2008 SUZUKI SWIFT Direction

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-29
5) Apply bearing puller (3) to 1st gear (2) and drive out low speed synchronizer sleeve & hub assembly (1)
with 1st gear using hydraulic press.
CAUTION!
To avoid gear tooth from being damaged,
support it at flat side of bearing puller.

6) Disassemble low speed synchronizer sleeve & hub assembly.
7) Take out 1st gear needle bearing from shaft.
8) Remove right bearing cone (2) using bearing puller (3), metal stick (1) and hydraulic press.
Reassembly 1) Clean all components thor oughly, inspect them for
any abnormality and replace with new ones as
necessary.
2) To ensure lubrication of countershaft (1), air blow oil holes (2) and make sure that they are free from any
obstruction. 3) Fit low speed synchronizer sleeve (4) to hub (3),
insert 3 keys (2) in it and then set springs (1) as
shown in figure.
NOTE
• No specific direction is assigned to each key but it is assigned as sleeve & hub
assembly.
• Size of low speed synchronizer keys and springs are the largest compared with
those of high speed and 5th speed ones.

Synchronizer key installation position
A = B
4) Install right bearing cone (1) to countershaft (2) using special tool and hammer.
Special tool
(A): 09923–78210
I2RH01520057-01
I2RH01520058-01
I2RH01520060-01
[A]: 1st gear side D: Short flange
C: Key way
I3RM0A520051-01
I2RH01520062-01

Downloaded from www.Manualslib.com manuals search engine 6C-2 Power Assisted Steering System:
General Description
P/S System DescriptionS7RS0B6301001
This power steering (P/S) system consists of a P/S control module (3), a torque sensor (4), a motor (5). In this system,
the P/S control module determines the level and direction of the assist force for the steering wheel (1) according to the
signals from the torque sensor and vehicle speed signal from ECM. The P/S control module runs the motor so as to
assist the operation of the steering wheel.
The P/S control module diagnoses troubles which may occur in the area including the following components when the
ignition switch is ON and the engine is running. When the P/S control module detects any malfunction, it stops the
motor operation.
• Torque sensor
• Vehicle speed signal
• Engine speed signal
• P/S motor
• P/S control module.
2. Steering column 7. Battery9. ABS/ESP® control module
6. Steering gear case assembly 8. ECM10. Wheel speed sensor (right-front, left-front)
7
3
9
10
10
1
2
4
5
6
8
I7RS0B630001-01

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-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 7A-8 Heater and Ventilation:
b. Move temperature control lever (1) and air flow control plate (2) fully to the arrow direction. c. Fix temperature control inner cable (1) to pin of
temperature control lever and air flow control inner
cable (2) to pin of air fl ow control plate, and then
fix each outer cable (3) to each cable lock clamp.
NOTE
After installing control cables, make sure that
control lever and plate move smoothly and
stop at proper position.

• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
• Make sure that air flow outlet changes correctly as air flow selector is changed.
[A]: LH steering vehicle [B]: RH steering vehicle
1
2
[A]
[B]
1
2
I4RS0B710014-01
[A]: LH steering vehicle [B]: RH steering vehicle
1
2
[B] [A] 3
3
1
3
23
I4RS0B710015-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-19
Charge
CAUTION!
• Because the sight glass is not used for this A/C system, do not perform an additional
charge to the A/C system. To charge the
proper amount of refrigerant, recover and
evacuate the A/C system first. And then,
charge the proper amount of refrigerant
into the A/C system.
• Always charge refrigerant through low pressure side of A/C system after the initial
charge is performed from the high
pressure side with the engine stopped.
• Never charge refrigerant through high pressure side of A/C system with engine
running.
• Do not charge refrigerant while compressor is hot.
• When installing tap valve to refrigerant container to make a hole there through,
carefully follow dire ctions given by
manufacturer.
• A pressure gauge should always be used before and during refrigerant charge.
• The refrigerant container should be emptied of refrigerant when discarding it.
• The refrigerant container should not be heated up to 40 °C (104 °F) or over.
• Refrigerant container should not be reversed in direction during refrigerant
charge. Reversing in direction causes
liquid refrigerant to enter compressor,
causing troubles, such as compression of
liquid refrigerant and the like.

NOTE
The air conditioning system contains HFC-
134a (R-134a).
Described here is a method to charge the air
conditioning system with refrigerant from the
refrigerant service container.
When charging refrigerant recovered by
using the refrigerant and recycling
equipment (when recycling refrigerant),
follow the procedure described in the
equipment manufacturer’s instruction
manual.

Charge proper amount of refrigerant accurately in
accordance with the following procedure.
Specified amount of refrigerant
370 ± 20 g (13.0 ± 0.7 oz)
The initial charge of the A/C system is performed
through the high pressure side with the engine stopped.
And next, this method must be followed by charging from
the low pressure side with the engine running.
1) Check if hoses are routed properly after evacuating the system.
2) Connect low charging hose (1) and high charging hose (2) of the manifold gauge set (3) in position.
Then, open refrigerant container valve (4) to purge
the charging line.
3) Open the high pressure side valve (5) and charge refrigerant to system.
4) After a while, open the low pressure side valve (6) and close the high pressure side valve.
WARNING!
Make sure that high pressure side valve is
closed securely.

5) Start engine and keep engine speed at 1500 r/min, and then operate A/C system.
6) Charge A/C system with refrigerant in vapor state. At this time, refrigerant container should be held
upright.
1
2 6 3
5 4
I4RS0A720015-01

Downloaded from www.Manualslib.com manuals search engine 7B-34 Air Conditioning System: Automatic Type
Automatic Type
Precautions
A/C System CautionS7RS0B7220001
Refer to “A/C System Caution”.
Precautions in Diagnosing TroubleS7RS0B7220002
• Do not disconnect couplers from HVAC control module, battery cable from battery, HVAC control module ground
wire harness from body or main fuse before confirming diagnostic information (diagnostic trouble code) stored in
HVAC control module memory.
• Diagnostic information (diagnostic trouble code) stored in HVAC control module can be checked by display of HVAC
control module. Also, it can be checked by using SU ZUKI scan tool. Before checking diagnostic information
(diagnostic trouble code), read this manual and operator's manual for SUZUKI scan tool to know how to read
diagnostic information (diagnostic trouble code).
• When trouble is diagnosed using diagnostic information (diagnostic trouble code) on display of HVAC control
module, keep in your mind that each diagnostic inform ation (diagnostic trouble code) has priority, and only
diagnostic information (diagnostic troub le code) which has the highest priority is indicated. Therefore, after
troubleshooting the malfunction, make sure if there exists any other diagnostic information (diagnostic trouble
code).
• Be sure to read “Precautions for Electrical Circuit Service in Section 00” before inspection.
Precautions on Servicing A/C SystemS7RS0B7220003
Refer to “Precautions on Servicing A/C System”.
General Description
Auto A/C System DescriptionS7RS0B7221001
The automatic type air conditioning system (auto A/C) is pr ovided with the function to automatically control the inside
air temperature, fan speed, air flow outl et direction and air intake position by HVAC control module in addition to
functions of the manual type air conditioning system (manua l A/C). Once the inside air temperature is set using the
temperature selector, HVAC control module automatically controls the inside air temperature at the constant level at all
times based on the inside air temperature, outside ai r temperature, amount of sunlight and engine coolant
temperature detected respectively by the inside air te mperature sensor, outside air temperature sensor, sunload
sensor and ECT sensor. At this time, “FULL AUTO A/ C” appears on the display of HVAC control module.
With the air intake selector pushed in the above state, it is possible to select any position of the air intake actuator.
Then, “FULL AUTO A/C” on the display changes to “AUTO A/C”.

Downloaded from www.Manualslib.com manuals search engine 7B-58 Air Conditioning System: Automatic Type
DTC Troubleshooting
NOTE
• When DTC B1502, B1503 and B1514 are indicated together, it is possible that “ORN” wire circuit open.
• When DTC B1514 is indicated together, it is possible that “WHT” wire circuit open.

Step Action YesNo
1 DTC check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Turn ON ignition switch and check DTC.
Is there DTC B1511? Go to applicable DTC
diag. flow.
Go to Step 2.
2 Visual check
1) Check if there is any obstruction in operating range of
actuator linkage and if actuator linkage operates
smoothly.
Is it in good condition? Go to Step 3.
Obstruction in operating
range of actuator
linkage, actuator linkage
faulty and/or internal
fault of HVAC unit.
3 Wire harness check
1) Disconnect connector from temperature control actuator
with ignition swit ch turned OFF.
2) Check for proper connection to temperature control actuator connector at “GRY /BLU” and “GRY/RED” wire
terminals.
3) If OK, measure voltage between “GRY/BLU” wire terminal of temperature control actuator connector and
vehicle body ground with ignition switch turned ON when
temperature selector is operation to COOL direction.
Is voltage 10 – 14 V? Go to Step 7.
Go to Step 4.
4 Wire harness check
1) Disconnect connector from HVAC control module with
ignition switch turned OFF.
2) Check for proper connection to HVAC control module connector at “G51-3” and “G51-4” terminals.
3) If OK, measure resistance between “GRY/BLU” wire terminal of temperature control actuator connector and
“G51-3” terminal of HVAC control module connector.
Is resistance below 5
Ω? Go to Step 5. “GRY/BLU” wire open or
high resistance circuit.
5 Wire harness check
1) Measure resistance between “GRY/BLU” wire terminal
of temperature control actuator connector and vehicle
body ground.
Is resistance infinity? Go to Step 6.
“GRY/BLU” wire shorted
to ground circuit.
6 Wire harness check
1) Measure voltage between “GRY/BLU” wire terminal of
temperature control actuator connector and vehicle body
ground with ignition switch turned ON.
Is voltage 0 V? Go to Step 7.
“GRY/BLU” wire shorted
to other circuit.