Contact coil SUZUKI SWIFT 2008 2.G Service User Guide

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 6B-3 Steering Wheel and Column:
Repair Instructions
Steering Wheel and Column ConstructionS7RS0B6206001
21
2 3
4
7
5
6
8
9
11
12 10
15
(a)
(b)
13(c)
14
(d)
16
I4RS0B620001-04
1. Driver air bag (inflator) module
8. Steering column lower cover 15. Audio control switch
2. Steering wheel 9. Steering column 16. Knee protector plate
3. Driver air bag (inflator) module mounting bolt 10. Steering lock assembly (ignition switch) : 9 N⋅m (0.9 kgf-m, 6.5 lb-ft)
4. Steering wheel nut 11. Steering lower shaft : 33 N⋅m (3.3 kgf-m, 24 lb-ft)
5. Contact coil cable assembly 12. Steering joint cover : 25 N⋅m (2.5 kgf-m, 18 lb-ft)
6. Wiper switch and lighting switch 13. Upper and lower joint bolt
: After tightening lower joint bolt, tighten upper joint bolt. : 14 N
⋅m (1.4 kgf-m, 10.5 lb-ft)
7. Steering column upper cover 14. Steering column mounting nut
: After tightening lower nut, tighten upper nut.

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

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

Downloaded from www.Manualslib.com manuals search engine 6C-42 Power Assisted Steering System:
2) Connect tie-rod end to knuckle. Tighten tie-rod end nut (1) to spec ified torque.
3) Bend new split pin (2).
NOTE
After tightening tie-rod end nut to specified
torque, match next first slot of nut with hole
of tie-rod end for insertion of split pin
(rotation angle 60 ° max).

Tightening torque
Tie-rod end nut (a): 45 N·m (4.5 kgf-m, 32.5 lb-ft)
4) Inspect for proper toe re ferring to “Front Wheel
Alignment Inspection and Adjustment in Section 2B”.
5) After confirming proper toe, 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)
6) Tighten wheel nuts to specified torque and lower hoist.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
Tie-Rod End InspectionS7RS0B6306004
• Inspect for play in ball joint.
• Inspect for play in rack end ball joint. In either case, if found defective, replace.
Steering Shaft Joint On-Vehicle InspectionS7RS0B6306005
Check shaft joint for wear, breakage and any other
damage and replace if any defect exists.
Steering Gear Case Assembly Removal and
Installation
S7RS0B6306006
Removal
CAUTION!
Be sure to set front wheels (tires) in straight
direction and remove ignition key from key
cylinder before performing the following
steps; otherwise, contact coil of air bag
system may get damaged.

1) Remove front suspension frame with steering gear case assembly referrin g to “Front Suspension
Frame, Stabilizer Bar and/ or Bushings Removal and
Installation in Section 2B”.
2) Remove steering gear case mounting No.3 bolts (4), No.1 bolts (1), No.2 bolts (2) and gear case bracket,
then remove gear case (3) from front suspension
frame (5).
2 1,(a)
I7RS0A630017-01
I3RM0A630030-01
I4RS0A630043-01
I4RS0B630012-01
25
3
14
I6RS0C630018-01

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4) Install magnet clutch lead wire clamp.
5) Install magnet clutch pulley (1).
6) Install new circlip (2) directing chamfer side (3) upward.
Special tool
(B): 09900–06107
7) Tighten armature plate bolt to specified torque. Tightening torque
Armature plate bolt (a): 15 N·m (1.5 kgf-m, 11.0
lb-ft)
Special tool
(A): 09991–06310
8) Adjust clearance between magnet clutch plate (1) and magnet clutch pulley by putting shim(s) on
compressor shaft. To measure the clearance,
perform the following steps.
a) Put compressor in a vise (2).
b) Set dial gauge (3) on magnet clutch plate, and then adjust its pointer at 0.
c) Connect battery positive terminal (+) to magnet clutch coil lead wire.
d) Connect battery negative terminal (–) to compressor body assemb ly. (At this point,
magnet clutch plate and magnet clutch pulley are
kept in contact.) e) Disconnect battery negative terminal (–) to
compressor body assembly. (At this point,
magnet clutch plate and magnet clutch pulley are
not in contact.)
f) Read stroke of magnet clutch plate from dial gauge by performing step d) and e) repeatedly.
(Stroke of magnet clutch plate is clearance
between magnet clutch plate and magnet clutch
pulley.)
Standard clearance between magnet clutch plate
and magnet clutch plate
0.3 – 0.5 mm (0.012 – 0.020 in.)
Relief Valve InspectionS7RS0B7216028
By using special tool, chec k if there is refrigerant
leakage. If there is refrigerant leakage, replace the relief
valve.
Special tool
(A): 09990–86012
1
32 (B)
I4RS0A720044-01
(a)
(A)
I4RS0A720045-01
21
3
I4RS0A720046-01
(A)
I5RS0C721014-01