battery SUZUKI SWIFT 2000 1.G RG413 Service Owner's Manual

1B-34 AIR CONDITIONING (OPTIONAL)
A/C EVAPORATOR TEMPERATURE SENSOR
Check resistance between terminals for A/C evaporator tempera-
ture sensor (1).
If check results are as not specified, replace A/C evaporator tem-
perature sensor.
A/C evaporator temperature sensor resistance
EXPANSION VALVE
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant from A/C system by referring to
“RECOVERY” in this section.
3) Remove attaching bolt (1).
4) Remove suction hose (2) and receiver/dryer outlet pipe (3)
from expansion valve (4).
5) Remove expansion valve (4).
INSTALLATION
Reverse removal procedure to install expansion valve noting the
following instructions.
Replenish specified amount of compressor oil to compressor
suction side by referring to “REPLENISHING COMPRES-
SOR OIL” in this section.
Evacuate and charge refrigerant by referring to “EVACUAT-
ING” and “CHARGING” in this section.
INSPECTION
Refer to “PERFORMANCE DIAGNOSIS” in this section. Sensor Temperature Resistance
0°C (32°F) 6.4 – 6.9 k
Ω
ΩΩ Ω
25°C (77°F) 1.8 – 2.2 k
Ω
ΩΩ Ω
NOTE:
When A/C evaporator temperature sensor removed, its
should be reinstalled in original position.
NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.

1B-36 AIR CONDITIONING (OPTIONAL)
A/C SWITCH
REMOVAL AND INSTALLATION
Refer to “HEATER CONTROL ASSEMBLY” in Section 1A.
INSPECTION
Press A/C switch button and check if there is continuity
between terminals “A” and “B”.
Connect battery voltage (+) to terminal “C” and (–) to termi-
nal “A”, and then press A/C Switch button and check if indi-
cator lamp lights.
RADIATOR/CONDENSER COOLING FAN
MOTOR RELAY No.1, No.2 and No.3
INSPECTION
Refer to “RADIATOR FAN RELAY” in Section 6B.
COMPRESSOR
REMOVAL
1) Run engine at idle speed with air conditioning ON for 10 min-
utes. After that stop the engine.
2) Disconnect negative (–) cable at battery.
3) Recover refrigerant from refrigeration system by referring to
“RECOVERY” in this section.
4) Remove front bumper by referring to “FRONT BUMPER” in
Section 8.
5) Remove engine food cover (1) from vehicle body.
NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.

MANUAL RACK AND PINION 3B-1
6F1
6F2
6G
6H
7A
3B
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3B
MANUAL RACK AND PINION
CONTENTS
GENERAL DESCRIPTION .............................. 3B-2
DIAGNOSIS ..................................................... 3B-3
ON-VEHICLE SERVICE .................................. 3B-4
LUBRICATION ............................................. 3B-4
TIE ROD END .............................................. 3B-6
MANUAL RACK AND PINION ASSEMBLY
(STEERING GEAR CASE) .......................... 3B-7
RACK BOOT/TIE ROD .............................. 3B-10STEERING RACK PLUNGER ................... 3B-12
STEERING PINION ................................... 3B-14
STEERING RACK...................................... 3B-15
PINION BEARING ..................................... 3B-17
RACK BUSHING ........................................ 3B-18
REQUIRED SERVICE MATERIAL................ 3B-19
SPECIAL TOOL ............................................ 3B-20

WARNING:
For vehicles equipped with a Air Bag System
Service on or around air bag system components or wiring must be performed only by an autho-
rized suzuki dealer. Please observe all WARNINGS and CAUTIONS in SECTION 10B and Precau-
tions, Air Bag System Components and Wiring Location view in Section 10B before performing
service on or around air bag system components or wiring. Failure to follow WARNINGS could
result in unintended 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 deployed by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
All steering gear fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with one
of the same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified dur-
ing reassembly to assure proper retention of these parts.

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

3B1-26 ELECTRICAL POWER STEERING (P/S) SYSTEM
INSPECTION OF P/S CONTROL MODULE
AND ITS CIRCUITS
P/S control module (1) and its circuits can be checked at P/S con-
trol module wiring couplers (2) by measuring voltage and resis-
tance.
Voltage Check
1) Remove steering column lower cover with ignition switch
OFF position.
2) Check voltage at each terminal with connectors (2) con-
nected P/S control module. CAUTION:
P/S control module cannot be checked by itself. It is
strictly prohibited to connect voltmeter or ohmmeter to
P/S control module with connector disconnected from it.
NOTE:
As each terminal voltage is affected by the battery volt-
age, confirm that it is 11V or more when ignition switch is
ON.

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.

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

3B1-30 ELECTRICAL POWER STEERING (P/S) SYSTEM
MOTOR AND CLUTCH
ON-VEHICLE INSPECTION
1) Remove steering column hole cover.
2) Disconnect motor and clutch connector (1) from P/S control
module with ignition switch OFF.
3) Check resistance between terminals of motor and clutch
connector (1)
If check result is not as specified above, replace steering col-
umn assembly.
Motor and clutch circuit resistance
4) Check continuity between terminal of motor and clutch con-
nector (1) and body ground.
If check result is not as specified above, replace steering col-
umn assembly.
Motor and clutch circuit resistance (to body ground)
5) Connect battery (1) between “G24-2-2” and “G24-2-1”.
Check that motor rotates smoothly, then measure current
between “G24-2-1” and “G24-2-2” using ammeter (2) as
shown in figure.
If check result is not satisfactory, replace steering column
assembly.
Motor and clutch circuit current (reference value)
Standard : About 0.65 A
6) Connect battery (1) between “G24-2-4” and “G24-2-3”, then
check that clutch operation sound is heard.
If check result is not satisfactory, replace steering column
assembly. “G24-2-2” and “G24-2-1”
(For motor)About 1
Ω
ΩΩ Ω
“G24-2-4” and “G24-2-3”
(For clutch)About 12
Ω
ΩΩ Ω
(at 20°C (68°F))
“G24-2-4” and body ground No continuity
“G24-2-2” and body ground No continuity

3C-4 STEERING WHEEL AND COLUMN
HANDLING AND STORAGE
For handling and storage, refer to “HANDLING AND STORAGE” under “SERVICE PRECAUTIONS” in Section
10B.
DISPOSAL
For disposal, refer to “DISPOSAL” under “SERVICE PRECAUTIONS” in Section 10B.
DRIVER AIR BAG (INFLATOR) MODULE
REMOVAL
1) Disconnect negative cable at battery.
2) Disable air bag system. Refer to “DISABLING AIR BAG
SYSTEM” under “SERVICE PRECAUTIONS” in Section
10B.
3) Loosen 2 bolts (1) mounting driver air bag (inflator) module
on its both side.
4) Remove driver air bag (inflator) module (3) from steering
wheel.
5) Disconnect yellow connector (1) of driver air bag (inflator)
module and horn connector (2) in order a) – d) shown in fig-
ure. WARNING:
When handling an air bag (inflator) module, be sure to
read “SERVICE PRECAUTIONS” in Section 10B and
observe each instruction. Failure to follow them could
cause a damage to the air bag (inflator) module or result
in personal injury.