2006 SUZUKI SWIFT Wheel cylinder assembly

Downloaded from www.Manualslib.com manuals search engine Table of Contents 5-iii
Gear Shift Control Lever and Cable Components...................................................... 5B-5
Gear Shift Control Le ver and Cable Removal
and Installation .................................................. 5B-6
Gear Select Control Cable Adjustment ............... 5B-6
Back Up Light Switch Removal and Installation ......................................................... 5B-7
Back Up Light Switch Inspection ......................... 5B-7
Manual Transaxle Unit Components ................... 5B-8
Manual Transaxle Unit Dismounting and Remounting....................................................... 5B-9
Gear Shift and Sele ct Shaft Assembly
Components.................................................... 5B-11
Gear Shift and Sele ct Shaft Assembly
Removal and Installation................................. 5B-11
Gear Shift and Select Shaft Disassembly and Assembly ........................................................ 5B-12
Manual Transaxle Assembly Components........ 5B-13
Fifth Gear Disassembly and Assembly ............. 5B-14
Manual Transaxle Assembly Disassembly and Reassembly ............................................. 5B-16
Transaxle Right Case Disassembly and Assembly ........................................................ 5B-23
Transaxle Left Case Disassembly and Assembly ........................................................ 5B-24
Input Shaft and Countershaft Components....... 5B-25
Input Shaft Assembly Disassembly and Reassembly .................................................... 5B-26
Countershaft Assembly Disassembly and Reassembly .................................................... 5B-28
Synchronizer Parts Inspec tion .......................... 5B-31
Gear Shift Shaft Components ........................... 5B-31
5th and Reverse Gear Shift Shafts Disassembly and Assembly ............................ 5B-32
Gear Shift Shaft and Fork Inspection ................ 5B-32
Differential Components ................................... 5B-33
Differential Disassembly and Assembly ............ 5B-33
Specifications ..................................................... 5B-35
Tightening Torque Specifications ...................... 5B-35
Special Tools and Equipmen t ........................... 5B-36
Recommended Service Material ....................... 5B-36 Special Tool ...................................................... 5B-36
Clutch ................
.............................. ......... 5C-1
General Description .............................................5C-1
Clutch Construction .............................................5C-1
Diagnostic Information and Procedures ............5C-2 Clutch System Symptom Diagnosis ....................5C-2
Repair Instructions ........... ...................................5C-2
Clutch Pedal Inspection ......................................5C-2
Clutch Fluid Level Inspection ..............................5C-3
Air Bleeding of Clutch System.............................5C-3
Clutch Pedal Position (CPP) Switch Removal and Installation ..................................................5C-4
Clutch Pedal Position (CPP) Switch Inspection and Adjustment ................................5C-5
Clutch Fluid Pipe and Hose Components ...........5C-5
Clutch Fluid Pipe Removal and Installation.........5C-6
Clutch Fluid Pipe Inspection................................5C-6
Clutch Master Cylinder Removal and Installation .........................................................5C-6
Clutch Operating Cylinder Removal and Installation .........................................................5C-7
Clutch Operating Cylinder Inspection..................5C-7
Clutch Pedal and Clutch Pedal Bracket Components ......................................................5C-7
Clutch Cover, Clutch Disc and Flywheel Components ......................................................5C-8
Clutch Cover, Clutch Disc and Flywheel Removal and Installation ...................................5C-8
Clutch Cover, Clutch Disc and Flywheel Inspection ........................................................5C-10
Clutch Release Syst em Removal and
Installation .......................................................5C-11
Clutch Release System Inspection ...................5C-13
Specifications .................... .................................5C-13
Tightening Torque Specifications ......................5C-13
Special Tools and Equipmen t ...........................5C-14
Recommended Service Material .......................5C-14
Special Tool ......................................................5C-14

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-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 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