start
System) ........................................................... 9F-13
Keyless Entry Answer Back Function
Change-over Procedure (If Equipped) ............ 9F-14
Keyless Entry Receiver Removal and
Installation ....................................................... 9F-14
Keyless Entry Receiver and Its Circuit Inspection ........................................................ 9F-15
Specifications .... ................................................. 9F-16
Tightening Torque Specifications ...................... 9F-16
Special Tools and Equipmen t ........................... 9F-16
Recommended Service Material ....................... 9F-16
Seats ............. ............................................ 9G-1
Repair Instructions ............................................. 9G-1
Front Seat Components ..................................... 9G-1
Front Seat Removal and In stallation .................. 9G-2
Rear Seat Components...................................... 9G-3
Rear Seat Removal and Installation................... 9G-4
Specifications .... .................................................. 9G-4
Tightening Torque Specifications ....................... 9G-4
Special Tools and Equipmen t ............................ 9G-4
Recommended Service Material ........................ 9G-4
Interior Trim ................. ............................ 9H-1
Repair Instructions ............ ..................................9H-1
Floor Carpet Removal and Installation ................9H-1
Head Lining Removal and Installation.................9H-1
Console Box Components ..................................9H-2
Specifications ..................... ..................................9H-3
Tightening Torque Specifications ........................9H-3
Hood / Fenders / Doors ...... ...................... 9J-1
Repair Instructions ............ .................................. 9J-1
Hood Removal and Installation ........................... 9J-1
Hood Inspection and Adjustment ........................ 9J-1
Front Fender Components .................................. 9J-2
Front Fender Removal and Installation ............... 9J-2
Front Door Assembly Comp onents ..................... 9J-3
Front Door Assembly Removal and Installation ......................................................... 9J-3
Rear Door Assembly Components...................... 9J-5
Rear Door Assembly Removal and Installation ......................................................... 9J-5
Rear End Door Assembly Components .............. 9J-6
Rear End Door Assembly Removal and Installation ......................................................... 9J-6
Specifications ..................... .................................. 9J-8
Tightening Torque Specifications ........................ 9J-8
Special Tools and Equipmen t ............................. 9J-8
Recommended Service Material ......................... 9J-8
Body Structure............... .......................... 9K-1
Repair Instructions ............ ..................................9K-1
Front Bumper and Rear Bumper Components .... 9K-1
Cowl Top Components........................................ 9K-2
Specifications ..................... ..................................9K-3
Body Dimensions ................................................ 9K-3
Panel Clearance................................................ 9K-10
Paint / Coatings ............. ...........................9L-1
General Description ............................................. 9L-1
Anti-Corrosion Treatment Construction............... 9L-1
Plastic Parts Finishing ......................................... 9L-2
Component Location ............ ............................... 9L-3
Sealant Application Areas ................................... 9L-3
Under Coating Application Areas ........................ 9L-8
Anti-Corrosion Compound Application Area ..... 9L-10
Exterior Trim ...... ...................................... 9M-1
Repair Instructions ......... .................................... 9M-1
Roof Molding Components................................. 9M-1
Splash Guard (If Equipped) Components .......... 9M-2

Downloaded from www.Manualslib.com manuals search engine Instrumentation / Driver Info. / Horn: 9C-18
Instrument Panel Removal and InstallationS7RS0B9306015
WARNING!
Refer to “Air Bag Warning in Section 00”
before starting service work.

Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove steering column hole cover (1).
4) Turn steering wheel to remove steering column cover screws (3).
5) Remove steering column covers (2).
6) Remove glove box (1).
7) Remove hood latch release lever (2).
8) Remove console box referring to “Console Box Components in Section 9H”.
9) Remove instrument panel center lower bracket (1). 10) Remove front pillar trims
(1) and dash side trims (2).
11) Remove instrument panel mounting screws (1).
12) Detach instrument panel from steering support member (2) and then remove foot duct (3).
13) Disconnect instrument panel harness connectors, heater control cables and antenna cable for
instrument panel removal.
14) Remove steering column mounting nuts referring to “Steering Column Remova l and Installation in
Section 6B”.
15) Remove instrument panel ground wire.
16) Remove instrument panel mounting bolts (1).
17) Remove instrument panel (2) with steering support member (3) and instrument panel harness.
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“A”
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Downloaded from www.Manualslib.com manuals search engine 9J-1 Hood / Fenders / Doors:
Body, Cab and Accessories
Hood / Fenders / Doors
Repair Instructions
Hood Removal and InstallationS7RS0B9A06001
Removal
CAUTION!
Place cloth to prevent body from any
damage.

1) Remove hood silencer (4).
2) Disconnect window washer hose (1) from hood.
3) Remove 4 mounting bolts (3) to detach hood (2).
Installation
Reverse removal procedure noting the following.
• Apply sealant to contact face “A” of hood hinge. Specified sealant.
“A”: Sealant 99000–31110 (SUZUKI Bond
No.1215)
• Adjust hood lock position if necessary referring to “Hood Inspection and Adjustment”.
Hood Inspection and AdjustmentS7RS0B9A06002
Inspection
• Check that hood opens and closes smoothly and properly. Lubricate if necessary.
• Check that hood stops in the secondary latched position properly (preventing hood from opening
freely) and that hood closes completely in the fully
latched position.
• Adjust hood locks position, if necessary.
Adjustment
Adjust the following point:
• Hood position adjustment. Fore-and-aft and right-and-left adjustment.
Adjust hood clearance by loosening hood mounting
bolts. Refer to “Panel Clearance in Section 9K”.
• Vertical adjustment If only one side (right or left) of hood is not level with
front fender, make it level by tightening or loosening
hood cushion (1).
• Hood lock position adjustment a. Loosen hood lock bolts.
b. Adjust hood lock height position so the hood is locked without looseness.
c. Tighten hood latch bolts to specified torque.
Tightening torque
Hood latch bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-
ft)
d. Make sure the hood is locked smoothly and securely.
“A”
“A”
3
2
4
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