Ignition coil SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

MANUAL RACK AND PINION 3B-7
2) Connect tie rod end to knuckle. Tighten castle nut (1) until
holes for split pin (2) are aligned, but only within specified
torque.
Tightening torque
Castle nut (a) : 43 N·m (4.3 kg-m, 31.5 lb-ft)
3) Bend new split pin as shown.
4) Tighten wheel nuts to specified torque and lower hoist.
Tightening torque
Wheel nut : 85 N·m (8.5 kg-m, 61.5 lb-ft)
5) Inspect for proper toe (Refer to Section 3A).
6) After confirming proper toe, tighten tie rod end lock nut to
specified torque.
Tightening torque
Tie rod end lock nut (b) : 45 N·m (4.5 kg-m, 32.5 lb-ft)
MANUAL RACK AND PINION ASSEMBLY
(STEERING GEAR CASE)
REMOVAL
1) Slide driver’s seat as far back as possible.
2) Pull off front part of floor mat on driver’s side and remove
steering shaft joint cover.
3) For ease of installation, loosen steering shaft upper joint bolt
(1) but don’t remove.
4) Remove steering shaft lower joint bolt (2) and disconnect
lower joint from pinion.
CAUTION:
Be sure to set front wheels in straight direction and
remove ignition key from key cylinder before these steps,
otherwise contact coil of air bag system may get dam-
aged.

3B1-10 ELECTRICAL POWER STEERING (P/S) SYSTEM
SERIAL DATA LINK CIRCUIT CHECK
DIAGNOSTIC FLOW TABLE
CAUTION:
Be sure to perform “SYSTEM CHECK FLOW TABLE” before starting diagnosis according to flow table.
1. Main fuse box 6. Combination meter 11. Data link connector (DLC)
2.“EPS” fuse (30 A) 7. Speedometer 12. To ECM, SDM and ABS hydraulic unit/control module
assembly (if equipped)
3. Ignition switch 8.“EPS” warning lamp 13. P/S control module
4. Circuit fuse box 9. To vehicle speed sensor (VSS) 14. Connector “G24”
5.“IG coil” fuse (15 A) 10. To main fuse box
Step Action Yes No
1Was “SYSTEM CHECK FLOW TABLE” per-
formed?Go to Step 2. Go to “SYSTEM CHECK
FLOW TABLE” in this sec-
tion.
2 1) Make sure that SUZUKI scan tool free from
malfunction and correct cartridge for P/S
system is used.
2) Turn ignition switch to OFF position.
3) Check proper connection of SUZUKI scan
tool to DLC.
Is connection in good condition?Go to Step 3. Properly connect SUZUKI
scan tool to DLC.

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.

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-7
INSTALLATION
1) Check that vehicle’s front tires are at straight-ahead position
and contact coil is centered. Refer to “CENTERING CON-
TACT COIL”.
2) Install steering wheel (1) to steering shaft with 2 lugs (2) on
contact coil fitted in two grooves (3) in the back of steering
wheel and also aligning marks (4) on steering wheel and
steering shaft.
3) Tighten steering shaft nut (1) to specified torque.
Tightening torque
Steering shaft nut (a) : 33 N·m (3.3 kg-m, 24.0 lb-ft)
4) Install driver air bag (inflator) module to steering wheel.
Refer to “DRIVER AIR BAG (INFLATOR) MODULE”.
CENTERING CONTACT COIL
1) Check that vehicle’s wheels (front tires) are set at straight-
ahead position.
2) Check that ignition switch is at “LOCK” position.
3) Turn contact coil counterclockwise slowly with a light force till
contact coil will not turn any further. CAUTION:
These two conditions are prerequisite for installation of
steering wheel. If steering wheel has been installed with-
out these conditions, contact coil will break when steer-
ing wheel is turned.
NOTE:
After installing the steering wheel, turn the steering
wheel about 1 full rotation so that the cancel cam pin fits
into the pin hole in the steering wheel and then check the
turn signal lever for proper function.
NOTE:
Contact coil can turn about 5 turns at maximum, that is, if
it is at the center position, can turn about two and a half
turns both clockwise and counterclockwise.

STEERING WHEEL AND COLUMN 3C-9
5) Remove contact coil and combination switch assembly
screws (1) and disconnect connectors (2) from combination
switch (3).
6) Disconnect horn connector (1) from instrument panel har-
ness.
7) Remove contact coil and combination switch assembly from
steering column.
INSPECTION
Check contact coil harness (1) for any signs of scorching, melting
or other damage.
If it is damaged, replace.
INSTALLATION
1) Check to make sure that vehicle’s front tires are set at
straight-ahead position and then ignition switch is at “LOCK”
position.
2) Connect all connectors disconnected in REMOVAL.

STEERING WHEEL AND COLUMN 3C-11
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) If it is necessary to remove steering wheel and contact coil
and combination switch assembly, remove them, referring to
“STEERING WHEEL” and “CONTACT COIL AND COMBI-
NATION SWITCH ASSEMBLY”.
If it is not necessary to remove steering wheel and contact
coil and combination switch assembly, perform the following
procedure.
a) Turn steering wheel so that vehicle’s front tires are at
straight-ahead position.
b) Turn ignition switch to “LOCK” position and remove key.
4) Remove steering column hole cover (1).
5) Loosen steering column mounting nuts (“A”, “B”). WARNING:
Never rest a steering column assembly on the steering
wheel with the air bag (inflator) module face down and
column vertical. Otherwise, personal injury may result.
1

STEERING WHEEL AND COLUMN 3C-17
5) Tighten new bolts (1) until head of each bolt is broken off.
6) Turn ignition key to “ACC” or “ON” position and check to be
sure that steering shaft (2) rotates smoothly. Also check for
lock operation.
7) Install steering column. Refer to “STEERING COLUMN”.
STEERING LOWER SHAFT
REMOVAL
1) Turn steering wheel so that vehicle’s front tires are at
straight-ahead position.
2) Turn ignition switch to “LOCK” position and remove key.
3) Remove steering joint cover (5).
4) Make alignment marks (4) on lower shaft (1) and shaft joint
of steering column (2) and lower shaft (1) and pinion shaft
(3) for a guide during reinstallation.
5) Remove lower shaft joint bolts (6).
6) Remove steering lower shaft (1).
CAUTION:
Never turn steering wheel while steering lower shaft is
removed.
Should it have been turned and contact coil (on combina-
tion switch) have got out of its centered position, it needs
to be centered again. Also, turning steering wheel more
than about two and a half turns will break contact coil.

6-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS
ENGINE DIAGNOSIS TABLE
Perform troubleshooting referring to following table when ECM has detected no DTC and no abnormality has
been found in visual inspection and engine basic inspection previously.
Condition Possible Cause Correction
Hard Starting
(Engine cranks OK) Faulty spark plug Spark plugs in Section 6F1.
Leaky high-tension cord High-tension cords in Section 6F1.
Loose connection or disconnection of high-
tension cords or lead wiresHigh-tension cords in Section 6F1.
Faulty ignition coil Ignition coil in Section 6F1.
Dirty or clogged fuel hose or pipe Diagnostic Flow Table B-3.
Malfunctioning fuel pump Diagnostic Flow Table B-3.
Air inhaling from intake manifold gasket or
throttle body gasket
Faulty idle air control system Diagnostic Flow Table B-4.
Faulty ECT sensor or MAP sensor ECT sensor or MAP sensor in Section
6E1.
Faulty ECM
Hard Starting
(Engine cranks OK) Poor spark plug tightening or faulty gasket Spark plugs in Section 6F1.
Compression leak from valve seat Valves inspection in Section 6A1.
Sticky valve stem Valves inspection in Section 6A1.
Weak or damaged valve springs Valve springs inspection in Section
6A1.
Compression leak at cylinder head gasket Cylinder head inspection in Section
6A1.
Sticking or damaged piston ring Cylinders, pistons and piston rings
inspection in Section 6A1.
Worn piston, ring or cylinder Cylinders, pistons and piston rings
inspection in Section 6A1.
Malfunctioning PCV valve PCV system in Section 6E1.
Low compression Compression check in Section 6A1.
Low oil pressure
Improper oil viscosity Engine oil and oil filter change in Sec-
tion 0B.
Malfunctioning oil pressure switch Oil pressure switch inspection in Sec-
tion 8.
Clogged oil strainer Oil pan and oil pump strainer cleaning
in Section 6A1.
Functional deterioration of oil pump Oil pump in Section 6A1.
Worn oil pump relief valve Oil pump in Section 6A1.
Excessive clearance in various sliding parts

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-29
Excessive detona-
tion
(Engine makes con-
tinuously sharp
metallic knocks that
change with throttle
opening. Sounds
like pop corn pop-
ping.)Faulty spark plug Spark plugs in Section 6F1.
Loose connection of high-tension cord High-tension cords in Section 6F1.
Engine overheating Refer to “Overheating” section.
Clogged fuel filter (faulty fuel pump) or fuel
linesDiagnostic Flow Table B-1 or B-2.
Air inhaling from intake manifold or throttle
body gasket
Malfunctioning EGR valve (if equipped) EGR system in Section 6E1.
Poor performance of knock sensor, ECT sen-
sor or MAP sensorKnock sensor in Section 6, ECT sensor
or MAP sensor in Section 6E1.
Faulty fuel injector(s) Diagnostic Flow Table B-1.
Faulty ECM
Excessive combustion chamber deposits Piston and cylinder head cleaning in
Section 6A1.
Engine has no
powerFaulty spark plug Spark plugs in Section 6F1.
Faulty ignition coil with ignitor Ignition coil in Section 6F1.
Leaks, loose connection or disconnection of
high-tension cordHigh-tension cords in Section 6F1.
Faulty knock sensor Knock sensor malfunction in this sec-
tion.
Clogged fuel hose or pipe Diagnostic Flow Table B-3.
Malfunctioning fuel pump Diagnostic Flow Table B-2.
Air inhaling from intake manifold gasket or
throttle body gasket
Engine overheating Refer to “Overheating” section.
Engine has no
powerMalfunctioning EGR valve (if equipped) EGR system inspection in Section 6E1.
Maladjusted accelerator cable play Accelerator cable play in Section 6E1.
Poor performance of TP sensor, ECT sensor
or MAP sensorTP sensor, ECT sensor or MAP sensor
in Section 6E1.
Faulty fuel injector(s) Diagnostic Flow Table B-1.
Faulty ECM
Dragging brakes Trouble diagnosis in Section 5.
Slipping clutch Trouble diagnosis in Section 7C.
Low compression Previously outlined. Condition Possible Cause Correction