2000 SUZUKI SWIFT ring

7F-16 REAR DIFFERENTIAL
8) Place zero-adjusted mounting dummy (1) and dial gauge set
on pinion dummy (2) and take measurement between zero
position and extended dial gauge measuring tip.
9) Obtain adjusting shim thickness by using measured value by
dial gauge in the following equation.
10) Select adjusting shim(s) (1) closest to calculated value from
among following available sizes and put it in place and then
press-fit rear bearing.
Special tool
(A) : 09913-80112
Available shim thickness
“a” : 0.30, 1.00, 1.03, 1.06, 1.09, 1.12, 1.15, 1.18, 1.21, 1.24,
1.27, and 1.30 mm (0.012, 0.039, 0.041, 0.042, 0.043, 0.044,
0.045, 0.046, 0.048, 0.049, 0.050 and 0.051 in.)
11) With new pinion spacer (3) inserted as shown, install front
bearing to differential carrier. NOTE:
 Repeat turning back and forth of dummy and measure
distance as far as top surface of pinion dummy accu-
rately.
 When dial gauge measuring tip extends from 0 (zero)
position, pointer turns counterclockwise.
 Measured value may exceed 1 mm. Therefore, it is also
necessary to know reading of short pointer.
Necessary shim thickness = Dial gauge measured value C
1. Drive bevel pinion mounting dummy
2. Drive bevel pinion dummy
C
1
2
NOTE:
 Make sure to use new spacer for reinstallation.
 Apply oil to bearings.
1. Drive bevel pinion
2. Rear bearing

REAR DIFFERENTIAL 7F-17
12) While tightening bevel pinion nut gradually with bevel pinion
holder (special tool), set preload of pinion to specification.
Pinion bearing preload
: 5.0 – 13.0 kg-cm ( 4.4 – 11.2 lb-in.)
Special tool
(A) : 09927-28010
Differential Assembly
1) Place differential gear case assembly to differential carrier,
push differential case to left side as shown in figure.
Then measure clearance “a” between side bearing and dif-
ferential carrier by using thickness gauge.
Select shims closest to measured value.
Available shim thickness
: 1.35,1.40,1.45, 1.50, 1.55, 1.60, 1.65, 1.70 and 1.75 mm
(0.0531, 0.0551, 0.0571, 0.0591, 0.0610, 0.0630, 0.0650,
0.669 and 0.0689 in.)
2) Divide selected shim(s) between both sides (right and left)
and install them to differential carrier. Then install differential
side bearing cap.
Tightening torque
Differential side bearing cap bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft) NOTE:
 Before taking measurement, check for smooth rotation
by hand.
 Bevel pinion bearing preload is adjusted by tightening
bevel pinon nut to deform spacer.
Therefore, be sure to use a new spacer for adjustment
and tighten pinion nut step by step and check for start-
ing torque (preload) as often as tightening to prevent
over crushing of spacer.
If exceeds specification given below during adjust-
ment, replace spacer and repeat preload adjustment
procedure. Attempt to decrease starting torque (pre-
load) by loosening pinon nut will not do.
1. Torque wrench
2. Differential input hub
3. Socket with adapter
NOTE:
 Align match marks (1) on cap and carrier.
 Apply gear oil to bearing.

7F-18 REAR DIFFERENTIAL
3) Measure backlash by using dial gauge.
Drive bevel gear backlash
: 0.10 – 0.20 mm (0.0039 – 0.0078 in.)
Special tool
(A) : 09900-20606
(B) : 09900-20701
4) Check gear tooth contact as follows.
a) After cleaning tooth surface of drive bevel gears, paint them
with gear marking compound evenly by using brush or
sponge etc.
b) Turn gear to bring its painted part in mesh with bevel pinion
and turn it back and forth by hand to repeat their contact.
c) Bring painted part up and check contact pattern, referring to
the following chart. If contact pattern is not normal, readjust
or replace as necessary according to instruction in chart.
5) After completing of gear tooth contact check caulk bevel pin-
ion nut with caulking tool and hammer. NOTE:
 Be sure to apply measuring tip of dial gauge at right
angles to convex side (drive side) of tooth.
 If backlash is out of specification, change division of
shims so that backlash is within specification.
CAUTION:
When applying red lead paste to teeth, be sure to paint
tooth surfaces uniformly. The paste must not be too dry
or too fluid.
NOTE:
Be careful not to turn bevel gear more than one full revo-
lution, for it will hinder accurate check.

7F-20 REAR DIFFERENTIAL
UNIT ASSEMBLY
Before installing viscous coupling case (1) to differential carrier
(2), clean mating surfaces of viscous coupling case and differen-
tial carrier, then apply sealant to differential carrier (2) by using a
nozzle as shown in figure by such amount that its section is
1.5mm (0.059 in.) in diameter.
“A” : Sealant 99000-31110
Tightening torque
Coupling case bolts (a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
TIGHTENING TORQUE SPECIFICATION
Irregular patterns: If the pattern is not oval, it means
that bevel gear is defective. High or low spots on tooth
surfaces or on the seat of bevel gear are the cause of
irregular patterns appearing on some teeth. The rem-
edy is to replace the pinion and-gear set and, if the
seat is defective, so is transfer case. TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY
Fastening partTightening torque
Nm kg-m lb-ft
Rear differential oil drain plug 55 5.5 40.0
Rear differential oil level/filler plug 50 5.0 36.5
Rear differential companion flange nut 130 13.0 94.0
Rear differential input flange bolts 23 2.3 17.0
Drive bevel gear bolts 80 8.0 58.0
Differential side bearing cap bolts 23 2.3 17.0
Coupling case bolts 25 2.5 18.0
Differential carrier bolts 23 2.3 17.0
Propeller shaft bolts 23 2.3 17.0

REAR DIFFERENTIAL 7F-21
REQUIRED SERVICE MATERIAL
SPECIAL TOOL
MaterialRecommended SUZUKI product
(Part Number)Use
Thread lock cement THREAD LOCK CEMENT 1322
(99000-32110)Bevel gear bolts
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Oil seal lips
Sealant SUZUKI BOND NO. 1215
(99000-31110)Thread part of differential carrier bolt
Mating surface of differential housing
Mating surface of rear axle housing
Mating surface of viscous coupling case
09951-16060 09951-76010 09927-28010 09925-88210
Lower arm bush remover Bearing installer Bevel pinion holder Bearing puller attachment
09913-60910 09913-80112 09900-20701 09900-20606
Bearing puller Bearing installer Magnetic stand Dial gauge
09922-76140 09922-76150 09922-76330 09922-76430
Bevel pinion shaft Bevel pinion nut Rear collar Front collar

7F-22 REAR DIFFERENTIAL
09922-76350 09922-76120 09922-76250 09924-74510
Gauge block Dummy shaft Bevel gear dummy Bearing installer handle
09925-68210 09925-98210 09924-84510-002 09930-40113
Bearing installer Bearing installer Bearing installer Flange holder
09913-65135 09913-50121
Bearing puller Oil seal remover

BODY ELECTRICAL SYSTEM 8-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8
8D
8E
9
10
10A
10B
SECTION 8
BODY ELECTRICAL SYSTEM
CONTENTS
DIAGNOSIS ........................................................ 8-3
HEADLIGHT .................................................... 8-3
HEADLIGHTS WITH LEVELING SYSTEM
(IF EQUIPPED) ............................................... 8-3
TURN SIGNAL AND HAZARD WARNING
LIGHT .............................................................. 8-3
CLEARANCE, TAIL AND LICENSE
PLATE LIGHT ................................................. 8-4
BACK-UP LIGHT ............................................. 8-4
BRAKE LIGHT ................................................ 8-4
FRONT FOG LIGHT (IF EQUIPPED) ............. 8-4
REAR FOG LIGHT (IF EQUIPPED) ................ 8-4
SPEEDOMETER AND VSS ............................ 8-5
FUEL METER AND FUEL LEVEL SENSOR
(GAUGE UNIT) ............................................... 8-5
ENGINE COOLANT TEMPERATURE (ECT)
METER AND ECT SENSOR ........................... 8-5
OIL PRESSURE WARNING LIGHT ................ 8-5
BRAKE AND PARKING BRAKE WARNING
LIGHT .............................................................. 8-6
REAR WINDOW DEFOGGER ........................ 8-6
WIPERS AND WASHERS .............................. 8-6
FRONT WIPER AND WASHER .................. 8-6
REAR WIPER AND WASHER (IF
EQUIPPED)................................................. 8-6
POWER WINDOW CONTROL SYSTEM
(IF EQUIPPED) ............................................... 8-7
CIGARETTE LIGHTER ................................... 8-7
POWER DOOR LOCK CONTROL SYSTEM
(IF EQUIPPED) ............................................... 8-7
KEYLESS ENTRY SYSTEM (IF
EQUIPPED) .................................................... 8-7POWER DOOR MIRROR CONTROL
SYSTEM (IF EQUIPPED) ............................... 8-8
INTERIOR LIGHT ........................................... 8-8
HORN ............................................................. 8-8
IGNITION KEY REMAINDER (IF EQUIPPED)
AND LIGHT REMAINDER WARNING
BUZZER.......................................................... 8-8
SEAT BELT WARNING LIGHT (IF
EQUIPPED) .................................................... 8-8
FRONT SEAT HEATER (IF EQUIPPED) ....... 8-9
ON-VEHICLE SERVICE ..................................... 8-9
CAUTIONS IN SERVICING ............................ 8-9
HEADLIGHT ................................................... 8-9
HEADLIGHT SWITCH ................................ 8-9
HEADLIGHT ASSEMBLY ......................... 8-10
HEADLIGHT BULB ................................... 8-10
HEADLIGHT AIMING ADJUSTMENT
WITH SCREEN ......................................... 8-11
HEADLIGHT LEVELING SWITCH (IF
EQUIPPED) .............................................. 8-12
TURN SIGNAL AND HAZARD WARNING
LIGHTS ......................................................... 8-12
TURN SIGNAL LIGHT SWITCH ............... 8-12
REMOVAL AND INSTALLATION ............. 8-12
TURN SIGNAL AND HAZARD RELAY ..... 8-13
HAZARD SWITCH .................................... 8-13
FRONT FOG LIGHTS (IF EQUIPPED)......... 8-13
FRONT FOG LIGHT SWITCH .................. 8-13
REAR FOG LIGHT (IF EQUIPPED) ............. 8-14
REAR FOG LIGHT SWITCH..................... 8-14
IGNITION SWITCH ....................................... 8-14
COMBINATION METER ............................... 8-15 WARNING:
For vehicles equipped with Supplemental Restraint (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.
 Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

BODY ELECTRICAL SYSTEM 8-3
DIAGNOSIS
HEADLIGHT
HEADLIGHTS WITH LEVELING SYSTEM (IF EQUIPPED)
TURN SIGNAL AND HAZARD WARNING LIGHT
NOTE:
Fuse name (“ ”) in the table below is shown on the fuse box cover.
Condition Possible Cause Correction
Headlights do not light
upLighting or dimmer switch faulty Check headlight switch.
Headlight R and L fuses blown Replace fuse to check for short.
Wiring or grounding faulty Repair circuit.
Only one headlight
does not light upBulb blown Replace bulb.
Headlight R or L fuse blown Replace fuse to check for short.
Wiring or grounding faulty Repair circuit.
Only one beam (“Hi”
or “Lo”) does not lightBulb blown Replace bulb.
Lighting or dimmer switch faulty Check switch.
Wiring or grounding faulty Repair circuit.
Condition Possible Cause Correction
Both headlights do
not move“WIPER/WASHER” fuse blown Replace fuse to check for short.
Leveling switch faulty Check switch.
Supply voltage too low Recharge or replace battery.
One of headlights
(either Right or Left)
does not moveSocket, wiring or grounding faulty Repair.
Actuator faulty Check actuator.
Vehicle body around headlight deformed Repair body.
Headlight assembly itself deformed Replace headlight assembly.
Condition Possible Cause Correction
Flash rate high or one
side only flashesBulb blown on “flash rate high”-side Replace bulb.
Incorrect bulb Replace bulb.
Turn signal/hazard warning relay faulty Check relay.
Open circuit or high resistance existing
between combination switch (turn signal/hazard
warning switch) and light on one sideRepair circuit.
Wiring or grounding faulty Repair circuit.
No flashing
“HORN HAZARD” fuse and/or “TURN/BACK”
fuse(s) blownReplace fuse(s) to check for short.
Open circuit or high resistance existing
between battery and switchRepair circuit.
Turn signal/hazard relay faulty Check relay.
Combination switch or hazard switch faulty Check switch.
Wiring or grounding faulty Repair circuit.
Flash rate low
Supply voltage low Check charging system.
Turn signal/hazard relay faulty Check relay.