seats SUZUKI SWIFT 2008 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 00
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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 Precautions: 00-4
General PrecautionsS7RS0B0000002
The WARNING and CAUTION describe some general
precautions that you should observe when servicing a
vehicle. These general precautions apply to many of the
service procedures, and they will not necessarily be
repeated with each procedure to which they apply.
WARNING!
• Whenever raising a vehicle for service, be sure to follow the instructions under
“Vehicle Lifting Points in Section 0A”.
• When it is necessary to do service work with the engine running, make sure that
the parking brake is set fully and the
transmission is in Neutral (for manual
transmission vehicles) or Park (for
automatic transmission vehicles), Keep
hands, hair, clothing, tools, etc. away from
the fan and belts when the engine is
running.
• When it is necessary to run the engine indoors, make sure that the exhaust gas is
forced outdoors.
• Do not perform service work in areas where combustible materials can come in
contact with a hot exhaust system. When
working with toxic or flammable materials
(such as gasoline and refrigerant), make
sure that the area you work in is well-
ventilated.
• To avoid getting burned, keep away from hot metal parts such as the radiator,
exhaust manifold, tail pipe, muffler, etc.
• New and used engine oil can be hazardous. Children and pets may be
harmed by swallowing new or used oil.
Keep new and used oil and used engine oil
filters away from children and pets.
Continuous contact with used engine oil
has been found to cause [skin] cancer in
laboratory animals. Brief contact with used
oil may irritate skin. To minimize your
exposure to used engine oil, wear a long-
sleeve shirt and moisture-proof gloves
(such as dish washing gloves) when
changing engine oil. If engine oil contacts
your skin, wash thoroughly with soap and
water. Launder any clothing or rags if wet
with oil, recycle or properly dispose of
used oil and filters. • Be sure to observe following instructions
when handling service materials such as
fuel, oil, fluid, coolant, grease, sealant,
thread lock cement, etc. Otherwise, your
health may be ruined.
– Whenever handling any of these service materials, wear safety glasses to protect
your eyes. If it gets into your eye, it may
cause inflammation.
– Whenever handling any of these service materials, wear moistu re-proof gloves to
protect your skin. If it adheres to your
skin, it may cause inflammation.
– Do not swallow any of these service materials. It would cause diarrhea or
nausea.
– Keep all these materials out of children’s reach.
• Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly
up unexpectedly during driving,
obstructing your view and resulting in an
accident.

• Before starting any service work, cover fenders, seats and any other parts that are likely to get scratched or
stained during servicing. Also, be aware that what you
wear (e.g., buttons) ma y cause damage to the
vehicle’s finish.
I2RH01010025-01

Downloaded from www.Manualslib.com manuals search engine 0B-12 Maintenance and Lubrication:
HVAC Air Filter (If Equipped) InspectionS7RS0B0206032
1) Remove HVAC air filter from HVAC unit referring to
“HVAC Air Filter Removal and Installation (If
Equipped) in Section 7A”.
2) Check for dirt and dust. If HVAC air filter is excessively dirty, replace HVAC air filter with new
one. If not, go to next step.
3) Blow compressed air on the air outlet side of HVAC air filter for removing dust.
4) Install HVAC air filter in to HVAC unit referring to
“HVAC Air Filter Removal and Installation (If
Equipped) in Section 7A”.
HVAC Air Filter (If Equipped) ReplacementS7RS0B0206033
Replace HVAC air filter with new one referring to “HVAC
Air Filter Removal and Installation (If Equipped) in
Section 7A”.
Final Inspection for Maintenance ServiceS7RS0B0206034
WARNING!
When carrying out road tests, select a safe
place where no man or no running vehicle is
seen so as to prevent any accident.

Seats
Check that seat slides smoot hly and locks securely at
any position. Also check that reclining mechanism of
front seat back allows it to be locked at any angle.
Seat Belt
Inspect belt system including webbing, buckles, latch
plates, retractors and anchors for damage or wear.
Check that seat belt is securely locked. If “REPLACE
BELT” label on seat belt is visible, replace belt.
Battery Electrolyte Level Check
Check that the electrolyte le vel of all battery cells is
between the upper and lower level lines on the case. If
battery is equipped with built-in indicator, check battery
condition by the indicator. Accelerator Pedal Operation
Check that pedal operates
smoothly without getting
caught or interfered by any other part.
Engine Start
Check engine start for readiness.
WARNING!
Before performing th e following check, be
sure to have enough room around the
vehicle. Then, firmly apply both the parking
brake and the regular brakes. Do not use the
accelerator pedal. If the engine starts, be
ready to turn off the ignition promptly. Take
these precautions because the vehicle could
move without warning and possibly cause
personal injury or property damage.

On automatic transaxle vehicles, try to start the engine in
each select lever position. The starting motor should
crank only in “P” (Park) or “N” (Neutral).
On manual transaxle vehicles, place the shift lever in
“Neutral,” depress clutch pedal fully and try to start.
On Automated Manual Transaxl e vehicles, try to start
the engine in each select le ver position. The starting
motor should crank only when select lever is in “N”
(Neutral) and brake pedal is depressed.
Exhaust System Check
Check for leakage, cracks or loose supports.
Clutch (for Manual Transaxle)
Check for the following.
• Clutch is completely released when depressing clutch pedal,
• No slipping clutch occurs when releasing pedal and accelerating.
• Clutch itself is free fr om any abnormal condition.
Gearshift or Select Lever (Transaxle)
Check gear shift or select lever for smooth shifting to all
positions and for good performance of transaxle in any
position.
With automatic transaxle or Automated Manual
Transaxle equipped vehicle, also check that shift
indicator indicates properly according to which position
select lever is shifted to.
With automatic transaxle equipped vehicle, make sure
that vehicle is at complete stop when shifting select lever
to “P” range position and release all brakes.
I4RS0A020018-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-42
Cylinder Head InspectionS7RS0B1406027
• Remove all carbon deposits from combustion chambers.
NOTE
Do not use any sharp-edged tool to scrape
off carbon deposits. Be careful not to scuff or
nick metal surfaces when decarbonizing. The
same applies to valves and valve seats, too.

• Check cylinder head for cracks on intake and exhaust ports, combustion chambers, and head surface. Using
a straightedge and thickness gauge, check flatness of
gasketed surface at a total of 6 locations. If distortion
limit is exceeded, correct gasketed surface with a
surface plate and abrasive paper of about #400
(Waterproof silicon carbide abrasive paper): place
abrasive paper on and over surface plate, and rub
gasketed surface against paper to grind off high spots.
Should this fail to reduce thickness gauge readings to
within limit, replace cylinder head.
Leakage of combustion gases from this gasketed joint
is often due to warped gasketed surface: such
leakage results in reduced power output.
Distortion for cylinder head surface on piston side
Limit: 0.03 mm (0.001 in.) • Distortion of manifold seating faces:
Check seating faces of cylinder head for manifolds,
using a straightedge and thickness gauge, in order to
determine whether these faces should be corrected or
cylinder head replaced.
Distortion for cylinder head surface on intake and
exhaust manifold
Limit: 0.05 mm (0.002 in.)
I2RH0B140105-01
I2RH0B140106-01
I2RH0B140107-01

Downloaded from www.Manualslib.com manuals search engine 2C-8 Rear Suspension:
3) Install coil springs (right & left) on spring seats of rear
axle referring to “Spring Upper Seat and Lower Seat
Removal and Installation” and “Rear Coil Spring
Removal and Installation”.
4) Install shock absorbers lower side (right & left) and washers referring to “Rear Shock Absorber Removal
and Installation”.
5) Install brake dust covers, spindles and wheel speed sensors (right and left) referring to “Spindle Removal
and Installation”.
6) Connect wheel speed sensors (1) and lead wire clamps (2) (right & left).
Tightening torque
Wheel speed sensor bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)
7) Connect brake flexible hoses (1) to bracket on rear axle with E-rings (3) (right & left) and tighten brake
pipe flare nuts (a) to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft) 8) Install wheel speed sensor clamp and parking brake
clamp and tighten parking brake clamp bolts (1) to
specified torque.
Tightening torque
Parking brake cable clamp bolt (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
9) Install rear wheel hubs (right & left) referring to “Rear Wheel Hub Removal and Installation”.
10) Install brake discs (right & left) and rear brake caliper assemblies (right & left) referring to “Rear Brake Disc
Removal and Installati on in Section 4C”.
11) Connect rear brake caliper flexible hoses (1) to brake pipes (2) with E-rings (3) (right & left).
Tighten brake pipe flare nuts to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft)
1 2
(a)
3
I6RS0B230005-01
I4RS0A230028-01
1, (a)I6RS0B230006-01
3
2 1
(a)
I6RS0B230007-01

Downloaded from www.Manualslib.com manuals search engine Wheels and Tires: 2D-8
Tire Mounting and DismountingS7RS0B2406004
CAUTION!
When installing tire which has arrow
indicating tire rotation direction to wheel,
make sure that this tire rotation direction is
same as actual tire rotation direction when
vehicle is moving forward. Otherwise, it is
not possible to install wheel with tire to
vehicle in specified direction.

Use a tire changing machine to mount or dismount tires.
Follow equipment manufacturer’s instructions. Do not
use hand tools or tire irons al one to change tires as they
may damage tire beads or wheel rim.
Rim bead seats should be cleaned with a wire brush or
coarse steel wool to remove lubricants, old rubber and
light rust. Before mounting or dismounting a tire, bead
area should be well lubricated with approved tire
lubricant.
After mounting, inflate to specified pressure shown on
tire placard so that beads are completely seated.
WARNING!
Do not stand over tire when inflating. Bead
may break when bead snaps over rim’s safety
hump and cause serious personal injury.
Do not exceed 330 kpa (47.9 psi) pressure
when inflating. If 330 kpa (47.9 psi) pressure
will not seat beads, deflate, re-lubricate and
reinflate.
Over inflation may cause bead to break and
cause serious personal injury.

Install valve core and inflate to proper pressure.
Tire RepairS7RS0B2406005
There are many different materials and techniques on
the market to repair tires. As not all of these work on all
types of tires, tire manufacturers have published detailed
instructions on how and when to repair tires. These
instructions can be obtained from each tire
manufacturer.
Tire Repair for Emergency Repaired-Tire with
Sealant
S7RS0B2406006
WARNING!
Be sure to observe “Precaution for
Emergency Flat Tire Repair Kit”. Otherwise,
your health may be ruined.

1) Remove flat tire repair sealant from tire using plug (1), filler hose (2), sealant bottle (3) and extension
hose (4) in kit as follows.
a) Remove plug from fille r hose of sealant bottle.
Then connect ext ension hose to tip of filler hose.
b) Remove tire containing flat tire repair sealant from vehicle.
c) Loosen valve core carefully to release air.
WARNING!
Take care not to make sealant blast out from
valve. Otherwise, your health may be ruined.

d) Remove tire bead inside rim of wheel.
e) Make a clearance by inserting a tire lever (2) between tire bead and rim, and then insert hose
(1) thought clearance as shown in figure.
f) Press the bottle and suck out sealant (4), using bottle (3) as a pump.
NOTE
To make sealant easy to suck up from tire,
set bottle lower than sealant surface.

g) Change hose end position and repeat above step f) until sealant is not sucked out.
h) Put cap on bottle so that collected sealant does not leak.
4
1
2
3
I6RS0B240004-01
1 4
3 2
I6RS0C240003-01

Downloaded from www.Manualslib.com manuals search engine 8A-7 Seat Belts:
Rear Seat Belt Removal and InstallationS7RS0B8106005
WARNING!
Be sure to read “Precautions on Service and
Diagnosis of Seat Belt” before starting to
work and observe every precaution during
work.

Removal1) Fold rear seats referring to “Folding Rear Seats” in Owners Manual.
2) Remove rear side sill scuff (1), quarter lower trim (2)
and quarter upper trim (3).
3) Remove rear seat belt referring to “Rear Seat Belt Components”. Installation
Reverse removal procedure for installation 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.Rear Seat Belt InspectionS7RS0B8106006
WARNING!
Be sure to read “Precautions on Service and
Diagnosis of Seat Belt” before starting to
work and observe every precaution during
work.

• Check the rear seat belt in the same way as “Front Seat Belt Inspection”.
• As to seat belts with A-ELR, check them as follows. – With vehicle at stop, pull seat belt all the way out, let it retract a little and try to pull it. It should not be
pulled out, that is, it should be locked where
retracted.
– Let seat belt retract to its original state. Next, pull it
half way out, let it retrac t a little and try to pull it
again. It should be pulled out smoothly, that is it
should not be locked at this time.
Specifications
Tightening Torque SpecificationsS7RS0B8107001
NOTE
The specified tightening torque is also described in the following.
“Front Seat Belt Components”
“Rear Seat Belt Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
3
2
1
I4RS0A810004-01

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-121
Deployment / Activation Inside of Vehicle
When the vehicle will be destroyed, or salvaged for
component parts, deploy the air bag modules and/or
activate seat belt pretensioners installed on vehicle.
NOTE
If equipped with the seat belt pretensioners,
activate both side of seat belt pretensioners
at the same time when using special tool (C).

1) Turn ignition switch to LOCK position, remove key
and put on safety glasses.
2) Remove all loose objects from front seats and instrument panel.
3) Disconnect air bag (inflator) module or seat belt pretensioner connector as follows.
• For driver and passenger air bag (inflator) module [A]
Remove glove box from instrument panel and
disconnect driver and passenger air bag (inflator)
module connector (1).
• For side-air bag (inflator) module [B] Disconnect side-air bag (inflator) module
connectors (2) under front seat cushion.
• For side curtain-air bag (inflator) module [C] Remove rear pillar trim and disconnect side
curtain-air bag (inflator) module connectors (3).
• For seat belt pretensioners (right and left) [D] Remove both side (driver and passenger side)
center pillar lower trim an d disconnect seat belt
pretensioner connectors (4).
4) Confirm that each air bag (inflator) module and/or seat belt pretensioners is securely mounted.
[A]
[B]
[C]
[D]
2
1
3
4
1
2
1
2
1
2
1
2
I4RS0A820093-01

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 Seats: 9G-1
Body, Cab and Accessories
Seats
Repair Instructions
Front Seat ComponentsS7RS0B9706001
2
4
1 3
11
6
3
4
6
7
8
(b)
(b)
10
5
(a)
or
94
5
(c)
(b)
10
or
A
A
B
AB
B
A
I6RS0C970001-02
1. Seat cushion 6. Knob or 11. Riser bolt
: Apply thread lock 99000-32100 or 99000-32030
to all around thread part of bolt.
2. Seat back 7. Side air bag module (if equipped) : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
3. Riser nut 8. Side air bag harness (if equipped) : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft)
4. Cover or 9. Seat mounting bolt
: Apply thread lock 99000-32100 or 99000-
32030 to all around thread part of bolt. :28 N
⋅m (2.8 kgf-m, 20.5 lb-ft) (Seat lifter type)
35 N ⋅m (3.5 kgf-m, 25.5 lb-ft) (Non seat lifter
type)
5. Seat adjuster 10. Seat back mounting bolt