Turn SUZUKI SWIFT 2008 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 5C-10 Clutch:
3) Aligning clutch disc to flywheel center using special
tool, install clutch cover (1) and bolts (2). Then
tighten bolts (2) to specification.
NOTE
• While tightening clutch cover bolts, compress clutch disc with special tool
(clutch center guide) by hand so that disc
is centered.
• Tighten cover bolts little by little evenly in diagonal order.

Special tool
(A): 09924–17811
(B): 09923–36320
Tightening torque
Clutch cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)
4) Slightly apply grease to input shaft (1), then join manual transaxle assembly with engine referring to
“Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
“A”: Grease 99000–25210 (SUZUKI Super
Grease I)
NOTE
When inserting transaxle input shaft to clutch
disc, turn crankshaft li ttle by little to match
the splines.

Clutch Cover, Clutch Disc and Flywheel
Inspection
S7RS0B5306015
Input Shaft Bearing
Check bearing (1) for smooth ro tation and replace it if
abnormality is found.
Clutch Disc
Measure depth of rivet head depression, i.e. distance
between rivet head and facing surface.
If depression is found to hav e reached service limit at
any of rivet holes (2), repl ace clutch disc assembly (1).
Rivet head depth
Standard: 1.65 – 2.25 mm (0.06 – 0.09 in.)
Limit: 0.5 mm (0.02 in.)
I4RS0A530017-01
I4RS0A530018-01
I3RM0A530014-01
I4RS0A530019-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-11
Clutch Cover1) Check diaphragm spring (1) for abnormal wear or damage.
2) Inspect pressure plate (2) for wear or heat spots.
3) If abnormality is found, replace clutch cover. Do not disassemble it into diaphragm spring and
pressure plate.
Flywheel
Check surface contacting clutch disc for abnormal wear
or heat spots. Replace or repair as required.
Clutch Release System Removal and
Installation
S7RS0B5306016
Removal 1) Remove release arm by loosening its bolt.
2) Take out release bearing by turning release shaft (1).
3) Drive out No.2 bush usin g special tool and hammer.
Release shaft seal will also be pushed out.
Special tool
(A): 09922–46010
4) Remove release shaft (1). 5) Install tap (M16 X 1.5) (1) to clutch release shaft
No.1 bush.
6) Pull No.1 bush out using tap (1) and special tools. Special tool
(B): 09923–46020
(C): 09930–30104
Installation 1) Drive in a new No.1 bush using special tools and
hammer, and then apply grease to bush inside.
Special tool
(A): 09943–88211
(B): 09923–46030
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
I3RM0A530015-01
I4RS0A530020-01
IYSY01531016-01
IYSY01531017-01
I3RM0A530016-01

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 Steering General Diagnosis: 6A-2
Diagnostic Information and Procedures
Steering Symptom DiagnosisS7RS0B6104001
ConditionPossible cause Correction / Reference Item
Hard steering Tire not adequately inflated Inflate tires to proper pressure.
Malfunction of power steering system Check and correct.
Bind in tie-rod end ball studs or lower
ball joints Replace tie-rod end or front suspension arm.
Disturbed front wheel alignment Check and adjust front wheel alignment.
Bind in steering column Repair or replace steering column.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Too much play in steering Wheel bearings worn Replace wheel bearing.
Loose steering gear case bolts Tighten gear case bolts.
Faulty steering gear case assembly Replace steering gear case assembly.
Worn steering shaft joints Replace joint.
Worn tie-rod ends or tie-rod inside ball
joints Replace tie-rod end or tie-rod.
Worn lower ball joints Replace front suspension control arm.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Poor return ability Bind in tie-rod end ball studs Replace tie-rod end.
Bind in ball joints Replace front suspension control arm.
Bind in steering column Repair or replace steering column.
Disturbed front end alignment Check and adjust front end alignment.
Faulty steering gear case assembly Replace steering gear case assembly.
Tires not adequately inflated Adjust tire pressure.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Rack and pinion noise
(Rattle or chuckle) Loose steering gear case bolts
Tighten steering gear case bolts.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Faulty steering gear case assembly Replace steering gear case assembly.
Broken or other wise damaged wheel
bearing(s) Replace wheel bearing(s).
Wander or poor steering
stability Mismatched or uneven tires
Replace or inflate tires to proper pressure.
Loosen ball joints and tie-rod ends Replace suspension control arm or tie-rod end.
Faulty struts or mountings Replace strut or repair mounting.
Loose stabilizer bar Tighten or replace stabilizer bar or bush.
Broken or sagging springs Replace spring.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Disturbed front wheel alignment Check and adjust front wheel alignment.
Faulty steering gear case assembly Replace steering gear case assembly.
Erratic steering when
braking Worn wheel bearing(s)
Replace wheel bearing(s).
Broken or sagging spring(s) Replace coil spring(s).
Wheel tires are inflated unequally Inflate tires to proper pressure.
Disturbed front wheel alignment Check and adjust front wheel alignment.
Brakes not working in unison Check and repair brake system.
Leaking caliper Repair or replace caliper.
Warped discs Replace brake disc.
Badly worn brake pads Replace brake pads.

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-9 Steering Wheel and Column:
Ignition Switch Cylinder Assembly Removal
and Installation (Non- Keyless Start Model)
S7RS0B6206008
Removal1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove steering column upper and lower covers.
4) Remove immobilizer co ntrol module referring to
“Immobilizer Control Modu le (ICM) Removal and
Installation in Section 10C”.
5) Remove ignition switch cy linder assembly as follows.
a) Turn ignition key to “ACC” position.
b) Insert 2 mm (0.078 in.) rod (2) through hole (3) and push ignition switch cylinder lock.
c) Detach ignition switch cylinder assembly (1) from steering lock assembly (4).
Installation 1) Install ignition switch cy linder assembly as follows.
a) Turn ignition key to “ACC” position.
b) In this state, push ignition switch cylinder assembly into steering lock assembly till it clicks.
2) Install immobilizer cont rol module referring to
“Immobilizer Control Modu le (ICM) Removal and
Installation in Section 10C”.
3) Install upper and lower cover and screws.
4) Connect negative (–) cable to battery.
5) Enabling air bag system referring to “Enabling Air Bag System in Section 8B”.
6) If ignition switch cylinder assembly (that is ignition
key) has replaced, register ignition key transponder
code to ECM referring to “R egistration of the Ignition
Key in Section 10C”.
Steering Lock Assembly (Ignition Switch)
Removal and Installation
S7RS0B6206009
Removal
1) Remove steering column. Refer to “Steering Column
Removal and Installation”.
2) Using center punch (1), loosen and remove steering lock mounting bolts (2).
NOTE
Use care not to damage aluminum part of
steering lock body with center punch.

3) Turn ignition key to “ACC” or “ON” position and remove steering lock a ssembly from steering
column.
Installation 1) Position oblong hole (1) of steering shaft (2) in the center of hole (3) in column (4).
2) Turn ignition key to “ACC” or “ON” position and install steering lock assemb ly (5) onto column (4).
3) Now turn ignition key to “LOCK” position and pull it out.
4) Align hub on lock with oblong hole (1) of steering shaft (2) and rotate shaft to assure that steering shaft
is locked.
2
3
1
4
I5JB0A620025-01
I4RS0B620005-02
1
32
4
5
I4RS0B620006-02

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 Power Assisted Steering System: 6C-3
EPS Diagnosis General DescriptionS7RS0B6301002
The P/S system in this vehicle is controlled by the P/S control module. T he P/S control module has an on-board
diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full
understanding of the outline of “On-Board Diagnostic Sy stem Description” and each item in “Precautions in
Diagnosing Troubles”, and then execute diagnosis according to “EPS System Check”.
On-Board Diagnostic System DescriptionS7RS0B6301003
The P/S control module performs the on -board diagnosis (self-diagnosis) on the system and operates the “EPS”
warning light (1) as follows.
• The “EPS” warning light lights when the ignition switch is turned to ON position (but the engine at stop) regardless
of the condition of the P/S co ntrol system. This is only to check if the “EPS” warning light is operated properly.
• If the areas monitored by the P/S control module is free from any trouble after the engine start (while engine is
running), the “EPS” warning light turns OFF.
• When the P/S control module detects a trouble which has occurred in th e monitored areas the “EPS” warning light
comes ON while the engine is running to warn the driver of such occurrence of the trouble and at the same time it
stores the exact trouble area in memory inside of the P/S control module.
Driving Cycle
A “Driving Cycle” consists of en gine startup and engine shutoff.
3 Driving Cycles Detection Logic
The malfunction detected in the first and second driving cycl e is stored in P/S control module memory (in the form of
pending DTC) but the “EPS” wa rning light does not light at these time. It lights up at t he third detection of same
malfunction also in the next driving cycle.
1
I6RS0C630002-01