Defect SUZUKI SWIFT 2007 2.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 5C-2 Clutch:
Diagnostic Information and Procedures
Clutch System Symptom DiagnosisS7RS0B5304001
Repair Instructions
Clutch Pedal InspectionS7RS0B5306001
Cylinder Push Rod Play “A”1) Press clutch pedal (1) gradually with finger, stop when slight increase of resistance is felt and
measure how much pedal has moved (push rod
play) as represented by “A” as shown.
Push rod play
“A”: Max. 3 mm (0.12 in.)
2) If “A” is not within specification, replace master cylinder (3) or pedal arm (2). Clutch Pedal Free Travel “B”
1) Depress clutch pedal (1), stop the moment clutch resistance is felt, and measure how much pedal has
moved (clutch pedal free travel) as represented by
“B” in figure.
Clutch pedal free travel
“B”
: 2 – 8 mm (0.08 – 0.31 in.)
2) If “B” is not within specification, check pedal arm (2) and master cylinder (3) and replace defective part.
Condition Possible cause Correction / Reference Item
Slipping Improper clutch pedal free travel Replace master cylinder or clutch pedal arm.
Worn or oily clutch disc facing Replace disc.
Warped disc, pressure plate or flywheel
surface Replace disc, clutch cover or flywheel.
Weakened diaphragm spring Replace clutch cover.
Master cylinder piston or seal cup not
returning Replace master cylinder.
Dragging clutch Improper clutch pedal free travel Replace master cylinder or clutch pedal arm.
Weakened diaphragm spring, or worn
spring tip Replace clutch cover.
Rusted input shaft splines Lubricate.
Damaged or worn splines of transaxle
input shaft Replace input shaft.
Excessively wobbly clutch disc Replace disc.
Clutch facings broken or dirty with oil Replace disc.
Fluid leakage Repair or replace.
Clutch vibration Glazed (glass-like) clutch facings Repair or replace disc.
Clutch facings dirty with oil Replace disc.
Release bearing slides unsmoothly on
input shaft bearing retainer Lubricate or replace input shaft bearing
retainer.
Wobbly clutch disc, or poor facing
contact Replace disc.
Weakened torsion springs in clutch disc Replace disc.
Clutch disc rivets loose Replace disc.
Distorted pressure plate or flywheel
surface Replace clutch cover or flywheel.
Weakened engine mounting Replace engine mounting.
Loosened engine mounting bolt or nut Retighten engine mounting bolt or nut.
Noisy clutch Worn or broken release bearing Replace release bearing.
Input shaft front bearing worn down Replace input shaft bearing.
Excessive rattle of clutch disc hub Replace disc.
Cracked clutch disc Replace disc.
Pressure plate and diaphragm spring
rattling Replace clutch cover.
Grabbing clutch Clutch disc facings soaked with oil Replace disc.
Clutch disc facings excessively worn Replace disc.
Rivet heads showing out of facing Replace disc.
Weakened torsion springs Replace disc.

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 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 6C-14 Power Assisted Steering System:
TroubleshootingStep Action Yes No 1 Was “EPS System Check” performed? Go to Step 2. Go to “EPS System
Check”.
2 1) Make sure that SUZUKI scan tool is free from malfunction and that correct program card (software) for
P/S system is used.
2) Turn ignition switch to OFF position.
3) Check proper connection of SUZUKI scan tool to DLC.
Is connection in good condition? Go to Step 3. Connect SUZUKI scan
tool to DLC properly.
3 1) Check if communication is possible by making communication with other controllers (ECM, BCM, ABS
or SDM) or other vehicles.
Is it possible to communic ate with the other controllers? Go to Step 4. Repair open in common
section of “serial data
circuit” (“PPL/WHT” wire
circuit) used by all
controllers or short to
ground or power circuit
which has occurred
somewhere in serial
data circuit (“PPL/WHT”
wire circuit).
4 1) Check power supply circuit and ground circuit for P/S control module referring to “P/S Control Module Power
Supply and Ground Circuit Check”.
Is check result in good condition? Go to Step 5. Repair or replace
defective circuit.
5 1) With ignition switch turned OFF, disconnect “E52” connector from P/S control module and check for
terminal to P/S control module connector.
2) If connections are OK, check t hat “Serial data circuit” is
as following.
• Insulation resistance of “Serial data circuit” wire is infinity between its terminal and other terminals at P/S
control module connector.
• Wiring resistance of “Seria l data circuit” wire is less
than 1 Ω.
• Insulation resistance of “Serial data circuit” wire is infinity between its terminal and vehicle body ground.
Is circuit in good condition? Substitute a known-
good P/S control
module and recheck.
Repair or replace
defective circuit.

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-15
“EPS” Warning Light Does Not Come ON with Ignition Switch Turned ON before Engine StartsS7RS0B6304010
Wiring Diagram
Circuit Description
Operation (ON/OFF) of “EPS” warning light is controlled by P/S control module through combination meter.
If the P/S system is in good condition, P/S control module turns “ EPS” warning light ON at the ignition switch ON, and
then turns it OFF at the engine start. If an abnormality in the system is detected, “EPS” warning light is turned ON
continuously by P/S control module. If P/S control module is disconnected, “EPS” warning light is not turned ON.
Troubleshooting
MBLK
REDE51-1
E51-2
[A ]
12 3
4 5 67
89
11
10
12 13
141516
17 18 19 2010 9 8 7654 3 21
16 15 14 13 12 11
26 25 24 2322 21 20 19 18 17
32 31 30 29 28 27
[C]
7
12V
E49-2BLK
[B ]
1 2
GRY
LT GRN
/BLK
E52-1
E52-5
E49-1
GRNGRNWHTBLK
WHY
G28-25G28-31
RED/BLK
8
3
4
4
5 6
4
4
1 2
4
9
I7RS0B630004-01
[A]: Connector “E52” (viewed from harness side) 2. Ignition switch6. “EPS” warning light
[B]: Connector “E49” (viewed from harness side) 3. Junction block assembly7. P/S control module
[C]: Connector “G28” (viewed from harness si de)4. Fuse 8. Individual circuit fuse box No.1
1. Main fuse box 5. Combination meter9. “EPS” warning light circuit
StepAction YesNo
1 1) Turn ignition switch ON.
Do the other warning lights come on? Go to Step 2.
“GRN”, “RED/BLK” wire
circuit or circuit fuse for
combination meter open
or short to ground.
2 1) Check power supply circuit and ground circuit for P/S control module referring to “P/S Control Module Power
Supply and Ground Circuit Check”.
Is check result in good condition? Go to Step 3.
Repair or replace
defective circuit.
3 1) Remove combination meter and disconnect combination meter connector (“G28”) with ignition switch turned OFF.
2) Check for proper connection to the combination meter at “G28-31” terminal.
3) If OK, check voltage between “G28-31” (“RED/BLK” wire) terminal and body ground with ignition switch ON.
Is it 10 – 14 V? Go to Step 4.
“RED/BLK” wire circuit
open or short to ground.

Downloaded from www.Manualslib.com manuals search engine 6C-18 Power Assisted Steering System:
4Torque sensor signal (main) voltage check
1) Check for voltage between “E53-5” (“WHT” wire)
terminal and body ground with ignition switch ON.
Is it about 0 V? Go to Step 5. Torque sensor signal
circuit is shorted to
other circuit.
5 Torque sensor signal (main) resistance check
1) Check for resistance “E53-5” (“WHT” wire) terminal and
body ground terminal with ignition switch OFF.
Is it about 1 M
Ω? Go to Step 6. Go to Step 8.
6 Torque sensor output voltage check
1) Connect connector to torque sensor with ignition switch
turned OFF.
2) Check torque sensor out put voltage referring to “Torque Sensor and Its Circuit Inspection”.
Is torque sensor in good condition? Substitute a known-
good P/S control
module and recheck.
Replace steering gear
case.
7 Torque sensor (sub) circuit wire check
1) Disconnect P/S control module.
2) Check that torque sensor signal (sub) circuit is as
follows.
• Insulation resistance of wire harness is infinity between “Torque sensor signal (sub) circuit” terminal
and other terminal at torque sensor connector.
• Wiring harness resistance of “Torque sensor signal (sub) circuit” is less than 1 Ω.
• Insulation resistance between “Torque sensor (sub) signal circuit” and vehicle body ground is infinity.
• Circuit voltage between “Torque sensor signal (sub) circuit” circuit and ground circuit is 0 – 1 V with ignition
switch turned ON.
Is circuit in good condition? Replace P/S control
module.
Repair or replace
defective circuit.
8 Torque sensor (main) circuit wire check
1) Disconnect P/S control module.
2) Check that torque sensor (main) signal circuit is as
follows.
• Insulation resistance of wire harness is infinity between “Torque sensor (main) signal circuit” terminal
and other terminal at torque sensor connector.
• Wiring harness resistance of “Torque sensor (main) signal circuit” is less than 1 Ω.
• Insulation resistance between “Torque sensor (main) signal circuit” and vehicle body ground is infinity.
Is circuit in good condition? Replace P/S control
module.
Repair or replace
defective circuit.
Step Action Yes No

Downloaded from www.Manualslib.com manuals search engine 6C-20 Power Assisted Steering System:
DTC TroubleshootingStep Action Yes No 1 Was “EPS System Check” performed? Go to Step 2. Go to “EPS System
Check”.
2 DTC check
Is DTC C1153 and/or DTC C1155 indicated together? Go to applicable DTC
diag. flow.
Go to Step 3.
3 Torque sensor 5 V reference power supply circuit
voltage check
1) With ignition switch turned OFF, disconnect torque
sensor connector and check for proper terminal
connection to torque sensor connector.
2) If connections are OK, check for voltage between “E53- 6” (“RED” wire) terminal and body ground with ignition
switch ON.
Is it approx. 5 V? Go to Step 4. Go to Step 5.
4 Torque sensor 5 V reference power supply circuit check
1) With ignition switch turned OFF, connect torque sensor
connector.
2) Check for P/S control module connector (“E52”) for proper connection.
3) Turn ignition switch ON.
4) Check for voltage between “Torque sensor 5 V reference power supply circuit” terminal and body ground with
connector (“E52”) connected to the P/S control module.
Is it about 5 V? Substitute a known-
good P/S control
module and recheck.
Replace steering gear
case.
5 Torque sensor 5 V reference power supply circuit check
1) With ignition switch turned OFF, disconnect P/S control
module connector.
2) Check that “Torque sensor 5 V reference power supply circuit” is as following.
• Insulation resistance of “Torque sensor 5 V reference power supply circuit” wire is infinity between its
terminal and other terminal at torque sensor
connector.
• Wiring resistance of “Torque sensor 5 V reference power supply circuit” is less than 1 Ω.
• Insulation resistance of “Torque sensor 5 V reference power supply circuit” between its circuit and vehicle
body ground is infinity.
Is circuit in good condition? Replace P/S control
module.
Repair or replace
defective circuit.
20
E52
I4RS0A630013-02

Downloaded from www.Manualslib.com manuals search engine 6C-22 Power Assisted Steering System:
DTC Troubleshooting
DTC C1118: Steering Torque Sensor Failure Signal Circuit HighS7RS0B6304015
Wiring Diagram
Refer to “DTC C1117: Steering Torque Sensor Failure Signal Circuit Low”.
DTC Detecting Condition and Trouble AreaStep Action Yes No
1 Was “EPS System Check” performed? Go to Step 2. Go to “EPS System
Check”.
2 DTC check
Is DTC C1113, C1114 and/or DTC C1119 indicated together? Go to applicable diag.
flow.
Go to Step 3.
3 Torque sensor internal failure signal circuit check
1) Check for P/S control module connector (“E52”) for
proper connection.
2) With ignition switch turned OFF, disconnect torque sensor connector.
3) Check for voltage between “E53-1” (“YEL” wire) terminal and body ground with ignition switch ON.
Is it about 5 V? Go to Step 4. Go to Step 5.
4 Torque sensor internal failure signal circuit check
1) With ignition switch turned OFF, connect torque sensor
connector.
2) Check that voltage between “E52-16” (“YEL” wire) terminal and body ground is about 5V at the moment of
ignition switch turned ON.
Is it about 5 V? Substitute a known-
good P/S control
module and recheck.
Replace steering gear
case.
5 Torque sensor internal failure signal circuit wire check
1) Disconnect P/S control module.
2) Check that torque sensor failure signal circuit is as
follows.
• Insulation resistance of wire harness is infinity between “Torque sensor internal failure signal circuit”
terminal and other terminal at torque sensor
connector.
• Insulation resistance between “Torque sensor internal failure signal circuit” and vehicle body ground is
infinity.
Is circuit in good condition? Substitute a known-
good P/S control
module and recheck.
Repair or replace
defective circuit.
DTC detecting condition
Trouble area
Torque sensor internal failure signal circuit voltage is more
than 3.7 V for 1 second continuously
(1 driving cycle detection logic) • Torque sensor signal circuit
• Torque sensor internal failure signal circuit
• Torque sensor
• P/S control module

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-23
DTC TroubleshootingStep Action Yes No 1 Was “EPS System Check” performed? Go to Step 2. Go to “EPS System
Check”.
2 DTC check
Is DTC C1113, C1114 and/or DTC C1119 indicated together? Go to applicable diag.
flow.
Go to Step 3.
3 Torque sensor internal failure signal voltage check
1) Check for P/S control module connector (“E52”) for
proper connection.
2) Check for voltage between “E52-16” (“YEL” wire) terminal and body ground with ignition switch ON.
Is voltage 0 – 1 V? Substitute a known-
good P/S control
module and recheck.
Go to Step 4.
4 Torque sensor internal failure signal circuit check
1) With ignition switch turned OFF, disconnect torque
sensor connector.
2) Check for voltage between “E53-1” (“YEL” wire) terminal and body ground with ignition switch ON.
Is it about 5 V? Go to Step 5. Go to Step 6.
5 Torque sensor internal failure signal circuit check
1) Disconnect P/S control module connector.
2) Check that torque sensor failure signal circuit is as
follows.
• Insulation resistance of wire harness is infinity between “Torque sensor internal failure signal circuit”
terminal and other terminal at torque sensor
connector.
Is circuit in good condition? Go to Step 7. Repair or replace
defective circuit.
6 Torque sensor internal failure signal circuit check
1) Disconnect P/S control module connector.
2) Check that torque sensor failure signal circuit is as
follows.
• Insulation resistance of wire harness is infinity between “Torque sensor internal failure signal circuit”
terminal and other terminal at torque sensor
connector.
• Wiring harness resistance of “Torque sensor internal failure signal circuit” is less than 1 Ω.
Is circuit in good condition? Substitute a known-
good P/S control
module and recheck.
Repair or replace
defective circuit.
7 Torque sensor signal circuit check
1) Check for torque sensor signal circuit referring to Step 3)
– 8) of “DTC C1113: Steering Torque Sensor (Main and
Sub) Circuit Correlation”.
Is torque sensor and its circuit in good condition? Replace steering gear
case.
Repair or replace
defective parts.

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-25
DTC TroubleshootingStep Action Yes No 1 Was “EPS System Check” performed? Go to Step 2. Go to “EPS System
Check”.
2 DTC check
Is DTC C1153 indicated together? Go to DTC C1153 diag.
flow.
Go to Step 3.
3 Torque sensor main power supply voltage check
1) With ignition switch turned OFF, disconnect torque
sensor connector.
2) Check for P/S control module connector (“E52”) for proper connection.
3) If connections are OK, check for voltage between “E52- 8” (“GRN” wire) terminal and body ground with ignition
switch ON.
Is it approx. 12 V? Go to Step 4. Go to Step 5.
4 Torque sensor main power supply voltage check
1) With ignition switch turned OFF, connect torque sensor
connector.
2) Check for P/S control module connector (“E52”) for proper connection.
3) Turn ignition switch ON.
4) Check for voltage between “Main power supply for torque sensor circuit” terminal and body ground with
connector (“E52”) connected to the P/S control module.
Is it about 12 V? Substitute a known-
good P/S control
module and recheck.
Replace steering gear
case assembly and
recheck.
5 Torque sensor main power supply circuit check
1) With ignition switch turned OFF, disconnect P/S control
module connector.
2) Check that “Main power supply for torque sensor circuit” is as following.
• Insulation resistance of “Main power supply for torque sensor circuit” wire is infinity between its terminal and
other terminal at torque sensor connector.
• Wiring resistance of “Main power supply for torque sensor circuit” is less than 1 Ω .
• Insulation resistance of “Main power supply for torque sensor circuit” between its circuit and vehicle body
ground is infinity.
Is circuit in good condition? Replace P/S control
module.
Repair or replace
defective circuit.
8
E52
I4RS0A630021-02