2007 SUZUKI SWIFT assembly removal

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 Manual Transmission/Transaxle: 5B-11
Gear Shift and Select Shaft Assembly ComponentsS7RS0B5206010
Gear Shift and Select Shaft Assembly Removal
and Installation
S7RS0B5206011
Removal1) Remove gear shift interlock bolt (1) and 5th to reverse interlock guide bolt (2) from transaxle case.
2) Remove gear shift & select shaft assembly (3). Installation
1) Apply grease to select lever shaft bush and select lever boss, and install gear shift and select shaft
assembly with new gasket into transaxle.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
2) Apply sealant to gear shift guide case bolts (1). Tighten gear shift guide case bolts to specified
torque.
B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Gear shift guide case bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lb-ft)
3) Tighten select lever brac ket bolt with select lever
bracket to specified torque.
Tightening torque
Select lever bracket bolt: 23 N·m (2.3 kgf-m, 17.0
lb-ft)
I6RS0C520010-01
1. Gear shift & select shaft 7. Gear shift guide case bolt
: Apply sealant 99000-31260 to bolt thread. 13. Select lever boss
: Apply grease 99000-25011 to internal and
external diameter.
2. 5th & reverse gear shift cam 8. Select lever bracket bolt : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
3. Gear shift interlock plate 9. 5th to reverse interlock guide bolt
: Apply sealant 99000-31260 to bolt thread. : Do not reuse.
4. Gear shift & select lever 10. Gear shift interlock bolt
: Apply sealant 99000-31260 to bolt thread. : Apply transaxle oil.
5. Shift cable lever 11. Guide case
6. Select cable lever 12. Select lever shaft bush
: Apply grease 99000-25011 to whole area of bush.
3
12I4RS0A520024-01

Downloaded from www.Manualslib.com manuals search engine 5B-14 Manual Transmission/Transaxle:
Fifth Gear Disassembly and AssemblyS7RS0B5206014
Disassembly1) Remove cover bolts and take off transaxle side cover (1).
CAUTION!
Care should be taken not to distort side cover
when it is removed from left case.

2) Using snap ring pliers, remove circlip (1).
3) Remove 5th shift fork bolt (2).
4) Remove gear shift fork (3), synchronizer sleeve &
hub assembly (4), synchron izer levers, synchronizer
ring and input shaft 5th gear (5) all together. Use
gear puller for removal if spline fitting of hub is tight. 5) Unfasten caulking of countershaft nut (2), install
input shaft 5th gear (1) and special tool to stop
rotation of shafts, and then remove countershaft nut
(2).
Special tool
(A): 09927–76060
6) Remove input shaft 5th gear, needle bearing and then countershaft 5th gear (1). Gear puller (2) would
be necessary if spline fitting of countershaft 5th gear
is tight.
11. Sensor cap 34. Washer
12. Oil gutter bolt : Apply thread lock 99000-32110 to all around thread part of bolt. 35. Side bearing retainer
13. Left case plate bolts : Apply thread lock 99000-32110 to all around thread part of bolt. 36. O-ring
14. Sensor cap bolt 37. Oil seal
: Apply grease 99000-25011 to oil seal lip.
15. Side cover bolts 38. Outer race
16. Transaxle case bolts 39. Breather hose
17. 5th speed synchronizer ring 40. Side bearing retainer bolt
18. 5th speed synchronizer lever : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
19. 5th speed synchronizer sleeve & hub : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
20. Circlip :10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
21. Bearing set shim : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft)
22. Countershaft 5th gear : Do not reuse.
23. Countershaft nut : After tightening nut to specified torque, caulk nut securely. : Apply transaxle oil.
I4RS0A520027-01
342
1
5
I4RS0A520028-01
1(A)
2
I3RM0B521014-01
I4RS0A520041-01

Downloaded from www.Manualslib.com manuals search engine 5B-16 Manual Transmission/Transaxle:
5) Fit 5th gear shift fork (1) to synchronizer sleeve (2) and hub (3) assembly and install them into input
shaft and gear shift shaft aligning punch mark (4)
with matching mark (5) on input shaft.
6) Tighten shift fork bolt (2) to which thread lock cement
has been applied.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Shift fork bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
7) Using snap ring pliers, inst all new circlip (1) to input
shaft (3) in specified direction as shown in figure. 8) Clean mating surface of both left case (2) and side
cover (1), apply sealant to side cover (1) as shown in
figure by such amount t hat its section is 1.5 mm
(0.059 in.) in diameter, mate it with left case and then
tighten bolts to specified torque.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
Manual Transaxle Assembly Disassembly and
Reassembly
S7RS0B5206015
Disassembly
1) Remove gear shift and select shaft assembly referring to “Gear Shift an d Select Shaft Assembly
Removal and Installation”.
2) Remove fifth gear referring to “Fifth Gear Disassembly and Assembly”.
3) Remove left case plate.
4) Remove snap ring (1) using snap ring pliers (2).
4. Polished surface
I4RS0A520029-01
2, (a), “A”
1 33
4
1
I4RS0A520030-01
2. Input shaft 3. Input shaft left bearing
I4RS0A520031-01
1
2
2
3
I6RS0C520012-01

Downloaded from www.Manualslib.com manuals search engine 5B-22 Manual Transmission/Transaxle:
14) With putting a shim (2) on bearing outer race (3), place straightedge (1) over it and compress it by
hand through straightedge, and then measure
clearance “a” between case surface (4) and
straightedge using feeler gauge (5).
Clearance between case surface and
straightedge (Shim protrusion)
“a”: 0.08 – 0.12 mm (0.0032 – 0.0047 in.)
15) By repeating Step 14), select a suitable shim which adjusts clearance “a” to specification and put it on
bearing outer race.
NOTE
Insert 0.10 mm (0.0039 in.) feeler to know
whether or not a shim fulfills specification
quickly.

Available shim thickness
16) Place left case plate (2) inserting its end in groove of shift guide shaft (4) and tighten bolts (1) to which
thread lock cement has been applied.
NOTE
After tightening bolts, make sure that
countershaft (5) can be rotated by hand
feeling certain load.

“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Left case plate bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
17) Install fifth gear referring to “Fifth Gear Disassembly and Assembly”.
18) Install gear shift and select shaft assembly referring to “Gear Shift and Select Shaft Assembly Removal
and Installation”.
19) Install back up light switch referring to “Back Up Light
Switch Removal and Installation”.
20) Check input shaft for rotation in each gear position.
21) Also confirm continuity of back up light switch in
reverse position using ohmmeter.
0.55 mm (0.021 in.) 0.90 mm (0.035 in.)
0.60 mm (0.023 in.) 0.95 mm (0.037 in.)
0.65 mm (0.025 in.) 1.00 mm (0.039 in.)
0.70 mm (0.027 in.) 1.05 mm (0.041 in.)
0.75 mm (0.029 in.) 1.10 mm (0.043 in.)
0.80 mm (0.031 in.) 1.15 mm (0.059 in.)
0.85 mm (0.033 in.)
I3RM0A520031-01
3. Input shaft
I4RS0A520042-01

Downloaded from www.Manualslib.com manuals search engine 5C-8 Clutch:
Clutch Cover, Clutch Disc and Flywheel ComponentsS7RS0B5306013
Clutch Cover, Clutch Disc and Flywheel
Removal and Installation
S7RS0B5306014
Removal1) Dismount manual transaxle assembly referring to “Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
2) Hold flywheel with specia l tool and remove clutch
cover bolts (1), clutch cover (2) and clutch disc.
Special tool
(A): 09924–17811
8. Clutch pedal : Apply grease 99000-25011 to outside surface of pin.
(a)
(b)
(b)
A
A
A
12
115
6
A3
A4
710
2
98
1
I4RS0A530013-02
1. Flywheel 9. Clutch disc
2. Flywheel bolt 10. Clutch cover bolt
3. Clutch release shaft seal : Apply grease 99000-25011 to seal lip. 11. Release arm
4. Clutch release shaft No.2 bush : Apply grease 99000-25011 to bush inside. 12. Release arm bolt
5. Clutch release shaft : Apply grease 99000-25011 to the end of release shaft arm. :70 N
⋅m (7.0 kgf-m, 51.0 lb-ft)
6. Clutch release shaft No.1 bush : Apply grease 99000-25011 to bush inside. :23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
7. Release bearing : Apply grease 99000-25011 to joint of bearing and release shaft and also bearing inside. Do not reuse.
8. Clutch cover
I4RS0A530014-01

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