2006 SUZUKI SWIFT Moto

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-9
Manual Transaxle Unit Dismounting and
Remounting
S7RS0B5206009
Dismounting1) Drain coolant and transaxle oil.
2) Remove coolant reservoir with reservoir hose.
3) Remove battery and tray.
4) Remove air cleaner case and resonator.
5) Disconnect gear shift and gear select control cables (1) while pressing claws (2) of clip (3).
6) Disconnect back up light switch coupler and undo wiring harness clamps.
7) Remove ground cable from transaxle.
8) Remove clutch operating cylinder with fluid hose from transaxle.
9) Remove water inlet No.2 pipe from transaxle.
10) Remove starting motor re ferring to “Starting Motor
Dismounting and Remounting in Section 1I”.
11) Remove transaxle to engine bolts (1) of upper side. 12) Support engine using supporting device (1).
CAUTION!
Do not apply supporting device to projection
part A. If do so, it may be deformed.

13) Remove front drive shafts and center shaft referring
to “Front Drive Shaft Assembly Removal and
Installation in Section 3A”.
14) Remove exhaust No.2 pipe referring to “Exhaust Pipe and Muffler Removal a nd Installation in Section
1K”.
15) Remove clutch housing lower plate (1).
1
2
3
I7RS0A521003-01
1
1
I4RS0A520018-01
1
A
I4RS0A520019-01
1I4RS0A520020-01

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 6C-2 Power Assisted Steering System:
General Description
P/S System DescriptionS7RS0B6301001
This power steering (P/S) system consists of a P/S control module (3), a torque sensor (4), a motor (5). In this system,
the P/S control module determines the level and direction of the assist force for the steering wheel (1) according to the
signals from the torque sensor and vehicle speed signal from ECM. The P/S control module runs the motor so as to
assist the operation of the steering wheel.
The P/S control module diagnoses troubles which may occur in the area including the following components when the
ignition switch is ON and the engine is running. When the P/S control module detects any malfunction, it stops the
motor operation.
• Torque sensor
• Vehicle speed signal
• Engine speed signal
• P/S motor
• P/S control module.
2. Steering column 7. Battery9. ABS/ESP® control module
6. Steering gear case assembly 8. ECM10. Wheel speed sensor (right-front, left-front)
7
3
9
10
10
1
2
4
5
6
8
I7RS0B630001-01

Downloaded from www.Manualslib.com manuals search engine 6C-4 Power Assisted Steering System:
Schematic and Routing Diagram
EPS System Wiring Circuit DiagramS7RS0B6302001
M
5V
BRNRED/
BLU
BLK
RED
WHT
BLU
GRN
BRN YEL
E52-11
E52-14E52-12
E23-4
E23-26
E23-25 E51-1
E51-2
E52-18
E53-5
E53-7
E52-6
E52-8
E53-2
E52-9
E52-16
E52-19
GRY
PPL/WHT
[A ]
[E ]
12 3
4 5 67
89
11
10
12 13
141516
17 18 19 20
1
2
[B ][C ]
1210 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
[D]
5V
PPL
E52-4
11
12
13 14
15
10
9
16
12V
5V
5V
12V
REDE52-20E53-6
E53-4
E53-1
7654321
5
REDRED/
BLKWHT
6WHTWHT/BLKWHTBLK
12V
12V
17BLK
GRY
LT GRN
/BLK
E52-1
E52-5
E49-1
GRNGRNWHTBLK
WHY
G28-25G28-31
RED/BLK
18
3
4
4
7 8
4
4
1 2
4
E49-2BLK
I7RS0B630002-01
[A]: Connector “E52” (viewed from harness side) 4. Fuse 12. P/S motor
[B]: Connector “E49” (viewed from harness side ) 5. Left-front wheel speed sensor 13. Shield
[C]: Connector “E51” (viewed from harness side) 6 . Right-front wheel speed sensor 14. Torque sensor
[D]: Connector “G28” (viewed from harness side) 7. Combination meter 15. Torque sensor amplifier
[E]: Connector “E53” (viewed from harness side) 8. “EPS” warning light16. To ECM, BCM, Air bag SDM and ABS control module assembly
1. Main fuse box 9. Date link connector (DLC) 17. ABS/ESP ® control module
2. Ignition switch 10. ECM18. Individual circuit fuse box No.1
3. Junction block assembly 11. P/S control module

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-5
Terminal Arrangement of P/S Control Module Coupler (Viewed from Harness Side)
Diagnostic Information and Procedures
EPS System CheckS7RS0B6304001
WARNING!
Carry out test drive in light traffic area to prevent an accident.

Refer to the following items for the details of each step.Terminal Circuit Terminal Circuit
E49-1 Main power supply for internal memory
and EPS motor E52-9 Ground for torque sensors
E49-2 Ground for P/S control module E52-10 —
E51-1 Motor output 1 E52-11 Serial communication for data link
connector
E51-2 Motor output 2 E52-12 Engine speed signal
E52-1 Ignition switch signal for P/S control
module E52-13 —
E52-2 — E52-14 P/S operation signal (idle up signal)
E52-3 — E52-15 —
E52-4 Vehicle speed signal E52-16 Torque sensor internal failure signal
E52-5 “EPS” warning light E52-17 —
E52-6 Torque sensor signal (Sub) E52-18 Torque sensor signal (Main)
E52-7 — E52-19 Ground for shield wire
E52-8 Main power supply for torque sensor E52-20 5 V reference power supply for torque
sensor
Step
Action YesNo
1 ) Customer complaint analysis
1) Perform customer complaint analysis referring to “Customer Complaint Analysis”.
Was customer complaint analysis performed? Go to Step 2.
Perform customer
complaint analysis.
2 ) DTC check, record and clearance
1) Check for DTC (including pending DTC) referring to “DTC Check”, Record and Clearance.
Is there any DTC(s)? Print DTC or write them
down and clear them by
referring to “DTC
Clearance” and go to
St ep 3 .Go to Step 4.
3 ) Visual inspection
1) Perform visual inspection referring to “Visual Inspection”.
Is there any faulty condition? Repair or replace
malfunction part, and go
to Step 11.
Go to Step 5.
4 ) Visual inspection
1) Perform visual inspection referring to “Visual Inspection”.
Is there any faulty condition? Repair or replace
malfunction part, and go
to Step 11.
Go to Step 8.
5 ) Trouble symptom confirmation
1) Confirm trouble symptom referring to “Trouble Symptom Confirmation”.
Is trouble symptom identified? Go to Step 6.
Go to Step 7.
6 ) 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 8.

Downloaded from www.Manualslib.com manuals search engine 6C-10 Power Assisted Steering System:
) C1121 No vehicle speed signal
(60 seconds or more) Vehicle speed signal is 0 km/h
even though engine speed is
more than 4000 rpm for more than
60 seconds continuously (before
elapse of 5 min from engine start)
or vehicle speed signal is 0 km/h
even though engine speed is
more than 2500 rpm for more than
60 seconds continuously (after
elapse of 5 min for engine start). • Vehicle speed signal circuit
• Wheel speed sensor
•ECM
• P/S control module
• ABS control module
• CAN communication circuit
Not
applicable
) C1122 Engine speed signal Engine speed signal is less than
220 rpm for more than 0.8
seconds.
or
Engine speed signal is less than
220 rpm for more than 20
seconds continuously even
though vehicle speed signal is
more than 50 km/h.• Engine speed signal circuit
•ECM
• P/S control module
• Vehicle speed signal
1 driving
cycle
) C1123 No vehicle speed signal
(30 seconds or more) Vehicle speed signal is 0 km/h
with continuously more than 3
driving cycles even though engine
speed is more than 4000 rpm for
more than 30 seconds
continuously (before elapse of 5
min from engine start).
or
vehicle speed signal is 0 km/h
with continuously more than 3
driving cycles even though engine
speed is more than 2500 rpm for
more than 30 seconds
continuously (after elapse of 5 min
for engine start). • Vehicle speed signal circuit
• Wheel speed sensor
•ECM
• P/S control module
• ABS control module
• CAN communication circuit
3 driving
cycles
) C1124 Vehicle speed performance
(Impossible deceleration) Vehicle speed signal is less than 5
km/h for more
than 5 seconds
continuously with more than
specified deceleration speed (–20
m/s
2) from over 20 km/h. Not
applicable
) C1141 P/S motor circuit voltage Voltage between both motor drive
circuits is more than 8.5 V or less
than 0.2 V for 0.5 seconds
continuously while motor is not
drived.
• P/S motor circuit
• P/S motor
• P/S control module1 driving
cycle
) C1142 P/S motor circuit range /
performance Measured motor drive current is
more than 10 A as compared with
target motor drive current. 1 driving
cycle
DTC No. Detecting item
Detecting condition
(DTC will set when detecting) Trouble area MIL

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-11
Scan Tool DataS7RS0B6304006
NOTE
When P/S motor is cold condition (that is, armature coil of P/S motor is not heated), normal value with
asterisk (*) mark in the following table is displayed on scan tool.

) C1143 P/S motor circuit current too
high Measured motor drive current is
more than 50 A.
• P/S motor circuit
• P/S motor
• P/S control module1 driving
cycle
) C1145 P/S motor circuit current too
low Measured motor drive current is
less than 2 A continuously for
more than 3 seconds even though
target motor drive current is more
than 4 A.
or
Measured motor drive current is
less than 0.8 A for total 1 second
even though motor control duty is
more than 90% while target motor
drive current is less than 8 A. 1 driving
cycle
) C1153 P/S control module power
supply circuit Power supply voltage of P/S
control module is less than 9 V for
5 seconds continuously. • P/S control module power
supply circuit
• Undercharged Battery
• P/S control module 1 driving
cycle
) C1155 P/S control module internal
failure Internal memory (EEPROM) is
data error.
• P/S control moduleNot
applicable
Internal circuit is faulty.
or
Power supply voltage of P/S
control module exceeded 17.5 V. • Overcharged Battery
• P/S control module
1 driving
cycle
DTC No. Detecting item
Detecting condition
(DTC will set when detecting) Trouble area MIL
Scan tool data
Vehicle conditionNormal condition
) Battery Voltage
Ignition switch ON 10 – 14 V
) TQS Power Supply 10 – 14 V
) TQS Main Torque Engine running at idle speed Steering wheel at fully turned to left –9.4 – 0 N
⋅m
Steering wheel at free 0 N⋅m
Steering wheel at fully turned to right 0 – 9.4 N ⋅m
) TQS Sub Torque Engine running at idle speed Steering wheel at fully turned to left –9.4 – 0 N
⋅m
Steering wheel at free 0 N⋅m
Steering wheel at fully turned to right 0 – 9.4 N ⋅m
) Assist Torque Engine running at idle speed Steering wheel at fully turned to left –9.4 – 0 N
⋅m
Steering wheel at free 0 N⋅m
Steering wheel at fully turned to right 0 – 9.4 N ⋅m
) Motor Control Engine running at idle speed Steering wheel at free
0 A
Steering wheel at fully turned to left or right *35 – 45 A
) Motor Monitor Engine running at idle speed Steering wheel at free
0 A
Steering wheel at fully turned to left or right *35 – 45 A
) Vehicle Speed Engine running and vehicle at stop 0 km/h
) Engine Speed Engine running at idle speed after warming up 700 ± 50 rpm
) Motor Volt Engine running at idle speed Steering wheel at free
0.8 – 1 V
Steering wheel at fully turned to right About 5 V
) Ignition switch Ignition switch ON ON