2008 SUZUKI SWIFT Turn

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-17
5) Remove gear shift locating bolts (1) with washers,
then take out locating springs and steel balls.
6) Remove back up light switch (2).
7) Remove reverse shaft bolt (2) with washer.
8) Remove case bolts (1) from outside and another bolts from clutch housing side.
9) Tapping left case flanges with plastic hammer, remove left case (3).
10) Pull out reverse gear shaft (1) with washer (2), then take off reverse idler gear (3).
11) Remove reverse gear shift lever bolts (4) and reverse gear shift lever (5).
12) Pull out 5th & reverse gear shift guide shaft (6) together with 5th & reverse gear shift shaft (7). 13) Tapping input shaft end with plastic hammer, push it
out as assembly from case a little, then take out
input shaft assembly (1), countershaft assembly (2),
high speed gear shift shaft (3) and low speed gear
shift shaft (4) all at once.
14) Remove countershaft left bearing outer race from left case (1) using special tool.
Special tool
(A): 09913–70123
15) Remove side bearing retainer bolts.
16) Turn side bearing retainer (1) counterclockwise until it stops, and remove side bearing retainer using 2 flat
end rods (2) or the like.
17) Remove O-ring from side bearing retainer.
I2RH01520032-01
I4RS0A520032-01
I4RS0A520033-01
I2RH01520035-01
(A)
1
I4RH01520021-01
1
2
2
I4RS0A520034-01

Downloaded from www.Manualslib.com manuals search engine 5C-2 Clutch:
Diagnostic Information and Procedures
Clutch System Symptom DiagnosisS7RS0B5304001
Repair Instructions
Clutch Pedal InspectionS7RS0B5306001
Cylinder Push Rod Play “A”1) Press clutch pedal (1) gradually with finger, stop when slight increase of resistance is felt and
measure how much pedal has moved (push rod
play) as represented by “A” as shown.
Push rod play
“A”: Max. 3 mm (0.12 in.)
2) If “A” is not within specification, replace master cylinder (3) or pedal arm (2). Clutch Pedal Free Travel “B”
1) Depress clutch pedal (1), stop the moment clutch resistance is felt, and measure how much pedal has
moved (clutch pedal free travel) as represented by
“B” in figure.
Clutch pedal free travel
“B”
: 2 – 8 mm (0.08 – 0.31 in.)
2) If “B” is not within specification, check pedal arm (2) and master cylinder (3) and replace defective part.
Condition Possible cause Correction / Reference Item
Slipping Improper clutch pedal free travel Replace master cylinder or clutch pedal arm.
Worn or oily clutch disc facing Replace disc.
Warped disc, pressure plate or flywheel
surface Replace disc, clutch cover or flywheel.
Weakened diaphragm spring Replace clutch cover.
Master cylinder piston or seal cup not
returning Replace master cylinder.
Dragging clutch Improper clutch pedal free travel Replace master cylinder or clutch pedal arm.
Weakened diaphragm spring, or worn
spring tip Replace clutch cover.
Rusted input shaft splines Lubricate.
Damaged or worn splines of transaxle
input shaft Replace input shaft.
Excessively wobbly clutch disc Replace disc.
Clutch facings broken or dirty with oil Replace disc.
Fluid leakage Repair or replace.
Clutch vibration Glazed (glass-like) clutch facings Repair or replace disc.
Clutch facings dirty with oil Replace disc.
Release bearing slides unsmoothly on
input shaft bearing retainer Lubricate or replace input shaft bearing
retainer.
Wobbly clutch disc, or poor facing
contact Replace disc.
Weakened torsion springs in clutch disc Replace disc.
Clutch disc rivets loose Replace disc.
Distorted pressure plate or flywheel
surface Replace clutch cover or flywheel.
Weakened engine mounting Replace engine mounting.
Loosened engine mounting bolt or nut Retighten engine mounting bolt or nut.
Noisy clutch Worn or broken release bearing Replace release bearing.
Input shaft front bearing worn down Replace input shaft bearing.
Excessive rattle of clutch disc hub Replace disc.
Cracked clutch disc Replace disc.
Pressure plate and diaphragm spring
rattling Replace clutch cover.
Grabbing clutch Clutch disc facings soaked with oil Replace disc.
Clutch disc facings excessively worn Replace disc.
Rivet heads showing out of facing Replace disc.
Weakened torsion springs Replace disc.

Downloaded from www.Manualslib.com manuals search engine 5C-6 Clutch:
Clutch Fluid Pipe Removal and InstallationS7RS0B5306007
Removal
CAUTION!
Do not allow fluid to get on painted surface. It
may cause painted surface damage.

1) Remove dust and dirt from each joint of pipe to be disconnected and clean around brake master
cylinder reservoir cap.
2) Take out fluid with syringe or such from brake master cylinder reservoir.
3) Pull clamp (1) of clutch master cylinder (3) and push clamp (5) of clutch operating cylinder (4) and then
disconnect clutch fluid pipe (2).
Installation
Reverse removal procedure for installation noting the
following.
CAUTION!
• Do not allow fluid to get on painted surface.
• Do not allow pipe to contact hard against vehicle body or other parts.

• Install each clamp securely.
• After installation, check clutch pedal free travel and bleed air from system referring to “Clutch Pedal
Inspection” and “Air Blee ding of Clutch System”.
• Check fluid leakage.
• Add fluid to MAX level of reservoir.
Clutch Fluid Pipe InspectionS7RS0B5306008
Check pipe (1) for dent, kink, crack, dirt and dust.
Replace if check result is not satisfactory.
Clutch Master Cylinder Removal and
Installation
S7RS0B5306009
Removal 1) 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 from clutch master cylinder (1) referring to “C lutch Fluid Pipe Removal
and Installation”.
3) Disconnect clutch reservoir hose (2).
4) Remove push rod from clutch pedal.
5) Turn clutch master cylinder (1) clockwise as shown in figure, and then remove it.
Installation
Reverse removal procedure for installation noting the
following.
• Apply grease to push rod tip.
“A”: Grease 99000–25100 (SUZUKI Silicone
Grease)
31
2
5
4
I4RS0B530003-01
3. Brake booster
1
I6RS0C530004-01
1
2
3
I4RS0B530005-01
“A”
I4RS0B530006-01

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 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 Clutch: 5C-11
Clutch Cover1) Check diaphragm spring (1) for abnormal wear or damage.
2) Inspect pressure plate (2) for wear or heat spots.
3) If abnormality is found, replace clutch cover. Do not disassemble it into diaphragm spring and
pressure plate.
Flywheel
Check surface contacting clutch disc for abnormal wear
or heat spots. Replace or repair as required.
Clutch Release System Removal and
Installation
S7RS0B5306016
Removal 1) Remove release arm by loosening its bolt.
2) Take out release bearing by turning release shaft (1).
3) Drive out No.2 bush usin g special tool and hammer.
Release shaft seal will also be pushed out.
Special tool
(A): 09922–46010
4) Remove release shaft (1). 5) Install tap (M16 X 1.5) (1) to clutch release shaft
No.1 bush.
6) Pull No.1 bush out using tap (1) and special tools. Special tool
(B): 09923–46020
(C): 09930–30104
Installation 1) Drive in a new No.1 bush using special tools and
hammer, and then apply grease to bush inside.
Special tool
(A): 09943–88211
(B): 09923–46030
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
I3RM0A530015-01
I4RS0A530020-01
IYSY01531016-01
IYSY01531017-01
I3RM0A530016-01

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 Steering General Diagnosis: 6A-2
Diagnostic Information and Procedures
Steering Symptom DiagnosisS7RS0B6104001
ConditionPossible cause Correction / Reference Item
Hard steering Tire not adequately inflated Inflate tires to proper pressure.
Malfunction of power steering system Check and correct.
Bind in tie-rod end ball studs or lower
ball joints Replace tie-rod end or front suspension arm.
Disturbed front wheel alignment Check and adjust front wheel alignment.
Bind in steering column Repair or replace steering column.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Too much play in steering Wheel bearings worn Replace wheel bearing.
Loose steering gear case bolts Tighten gear case bolts.
Faulty steering gear case assembly Replace steering gear case assembly.
Worn steering shaft joints Replace joint.
Worn tie-rod ends or tie-rod inside ball
joints Replace tie-rod end or tie-rod.
Worn lower ball joints Replace front suspension control arm.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Poor return ability Bind in tie-rod end ball studs Replace tie-rod end.
Bind in ball joints Replace front suspension control arm.
Bind in steering column Repair or replace steering column.
Disturbed front end alignment Check and adjust front end alignment.
Faulty steering gear case assembly Replace steering gear case assembly.
Tires not adequately inflated Adjust tire pressure.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Rack and pinion noise
(Rattle or chuckle) Loose steering gear case bolts
Tighten steering gear case bolts.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Faulty steering gear case assembly Replace steering gear case assembly.
Broken or other wise damaged wheel
bearing(s) Replace wheel bearing(s).
Wander or poor steering
stability Mismatched or uneven tires
Replace or inflate tires to proper pressure.
Loosen ball joints and tie-rod ends Replace suspension control arm or tie-rod end.
Faulty struts or mountings Replace strut or repair mounting.
Loose stabilizer bar Tighten or replace stabilizer bar or bush.
Broken or sagging springs Replace spring.
Rack and pinion adjustment Check and adjustment rack and pinion torque.
Disturbed front wheel alignment Check and adjust front wheel alignment.
Faulty steering gear case assembly Replace steering gear case assembly.
Erratic steering when
braking Worn wheel bearing(s)
Replace wheel bearing(s).
Broken or sagging spring(s) Replace coil spring(s).
Wheel tires are inflated unequally Inflate tires to proper pressure.
Disturbed front wheel alignment Check and adjust front wheel alignment.
Brakes not working in unison Check and repair brake system.
Leaking caliper Repair or replace caliper.
Warped discs Replace brake disc.
Badly worn brake pads Replace brake pads.