steering module SUZUKI SWIFT 2008 2.G Service Owners Manual

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Inspection of P/S Control Module and Its CircuitsS7RS0B6304023
The P/S control module (1) and its circuits can be checked at the P/S control module wiring couplers (2) by measuring
voltage and resistance.
CAUTION!
P/S control module cannot be checked by itself. It is strictly prohibited to connect voltmeter or
ohmmeter to the P/S control module with connectors disconnected from the P/S control module.

5 P/S control module ground circuit check
1) Connect connectors to P/S control module.
2) Start engine.
3) Measure voltage between “E49-2” terminals of P/S
control module connector and body ground when
steering wheel fully turned to left or right.
Is voltage 0.3 V or less? P/S Control Module
Power Supply and
Ground Circuit is in
good condition.
“BLK” wire is open or
high resistance circuit.
Step Action Yes No
[A]
12
3
4 5 67
89
11
10
12 13
141516
17 18 19 20
[B]
[C]
12
1
1 2
2
I6RS0C630016-03
[A]: Connector “E52” (viewed from harness side) [C]: Connector “E49” (viewed from harness side)
[B]: Connector “E51” (viewed from harness side)

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Voltage Check1) Remove console box.
2) Check for voltage at each terminal with co nnectors connected to the P/S control module.
NOTE
As each terminal voltage is affected by the battery voltage, confirm if the battery voltage is 11 V or
more when ignition switch is ON.
*: The voltage of this circuit may not be checked by voltmeter. If so, use oscilloscope.

Terminal Wire colorCircuit Normal voltage Remarks
E49-1 GRN Main power supply for
internal memory and P/S
motor 10 – 14 V
—
E49-2 BLK Ground for P/S control
module Below 0.3 V
—
E51-1 BLK Motor output 1 *0 – 1 V
↑↓
10 – 14 V
(“Reference
waveform No.1: ”, “Reference
waveform No.2:
”and “Reference
waveform No.3: ”) • Engine idling and steering wheel at
straight position
• Voltage between “E51-1” and vehicle body ground
E51-2 RED Motor output 2 *0 – 1 V
↑↓
10 – 14 V
(“Reference
waveform No.1: ”, “Reference
waveform No.2: ” and “Reference
waveform No.3: ”) • Engine idling and steering wheel at
straight position
• Voltage between “E51-2” and vehicle body ground
E52-1 LT GRN/BLK Ignition switch signal for P/S
control module 10 – 14 V Ignition switch ON
E52-2 — —— —
E52-3 — —— —
E52-4 PPL Vehicle speed signal *0 – 1 V
↑↓
8 – 14 V
(“Reference
waveform No.9”
under “Inspection of
ECM and Its Circuits in Section 1A”.) • Ignition switch ON
•Front left tire tu
rned quickly with right
tire locked
E52-5 GRY “EPS” warning light 0 V “EPS” warning light OFF
E52-6 BLU Torque sensor signal (Sub) About 0 – 2.5 V
• Steering wheel with left turn
• Out put voltage varies linearly
depending on steering force
About 2.5 V Steering wheel at free
About 2.5 – 6 V • Steering wheel with right turn
• Out put voltage varies linearly
depending on steering force
E52-7 — —— —
E52-8 GRN Main power supply for torque
sensor About 12 V• Ignition switch ON
• Check voltage between “E52-8” and
“E52-9” terminals
E52-9 BRN Ground for torque sensors Below 0.3 V —
E52-10 — —— —

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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

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P/S Control Module Removal and InstallationS7RS0B6306011
Removal1) Disconnect negative cable at battery.
2) Remove console box.
3) Disconnect connectors (1) from P/S control module (2).
4) Disconnect connector from yaw rate / G sensor
(ESP ® model).
5) Remove P/S control module (2) with bracket (3) from floor panel.
6) Separate P/S control module and bracket.
Installation
Reverse removal procedure for installation noting the
following.
• Tighten each screw to the specified torque. Tightening torque
P/S control module bracket screw (ABS model)
(a): 9 N·m (0.9 kgf-m, 6.5 lb-ft)
P/S control module bracket screw (ESP ® model)
(a): 7 N·m (0.7 kgf-m, 5.0 lb-ft)
P/S control module mounting screw (b): 5 N·m (
0.5 kgf-m, 3.7 lb-ft)
Torque Sensor and Its Circuit InspectionS7RS0B6306012
1) Remove console box.
2) With ignition switch turned OFF, connect scan tool to DLC or connect voltage tester between “E52-18” –
“E52-9” (main sensor) or “E52-6” – “E52-9” (sub
sensor) with connected connector (1) to P/S control
module. 3) Set torque wrench to stee
ring wheel referring to
“Steering Force Check” for checking steering force.
4) Turn ON ignition switch without engine running and select scan tool “Data list” mode due to check of
“TQS Main Torque”, “TQS Sub Torque” and “Assist
Torque” display on scan tool when steering wheel
turned left and right (if used).
5) Check that characteristic of torque sensor (main and sub) output voltage or scan tool data and steering
force is as following graph when steering wheel is
turned left and right. If sensor voltage or scan tool
data is out of specified value or does not vary linearly
as the following graph, check P/S control module
and its circuit.
If they are OK, replace steering gear case assembly.
1
(a)
2
3
(b)
I7RS0A630020-01
[A]: Steering force at left turn
[B]: Steering force at right turn
[C]: Steering wheel at free
[D]: “TQS Main Torque”, “TQS Sub Torque” and “Assist Torque” in “Data List” displayed on scan tool
E52
18
9
6
9
6 18
1
I6RS0C630024-01
I3RM0A630022-01
0
[C] [N.m]
MAX MAX
[B]
[A]
2.33 - 2.68 [V]
[D]
0.65 - 0.72
(0 - 0.4)
4.21 - 4.41
(5.1 - 5.6)
6.86
-6.86
0
6.86
- 6.86
I6RS0C630021-04

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P/S Motor and Its Circuit InspectionS7RS0B6306013
1) Remove console box.
2) Disconnect motor connector (“E51”) from P/S control module with ignition switch OFF.
3) Check for resistance between terminals of motor connector (“E51”).
If check result is not as specified, replace steering
gear case assembly.
Motor circuit resistance
4) Check for continuity between terminal of motor connector (“E51”) and body ground.
If check result is not as specified, replace steering
gear case assembly.
Motor circuit resistance
5) Hoist vehicle.
6) Connect “E51” connector to P/S control module with ignition switch OFF position.
7) Using ammeter (2), check that P/S motor (1) current is as following table with id ling engine. If check result
is not satisfactory, check P/S control module
referring to “Inspection of P/S Control Module and Its
Circuits”. If OK, replace steering gear case
assembly.
Motor current at hoisted vehicle
“E51-1” and “E51-2” (For motor) About 1 Ω
“E51-2” and body ground No continuity
1. Connector “E51” (viewed from harness side)
E51
11 2
I6RS0C630025-01
Condition When
steering
wheel is left at straight
position: [A] When
steering
wheel is
turned left or right by turning
speed with
90° /sec: [B] When
steering
wheel is kept fully turned left or right
until it stops.: [C]
Motor
current Approx. 0 A Approx.
0 – 4 A Approx.
30 – 45 A
1
32
E51-1
E51-2
[C] [A]
[B] [B]
I6RS0C630022-01

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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 )

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HVAC Control Unit Removal and InstallationS7RS0B7106009
Removal1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove passenger air bag module from instrument panel referring to “Passenger Air Bag (Inflator)
Module Removal and Installation in Section 8B”.
4) Remove radio assembly from instrument panel referring to “Audio Unit Re moval and Installation in
Section 9C”.
5) Remove driver side foot duct (1) from HVAC unit by removing screw (2).
6) Disconnect temperature control cable (1) and air flow control cable (2) from HVAC unit. 7) Remove two connectors from HVAC control unit.
8) Remove HVAC control unit (1) from instrument
panel.
NOTE
Be careful not to damage HVAC control unit
and instrument panel by using rag.

Installation
Reverse removal procedure noting the following
instructions.
• Connect temperature control cable and air flow control
cable of HVAC control unit to links of HVAC unit.
a. For LH steering vehicle, set air flow selector (1) to “DEF” position and temperature selector (2) to
“MAX HOT” position.
For RH steering vehicle, set air flow selector (1) to
“VENT” position and temperature selector (2) to
“MAX COOL” position.
[A]: LH steering vehicle [B]: RH steering vehicle
2
1
I4RS0B710010-01
2
1
1
2
[B] [A]
I4RS0B710011-01
1
I4RS0B710012-01
12I4RS0B710013-01
12I4RS0A710016-01

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Side Ventilation Louver Removal and
Installation
S7RS0B7106015
Driver side ventilation louver
Removal1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove steering column hol e cover from instrument
panel.
4) Remove combination meter cluster panel from instrument panel, and then disconnect connectors
from front fog lamp switch, illumination cancel switch
and headlight leveling switch (if equipped) of
combination meter cluster panel.
5) Separate driver side ventilation louver (1) and combination meter cluster (2).
Installation
Reverse removal procedure noting the following
instruction.
• Driver side ventilation louver is fitted to combination meter cluster panel with four clips (1). When installing
driver side ventilation louv er to combination meter
cluster panel, position the smallest clip to the top. Passenger side ventilation louver
Removal
1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove glove box from instrument panel.
4) Remove passenger air bag module from instrument panel referring to “Passenger Air Bag (Inflator)
Module Removal and Installation in Section 8B”.
5) Separate passenger side ventilation louver (1) and passenger air bag module (2).
Installation
Reverse removal procedure noting the following
instruction.
• Passenger side ventilation louver is fitted to passenger air bag module with four clips (1). When
installing passenger side ventilation louver to
passenger air bag module, position the smallest clip
to the top.
2
1
I4RS0B710018-01
1
I4RS0B710019-01
2
1
I4RS0B710020-01
1I4RS0B710021-01

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Electronic Control System Location
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

1
2
3 * 4 *
5
6 *
7 *
8 *
9 *
10 *
21
11
12 13
14
15161718
19
20
I5RS0C722001-01
1. ECT sensor
7. Blower motor13. AUTO switch19. MODE (air flow) selector
2. Outside air temperature sensor 8. Blower motor controller 14. Temperature selector 20. Blower speed selector
3. Sunload sensor 9. Temperature control actuator15. OFF switch21. HVAC control module
4. Air flow control actuator 10. Inside air temperature sensor 16. Air intake selector
5. Evaporator temperature sensor 11. Defroster switch 17. A/C switch
6. Air intake actuator 12. Display 18. Rear defogger switch

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HVAC Unit Removal and InstallationS7RS0B7226003
Refer to “HVAC Unit Removal and Installation”.
Temperature Control Actuator Removal and
Installation
S7RS0B7226004
Removal1) Disconnect negative (–) cable at battery.
2) Remove steering column hol e cover from instrument
panel.
3) Remove foot duct from HVAC unit.
4) Disconnect temperature control actuator connector (1).
5) Detach temperature control actuator rods (2) from linkage (3).
6) Remove temperature control actuator (4) from HVAC unit.
Installation
Reverse removal procedure.
Temperature Control Actuator InspectionS7RS0B7226005
1) Remove temperature control actuator from HVAC unit referring to “Temperature Control Actuator
Removal and Installation”.
2) Connect connector to temperature control actuator.
3) Set temperature selector of HVAC control module to MAX HOT position with ignition switch ON, and
make sure if the position of actuator lever is MAX
HOT position (A).
4) Turn ignition switch OFF, and then disconnect connector from temperature control actuator.
5) Measure resistance between terminal “3” and “5”.
Temperature control actuator resistance between
terminal “3” and “5” (MAX HOT position)
Approximately 2.5 k Ω at 25 °C (77 °F) 6) Connect connector to tem
perature control actuator.
7) Set temperature selector of HVAC control module to MAX COOL position with ignition switch ON, and
make sure if the position of actuator lever is MAX
COOL position (B).
8) Turn ignition switch OFF, and then disconnect connector from temperature control actuator.
9) Measure resistance between terminal “3” and “5”
Temperature control actuator resistance between
terminal “3” and “5” (MAX COOL position)
Approximately 4.8 k Ω at 25 °C (77 °F)
If check result is not satisfactory, replace the actuator
with new one.
2. Blower upper case 9. Blower motor controller 16. Evaporator 23. Temperature control actuator
3. Air intake control actuator 10. Blower lower case 17. O-ring24. Air flow control actuator
4. Air filter (if equipped) 11. Blower motor 18. Expansion valve25. Inside air temperature sensor
5. Heater unit upper case 12. Heater unit lower case 19. Evaporator temperature sensor 26. Aspirator hose
6. Foot duct 13. Heater core 20. Packing : Do not reuse.
7. Air flow control door assembly 14. Temperature control links 21. Filter cover
1
2
2
3
4
I5RS0A722020-02
I5RS0A722021-03
I5RS0A722022-03