ring SUZUKI SWIFT 2000 1.G Transmission Service Workshop Manual

AUTOMATIC TRANSMISSION (4 A/T) 7B-131
52) Install O-rings to each accumulator piston and apply grease
or ATF to them.
Grease 99000-25030
53) Install C1 and B0 accumulator pistons (1 and 6), springs (2,
3 and 7) and spacers (4).
Hold them with snap rings (5).
54) Install C0, B1, C2 accumulator springs (9, 12, 13, 15 and
16), spacer (11) and pistons (8, 10 and 14) as shown in fig-
ure.
55) Install wire-to-solenoid assembly (1).
Tightening torque
Wire - to - solenoid assembly bolt
(a) : 8 N·m (0.8 kg-m, 6.0 lb-ft)
Grease 99000-25030 NOTE:
C1 and B0 accumulator pistons are the same.
NOTE:
 Make sure that snap rings are fitted to the groove of
each cylinder.
 Make sure that O-rings are not twisted or caught when
installing.
NOTE:
Make sure that O-rings are not twisted or caught when
installing.
1. C1 accumulator piston 9. C0 accumulator spring
(with Pink paint)
2. C1 accumulator outer spring
(with Yellow paint)10. B1 accumulator piston
3. C1 accumulator inner spring
(with Yellow paint)11. B1 accumulator spacer
4. Spacer 12. B1 accumulator inner spring
(with Orange paint)
5. Snap ring 13. B1 accumulator outer spring
(with Orange paint)
6. B0 accumulator piston 14. C2 accumulator piston
7. B0 accumulator spring
(with Purple paint)15. C2 accumulator inner spring
(with Light Blue paint)
8. C0 accumulator piston 16. C2 accumulator outer spring
(with Light Blue paint)
NOTE:
Apply grease to O-ring of wire-to-solenoid assembly.

AUTOMATIC TRANSMISSION (4 A/T) 7B-133
58) Install O-ring to oil strainer assembly (1). Make sure that O-
ring is not twisted.
59) Install oil strainer assembly to the top of valve body assem-
bly.
Connect transmission temperature sensor (2) coupler.
Fix transmission temperature sensor and oil strainer assem-
bly with bolts.
Tightening torque
Transmission temperature sensor bolt
(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
60) Install magnet (1) in oil pan (2).
61) Install gasket to transmission case and install oil pan (1).
Tightening torque
A/T oil pan bolts (a) : 7.5 N·m (0.75 kg-m, 5.5 lb-ft)
62) Install oil cooler (1) and ground cable (2).
Tightening torque
A/T oil cooler bolt (a): 60 N·m (6.0 kg-m, 43.5 lb-ft)
NOTE:
If metal particles are attached to the magnet, clean them
before installing.

7B-134 AUTOMATIC TRANSMISSION (4 A/T)
63) Install vehicle speed sensor (for speedometer) (1), shift
cable bracket (2) and connector clamp bracket (3).
Tightening torque
Vehicle speed sensor bolt
(a) : 5.5 N·m (0.55 kg-m, 4.0 lb-ft)
Shift cable bracket bolts
(b) : 13 N·m (1.3 kg-m, 9.5 lb-ft)
Connector clamp bracket bolt : 8 N·m (0.8 kg-m, 6.0 lb-ft)
64) Install A/T fluid filler tube (2) and level gauge (1).
Tightening torque
A/T fluid filler tube bolt (a) : 19.5 N·m (1.95 kg-m, 14.5 lb-ft)
65) Install output shaft speed sensor (1) and input shaft speed
sensor (2).
Apply grease to O-ring of each sensor.
Tightening torque
Output shaft speed sensor bolt
(a) : 8 N·m (0.8 kg-m, 6.0 lb-ft)
Input shaft speed sensor bolt
(b) : 8 N·m (0.8 kg-m, 6.0 Ib-ft)
Grease : 99000-25030
66) Install engine mounting LH bracket.
Tightening torque
Engine mounting LH bracket bolts
(a) : 55 N·m (5.5 kg-m, 40.0 lb-ft)

7B-136 AUTOMATIC TRANSMISSION (4 A/T)
TIGHTENING TORQUE SPECIFICATION
Fastening partTightening torque
Nm kg-m lb-ft
A/T fluid drain plug 23 2.3 16.5
Transmission rage sensor bolt 18 1.8 13.0
Output shaft speed sensor bolt 8 0.8 6.0
Input shaft speed sensor bolt 8 0.8 6.0
Dropping resistor bolts 20 2.0 14.5
Shift solenoid bolts 8 0.8 6.0
Transmission temperature sensor bolt 10 1.0 7.5
Transmission to engine bolts and nut 85 8.5 61.5
Drive plate to torque converter bolts 20 2.0 14.5
Starter motor bolts 23 2.3 16.5
Oil pump cover bolts 10 1.0 7.5
Valve body bolts 5.5 0.55 4.0
Final gear bolts 90 9.0 65.0
Counter drive gear installing bolts 5.5 0.55 4.0
Rear cover bolts 19 1.9 14.0
Control shift lever nuts 30 3.0 22.0
Detent spring bolt 11 1.1 8.0
Parking lock pawl sleeve bolt 19 1.9 14.0
Parking lock pawl bolts 11 1.1 8.0
Oil pump assembly bolts 12 1.2 9.0
Torque converter housing bolts 19 1.9 14.0
Wire-to-solenoid assembly bolt 8 0.8 6.0
Valve body to transmission case bolts 10 1.0 7.5
A/T oil pan bolts 7.5 0.75 5.5
A/T oil cooler bolt 60 6.0 43.5
Vehicle speed sensor bolt 5.5 0.55 4.0
Shift cable bracket bolt 13 1.3 9.5
Connector clamp bracket bolt 8 0.8 6.0
A/T fluid filler tube bolt 19.5 1.95 14.5
Engine mounting LH bracket bolts 55 5.5 40.0

AUTOMATIC TRANSMISSION (4 A/T) 7B-137
SPECIAL TOOL
09900-06108 09900-20606 09900-20701 09913-75510
Snap ring plier
(Closing type)Dial gauge Magnetic stand Bearing installer
09913-80112 09913-85210 9922-85811 09923-74510
Bearing installer Bearing installer Spring pin remover
(6 mm)Bearing remover
09924-74510 09925-37811-001 09925-88210 09926-26030
Installer handle Oil pressure gauge Bearing puller attachment Air installer No.1
09926-26040 09926-68310 09926-96010 09926-96020
Air installer No.2 Bearing installer Clutch spring compressor Clutch spring compressor

7B-138 AUTOMATIC TRANSMISSION (4 A/T)
09926-96030 09926-96040 09930-30102 09931-76030
Clutch spring compressor
No.7Clutch spring compressor
No.8Sliding shaft 16/14 pin DLC adapter
09931-76011 09941-64511 09944-68510 09951-16060
Tech 1A kit
See NOTE below.Bearing remover Bearing installer Bush remover
09952-06010 09952-06020 09926-26050
Dial gauge plate No.1 Dial gauge plate No.2 Mass storage cartridge Air installer No.3
09940-53111
Oil seal install tool

AUTOMATIC TRANSMISSION (4 A/T) 7B-139
REQUIRED SERVICE MATERIAL
NOTE:
This kit includes the following items.
1. Storage case, 2. Operator’s manual, 3. SUZUKI scan tool (Tech-1A), 4. DLC cable,
5. Test lead / probe, 6. Power source cable, 7. DLC cable adaptor, 8. Self-test adaptor
MaterialRecommended SUZUKI product
(Part Number)Use
Automatic transmission fluid
An equivalent of DEXRON
®-III or
DEXRONR
®-IIEAutomatic transmission
Parts lubrication when installing
Sealant SUZUKI BOND No. 1215
(99000-31110)Case housing star-shaped recess
bolts
(3 pcs only)
Lithium grease SUZUKI SUPER GREASE C
(99000-25030)Retaining parts in place when
assembling
Oil seal lips
D-rings
O-rings
SUZUKI SUPER GREASE A
(99000-25010)Cable ends
Converter center cup
Thread lock cement THREAD LOCK 1322
(99000-32110)Final gear bolts
Torque converter housing bolts

CLUTCH 7C-1
6F1
6F2
6G
6H
6K
7A1
7B1
7C1
7D
7E
7C
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 7C
CLUTCH
CONTENTS
GENERAL DESCRIPTION .............................. 7C-2
DIAGNOSIS ..................................................... 7C-3
ON-VEHICLE SERVICE .................................. 7C-4
CLUTCH CABLE .......................................... 7C-4
CLUTCH PEDAL AND CLUTCH PEDAL
BRACKET .................................................... 7C-6
CLUTCH PEDAL HEIGHT ....................... 7C-7
CLUTCH PEDAL FREE TRAVEL ............ 7C-7UNIT REPAIR OVERHAUL ............................. 7C-8
CLUTCH COVER, CLUTCH DISC AND
FLYWHEEL.................................................. 7C-8
CLUTCH RELEASE SYSTEM ................... 7C-11
TIGHTENING TORQUE SPECIFICATION.... 7C-14
REQUIRED SERVICE MATERIAL................ 7C-14
SPECIAL TOOL ............................................ 7C-14

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
 Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
 Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

7C-2 CLUTCH
GENERAL DESCRIPTION
The clutch is a diaphragm-spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger
type, which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward.
The disc, carrying four torsional coil springs, is positioned on the transmission input shaft with an involute spline
fit.
The clutch cover is secured to the flywheel, and carries the diaphragm spring in such a way that the peripheral
edge part of the spring pushes on the pressure plate against the flywheel (with the disc in between), when the
clutch release bearing is held back. This is the engaged condition of the clutch.
Depressing the clutch pedal causes the release bearing to advance and pushes on the tips of the tapered fin-
gers of the diaphragm spring. When this happens, the diaphragm spring pulls the pressure plate away from the
flywheel, thereby interrupting the flow of drive from flywheel through clutch disc to transmission input shaft.
1. Crankshaft 6. Diaphragm spring
2. Flywheel 7. Release bearing
3. Clutch disc 8. Input shaft bearing
4. Pressure plate 9. Input shaft
5. Clutch cover 10. Release shaft

CLUTCH 7C-3
DIAGNOSIS
Condition Possible Cause Correction
Slipping
Improper clutch pedal free travel Adjust free travel.
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.
Rusted clutch cable Replace cable.
Dragging clutch
Improper clutch pedal free travel Adjust free travel.
Weakened diaphragm spring, or worn spring tip Replace clutch cover.
Rusted input shaft splines Lubricate.
Damaged or worn splines of transmission input shaft Replace input shaft.
Excessively wobbly clutch disc Replace disc.
Clutch facings broken or dirty with oil Replace disc.
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 retainerLubricate 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 fly-
wheel.
Weakened engine mounting or loosened engine
mounting bolt or nutRetighten or replace mount-
ing.
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.