2008 SUZUKI SWIFT tightening torque

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-5
Clutch Pedal Position (CPP) Switch Inspection
and Adjustment
S7RS0B5306005
Inspection
Check for resistance between terminals under each
condition below. If check result is not satisfactory,
replace.
CPP switch resistance
When switch shaft is pushed (1): Continuity
When switch shaft is free (2): No continuityAdjustment
With clutch pedal depressed,
adjust switch (1) position
so that clearance between end of thread and clutch
pedal arm is within specification, and then tighten lock
nut to specified torque.
Clearance between end of thread and clutch pedal
arm
“a”: 3.5 – 4.0 mm (0.14 – 0.16 in.)
Tightening torque
CPP switch lock nut (a): 7.5 N·m (0.75 kgf-m, 5.5 lb-
ft)
Clutch Fluid Pipe and Hose ComponentsS7RS0B5306006
I5JB0A530006-01
(a)
1
“a”
I6RS0C530002-01
6
1
5
2 5
4(a)
3
I6RS0C530003-01
1. Master cylinder
: Apply grease 99000-25100 to push rod end. 5. Clamp
2. Pipe 6. Clutch reservoir hose
3. Operating cylinder : Apply grease 99000-25100 to rod tip. : 23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Operating cylinder bolt

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-7
Clutch Operating Cylinder Removal and
Installation
S7RS0B5306010
Removal1) Clean around brake master cylinder reservoir cap and take out fluid with syringe or such from brake
master cylinder reservoir.
2) Disconnect clutch fluid pipe (2) from operating cylinder referring to “Clutch Fluid Pipe Removal and
Installation”.
3) Remove clutch operating cylinder (1).
Installation
Reverse removal procedure for installation noting the
following. • Apply grease to push rod tip.
“A”: Grease 99000–25100 (SUZUKI Silicone
Grease)
• Tighten clutch operating cylinder bolt to specified torque.
Tightening torque
Clutch operating cylinder bolt: 23 N·m (2.3 kgf-
m, 17.0 lb-ft)
Clutch Operating Cylinder InspectionS7RS0B5306011
Check operating cylinder for damage and fluid leakage.
If malfunction is found, repl ace clutch operating cylinder.
Clutch Pedal and Clutch Pedal Bracket ComponentsS7RS0B5306012
2
1I4RS0A530010-01
“A”
I4RS0A530011-01
I6RS0C530005-01
1. Clutch pedal bracket 9. Pedal pad
2. Pedal bracket nut 10. Cushion
3. Pedal bracket bolt : Pedal bracket bolt must be tighten after pedal bracket nut. 11. Return spring
: Apply grease 99000-25011 to inside of spring.
4. Pedal shaft bolt 12. Pedal cover plate
5. Pedal bush : Apply grease 9900-25011 to outside of bush. 13. Pedal plate cushion
6. Pedal shaft spacer : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
7. Pedal shaft nut : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-9
3) Pull out input shaft bearing (1) from flywheel (2), use the following special tool if necessary.
Special tool
(A): 09921–26020
(B): 09930–30104
4) Remove flywheel (1) from crank shaft using special tool.
Special tool
(A): 09924–17811 Installation
CAUTION!
Do not reuse flywheel bolts. Otherwise, bolts
may loosen. Be sure to use new bolts with
pre-coated adhesive.

NOTE
Before assembling, make
sure that flywheel
surface and pressure plate surface have
been cleaned and dried thoroughly.

1) Install flywheel (2) to crankshaft and tighten new bolts (1) to specification.
Special tool
(A): 09924–17811
Tightening torque
Flywheel bolt (a): 70 N·m (7.0 kgf-m, 51.0 lb-ft)
2) Using special tool, install input shaft bearing to flywheel (1).
Special tool
(B): 09925–98210
I2RH01530023-01
I4RS0A530015-02
I2RH01530024-01
I4RS0A530016-01

Downloaded from www.Manualslib.com manuals search engine 5C-10 Clutch:
3) Aligning clutch disc to flywheel center using special
tool, install clutch cover (1) and bolts (2). Then
tighten bolts (2) to specification.
NOTE
• While tightening clutch cover bolts, compress clutch disc with special tool
(clutch center guide) by hand so that disc
is centered.
• Tighten cover bolts little by little evenly in diagonal order.

Special tool
(A): 09924–17811
(B): 09923–36320
Tightening torque
Clutch cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)
4) Slightly apply grease to input shaft (1), then join manual transaxle assembly with engine referring to
“Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
“A”: Grease 99000–25210 (SUZUKI Super
Grease I)
NOTE
When inserting transaxle input shaft to clutch
disc, turn crankshaft li ttle by little to match
the splines.

Clutch Cover, Clutch Disc and Flywheel
Inspection
S7RS0B5306015
Input Shaft Bearing
Check bearing (1) for smooth ro tation and replace it if
abnormality is found.
Clutch Disc
Measure depth of rivet head depression, i.e. distance
between rivet head and facing surface.
If depression is found to hav e reached service limit at
any of rivet holes (2), repl ace clutch disc assembly (1).
Rivet head depth
Standard: 1.65 – 2.25 mm (0.06 – 0.09 in.)
Limit: 0.5 mm (0.02 in.)
I4RS0A530017-01
I4RS0A530018-01
I3RM0A530014-01
I4RS0A530019-01

Downloaded from www.Manualslib.com manuals search engine 5C-12 Clutch:
2) Install release shaft.
3) Apply grease to No.2 bush (1) inside and press-fit it using the same special tool as in removal.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
Special tool
(A): 09922–46010
4) Coat grease to release shaft seal (2) lip and then install it till it is flush wit h case surface. Use special
tool for this installation a nd face seal lip downward
(inside).
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
Special tool
(B): 09925–98221
5) Caulk seal at A using caulking tool and hammer. 6) Apply grease to release bearing inside and release
shaft (2), then set release bearing (1).
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
7) Apply small amount of grease to input shaft (3) spline (0.3 g (0.01 oz)) and front end (0.15 g (0.005
oz)) as well.
“B”: Grease 99000–25210 (SUZUKI Super
Grease I)
8) Set release arm (1) to release shaft (2) aligning punch mark (4) of release arm and punch mark (3) of
release shaft, then tighten bolt to specified torque.
Tightening torque
Release lever bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)
I3RM0A530017-01
I4RS0A530021-01
(a)3
241
I4RS0A530022-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-13
Clutch Release System InspectionS7RS0B5306017
Clutch Release Bearing
Check clutch release bearing for smooth rotation. If
abnormality is found, replace it.
CAUTION!
Do not wash release bearing. Washing may
cause grease leakage and consequential
bearing damage.

Clutch Release Shaft
Check clutch release shaft and its pin for deflection or
damage.
If abnormality is found, replace it.
Specifications
Tightening Torque SpecificationsS7RS0B5307001
NOTE
The specified tightening torque is also described in the following.
“Clutch Fluid Pipe and Hose Components”
“Clutch Pedal and Clutch Pedal Bracket Components”
“Clutch Cover, Clutch Disc and Flywheel Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I3RM0A530020-01
I3RM0A530021-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
CPP switch lock nut 7.5 0.75 5.5 )
Clutch operating cylinder bolt 23 2.3 17.0 )
Flywheel bolt 70 7.0 51.0 )
Clutch cover bolt 23 2.3 17.0 )
Release lever bolt 23 2.3 17.0 )

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