Part SUZUKI SWIFT 2008 2.G Service Workshop Manual

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NOTE
• As execution of “DTC Clearance” will clear all DTCs, be sure to record all DTCs before service.
• DTC C1122 is indicated when ignition switch is at ON position and engine is not running, it means
that nothing is abnormal.
• Current DTC and history DTC ca n be identified by condition of the “EPS” warning light.
“EPS” warning light operates as follows.

7 ) 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 10.
8 ) Steering symptom diagnosis and P/S system
symptom diagnosis
1) Check and repair according to “Steering Symptom Diagnosis in Section 6A” and “P/S System Symptom
Diagnosis”.
Are check and repair complete? Go to Step 11. Check and repair
malfunction part(s), and
go to Step 11.
9 ) Troubleshooting for DTC
1) Check and repair according to applicable DTC diag. flow.
Are check and repair complete? Go to Step 11. Check and repair
malfunction part(s), and
go to Step 11.
10 ) Intermittent problems check
1) Check for intermittent problems referring to “Intermittent Problems Check”.
Is there any faulty condition? Repair or replace
malfunction part(s), and
go to Step 11.
Go to Step 11.
11 ) Final confirmation test
1) Clear DTC if any.
2) Perform final confirmation test referring to “Final Confirmation Test”.
Is there any problem symptom, DTC or abnormal condition? Go to Step 6. End.
Step Action Yes No
Current DTC is set.
(Abnormality exists at
present.)
Only history DTC is set.
(Faulty condition occurred once
in the past, but normal condition
is detected at present.)
Current and history DTC
exist.
“EPS” warning light
after engine started Remains ON. Turns OFF. Remains ON.

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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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Scan Tool Data Definitions
Battery Voltage
This parameter indicates battery positive voltage.
TQS Power Supply (Torque Sensor Power Supply, V)
This parameter indicates the power supply voltage which
the P/S control module supplies to the torque sensor.
TQS Main Torque (Torque Sensor Main Torque, N ⋅m)
The torque sensor is installed to detect the steering force
and the steering directio n. It consists of two
potentiometers and the main torque sensor is one of
these.
TQS Sub Torque (Torque Sensor Sub Torque, N ⋅m)
The torque sensor is installed to detect the steering force
and the steering directio n. It consists of two
potentiometers and the sub-torque sensor is one of
these. Its output characteristics are compared with those
of the main torque sensor.
Assist Torque (N ⋅m)
This parameter is an internal parameter of the P/S
control module. It is obtained by computing the torque
sensor input signal. Motor Control (Motor Control Current, A)
Based on the input signal, the P/S control module
determines the assist amount
and controls the current to
the motor suitable for that a ssist amount. This parameter
indicates that control value.
Motor Monitor (Motor Monitor Current, A)
This parameter indicates the actually measured value of
the current flowing to the motor. The motor circuit
condition is diagnosed by co mparing this parameter with
“Motor Control” parameter described previously.
Vehicle Speed (km/h, MPH)
Vehicle speed signal is fed from BCM. P/S control
module determines the amount of power assist based on
this vehicle speed signal and the torque sensor signal.
Engine Speed (rpm)
Engine speed signal is fed from the ECM so that it can
be used for trouble diagnos is of the electric power
steering system.
Motor Volt (V)
This parameter indicates the voltage between motor
terminals.
Ignition switch (ON, OFF)
This parameter indicates the condition of the power
supply through the ignition switch.
Visual InspectionS7RS0B6304007
Visually check the following pats and system.
P/S System Symptom DiagnosisS7RS0B6304008
This section describes trouble diagnosis of the P/S system parts whose trouble is not indicated by the on-board
diagnostic system (self-diagnostic functi on). When no malfunction is indicated by the on-board diagnostic system
(self-diagnosis function) and those stee ring basic parts as described in “Steering Symptom Diagnosis in Section 6A”
are all in good condition, check the following power steer ing system parts which may be a possible cause for each
symptom of the steering. Inspection Item Referring section
Battery Level, leakage, color “Batte ry Description in Section 1J”
Connectors of electric wire
harness Disconnection friction “Intermittent and Poor
Connection Inspection in Section 00”
Fuses Burning “Cautions in Body Electric al System Servicing in Section 9A”
Parts Installation, damage
Other parts that can be checked visually
Condition Possible cause Correction / Reference Item
Steering wheel feels
heavy (Perform “Steering
Force Check” before
diagnosis.) Steering wheel installed improperly
(twisted)
Install steering wheel correctly.
Poor performance of torque sensor Check torque sensor referring to “Torque
Sensor and Its Circuit Inspection”.
Poor performance of P/S motor Check motor referring to “P/S Motor and Its
Circuit Inspection”.
Steering gear case assembly faulty Replace.
Poor performance of vehicle speed
signal from ECM Check vehicle speed signal circuit referring to
“DTC C1121 / C1123 / C1124: VSS Circuit
Failure”.

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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.

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Reference waveform No.3
Motor output signal 1(1), Motor output signal 2(2), with
engine idling
Steering Wheel Play CheckS7RS0B6304024
• Check steering wheel for looseness or rattle by moving it in its shaft direction and lateral direction.
If found defective, repair or replace.
• Check steering wheel for play, holding vehicle in straight forward condition on the ground with engine
stopped.
If steering wheel play is not within specification,
inspect as follows and replace if found defective.
• Tie-rod end ball stud for wear (Ball stud should move when more than 0.2 N ⋅m (2 kg-cm, 0.44 lb-ft) torque is
applied.)
• Lower ball joint for wear
• Steering shaft joint for wear • Steering pinion or rack gear for wear or breakage
• Each part for looseness
Steering wheel play
“a”
: 0 – 30 mm (0 – 1.18 in.)
Steering Force CheckS7RS0B6304025
1) Place vehicle on level road and set steering wheel at
straight-ahead position.
2) Check if tire inflation pressure is as specified referring to the tire placard.
3) Remove driver air bag (inflator) module referring to “Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
4) Start engine.
5) With engine idling, measure steering force by turning torque wrench.
Steering force
: Less than 6.4 N ⋅m (0.64 kgf-m, 4.6 lb-ft)
6) Install driver air bag (inflator) module referring to “Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
Measurement
terminal
CH1: “E51-1” to vehicle body ground
CH2: “E51-2” to vehicle body ground
Oscilloscope
setting CH1: 5 V/DIV, CH2: 5 V/DIV
TIME: 20
µs/DIV
Measurement
condition • Engine is idling and steering wheel
is kept fully turned to left or right
until it stops
[A]: Steering wheel is kept fully turned left until it stops
[B]: Steering wheel is kept fully turned right until it stops
[C]: 12 V ON
[D]: GND ON
I6RS0B630019-01
I3RM0A630021-01
I3RM0A630022-01

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Repair Instructions
Steering Gear Case Assembly ComponentsS7RS0B6306001
3(a)
10
(c) 2
3
(a)
2 1
19
(g)
19 18(g) 6
11
8
9
(b) 7
(b)
22 23
24 4
5
14
15
16
(e)
17
(f)
12
(d) 21
(c)
20
4 6
5 7
(b)
9
(b)
8
13
22
23
24
A
A
1322
I7RS0B630013-02
1. Steering gear case 12. Steering gear case mounting No.3 bolt 23. Boot
2. Tie-rod lock washer 13. Gear rack side No.1 bracket 24. split pin
3. Tie-rod 14. Steering rack plunger
: Apply grease 99000-25050 to rack plunger. : 93 N
⋅m (9.3 kgf-m, 67.5 lb-ft)
4. Band 15. Steering rack plunger spring
: Apply grease 99000-25050 to spring end. : 45 N
⋅m (4.5 kgf-m, 32.5 lb-ft)
Refer to “Tie-Rod End Removal and
Installation”.
5. Boot 16. Steering rack damper screw
: Apply thread lock 99000-32110 to all around
thread part of rack damper screw. : 55 N
⋅m (5.5 kgf-m, 40.0 lb-ft)
6. Rack boot clip 17. Steering rack damper lock nut : 40 N⋅m (4.0 kgf-m, 29.0 lb-ft)
7. Tie-rod end lock nut 18. Heat insulator : Refer to “Steering Rack Plunger Removal
and Installation”.
8. Tie-rod end 19. Heat insulator bolt : 64 N⋅m (6.4 kgf-m, 46.5 lb-ft)

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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

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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

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Specifications
Tightening Torque SpecificationsS7RS0B6307001
NOTE
The specified tightening torque is also described in the following.
“Steering Gear Case Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
Tie-rod end nut 454.5 32.5 )
Tie-rod end lock nut 454.5 32.5 ) / )
Wheel nut 858.5 61.5 )
Steering gear case mounting No.1 bolt 555.5 40.0 )
Steering gear case mounting No.2 bolt 555.5 40.0 )
Steering gear case mounting No.3 bolt 404.0 29.0 )
Earth cable bolt 4.5 0.45 3.5)
Tie-rod 939.3 67.5 )
Rack damper screw 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. )
Rotation torquer of pinion 2.00.2 1.5 )
Rack damper screw lock nut 646.4 46.5 )
P/S control module bracket screw (ABS model) 9 0.9 6.5)
P/S control module bracket screw (ESP ®
model) 70
.7 5 .0 )
P/S control module mounting screw 50.5 3.7 )

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HVAC
Heater and Ventilation
General Description
Heater and Ventilation ConstructionS7RS0B7101001
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

I4RS0B710001-01
1. HVAC unit 5. Side ventilation air 9. Fresh air 13. Blower motor