spec SUZUKI SWIFT 2005 2.G Service Workshop Manual

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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

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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

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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

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Specifications
Tightening Torque SpecificationsS7RS0B6207001
NOTE
The specified tightening torque is also described in the following.
“Steering Wheel and Column Construction”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Special ToolS7RS0B6208001
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Steering shaft nut 33 3.3 24.0 )
Steering column nut 14 1.4 10.5 )
Steering shaft joint bolt 25 2.5 18.5 ) / )
09944–36011
Steering wheel remover
)

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Steeri ng
Power Assisted Steering System
Precautions
Steering System NoteS7RS0B6300001
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
during reassembly to assure proper retention of these parts.

Precautions in Diagnosing TroublesS7RS0B6300002
• Take a note of DTC indicated on the SUZUKI scan tool.
• Before inspection, be sure to read “Pre cautions for Electrical Circuit Service in Section 00” and understand what is
written there.
• DTC C1122 (engine speed signal failure) is indicated when ignition switch is at ON position and engine is not
running, but it means there is nothing abnormal if indica tion changes to a normal one when engine is started.
• As DTC is stored in memory of the P/S control module, be sure to clear memory after repair by performing the
procedure described in “DTC Clearance”.

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Terminal Arrangement of P/S Control Module Coupler (Viewed from Harness Side)
Diagnostic Information and Procedures
EPS System CheckS7RS0B6304001
WARNING!
Carry out test drive in light traffic area to prevent an accident.

Refer to the following items for the details of each step.Terminal Circuit Terminal Circuit
E49-1 Main power supply for internal memory
and EPS motor E52-9 Ground for torque sensors
E49-2 Ground for P/S control module E52-10 —
E51-1 Motor output 1 E52-11 Serial communication for data link
connector
E51-2 Motor output 2 E52-12 Engine speed signal
E52-1 Ignition switch signal for P/S control
module E52-13 —
E52-2 — E52-14 P/S operation signal (idle up signal)
E52-3 — E52-15 —
E52-4 Vehicle speed signal E52-16 Torque sensor internal failure signal
E52-5 “EPS” warning light E52-17 —
E52-6 Torque sensor signal (Sub) E52-18 Torque sensor signal (Main)
E52-7 — E52-19 Ground for shield wire
E52-8 Main power supply for torque sensor E52-20 5 V reference power supply for torque
sensor
Step
Action YesNo
1 ) Customer complaint analysis
1) Perform customer complaint analysis referring to “Customer Complaint Analysis”.
Was customer complaint analysis performed? Go to Step 2.
Perform customer
complaint analysis.
2 ) DTC check, record and clearance
1) Check for DTC (including pending DTC) referring to “DTC Check”, Record and Clearance.
Is there any DTC(s)? Print DTC or write them
down and clear them by
referring to “DTC
Clearance” and go to
St ep 3 .Go to Step 4.
3 ) Visual inspection
1) Perform visual inspection referring to “Visual Inspection”.
Is there any faulty condition? Repair or replace
malfunction part, and go
to Step 11.
Go to Step 5.
4 ) Visual inspection
1) Perform visual inspection referring to “Visual Inspection”.
Is there any faulty condition? Repair or replace
malfunction part, and go
to Step 11.
Go to Step 8.
5 ) Trouble symptom confirmation
1) Confirm trouble symptom referring to “Trouble Symptom Confirmation”.
Is trouble symptom identified? Go to Step 6.
Go to Step 7.
6 ) Rechecking and record of DTC
1) Recheck for DTC referring to “DTC Check”.
Is there any DTC(s)? Go to Step 9.
Go to Step 8.

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Step 1: Customer Complaint Analysis
Record details of the problem (failure, co mplaint) and how it occurred as described by the customer. For this purpose,
use of such an inspection form will fac ilitate collecting information to the point required for proper analysis and
diagnosis. Check if the problem described in “Customer ques tionnaire” occurs actually in the vehicle if necessary.
(This step should be performed with the customer if possible.) Customer problem inspection form (Example)
NOTE
This form is a standard sample. It should be modified according to conditions characteristic of each
market.

I7RW01632004-02

Downloaded from www.Manualslib.com manuals search engine 6C-8 Power Assisted Steering System:
Step 2: DTC Check, Record and Clearance
First, check DTC, referring to “DTC Check”. If DTC is
indicated, print it or write them down and then clear them
by referring to “DTC Clearance”. DTC indicates
malfunction that occurred in the system but does not
indicate whether it exists now or it occurred in the past
and the normal condition has been restored now. To
check which case applies, check the symptom in
question according to Step 5 and recheck DTC
according to Step 6 and 7.
Attempt to diagnose a trouble based on DTC in this step
only or failure to clear the DTC in this step will lead to
incorrect diagnosis, trouble diagnosis of a normal circuit
or difficulty in troubleshooting.
Step 3 and 4: Visual Inspection
As a preliminary step, be sure to perform visual check of
the items that support proper function of the P/S system
referring to “Visual Inspection”.
Step 5: Trouble Symptom Confirmation
Based on information obtained in “Step 1: Customer
Complaint Analysis: ” and “S tep 2: DTC Check, Record
and Clearance: ”, confirm trouble symptoms. Also,
reconfirm trouble symptom by performing test drive and
turning steering wheel fully to right and left at stopped
vehicle.
Step 6 and 7: Rechecking and Record of DTC
Refer to “DTC Check” for checking procedure.
Step 8: Steering Symptom Diagnosis and P/S
System Symptom Diagnosis
Perform basic steering system check according to
“Steering Symptom Diagnosis in Section 6A” first. When
the end of the flow has been reached, check the parts of
the system suspected as a possible cause referring to
“P/S System Symptom Diagnosis” and based on
symptoms appearing on the vehicle (symptoms obtained
through steps of customer complaint analysis, trouble
symptom confirmation and/or basic P/S system check)
and repair or replace faulty parts, if any.
Step 9: Troubleshooting for DTC (See each DTC
Diag. Flow)
Based on the DTC indicated in Step 6 or 7 and referring
to the applicable DTC diag. flow, locate the cause of the
trouble, namely in a sensor, switch, wire harness,
connector, actuator, P/S control module or other part and
repair or replace faulty parts.
Step 10: Intermittent Problems Check
Check parts where an intermittent trouble is easy to
occur (e.g., wire harness, connector, etc.), referring to
“Intermittent and Poor Connection Inspection in Section
00” and related circuit of DTC recorded in Step 2. Step 11: Final Confirmation Test
Confirm that the problem symptom has gone and the P/
S system is free from any abnormal conditions. If what
has been repaired is related to the DTC, clear the DTC
once, perform DTC confirmation procedure and confirm
that no DTC is indicated.
“EPS” Warning Light CheckS7RS0B6304002
1) Turn ignition switch to ON position (without engine
running) and chec k if the “EPS” warning light (1)
lights up. If the light dose not light up, go to ““EPS”
Warning Light Does Not Come ON with Ignition
Switch Turned ON before Engine Starts” of the
diagnostic flows.
2) Start engine and check if the “EPS” warning light turns OFF. If light remains ON and no DTC is stored
in P/S control module, go to ““EPS” Warning Light
Remains ON Steady after Engine Starts” for
troubleshooting.
DTC CheckS7RS0B6304003
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector (DLC) (1) located on underside of instrument panel
at driver’s seat side.
Special tool
(A): SUZUKI scan tool
1
I6RS0C630002-01
(A)
1
I4RS0B450003-01

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3) Start engine.
4) Read DTC according to the instructions displayed on
SUZUKI scan tool. For further details, refer to
operator’s manual for SUZUKI scan tool.
NOTE
• If communication between SUZUKI scan tool and the vehicle can not be
established, perform “Serial Data Link
Circuit Check”.
• DTC C1122 (engine speed signal failure) is indicated when ignition switch is at ON
position and engine is not running, but it
means there is nothing abnormal if
indication changes to a normal one when
engine is started.

5) After completing the check, turn ignition switch to
OFF position and disconnect SUZUKI scan tool from
DLC.
DTC ClearanceS7RS0B6304004
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector (DLC) (1) located on underside of instrument panel
at driver’s seat side.
Special tool
(A): SUZUKI scan tool
3) Turn ignition switch to ON position.
4) Erase DTC according to the instructions displayed on SUZUKI scan tool. For further details, refer to
operator’s manual for SUZUKI scan tool.
5) After completing the clearance, turn ignition switch to OFF position and disconnect SUZUKI scan tool from
DLC.
DTC TableS7RS0B6304005
CAUTION!
Be sure to perform the “EPS Syst em Check” before starting troubleshooting corresponding to each
DTC.

(A)
1
I4RS0B450003-01
DTC No. Detecting item Detecting condition
(DTC will set when detecting) Trouble area MIL
No
CODES Normal — — —
) C1113 Steering torque sensor (Main
and Sub) circuit correlation Voltage difference between torque
sensor main signal and sub signal
is more than 0.6 V for 1 second
continuously. • Torque sensor signal circuit
• Torque sensor
• P/S control module
1 driving
cycle
) C1114 Steering torque sensor
reference power supply
circuit Circuit voltage of torque sensor 5
V reference power supply voltage
is more than 5.7 V or less than 4.3
V for 1 second continuously. • Torque sensor circuit
• Torque sensor
• P/S control module
1 driving
cycle
) C1117 Steering torque sensor
failure signal circuit low Torque sensor internal failure
signal circuit voltage is less than
1.7 V when ignition switch turned
ON.
• Torque sensor signal circuit
• Torque sensor
• P/S control module1 driving
cycle
) C1118 Steering torque sensor
failure signal circuit high Torque sensor internal failure
signal circuit voltage is more than
3.7 V for 1 second continuously. 1 driving
cycle
) C1119 Steering torque sensor
power supply circuit Circuit voltage of torque sensor
main power supply
is less than
7.5 V for 1 second continuously. • Torque sensor circuit
• Torque sensor
• P/S control module
1 driving
cycle

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) C1121 No vehicle speed signal
(60 seconds or more) Vehicle speed signal is 0 km/h
even though engine speed is
more than 4000 rpm for more than
60 seconds continuously (before
elapse of 5 min from engine start)
or vehicle speed signal is 0 km/h
even though engine speed is
more than 2500 rpm for more than
60 seconds continuously (after
elapse of 5 min for engine start). • Vehicle speed signal circuit
• Wheel speed sensor
•ECM
• P/S control module
• ABS control module
• CAN communication circuit
Not
applicable
) C1122 Engine speed signal Engine speed signal is less than
220 rpm for more than 0.8
seconds.
or
Engine speed signal is less than
220 rpm for more than 20
seconds continuously even
though vehicle speed signal is
more than 50 km/h.• Engine speed signal circuit
•ECM
• P/S control module
• Vehicle speed signal
1 driving
cycle
) C1123 No vehicle speed signal
(30 seconds or more) Vehicle speed signal is 0 km/h
with continuously more than 3
driving cycles even though engine
speed is more than 4000 rpm for
more than 30 seconds
continuously (before elapse of 5
min from engine start).
or
vehicle speed signal is 0 km/h
with continuously more than 3
driving cycles even though engine
speed is more than 2500 rpm for
more than 30 seconds
continuously (after elapse of 5 min
for engine start). • Vehicle speed signal circuit
• Wheel speed sensor
•ECM
• P/S control module
• ABS control module
• CAN communication circuit
3 driving
cycles
) C1124 Vehicle speed performance
(Impossible deceleration) Vehicle speed signal is less than 5
km/h for more
than 5 seconds
continuously with more than
specified deceleration speed (–20
m/s
2) from over 20 km/h. Not
applicable
) C1141 P/S motor circuit voltage Voltage between both motor drive
circuits is more than 8.5 V or less
than 0.2 V for 0.5 seconds
continuously while motor is not
drived.
• P/S motor circuit
• P/S motor
• P/S control module1 driving
cycle
) C1142 P/S motor circuit range /
performance Measured motor drive current is
more than 10 A as compared with
target motor drive current. 1 driving
cycle
DTC No. Detecting item
Detecting condition
(DTC will set when detecting) Trouble area MIL