AIR CON SUZUKI SWIFT 2008 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-79
Compressor Drive Belt Removal and
Installation
S7RS0B7226032
Refer to “Compressor Drive Belt Removal and
Installation”.
Compressor Assembly Removal and
Installation
S7RS0B7226033
Refer to “Compressor Assembly Removal and
Installation”.
Compressor Assembly ComponentsS7RS0B7226034
Refer to “Compressor Assembly Components”.
Magnet Clutch Removal and InstallationS7RS0B7226035
Refer to “Magnet Clutch Removal and Installation”.
Magnet Clutch InspectionS7RS0B7226036
Refer to “Magnet Clutch Inspection”.
Relief Valve InspectionS7RS0B7226039
Refer to “Relief Valve Inspection”.
Special Tools and Equipment
Special ToolS7RS0B7228001
SUZUKI scan tool
—
This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12.) / )

Downloaded from www.Manualslib.com manuals search engine 7B-80 Air Conditioning System: Automatic Type

Downloaded from www.Manualslib.com manuals search engine Table of Contents 8- i
8
Section 8
CONTENTS
Restraint
Precautions ................................................. 8-1
Precautions............................................................. 8-1
Precautions on Restraint ....................................... 8-1
Seat Belts .......... ............................... ........ 8A-1
Precautions........................................................... 8A-1
Precautions on Service a nd Diagnosis of Seat
Belt .................................................................... 8A-1
General Description ............................................. 8A-1 Seat Belt Construction ........................................ 8A-1
Diagnostic Information and Procedures ............ 8A-2 Repair and Inspection Required after Accident ............................................................ 8A-2
Repair Instructions .............................................. 8A-3 Front Seat Belt Components ............................... 8A-3
Front Seat Belt Removal and Installation ............ 8A-4
Front Seat Belt Inspection ................................... 8A-4
Rear Seat Belt Components ............................... 8A-6
Rear Seat Belt Removal and Installation ............ 8A-7
Rear Seat Belt Inspection ................................... 8A-7
Specifications ....................................................... 8A-7
Tightening Torque Specifications ........................ 8A-7
Air Bag System ............... ......................... 8B-1
Precautions........................................................... 8B-1
Precautions on Service and Diagnosis of Air Bag System....................................................... 8B-1
Precautions on Handling and Storage of Air Bag System Components . ................................ 8B-2
Precautions on Disposal of Air Bag and Seat
Belt Pretensioner .............................................. 8B-5
General Description ............................................. 8B-5 Air Bag System Construction .............................. 8B-5
Air Bag System Input / Output Table .................. 8B-6
Schematic and Routing Diagram ........................ 8B-7 Air Bag System Wiring Circuit Diagram .............. 8B-7
Component Locatio n ........................................... 8B-9
Air Bag System Components, Wiring and Connectors Location ......................................... 8B-9
Diagnostic Information and Procedures .......... 8B-10 Air Bag Diagnostic System Check .................... 8B-10
Air Bag Diagnostic System Check Flow ............ 8B-10
DTC Table ......................................................... 8B-11
DTC Check ....................................................... 8B-12 DTC Clearance ................................................. 8B-12
Scan Tool Data ................................................. 8B-13
“AIR BAG” Warning Right Comes ON Steady .. 8B-13
“AIR BAG” Warning Right Does Not Come
ON ................................................................... 8B-15
“AIR BAG” Warning Right Flashes .................... 8B-16
DTC B1013: SDM fault...................................... 8B-17
DTC B1014: “AIR BAG” Warning Right Circuit Failure ............................................................. 8B-17
DTC B1016: Power Source Voltage High ......... 8B-18
DTC B1017: Power Source Voltage Low .......... 8B-20
DTC B1021: Front Air Bag Module Deployed ... 8B-22
DTC B1024 / B1025: Side-Air Bag (Driver / Passenger) Deployed...................................... 8B-22
DTC B1026: Pretensioner Activated ................. 8B-23
DTC B1027: Reusable Number Exceeded ....... 8B-24
DTC B1031: Driver Air Bag Initiator Circuit
Resistance High .............................................. 8B-24
DTC B1032: Driver Air Bag Initiator Circuit
Resistance Low ............................................... 8B-29
DTC B1033: Driver Air Bag Initiator Circuit
Short to Ground............................................... 8B-34
DTC B1034: Driver Air Bag Initiator Circuit
Short to Power Circuit .... ................................. 8B-39
DTC B1041: Passenger Air Bag Initiator Circuit Resistance High ................................... 8B-44
DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low.................................... 8B-47
DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground ................................... 8B-50
DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circ uit .......................... 8B-53
DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance
High ................................................................. 8B-56
DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circu it Resistance Low .. 8B-58
DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground .. 8B-60
DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power
Circuit .............................................................. 8B-62
DTC B1061 / B1065: Driver / Passenger Side- Air Bag Initiator Circuit Resistance High ......... 8B-64

Downloaded from www.Manualslib.com manuals search engine 8-ii Table of Contents
DTC B1062 / B1066: Driver / Passenger Side-Air Bag Initiator Circuit Resistance Low .......... 8B-67
DTC B1063 / B1067: Driver / Passenger Side- Air Bag Initiator Circuit S hort to Ground .......... 8B-70
DTC B1064 / B1068: Driver / Passenger Side- Air Bag Initiator Circu it Short to Power
Circuit .............................................................. 8B-73
DTC B1071: Forward-Sensor Performance Problem ........................................................... 8B-76
DTC B1072: Forward-Sensor Communication Error ................................................................ 8B-76
DTC B1073: Forward-Sensor Circuit Short to Ground ............................................................ 8B-76
DTC B1074: Forward-Sensor Circuit Short to Power Circuit or Open ..................................... 8B-78
DTC B1081 / B1091: Driver / Passenger Side- Sensor Performance Probl em ......................... 8B-80
DTC B1082 / B1092: Driver / Passenger Side- Sensor Communication Erro r .......................... 8B-80
DTC B1083 / B1093: Driver / Passenger Side- Sensor Circuit Short to Ground ....................... 8B-80
DTC B1084 / B1094: Driver / Passenger Side- Sensor Circuit Short to Power Circuit or
Open ............................................................... 8B-81
DTC B1085 / B1095: Wrong Side-Sensor (Driver Side / Passenger) ID ........................... 8B-83
DTC B1361 / B1365: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance
High ................................................................. 8B-84
DTC B1362 / B1366: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance
Low ................................................................. 8B-86
DTC B1363 / B1367: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to
Ground ............................................................ 8B-88
DTC B1364 / B1368: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to
Power Circuit ................................................... 8B-90
Contact Coil Cable and Its Circuit Check .......... 8B-93 Inspection of Intermittent and Poor
Connections .................................................... 8B-95
Repair and Inspection Required after Accident .......................................................... 8B-96
Repair Instructions ............ ................................8B-98
Disabling Air Bag System.................................. 8B-98
Enabling Air Bag System .................................. 8B-99
SDM Removal and Installation ........................ 8B-100
SDM Inspection ............................................... 8B-101
Driver Air Bag (Inflato r) Module Removal and
Installation ..................................................... 8B-101
Driver Air Bag (Inflator) Module Inspection ..... 8B-103
Passenger Air Bag (Inflator) Module Removal and Installation .............................................. 8B-103
Passenger Air Bag (I nflator) Module
Inspection ...................................................... 8B-105
Side-Air Bag (Inflator) Module Removal and
Installation ..................................................... 8B-105
Side-Air Bag (Inflator) Inspection .................... 8B-107
Side Curtain-Air Bag (Inflator) Module Removal and Installation ............................... 8B-107
Side Curtain-Air Bag (Inflator) Module Inspection ...................................................... 8B-109
Forward-Sensor Removal and Installation ...... 8B-109
Forward-Sensor In spection ............................. 8B-110
Side-Sensor Removal and Installation ............ 8B-110
Side-Sensor Inspection ................................... 8B-111
Passenger Air Bag (Inflator) Module Repair
Harness Installation....................................... 8B-112
Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal ................................... 8B-113
Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal.... 8B-124
Specifications .................. .................................8B-125
Tightening Torque Specifications .................... 8B-125
Special Tools and Equipmen t .........................8B-125
Use of Special Tools ....................................... 8B-125
Recommended Service Material ..................... 8B-127
Special Tool .................................................... 8B-127

Downloaded from www.Manualslib.com manuals search engine 8A-1 Seat Belts:
Restraint
Seat Belts
Precautions
Precautions on Service and Diagnosis of Seat
Belt
S7RS0B8100001
WARNING!
If replacing seat belt is necessary, replace
buckle and seat belt assembly together as a
set. This is for the reason of ensuring locking
of tongue plate with buckle. If these parts are
replaced individually, such a locking
condition may become unreliable. For this
reason, SUZUKI will supply only the spare
buckle and seat belt assembly in a set part.

Before servicing or replacing seat belts, refer to the
following precautionary items.
• Seat belts should be normal relative to strap retractor and buckle portions. • Keep sharp edges and damaging objects away from
belts.
• Avoid bending or damaging any portion of belt buckle or latch plate.
• Do not bleach or dye belt webbing. (Use only mild soap and lukewarm water to clean it.)
• When installing a seat belt anchor bolt, it should be tightened by hand at first to prevent cross-threading
and then to specified torque.
• Do not attempt any repair s on retractor mechanisms
or retractor covers. Replace defective assemblies with
new replacement parts.
• Keep belts dry and clean at all times.
• If there exist any parts in question, replace such parts.
• Replace belts whose webbing is cut or otherwise damaged.
• Do not put anything into trim panel opening which seat belt webbing passes through.
General Description
Seat Belt ConstructionS7RS0B8101001
1
1
6
6
6
5
5
7
6
6
2
2
3
4
I4RS0A810001-02
1. Front seat belt assembly (with ELR and pretensioner) 4. Buckle for front seat belt assembly7. Buckle for rear center seat belt
2. Rear seat belt assembly (with A-ELR or ELR) 5. Buckle for rear seat belt assembly
3. Rear center seat belt (with A-ELR or ELR) 6. Retractor assembly

Downloaded from www.Manualslib.com manuals search engine Seat Belts: 8A-2
Seat Belt with ELR
The seat belt with emergency locking retractor (ELR) is
designed so that it locks immediately (to prevent the
webbing from being pulled out of the retractor any
further) when any of the following items is detected as
exceeding each set value;
• Speed at which the webbing is pulled out of the retractor.
• Acceleration or deceleration of the vehicle speed.
• Inclination.
Seat Belt with A-ELR
The automatic and emergency locking retractor (A-ELR)
works as an Emergency Locking Retractor (ELR) till its
webbing is pulled all the way out and then on as an
Automatic Locking Retractor (ALR ) till it is retracted fully.
ALR: Automatically locks when the webbing is pulled out
from the retractor and allowed to retract even a little.
Then the webbing can not be pulled out any further,
unless it is wound all the way back into the retractor,
which releases the lock and allows the webbing to be
pulled out.
Seat Belt with ELR and Pretensioner
The seat belt with ELR and a pretensioner has a
pretensioner mechanism whic h operates in linkage with
the air bag in addition to the described ELR.
The pretensioner is incorporated in retractor assembly
and controlled by SDM as one of air bag system
components. It will be activated at the same time as the
driver and passenger air bag module when an impact at
the front of vehicle exceeds the specified value.
When servicing seat belt (retractor assembly) with
pretensioner, be sure to observe all WARNINGS and
CAUTIONS and “Precautions on Service and Diagnosis
of Air Bag System in Section 8B”. CAUTION!
Do not reuse the seat belt pretensioner
(retractor assembly) that has activated.
Replace it with a new seat belt assembly and
buckle together as a set. For checking
procedure of its activation, refer to “Repair
and Inspection Required after Accident in
Section 8B”.

Seat Belt Remainder
When driver’s seat belt is unfastened (under the
following conditions), seat belt reminder light and
warning buzzer inform that driver’s seat belt is
unfastened. Seat belt reminder light located in
combination meter and warning buzzer located inside
BCM operate as follows:
• Seat belt reminder light comes on when driver’s seat belt is unfastened while igni tion key switch is at ON
position.
• If vehicle speed exceeds 15 km/h with seat belt unfastened, warning buzzer operates for
approximately 95 seconds and seat belt reminder light
flashes synchronously with buzzer. When warning
buzzer stops operating, seat belt reminder light is
turned on.
• If driver’s seat belt state is changed from “fastened” to “unfastened” while vehicle speed is above 15 km/h,
warning buzzer operates for approximately 95
seconds and seat belt reminder light flashes
synchronously with buzzer. When warning buzzer
stops operating, seat belt reminder light is turned on.
Diagnostic Information and Procedures
Repair and Inspection Required after AccidentS7RS0B8104001
After an accident, whether the seat belt pretensioner has been activated or not, be sure to perform checks and repairs
described on “Repair and Inspection Required after Accident in Section 8B”.

Downloaded from www.Manualslib.com manuals search engine 8A-3 Seat Belts:
Repair Instructions
Front Seat Belt ComponentsS7RS0B8106001
WARNING!
• Never attempt to disassemble or repair the seat belt pretensioner (retractor assembly). If any abnormality is found, be sure to replace it with new one as an assembly.
• Be sure to read “Precautions on Service and Diagnosis of Seat Belt” before starting to work and observe every precaution during work. Neglecting them may result in personal injury or
unactivation of the seat belt pretensioner when necessary.

(a)
(a)
(a)
1
2
3
5
a)
b)
(a)
3
7
(b)
6
2
4
(a)
7
810
9
7 2 11
9
1012
I6RS0C810001-01
1. Upper anchor
6. Shoulder adjuster mounting bolt
: Tighten upper bolt first, then tighten lower bolt. 11. Spring washer
2. Lower anchor 7. Anchor bolt
: Tighten upper bolt first, then tighten lower bolt. 12. Wave washer
3. Retractor assembly 8. Cushion : 43 N⋅m (4.3 kgf-m, 31.5 lb-ft)
4. Buckle 9. Spacer : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
5. Yellow connector (for seat belt pretensioner) 10. Washer

Downloaded from www.Manualslib.com manuals search engine Seat Belts: 8A-4
Front Seat Belt Removal and InstallationS7RS0B8106002
WARNING!
• Never attempt to disassemble or repair the seat belt pretensioner (retractor
assembly). If any abnormality is found, be
sure to replace it with new one as an
assembly.
• Be sure to read “Precautions on Service and Diagnosis of Seat Belt” before starting
to work and observe every precaution
during work. Ne glecting them may result in
personal injury or una ctivation of the seat
belt pretensioner when necessary.

Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system. Refer to “Disabling Air Bag System in Section 8B”.
3) Remove center pillar lower trim.
4) Disconnect Yellow connector (1) from seat belt pretensioner (2).
a) Release locking of lock button (3).
b) After unlocked, disconnect to connector.
5) Remove front seat belts from the vehicle.
Installation
Install in reverse order of removal, noting the following.
• Seat belt anchor bolts should have an unified fine thread (7/16-20 UNF). Under no circumstances
should any different sized or metric screw threads be
used.
• Connect Yellow connector (1) to seat belt pretensioner securely.
a. Connect connector.
b. Lock connector with lock slider (2). • Enable air bag system. Refer to “Enabling Air Bag
System in Section 8B”.
Front Seat Belt InspectionS7RS0B8106003
WARNING!
• Never attempt to disassemble or repair the seat belt pretensioner (retractor
assembly). If any abnormality is found, be
sure to replace it with new one as an
assembly.
• Be sure to read “Precautions on Service and Diagnosis of Seat Belt”, before
starting to work and observe every
precaution during work. Neglecting them
may result in personal injury or
unactivation of the seat belt pretensioner
when necessary.
• Never measure resistance of pretensioner or disassemble it. Otherwise, personal
injury may result.

CAUTION!
If seat belt pretensioner (retractor assembly)
was dropped from a height of 30 cm (1 ft) or
more, it should be replaced.

Seat belts and attaching parts can affect the vital
components and systems of a vehicle.
Therefore, they should be inspected carefully and
replaced with genuine parts only.
a
b
21 3I6RS0B810003-01
1
1
2
b)
a)
I6RS0B810004-01
I2RH01810004-01

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-1
Restraint
Air Bag System
Precautions
Precautions on Service and Diagnosis of Air
Bag System
S7RS0B8200001
WARNING!
• If the air bag system and another vehicle system both need repair, SUZUKI
recommends that the air bag system be
repaired first, to help avoid unintended air
bag system activation.
• Do not modify the steering wheel, dashboard, both front seat or any other on
or around air bag system components.
Modifications can adversely affect air bag
system performance and lead to injury.
• Be sure to follow the procedures described in this section. Failure to follow
procedures could result in possible air bag
system activation, personal injury or
unneeded air bag system repairs.

• WARNING / CAUTION labels are attached on each
part of air bag system components (SDM, air bag
(inflator) modules and seat belt pretensioners). Be
sure to follow the instructions.
• Many of service procedures require disconnection of
“A/BAG” fuse and air bag (inflator) module(s) (driver,
passenger, side of both si des and curtain of both
sides) from initiator circuit to avoid an accidental
deployment.
• Do not apply power to the air bag system unless all components are connected or a diagnostic flow
requests it, as this will set a DTC.
• The “Air Bag Diagnostic S ystem Check” must be the
starting point of any air bag diagnostics. The “Air Bag
Diagnostic System Check” will verify proper “AIR
BAG” warning right operatio n and will lead you to the
correct flow to diagnose any air bag malfunctions.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacements. • Never use air bag component parts from another
vehicle.
• If the vehicle will be exposed to temperatures over 93
° C (200 °F) (for example, during a paint baking
process), remove the air bag system components
beforehand to avoid component damage or
unintended system activation.
• When handling the air bag (inflator) modules (driver, passenger, side of both si des and curtain of both
sides), seat belt pretensio ners (driver and passenger),
SDM, forward-sensor or side-sensor, be careful not to
drop it or apply an impact to it. If an excessive impact
was applied (e.g., SDM, forward-sensor and side-
sensor are dropped, air bag (inflator) module is
dropped from a height of 90 cm (3 ft) or more, seat
belt pretensioner (retractor assembly) is dropped from
a height of 30 cm (1 ft) or more), never attempt
disassembly or repair but replace it with a new one.
• When using electric welding, be sure to disconnect air bag (inflator) module connectors (driver, passenger,
side of both sides and curtain of both sides) and seat
belt pretensioner connectors (driver and passenger)
respectively.
• When applying paint around the air bag system related parts, use care so that the harness or
connector will not be expo sed to the paint mist.
• Never expose air bag system component parts directly to hot air (drying or baking the vehicle after
painting) or flames.
WARNING!
When performing service on or around air
bag system components or air bag wiring,
follow the procedures listed in “Disabling Air
Bag System” to temporarily disable the air
bag system.
Failure to follow procedures could result in
possible air bag system activation, personal
injury or unneeded air bag system repairs.

Downloaded from www.Manualslib.com manuals search engine 8B-2 Air Bag System:
Precautions on Handling and Storage of Air Bag
System Components
S7RS0B8200002
SDM
WARNING!
Never power up air bag system when SDM is
not rigidly attached to the vehicle. Otherwise,
personal injury may result.

CAUTION!
After detecting one time of such collision as
to meet deployment conditions, SDM must
not be used. Refer to “Air Bag Diagnostic
System Check” when checking SDM.

• Never attempt disassembly of SDM.
• When storing SDM, select a place where neither high temperature nor high humidity is anticipated and oil,
water and dust are kept off.
• If SDM has been dropped, replace it with a new one.
• If SDM installation part of floor was damaged, repair that part completely before reinstallation.
• All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointed
toward the front of the vehicle to ensure proper
operation of the air bag system. Live (Undeployed) Air Bag (Inflator) Modules
Special care is necessary when handling and storing a
live (undeployed) air bag (inflator) modules.
The rapid gas generation produced during deployment
of the air bag could cause the air bag (inflator) module,
or an object in front of the air bag (inflator) module, to be
thrown through the air in the unlikely event of an
accidental deployment.
WARNING!
Never attempt to measure the resistance of
the air bag (inflator) modules (driver,
passenger and side of both sides and curtain
of both sides). It is
very dangerous as the
electric current from the tester may deploy
the air bag.

I5RH01820001-01
I4RS0A820001-03