2007 SUZUKI SWIFT pin

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 6C-48 Power Assisted Steering System:
Specifications
Tightening Torque SpecificationsS7RS0B6307001
NOTE
The specified tightening torque is also described in the following.
“Steering Gear Case Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
Tie-rod end nut 454.5 32.5 )
Tie-rod end lock nut 454.5 32.5 ) / )
Wheel nut 858.5 61.5 )
Steering gear case mounting No.1 bolt 555.5 40.0 )
Steering gear case mounting No.2 bolt 555.5 40.0 )
Steering gear case mounting No.3 bolt 404.0 29.0 )
Earth cable bolt 4.5 0.45 3.5)
Tie-rod 939.3 67.5 )
Rack damper screw 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. )
Rotation torquer of pinion 2.00.2 1.5 )
Rack damper screw lock nut 646.4 46.5 )
P/S control module bracket screw (ABS model) 9 0.9 6.5)
P/S control module bracket screw (ESP ®
model) 70
.7 5 .0 )
P/S control module mounting screw 50.5 3.7 )

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-49
Special Tools and Equipment
Recommended Service MaterialS7RS0B6308001
NOTE
Required service material is also described in the following.
“Steering Gear Case Assembly Components”

Special ToolS7RS0B6308002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease E P/No.: 99000–25050)
Silicone sealant Silicone sealant P/No.: 99000–31120)
Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 )
09943–5501009944–18310
Boot clamp plier Pinion torque checking
socket
))
SUZUKI scan tool
—
This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12. ) / )

Downloaded from www.Manualslib.com manuals search engine 7A-8 Heater and Ventilation:
b. Move temperature control lever (1) and air flow control plate (2) fully to the arrow direction. c. Fix temperature control inner cable (1) to pin of
temperature control lever and air flow control inner
cable (2) to pin of air fl ow control plate, and then
fix each outer cable (3) to each cable lock clamp.
NOTE
After installing control cables, make sure that
control lever and plate move smoothly and
stop at proper position.

• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
• Make sure that air flow outlet changes correctly as air flow selector is changed.
[A]: LH steering vehicle [B]: RH steering vehicle
1
2
[A]
[B]
1
2
I4RS0B710014-01
[A]: LH steering vehicle [B]: RH steering vehicle
1
2
[B] [A] 3
3
1
3
23
I4RS0B710015-01

Downloaded from www.Manualslib.com manuals search engine Heater and Ventilation: 7A-9
Blower Speed Selector InspectionS7RS0B7106010
Check blower speed selector for each terminal to
terminal continuity. If check result does not meet the
following conditions, replace HVAC control unit.
Air Intake Selector InspectionS7RS0B7106011
• Check that there is continuity between terminal (1) and terminal (2) when air intake selector is at fresh
position.
• Check that there is no continuity between terminal (1) and terminal (2) when air intake selector is at
recirculation position.
If check result does not meet the above conditions,
replace HVAC control unit.
Air Intake Control Actuator Removal and
Installation
S7RS0B7106012
Removal
1) Remove instrument panel from vehicle body referring to “Instrum ent Panel Removal and
Installation in Section 9C”.
2) Remove screws (1).
3) Remove air intake control actuator (2) from HVAC unit.
Installation
Reverse removal procedure noting the following
instruction.
• Be sure to insert the linkage pin (1) into the groove (2) of air intake control actuator.
IHMH
GND LML
PositionTerminalI
OFF 1
2
3
4 LMLMHHGND
I4RS0A710019-01
1
2
I5RS0A710001-01
1 1
2
I4RS0A710021-01
1
2
I4RS0A710022-01

Downloaded from www.Manualslib.com manuals search engine 7B-10 Air Conditioning System: Manual Type
Abnormal Noise from Tension Pulley
Abnormal Noise from A/C Evaporator
Abnormal Noise from Blower Motor
A/C System Performance InspectionS7RS0B7214003
1) Confirm that vehicle and environmental conditions are as follows.
• Vehicle is put indoors.
• Ambient temperature is within 25 – 35 °C (77 – 95
° F).
• Relative humidity is within 30 – 70%.
• There is no wind indoors.
• HVAC unit is normal.
• Blower motor is normal.
• There is no air leakage from air ducts.
• Condenser fins are clean.
• Air filter in HVAC unit is not clogged with dirt and
dust.
• Battery voltage is about 12 V.
• Radiator cooling fan operates normally.
2) Make sure that high pressure valve (1) and low pressure valve (2) of manifold gauge are firmly
closed.
3) Connect high pressure charging hose (3) to high pressure service valve (5) on vehicle and low
pressure charging hose (4) to low pressure service
valve (6).
4) Bleed the air in charging hoses (3) and (4) by loosening their nuts respectively utilizing the
refrigerant pressure. When a hissing sound is heard,
immediately tighten nut.
CAUTION!
Do not connect high and low pressure
charging hoses in reverse.

Condition Possible cause Correction / Reference Item
Clattering noise is heard
from pulley Worn or damaged bearing
Replace tension pulley.
Pulley cranks upon
contact Cracked or loose bracket
Replace or retighten bracket.
ConditionPossible cause Correction / Reference Item
Whistling sound is heard
from A/C evaporator Depending on the combination of the
interior / exterior temperatures, engine
rpm and refrigerant pressure, the
refrigerant flowing out of the expansion
valve may, under certain conditions,
make a whistling sound At times, slightly decrea
sing refrigerant volume
may stop this noise.
Inspect expansion valve and replace if faulty.
Condition Possible cause Correction / Reference Item
Blower motor emits a
chirping sound in
proportion to its speed of
rotation Worn or damaged motor brushes or
commutator
Replace blower motor.
Fluttering noise or large
droning noise is heard
from blower motor Leaves or other debris introduced from
fresh air inlet to blower motor
Remove debris and make sure that the screen
at fresh air inlet is intact.
53
2
1
4 6
I4RS0A720006-01

Downloaded from www.Manualslib.com manuals search engine 7B-16 Air Conditioning System: Manual Type
Repair Instructions
Operation Procedure for Refrigerant ChargeS7RS0B7216001
WARNING!
• Your eyes should not be exposed to refrigerant (liquid).Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately –
6 °C (21.2 ° F) below freezing point. Should liquid HFC-134a (R-134a) is exposed to your eyes, it may
cause a serious injury. To protect your eyes from such accident, it is necessary to always wear
goggles. Should it occur that HFC-134a (R-134a) is exposed to your eyes, consult a doctor
immediately.
– Do not use your hand to rub the affected eye(s). Instead, use fresh cold water to splash it over the affected area to gradually raise temperature of such area above freezing point.
– Obtain proper treatment as soon as possible from a doctor or eye specialist.
• Should the liquid refrigerant HFC-134a (R-134a) is exposed to your skin, the affected area should be treated in the same manner as when skin is frostbitten or frozen.
• Do not handle refrigerant near any place where welding or steam cleaning is performed.
• Refrigerant should be kept in a cold and dark pl ace. It should never be stored in any place where
temperature is high, e.g. where exposed to direct su n light, close to fire or inside vehicle (including
trunk room).
• Avoid breathing fume produced when HFC-134a (R-134a) is burned. Such fume may be hazardous to your health.

Recovery
When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling
equipment because discharging refrigerant HFC-134a (R-1 34a) into atmosphere would cause adverse effect to
environments.
Start evacuation.Start evacuation.
Stop evacuation.Stop evacuation.
Wait 10 minutesWait 10 minutes
Check A/C system forCheck A/C system for
pressure tighteness.pressure tighteness.
Recharge A/C system withRecharge A/C system withrefrigerant.refrigerant.
Check A/C system for refrigerantCheck A/C system for refrigerantleaks and amount of refrigerantleaks and amount of refrigerantcharged.charged.
Performance testPerformance test
Inspect and repair connections.Inspect and repair connections.
If gauge showsIf gauge showsabnormal conditionsabnormal conditions
Recharge 370 20 g ofRecharge 370 20 g ofrefrigerant.refrigerant.
I5RS0C721005-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-21
Removal of Manifold Gauge Set
WARNING!
High pressure side is under high pressure.
Therefore, be careful not to get injured
especially on your eyes and skin.

For the A/C system charged with the specified amount of
refrigerant, remove manifold gauge set as follows:
1) Close low pressure side valve of manifold gauge set. (The high pressure side valve is closed continuously
during the process of charging.)
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service valves. This operation must be performed quickly.
5) Put caps on service valves.
Check A/C System for Refrigerant Leaks
Whenever a refrigerant leak is suspected in the system
or any service operation has been performed which may
result in malfunction of lines and connections, it is
advisable to check for leaks.
Common sense should be used during refrigerant leak
test, since the need and extent of any such test will, in
general, depend upon the nature of a complaint and the
type of a service performed on the system.
Liquid leak detector
WARNING!
• To prevent explosions and fires, make sure that there are no flammables in the vicinity.
• When the refrigerant exposed to fire, it turns into a poisonous gas (phosgene). Do
not inhale this gas.

There is a number of fittings and places throughout the
A/C system where a liquid leak detector solution may be
used to pinpoint refrigerant leaks.
By merely applying the solution to the area in question
with a swab, such as attached to the cap of a vial,
bubbles will form within seconds if there is a leak.
For confined areas, such as sections of the evaporator
and condenser, an electronic (refrigerant) leak detector
is more practical fo r determining leaks.
Special tool
(A): 09990–86012
Condenser Assembly On-Vehicle InspectionS7RS0B7216002
Check the followings.
• Clog of condenser fins If any clog is found, cond enser fins should be washed
with water and should be dried with compressed air.
• Condenser fins for leakage and breakage If any defects are found, repair or replace condenser.
• Condenser fittings for leakage. If any defects are found, repair or replace condenser.
Condenser Assembly Removal and InstallationS7RS0B7216003
CAUTION!
Do not damage condenser fins. If condenser
fin is bent, straighten it by using flat head
screwdriver or pair of pliers.

Removal
1) Recover refrigerant from A/C system referring to “Operation Procedure for Refrigerant Charge”.
NOTE
The amount of removed compressor oil must
be measured for replenishing compressor
oil.

2) Remove front bumper referring to “Front Bumper and Rear Bumper Components in Section 9K”.
3) Disconnect discharge hose (1) and liquid pipe (2) from condenser assembly (3).
4) Remove condenser assembly mounting bolts (4).
(A)
I5RS0C721006-01
4
1
3
2
I4RS0A720017-01