hold SUZUKI SWIFT 2008 2.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 6C-44 Power Assisted Steering System:
6) Unbend bent part of tie-rod lock washer (1).
7) Hold rack with soft jawed vise (3) and remove tie-rod
from rack (2).
Installation 1) Install tie-rod (1) and new tie-rod lock washer (3) to rack (2).
2) Hold rack with soft jawed vise and tighten tie-rod to specified torque.
Tightening torque
Tie-rod (a): 93 N·m (9.3 kgf-m, 67.5 lb-ft)
3) Bend lock washer at 2 places (1) as shown in figure. 4) Apply sealant to gear case groove “A” indicated in
figure. Position boot properly in grooves of gear case
(or rack side mount) and tie-rod.
After this, check to ensure that boot is free from twist
and dent.
“A”: Silicone sealant 99000–31120 (Silicone
sealant)
5) Fasten boot with new band and clip securely. Special tool
(A): 09943–55010
6) Install tie-rod end lock nut and tie-rod end to tie-rod. Position lock nut to marking (1) made in removal.
NOTE
When tie-rod was replaced, measure length
“a” on removed tie-rod and use it on new
replacement tie-rod so as to position lock nut
properly.

7) Tighten tie-rod end lock nut to specified torque.
Tightening torque
Tie-rod end lock nut (a): 45 N·m (4.5 kgf-m, 32.5
lb-ft)
I4RS0A630033-01
3 1, (a)
2
I6RS0C630027-01
I4RS0A630035-01
I3RM0A630050-01
I3RM0A630051-01
I3RM0A630052-01
(a)I7RS0A630018-01

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-45
8) Install steering gear case assembly referring to “Steering Gear Case Assembly Removal and
Installation”.
Steering Rack Plunger Removal and InstallationS7RS0B6306009
Removal
1) Remove gear case assembly referring to “Steering
Gear Case Assembly Removal and Installation”.
2) Loosen lock nut (1) with holding damper screw (2).
3) Remove lock nut (1), rack damper screw (2), rack plunger spring (3) and rack plunger (4).
Installation 1) Apply grease lightly to sliding part of plunger (1) against rack.
“A”: Grease 99000–25050 (SUZUKI Super
Grease E)
2) Install plunger and spring (2) as shown.
3) Apply thread lock cement to rack damper screw (3)
and tighten them as follows.
a) Tighten damper screw to 25 N ⋅m (2.5 kgf-m, 18.0
lb-ft).
b) Loosen damper screw until 180 °.
c) Retighten damper screw to 3.9 N ⋅m (0.39 kgf-m,
3.0 lb-ft).
d) After tightening rack damper screw to specified torque, turn it back by 7 ± 3°.
“B”: Thread lock cement 99000–32110
(Thread Lock Cement Super 1322)
Tightening torque
Rack damper screw (a): Tighten 25 N ⋅m (2.5
kgf-m, 18.0 lb-ft) and loosen 180° and then
tighten 3.9 N ⋅m (0.39 kgf-m, 3.0 lb-ft) and turn
it back by 7 ± 3° by the specified procedure. 4) Pinion rotation torque should be checked with rack
position centered.
Also, check if rack as a whole moves smoothly.
Special tool
(A): 09944–18310
Tightening torque
Rotation torquer of pinion (a): 2.0 N·m (0.2 kgf-
m, 1.5 lb-ft)
5) After adjustment, tighten lo ck nut to specified torque
with holding damper screw at the position.
Tightening torque
Rack damper screw lock nut (a): 64 N·m (6.4
kgf-m, 46.5 lb-ft)
6) Install gear case assembly referring to “Steering Gear Case Assembly Re moval and Installation”.
Steering Rack Plunger InspectionS7RS0B6306010
• Inspect rack plunger (1) for wear or damage.
• Inspect rack plunger spring (2) for deterioration.
I4RS0A630045-01
I4RS0A630046-01
I3RM0A630055-02
I4RS0A630047-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-25
Evaporator Thermistor (Evaporator
Temperature Sensor) Removal and Installation
S7RS0B7216008
Removal1) Disconnect negative (–) cable from battery.
2) Remove HVAC unit from vehicle body referring to “HVAC Unit Removal and Installation”.
3) Remove evaporator thermistor (evaporator temperature sensor) (1) from evaporator by
disassembling HVAC unit.
Installation
Reverse the removal procedure noting the following
instruction.
• Install evaporator thermistor (evaporator temperature sensor) (1) onto evaporator (2) as shown.
Evaporator Thermistor (Evaporator
Temperature Sensor) Inspection
S7RS0B7216009
Check resistance between terminals of evaporator
thermistor (1).
If check results are as not specified, replace evaporator
thermistor.
Evaporator thermistor resistance
0 °C (32 °F): 6.6 – 6.9 k Ω
25 °C (77 °F): 1.9 – 2.3 kΩ
[A]: LH steering vehicle
[B]: RH steering vehicle
3. 50 ± 5 mm (2 ± 0.2 in.)
4. Sensor part fixed to 10th fin from the bottom
5. Holding part fixed to 8th fin from the bottom
6. Holding part fixed to 12th fin from the bottom
1
I4RS0B720011-01
5
1
4
2
3
[A]
1
4 2
3
6 [B]
I5RS0C721008-01
[A]: Resistance (k Ω) [B]: Temperature
I4RS0B720012-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-33
Special Tools and Equipment
Recommended Service MaterialS7RS0B7218001
NOTE
Required service material is also described in the following.
“Precautions on Servicing A/C System”

Special ToolS7RS0B7218002
Material SUZUKI recommended product or Specification Note
Compressor oil MATSUSHITADEN KI GU10 P/No.: 99000–99015–
00A )
/ )
Silicon sealant SUZUKI SILICON SEALANT KE-
347W (100g) P/No.: 99000–34220
)
09900–06107 09990–86012
Snap ring pliers (opening
type) Gas leak detector
) / ) / ) / ) This kit includes following
items. 1. Gas leak detector,
2. Instruction manual, 3.
Filter, 4. Sensor, 5. Dri-sell
battery (size D)) / )
09991–06310
Armature plate holder
) / )
1 2
3 4
5

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-3
• Never attempt disassembly of the air bag (inflator) modules.
• If any abnormality is found, be sure to replace it with
new one as an assembly.
• When an abnormality is noted as existing in the live (undeployed) air bag (inflator) module, be sure to
deploy it before discarding it.
• When grease, cleaning agent, oil, water, etc., got on the air bag (inflator) modules (driver, passenger, side
of both sides and curtain of both sides), wipe it off
immediately with a dry cloth.
• If air bag (inflator) module was dropped from a height of 90 cm (3 ft) or more, it should be replaced with a
new one as an assembly.
WARNING!
• For handling and storage of a live air bag (inflator) module, select a place where the
ambient temperature below 65 °C (150 ° F),
without high humidity and away from
electric noise.
• When carrying a live air bag (inflator) module, make sure the bag opening is
pointed away from you. In case of an
accidental deployment, the bag will then
deploy with minimal chance of injury.
Never carry the air bag (inflator) module by
the wires or connector on the underside of
the module.
Otherwise, personal injury may result.

WARNING!
When placing a live air bag (inflator) module
on bench or other surface, always face the
bag up, away from the surface. As the live
passenger air bag (inflator) module must be
placed with its bag (trim cover) facing up,
place it on the workbench with a slit (1) or
use the workbench vise (2) to hold it securely
at its lower mounting bracket (3).
It is also prohibited to place anything on top
of the trim cover and stack air bag (inflator)
modules.
This is necessary so that a free space is
provided to allow the air bag to expand in the
unlikely event of accidental deployment.
Otherwise, personal injury may result.

Live (Inactivated) Seat Belt Pretensioner
Special care is necessary when handling and storing a
live (inactivated) seat belt pretensioners.
Also, when the seat belt pretensioners activate, gas is
generated and the seat belt (1) is retracted into the
retractor assembly (2) quickly.
Note, therefore, that if they activate accidentally, the seat
belt pretensioners and other object(s) around them may
be thrown through the air.
I4RS0A820002-01
1
2
3
I4RS0A820003-02
I3JA01820043-01

Downloaded from www.Manualslib.com manuals search engine 8B-104 Air Bag System:
5) Remove passenger air bag (inflator) module (1) from air bag hole cover (2).
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 passenger air bag (inflator) module must be kept with its bag (trim
cover) facing up while being stored or left
standing, place it on the workbench with a
slit facing down or use the workbench vise
to hold it securely at its lower mounting
bracket. 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
1) Install passenger air bag (inflator) module to air bag hole cover (2).
CAUTION!
Confirm claw (1) of passenger air bag
(inflator) module hangs in air bag hole cover
(2).

2) Install passenger air bag (inflator) module with air bag hole cover (1) to instrument panel as shown.
3) Tighten passenger air bag (inflator) module attaching bolts (1) to sp ecified torque.
Tightening torque
Passenger air bag (inflator) module attaching
bolt (a): 23 N·m (2.3 kgf-m, 16.5 lb-ft)
1
2
I4RS0A820063-01
2 1I4RS0A820064-01
“A”
“A”“A”
1
I4RS0A820062-01
1,(a)I4RS0A820065-01

Downloaded from www.Manualslib.com manuals search engine 8B-114 Air Bag System:
Deployment / Activation Outside of Vehicle
When you intend to return the vehicle to service, deploy
the air bag (inflator) module(s) or activate seat belt
pretensioner(s) outside of the vehicle.1) Turn ignition switch to LOCK position and remove key.
2) Wear safety glasses during this deployment / activation procedure.
3) Check that there is no open, short or damage in special tools (deployment harness (A) and adapter
cable (B)). If any faulty is found, do not use it and be
sure to use new special tool.
Special tool
(A): 09932-75031
(B): 09932–76510
4) Short two deployment harness leads (1) together by fully seating one banana plug into the other.
WARNING!
Deployment harness (A) shall remain shorted
and not be connected to 12 volts vehicle
battery till you are ready to deploy air bag
module or activate seat belt pretensioner.

5) Remove air bag (inflator) module(s) or seat belt pretensioner(s) from vehicle referring to “Driver Air
Bag (Inflator) Module Re moval and Installation”,
“Passenger Air Bag (Inflator) Module Removal and
Installation”or “Front Seat Belt Removal and
Installation in Section 8A”.
WARNING!
• For handing and storage of live air bag (inflator) module, select place where
ambient temperature below 65 °C (150 °F),
without high humidity and away from
electric noise.
• Always carry live air bag (inflator) module with trim cover away from you.
• When storing live air bag (inflator) module or when leaving live air bag (inflator)
module unattended on bench or other
surface, always face trim cover up and
away from surface. As the live passenger
air bag (inflator) module must be placed
with its bag (trim cover) facing up, place it
on the workbench with a slit (1) or use the
workbench vise (2) to hold it securely at its
lower mounting bracket (3). It is also
prohibited to place anything on top of the
trim cover and stack air bag (inflator)
modules. This is necessary so that free
space is provided to allow air bag (inflator)
module to expand in the unlikely event of
accidental deployment.
Failure to follow procedures may result in
personal injury.

I4RS0A820084-01

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-117
• For side curtain-air bag (inflator) modulea. Cut off bag (1) of side curtain-air bag (inflator) module.
b. Tie side curtain-air bag inflator (1) to tire (3) with wire harness (2) as shown.
Wire harness specifications
Stripped wire harness section 1.25 mm2
(0.0019 in.2) or more (Stripped wire harness
diameter 1.25 mm (0.05 in.) or more)
CAUTION!
Make sure that wire harness is tight. It is very
dangerous if looseness in wire harness
results in side curtain-air bag inflator flying
off due to shock from inflator deploying.

NOTE
Wind wire harness (2) around at least 3 times.

c. Clear space (5) on ground about 185 cm (6 ft) in diameter where side curtain-air bag
(inflator) module (1) is set for deployment.
Paved, outdoor location where there is no
activity is preferred. If outdoor location is not
available, use space on shop floor where
there is no activity and sufficient ventilation is
provided. Ensure no loose or flammable
object exists within activation area.
d. Pile tire with side curtain-air bag (inflator) module on tire (4). • For seat belt pretensioner
a. Cut webbing (1) at tongue plate stopper (3) of seat belt pretensioner (2) side as shown.
NOTE
Hold seat belt pretensioner (2) vertically in
the same condition as it is installed.
Otherwise, webbing can’t be pulled out.

b. Remove tongue plate (4) and shoulder anchor (5) from webbing.
c. Tie webbing (1) tightly at 10 cm (3.9 in.) from
cutting edge as shown.
1
I4RS0A820090-01
1
2
3
4
5
I4RS0A820091-01
3 1 4
5 2I3JA01820037-01
10 cm (3.9 in.)
1
I4RS0A820104-01

Downloaded from www.Manualslib.com manuals search engine Lighting Systems: 9B-11
Front Fog Light Removal and Installation (If
Equipped)
S7RS0B9206014
Removal1) Disconnect negative (–) cable at battery.
2) Remove front bumper, and then remove front bumper guard from front bumper referring to “Front
Bumper and Rear Bumper Components in Section
9K”.
3) Disconnect coupler from fog light.
4) Remove fog light screws (1), and remove front fog light (2).
Installation
Reverse removal procedure for installation nothing the
following:
• After installing, adjust aimi ng referring to “Front Fog
Light Aiming Adjustment with Screen (If Equipped)”.
Front Fog Light Bulb Replacement (If Equipped)S7RS0B9206015
WARNING!
• To avoid danger of being burned, don’t touch when the bulb is hot.
• Don’t touch glass surface of bulb to avoid deteriorate as the case may be unclear
when bulb light on at dirty condition.

1) Remove front bumper referring to “Front Bumper and Rear Bumper Components in Section 9K”.
2) Remove fog light bulb (1) as shown.
3) Replace fog light bulb and assemble all removed parts.
Front Fog Light Switch Inspection (If Equipped)S7RS0B9206016
NOTE
Front fog lights light up only when headlight
switch is in HEADLIGHT position (low or high
beams) or SMALL position. Front fog lights
turn OFF automatically when headlight
switch is turned to OFF position. If front fog
light switch holds ON position, front fog
lights turn ON automa tically when headlight
switch is tuned to HEADLIGHT position (low
or high beams) or SMALL position again.

Check for continuity between terminals at each switch
position. If check result is not as specified, replace
switch.
Front Fog Light Relay Inspection (If Equipped)S7RS0B9206017
1) Check that there is no continuity between terminals “3” and “4”. If there is continuity, replace relay.
2) Connect battery positive (+ ) terminal to terminal “2”
of relay.
3) Connect battery negative (–) terminal to terminal “1” of relay.
4) Check continuity between terminals “3” and “4”. If there is no continuity when relay is connected to the
battery, replace relay.
1
2
I6RS0C920003-01
1
I4RS0A920020-01
1
2
3
4
5
Switch Position Terminal
ON (PUSH IN) 23
1
54
OFF
I4RS0A920021-01
“4”
“2” “1”
“3”
I4RS0A920022-01

Downloaded from www.Manualslib.com manuals search engine Glass / Windows / Mirrors: 9E-6
8) Using new brush, apply sufficient amount of primer onto glass along glass edge.
NOTE
• Be sure to refer to maker’s instruction for
proper handling and drying time.
• Do not apply primer on outside of ceramic coated surface.
• Do not touch primer coated surface.

Width applied primer for windshield
“a”: 15 mm (0.59 in.)
9) Apply primer for molding along molding surface all around.
10) Apply adhesive (1) referring to figure.
NOTE
• Press glass (2) against fittings surface of body panel quickly after adhesive (1) is
applied.
• Use of rubber sucker gr ip is helpful to hold
and carry glass after adhesive (1) is
applied.
• Perform steps 8) to 9) within 10 min. to ensure sufficient adhesion.
• Be sure to refer to adhesive maker’s instruction for proper handling and drying
time.
• Start from bottom side of glass (2).
• Be careful not to damage primer.

Adhesive amount specifications and position for
windshield
Width “a”: Approx. 7 mm (0.27 in.)
Height “b”: Approx. 15 mm (0.59 in.)
Position “c”: Approx. 11 mm (0.43 in.) for front,
rear and upper sections
Position “d”: Approx. 35 mm (1.38 in.) for bottom
section
1. Molding
2. Windshield side garnish clip
3. 32.5 mm (1.28 in.)
“a”
1
“a”
“a”
2
3
I4RS0A950003-01
3. Molding
4. Windshield glass spacer
5. Windshield side garnish clip
2
2
4
1
“b” “d”
“b”
“c”
2
1
“a”
3
2
1
“b”
“c”
5
“a”
“a”
I4RS0A950004-01