2006 SUZUKI SWIFT 1.1

Downloaded from www.Manualslib.com manuals search engine 5B-22 Manual Transmission/Transaxle:
14) With putting a shim (2) on bearing outer race (3), place straightedge (1) over it and compress it by
hand through straightedge, and then measure
clearance “a” between case surface (4) and
straightedge using feeler gauge (5).
Clearance between case surface and
straightedge (Shim protrusion)
“a”: 0.08 – 0.12 mm (0.0032 – 0.0047 in.)
15) By repeating Step 14), select a suitable shim which adjusts clearance “a” to specification and put it on
bearing outer race.
NOTE
Insert 0.10 mm (0.0039 in.) feeler to know
whether or not a shim fulfills specification
quickly.

Available shim thickness
16) Place left case plate (2) inserting its end in groove of shift guide shaft (4) and tighten bolts (1) to which
thread lock cement has been applied.
NOTE
After tightening bolts, make sure that
countershaft (5) can be rotated by hand
feeling certain load.

“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Left case plate bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
17) Install fifth gear referring to “Fifth Gear Disassembly and Assembly”.
18) Install gear shift and select shaft assembly referring to “Gear Shift and Select Shaft Assembly Removal
and Installation”.
19) Install back up light switch referring to “Back Up Light
Switch Removal and Installation”.
20) Check input shaft for rotation in each gear position.
21) Also confirm continuity of back up light switch in
reverse position using ohmmeter.
0.55 mm (0.021 in.) 0.90 mm (0.035 in.)
0.60 mm (0.023 in.) 0.95 mm (0.037 in.)
0.65 mm (0.025 in.) 1.00 mm (0.039 in.)
0.70 mm (0.027 in.) 1.05 mm (0.041 in.)
0.75 mm (0.029 in.) 1.10 mm (0.043 in.)
0.80 mm (0.031 in.) 1.15 mm (0.059 in.)
0.85 mm (0.033 in.)
I3RM0A520031-01
3. Input shaft
I4RS0A520042-01

Downloaded from www.Manualslib.com manuals search engine 5B-34 Manual Transmission/Transaxle:
Assembly
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
after disassembly, prepare replacing parts and proceed
to reassembly. Make sure that all parts are clean.
1) Assemble differential gear and measure thrust play
of differential gear as follows.
Special tool
(A): 09900–20607
(B): 09900–20701
Differential gear thrust play
0.03 – 0.31 mm (0.001 – 0.012 in.)
Left side
1. Hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to top
surface of gear (2).
2. Using 2 screwdrivers (1), move gear up and down and read movement of dial gauge pointer.
Right side
1. Using similar procedure to the left side, set dial gauge tip to gear (2) shoulder.
2. Move gear up and down by hand and read dial gauge.
2) If thrust play is out of sp ecification, select suitable
thrust washer from among the following available
size, install it and check again that specified gear
play is obtained.
Available thrust washer thickness
3) Drive in new differential pinion shaft pin (2) till the depth from differential case (3) surface is about 1
mm (0.04 in.).
4) Press-fit left bearing (2) using special tool and copper hammer.
Special tool
(A): 09913–76010
5) Support differential assembly (1) as illustrated so as to left bearing is floating , and then press-fit right
bearing (3) using special tools.
Special tool
(A): 09913–76010
(B): 09951–16060
0.85 mm (0.033 in.) 1.05 mm (0.041 in.)
0.90 mm (0.035 in.) 1.10 mm (0.043 in.)
0.95 mm (0.037 in.) 1.15 mm (0.045 in.)
1.00 mm (0.039 in.)
[A]: Left side
[B]: Right side
I3RH0A520083-01
1
(A)
3
2 (B)
I6RS0C520008-01

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-39
Reference waveform No.3
Motor output signal 1(1), Motor output signal 2(2), with
engine idling
Steering Wheel Play CheckS7RS0B6304024
• Check steering wheel for looseness or rattle by moving it in its shaft direction and lateral direction.
If found defective, repair or replace.
• Check steering wheel for play, holding vehicle in straight forward condition on the ground with engine
stopped.
If steering wheel play is not within specification,
inspect as follows and replace if found defective.
• Tie-rod end ball stud for wear (Ball stud should move when more than 0.2 N ⋅m (2 kg-cm, 0.44 lb-ft) torque is
applied.)
• Lower ball joint for wear
• Steering shaft joint for wear • Steering pinion or rack gear for wear or breakage
• Each part for looseness
Steering wheel play
“a”
: 0 – 30 mm (0 – 1.18 in.)
Steering Force CheckS7RS0B6304025
1) Place vehicle on level road and set steering wheel at
straight-ahead position.
2) Check if tire inflation pressure is as specified referring to the tire placard.
3) Remove driver air bag (inflator) module referring to “Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
4) Start engine.
5) With engine idling, measure steering force by turning torque wrench.
Steering force
: Less than 6.4 N ⋅m (0.64 kgf-m, 4.6 lb-ft)
6) Install driver air bag (inflator) module referring to “Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
Measurement
terminal
CH1: “E51-1” to vehicle body ground
CH2: “E51-2” to vehicle body ground
Oscilloscope
setting CH1: 5 V/DIV, CH2: 5 V/DIV
TIME: 20
µs/DIV
Measurement
condition • Engine is idling and steering wheel
is kept fully turned to left or right
until it stops
[A]: Steering wheel is kept fully turned left until it stops
[B]: Steering wheel is kept fully turned right until it stops
[C]: 12 V ON
[D]: GND ON
I6RS0B630019-01
I3RM0A630021-01
I3RM0A630022-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-11
5) Warm up engine to the normal operating temperature and keep it at the specified idle speed.
6) Turn A/C switch ON, set blower speed selector at maximum speed position, temperature selector at
maximum cold position, airflow selector at face
position, and air intake switch at recirculation
position. (Confirm that A/C compressor and
condenser fans are working.)
7) Wait for ten minutes to stabilize the A/C operation.
8) Open front windows, front doors and engine hood.
9) With about 20 mm (0.8 in.) of dry bulb thermometer
(1) put right in front of center ventilation louver and a
wet and dry bulb thermometer (2) near air inlet of
HVAC unit. 10) Check for each pressure of low side and high side if
it is within shaded range of graph. If each gauge
reading is out of specified pressure, correct defective
part referring to the following table.
NOTE
Pressure registered on gauge varies with
ambient temperature. Therefore, use the
graphs when determining if pressures are
normal or not.

Low side and high side pressure example,
Gauges should read as follows when ambient
temperature is 30 °C (86 °F)
Pressure on high pressure gauge (HI): 1590 –
1940 kPa (15.9 – 19.4 kg/cm2)
Pressure on low pressure gauge (LO): 270 – 430
kPa (2.7 – 4.3 kg/cm
2)
2
1
I4RS0B720004-01
[A]: Pressure of high pressure gauge
[B]: Pressure of low pressure gauge
[C]: Ambient temperature
[D]: Humidity [E]: Acceptable range
22
312.9 2200
0 1
2 3 30 70 30 70 %
4 5 6 7 8 9
10
11 12 13 14 15
16 17
18
19 21
298.7 2100
20
14.2 28.4 42.7 56.9 71.1 85.3 99.5
113.8 128.0 142.2
151.4
170.6
184.9 199.1
213.3 227.5
241.7
256.0
270.2
284.4
100 200 300 400 500 600 700 800 900
1000 1100 1200
1300
1400 1500 1600
1700 1800
1900
2000
25 30 35
77 86 95
psi kPa kg/cm
2
C
F
“A”
“B”
“C”
“D”
23
2300
327.1
[A]
[B]
[C][D][E]
[E]
I7RS0A721006-01

Downloaded from www.Manualslib.com manuals search engine 7B-26 Air Conditioning System: Manual Type
Expansion Valve Removal and InstallationS7RS0B7216010
Removal1) Recover refrigerant fr om the A/C system with
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
2) Loosen a bolt (1) and remove pipes from expansion valve (2).
3) Loosen bolts (3) and remove expansion valve.
Installation
Reverse removal procedure noting the following
instructions.
• Apply compressor oil to O-ring of expansion valve and pipes.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
Tightening torque
Expansion valve mount bolt: 3.5 N·m (0.35 kgf-m,
2.5 lb-ft)
Expansion Valve InspectionS7RS0B7216011
Refer to “A/C System Performance Inspection”.
A/C Refrigerant Pressure Sensor and Its Circuit
Inspection
S7RS0B7216012
1) Disconnect A/C refrigerant pressure sensor connector.
2) Turn ignition switch to ON position.
3) Check if voltage between “RED” wire terminal and “ORN” wire terminal of A/C refrigerant pressure
sensor connector is 4.75 V to 5.25 V.
If not, check A/C refrigerant pressure sensor circuit.
4) Connect A/C refrigerant pressure sensor connector with ignition switch turned OFF.
5) Connect manifold gauge set to the charging valves.
6) Check A/C refrigerant pressure sensor voltage of ECM connector referring to “A/C System Inspection
at ECM”.
If voltage is not as specified below, replace A/C
refrigerant pressure sensor. A/C refrigerant pressure sensor voltage
specifications (A/C refrigerant pressure measured
by manifold gauge)
0.8 MPa (8.0 kg/cm2, 116 psi): 1.46 – 1.71 V
1.4 MPa (14 kg/cm2, 203 psi): 2.28 – 2.53 V
1.6 MPa (16 kg/cm2, 232 psi): 2.55 – 2.80 V
1.8 MPa (18 kg/cm2, 261 psi): 2.82 – 3.03 V
A/C Refrigerant Pressure Sensor Removal and
Installation
S7RS0B7216013
Removal
1) Recover refrigerant from the A/C system with the recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
2) Disconnect negative (–) cable from battery.
3) Disconnect A/C refrigerant pressure sensor connector.
4) Remove A/C refrigerant pressure sensor (1) from liquid pipe (2).
Installation
Reverse removal procedure noting the following
instructions.
• Apply compressor oil to O-ring of A/C refrigerant
pressure sensor.
• Tighten A/C refrigerant pressure sensor to specified torque.
Tightening torque
A/C refrigerant pressure sensor (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
1
2 2
3
I4RS0A720028-01
1 2I4RS0A720029-01
(a)I4RS0A720031-01

Downloaded from www.Manualslib.com manuals search engine 7B-32 Air Conditioning System: Manual Type
Relief Valve Removal and InstallationS7RS0B7216030
Removal1) Recover refrigerant fr om the A/C system with
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
2) Remove relief valve (1) from compressor (2). Installation
Reverse removal procedure nothing the following
instructions.
• Use new O-ring.
• Apply compressor oil to O-ring.
• Tighten relive valve to the specified torque.
Tightening torque
Relief valve (a): 8 N·m (0.8 kgf-m, 6.0 lb-ft)
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
Specifications
Tightening Torque SpecificationsS7RS0B7217001
NOTE
The specified tightening torque is also described in the following.
“Compressor Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
12I4RS0A720048-01
(a)I4RS0A720049-01
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
Receiver/dryer bolt 10 1.0 7.5 )
Expansion valve mount bolt 3.5 0.35 2.5 )
A/C refrigerant pressure sensor 11 1.1 8.0 )
Armature plate bolt 15 1.5 11.0 )
Relief valve 8 0.8 6.0 )

Downloaded from www.Manualslib.com manuals search engine 8B-108 Air Bag System:
4) Remove side curtain-air bag (inflator) module fixing bolts (1) and clips (2).
5) Remove side curtain-air bag (inflator) module.
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 curtain air bag (inflator) module must be kept with it s bag facing up while
being stored or left standing. 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
WARNING!
Do not install side curtain-air bag (inflator)
module while twisted or bended. Otherwise,
side curtain-air bag (inflator) module may not
deploy and injury may result.

1) Install side curtain-air bag (inflator) module (1) with
clips and new bolts.
2) Tighten side curtain-air bag (inflator) module attaching bolts (1) to specified torque.
Tightening torque
Side curtain-air bag (inflator) module attaching
bolts (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Connect side curtain-air bag (inflator) module connector (1) securely as shown in figure.
a) Connect connector.
b) Lock connector wi th lock button (2).
4) Install head lining referring to “Head Lining Removal and Installation in Section 9H”.
5) Enable air bag system. Refer to “Enabling Air Bag System”.1 2
2
22
1
I4RS0A820076-01
1,(a) 1,(a)
I4RS0A820110-01
1
2
a)
b)
I4RS0A820055-01

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-125
Specifications
Tightening Torque SpecificationsS7RS0B8207001
NOTE
The specified tightening torque is also described in the following.
“Air Bag System Components, Wiring and Connectors Location”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Use of Special ToolsS7RS0B8208001
WARNING!
To avoid deployment when troubleshooting
the air bag system, do not use electrical test
equipment such as a battery powered or AC
powered voltmeter, ohmmeter, etc., or any
type of electrical equipment other than that
specified. Do not use a non-powered probe
type tester.
Instructions must be followed carefully,
otherwise personal injury may result.

You should be familiar with the tools listed under the
heading “Special Tool”. You should be able to measure
voltage and resistance. You should be familiar with
proper use of a scan tool such as Air Bag Driver /
Passenger Load Tool, Connector Test Adapter Kit and
the Digital Multimeter.
Special tool
(A): 09932–76010 Connector Test Adapter Kit
This must be used whenever a diagnostic procedure
requests checking or probing a terminal.
Using the appropriate adapter in the special tool will
ensure that no damage to the terminal will occur from the
multimeter probe, such as spreading or bending.
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
SDM bolt 9 0.9 6.5 )
Driver air bag (inflator) module mounting bolt 9 0.9 6.5 )
Passenger air bag (inflator) module attaching
bolt 23 2.3 16.5)
Sleeve lock nut 2.5 0.25 2.0 )
Side curtain-air bag (inflator) module attaching
bolts 11 1.1 8.0)
Forward-sensor mounting bolt 9 0.9 6.5 )
Side-sensor bolt 9 0.9 6.5 )
I3JA01820041-01