wheel torque SUZUKI SWIFT 2000 1.G RG413 Service User Guide

ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-1
6F1
6F2
6G
6H
6K
7A
7A1
3B1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3B1
ELECTRICAL POWER STEERING (P/S) SYSTEM
CONTENTS
GENERAL DESCRIPTION .............................3B1-2
SYSTEM COMPONENTS ........................... 3B1-2
WIRING DIAGRAM ..................................... 3B1-3
DIAGNOSIS ....................................................3B1-4
ON-BOARD DIAGNOSTIC SYSTEM .......... 3B1-4
PRECAUTIONS IN DIAGNOSING
TROUBLES ................................................. 3B1-4
SYSTEM CHECK FLOW TABLE ................ 3B1-5
MALFUNCTION INDICATOR LAMP
(“EPS” WARNING LAMP) CHECK.............. 3B1-7
DTC CHECK ............................................... 3B1-8
DTC CLEARANCE ...................................... 3B1-9
SERIAL DATA LINK CIRCUIT CHECK ..... 3B1-10
DTC TABLE .............................................. 3B1-11
TABLE A - MALFUNCTION INDICATOR
LAMP DOES NOT COME ON AT
IGNITION SWITCH ON BUT LEAVING
ENGINE OFF ............................................ 3B1-13
TABLE B - MALFUNCTION INDICATOR
LAMP FLASHES AT IGNITION SWITCH
ON ............................................................. 3B1-15
TABLE C - MALFUNCTION INDICATOR
LAMP DOES NOT FLASH, JUST
REMAINS ON OR JUST REMAINS OFF
EVEN WITH DIAGNOSIS SWITCH
TERMINAL GROUNDED .......................... 3B1-15
DTC C1111 (DTC No.11) TORQUE
SENSOR MAIN CIRCUIT FAILURE ......... 3B1-16
DTC C1113 (DTC No.13) TORQUE
SENSOR MAIN AND SUB CIRCUIT
FAILURE ................................................... 3B1-16DTC C1115 (DTC No.15) TORQUE
SENSOR SUB CIRCUIT FAILURE........... 3B1-16
DTC C1114 (DTC No.14) TORQUE
SENSOR 5V POWER SUPPLY CIRCUIT
FAILURE ................................................... 3B1-17
DTC C1116 (DTC No.16) TORQUE
SENSOR 8V POWER SUPPLY CIRCUIT
FAILURE ................................................... 3B1-18
DTC C1121/C1123/C1124
(DTC No.21/23/24) VSS CIRCUIT
FAILURE ................................................... 3B1-19
DTC C1122 (DTC No.22) ENGINE
SPEED SIGNAL CIRCUIT FAILURE ........ 3B1-20
DTC C1141/C1142/C1143/C1144/C1145
(DTC No.41/42/43/44/45) MOTOR
CIRCUIT FAILURE ................................... 3B1-21
DTC C1151 (DTC No.51) CLUTCH
CIRCUIT FAILURE ................................... 3B1-22
DTC C1153(DTC No.53) P/S CONTROL
MODULE POWER SUPPLY CIRCUIT
FAILURE ................................................... 3B1-24
DTC C1152/C1154/C1155
(DTC No.52/54/55) P/S CONTROL
MODULE FAILURE .................................. 3B1-24
TROUBLE DIAGNOSIS (FOR TROUBLE
NOT INDICATED BY ON BOARD
DIAGNOSTIC SYSTEM)........................... 3B1-25
INSPECTION OF P/S CONTROL
MODULE AND ITS CIRCUITS ................. 3B1-26
STEERING WHEEL PLAY
INSPECTION ............................................ 3B1-28 WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System :
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

3B1-2 ELECTRICAL POWER STEERING (P/S) SYSTEM
STEERING FORCE INSPECTION ........... 3B1-28
ON-VEHICLE SERVICE ............................... 3B1-29
P/S CONTROL MODULE ......................... 3B1-29
TORQUE SENSOR .................................. 3B1-29MOTOR AND CLUTCH ............................ 3B1-30
STEERING COLUMN ASSEMBLY .......... 3B1-31
SPECIAL TOOL ........................................... 3B1-31

GENERAL DESCRIPTION
SYSTEM COMPONENTS
This power steering (P/S) system consists of a P/S control module, a torque sensor, a motor and clutch installed
to the steering column.
In this system, the P/S control module determines the level and direction of the assist force for the steering
wheel according to the signals from the torque sensor and the vehicle speed, runs the motor so as to assist
operation of the steering wheel.
P/S control module diagnoses troubles which may occur in the area including the following components when
the ignition switch is ON and the engine is running. When P/S control module detects malfunction, it stops the
motor and clutch control.
Torque sensor
Vehicle speed sensor (VSS) circuit
Engine speed signal circuit
Motor
Clutch
P/S control module
NOTE:
The location of steering wheel/column and ECM to RH steering vehicle are opposite to those location
to LH steering vehicle.
1. Steering wheel 4. Torque sensor 7. Battery
2. Steering column assembly 5. Motor and clutch 8. VSS
3. P/S control module 6. Steering gear box 9. ECM

ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-25
TROUBLE DIAGNOSIS (FOR TROUBLE NOT INDICATED BY ON BOARD DIAG-
NOSTIC SYSTEM)
This section describes trouble diagnosis of P/S system parts whose trouble is not indicated by the on-board
diagnostic system (self-diagnostic function).
When DTC No.12 is indicated by the on-board diagnostic system (self-diagnosis function) and assuredly those
steering basic parts as described in “DIAGNOSIS TABLE” in Section 3 are all in good condition, check the fol-
lowing power steering system parts which may be a possible cause for each symptom of the steering.
Condition Possible Cause Correction
Steering wheel feels
heavy (Perform
STEERING FORCE
INSPECTION before
diagnosis.)Steering wheel installed improperly (twisted) Install steering wheel correctly.
Poor performance of torque sensor Check torque sensor. Refer to
“TORQUE SENSOR”.
Poor performance of motor and clutch Check motor and clutch. Refer to
“MOTOR AND CLUTCH”.
Faulty steering column Replace.
Poor performance of VSS Check VSS. Refer to Section 6E.
Vehicle pulls to one
side during straight
drivingPoor performance of torque sensor Check torque sensor. Refer to
“TORQUE SENSOR”.
Poor recovery from
turnsPoor performance of torque sensor Check torque sensor. Refer to
“TORQUE SENSOR”.
Faulty steering column Replace.

ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-27
TERMINAL
NO.CIRCUIT NORMAL VOLTAGE CONDITION
G24-2 Ground––
G24-1 P/S control module
power supply from battery10 – 14V–
G24-8 P/S control module
power supply from igni-
tion switch10 – 14V Ignition switch ON
G24-7 VSS✱ Indicator
deflection repeated
0 – 1V and 9 – 11VIgnition switch ON
Front left tire turned quickly with right
tire locked
G24-6 Engine speed signal✱ Indicator
deflection repeated
0 – 1V and 10 – 14VEngine idling
G24-5“EPS” light 0V“EPS” warning lamp ON
G24-4 Diagnosis switch terminal 0 – 14V Ignition switch ON
G24-3 Data link connector––
G24-2-2 Motor output 2 5 – 7V Engine idling and steering wheel
held at position for vehicle to run
straight
G24-2-1 Motor output 1 5 – 7V Engine idling and steering wheel
held at position for vehicle to run
straight
G24-2-4 Clutch output 2 0V–
G24-2-3 Clutch output 1 10 – 14V Engine idling
G24-1-5 Torque sensor (Main) About 2.5V Ignition switch ON and steering
wheel held at position for vehicle to
run straight
Check voltage between “G24-1-5”
and “G24-1-3” terminals
G24-1-4 Torque sensor (Sub) About 2.5V Ignition switch ON and steering
wheel held at position for vehicle to
run straight
Check voltage between “G24-1-4”
and “G24-1-3” terminals
G24-1-3 Torque sensor (GND) 0V–
G24-1-2 5V power supply
for torque sensorAbout 5V Ignition switch ON
Check voltage between “G24-1-2”
and “G24-1-3” terminals
G24-1-1 8V power supply
for torque sensorAbout 8V Ignition switch ON
Check voltage between “G24-1-1”
and “G24-1-3” terminals
NOTE:
✱
✱✱ ✱ : The voltage of this circuit may fail to check by voltmeter.
If so, use oscilloscope.

3B1-28 ELECTRICAL POWER STEERING (P/S) SYSTEM
STEERING WHEEL PLAY INSPECTION
Check steering wheel for looseness or rattle by trying to move it in
its shaft direction and lateral direction.
If found defective, repair or replace.
Check steering wheel play, holding vehicle in straight forward con-
dition on the ground and 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
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 - 1.2 in.)
STEERING FORCE INSPECTION
1) Place vehicle on level road and set steering wheel at
straight-ahead position.
2) Check that tire inflation pressure is as specified. (Refer to
“TIRE PLACARD” on vehicle.)
3) Remove driver air bag (inflator) module referring to DRIVER
AIR BAG (INFLATOR) MODULE in Section 3C.
4) Start engine.
5) With engine idling, measure steering force by turning torque
wrench.
Steering force
: Less than 6.4 N·m (0.64 kg·m, 4.6 lb-ft)
6) Install drive air bag (inflator) module referring to DRIVER AIR
BAG (INFLATOR) MODULE in Section 3C.

ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-29
ON-VEHICLE SERVICE
P/S CONTROL MODULE
REMOVAL
1) Disconnect negative cable at battery.
2) Remove steering column hole cover.
3) Disconnect connectors (1) from P/S control module.
4) Remove P/S control module (2) from steering column
assembly.
INSTALLATION
Reverse removal procedure for installation, noting the following.
Tighten P/S control module screw to specified torque.
Tightening torque
P/S control module screw
(a) : 3 N·m (0.3 kg-m, 2.0 lb-ft)
TORQUE SENSOR
ON-VEHICLE INSPECTION
1) Remove steering column hole cover.
2) Turn ignition switch to ON position.
3) Check voltage between terminals of torque sensor connector
with connecting it to P/S control module and not running
engine.
If check result is not satisfactory, replace steering column
assembly.
Torque sensor specification
Steering
wheel
turned fully
leftSteering wheel
held at position
for vehicles
torque straightSteering
wheel
turned fully
right
Main sensor
(“G24-1-4” –
“G24-1-3”)1.5 V below About 2.5 V Above 3.5 V
Sub sensor
(“G24-1-5” –
“G24-1-3”)1.5 V below About 2.5 V Above 3.5 V

STEERING WHEEL AND COLUMN 3C-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
3C1
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3C
STEERING WHEEL AND COLUMN
CONTENTS
GENERAL DESCRIPTION .............................. 3C-2
STEERING COLUMN .................................. 3C-2
STEERING WHEEL AND DRIVER AIR
BAG (INFLATOR) MODULE ........................ 3C-2
DIAGNOSIS ..................................................... 3C-2
INSPECTION AND REPAIR REQUIRED
AFTER ACCIDENT ...................................... 3C-2
ON-VEHICLE SERVICE .................................. 3C-3
SERVICE PRECAUTIONS........................... 3C-3
SERVICE AND DIAGNOSIS .................... 3C-3
DISABLING AIR BAG SYSTEM ............... 3C-3
ENABLING AIR BAG SYSTEM ................ 3C-3
HANDLING AND STORAGE.................... 3C-4
DISPOSAL ............................................... 3C-4DRIVER AIR BAG (INFLATOR) MODULE .. 3C-4
STEERING WHEEL ..................................... 3C-6
CENTERING CONTACT COIL .................... 3C-7
CONTACT COIL AND COMBINATION
SWITCH ASSEMBLY .................................. 3C-8
STEERING COLUMN ASSEMBLY............ 3C-10
STEERING LOCK ASSEMBLY
(IGNITION SWITCH) ................................. 3C-16
STEERING LOWER SHAFT...................... 3C-17
CHECKING STEERING COLUMN
ASSEMBLY AND LOWER SHAFT FOR
ACCIDENT DAMAGE ................................... 3C-18
SPECIAL TOOL ............................................ 3C-19

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-
Vehicle Service” in air bag system section before performing service on or around the air bag sys-
tem components or wiring. Failure to follow WARNINGS could result in unintentional activation of
the system or could render the system inoperative. Either of these two conditions may result in
severe injury.
The procedures in this section must be followed in the order listed to temporarily disable the air
bag system and prevent false diagnostic codes from setting. Failure to follow procedures could
result in possible air bag system activation, personal injury or otherwise unneeded air bag system
repairs.
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application.
If the correct part number fastener is not available, a fastener of equal size and strength (or stronger)
may be used. Fasteners that are not reused, and those requiring thread-locking compound, will be
called out. The correct torque value must be used when installing fasteners that require it. If the above
procedures are not followed, parts or system damage could result.

3C-2 STEERING WHEEL AND COLUMN
GENERAL DESCRIPTION
STEERING COLUMN
This double tube type steering column has following three important features in addition to the steering function
:
The column is energy absorbing, designed to compress in a front-end collision.
The ignition switch and lock are mounted conveniently on this column.
With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehi-
cle.
To insure the energy absorbing action, it is important that only the specified screws, bolts, and nuts be used as
designated and that they are tightened to the specified torque.
When the column assembly is removed from the vehicle, special care must be taken in handling it. Use of a
steering wheel puller other than the one recommended in this manual or a sharp blow on the end of the steering
shaft, leaning on the assembly, or dropping the assembly could shear the plastic shear pins which maintain col-
umn length and position.
STEERING WHEEL AND DRIVER AIR BAG (INFLATOR) MODULE
The driver air bag (inflator) module is one of the supplemental restraint (air bag) system components and is
mounted to the center of the steering wheel. During certain frontal crashes, the air bag system supplements the
restraint of the driver’s and passenger’s seat belts by deploying the air bags.
The air bag (inflator) module should be handled with care to prevent accidental deployment. When servicing, be
sure to observe all WARNINGS and CAUTIONS and “SERVICE PRECAUTIONS” under “ON-VEHICLE SER-
VICE” in Section 10B.
DIAGNOSIS
For maintenance service of the steering wheel and column, refer to Section 0B.
For diagnosis of the steering wheel and column, refer to Section 3.
For diagnosis of the air bag system, refer to Section 10B.
INSPECTION AND REPAIR REQUIRED AFTER ACCIDENT
After an accident, whether the air bag has been deployed or not, be sure to perform checks, inspections and
repairs described under “CHECKING STEERING COLUMN ASSEMBLY AND LOWER SHAFT FOR ACCI-
DENT DAMAGE” as well as “REPAIRS AND INSPECTIONS REQUIRED AFTER ACCIDENT” under “DIAGNO-
SIS” in Section 10B.

STEERING WHEEL AND COLUMN 3C-3
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
For service precautions, refer to “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in Section 10B.
SERVICE AND DIAGNOSIS
For diagnosis and servicing, refer to “SERVICE AND DIAGNOSIS” under “SERVICE PRECAUTIONS” in Sec-
tion 10B.
DISABLING AIR BAG SYSTEM
For disabling air bag system, refer to “DISABLING AIR BAG SYSTEM” under “SERVICE PRECAUTIONS” in
Section 10B.
ENABLING AIR BAG SYSTEM
For enabling air bag system, refer to “ENABLING AIR BAG SYSTEM” under “SERVICE PRECAUTIONS” in
Section 10B.
1. Driver air bag (inflator) module 7. Steering column assembly 13. Immobilizer control module (if equipped)
2. Steering wheel 8. Steering lock assembly (ignition switch) 14. Upper and lower joint bolt
: After tightening lower joint bolt, tighten upper joint bolt.
3. Steering wheel nut 9. P/S control module (if equipped) 15. Steering column mounting nut
: After tightening lower nut, tightening upper nut.
4. Contact coil and combination
switch assembly10. Motor for P/S system (if equipped) Tightening torque
5. Steering column upper cover 11. Steering lower shaft
6. Steering column lower cover 12. Steering joint cover

STEERING WHEEL AND COLUMN 3C-5
INSPECTION
Check air bag (inflator) module visually and if any of the following
is found, replace it with a new one.
Air bag being deployed
Trim cover (pad surface) (1) being cracked
Wire harness or connector (2) being damaged
Air bag (inflator) module being damaged or having been
exposed to strong impact (dropped)
INSTALLATION
1) Check that horn wire is connected to horn connector (2)
securely.
2) Connect yellow connector (1) of driver air bag (inflator) mod-
ule (3) and horn connector in order a) – d) shown in figure
securely.
3) Install driver air bag (inflator) module to steering wheel, tak-
ing care so that no part of wire harness is caught between
them.
4) Make sure that clearance between module and steering
wheel is uniform all the way.
5) Tighten driver air bag (inflator) module mounting bolts (1) to
specified torque.
Tightening torque
Driver air bag (inflator) module mounting bolt
(a) : 9 N·m (0.9 kg-m, 6.5 lb-ft)
6) Connect negative cable at battery.
7) Enable air bag system. Refer to “ENABLING AIR BAG SYS-
TEM” under “SERVICE PRECAUTIONS” in Section 10B. WARNING:
Never disassemble driver air bag (inflator) module or
measure its resistance. Otherwise, personal injury may
result.
CAUTION:
If air bag (inflator) module was dropped from a height of
90 cm (3 ft) or more, it should be replaced.