engine SUZUKI SWIFT 2000 1.G Transmission Service Workshop Manual

7A-6 MANUAL TRANSMISSION
OIL CHANGE
1) Before changing or inspecting oil, be sure to stop engine and
lift vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage.
If leakage exists, correct it.
3) Drain old oil and fill new specified oil by specified amount (up
to level hole).
4) Apply sealant to thread of drain plug (2) and level/filler plug
(3) and torque them as specified below.
“A” : Sealant 99000-31110
Tightening torque
Transmission oil level/filler and drain plugs
(a) : 21 N·m (2.1 kg-m, 15.5 lb-ft)
Transmission oil
: API GL-4
For SAE classification, refer to viscosity chart in the fig-
ure.
Transmission oil capacity
: 2.2 liters (4.6/3.9 US/lmp. pt)
DIFFERENTIAL SIDE OIL SEAL
REPLACEMENT
1) Lift up vehicle and drain transmission oil.
2) Remove wheel, and then remove tie-rod end (1) split pin (4)
and castle nut (3).
3) Disconnect tie-rod end from knuckle (2) by using special tool.
Special tool
(A) : 09913-65210
4) Remove two stabilizer mount brackets from vehicle body.
5) Remove ball stud bolt and then separate suspension arm
from knuckle.
6) Separate transfer from transmission assembly. (for 4WD
vehicle)
For detail, refer to Section 7D. NOTE:
 It is highly recommended to use API GL-4 75W-90 gear
oil.
 Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage.
1. Drive shaft (LH)

MANUAL TRANSMISSION 7A-11
UNIT REPAIR OVERHAUL
TRANSMISSION UNIT
1. Engine 10. VSS connector 19. Engine rear mounting
2. Transmission 11. Transmission to engine bolts 20. Engine rear mounting No.2 bracket bolts
3. Engine rear mounting No.1 bracket 12. Engine left mounting bracket bolts 21. Transmission to engine rear mounting No.2 bracket bolt
4. Engine rear mounting No.2 bracket 13. Starting motor 22. Transmission to engine bolts
5. Engine left mounting 14. Starting motor bolt 23. Transmission to engine nut
6. Engine left mounting bracket 15. Engine rear mounting bracket stiffener 24. Ground cable
7. Shift & select control cables 16. Stiffener bolts 25. Clutch housing lower plate bolts
8. Clutch cable 17. Clutch housing lower plate 26. Starting motor nut
9. Backup lamp switch connector 18. Engine rear mounting bolt Tightening torque

7A-16 MANUAL TRANSMISSION
TRANSMISSION UNIT
DISMOUNTING
Under Hood
1) Disconnect negative cable at battery.
2) Undo wiring harness clamps, disconnect backup lamp switch
coupler, VSS coupler and ground cable.
3) Disconnect clutch cable from clutch release lever and
bracket.
4) Disconnect gear shift and select control cables.
5) Remove water pipe bracket bolts from transmission.
6) Remove transmission bolts (1).
7) Remove starting motor taking out its bolts.
8) Support engine by using lifting device.
On Lift
9) Drain transmission oil referring to “OIL CHANGE” in this sec-
tion.
10) Remove left and right drive shaft referring to Section 4A.
11) Remove left side of engine under cover.
12) Remove engine rear mounting bracket stiffener (1).
13) Remove clutch housing lower plate.
14) Remove engine rear mounting No.1 bracket (2) with No.2
bracket (3).
15) Remove transfer referring to Section 7D (if equipped).
16) Remove transmission to engine bolt and nut.
17) Lower vehicle and support transmission with transmission
jack.

MANUAL TRANSMISSION 7A-17
18) Remove engine left mounting (1) with bracket (2).
19) Remove other attached parts from transmission, if any.
20) Pull transmission out so as to disconnect input shaft from
clutch disc and then lower it.
REMOUNTING
Remount transmission in reverse order of dismounting procedure
noting the following.
 Refer to Section 7D for installing transfer (if equipped).
 Refer to the first figure of “UNIT REPAIR OVERHAUL” for
fastener specified torque.
 Push in drive shaft joints (right & left) fully so as to snap ring
of shaft engages with differential gear.
 Set each clamp for wiring securely.
 After connecting clutch cable, be sure to adjust its play prop-
erly.
Refer to Section 7C.
 Fill transmission with oil as specified.
 Connect battery and check function of engine, clutch and
transmission.
UNIT DISASSEMBLY
FIFTH GEARS
1) Remove side cover bolts and take off transmission side
cover.
CAUTION:
Care should be taken not to scratch oil seal lip with drive
shaft while raising transmission.
Do not hit drive shaft joint with hammer when installing it
into differential gear.
CAUTION:
Care should be taken not to distort side cover when it is
removed from left case.

AUTOMATIC TRANSMISSION (4 A/T) 7B-1
6F1
6F2
6G
6H
6K
7A
7A1
7C1
7D
7B
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 7B
AUTOMATIC TRANSMISSION (4 A/T)
CONTENTS
GENERAL DESCRIPTION ...............................7B-3
ELECTRONIC SHIFT CONTROL SYSTEM . 7B-6
TRANSMISSION CONTROL MODULE
(TCM) ........................................................ 7B-7
FAIL SAFE FUNCTION ............................. 7B-8
CHANGE MECHANISM .......................... 7B-10
AUTOMATIC GEAR SHIFT DIAGRAM ... 7B-11
DIAGNOSIS ....................................................7B-13
AUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLE ...................... 7B-13
TROUBLE DIAGNOSIS TABLE .................. 7B-18
STALL TEST ........................................... 7B-20
TIME LAG TEST ..................................... 7B-21
LINE PRESSURE TEST ......................... 7B-22
ENGINE BRAKE TEST ........................... 7B-23
“P” RANGE TEST.................................... 7B-23
ELECTRONIC CONTROL SYSTEM
DIAGNOSIS ................................................ 7B-24
PRECAUTIONS IN DIAGNOSING
TROUBLES ............................................. 7B-24
DTC CHECK ........................................... 7B-25
DTC CLEARANCE .................................. 7B-27
DTC TABLE............................................. 7B-28
TCM POWER AND GROUND CIRCUIT
CHECK .................................................... 7B-30
DTC P0715 (DTC NO.14) INPUT/
TURBINE SPEED SENSOR CIRCUIT
MALFUNCTION ...................................... 7B-31
DTC P0730 (DTC NO. 18) INCORRECT
GEAR RATIO .......................................... 7B-33
DTC P0753 (DTC NO.21/22) SHIFT
SOLENOID-A (NO.1) ELECTRICAL ....... 7B-35DTC P0758 (DTC NO.23/24) SHIFT
SOLENOID-B (NO.2) ELECTRICAL ....... 7B-35
DTC P0743 (DTC NO.25/26) TCC
(LOCK-UP CLUTCH) SYSTEM
ELECTRICAL .......................................... 7B-35
DTC P0741 (DTC NO.29) TCC
(LOCK-UP) SOLENOID
PERFORMANCE OR STUCK OFF ........ 7B-37
DTC P0720 (DTC NO. 31) OUTPUT
SHAFT SPEED SENSOR CIRCUIT
MALFUNCTION ...................................... 7B-38
DTC P1700 (DTC NO.32/33)
THROTTLE POSITION SIGNAL INPUT
MALFUNCTION ...................................... 7B-41
DTC P0705 (DTC NO.34)
TRANSMISSION RANGE SENSOR
(SWITCH) CIRCUIT MALFUNCTION ..... 7B-43
DTC P0725 (DTC NO.35) ENGINE
SPEED INPUT CIRCUIT
MALFUNCTION ...................................... 7B-45
DTC P0710 (DTC No.36/38)
TRANSMISSION TEMPERATURE
SENSOR CIRCUIT MALFUNCTION ...... 7B-47
DTC P0763 (DTC NO.43) SHIFT
SOLENOID-C (NO.3) ELECTRICAL ....... 7B-49
DTC P0768 (DTC NO.45) SHIFT
SOLENOID-B (NO.4) ELECTRICAL ....... 7B-49
DTC P0773 (DTC NO.48) SHIFT
SOLENOID-E (NO.5) ELECTRICAL ....... 7B-49
DTC P1709 (DTC NO.51) ENGINE
COOLANT TEMPERATURE/BAROMETRIC
PRESSURE SIGNAL CIRCUIT............... 7B-51 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).

7B-2 AUTOMATIC TRANSMISSION (4 A/T)
DTC P0702/P1702 (DTC No.52)
TRANSMISSION CONTROL SYSTEM
ELECTRICAL OR INTERNAL
MALFUNCTION OF TCM ....................... 7B-52
INSPECTION OF TCM AND ITS
CIRCUITS ............................................... 7B-53
ON-VEHICLE SERVICE ................................. 7B-55
MAINTENANCE SERVICE ......................... 7B-55
FLUID LEVEL AT NORMAL OPERATING
TEMPERATURE ..................................... 7B-55
FLUID LEVEL AT ROOM
TEMPERATURE ..................................... 7B-56
FLUID CHANGE ..................................... 7B-56
SELECTOR LEVER .................................... 7B-57
TRANSMISSION RANGE SENSOR
(SHIFT SWITCH) ........................................ 7B-58
SELECTOR CABLE .................................... 7B-60
OUTPUT SHAFT SPEED SENSOR
(A/T VSS) .................................................... 7B-62
INPUT SHAFT SPEED SENSOR ............... 7B-63
VEHICLE SPEED SENSOR (VSS)............. 7B-63
THROTTLE POSITION SENSOR............... 7B-63
ENGINE COOLANT TEMP. (ECT)
SENSOR ..................................................... 7B-64
DROPPING RESISTOR ............................. 7B-64
O/D OFF SWITCH ...................................... 7B-65
SHIFT SOLENOID VALVES AND
TRANSMISSION TEMPERATURE
SENSOR ..................................................... 7B-65
SHIFT SOLENOID VALVES ................... 7B-66
TRANSMISSION TEMPERATURE
SENSOR ................................................. 7B-66
DIFFERENTIAL SIDE OIL SEAL ................ 7B-68TRANSMISSION CONTROL MODULE
(TCM).......................................................... 7B-69
LEARNING CONTROL INITIALIZATION 7B-70
BRAKE INTERLOCK SYSTEM
(IF EQUIPPED)........................................... 7B-70
KEY INTERLOCK CABLE
(IF EQUIPPED)........................................... 7B-72
TRANSMISSION UNIT REPAIR
OVERHAUL ................................................... 7B-75
DISMOUNTING .......................................... 7B-76
REMOUNTING ........................................... 7B-77
UNIT DISASSEMBLY ................................. 7B-78
DISASSEMBLY/ASSEMBLY OF
SUBASSEMBLY ......................................... 7B-88
OIL PUMP ............................................... 7B-88
FRONT CLUTCH (C2 CLUTCH) ............ 7B-91
REAR CLUTCH (C1 CLUTCH) ............... 7B-95
DIRECT CLUTCH (C0 CLUTCH) ......... 7B-100
PLANETARY SET................................. 7B-104
VALVE BODY ....................................... 7B-106
DIFFERENTIAL ASSEMBLY ................ 7B-112
REAR COVER (O/D BRAKE PISTON
ASSEMBLY) ......................................... 7B-115
PLANETARY SUN GEAR NO.1
ASSEMBLY .......................................... 7B-115
TORQUE CONVERTER HOUSING ..... 7B-116
TRANSMISSION CASE ........................ 7B-117
UNIT ASSEMBLY ..................................... 7B-118
TIGHTENING TORQUE SPECIFICATION .. 7B-136
SPECIAL TOOL ........................................... 7B-137
REQUIRED SERVICE MATERIAL .............. 7B-139

7B-4 AUTOMATIC TRANSMISSION (4 A/T)
Item Specifications
Torque
converterType
Stall torque ratio3-element, 1-step, 2-phase type
1.65 –1.85
Oil pumpType
Drive systemInternal gear type oil pump
Engine driven
Gear
change
deviceType Forward 4-step, reverse 1-step planetary gear type
Shift position“P” range Gear in neutral, output shaft fixed, engine start
“R” range Reverse
“N” range Gear in neutral, engine start
“D” range
(O/D ON)Forward 1st ↔
2nd ↔
3rd ↔
4th (O/D)
automatic gear change
“D” range
(O/D OFF)Forward 1st ↔
2nd ↔
3rd ←
4th
automatic gear change
“2” range Forward 1st ↔
2nd ←
3rd automatic gear change
“L” range Forward 1st ←
2nd reduction, and fixed at 1st gear
Gear
ratio1st 2.962
2nd 1.515 Number of teeth Front sun gear : 34
Rear sun gear : 21
Front pinion gear : 16
Rear pinion gear : 19
Front internal gear : 66
Rear internal gear : 59 3rd 1.000
4th
(overdrive gear)0.737
Reverse
(reverse gear2.809
Control elementsWet type multi-disc clutch ... 3 sets
One-way clutch ... 1 set
Wet type multi-disc brake ... 3 sets
Reduction gear ratio 1.209
Final gear ratio
(Differential)3.578 (for 2WD vehicle), 3.894 (for 4WD vehicle)
Lubrication Lubrication system Force feed system by oil pump
Cooling Cooling system Water-cooled
Fluid used
Equivalent of DEXRON
-III or DEXRON-IIE

7B-6 AUTOMATIC TRANSMISSION (4 A/T)
ELECTRONIC SHIFT CONTROL SYSTEM
1. Engine 15. O/D off switch F. Range signal
2. Transmission 16. Combination meter (O/D off lamp) G. O/D off switch signal
3. TCM 17. A/C compressor G’. O/D off lamp signal
4. ECM 18. Brake lamp switch H. A/C clutch signal
5. Input shaft speed sensor (Turbine rev. sensor) 19. Monitor connector NO. 2 I. Brake signal
6. Transmission temp. sensor (A/T fluid temp. sensor) 20. Suzuki scan tool J. Diagnosis switch signal
7. TCC solenoid (Lock-up solenoid) 21. Ignition switch K. Serial communication with Suzuki scan tool
8. Shift solenoid-A (Shift solenoid No.1) 22. Battery L. Power supply
9. Shift solenoid-B (Shift solenoid No.2) 23. A/T relay M. Throttle opening signal
10. Shift solenoid-C (Shift solenoid No.3) A. Turbine speed signal N. Engine coolant temp./Barometric pressure signal
11. Shift solenoid-D (Shift solenoid No.4) B. A/T fluid temp signal O. Idle up signal
12. Shift solenoid-E (Shift solenoid No.5) C. TCC (lock-up) control signal P. A/T failure signal
13. Output shaft speed sensor (A/T VSS) D. Shift control signal Q. Engine speed (rev.) signal.
14. Transmission range sensor (Shift switch) E. A/T output shaft speed signal
14
3
19
15
1816
14 13 5
2
7
9
12
8
6
10 17
11

AUTOMATIC TRANSMISSION (4 A/T) 7B-9
A/T hardware itself
(DTC P0730)Difference in detected
revolution between
input shaft speed
sensor and output
shaft speed sensor is
too wide.“P” range →
P, “R” range →
R, “N” range →
N,
“D”/“2”/“L” range “To be controlled as follows :
1) When detecting trouble at first, gear is selected well-suited
gear calculated with parameters of each sensor’s rev. num-
ber and gear position just when the trouble occurred. Lock-
up function is turned OFF.
2) If A/T can transmit driving force under the above condition,
gear is fixed the selected gear until ignition switch is turned
OFF.
3) If A/T can not transmit driving force under the above condi-
tion, after once vehicle stop, gear which can transmit drive
force is searched one by one until gear is found out. After
gear is found out, position of gear is held until ignition switch
is turned OFF.
Transmission
range sensor cir-
cuit
(DTC P0705)No shift switch signal
is inputted or two or
more shift switch sig-
nals are inputted at
the same time.When vehicle running, shift range position is fixed to shift
range position right before the trouble occurred until vehicle
stop and lock-up function is turned OFF.
When vehicle is at stop after or during detecting the trouble,
gear is fixed as the followings and lock-up function is turned
OFF.
–When 2 adjoining gear position signals are inputted.
“P”, “R” range →
R, “R”, “N” range →
R,
“N”, “D” range →
D, “D”, “2” range →
D,
“2”, “L” range →
2nd
–When 2 or more signals excepting above or no signal are
inputted.
“P” range →
P, “R” range →
R,
“N” range →
N, “D”/“2”/“L” range →
3rd
Transmission tem-
perature sensor cir-
cuit
(DTC P0710)A/T fluid temp. sig-
nal input voltage is
too low.
A/T fluid temp. sig-
nal input voltage
does not go down
although standard
value of engine
rev. signal is input-
ted.When detecting circuit open, TCM control as fluid tempera-
ture is 100°C (212°F).
Lock-up function is turned OFF.
Engine speed input
circuit
(DTC P0725)Inputted engine rev.
signal is too low or
too high.Engine rev. is processed as 4000 rpm.
No compensation or judgement for gear shift control, for
which engine rev. is considered, is processed.
Lock-up function is turned OFF.
Engine coolant
temp./Barometric
pressure signal cir-
cuit
(DTC P1709)No or abnormal
engine coolant temp.
signal is inputtedNo compensation for gear shift control, for which engine cool-
ant temp. and barometric pressure are considered, is pro-
cessed.
Lock -up function is turned OFF. Area Detecting condition Fail safe function

7B-10 AUTOMATIC TRANSMISSION (4 A/T)
CHANGE MECHANISM
The same select pattern shift lever is used as the floor type and
frequently used “N” and “D” ranges are made selectable freely. Throttle position
signal circuit
(DTC P1700)No or abnormal throt-
tle opening signal is
inputtedScheduling of automatic gear shift is performed as throttle
valve opening is 0%.
Control of automatic gear shift (i.e. control of oil pressure) is
performed as throttle valve opening is 100%.
Coast down shifting is performed when brake is applied and
engine rev. is less than 1,500 rpm.
Lock-up function is turned OFF.
Transmission con-
trol system electri-
cal
(DTC P0702)Solenoid power sup-
ply relay output volt-
age is too high
although TCM orders
relay to turn off or
relay output voltage is
too low although TCM
orders relay to turn
on.When relay shorted, the gear is fixed as the followings and
lock-up function is turned OFF.
“P” range →
P, “R” range →
R, “N” range →
N,
“D” range →
3rd, “2” range →
2nd, “L” range →
1st
When relay open, power supply to all solenoids is cut and the
gear is fixed as the followings. Lock-up function is turned
OFF.
“P” range →
P, “R” range →
R, “N” range →
N,
“D”/“2”/“L” range →
3rd
Internal malfunc-
tion of TCM
(DTC P1702)Incorrect calculations
of checking TCM pro-
grammed data indi-
cated.Power supply to all solenoid is cut and the gear is fixed as fol-
lows :
“P” range P, “R” range R, “N” range N,
“D”/“2”/“L” range “3rd Area Detecting condition Fail safe function