Suzuki SWIFT RS415 2017 User manual

IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by
these signal words.
The circle with a slash in this manual means “Don’t do this” or “Don’t let this happen”.
WARNING:
Indicates a potential hazard that could result in death or injury.
CAUTION:
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
WARNING:
This service manual is intended for authorized Suzuki dealers and qualified service technicians only.
Inexperienced technicians or technicians without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the technician and may render the vehicle unsafe for the driver
and passengers.
WARNING:
For vehicles equipped with a Supplemental Restraint or Air Bag System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
•Iftheairbagsystemandanothervehiclesystemboth need repair, Suzuki recommends that the air
bag system be repaired first, to help avoid unintended air bag system activation.
•Donotmodifythesteeringwheel,instrumentpanel or any other air bag system component on or
around air bag system components or wiring. Modifications can adversely affect air bag system
performance and lead to injury.
•Ifthevehiclewillbeexposedtotemperaturesover93°C(200°F),forexample,duringapaintbaking
process, remove the air bag system components, that is air bag or inflator modules, SDM and/or
seat belt with pretensioner, beforehand to avoid component damage or unintended activation.

FOREWORD
This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service
operations, replacement of components (Service) and for disassembly and assembly of major components (Unit
Repair-Overhaul).
VOLUME 1 contains General information, Engine, Suspension, Drive/Axle and Brakes sections (Sections 0 – 4).
VOLUME 2 contains Transmmision/Transaxle, Steering, HVAC, Restraint, Body/Cab/Accessories and
Control Systems sections (Sections 5 – 10).
Applicable model:
SWIFT (RS415) vehicles on and after following vehicle identification numbers (VINs).
JSAEZC21S00100001
The contents are classified into sections each of which is given a section number as indicated in the Table of
Contents on following page. And on the first page of each individual section is an index of that section.
This manual should be kept in a handy place for ready reference of the service work.
Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials as specified in each description.
All information, illustrations and specifications contained in this literature are based on the latest product infor-
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2004

00
0
1
2
3
4
5
6
7
8
9
10
11
Volume 1
Precautions............................................................... 00-i
Precautions ............................................................ 00-1
General Information ................................................... 0-i
General Information ...............................................0A-1
Maintenance and Lubrication.................................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
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
Volume 2
Precautions............................................................... 00-i
Precautions ............................................................ 00-1
Transmission / Transaxle .......................................... 5-i
Precautions .............................................................. 5-1
Automatic Transmission.........................................5A-1
Manual Transmission .............................................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 System............................10B-1
Immobilizer Control System .................................10C-1
TABLE OF CONTENTS

Table of Contents 00- i
00
Section 00
CONTENTS
Precautions
Precautions ...............................................00-1
Precautions........................................................... 00-1
Precautions for Vehicles Equipped with
a Supplemental Restraint (Air Bag) System ..... 00-1
General Precautions ........................................... 00-3
Precautions for Catalytic Converter .................... 00-6
Precautions for Installing Mobile
Communication Equipment ............................... 00-6
Precaution for CAN Communication System ...... 00-7
Precautions for Electrical Circuit Service ............ 00-7
Air Bag Warning .................................................. 00-9
Air Bag System Service Warning ........................ 00-9
Fastener Caution................................................. 00-9
Suspension Caution ............................................ 00-9
Wheels and Tires Caution................................... 00-9
Brake Caution ................................................... 00-10
Repair Instructions ............................................ 00-10
Electrical Circuit Inspection Procedure ............. 00-10
Intermittent and Poor Connection Inspection .... 00-12

00-1 Precautions:
Precautions
Precautions
Precautions for Vehicles Equipped with a
Supplemental Restraint (Air Bag) System
S4RS0A0000001
WARNING:
•Theconfigurationofairbagsystemparts
are as shown in the figure. When it is
necessary to service (remove, reinstall and
inspect) these parts, be sure to follow
procedures described in Air Bag System
section. Failure to follow proper
procedures could result in possible air bag
system activation, personal injury, damage
to parts or air bag system being unable to
activate when necessary.
•Iftheairbagsystemandanothervehicle
system both need repair, SUZUKI
recommends that the air bag system be
repaired first, to help avoid unintended air
bag system activation.
•Donotmodifythesteeringwheel,
dashboard, or any other air bag system
components. Modifications can adversely
affect air bag system performance and
lead to injury.
•Ifthevehiclewillbeexposedto
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 air bag system activation.
Diagnosis
• When troubleshooting air bag system, be sure to
follow “Diagnosis” in Air Bag System section.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacement.
• Never use electrical test equipment other than that
specified.
WARNING:
Never attempt to measure the resistance of
the air bag (inflator) modules (driver,
passenger, side and curtain) and seat belt
pretensioners (driver and passenger). It is
very dangerous as the electric current from
the tester may deploy the air bag or activate
the pretensioner.
1. Air bag wire harness (in floor, main
and instrument panel harness)
6. Driver air bag (inflator) module
2. Passenger air bag (inflator)
module
7. Side air bag (inflator) module
(if equipped)
3. SDM 8. Curtain air bag (inflator)
module (if equipped)
4. Seat belt pretensioner 9. Forward sensor
5. Contact coil 10. Side sensor (if equipped)
44
10
10
7
9
1
6
5
23
7
8
I4RS0A000001-
I4RS0A000002-

Precautions: 00-2
Servicing and Handling
WARNING:
Many of service procedures require
disconnection of “A/BAG” fuse and all air
bag (inflator) module(s) from initiator circuit
to avoid an accidental deployment.
Driver, Passenger, Side and Curtain Air Bag
(Inflator) Modules
•Forhandlingandstorageofaliveairbag
(inflator) module, select a place where the
ambient temperature below 65 C (150 F),
without high humidity and away from
electric noise.
•Whencarryingaliveairbag(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. When placing a live air bag
(inflator) module on a 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.
•Neverdisposeoflive(undeployed)airbag
(inflator) modules (driver, passenger, side
and curtain). If disposal is necessary, be
sure to deploy them according to
deployment procedures described in “Air
Bag (Inflator) Module and Seat Belt
Pretensioner Disposal: in Section 8B”
before disposal.
•Theairbag(inflator)module immediately
after deployment is very hot. Wait for at
least half an hour to cool it off before
proceeding the work.
•Afteranairbag(inflator)modulehasbeen
deployed, the surface of the air bag may
contain a powdery residue. This powder
consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by-
products of the chemical reaction. As with
many service procedures, gloves and
safety glasses should be worn.
[A]: Always carry air bag (inflator) module with trim cover (air bag opening)
away from body.
[B]: Always place air bag (inflator) module on workbench with trim cover (air
bag opening) up, away from loose objects.
1
2
3
[A]
[B]
I4RS0A000003-

00-3 Precautions:
WARNING:
SDM
•ForhandlingandstorageofaSDM,select
a place where the ambient temperature
below 65 C (150 F), without high humidity
and away from electric noise.
•Duringserviceprocedures,beverycareful
when handling a Sensing and Diagnostic
Module (SDM). Never strike or jar the SDM.
•Neverpoweruptheairbagsystemwhen
the SDM is not rigidly attached to the
vehicle. All SDM and mounting bracket
fasteners must be carefully torqued and
the arrow must be pointing toward the
front of the vehicle to ensure proper
operation of the air bag system.
The SDM could be activated when powered
while not rigidly attached to the vehicle
which could cause deployment and result
in personal injury.
WARNING:
Driver and Passenger Seat Belt
Pretensioners
•Forhandlingandstorageofaliveseatbelt
pretensioner, select a place where the
ambient temperature below 65 C (150 F),
without high humidity and away from
electric noise.
•Nevercarryseatbeltpretensionerbywire
or connector of pretensioner. When
placing a live seat belt pretensioner on the
workbench or some place like that, never
put something on seat belt pretensioner.
Otherwise, personal injury may result.
•Neverdisposeoflive(inactivated)seatbelt
pretensioners (drive and passenger). If
disposal is necessary, be sure to activate
them according to activation procedures
described in “Air Bag (Inflator) Module and
Seat Belt Pretensioner Disposal: in
Section 8B” before disposal.
•Theseatbeltpretensionerimmediately
after activation is very hot. Wait for at least
half an hour to cool it off before
proceeding the work.
•Withmanyserviceprocedures,glovesand
safety glasses should be worn to prevent
any possible irritation of the skin or eyes.
•Evenwhentheaccidentwaslightenoughnotto
cause air bags to activate, be sure to inspect system
parts and other related parts according to instructions
under “Repair and Inspection Required after Accident:
in Section 8B”.
•Whenservicingpartsotherthanairbagsystem,if
shocks may be applied to air bag system component
parts, remove those parts beforehand.
•Whenhandlingtheairbag(inflator)modules(driver,
passenger, side and curtain), seat belt pretensioners
(driver and passenger), forward sensor, side sensors
or SDM, be careful not to drop it or apply an impact to
it. If an excessive impact was applied, never attempt
disassembly or repair but replace it with a new one.
•Whengrease,cleaningagent,oil,water,etc.hasgot
onto air bag (inflator) modules (driver, passenger, side
and curtain) or seat belt pretensioners (drive and
passenger), wipe off immediately with a dry cloth.
•Airbagwireharnessisincludedinfloorand
instrument panel wire harnesses. Air bag wire
harness branched off from floor and instrument panel
wire harnesses can be identified easily as it is covered
with a yellow protection tube and it has yellow
connectors. Be very careful when handling it.
•Whenanopeninairbagwireharness,damagedwire
harness, connector or terminal is found, replace wire
harness, connectors and terminals as an assembly.
•Donotapplypowertotheairbagsystemunlessall
components are connected or a diagnostic flow
requests it, as this will set a DTC.
•Neveruseairbagsystemcomponentpartsfrom
another vehicle.
•Whenusingelectricwelding,besuretodisconnectall
air bag (inflator) module connectors and pretensioner
connectors from air bag wire harness respectively.
•Neverexposeairbagsystemcomponentparts
directly to hot air (drying or baking the vehicle after
painting) or flames.
• WARNING / CAUTION labels are attached on each
part of air bag system components. Be sure to follow
the instructions.
•Aftervehicleiscompletelyrepaired,perform“AirBag
Diagnostic System Check: in Section 8B”.
General Precautions
S4RS0A0000002
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.