2007 SUZUKI SWIFT Defect

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Reference waveform No.3
Motor output signal 1(1), Motor output signal 2(2), with
engine idling
Steering Wheel Play CheckS7RS0B6304024
• Check steering wheel for looseness or rattle by moving it in its shaft direction and lateral direction.
If found defective, repair or replace.
• Check steering wheel for play, holding vehicle in straight forward condition on the ground with engine
stopped.
If steering wheel play is not within specification,
inspect as follows and replace if found defective.
• Tie-rod end ball stud for wear (Ball stud should move when more than 0.2 N ⋅m (2 kg-cm, 0.44 lb-ft) torque is
applied.)
• Lower ball joint for wear
• Steering shaft joint for wear • Steering pinion or rack gear for wear or breakage
• Each part for looseness
Steering wheel play
“a”
: 0 – 30 mm (0 – 1.18 in.)
Steering Force CheckS7RS0B6304025
1) Place vehicle on level road and set steering wheel at
straight-ahead position.
2) Check if tire inflation pressure is as specified referring to the tire placard.
3) Remove driver air bag (inflator) module referring to “Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
4) Start engine.
5) With engine idling, measure steering force by turning torque wrench.
Steering force
: Less than 6.4 N ⋅m (0.64 kgf-m, 4.6 lb-ft)
6) Install driver air bag (inflator) module referring to “Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
Measurement
terminal
CH1: “E51-1” to vehicle body ground
CH2: “E51-2” to vehicle body ground
Oscilloscope
setting CH1: 5 V/DIV, CH2: 5 V/DIV
TIME: 20
µs/DIV
Measurement
condition • Engine is idling and steering wheel
is kept fully turned to left or right
until it stops
[A]: Steering wheel is kept fully turned left until it stops
[B]: Steering wheel is kept fully turned right until it stops
[C]: 12 V ON
[D]: GND ON
I6RS0B630019-01
I3RM0A630021-01
I3RM0A630022-01

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Tie-Rod End Boot On-Vehicle InspectionS7RS0B6306002
Check boot for crack and damage.
If any defect is found, replace it with a new one.
Tie-Rod End Removal and InstallationS7RS0B6306003
Removal1) Hoist vehicle, and then remove wheel referring to “Wheel Removal and Installation in Section 2D”.
2) Remove split pin (2) and tie-rod end nut (1) from steering knuckle.
3) Disconnect tie-rod end (1) from knuckle (2) using puller (3). 4) For ease of adjustment after installation, make
marking (1) of tie-rod end lock nut (2) position on tie-
rod end thread. Then, loosen lock nut and remove
tie-rod end (3) from tie-rod (4).
Installation 1) Install tie-rod end lock nut (1) and tie-rod end (2) to tie-rod (3). Align lock nut with mark (4) on tie-rod
thread.
9. Tie-rod end nut 20. Gear rack side No.2 bracket : 9.5 N⋅m (0.95 kgf-m, 7.0 lb-ft)
10. Steering gear case mounting No.1 bolt 21. Steering gear case mounting No.2 bolt : Do not reuse.
11. Steering gear case grommet 22. Clip
I3RM0A630024-01
21
I7RS0A630016-01
2 1
3
I4RS0A630040-01
I4RS0A630041-01
I4RS0A630042-01

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

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-11
5) Warm up engine to the normal operating temperature and keep it at the specified idle speed.
6) Turn A/C switch ON, set blower speed selector at maximum speed position, temperature selector at
maximum cold position, airflow selector at face
position, and air intake switch at recirculation
position. (Confirm that A/C compressor and
condenser fans are working.)
7) Wait for ten minutes to stabilize the A/C operation.
8) Open front windows, front doors and engine hood.
9) With about 20 mm (0.8 in.) of dry bulb thermometer
(1) put right in front of center ventilation louver and a
wet and dry bulb thermometer (2) near air inlet of
HVAC unit. 10) Check for each pressure of low side and high side if
it is within shaded range of graph. If each gauge
reading is out of specified pressure, correct defective
part referring to the following table.
NOTE
Pressure registered on gauge varies with
ambient temperature. Therefore, use the
graphs when determining if pressures are
normal or not.

Low side and high side pressure example,
Gauges should read as follows when ambient
temperature is 30 °C (86 °F)
Pressure on high pressure gauge (HI): 1590 –
1940 kPa (15.9 – 19.4 kg/cm2)
Pressure on low pressure gauge (LO): 270 – 430
kPa (2.7 – 4.3 kg/cm
2)
2
1
I4RS0B720004-01
[A]: Pressure of high pressure gauge
[B]: Pressure of low pressure gauge
[C]: Ambient temperature
[D]: Humidity [E]: Acceptable range
22
312.9 2200
0 1
2 3 30 70 30 70 %
4 5 6 7 8 9
10
11 12 13 14 15
16 17
18
19 21
298.7 2100
20
14.2 28.4 42.7 56.9 71.1 85.3 99.5
113.8 128.0 142.2
151.4
170.6
184.9 199.1
213.3 227.5
241.7
256.0
270.2
284.4
100 200 300 400 500 600 700 800 900
1000 1100 1200
1300
1400 1500 1600
1700 1800
1900
2000
25 30 35
77 86 95
psi kPa kg/cm
2
C
F
“A”
“B”
“C”
“D”
23
2300
327.1
[A]
[B]
[C][D][E]
[E]
I7RS0A721006-01

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Removal of Manifold Gauge Set
WARNING!
High pressure side is under high pressure.
Therefore, be careful not to get injured
especially on your eyes and skin.

For the A/C system charged with the specified amount of
refrigerant, remove manifold gauge set as follows:
1) Close low pressure side valve of manifold gauge set. (The high pressure side valve is closed continuously
during the process of charging.)
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service valves. This operation must be performed quickly.
5) Put caps on service valves.
Check A/C System for Refrigerant Leaks
Whenever a refrigerant leak is suspected in the system
or any service operation has been performed which may
result in malfunction of lines and connections, it is
advisable to check for leaks.
Common sense should be used during refrigerant leak
test, since the need and extent of any such test will, in
general, depend upon the nature of a complaint and the
type of a service performed on the system.
Liquid leak detector
WARNING!
• To prevent explosions and fires, make sure that there are no flammables in the vicinity.
• When the refrigerant exposed to fire, it turns into a poisonous gas (phosgene). Do
not inhale this gas.

There is a number of fittings and places throughout the
A/C system where a liquid leak detector solution may be
used to pinpoint refrigerant leaks.
By merely applying the solution to the area in question
with a swab, such as attached to the cap of a vial,
bubbles will form within seconds if there is a leak.
For confined areas, such as sections of the evaporator
and condenser, an electronic (refrigerant) leak detector
is more practical fo r determining leaks.
Special tool
(A): 09990–86012
Condenser Assembly On-Vehicle InspectionS7RS0B7216002
Check the followings.
• Clog of condenser fins If any clog is found, cond enser fins should be washed
with water and should be dried with compressed air.
• Condenser fins for leakage and breakage If any defects are found, repair or replace condenser.
• Condenser fittings for leakage. If any defects are found, repair or replace condenser.
Condenser Assembly Removal and InstallationS7RS0B7216003
CAUTION!
Do not damage condenser fins. If condenser
fin is bent, straighten it by using flat head
screwdriver or pair of pliers.

Removal
1) Recover refrigerant from A/C system referring to “Operation Procedure for Refrigerant Charge”.
NOTE
The amount of removed compressor oil must
be measured for replenishing compressor
oil.

2) Remove front bumper referring to “Front Bumper and Rear Bumper Components in Section 9K”.
3) Disconnect discharge hose (1) and liquid pipe (2) from condenser assembly (3).
4) Remove condenser assembly mounting bolts (4).
(A)
I5RS0C721006-01
4
1
3
2
I4RS0A720017-01

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HVAC Unit Removal and InstallationS7RS0B7216006
Removal1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Recover refrigerant from A/C system with recovery and recycling equipment referring to “Recovery” in
“Operation Procedure for Refrigerant Charge”.
4) Remove cowl top panel referring to “Cowl Top Components in Section 9K”.
5) Drain engine coolant, and then disconnect heater hoses (1) from HVAC unit (2).
6) Remove instrument panel from vehicle body referring to “Audio Unit Re moval and Installation in
Section 9C”.
7) Loosen suction hose and liquid pipe bolt (4).
8) Remove nuts (3).
9) Remove HVAC unit from vehicle body. Installation
Reverse removal procedure noting the following
instructions.
• Replenish specified amount of compressor oil to
compressor suction side referring to “Replenishing
Compressor Oil” in “Operation Procedure for
Refrigerant Charge”.
• Install the padding (1) to the installation hole uniformly.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
• Adjust control cables referr ing to “HVAC Control Unit
Removal and Installati on in Section 7A”.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Evaporator InspectionS7RS0B7216007
Check the followings.
• Clog of A/C evaporator fins.If any clogs are found, A/C evaporator fins should be
washed with water, and then should be dried with
compressed air.
• A/C evaporator fins for leakage and breakage. If any defects are found, repair or replace A/C
evaporator.
• A/C evaporator fittings for leakage. If any defects are found, repair or replace A/C
evaporator.
2. Blower upper case 8. Temperature control door assembly 14. Temperature control lever 20. Packing
3. Air intake control actuator 9. Blower motor resistor 15. Airflow control lever21. Filter cover (if equipped)
4. HVAC Air filter (if equipped) 10. Blower lower case 16. Evaporator22. Drain hose
5. Heater unit upper case 11. Blower motor 17. O-ring23. Cable lock clamp
6. Foot duct 12. Heater unit lower case 18. Expansion valve: Do not reuse.
3
2
3
3
1
4
I4RS0B720009-01
1
I4RS0B720010-01

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A/C Switch InspectionS7RS0B7216014
• Check that there is continuity between terminal (1) and terminal (2) when A/C s witch is at ON position.
• Check that there is no continuity between terminal (1) and terminal (2) when A/C s witch is at OFF position.
If check result does not meet the above conditions,
replace HVAC control unit.
Compressor Relay InspectionS7RS0B7216015
1) Disconnect negative (–) cable from battery.
2) Remove compressor relay (1) from main fuse box.
3) Check that there is no continuity between terminal “c” and “d”. If there is continuity, replace relay.
4) Connect battery positive (+ ) terminal to terminal “b”
of relay and battery negative (–) terminal to terminal
“a” of relay, and then check continuity between
terminal “c” and “d”. If there is no continuity, replace
relay.
Compressor Drive Belt Inspection and
Adjustment
S7RS0B7216016
Inspection
• Check compressor drive belt (1) for wear, crack, deformation and cleanliness. If any defect is found,
replace the belt with new one referring to
“Compressor Drive Belt Re moval and Installation”.
• Check compressor drive belt tension by measuring how much it deflects when pushed intermediate point
between magnet clutch pulley (6) and crankshaft
pulley (3) with about 100 N (10 kg) force after rotating
crankshaft pulley 360 °. If belt tension is out of
specification, adjust belt tension referring to
“Adjustment”.
Compressor drive belt tension
“a”
: 7 – 8mm (0.28 – 0.31 in.)
NOTE
When replacing drive belt, adjust drive belt
tension to the following specification.

New compressor dr ive belt tension “a”
: 6 – 7mm (0.24 – 0.28 in.)
Adjustment 1) Loosen tension pulley nut (4).
2) Adjust belt tension by ti ghten or loosen tension
pulley adjusting bolt (5).
3) Tighten tension pulley nut.
4) Rotate the crankshaft pulley 360 °, and then recheck
belt tension.
1 2
I4RS0B720013-01
"d"
"b" "a"
"c"
1
I4RS0B720014-01
2. Tension pulley
I4RS0A720033-01

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DTC B1546: A/C Refrigerant Pressure MalfunctionS7RS0B7224018
DTC Detecting Condition and Trouble Area
DTC Troubleshooting
DTC B1551: Serial Communication Circuit MalfunctionS7RS0B7224019
Wiring DiagramDTC detecting condition Trouble area
A/C refrigerant pressure sensor signal voltage is lower t han specified value
even though outside air temperature is higher than specified value for
specified time continuously. • Insufficient of refrigerant
• A/C refrigerant pressure sensor
• Outside air temperature sensor
• HVAC control module
Step
Action YesNo
1 A/C refrigerant pressure and outside air temperature
check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Start engine and select “DATA LIST” mode on scan tool.
3) Check “Refrigerant Pressure” and “Outside Air Temp” varies displayed on scan tool.
Is displayed each va ries described varies in “Scan Tool
Data”? Go to Step 2.
Check the amount of
refrigerant and system
for leaks.
2 A/C system performance check
1) Check A/C system performance referring to “A/C System
Performance Inspection”.
Is check result satisfactory? Go to Step 3.
Repair or replace
defective part.
3 A/C refrigerant pressure sensor check
1) Check A/C refrigerant pressure sensor referring to “A/C
Refrigerant Pressure Sensor and Its Circuit Inspection”.
Is check result satisfactory? Go to Step 4.
A/C refrigerant pressure
sensor faulty.
4 Outside air temperature sensor check
1) Check outside air temperature sensor referring to
“Information Display (Clock) Removal and Installation in
Section 9C”.
Is check result satisfactory? HVAC control module
faulty.
Outside air temperature
sensor faulty.
YEL17812910
65 431516 14 13 12 11
G52
789101920121112
65 431718 16 15 14 13
G51
G51-7
12V
2
3
G37-11
I5RS0A722016-01
1. HVAC control module 2. BCM3. Information display