check engine SUZUKI SWIFT 2005 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-13
Clutch Release System InspectionS7RS0B5306017
Clutch Release Bearing
Check clutch release bearing for smooth rotation. If
abnormality is found, replace it.
CAUTION!
Do not wash release bearing. Washing may
cause grease leakage and consequential
bearing damage.

Clutch Release Shaft
Check clutch release shaft and its pin for deflection or
damage.
If abnormality is found, replace it.
Specifications
Tightening Torque SpecificationsS7RS0B5307001
NOTE
The specified tightening torque is also described in the following.
“Clutch Fluid Pipe and Hose Components”
“Clutch Pedal and Clutch Pedal Bracket Components”
“Clutch Cover, Clutch Disc and Flywheel Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I3RM0A530020-01
I3RM0A530021-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
CPP switch lock nut 7.5 0.75 5.5 )
Clutch operating cylinder bolt 23 2.3 17.0 )
Flywheel bolt 70 7.0 51.0 )
Clutch cover bolt 23 2.3 17.0 )
Release lever bolt 23 2.3 17.0 )

Downloaded from www.Manualslib.com manuals search engine Table of Contents 6- i
6
Section 6
CONTENTS
Steering
Precautions ................................................. 6-1
Precautions............................................................. 6-1
Precautions on Steering........................................ 6-1
Steering General Diagnosi s.................... 6A-1
Precautions........................................................... 6A-1
Precautions for Steering Diagnosis ..................... 6A-1
Diagnostic Information and Procedures ............ 6A-2 Steering Symptom Diagnosis .............................. 6A-2
Steering Wheel and Column ................... 6B-1
Precautions........................................................... 6B-1
Service Precautions of Steering Wheel and Column.............................................................. 6B-1
General Description ............................................. 6B-1 Steering Wheel and Column Construction .......... 6B-1
Diagnostic Information and Procedures ............ 6B-2 Checking Steering Column for Accident Damage ............................................................ 6B-2
Repair Instructions .............................................. 6B-3 Steering Wheel and Column Construction .......... 6B-3
Steering Wheel Removal and Installation ........... 6B-4
Contact Coil Cable Assembly Removal and Installation ......................................................... 6B-5
Centering Contact Coil Cable Assembly ............. 6B-6
Contact Coil Cable Assembly Inspection ............ 6B-6
Steering Angle Sensor Removal and Installation ......................................................... 6B-6
Steering Angle Sensor Inspection ....................... 6B-6
Steering Column Removal and Installation ......... 6B-7
Steering Column Inspecti on ................................ 6B-8
Ignition Switch Cylinder Assembly Removal and Installation (Non- Keyless Start Model)...... 6B-9
Steering Lock Assembly (Ignition Switch) Removal and Installation................................... 6B-9
Steering Lower Shaft Removal and Installation ....................................................... 6B-10
Specifications ..................................................... 6B-11
Tightening Torque Specifications ...................... 6B-11
Special Tools and Equipmen t ........................... 6B-11
Special Tool ...................................................... 6B-11
Power Assisted Steering System........... 6C-1
Precautions........................................................... 6C-1 Steering System Note .........................................6C-1
Precautions in Diagnosing Troubles ...................6C-1
General Description .............................................6C-2 P/S System Description ......................................6C-2
EPS Diagnosis General Descr iption ...................6C-3
On-Board Diagnostic System Description ...........6C-3
Schematic and Routing Diagram ........................6C-4 EPS System Wiring Circuit Diagram ...................6C-4
Diagnostic Information and Procedures ............6C-5 EPS System Check .............. ...............................6C-5
“EPS” Warning Light Check . ...............................6C-8
DTC Check..........................................................6C-8
DTC Clearance ...................................................6C-9
DTC Table ...........................................................6C-9
Scan Tool Data .................................................6C-11
Visual Inspection ...............................................6C-12
P/S System Symptom Diagnosis ......................6C-12
Serial Data Link Circuit Check ..........................6C-13
“EPS” Warning Light Do es Not Come ON with
Ignition Switch Turn ed ON before Engine
Starts ...............................................................6C-15
“EPS” Warning Light Remains ON Steady after Engine Starts ..........................................6C-16
DTC C1113: Steering Torque Sensor (Main and Sub) Circuit Correlation ............................6C-17
DTC C1114: Steering Torque Sensor Reference Power Supply Circuit .....................6C-19
DTC C1117: Steering Torque Sensor Failure Signal Circuit Low ...........................................6C-21
DTC C1118: Steering Torque Sensor Failure Signal Circuit High...........................................6C-22
DTC C1119: Steering Torque Sensor Power Supply Circuit ..................................................6C-24
DTC C1121 / C1123 / C1124: VSS Circuit
Failure .............................................................6C-26
DTC C1122: Engine Speed Signal....................6C-28
DTC C1141 / C1142 / C1143 / C1145: P/S Motor Circuit Failure ........................................6C-30
DTC C1153: P/S Control Module Power Supply Circuit Voltage Low .............................6C-32
DTC C1155: P/S Control Module Failure ..........6C-33
P/S Control Module Power Supply and Ground Circuit Check ......................................6C-34
Inspection of P/S Control Module and Its Circuits ............................................................6C-35

Downloaded from www.Manualslib.com manuals search engine 6-ii Table of Contents
Steering Wheel Play Check ..............................6C-39
Steering Force Check .......................................6C-39
Repair Instructions ........... .................................6C-40
Steering Gear Case Assembly Components ....6C-40
Tie-Rod End Boot On-Vehic le Inspection .........6C-41
Tie-Rod End Removal and Installation..............6C-41
Tie-Rod End Inspection.....................................6C-42
Steering Shaft Joint On-Vehicle Inspection.......6C-42
Steering Gear Case Assembly Removal and Installation .......................................................6C-42
Steering Rack Boot Inspec tion ..........................6C-43
Tie-Rod / Rack Boot Removal and Installation ..6C-43 Steering Rack Plunger Removal and
Installation .......................................................6C-45
Steering Rack Plunger Inspection .....................6C-45
P/S Control Module Removal and Installation...6C-46
Torque Sensor and Its Circuit Inspection ..........6C-46
P/S Motor and Its Circuit Inspection ..................6C-47
Specifications ..................... ................................6C-48
Tightening Torque Specifications ......................6C-48
Special Tools and Equipmen t ...........................6C-49
Recommended Service Material .......................6C-49
Special Tool ......................................................6C-49

Downloaded from www.Manualslib.com manuals search engine Steering General Diagnosis: 6A-2
Diagnostic Information and Procedures
Steering Symptom DiagnosisS7RS0B6104001
ConditionPossible cause Correction / Reference Item
Hard steering Tire not adequately inflated Inflate tires to proper pressure.
Malfunction of power steering system Check and correct.
Bind in tie-rod end ball studs or lower
ball joints Replace tie-rod end or front suspension arm.
Disturbed front wheel alignment Check and adjust front wheel alignment.
Bind in steering column Repair or replace steering column.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Too much play in steering Wheel bearings worn Replace wheel bearing.
Loose steering gear case bolts Tighten gear case bolts.
Faulty steering gear case assembly Replace steering gear case assembly.
Worn steering shaft joints Replace joint.
Worn tie-rod ends or tie-rod inside ball
joints Replace tie-rod end or tie-rod.
Worn lower ball joints Replace front suspension control arm.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Poor return ability Bind in tie-rod end ball studs Replace tie-rod end.
Bind in ball joints Replace front suspension control arm.
Bind in steering column Repair or replace steering column.
Disturbed front end alignment Check and adjust front end alignment.
Faulty steering gear case assembly Replace steering gear case assembly.
Tires not adequately inflated Adjust tire pressure.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Rack and pinion noise
(Rattle or chuckle) Loose steering gear case bolts
Tighten steering gear case bolts.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Faulty steering gear case assembly Replace steering gear case assembly.
Broken or other wise damaged wheel
bearing(s) Replace wheel bearing(s).
Wander or poor steering
stability Mismatched or uneven tires
Replace or inflate tires to proper pressure.
Loosen ball joints and tie-rod ends Replace suspension control arm or tie-rod end.
Faulty struts or mountings Replace strut or repair mounting.
Loose stabilizer bar Tighten or replace stabilizer bar or bush.
Broken or sagging springs Replace spring.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Disturbed front wheel alignment Check and adjust front wheel alignment.
Faulty steering gear case assembly Replace steering gear case assembly.
Erratic steering when
braking Worn wheel bearing(s)
Replace wheel bearing(s).
Broken or sagging spring(s) Replace coil spring(s).
Wheel tires are inflated unequally Inflate tires to proper pressure.
Disturbed front wheel alignment Check and adjust front wheel alignment.
Brakes not working in unison Check and repair brake system.
Leaking caliper Repair or replace caliper.
Warped discs Replace brake disc.
Badly worn brake pads Replace brake pads.

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-2
Diagnostic Information and Procedures
Checking Steering Column for Accident
Damage
S7RS0B6204001
NOTE
Vehicles involved in accidents resulting in
body damage, where steering column has
been impacted or air bag deployed may have
a damaged or misaligned steering column.

Checking Procedure
NOTE
The steering column used in each vehicle is
one of the two types as shown.

1) Check that two capsules (1) are attached to steering column bracket securely. If found loose, replace
steering column assembly.
2) Take measurement “a”, “b” and “c” as shown. If it is shorter than spec ified length, replace steering
column assembly with new one.
Ty p e A
Power steering column length
“a”: 459 ± 2 mm (18.1 ± 0.08 in.)
“b”: 64.1 ± 1 mm (2.5 ± 0.03 in.)
“c”: 306.7 ± 1 mm (12.0 ± 0.03 in.)
Ty p e B
Power steering column length
“a”: 466 ± 2 mm (18.3 ± 0.08 in.)
“b”: 60.0 ± 1 mm (2.4 ± 0.03 in.)
“c”: 300.5 ± 1 mm (11.8 ± 0.03 in.) 3) Check steering shaft joints and shaft for any
damages such as crack, breakage, malfunction or
excessive play.
If anything is found faulty, replace as lower shaft
assembly or steering column assembly.
4) Check steering shaft for smooth rotation. If found defective, replace as steering column
assembly.
5) Check steering shaft and steering column for bend, cracks or deformation.
If found defective, replace.
[A]: Type A [B]: Type B
[A] [B]
1
1
1
1
I6RS0C620004-01
I6RS0C620001-01
I4RS0A620003-01

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-4
Steering Wheel Removal and InstallationS7RS0B6206002
CAUTION!
Do not turn the contact coil more than
allowable number of turns (about two and a
half turns from the center position clockwise
or counterclockwise respectively) with
steering wheel removed, or coil will break.

Removal
CAUTION!
Do not hammer the end of the shaft.
Hammering it will loosen the plastic shear
pins which maintain the column length and
impair the collapsible design of the column.

1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air
Bag System in Section 8B”.
3) Remove driver air bag (inflator) module from steering wheel. Refer to “Driver Air Bag (Inflator)
Module Removal and Installation in Section 8B”.
4) Disconnect horn connector and audio control switch connector, if equipped.
5) Remove steering shaft nut and then make alignment marks (1) on steering wheel and shaft for a guide
during reinstallation.
6) Remove steering wheel using special tool. Special tool
(A): 09944–36011 Installation
CAUTION!
Following 2 Steps (Step 1) and 2)) are
prerequisite for installation of steering wheel.
If steering wheel has
been installed without
these 2 Steps, contact coil will break when
steering wheel is turned.

1) Check that vehicle’s front tires are at straight-ahead position and contact coil is centered. If contact coil is
turned after removing steering wheel, center contact
coil referring to “Centering Contact Coil Cable
Assembly”.
2) Install steering wheel to steering shaft with 2 grooves (1) on contact coil fitted in 2 lugs (2) in the back of
steering wheel and also aligning marks (3) on
steering wheel and steering shaft.
3) Tighten steering shaft nut (4) to specified torque.
Tightening torque
Steering shaft nut (a): 33 N·m (3.3 kgf-m, 24.0 lb-
ft)
4) Connect horn connector and audio control switch connector, if necessary.
5) Install driver air bag (inflator) module to steering wheel. Refer to “Driver Air Bag (Inflator) Module
Removal and Installati on in Section 8B”.
6) Connect negative (–) battery cable.
7) Enable air bag system refe rring to “Enabling Air Bag
System in Section 8B”.
I4RS0A620005-01
(A)
I4RS0A620006-01
I4RS0A620007-01

Downloaded from www.Manualslib.com manuals search engine 6B-5 Steering Wheel and Column:
Contact Coil Cable Assembly Removal and
Installation
S7RS0B6206003
CAUTION!
Do not turn contact coil more than allowable
number of turns (about two and a half turns
from the center position clockwise or
counterclockwise respectively), or coil will
break.

Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove steering wheel from steering column referring to “Steering Wheel Removal and
Installation”.
4) Remove steering column lower cover (2) and upper cover (1).
5) Remove contact coil cable assembly (1) from steering column. 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) Install contact coil cable assembly to steering column securely.
NOTE
New contact coil cable assembly is supplied
with contact coil set and held at its center
position with a lock pin (1). Remove this lock
pin after installing contact coil cable
assembly to steering column.

3) Install steering column upper cover (1) and lower cover (2).
4) Install steering wheel to steering column. Refer to
“Steering Wheel Removal and Installation”.
5) Connect battery negative (–) cable.
6) Enable air bag system refe rring to “Enabling Air Bag
System in Section 8B”.
2
1
I4RS0B620002-04
1I6RS0B620001-01
I4RS0A620010-01
2
1
I4RS0B620002-04

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-6
Centering Contact Coil Cable AssemblyS7RS0B6206004
1) Check that vehicle’s wheels (front tires) are set at straight-ahead position.
2) Check that ignition swit ch is at LOCK position.
3) Turn contact coil counterclockwise slowly with a light force till contact coil will not turn any further.
NOTE
Contact coil can turn about 5 turns at the
maximum, that is, if it is at the center
position, can turn about two and a half turns
both clockwise and counterclockwise.

4) From the position where contact coil became unable to turn any further (it stopped), turn it back clockwise
about two and a half rotations and align center mark
with alignment mark (1).
Contact Coil Cable Assembly InspectionS7RS0B6206005
Refer to “Contact Coil Cable and Its Circuit Check in
Section 8B”.
Steering Angle Sensor Removal and InstallationS7RS0B6206011
Removal
1) Remove steering wheel and contact coil cable assembly. Refer to “Ste ering Wheel Removal and
Installation” and “Contact Coil Cable Assembly
Removal and Installation”.
2) Remove steering angle sensor (2) from contact coil cable assembly (3) while op ening fitting parts (1) of
contact coil cable assembly.
Installation 1) Install steering angle sensor (2) by fitting engagement parts (1) of contact coil cable assembly
to claws of steering angle sensor as shown in figure.
2) Install contact coil cable assembly and steering wheel. Refer to “Contact Coil Cable Assembly
Removal and Installation” and “Steering Wheel
Removal and Installation”.
Steering Angle Sensor InspectionS7RS0B6206012
Refer to “Steering Angle Sens or Inspection in Section
4F”.
I4RS0A620012-01
1
I4RS0A620013-01
1
1
2
3I6JB01620003-01
1
1
2
I6JB01620004-01

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-8
Installation
CAUTION!
After tightening steering column mounting
nuts, shaft joint bolts should be tightened.
Wrong tightening order could cause a
damage to shaft joint.

1) Be sure that front wheels are in straight.
2) Install steering column assembly to lower and upper brackets. Tighten steering column lower nuts (1) first
and then upper nuts (2) to specifications as given
below.
Tightening torque
Steering column nut (a): 14 N·m (1.4 kgf-m, 10.5
lb-ft)
NOTE
After installing tilt steering column, make
sure that steering column moves backwards
and forwards smoothly and stops when tilt
lever is fixed.

3) Align flat part “A” of stee ring lower shaft (1) with bolt
hole “B” of shaft joint (2) of column as shown. Then
insert lower shaft into shaf t joint of steering column
with matching marks (4).
4) Insert lower shaft (1) into pinion shaft (3) with matching marks (4).
5) Tighten joint bolt (pinion shaft side) (6) to specified torque first and then joint bolt (steering column side)
(5) to specified torque.
CAUTION!
After tightening column nuts, tighten steering
shaft upper joint bolt. Otherwise shaft joint
bearing is damaged.

Tightening torque
Steering shaft joint bolt (a): 25 N·m (2.5 kgf-m,
18.5 lb-ft) 6) Install steering joint cover.
7) Install immobilizer cont
rol module from steering
column, referring to “Immo bilizer Control Module
(ICM) Removal and Installation in Section 10C”.
8) Install lighting switch and wiper switch to steering column.
9) Install contact coil cable assembly and steering wheel referring to “Conta ct Coil Cable Assembly
Removal and Installation” and “Steering Wheel
Removal and Installation”.
10) Install steering column hole cover. 11) Connect negative (–) battery to cable.
12) Enable air bag system refe rring to “Enabling Air Bag
System in Section 8B”.
Steering Column InspectionS7RS0B6206007
Check steering column for damage and operation
referring to “Checking Steering Column for Accident
Damage”.
2,(a)
1,(a)
1,(a)
2,(a)
I4RS0B620009-02
I6RS0C620003-01

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-10
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 st eering shaft (2) rotates
smoothly. Also check for lock operation.
7) Install steering column. Re fer to “Steering Column
Removal and Installation”.
8) If steering lock assembly has replaced, after completing installation, register ignition key
transponder code in ECM referring to “Registration
of the Ignition Key in Section 10C”.
Steering Lower Shaft Removal and InstallationS7RS0B6206010
CAUTION!
Never turn steering wheel while steering
lower shaft is removed.
Should it have been turned and contact coil
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.

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.
4) Make alignment marks (4) on lower shaft (1) and shaft joint of steering colu mn (2) and lower shaft (1)
and pinion shaft (3) for a guide during reinstallation.
5) Remove lower shaf t joint bolts (5).
6) Remove steering lower shaft (1). Installation
1) Be sure that front wheels are in straight forward state.
2) Align flat part “A” of steering lower shaft (1) with bolt hole “B” of shaft joint (2) of column as shown. Then
insert lower shaft into shaf t joint of steering column
with matching marks (4).
3) Insert lower shaft (1) into pinion shaft (3) with matching marks (4).
4) Tighten joint bolt (pinion shaft side) (6) to specified
torque first and then joint bolt (steering column side)
(5) to specified torque.
Tightening torque
Steering shaft joint bolt (a ): 25 N·m (2.5 kgf-m,
18.5 lb-ft)
I4RS0B620007-02
I4RS0A620020-01
I6RS0C620002-01