System check SUZUKI SWIFT 2006 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 6C-44 Power Assisted Steering System:
6) Unbend bent part of tie-rod lock washer (1).
7) Hold rack with soft jawed vise (3) and remove tie-rod
from rack (2).
Installation 1) Install tie-rod (1) and new tie-rod lock washer (3) to rack (2).
2) Hold rack with soft jawed vise and tighten tie-rod to specified torque.
Tightening torque
Tie-rod (a): 93 N·m (9.3 kgf-m, 67.5 lb-ft)
3) Bend lock washer at 2 places (1) as shown in figure. 4) Apply sealant to gear case groove “A” indicated in
figure. Position boot properly in grooves of gear case
(or rack side mount) and tie-rod.
After this, check to ensure that boot is free from twist
and dent.
“A”: Silicone sealant 99000–31120 (Silicone
sealant)
5) Fasten boot with new band and clip securely. Special tool
(A): 09943–55010
6) Install tie-rod end lock nut and tie-rod end to tie-rod. Position lock nut to marking (1) made in removal.
NOTE
When tie-rod was replaced, measure length
“a” on removed tie-rod and use it on new
replacement tie-rod so as to position lock nut
properly.

7) Tighten tie-rod end lock nut to specified torque.
Tightening torque
Tie-rod end lock nut (a): 45 N·m (4.5 kgf-m, 32.5
lb-ft)
I4RS0A630033-01
3 1, (a)
2
I6RS0C630027-01
I4RS0A630035-01
I3RM0A630050-01
I3RM0A630051-01
I3RM0A630052-01
(a)I7RS0A630018-01

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-45
8) Install steering gear case assembly referring to “Steering Gear Case Assembly Removal and
Installation”.
Steering Rack Plunger Removal and InstallationS7RS0B6306009
Removal
1) Remove gear case assembly referring to “Steering
Gear Case Assembly Removal and Installation”.
2) Loosen lock nut (1) with holding damper screw (2).
3) Remove lock nut (1), rack damper screw (2), rack plunger spring (3) and rack plunger (4).
Installation 1) Apply grease lightly to sliding part of plunger (1) against rack.
“A”: Grease 99000–25050 (SUZUKI Super
Grease E)
2) Install plunger and spring (2) as shown.
3) Apply thread lock cement to rack damper screw (3)
and tighten them as follows.
a) Tighten damper screw to 25 N ⋅m (2.5 kgf-m, 18.0
lb-ft).
b) Loosen damper screw until 180 °.
c) Retighten damper screw to 3.9 N ⋅m (0.39 kgf-m,
3.0 lb-ft).
d) After tightening rack damper screw to specified torque, turn it back by 7 ± 3°.
“B”: Thread lock cement 99000–32110
(Thread Lock Cement Super 1322)
Tightening torque
Rack damper screw (a): Tighten 25 N ⋅m (2.5
kgf-m, 18.0 lb-ft) and loosen 180° and then
tighten 3.9 N ⋅m (0.39 kgf-m, 3.0 lb-ft) and turn
it back by 7 ± 3° by the specified procedure. 4) Pinion rotation torque should be checked with rack
position centered.
Also, check if rack as a whole moves smoothly.
Special tool
(A): 09944–18310
Tightening torque
Rotation torquer of pinion (a): 2.0 N·m (0.2 kgf-
m, 1.5 lb-ft)
5) After adjustment, tighten lo ck nut to specified torque
with holding damper screw at the position.
Tightening torque
Rack damper screw lock nut (a): 64 N·m (6.4
kgf-m, 46.5 lb-ft)
6) Install gear case assembly referring to “Steering Gear Case Assembly Re moval and Installation”.
Steering Rack Plunger InspectionS7RS0B6306010
• Inspect rack plunger (1) for wear or damage.
• Inspect rack plunger spring (2) for deterioration.
I4RS0A630045-01
I4RS0A630046-01
I3RM0A630055-02
I4RS0A630047-01

Downloaded from www.Manualslib.com manuals search engine 6C-46 Power Assisted Steering System:
P/S Control Module Removal and InstallationS7RS0B6306011
Removal1) Disconnect negative cable at battery.
2) Remove console box.
3) Disconnect connectors (1) from P/S control module (2).
4) Disconnect connector from yaw rate / G sensor
(ESP ® model).
5) Remove P/S control module (2) with bracket (3) from floor panel.
6) Separate P/S control module and bracket.
Installation
Reverse removal procedure for installation noting the
following.
• Tighten each screw to the specified torque. Tightening torque
P/S control module bracket screw (ABS model)
(a): 9 N·m (0.9 kgf-m, 6.5 lb-ft)
P/S control module bracket screw (ESP ® model)
(a): 7 N·m (0.7 kgf-m, 5.0 lb-ft)
P/S control module mounting screw (b): 5 N·m (
0.5 kgf-m, 3.7 lb-ft)
Torque Sensor and Its Circuit InspectionS7RS0B6306012
1) Remove console box.
2) With ignition switch turned OFF, connect scan tool to DLC or connect voltage tester between “E52-18” –
“E52-9” (main sensor) or “E52-6” – “E52-9” (sub
sensor) with connected connector (1) to P/S control
module. 3) Set torque wrench to stee
ring wheel referring to
“Steering Force Check” for checking steering force.
4) Turn ON ignition switch without engine running and select scan tool “Data list” mode due to check of
“TQS Main Torque”, “TQS Sub Torque” and “Assist
Torque” display on scan tool when steering wheel
turned left and right (if used).
5) Check that characteristic of torque sensor (main and sub) output voltage or scan tool data and steering
force is as following graph when steering wheel is
turned left and right. If sensor voltage or scan tool
data is out of specified value or does not vary linearly
as the following graph, check P/S control module
and its circuit.
If they are OK, replace steering gear case assembly.
1
(a)
2
3
(b)
I7RS0A630020-01
[A]: Steering force at left turn
[B]: Steering force at right turn
[C]: Steering wheel at free
[D]: “TQS Main Torque”, “TQS Sub Torque” and “Assist Torque” in “Data List” displayed on scan tool
E52
18
9
6
9
6 18
1
I6RS0C630024-01
I3RM0A630022-01
0
[C] [N.m]
MAX MAX
[B]
[A]
2.33 - 2.68 [V]
[D]
0.65 - 0.72
(0 - 0.4)
4.21 - 4.41
(5.1 - 5.6)
6.86
-6.86
0
6.86
- 6.86
I6RS0C630021-04

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-47
P/S Motor and Its Circuit InspectionS7RS0B6306013
1) Remove console box.
2) Disconnect motor connector (“E51”) from P/S control module with ignition switch OFF.
3) Check for resistance between terminals of motor connector (“E51”).
If check result is not as specified, replace steering
gear case assembly.
Motor circuit resistance
4) Check for continuity between terminal of motor connector (“E51”) and body ground.
If check result is not as specified, replace steering
gear case assembly.
Motor circuit resistance
5) Hoist vehicle.
6) Connect “E51” connector to P/S control module with ignition switch OFF position.
7) Using ammeter (2), check that P/S motor (1) current is as following table with id ling engine. If check result
is not satisfactory, check P/S control module
referring to “Inspection of P/S Control Module and Its
Circuits”. If OK, replace steering gear case
assembly.
Motor current at hoisted vehicle
“E51-1” and “E51-2” (For motor) About 1 Ω
“E51-2” and body ground No continuity
1. Connector “E51” (viewed from harness side)
E51
11 2
I6RS0C630025-01
Condition When
steering
wheel is left at straight
position: [A] When
steering
wheel is
turned left or right by turning
speed with
90° /sec: [B] When
steering
wheel is kept fully turned left or right
until it stops.: [C]
Motor
current Approx. 0 A Approx.
0 – 4 A Approx.
30 – 45 A
1
32
E51-1
E51-2
[C] [A]
[B] [B]
I6RS0C630022-01

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-49
Special Tools and Equipment
Recommended Service MaterialS7RS0B6308001
NOTE
Required service material is also described in the following.
“Steering Gear Case Assembly Components”

Special ToolS7RS0B6308002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease E P/No.: 99000–25050)
Silicone sealant Silicone sealant P/No.: 99000–31120)
Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 )
09943–5501009944–18310
Boot clamp plier Pinion torque checking
socket
))
SUZUKI scan tool
—
This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12. ) / )

Downloaded from www.Manualslib.com manuals search engine 7-ii Table of Contents
Recommended Service Material ....................... 7B-33
Special Tool ...................................................... 7B-33
Automatic Type .................... .................................7B-34
Precautions.........................................................7B-34 A/C System Caution .......................................... 7B-34
Precautions in Diagnosing Trouble ................... 7B-34
Precautions on Servicing A/C System .............. 7B-34
General Description .......... .................................7B-34
Auto A/C System Descript ion ............................ 7B-34
HVAC Control Module Operation Description ... 7B-36
Refrigerant Type Identifica tion .......................... 7B-36
Sub-Cool A/C System Description .................... 7B-36
A/C Operation Description ................................ 7B-36
On-Board Diagnostic System Description ......... 7B-37
Schematic and Routing Diagram ......................7B-37 Major Components of A/C System .................... 7B-37
A/C System Wiring Diagra m ............................. 7B-38
Diagnostic Information and Procedures ..........7B-39 A/C System Symptom Diagnosis ...................... 7B-39
Abnormal Noise Sympto m Diagnosis of A/C
System ............................................................ 7B-42
DTC Check........................................................ 7B-42
DTC Clearance ................................................. 7B-43
DTC Table ......................................................... 7B-44
Fail-Safe Table ................. ................................. 7B-45
Scan Tool Data ................................................. 7B-46
Air Conditioning System Check......................... 7B-47
Visual Inspection ............................................... 7B-49
DTC B1502: Inside Air Temperature Sensor and/or Its Circuit Malfunction .......................... 7B-49
DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction .............. 7B-50
DTC B1504: Sunload Sensor and/or Its Circuit Malfunction ......... ................................. 7B-52
DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit
Malfunction ...................................................... 7B-53
DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit
Malfunction ...................................................... 7B-55
DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction .......................... 7B-57
DTC B1514: Air Flow Co ntrol Actuator and/or
Its Circuit Malfunction ...................................... 7B-60
DTC B1541: HVAC Control Module Back-Up Power Supply Malfunction .............................. 7B-62
DTC B1546: A/C Refrigerant Pressure Malfunction ...................................................... 7B-63
DTC B1551: Serial Communication Circuit Malfunction ...................................................... 7B-63
DTC B1552: Serial Communication Signal Malfunction ...................................................... 7B-64
DTC B1553: CAN Communication Signal Malfunction ...................................................... 7B-65
DTC B1557: Vehicle Speed Sensor Signal Malfunction ...................................................... 7B-65
DTC B1561: Engine Coolant Temperature Sensor Signal Malfunctio n .............................. 7B-66 DTC B1562: Outside Air Temperature Sensor
Signal Malfunction ........................................... 7B-66
DTC B1563: A/C Refr igerant Pressure
Sensor Signal Malfunction .............................. 7B-66
Inspection of HVAC Control Module and Its Circuit .............................................................. 7B-67
A/C System Performance Inspection ................ 7B-70
A/C System Inspection at ECM ......................... 7B-70
Repair Instructions ............ ................................7B-71
Operation Procedure for Refrigerant Charge .... 7B-71
HVAC Unit Components ................................... 7B-72
HVAC Unit Removal and In stallation ................ 7B-73
Temperature Control Actuator Removal and Installation ....................................................... 7B-73
Temperature Control Actuat or Inspection ......... 7B-73
Air Flow Control Actuator Removal and Installation ....................................................... 7B-74
Air Flow Control Actuator Inspection ................. 7B-74
Air Intake Control Actuator Removal and Installation ....................................................... 7B-75
Air Intake Control Actuator Inspection............... 7B-75
Actuator Linkage Inspection .............................. 7B-76
Blower Motor Controller Removal and Installation ....................................................... 7B-76
Blower Motor Controller Inspection ................... 7B-76
HVAC Control Module Removal and Installation ....................................................... 7B-77
Sunload Sensor Removal and Installation ........ 7B-77
Sunload Sensor Inspection ............................... 7B-77
Outside Air Temperature Sensor Removal and Installation ................................................ 7B-77
Outside Air Temperature Sensor Inspection ..... 7B-77
Inside Air Temperature Sensor Removal and Installation ....................................................... 7B-78
Inside Air Temperature Sens or Inspection ........ 7B-78
Condenser Assembly On-Vehicle Inspection .... 7B-78
Condenser Assembly Removal and Installation ....................................................... 7B-78
Receiver/Dryer Removal and Installation .......... 7B-78
Evaporator Inspection ....................................... 7B-78
Evaporator Temperature Sensor Removal and Installation ................................................ 7B-78
Evaporator Temperature Se nsor Inspection ..... 7B-78
Expansion Valve Removal an d Installation ....... 7B-78
Expansion Valve Inspection .............................. 7B-78
A/C Refrigerant Pressure Sensor and Its Circuit Inspection............................................. 7B-78
A/C Refrigerant Pressu re Sensor Removal
and Installation ................................................ 7B-78
Compressor Relay Inspection .
.......................... 7B-78
Compressor Drive Belt Inspection and Adjustment ...................................................... 7B-78
Compressor Drive Belt Removal and Installation ....................................................... 7B-79
Compressor Assembly Removal and Installation ....................................................... 7B-79
Compressor Assembly Components................. 7B-79
Magnet Clutch Removal and Installation........... 7B-79
Magnet Clutch Inspection.................................. 7B-79
Relief Valve Inspection...................................... 7B-79

Downloaded from www.Manualslib.com manuals search engine 7A-4 Heater and Ventilation:
Repair Instructions
HVAC Unit ComponentsS7RS0B7106001
For manual type A/C, refer to “HVAC Unit Components
in Section 7B”.
For automatic type A/C, refer to “HVAC Unit
Components in Section 7B”.
HVAC Unit Removal and InstallationS7RS0B7106002
Removal
1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove cowl top panel from vehicle body referring to “Cowl Top Components in Section 9K”.
4) Drain engine coolant, and then disconnect heater hoses (1) from HVAC unit (2).
5) Remove instrument panel from vehicle body referring to “Instrument Panel Removal and
Installation in Section 9C”.
6) Remove nuts (3).
7) Remove HVAC unit from vehicle body.
Installation
Reverse removal procedure noting the following
instructions.
• Be careful not to catch any cable and wiring harness in inappropriate position.
• Adjust control cables of HVAC control unit referring to “HVAC Control Unit Remo val and Installation”.
• Fill engine coolant to radiator.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Blower Motor Removal and InstallationS7RS0B7106003
Removal
1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Disconnect connector (1) from blower motor (2).
4) Remove blower motor from HVAC unit by removing screws (3).
Installation
Reverse removal procedure noting the following
instruction.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Blower Motor InspectionS7RS0B7106004
• Check for continuity between two terminals as shown. If there is no continuity, replace blower motor.
3
2
3
1
3I4RS0B710004-01
3
1
2
3
3
I4RS0B710005-01
I4RS0A710006-01

Downloaded from www.Manualslib.com manuals search engine Heater and Ventilation: 7A-5
• Check for operation and current.a. Put blower motor (1) in a soft-jawed vise.
b. Connect battery to blower motor as shown.
c. Check if blower motor operates smoothly without noise.
d. Check if ammeter indicates the specified current. If measured current is out of specification, replace
blower motor.
Blower motor specified current at 12 V
16 A maximum
Blower Motor Resistor Removal and InstallationS7RS0B7106005
Removal
1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove glove box from instrument panel.
4) Remove bolts (1) from instrument panel.
5) Remove foot duct (1) from HVAC unit by removing screw (2). 6) Remove connector (1) from blower motor resistor
(2), and then remove blower motor resistor from
HVAC unit by removing screws (3).
Installation
Reverse removal procedure noting the following
instruction.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Blower Motor Resistor InspectionS7RS0B7106006
Measure each terminal-to-terminal resistance. If
measured resistance is out of specification, replace
blower motor resistor.
Blower motor resistor resistance
“H” – “MH”: Approximately 0.6 Ω at 20 – 25 °C (68 –
77 °F)
“MH” – “ML”: Approximately 1.6 Ω at 20 – 25 °C (68 –
77 °F)
“ML” – “L”: Approximately 3.4 Ω at 20 – 25 °C (68 –
77 °F)
1
I4RS0A710007-01
11I4RS0B710006-01
12I4RS0B710007-01
1
3
23
I4RS0A710010-01
MHL
HMLI4RS0B710024-01

Downloaded from www.Manualslib.com manuals search engine 7A-10 Heater and Ventilation:
Air Intake Control Actuator InspectionS7RS0B7106013
Check air intake control actuator as follows:1) Using service wire, connect battery positive terminal to “a” terminal and battery negative terminal to
terminal “b”. And, check if air intake selector link
operates smoothly and it st ops at fresh position (1).
2) Using service wire, connect battery positive terminal to “a” terminal and battery negative terminal to
terminal “c”. And, check if air intake selector link
operates smoothly and it stops at recirculation
position (2).
If malfunction is found, replace air intake control
actuator.
Center Ventilation Louver Removal and
Installation
S7RS0B7106014
Removal
1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove passenger air bag module from instrument panel referring to “Passenger Air Bag (Inflator)
Module Removal and Installation in Section 8B”.
4) Remove radio assembly from instrument panel referring to “Audio Unit Re moval and Installation in
Section 9C”.
5) Remove center ventilation louver (1) with garnish (2) from instrument panel, and then disconnect
connector from hazard switch.
NOTE
Garnish is fitted to in strument panel with six
clips. When removing garnish from
instrument panel, be careful not to break
them.

6) Separate center ventilation louver and garnish.
Installation
Reverse removal procedure.
a
b
c
1
2
I4RS0A710023-01
1
2
I4RS0B710017-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-1
HVAC
Air Conditioning System
Manual Type
Precautions
A/C System CautionS7RS0B7210001
CAUTION!
• The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a).
None of refrigerant, compressor oil and component parts is interchangeable between two types of
A/C: one using refrigerant HFC-134a (R-134a) and the other using refrigerant CFC-12 (R-12).
Be sure to check which refrigerant is used be fore any service work including inspection and
maintenance. For identification between these two types, refer to “Refrigerant Type Identification”.
When replenishing or changing refrigerant and comp ressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being
serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.
• When servicing the compressor, keep dirt or foreign material away from getting on or into the compressor parts and system. Clean tools and a clean work area are important for proper service.
The compressor connection and the outside of the compressor should be cleaned before any “On
vehicle” repair or before removal of the compressor. The parts must be kept clean at all times and
any parts to be reassembled should be cleaned with trichloromethane, naphtha, kerosene or
equivalent solvent and dried with dry air. Use only lint free cloths to wipe parts.
• When compressor is removed from the vehicle for servicing, the oil remaining in the compressor
should be discarded and new refrigerant oil added to the compressor.
Minor repair procedures may be done on the vehicle without discharging the system. Major repair
procedures require that the system be discharged of refrigerant.

Precautions on Servicing A/C SystemS7RS0B7210002
WARNING!
Should refrigerant HFC-134a (R-134a) is exposed to your eye(s), consult a doctor immediately.
• Do not use your hand to rub affected eye(s). Instead, use 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 refrigerant HFC-134a (R-134a) is exposed to your skin, such affected part should be treated in the
same manner as when skin is frostbitten or frozen.

Handling Refrigerant HFC-134a (R-134a)
• Always wear goggles to protect your eyes.
• Avoid direct contact to liquid refrigerant.
• Do not heat refrigerant container higher than 40 °C (104 ° F).
• Do not discharge refrigerant into atmosphere.
• Do not expose bright metals to liquid refrigerant. Refrig erant combined with moisture is corrosive and tarnishes
surfaces of bright metals including chrome.