2006 SUZUKI SWIFT System check

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
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1I6RS0B620001-01
I4RS0A620010-01
2
1
I4RS0B620002-04

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)
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I6RS0C620003-01

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.
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I6RS0C630002-01

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-6 Power Assisted Steering System:
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.

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-7
Step 1: Customer Complaint Analysis
Record details of the problem (failure, co mplaint) and how it occurred as described by the customer. For this purpose,
use of such an inspection form will fac ilitate collecting information to the point required for proper analysis and
diagnosis. Check if the problem described in “Customer ques tionnaire” occurs actually in the vehicle if necessary.
(This step should be performed with the customer if possible.) Customer problem inspection form (Example)
NOTE
This form is a standard sample. It should be modified according to conditions characteristic of each
market.

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