2007 SUZUKI SWIFT Coolant removal

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-9
Manual Transaxle Unit Dismounting and
Remounting
S7RS0B5206009
Dismounting1) Drain coolant and transaxle oil.
2) Remove coolant reservoir with reservoir hose.
3) Remove battery and tray.
4) Remove air cleaner case and resonator.
5) Disconnect gear shift and gear select control cables (1) while pressing claws (2) of clip (3).
6) Disconnect back up light switch coupler and undo wiring harness clamps.
7) Remove ground cable from transaxle.
8) Remove clutch operating cylinder with fluid hose from transaxle.
9) Remove water inlet No.2 pipe from transaxle.
10) Remove starting motor re ferring to “Starting Motor
Dismounting and Remounting in Section 1I”.
11) Remove transaxle to engine bolts (1) of upper side. 12) Support engine using supporting device (1).
CAUTION!
Do not apply supporting device to projection
part A. If do so, it may be deformed.

13) Remove front drive shafts and center shaft referring
to “Front Drive Shaft Assembly Removal and
Installation in Section 3A”.
14) Remove exhaust No.2 pipe referring to “Exhaust Pipe and Muffler Removal a nd Installation in Section
1K”.
15) Remove clutch housing lower plate (1).
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I7RS0A521003-01
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I4RS0A520018-01
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I4RS0A520019-01
1I4RS0A520020-01

Downloaded from www.Manualslib.com manuals search engine 7-ii Table of Contents
Recommended Service Material ....................... 7B-33
Special Tool ...................................................... 7B-33
Automatic Type .................... .................................7B-34
Precautions.........................................................7B-34 A/C System Caution .......................................... 7B-34
Precautions in Diagnosing Trouble ................... 7B-34
Precautions on Servicing A/C System .............. 7B-34
General Description .......... .................................7B-34
Auto A/C System Descript ion ............................ 7B-34
HVAC Control Module Operation Description ... 7B-36
Refrigerant Type Identifica tion .......................... 7B-36
Sub-Cool A/C System Description .................... 7B-36
A/C Operation Description ................................ 7B-36
On-Board Diagnostic System Description ......... 7B-37
Schematic and Routing Diagram ......................7B-37 Major Components of A/C System .................... 7B-37
A/C System Wiring Diagra m ............................. 7B-38
Diagnostic Information and Procedures ..........7B-39 A/C System Symptom Diagnosis ...................... 7B-39
Abnormal Noise Sympto m Diagnosis of A/C
System ............................................................ 7B-42
DTC Check........................................................ 7B-42
DTC Clearance ................................................. 7B-43
DTC Table ......................................................... 7B-44
Fail-Safe Table ................. ................................. 7B-45
Scan Tool Data ................................................. 7B-46
Air Conditioning System Check......................... 7B-47
Visual Inspection ............................................... 7B-49
DTC B1502: Inside Air Temperature Sensor and/or Its Circuit Malfunction .......................... 7B-49
DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction .............. 7B-50
DTC B1504: Sunload Sensor and/or Its Circuit Malfunction ......... ................................. 7B-52
DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit
Malfunction ...................................................... 7B-53
DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit
Malfunction ...................................................... 7B-55
DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction .......................... 7B-57
DTC B1514: Air Flow Co ntrol Actuator and/or
Its Circuit Malfunction ...................................... 7B-60
DTC B1541: HVAC Control Module Back-Up Power Supply Malfunction .............................. 7B-62
DTC B1546: A/C Refrigerant Pressure Malfunction ...................................................... 7B-63
DTC B1551: Serial Communication Circuit Malfunction ...................................................... 7B-63
DTC B1552: Serial Communication Signal Malfunction ...................................................... 7B-64
DTC B1553: CAN Communication Signal Malfunction ...................................................... 7B-65
DTC B1557: Vehicle Speed Sensor Signal Malfunction ...................................................... 7B-65
DTC B1561: Engine Coolant Temperature Sensor Signal Malfunctio n .............................. 7B-66 DTC B1562: Outside Air Temperature Sensor
Signal Malfunction ........................................... 7B-66
DTC B1563: A/C Refr igerant Pressure
Sensor Signal Malfunction .............................. 7B-66
Inspection of HVAC Control Module and Its Circuit .............................................................. 7B-67
A/C System Performance Inspection ................ 7B-70
A/C System Inspection at ECM ......................... 7B-70
Repair Instructions ............ ................................7B-71
Operation Procedure for Refrigerant Charge .... 7B-71
HVAC Unit Components ................................... 7B-72
HVAC Unit Removal and In stallation ................ 7B-73
Temperature Control Actuator Removal and Installation ....................................................... 7B-73
Temperature Control Actuat or Inspection ......... 7B-73
Air Flow Control Actuator Removal and Installation ....................................................... 7B-74
Air Flow Control Actuator Inspection ................. 7B-74
Air Intake Control Actuator Removal and Installation ....................................................... 7B-75
Air Intake Control Actuator Inspection............... 7B-75
Actuator Linkage Inspection .............................. 7B-76
Blower Motor Controller Removal and Installation ....................................................... 7B-76
Blower Motor Controller Inspection ................... 7B-76
HVAC Control Module Removal and Installation ....................................................... 7B-77
Sunload Sensor Removal and Installation ........ 7B-77
Sunload Sensor Inspection ............................... 7B-77
Outside Air Temperature Sensor Removal and Installation ................................................ 7B-77
Outside Air Temperature Sensor Inspection ..... 7B-77
Inside Air Temperature Sensor Removal and Installation ....................................................... 7B-78
Inside Air Temperature Sens or Inspection ........ 7B-78
Condenser Assembly On-Vehicle Inspection .... 7B-78
Condenser Assembly Removal and Installation ....................................................... 7B-78
Receiver/Dryer Removal and Installation .......... 7B-78
Evaporator Inspection ....................................... 7B-78
Evaporator Temperature Sensor Removal and Installation ................................................ 7B-78
Evaporator Temperature Se nsor Inspection ..... 7B-78
Expansion Valve Removal an d Installation ....... 7B-78
Expansion Valve Inspection .............................. 7B-78
A/C Refrigerant Pressure Sensor and Its Circuit Inspection............................................. 7B-78
A/C Refrigerant Pressu re Sensor Removal
and Installation ................................................ 7B-78
Compressor Relay Inspection .
.......................... 7B-78
Compressor Drive Belt Inspection and Adjustment ...................................................... 7B-78
Compressor Drive Belt Removal and Installation ....................................................... 7B-79
Compressor Assembly Removal and Installation ....................................................... 7B-79
Compressor Assembly Components................. 7B-79
Magnet Clutch Removal and Installation........... 7B-79
Magnet Clutch Inspection.................................. 7B-79
Relief Valve Inspection...................................... 7B-79

Downloaded from www.Manualslib.com manuals search engine 7A-4 Heater and Ventilation:
Repair Instructions
HVAC Unit ComponentsS7RS0B7106001
For manual type A/C, refer to “HVAC Unit Components
in Section 7B”.
For automatic type A/C, refer to “HVAC Unit
Components in Section 7B”.
HVAC Unit Removal and InstallationS7RS0B7106002
Removal
1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove cowl top panel from vehicle body referring to “Cowl Top Components in Section 9K”.
4) Drain engine coolant, and then disconnect heater hoses (1) from HVAC unit (2).
5) Remove instrument panel from vehicle body referring to “Instrument Panel Removal and
Installation in Section 9C”.
6) Remove nuts (3).
7) Remove HVAC unit from vehicle body.
Installation
Reverse removal procedure noting the following
instructions.
• Be careful not to catch any cable and wiring harness in inappropriate position.
• Adjust control cables of HVAC control unit referring to “HVAC Control Unit Remo val and Installation”.
• Fill engine coolant to radiator.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Blower Motor Removal and InstallationS7RS0B7106003
Removal
1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Disconnect connector (1) from blower motor (2).
4) Remove blower motor from HVAC unit by removing screws (3).
Installation
Reverse removal procedure noting the following
instruction.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Blower Motor InspectionS7RS0B7106004
• Check for continuity between two terminals as shown. If there is no continuity, replace blower motor.
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3I4RS0B710004-01
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I4RS0B710005-01
I4RS0A710006-01

Downloaded from www.Manualslib.com manuals search engine 7B-24 Air Conditioning System: Manual Type
HVAC Unit Removal and InstallationS7RS0B7216006
Removal1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Recover refrigerant from A/C system with recovery and recycling equipment referring to “Recovery” in
“Operation Procedure for Refrigerant Charge”.
4) Remove cowl top panel referring to “Cowl Top Components in Section 9K”.
5) Drain engine coolant, and then disconnect heater hoses (1) from HVAC unit (2).
6) Remove instrument panel from vehicle body referring to “Audio Unit Re moval and Installation in
Section 9C”.
7) Loosen suction hose and liquid pipe bolt (4).
8) Remove nuts (3).
9) Remove HVAC unit from vehicle body. Installation
Reverse removal procedure noting the following
instructions.
• Replenish specified amount of compressor oil to
compressor suction side referring to “Replenishing
Compressor Oil” in “Operation Procedure for
Refrigerant Charge”.
• Install the padding (1) to the installation hole uniformly.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
• Adjust control cables referr ing to “HVAC Control Unit
Removal and Installati on in Section 7A”.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Evaporator InspectionS7RS0B7216007
Check the followings.
• Clog of A/C evaporator fins.If any clogs are found, A/C evaporator fins should be
washed with water, and then should be dried with
compressed air.
• A/C evaporator fins for leakage and breakage. If any defects are found, repair or replace A/C
evaporator.
• A/C evaporator fittings for leakage. If any defects are found, repair or replace A/C
evaporator.
2. Blower upper case 8. Temperature control door assembly 14. Temperature control lever 20. Packing
3. Air intake control actuator 9. Blower motor resistor 15. Airflow control lever21. Filter cover (if equipped)
4. HVAC Air filter (if equipped) 10. Blower lower case 16. Evaporator22. Drain hose
5. Heater unit upper case 11. Blower motor 17. O-ring23. Cable lock clamp
6. Foot duct 12. Heater unit lower case 18. Expansion valve: Do not reuse.
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I4RS0B720009-01
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I4RS0B720010-01

Downloaded from www.Manualslib.com manuals search engine 9-ii Table of Contents
List of Connectors ........................................... 9A-103
C Connector .................................................... 9A-103
D Connector (M16A engine) ........................... 9A-104
E Connector .................................................... 9A-104
G Connector .................................................... 9A-106
J Connector ..................................................... 9A-108
K Connector .................................................... 9A-109
L Connector..................................................... 9A-109
M Connector (SPORT model) ......................... 9A-111
O Connector .................................................... 9A-111
R Connector .................................................... 9A-111
Lighting Systems .................................... 9B-1
Component Location ........... ................................9B-1
Lighting System Component s Location............... 9B-1
Interior Light System Location............................. 9B-2
Diagnostic Information and Procedures ............ 9B-2 Headlight Symptom Diagnosis ............................ 9B-2
Headlight Leveling System Symptom Diagnosis (If Equipped) ..................................... 9B-2
Turn Signal and Hazard Warning Light Symptom Diagnosis .......................................... 9B-3
Clearance, Tail and License Plate Light Symptom Diagnosis .......................................... 9B-3
Back-Up Light Symptom Diagnosis..................... 9B-4
Brake Light Symptom Diagnosis ......................... 9B-4
Front Fog Light Symptom Diagnosis (If Equipped) .......................................................... 9B-4
Interior Light Symptom Diagnosis ....................... 9B-5
Repair Instructions ..............................................9B-5 Headlight Housing Removal and Installation ...... 9B-5
Headlight Bulb Replacemen t............................... 9B-6
Headlight Aiming Adjustment with Screen .......... 9B-6
Headlight Switch (in Lighting Switch) Removal and Installation ................................... 9B-8
Headlight Switch (in Lighting Switch) Inspection .......................................................... 9B-8
Hazard Warning Switch Removal and Installation ......................................................... 9B-8
Hazard Warning Switch Inspection ..................... 9B-9
Brake Light Switch Inspection ............................. 9B-9
Turn Signal Light Switch (in Lighting Switch) Removal and Installation ................................... 9B-9
Turn Signal Light Switch (in Lighting Switch) Inspection .......................................................... 9B-9
Turn Signal and Hazard Warning Relay Removal and Installation ................................... 9B-9
Turn Signal and Hazard Warning Relay Inspection ........................................................ 9B-10
License Light Removal and Installation............. 9B-10
Front Fog Light Removal and Installation (If Equipped) ........................................................ 9B-11
Front Fog Light Bulb Replacement (If Equipped) ........................................................ 9B-11
Front Fog Light Switch Inspection (If Equipped) ........................................................ 9B-11
Front Fog Light Relay Inspection (If Equipped) ........................................................ 9B-11
Front Fog Light Aiming Adjustment with Screen (If Equipped) ....................................... 9B-12 Headlight Leveling Switch Inspection (If
Equipped) ........................................................ 9B-13
Headlight Leveling Actuator Inspection (If Equipped) ........................................................ 9B-13
Instrumentation / Driver Info. / Horn ...... 9C-1
Precautions ...........................................................9C-1 Precautions in Diagnosing Troubles for Combination Meter ............................................9C-1
General Description .............................................9C-1 CAN Communication System Description...........9C-1
Auto Volume Co ntrol System Description (If
Equipped) ..........................................................9C-3
Schematic and Routing Diagram ........................9C-4 Combination Meter Circuit Diagram ....................9C-4
Component Location ............ ...............................9C-6
Audio System Component Location ....................9C-6
Diagnostic Information and Procedures ............9C-6 Speedometer and VSS Symp tom Diagnosis ......9C-6
Tachometer Symptom Diagnosis ........................9C-6
Engine Coolant Temperature (ECT) Meter Symptom Diagnosis ..........................................9C-7
Fuel Meter Symptom Diagnosis ..........................9C-7
Low Fuel Warning Light Symptom Diagnosis .....9C-7
Oil Pressure Warning Light Symptom Diagnosis ..........................................................9C-8
Brake and Parking Brake Warning Light Symptom Diagnosis ..........................................9C-8
Seat Belt Reminder Light Symptom Diagnosis (If Equipped)......................................................9C-8
A/T Shift Position Indicator Symptom Diagnosis (A/T Model).......................................9C-9
Charge Warning Light Sy mptom Diagnosis ........9C-9
Main Beam (High Beam) Indicator Symptom Diagnosis ..........................................................9C-9
Warning Buzzer Circuit Sy mptom Diagnosis ....9C-10
Cigarette Lighter Symptom Diagnosis (If Equipped) ........................................................9C-10
Horn Symptom Diagnosis .................................9C-10
Information Display Symptom Diagnosis (If Equipped) ........................................................9C-11
Clock Symptom Diagnosis (If Equipped)...........9C-12
Audio System Symptom Diagnosis (If Equipped) ........................................................9C-12
Remote Audio Control Switch Symptom Diagnosis (If Equipped) ...................................9C-13
Navigation Symptom Diagnosis (If Equipped)...9C-14
Repair Instructions ............ ................................9C-14
Ignition Switch Removal and Installation...........9C-14
Ignition Switch Inspection..................................9C-14
Combination Meter Removal and Installation ...9C-15
Fuel Level Sensor Removal and Installation .....9C-15
Fuel Level Sensor Inspection ............................9C-15
Oil Pressure Switch Remova l and Installation ..9C-15
Oil Pressure Switch Inspec tion .........................9C-16
Engine Coolant Temperature (ECT) Sensor Inspection ........................................................9C-16
Brake Fluid Level Switch Inspection .................9C-16
Parking Brake Switch Inspec tion.......................9C-16