engine SUZUKI SWIFT 2000 1.G RG413 Service Owner's Guide

1B-24 AIR CONDITIONING (OPTIONAL)
CHARGING
CHARGING PROCEDURE
The initial charging of the A/C system is performed from the high
pressure side with the engine stopped.
And next, this method must be followed by charging from the low
pressure side with the engine running.
1) Check to make sure that hoses are routed properly after
evacuating the system.
2) Connect Low charging hose (1) and High charging hose (2)
of the manifold gauge set (3) in position. Thus open refriger-
ant container valve (4) to purge the charging line.
3) Open the high pressure side valve (5) and charge refrigerant
to system.
4) After a while, open the low pressure side valve (6) and close
the high pressure side valve (5).
5) Start engine and keep engine speed at 1500 r/min. Then,
operate air conditioning.
6) Charge A/C system with refrigerant in vapor state. At this
time, refrigerant container (4) should be held upright. CAUTION:
 Always charge through low pressure side of A/C system at after the initial charging is performed
from the high pressure side with the engine stopped.
 Never charge to high pressure side of A/C system with engine running.
 Do not charge while compressor is hot.
 When installing tap valve to refrigerant container to make a hole there through, carefully follow
directions given by manufacturer.
 A pressure gauge should always be used before and during charging.
 The refrigerant container should be emptied of refrigerant when discarding it.
 The refrigerant container should not be heated up to 40°C (104°F) or over.
 Refrigerant container should not be reversed in direction during charging. Reversing in direction
causes liquid refrigerant to enter compressor, causing troubles, such as compression of liquid
refrigerant and the like.
NOTE:
The air conditioning system contains HFC-134a (R-134a).
Described here is a method to charge the air conditioning system with refrigerant from the refrigerant
service container.
When charging refrigerant recovered by using the refrigerant and recycling equipment (when recy-
cling refrigerant), follow the procedure described in the equipment manufacturer’s instruction man-
ual.
WARNING:
Make sure that high pressure side valve is closed
securely.

1B-26 AIR CONDITIONING (OPTIONAL)
REMOVING MANIFOLD GAUGE SET
When A/C system has been charged with a specified amount of refrigerant, remove manifold gauge set as fol-
lows :
1) Close low pressure side valve of manifold gauge set. (The high pressure side valve is closed continuously
during the process of charging.)
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service valves. This operation must be performed rapidly.
5) Put caps on service valves.
LEAK TEST
Whenever a refrigerant leak is suspected in the system or any
service operation has been performed which may result in dis-
turbing lines or connections, it is advisable to test for leaks.
Common sense should be used in performing any refrigerant leak
test, since the need and extent of any such test will, in general,
depend upon the nature of a complaint and the type of a service
performed on the system.
LIQUID LEAK DETECTORS
There are a number of fittings and places throughout the air con-
ditioning system where a liquid leak detector solution may be
used to pinpoint refrigerant leaks.
By merely applying the solution to the area in question with a
swab, such as attached to the cap of a vial, bubbles will form
within seconds if there is a leak.
For confined areas, such as sections of the evaporator and con-
denser, an electronic (refrigerant) leak detector is more practical
for determining leaks.
Special tool
(A) : 09990 - 86011 WARNING:
High pressure side is naturally under high pressure. So, care must be used to protect your eyes and
skin.
WARNING:
 To prevent explosions or fires, make sure that there
are no flammables in the vicinity.
 When exposed to fire, the refrigerant turns into a poi-
sonous gas (phosgene). Do not inhale this gas.

AIR CONDITIONING (OPTIONAL) 1B-29
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant from A/C system by referring to
“RECOVERY” in this section.
3) Remove front bumper referring to “FRONT BUMPER” in
Section 8.
4) Remove front cross member cover (1) and engine food
cover (2) from vehicle body.
5) Disconnect discharge hose (1) and condenser outlet pipe (2)
from condenser (3).
6) Remove condenser mounting bolts (4).
7) Remove condenser (3).
INSTALLATION
Reverse removal procedure to install condenser noting the follow-
ing 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. 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.

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

3B1-4 ELECTRICAL POWER STEERING (P/S) SYSTEM
DIAGNOSIS
The P/S system in this vehicle is controlled by P/S control module. P/S control module has an on-board diagnos-
tic system which detects a malfunction in this system.
When diagnosing troubles, be sure to have full understanding of the outline of “ON-BOARD DIAGNOSTIC SYS-
TEM” and each item in “PRECAUTION IN DIAGNOSING TROUBLE” and execute diagnosis according to “SYS-
TEM CHECK FLOW TABLE”.
ON-BOARD DIAGNOSTIC SYSTEM
P/S control module performs on-board diagnosis (self-diagnosis)
on the system and operates “EPS” warning lamp (1) (malfunction
indicator lamp) as follows.
Malfunction indicator lamp (“EPS” warning lamp) lights when
the ignition switch is turned to ON position (but the engine at
stop) regardless of the condition of P/S control system. This
is only to check the malfunction indicator lamp (“EPS” warn-
ing lamp) bulb and its circuit.
If the areas monitored by P/S control module is free from any
trouble after the engine start (while engine is running), mal-
function indicator lamp (“EPS” warning lamp) turns OFF.
When P/S control module detects a trouble which has
occurred in the areas it monitors, malfunction indicator lamp
(“EPS” warning lamp) turns ON while the engine is running
to warn the driver of such occurrence of trouble and at the
same time it stores the exact trouble area in memory inside
of P/S control module.
PRECAUTIONS IN DIAGNOSING TROUBLES
Take a note of DTC indicated first.
Be sure to read “PRECAUTIONS FOR ELECTRONIC CIRCUIT SERVICE” in Section 0A before inspection
and observe what is written there.
When two or more troubles have occurred, their DTCs are indicated 3 times each starting with the smallest
code number and up.
DTC C1122 (DTC No.22) (engine speed signal failure) is indicated when ignition switch is ON position and
engine is not running but if indication changes to a normal one when engine is started, it means nothing
abnormal.
As DTC is stored in memory of P/S control module, be sure to clear memory after repair by performing the
procedure described in “DTC CLEARANCE”.
1

3B1-6 ELECTRICAL POWER STEERING (P/S) SYSTEM
For identify current DTC, clear history DTC referring to “DTC CLEARANCE” in this section. NOTE:
As execution of “DTC CLEARANCE” will clear all malfunction DTCs, be sure to record all DTCs
before servicing.
When 2 or more codes are indicated, the lowest numbered code will appear first.
If a code not listed on “DTC TABLE” is displayed, then the P/S control module is faulty.
DTC C1122 or DTC No.22 (flashing pattern : 22) is indicated when ignition switch is ON and engine
is not running but if DTC No.12 (flashing pattern : 12) is indicated when engine is started, it means
nothing abnormal.
Current DTC and history DTC can be identified by lighting and flashing of “EPS” warning lamp.
“EPS” warning lamp operates as follow depending on the trouble condition.
Current DTC is set.
(Abnormality exists at
present.)History DTC is set only.
(Faulty condition occurred
once in the past but normal
condition is restored at
present.)Current DTC and history
DTC exist.
“EPS” warning lamp after
engine startedRemains ON. Turn OFF. Remains ON.
“EPS” warning lamp when
shorting diagnosis switch ter-
minal and ground terminalDisplays current DTC. Displays history DTC.Displays current DTC and
history DTC.

ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-7
CUSTOMER QUESTIONNAIRE (EXAMPLE)
MALFUNCTION INDICATOR LAMP
(“EPS” WARNING LAMP) CHECK
1) Turn ignition switch to ON position (but without running
engine), check that malfunction indicator lamp (“EPS” warn-
ing lamp) lights up. If lamp does not light up, go to “TABLE
A”. If lamp flashes, go to “TABLE B”.
2) Start engine and check that malfunction indictor lamp
(“CHECK ENGIE” light) turns OFF.
If lamp comes OFF, P/S system is in good condition.

3B1-8 ELECTRICAL POWER STEERING (P/S) SYSTEM
DTC CHECK
USING SUZUKI SCAN TOOL
1) Turn ignition switch to OFF position.
2) After setting cartridge connect SUZUKI scan tool to data link
connector (DLC) (1) located on underside of instrument
panel at driver’s seat side.
Special tool
(A) : 09931-76011
(B) : Master storage cartridge
(C) : 09931-76030
3) Turn ignition switch to ON position.
4) Read DTC according to instructions displayed on SUZUKI
scan tool and print it or write it down referring to SUZUKI
SCAN TOOL OPERATOR’S MANUAL for further details.
5) After completing the check, turn ignition switch to OFF posi-
tion and disconnect SUZUKI scan tool from DLC.
NOT USING SUZUKI SCAN TOOL
1) Remove glove box.
2) Apply chocks to wheels, set shift lever to neutral position and
pull parking brake fully.
3) Start engine.
4) Using jumper wire (4), short diagnosis switch terminal (1) to
ground terminal (2) of monitor coupler (3).
5) Read flashing of “EPS” warning lamp which represents DTC
and write it down. When more than 2 DTCs are stored in
memory, each DTC is repeated 3 times starting with the
smallest DTC number in increasing order.
For details and example of DTC, refer to “DTC TABLE”.
6) After completing the check, turn ignition switch to OFF posi-
tion and disconnect jumper wire (4) from monitor coupler. NOTE:
If Suzuki scan tool cannot display DTC, perform “SERIAL
DATA LINK CIRCUIT CHECK” described in this section.
(B)(A) (C)1
NOTE:
DTC No.22 is indicated when ignition switch is ON and
engine is not running but if DTC No.12 is indicated when
engine is started, it means nothing abnormal.
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