Clé SUZUKI SWIFT 2007 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-9
3) Pull out input shaft bearing (1) from flywheel (2), use the following special tool if necessary.
Special tool
(A): 09921–26020
(B): 09930–30104
4) Remove flywheel (1) from crank shaft using special tool.
Special tool
(A): 09924–17811 Installation
CAUTION!
Do not reuse flywheel bolts. Otherwise, bolts
may loosen. Be sure to use new bolts with
pre-coated adhesive.

NOTE
Before assembling, make
sure that flywheel
surface and pressure plate surface have
been cleaned and dried thoroughly.

1) Install flywheel (2) to crankshaft and tighten new bolts (1) to specification.
Special tool
(A): 09924–17811
Tightening torque
Flywheel bolt (a): 70 N·m (7.0 kgf-m, 51.0 lb-ft)
2) Using special tool, install input shaft bearing to flywheel (1).
Special tool
(B): 09925–98210
I2RH01530023-01
I4RS0A530015-02
I2RH01530024-01
I4RS0A530016-01

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 6A-1 Steering General Diagnosis:
Steeri ng
Steering General Diagnosis
Precautions
Precautions for Steering DiagnosisS7RS0B6100001
Since the problems in steering involve several systems, they must all be considered when diagnosing a complaint. To
avoid using the wrong symptom, always road test the vehicl e first. Proceed with the following preliminary inspection
and correct any defects which are found.
1) Inspect tires for proper pressure and uneven wear.
2) Raise vehicle on a hoist and inspect steering system for loose or damaged parts.
3) Spin front wheels. Inspect for out-of-round tires, out- of-balance tires, bent rims, loosen and/or rough wheel
bearings.

Downloaded from www.Manualslib.com manuals search engine 6B-1 Steering Wheel and Column:
Steeri ng
Steering Wheel and Column
Precautions
Service Precautions of Steering Wheel and
Column
S7RS0B6200001
For service precautions, refer to “Precautions on Service
and Diagnosis of Air Bag System in Section 8B”.
Service and Diagnosis
For diagnosis and servicing, refer to “Precautions on
Service and Diagnosis of Air Bag System in Section 8B”.
Disabling Air Bag System
For disabling air bag system, refer to “Disabling Air Bag
System in Section 8B”. Enabling Air Bag System
For enabling air bag system, refer to “Enabling Air Bag
System in Section 8B”.
Handling and Storage
For handling and storage, refer to “Precautions on
Handling and Storage of Air Bag System Components in
Section 8B”.
Disposal
For disposal, refer to “Prec
autions on Disposal of Air
Bag and Seat Belt Pretensioner in Section 8B”.
General Description
Steering Wheel and Column ConstructionS7RS0B6201001
This double tube type steering column has the following three important features in addition to the steering function:
• The column is energy absorbing, desig ned to compress in a front-end collision.
• The ignition switch and lock are mounted conveniently on this column.
• With the column mounted lock, the ignition and steering op erations can be locked to inhibit theft of the vehicle.
To insure the energy absorbing action, it is important th at only the specified screws, bolts and nuts be used as
designated, and that they are tightened to the specified torque. When the column assembly is removed from the
vehicle, special care must be taken in handling it. Use of a steering wheel puller or a sharp blow on the end of the
steering shaft, leaning on the assembly, or dropping the a ssembly could shear the plastic shear pins which maintain
column length and position.
The driver air bag (inflator) module is one of the supplemental restraint (air bag) system components and is mounted
to the center of the steering wheel. During certain frontal crashes, the air bag system supplements the restraint of the
driver’s and passenger’s seat belts by deploying the air b ags. The air bag (inflator) module should be handled with
care to prevent accidental deployment. When servicing, be sure to observe “Precautions on Service and Diagnosis of
Air Bag System in Section 8B”.

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 6B-7 Steering Wheel and Column:
Steering Column Removal and InstallationS7RS0B6206006
CAUTION!
Once the steering column is removed from
the vehicle, the column is extremely
susceptible to damage.
• Dropping the column assembly on its end could collapse the steering shaft or loosen
the plastic shear pins which maintain
column length.
• Leaning on the column assembly could cause it to bend or deform.
Any of the damage could impair the column’s
collapsible design.
Steering column mounting nuts should not
be loosened with steering shaft joint upper
side bolt tightened as this could cause
damage to shaft joint bearing.

NOTE
When servicing steering column or any
column-mounted component, remove
steering wheel. But when removing steering
column simply to gain access to instrument
panel components, leave steering wheel
installed on steering column.

Removal
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) Disconnect negative (–) cable at battery.
2) Disable air bag system. Re fer to “Disabling Air Bag
System in Section 8B”.
3) Remove steering wheel and contact coil cable assembly referring to “S teering Wheel Removal and
Installation” and “Contact Coil Cable Assembly
Removal and Installation”.
4) Detach lighting switch and wiper switch from steering column.
5) Remove immobilizer cont rol module from steering
column, referring to “Immo bilizer Control Module
(ICM) Removal and Installation in Section 10C”.
6) Remove steering column hole cover.
7) Remove steering joint cover.
8) 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.
9) Remove lower shaf t joint bolts (5).
10) Remove steering lower shaft (1).
11) Remove steering column mounting nuts (1).
12) Remove steering column from vehicle.
I4RS0A620016-01
1
1
I4RS0A620017-01