AIR CON SUZUKI SWIFT 2008 2.G Service Workshop Manual

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DTC TroubleshootingStep Action Yes No 1 Was “EPS System Check” performed? Go to Step 2. Go to “EPS System
Check”.
2 DTC check
Is DTC C1113, C1114 and/or DTC C1119 indicated together? Go to applicable diag.
flow.
Go to Step 3.
3 Torque sensor internal failure signal voltage check
1) Check for P/S control module connector (“E52”) for
proper connection.
2) Check for voltage between “E52-16” (“YEL” wire) terminal and body ground with ignition switch ON.
Is voltage 0 – 1 V? Substitute a known-
good P/S control
module and recheck.
Go to Step 4.
4 Torque sensor internal failure signal circuit check
1) With ignition switch turned OFF, disconnect torque
sensor connector.
2) Check for voltage between “E53-1” (“YEL” wire) terminal and body ground with ignition switch ON.
Is it about 5 V? Go to Step 5. Go to Step 6.
5 Torque sensor internal failure signal circuit check
1) Disconnect P/S control module connector.
2) Check that torque sensor failure signal circuit is as
follows.
• Insulation resistance of wire harness is infinity between “Torque sensor internal failure signal circuit”
terminal and other terminal at torque sensor
connector.
Is circuit in good condition? Go to Step 7. Repair or replace
defective circuit.
6 Torque sensor internal failure signal circuit check
1) Disconnect P/S control module connector.
2) Check that torque sensor failure signal circuit is as
follows.
• Insulation resistance of wire harness is infinity between “Torque sensor internal failure signal circuit”
terminal and other terminal at torque sensor
connector.
• Wiring harness resistance of “Torque sensor internal failure signal circuit” is less than 1 Ω.
Is circuit in good condition? Substitute a known-
good P/S control
module and recheck.
Repair or replace
defective circuit.
7 Torque sensor signal circuit check
1) Check for torque sensor signal circuit referring to Step 3)
– 8) of “DTC C1113: Steering Torque Sensor (Main and
Sub) Circuit Correlation”.
Is torque sensor and its circuit in good condition? Replace steering gear
case.
Repair or replace
defective parts.

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DTC TroubleshootingStep Action Yes No 1 Was “EPS System Check” performed? Go to Step 2. Go to “EPS System
Check”.
2 DTC check
Is DTC C1153 indicated together? Go to DTC C1153 diag.
flow.
Go to Step 3.
3 Torque sensor main power supply voltage check
1) With ignition switch turned OFF, disconnect torque
sensor connector.
2) Check for P/S control module connector (“E52”) for proper connection.
3) If connections are OK, check for voltage between “E52- 8” (“GRN” wire) terminal and body ground with ignition
switch ON.
Is it approx. 12 V? Go to Step 4. Go to Step 5.
4 Torque sensor main power supply voltage check
1) With ignition switch turned OFF, connect torque sensor
connector.
2) Check for P/S control module connector (“E52”) for proper connection.
3) Turn ignition switch ON.
4) Check for voltage between “Main power supply for torque sensor circuit” terminal and body ground with
connector (“E52”) connected to the P/S control module.
Is it about 12 V? Substitute a known-
good P/S control
module and recheck.
Replace steering gear
case assembly and
recheck.
5 Torque sensor main power supply circuit check
1) With ignition switch turned OFF, disconnect P/S control
module connector.
2) Check that “Main power supply for torque sensor circuit” is as following.
• Insulation resistance of “Main power supply for torque sensor circuit” wire is infinity between its terminal and
other terminal at torque sensor connector.
• Wiring resistance of “Main power supply for torque sensor circuit” is less than 1 Ω .
• Insulation resistance of “Main power supply for torque sensor circuit” between its circuit and vehicle body
ground is infinity.
Is circuit in good condition? Replace P/S control
module.
Repair or replace
defective circuit.
8
E52
I4RS0A630021-02

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DTC TroubleshootingStep Action Yes No 1 Was “EPS System Check” performed? Go to Step 2. Go to “EPS System
Check”.
2 DTC check
DTC Check for ECM referring to “DTC Check in Section 1A”.
Is there any DTC detected? Go to applicable DTC
diag. flow.
Go to Step 3.
3 DTC check
1) Check ABS control module for DTC referring to “DTC
Check in Section 4E”.
Is there any DTC detected? Go to applicable DTC
diag. flow.
Go to Step 4.
4 Vehicle speed signal circuit check
1) With ignition switch turned OFF, disconnect connectors
from ECM.
2) Check ECM connector for proper connection.
3) If OK, turn ON ignition switch, measure voltage between “E23-25” wire terminal of ECM connector and body
ground.
Is voltage 4 – 5 V? Go to Step 6.
Go to Step 5.
5 Vehicle speed signal circuit check
1) With ignition switch turned OFF, disconnect P/S control
module connector “E52”.
2) Check for proper terminal connection to P/S control module connector and ECM connector.
3) If connections are OK, chec k that “Vehicle speed signal
circuit” is as following.
• Insulation resistance of “Vehicle speed signal circuit” wire harness is infinity between its terminal and other
terminals at ECM and P/S control module connector.
• Wiring resistance of “Vehicle speed signal circuit” is less than 1 Ω.
• Insulation resistance of “Vehicle speed signal circuit” between its circuit and vehicle body ground is infinity.
• Circuit voltage between “Vehicle speed signal” circuit and ground circuit is 0 – 1 V with ignition switch turned
ON.
Is circuit in good condition? Replace P/S control
module.
Repair or replace
defective circuit.
6 ECM voltage check
1) Connect P/S control mo dule and ECM connectors.
2) Check ECM for vehicle speed signal output referring to “Inspection of ECM and Its Circuits in Section 1A”.
Is check result in good condition? Replace P/S control
module.
Replace ECM.

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DTC TroubleshootingStep Action Yes No 1 Was “EPS System Check” performed? Go to Step 2. Go to “EPS System
Check”.
2 DTC check
1) Clear DTC(s) referring to “DTC Clearance”.
2) Run engine at idle speed.
3) Check if any DTC is detecte d referring to “DTC Check”.
Is DTC C1122 still detected? Go to Step 3. Check intermittent
trouble referring to
“Intermittent and Poor
Connection Inspection
in Section 00”.
3 DTC check
1) Check ECM for DTC referring to “DTC Check in Section
1A”.
Is there any DTC related to engine speed? Go to applicable DTC
diag. flow.
Go to Step 4.
4 Engine speed signal circuit check
1) With ignition switch turned OFF, disconnect P/S control
module connector.
2) Check P/S control module connector for proper connection.
3) If OK, turn ON ignition switch, measure voltage between “E52-12” wire terminal of P/S control module connector
and vehicle body ground.
Is voltage 10 – 14 V? Go to Step 6.
Go to Step 5.
5 1) With ignition switch turned OFF, disconnect ECM connector.
2) Check for proper connection to the P/S control module and ECM at each “Engine speed signal circuit” terminal.
3) If connections are OK, chec k that “Engine speed signal
circuit” is as following.
• Insulation resistance of “Engine speed signal circuit” wire is infinity between its terminal and other terminals
at ECM and P/S control module connector.
• Wiring resistance of “Engine speed signal circuit” terminal are less than 1 Ω.
• Insulation resistance of “Engine speed signal circuit” between its terminal and vehicle body ground is
infinity.
• Circuit voltage between “Engine speed signal circuit” and ground circuit is 0 – 1 V with ignition switch turned
ON.
Is circuit in good condition? Go to Step 6.
Repair engine speed
signal circuit.
6 ECM voltage check
1) Connect P/S control mo dule and ECM connectors.
2) Check ECM for engine speed signal and vehicle speed signal output voltage to P/S control module referring to
“Inspection of ECM and Its Circuits in Section 1A”.
Is check result in good condition? Substitute a known-
good P/S control
module and recheck.
Substitute a known-
good ECM and recheck.

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DTC Detecting Condition and Trouble Area
DTC TroubleshootingDTC detecting condition Trouble area
DTC C1141:
Voltage between both motor drive circuits is more than 8.5
V or less than 0.2 V for 0.5 seconds continuously while
motor is not drived
(1 driving cycle detection logic)
DTC C1142:
Measured motor drive current is more than 10 A as
compared with target motor drive current.
(1 driving cycle detection logic)
DTC C1143:
Measured motor drive current is more than 50 A.
(1 driving cycle detection logic)
DTC C1145:
Measured motor drive current is less than 2 A
continuously for more than 3 seconds even though target
motor drive current is more than 4 A.
or
Measured motor drive current is less than 0.8 A for total 1
second even though motor cont rol duty is more than 90%
while target motor drive current is less than 8 A.
(1 driving cycle detection logic) • P/S motor circuit
• P/S motor
• P/S control module
Step
Action YesNo
1 Was “EPS System Check” performed? Go to Step 2.Go to “EPS System
Check”.
2 DTC check
Is DTC C1153 and/or DTC C1155 indicated together? Go to applicable DTC
diag. flow.
Go to Step 3.
3 Power supply and ground circuit check
1) Check P/S control module power supply and ground
circuit referring to “P/S Control Module Power Supply
and Ground Circuit Check”.
Is it in good condition? Go to Step 4.
Repair or replace
defective circuit.
4 Motor circuit check
1) With ignition switch tuned OFF, disconnect P/S motor
connector (“E51”).
2) Check that P/S motor circuit is as follows. • Insulation resistance of wire harness is infinity between each “P/S motor circuit” terminal and other
terminal at P/S motor connector.
• Wiring harness resistance of each “P/S motor circuit”
is less than 1 Ω.
• Insulation resistance between each “P/S motor circuit” and vehicle body ground is infinity.
• Circuit voltage between each “P/S motor circuit” and ground circuit is 0 – 1 V with ignition switch turned
ON.
Is circuit in good condition? Go to Step 5.
Repair or replace
defective circuit.
5 P/S motor check
1) Check motor and its circuit referring to “P/S Motor and Its
Circuit Inspection”.
Is motor in good condition? Substitute a known-
good P/S control
module, and recheck.
Replace the steering
gear case assembly.

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DTC C1153: P/S Control Module Power Supply Circuit Voltage LowS7RS0B6304020
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Troubleshooting
MBLK
REDE51-1
E51-2
12V
5
[A ]
12 3
4 5 67
89
11
10
12 13
141516
17 18 19 20
[B ]
1
2
LT GRN
/BLKE52-1 E49-1
GRNGRNWHTBLK
WHY
6
3
4
4
4
4
1 2
E49-2BLK
I7RS0B630011-01
[A]: Connector “E52” (viewed from harness side)
2. Ignition switch5. P/S control module
[B]: Connector “E49” (viewed from harness side) 3. Junction block assembly 6. Individual circuit fuse box No.1
1. Main fuse box 4. Fuse
DTC detecting condition Trouble area
Power supply voltage of P/S control module is less than 9
V for 5 seconds continuously
(1 driving cycle detection logic) • P/S control module power supply circuit
• Undercharged Battery
• P/S control module
Step
Action YesNo
1 Was “EPS System Check” performed? Go to Step 2.Go to “EPS System
Check”.
2 Battery voltage check
1) Check circuit fuse for P/S control module.
2) If OK, measure voltage between positive battery terminal
and vehicle body ground with engine running.
Is voltage 10 V or more? Go to Step 3.
Check charging system
referring to “Generator
Test (Undercharged
Battery Check) in
Section 1J”.
3 P/S control module power supply circuit check
1) Check power supply circuit and ground circuit for P/S
control module referring to “P/S Control Module Power
Supply and Ground Circuit Check”.
Is check result in good condition? Substitute a known-
good P/S control
module and recheck.
Repair defective circuit.

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DTC C1155: P/S Control Module FailureS7RS0B6304021
Wiring Diagram
Refer to “DTC C1153: P/S Control Module Power Supply Circuit Voltage Low”.
DTC Detecting Condition and Trouble Area
DTC Troubleshooting DTC detecting condition Trouble area
Internal memory (EEPROM) is data error.
(In this case, MIL does not light up)
or
Internal circuit is faulty.
or
Power supply voltage of P/S control module exceeded
17.5 V.
(1 driving cycle detection logic) • Overcharged Battery
• P/S control module
Step
Action YesNo
1 Was “EPS System Check” performed? Go to Step 2.Go to “EPS System
Check”.
2 P/S control module power supply and ground circuit
check
Check power supply circuit and ground circuit for P/S control
module referring to “P/S Control Module Power Supply and
Ground Circuit Check”.
Is check result in good condition? Go to Step 3.
Repair or replace
defective circuit.
3 Battery voltage check
1) Check voltage between positive (+) battery terminal and
vehicle body ground with engine speed at 3000 rpm.
Is voltage 15.5 V or less? Replace P/S control
module.
Check charging system
referring to “Generator
Test (Overcharged
Battery Check) in
Section 1J”.

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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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2) Connect tie-rod end to knuckle. Tighten tie-rod end nut (1) to spec ified torque.
3) Bend new split pin (2).
NOTE
After tightening tie-rod end nut to specified
torque, match next first slot of nut with hole
of tie-rod end for insertion of split pin
(rotation angle 60 ° max).

Tightening torque
Tie-rod end nut (a): 45 N·m (4.5 kgf-m, 32.5 lb-ft)
4) Inspect for proper toe re ferring to “Front Wheel
Alignment Inspection and Adjustment in Section 2B”.
5) After confirming proper toe, tighten tie-rod end lock nut to specified torque.
Tightening torque
Tie-rod end lock nut (a): 45 N·m (4.5 kgf-m, 32.5
lb-ft)
6) Tighten wheel nuts to specified torque and lower hoist.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
Tie-Rod End InspectionS7RS0B6306004
• Inspect for play in ball joint.
• Inspect for play in rack end ball joint. In either case, if found defective, replace.
Steering Shaft Joint On-Vehicle InspectionS7RS0B6306005
Check shaft joint for wear, breakage and any other
damage and replace if any defect exists.
Steering Gear Case Assembly Removal and
Installation
S7RS0B6306006
Removal
CAUTION!
Be sure to set front wheels (tires) in straight
direction and remove ignition key from key
cylinder before performing the following
steps; otherwise, contact coil of air bag
system may get damaged.

1) Remove front suspension frame with steering gear case assembly referrin g to “Front Suspension
Frame, Stabilizer Bar and/ or Bushings Removal and
Installation in Section 2B”.
2) Remove steering gear case mounting No.3 bolts (4), No.1 bolts (1), No.2 bolts (2) and gear case bracket,
then remove gear case (3) from front suspension
frame (5).
2 1,(a)
I7RS0A630017-01
I3RM0A630030-01
I4RS0A630043-01
I4RS0B630012-01
25
3
14
I6RS0C630018-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 7- i
7
Section 7
CONTENTS
HVAC
Precautions ................................................. 7-1
Precautions............................................................. 7-1
Precautions on HVAC ........................................... 7-1
Heater and Ventilation.... ......................... 7A-1
General Description ............................................. 7A-1
Heater and Ventilation Construction ................... 7A-1
Schematic and Routing Diagram ........................ 7A-2 Heater and Ventilation Wiring Circuit Diagram .... 7A-2
Diagnostic Information and Procedures ............ 7A-3 Heater and Ventilation Symptom Diagnosis........ 7A-3
Repair Instructions .............................................. 7A-4 HVAC Unit Components ..................................... 7A-4
HVAC Unit Removal and Installation .................. 7A-4
Blower Motor Removal and Installation............... 7A-4
Blower Motor Inspection ..................................... 7A-4
Blower Motor Resistor Removal and Installation ......................................................... 7A-5
Blower Motor Resistor Inspection ....................... 7A-5
Blower Motor Relay Inspection ........................... 7A-6
HVAC Control Unit Components ......................... 7A-6
HVAC Control Unit Remova l and Installation ...... 7A-7
Blower Speed Selector In spection ...................... 7A-9
Air Intake Selector Inspec tion ............................. 7A-9
Air Intake Control Actuator Removal and Installation ......................................................... 7A-9
Air Intake Control Actuator Inspection .............. 7A-10
Center Ventilation Louver Removal and Installation ....................................................... 7A-10
Side Ventilation Louver Removal and Installation ....................................................... 7A-11
HVAC Air Filter Removal and Installation (If Equipped)........................................................ 7A-12
HVAC Air Filter Inspection (If Equipped) ........... 7A-12
Air Conditioning System... ...................... 7B-1
Manual Type ............................................................ 7B-1
Precautions........................................................... 7B-1A/C System Caution ............................................ 7B-1
Precautions on Servicing A/C System ................ 7B-1
General Description ............................................. 7B-3 Refrigerant Type Identifica tion ............................ 7B-3
Sub-Cool A/C System Description ...................... 7B-4
A/C Operation Description .................................. 7B-4 Schematic and Routing Diagram ........................7B-5
Major Components of A/C System ...................... 7B-5
A/C System Wiring Diagram ............................... 7B-6
Diagnostic Information and Procedures ............7B-7 A/C System Symptom Diagnosis ........................ 7B-7
Abnormal Noise Sympto m Diagnosis of A/C
System .............................................................. 7B-9
A/C System Performance Inspection ................ 7B-10
A/C System Inspection at ECM ......................... 7B-15
Repair Instructions ........... .................................7B-16
Operation Procedure for Re frigerant Charge .... 7B-16
Condenser Assembly On-Vehicle Inspection .... 7B-21
Condenser Assembly Removal and Installation ....................................................... 7B-21
Receiver/Dryer Removal and Installation .......... 7B-22
HVAC Unit Components ................................... 7B-23
HVAC Unit Removal and In stallation ................ 7B-24
Evaporator Inspection ....................................... 7B-24
Evaporator Thermistor (Evaporator Temperature Sensor) Removal and
Installation ....................................................... 7B-25
Evaporator Thermistor (Evaporator Temperature Sensor) Inspec tion..................... 7B-25
Expansion Valve Removal and Installation ....... 7B-26
Expansion Valve Inspection .............................. 7B-26
A/C Refrigerant Pressure Sensor and Its Circuit Inspection............................................. 7B-26
A/C Refrigerant Pressu re Sensor Removal
and Installation ................................................ 7B-26
A/C Switch Inspection ....................................... 7B-27
Compressor Relay Inspection ........................... 7B-27
Compressor Drive Belt Inspection and Adjustment ...................................................... 7B-27
Compressor Drive Belt Removal and Installation ....................................................... 7B-28
Compressor Assembly Removal and Installation ....................................................... 7B-28
Compressor Assembly Components................. 7B-29
Magnet Clutch Inspection.................................. 7B-29
Magnet Clutch Removal and Installation........... 7B-29
Relief Valve Inspection...................................... 7B-31
Relief Valve Removal and Installation............... 7B-32
Specifications .................... .................................7B-32
Tightening Torque Specifications ...................... 7B-32
Special Tools and Equipmen t ...........................7B-33