warning light SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
WARNING, CAUTION
and NOTE
have special meanings. Pay special attention to the messages highlighted by
these signal words.
WARNING:
Indicates a potential hazard that could result in death or injury.
CAUTION:
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
WARNING:
This service manual is intended for authorized Suzuki dealers and qualified service mechanics only.
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the driver
and passengers.
WARNING:
For vehicles equipped with a 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.
 If the air bag system and another vehicle system both need repair, Suzuki recommends that the air
bag system be repaired first, to help avoid unintended air bag system activation.
 Do not modify the steering wheel, instrument panel or any other air bag system component (on or
around air bag system components or wiring). Modifications can adversely affect air bag system
performance and lead to injury.
 If the vehicle will be exposed to temperatures over 93°C (200°F) (for example, during a paint baking
process), remove the air bag system components (air bag (inflator) modules, SDM and/or seat belt
with pretensioner) beforehand to avoid component damage or unintended activation.

GENERAL INFORMATION 0A-5
 Even when the accident was light enough not to cause air bags to activate, be sure to inspect sys-
tem parts and other related parts according to instructions under “REPAIR AND INSPECTION
REQUIRED AFTER AN ACCIDENT” in SECTION 10B.
 When servicing parts other than air bag system, if shocks may be applied to air bag system compo-
nent parts, remove those parts beforehand.
 When handling the air bag (inflator) modules (driver and passenger), seat belt pretensioners (driver
and passenger) or SDM, be careful not to drop it or apply an impact to it. If an excessive impact was
applied, never attempt disassembly or repair but replace it with a new one.
 When grease, cleaning agent, oil, water, etc. has got onto air bag (inflator) modules (driver and pas-
senger) or seat belt pretensioners (drive and passenger), wipe off immediately with a dry cloth. WARNING:
SDM
 For handling and storage of a SDM, select a place where the ambient temperature below 65°C
(150°F), without high humidity and away from electric noise.
 During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM).
Never strike or jar the SDM.
 Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and
mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the
front of the vehicle to ensure proper operation of the air bag system.
The SDM could be activated when powered while not rigidly attached to the vehicle which could
cause deployment and result in personal injury.
WARNING:
Driver and Passenger Seat Belt Pretensioners
(If equipped)
 For handling and storage of a live seat belt preten-
sioner, select a place where the ambient temperature
below 65°C (150°F), without high humidity and away
from electric noise.
 Never carry seat belt pretensioner by wire or connec-
tor of pretensioner. When placing a live seat belt pre-
tensioner on the workbench or some place like that, be
sure not to lay it with its exhaust hole (1) provided side
facing down. It is also prohibited to put something on
its face with an exhaust hole or to put a seat belt pre-
tensioner on top of another. Otherwise, personal injury
may result.
 Never dispose of live (inactivated) seat belt pretension-
ers (drive and passenger). If disposal is necessary, be
sure to activate them according to activation proce-
dures described in SECTION 10B before disposal.
 The seat belt pretensioner immediately after activation
is very hot. Wait for at least half an hour to cool it off
before proceeding the work.
 With many service procedures, gloves and safety
glasses should be worn to prevent any possible irrita-
tion of the skin or eyes.

1B-20 AIR CONDITIONING (OPTIONAL)
REFRIGERANT RECOVERY, EVACUATING AND CHARGING
OPERATION PROCEDURE FOR REFRIGERANT CHARGING
WARNING:
 Your eyes should not be exposed to refrigerant (liquid).
Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately
–6°C (32°F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause a
serious injury. To protect your eyes against such accident, it is necessary to always wear goggles.
Should it occur that HFC-134a (R-134a) strikes your eyes, consult a doctor immediately.
– Do not use your hand to rub the affected eye(s). Instead, use quantities of fresh cold water to
splash it over the affected area to gradually raise temperature of such area above freezing point.
– Obtain proper treatment as soon as possible from a doctor or eye specialist.
 Should the HFC-134a (R-134a) liquid come into contact with your skin, the affected area should be
treated in the same manner as when skin is frostbitten or frozen.
 Refrigerant must not be handled near where welding or steam cleaning is performed.
 Refrigerant should be kept at a cold and dark place. It should never be stored where a high temper-
ature is anticipated, e.g. where exposed to direct sun light, close to fire or inside vehicle (including
trunk room).
 Avoid breathing fumes produced when HFC-134a (R-134a) is burned. Such fumes may be hazard-
ous to health.
Replenish compressor oil
Start evacuating
Inspect and repair connections
Charge 360 ± 30 g of
refrigerant in gas form Stop evacuating 15 minutes (below –760 mmHg)
Wait 10 mintues
If gauge shows
abnormal conditions Check system for
pressure tightness
Check A/C system
With refrigerant
Check system for refrigerant
leaks and refrigerant
charging quantity
Performance test

AIR CONDITIONING (OPTIONAL) 1B-27
ON-VEHICLE SERVICE
SERVICE PRECAUTION
When servicing air conditioning system, note the following instructions.
REFRIGERANT LINE
Never use heat for bending pipes. When bending a pipe, try to make its bending radius as slight as possible.
Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system,
install a blind plug or cap to the fitting immediately.
When connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to seats of coupling
nuts and O-ring.
When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.
Tighten flared nuts by the following specified torque.
Tightening torque
8 mm pipe : 13 N·m (1.3 kg-m, 9.5 lb-ft)
12 mm pipe : 23 N·m (2.3 kg-m, 16.6 lb-ft)
14.5 mm pipe : 33 N·m (3.3 kg-m, 23.8 lb-ft) WARNING:
Should refrigerant HFC-134a (R-134a) strike your eye(s), consult a doctor immediately.
 Do not use your hand to rub affected eye(s). Instead, use quantities of fresh cold water to splash it
over affected area to thus gradually raise its temperature above the freezing point.
 Obtain proper treatment as soon as possible from a doctor or eye specialist. Should liquid refriger-
ant HFC-134a (R-134a) get on your skin, such affected part should be treated in the same manner as
when skin is frostbitten or frozen.
1. Suction hose:
Apply compressor oil (refrigerant oil) to O-ring.4. Expansion valve:
Apply compressor oil (refrigerant oil) to O-ring.
2. Discharge hose:
Apply compressor oil (refrigerant oil) to O-ring.5. A/C refrigerant pressure switch:
Apply compressor oil (refrigerant oil) to O-ring.
3. Condenser outlet pipe:
Apply compressor oil (refrigerant oil) to O-ring.

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

ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-5
SYSTEM CHECK FLOW TABLE
Step Action Yes No
1 1) Record details of the problem (failure, complaint) and how it
occurred as described by the customer.
For this purpose, use of such a questionnaire from as shown
below will facilitate collecting information to the point required for
proper analysis and diagnosis.
2) Check if what the customer claimed in “CUSTOMER QUES-
TIONNAIRE” is actually found in the vehicle and if that symptom
is found, whether it is identified as a failure.
(This step should be shared with the customer if possible.)
3) Check malfunction indicator lamp (“EPS” warning lamp) opera-
tion referring to “MALFUNCTION INDICATOR LAMP (“EPS”
LIGHT) CHECK”.
4) Check DTC referring to “DTC CHECK” in this section and record
the DTC(s).
5) Clear DTC if any malfunction DTC exists referring to “DTC
CLEARANCE” in this section, then recheck DTC.
Is any malfunction DTC detected?Go to Step 2. Go to Step 3.
2 1) Inspect and repair referring to applicable “DTC TABLE” in this
section.
2) Clear DTC referring to “DTC CLEARANCE” in this section.
Does the trouble recur?Go to Step 5. Go to Step 4.
3 1) Test drive the vehicle and turn steering wheel fully to the right
and left during test driving. See WARNING. Check if any trouble
exists.
2) Inspect and repair basic parts referring to “DIAGNOSIS CHART”
in SECTION 3.
3) If the trouble cannot be repaired in Step 3-2), inspect and repair
referring to “TROUBLE DIAGNOSIS (FOR TROUBLE NOT INDI-
CATED BY ON-BOARD DIAGNOSTIC SYSTEM)” in this sec-
tion.
Does the trouble recur?Go to Step 5. Go to Step 4.
4 1) Confirm that the problem symptom has gone and P/S system is
free from any abnormal conditions. If what has been repaired is
related to the malfunction DTC, clear the DTC once and perform
test driving as in Step 3-1) and confirm that no DTC is indicated.
Is any malfunction DTC detected?Go to Step 5. END
5 1) Check DTC referring to “DTC CHECK” in this section.
Is any malfunction DTC detected?Go to Step 2. Go to Step 3.
WARNING:
Carry out test in very little traffic area to prevent an accident.

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.

3B1-14 ELECTRICAL POWER STEERING (P/S) SYSTEM
INSPECTION
Step Action Yes No
1 1) Set parking brake.
2) Note combination meter when ignition
switch is turned to ON position.
Does the “BRAKE” indicator (warning lamp)
come ON?Go to Step 2.“BLK/YEL”, “BLK/WHT”
wire circuit or “IG METER”
fuse open or short to
ground.
2 1) Ignition switch OFF.
2) Remove and inspect “P/S” fuse.
Is fuse in good condition?Go to Step 3. Check “BLK/RED” wire
circuit for short to ground.
If OK, replace “P/S” fuse.
3 1) With ignition switch OFF, reinstall fuse and
disconnect P/S control module connector
(“G24”).
2) Check proper connection to P/S control
module at “G24-1” terminal.
3) If OK, check voltage between “G24-1”
(“BLK/RED” wire) terminal and body ground
with ignition switch ON.
Is it 10 – 14 V?Go to Step 4.“BLK/RED” wire circuit
open or short to ground.
4 1) Check proper connection to P/S control
module at “G24-8” terminal.
2) If OK, check voltage between “G24-8”
(“BLK/WHT” wire) terminal and body ground
with ignition switch ON.
Is it 10 – 14 V?Go to Step 5.“BLK/WHT” wire circuit
open or short to ground.
5 1) Check proper connection to P/S control
module at “G24-5” terminal.
2) If OK, check voltage between “G24-5”
(“YEL” wire) terminal and body ground with
ignition switch ON.
Is it 10 – 14 V?Substitute a known-good
P/S control module and
recheck.Go to Step 6.
6 1) Remove combination meter. Refer to “COM-
BINATION METER” in Section 8.
2) Remove and inspect “EPS” light bulb.
Is bulb in good condition?“YEL”, “BLK/WHT” wire
circuit or inside of combi-
nation meter open or
short to other circuit.Check “YEL” wire circuit
for short to ground.
If OK, replace “EPS” light
bulb.

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.