2008 SUZUKI SWIFT 001

Downloaded from www.Manualslib.com manuals search engine 6C-32 Power Assisted Steering System:
DTC C1153: P/S Control Module Power Supply Circuit Voltage LowS7RS0B6304020
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Troubleshooting
MBLK
REDE51-1
E51-2
12V
5
[A ]
12 3
4 5 67
89
11
10
12 13
141516
17 18 19 20
[B ]
1
2
LT GRN
/BLKE52-1 E49-1
GRNGRNWHTBLK
WHY
6
3
4
4
4
4
1 2
E49-2BLK
I7RS0B630011-01
[A]: Connector “E52” (viewed from harness side)
2. Ignition switch5. P/S control module
[B]: Connector “E49” (viewed from harness side) 3. Junction block assembly 6. Individual circuit fuse box No.1
1. Main fuse box 4. Fuse
DTC detecting condition Trouble area
Power supply voltage of P/S control module is less than 9
V for 5 seconds continuously
(1 driving cycle detection logic) • P/S control module power supply circuit
• Undercharged Battery
• P/S control module
Step
Action YesNo
1 Was “EPS System Check” performed? Go to Step 2.Go to “EPS System
Check”.
2 Battery voltage check
1) Check circuit fuse for P/S control module.
2) If OK, measure voltage between positive battery terminal
and vehicle body ground with engine running.
Is voltage 10 V or more? Go to Step 3.
Check charging system
referring to “Generator
Test (Undercharged
Battery Check) in
Section 1J”.
3 P/S control module power supply circuit check
1) Check power supply circuit and ground circuit for P/S
control module referring to “P/S Control Module Power
Supply and Ground Circuit Check”.
Is check result in good condition? Substitute a known-
good P/S control
module and recheck.
Repair defective circuit.

Downloaded from www.Manualslib.com manuals search engine 6C-34 Power Assisted Steering System:
P/S Control Module Power Supply and Ground Circuit CheckS7RS0B6304022
Wiring Diagram
1
[A ]
123
4 5 67
89
11
10
12 13
141516
17 18 19 20
[B ]
7
1
2
MBLK
REDE51-1
E51-2
12V
LT GRN
/BLKE52-1 E49-1
GRNGRNWHTBLK
WHY
3
3
5
6
1 2
E49-2BLK
I7RS0B630012-01
[A]: Connector “E52” (viewed from harness side)
2. Ignition switch5. “EPS” fuse
[B]: Connector “E49” (viewed from harness side) 3. Individual circuit fuse box No.1 6. “IG1 SIG” fuse
1. Main fuse box 4. Junction block assembly7. P/S control module
StepAction YesNo
1 Circuit fuse check
1) Disconnect P/S control modu le connector with ignition
switch turned OFF.
2) Check for proper connection to P/S control module connector at “E49-1”, “E49-2” and “E52-1” terminals.
3) If OK, check “P/S” fuse and “IG1 SIG” fuse for blowing.
Are “P/S” fuse and “IG1 SIG” fuse in good condition? Go to Step 2.
Replace fuse(s) and
check for short in
circuits connected to
fuse(s).
2 Power supply circuit check
1) Measure voltage between “E49-1” terminal of P/S
control module connector and body ground.
Is voltage 10 - 14 V? Go to Step 3.
“GRN” or “BLK” wire is
open circuit.
3 Ignition signal check
1) Turn ignition switch to ON position.
2) Measure voltage between “E52-1” terminal of P/S
control module connector and body ground.
Is voltage 10 - 14 V? Go to Step 4.
“LT GRN/BLK” or “GRN”
wire is open circuit.
4 P/S control module ground circuit check
1) Turn ignition switch to OFF position.
2) Disconnect connectors from P/S control module.
3) Measure resistance between “E49-2” terminals of P/S
control module connector and body ground.
Is resistance 1
Ω or less? Go to Step 5. “BLK” wire is open or
high resistance circuit.

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Inspection of P/S Control Module and Its CircuitsS7RS0B6304023
The P/S control module (1) and its circuits can be checked at the P/S control module wiring couplers (2) by measuring
voltage and resistance.
CAUTION!
P/S control module cannot be checked by itself. It is strictly prohibited to connect voltmeter or
ohmmeter to the P/S control module with connectors disconnected from the P/S control module.

5 P/S control module ground circuit check
1) Connect connectors to P/S control module.
2) Start engine.
3) Measure voltage between “E49-2” terminals of P/S
control module connector and body ground when
steering wheel fully turned to left or right.
Is voltage 0.3 V or less? P/S Control Module
Power Supply and
Ground Circuit is in
good condition.
“BLK” wire is open or
high resistance circuit.
Step Action Yes No
[A]
12
3
4 5 67
89
11
10
12 13
141516
17 18 19 20
[B]
[C]
12
1
1 2
2
I6RS0C630016-03
[A]: Connector “E52” (viewed from harness side) [C]: Connector “E49” (viewed from harness side)
[B]: Connector “E51” (viewed from harness side)

Downloaded from www.Manualslib.com manuals search engine 6C-38 Power Assisted Steering System:
Reference waveform No.1
Motor output signal 1(1), Motor output signal 2(2), with
engine idlingReference waveform No.2
Motor output signal 1(1), Motor output signal 2(2), with
engine idling
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
at straight position
I6RS0B630017-01
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 µ
s/DIV
Measurement
condition • Engine is idling and steering wheel
is turned to left or right at turning
speed of 90 ° /sec
[A]: Steering wheel is turned left at turning speed of 90 ° /sec
[B]: Steering wheel is turned right at turning speed of 90 ° /sec
[C]: 12 V ON
[D]: GND ON [E]: 1 duty cycle
I6RS0B630018-01

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-39
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

Downloaded from www.Manualslib.com manuals search engine 6C-40 Power Assisted Steering System:
Repair Instructions
Steering Gear Case Assembly ComponentsS7RS0B6306001
3(a)
10
(c) 2
3
(a)
2 1
19
(g)
19 18(g) 6
11
8
9
(b) 7
(b)
22 23
24 4
5
14
15
16
(e)
17
(f)
12
(d) 21
(c)
20
4 6
5 7
(b)
9
(b)
8
13
22
23
24
A
A
1322
I7RS0B630013-02
1. Steering gear case 12. Steering gear case mounting No.3 bolt 23. Boot
2. Tie-rod lock washer 13. Gear rack side No.1 bracket 24. split pin
3. Tie-rod 14. Steering rack plunger
: Apply grease 99000-25050 to rack plunger. : 93 N
⋅m (9.3 kgf-m, 67.5 lb-ft)
4. Band 15. Steering rack plunger spring
: Apply grease 99000-25050 to spring end. : 45 N
⋅m (4.5 kgf-m, 32.5 lb-ft)
Refer to “Tie-Rod End Removal and
Installation”.
5. Boot 16. Steering rack damper screw
: Apply thread lock 99000-32110 to all around
thread part of rack damper screw. : 55 N
⋅m (5.5 kgf-m, 40.0 lb-ft)
6. Rack boot clip 17. Steering rack damper lock nut : 40 N⋅m (4.0 kgf-m, 29.0 lb-ft)
7. Tie-rod end lock nut 18. Heat insulator : Refer to “Steering Rack Plunger Removal
and Installation”.
8. Tie-rod end 19. Heat insulator bolt : 64 N⋅m (6.4 kgf-m, 46.5 lb-ft)

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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