sensor SUZUKI SWIFT 2004 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 5A-4 Automatic Transmission/Transaxle:
1
2
3
4567891011121314151617
18 19 20 21 22 23
24 25
26
27
28I3RM0B510001-01
1. Drive plate 11. 1st and reverse brake 21. Rear sun gear
2. Torque converter clutch (TCC) 12. Ring gear22. Front sun gear
3. Torque converter 13. Long planet pinion23. Short planet pinion
4. Input shaft 14. One-way No.2 clutch 24. Countershaft
5. Oil pump 15. 2nd brake25. Reduction driven gear
6. Direct clutch drum (double as sensor ro tor for input shaft speed sensor) 16. One-way No.1 clutch 26. Differential case assembly
7. Direct clutch 17. O/D and 2nd coast brake 27. Final gear
8. Parking lock gear 18. Intermediate shaft28.Output shaft speed sensor drive gear
9. Reduction drive gear 19. Forward clutch
10. Planet carrier 20. Reverse clutch

Downloaded from www.Manualslib.com manuals search engine 5A-10 Automatic Transmission/Transaxle:
Schematic and Routing Diagram
Transmission Control Module (TCM) Wiring DiagramS7RS0B5102001
IG1
115
5
5
8
9
10 7
P
R
N
D
2
L
12
12V 2.5V
5V
12V
5V
12V
12V
12V
12V
WHT
BLK
BLK
BLK
BLK
PPLBLK/RED
BLK/ORN
IG11
RED/BLK
YEL/BLKYEL/BLU
LT GRN/BLK
+BB
WHT/RED
14
20
15
16
17
19
12V18
1
2
3
4
6
13 21
26
24
27
28 29
30
WHT
WHT
RED
RED
WHT
RED
65
16 15 14 13 12 11 43
24 23 2122 10 9 8 721
1920 18 17
C34
17 16
26 25
15 14
65 3
42
13 12
23 2224 11 10 9
21 20 19 87
18
1
C35
[A]
22
25
YELYEL/GRN
WHT
P
N
BRN
LT GRN
ORN
BLK/YEL
BLU/BLK
GRY
LT GRN/BLK WHT/BLU
WHT/BLK
C34-11
C34-12
C34-16
C34-15
C34-14
C34-4
C34-2
C34-1
C34-23 C34-6
C34-24 C34-5
C34-3
RED
GRN
GRN/ORN PNK/BLK
GRN/YEL
LT GRN/BLKC35-6
C35-16
C35-23 C35-25
C35-20
C35-1
C35-8
C35-7
C35-19
C35-18 C34-17 C34-7
4IG11
12V
23
PPL/WHT
LT GRN
I6RS0C510005-01
1. TCM 12. Backup lamp 23. Starter motor relay
2. Input shaft speed sensor 13. Data link connector DLC 24. Ignition switch
3. Output shaft speed sensor 14. Transmission fluid temperature sensor 25. Starter motor
4. ECM 15. Shift solenoid valve-A (No.1) 26. “DOME” fuse
5. CAN driver 16. Shift solenoid valve-B (No.2) 27. “AT ETM” fuse
6. BCM 17. Timing solenoid valve 28. “IG SIG” fuse
7. Meter driver 18. TCC lock-up pressure control solenoid valve 29. “ST SIG” fuse
8. “3” position switch 19. Pressure control solenoid valve 30. “ST MOT” fuse
9. Shift lock solenoid 20. A/T [A]: Terminal arrangement of TCM connector
(viewed from harness side)
10. Brake light switch 21. A/T relay
11. Transmission range sensor 22. Inhibitor switch (including transmission range sensor)

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-13
Component Location
Electronic Shift Control System Components LocationS7RS0B5103001
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

3 4
5*
1 2
6
7 8
9 10 11
12
13 14
16*
18
19
17
15
20
I6RS0C510006-01
1. Engine
8. TCC pressure control solenoid valve (TCC
solenoid valve) 15. ECM
2. Transaxle 9. Transmission fluid temperature sensor 16. TCM
3. MIL 10. Timing solenoid valve17. AT relay
4. Shift position indicator light 11. Pressure control solenoid valve18. “3” position switch
5. Junction block assembly (included in BCM) 12. Shift solenoid valve-B (No.2)19. Select lever

Downloaded from www.Manualslib.com manuals search engine 5A-14 Automatic Transmission/Transaxle:
6. Output shaft speed sensor 13. Shift solenoid valve-A (No.1) 20. Transmission warning light
7. Input shaft speed sensor 14. Transmission range sensor
INPUT OUTPUT
TCMECM
Gear shift control
4th gear inhibit control
Slope shift control
Slip control
Lock up control
Torque control
Line pressure control
Overrun control
Reverse control
Squat control
Input shaft speed sensor
Output shaft speed sensor
"3" position switch ATF temp. sensor
Shift switch
- Range "P" signal
- Range "R" signal
- Range "N" signal
- Range "D" signal
- Range "2" signal
- Range "L" signal
Fail safe function
Self diagnosis
Warning function
ECM
Shift solenoid valve-A
Shift solenoid valve-B
TCC pressure control
solenoid valve
Pressure control
solenoid valve
Signal on CAN
communincation line
COMB. METER
-Engine torque
-Engine speed
-Throttle position
-A/C compressor clutch
-Coolant temperature
-Brake pedal switch -ATF temp.
-Torque request
-Vehicle speed pulse
-Transmission actual gear
position
-A/T select lever position
-Accelerator pedal position
-Transmission warning light
-A/T select lever position
I7RS0B510005-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-17
Step 2. DTC / Freeze Frame Data Check, Record and Clearance
First, referring to “DTC Check”, check DTC and pending DTC. If DTC exists, print or write down DTC and freeze frame
data and then clear malfunction DTC(s) by referring to “DTC Clearance”. Malfunction DTC indicates malfunction in the
system but it is not possible to know from it whether the malfunction is occurring now or it occurred in the past and
normal condition has been restored. In order to know that, check symptom in question according to Step 5 and then
recheck DTC according to Step 6.
Diagnosing a trouble based on the DTC in this step only or fa ilure to clear the DTC in this step may result in an faulty
diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting which is otherwise unnecessary.
Step 3 and 4. Visual Inspection
As a preliminary step, be sure to perform visual check of the items that support proper function of the engine and
automatic transaxle referring to “Visual Inspection”.
Step 5. Trouble Symptom Confirmation
Check trouble symptoms based on information obtained in “Step 1. Customer Complaint Analysis: ” and “Step 2. DTC
/ Freeze Frame Data Check, Record and Clearance: ”.
Also, reconfirm DTC according to “DTC Confirmation Procedure” described in each DTC flow.
Step 6 and 7. Rechecking and Record of DTC and Freeze Frame Data
Refer to “DTC Check” for checking procedure.
Step 8. A/T Basic Check and A/T Symptom Diagnosis
Perform basic check of A/T according to “A/T Basic Check” first. When the end of the flow has been reached, check
the parts of the system suspected as a possible cause referring to “A/T Symptom Diagnosis” and based on symptoms
appearing on the vehicle (symptoms obtained through step s of customer complaint analysis, trouble symptom
confirmation and/or A/T basic check) and re pair or replace faulty parts, if any.
Step 9. Troubleshooting for DTC
Based on the DTC indicated in Step 6 / 7 and referring to “a pplicable DTC flow”, locate the cause of the trouble,
namely in a sensor, switch, wire harness, connector, actuator, TCM or other part and repair or replace faulty parts.
Step 10. Check for Intermittent Problem
Check parts where an intermittent trouble is easy to occur (e.g . wire harness, connector, etc.), referring to “Intermittent
and Poor Connection Inspection in Section 00” and related circuit of DTC recorded in Step 2.
Step 11. Final Confirmation Test
Confirm that the problem symptom has gone and the vehicl e is free from any abnormal conditions. If what has been
repaired is related to the malfunction DTC, clear the DTC once and check to ensure that no malfunction DTC is
indicated.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-19
DTC TableS7RS0B5104005
NOTE
• A: Driving cycles when transmission warning light lighting and storing DTC in TCM memory.
• *1: Transmission warning light does not light up but TCM detects and stores DTC.
• For details of driving cycle, refer to “On-Board Diagnostic System Description”.

DTC No.Detecting item Detecting condition
(DTC will set when detecting) A
) P0602 Control module programming error D ata programming error. *1, 1 driving cycle
) P0705 Transmission range sensor circuit
malfunction (PRNDL input) Multiple signals are inputted
simultaneously. 1 driving cycle
) P0707 Transmission range sensor circuit
low No sensor signal is inputted.
2 driving cycles
) P0712 Transmission fluid temperature
sensor “A” circuit low Sensor output voltage is too low.
1 driving cycle
) P0713 Transmission fluid temperature
sensor “A” circuit high Sensor output voltage is too high.
1 driving cycle
) P0717 Input / Turbine speed sensor circuit
no signal No sensor signal is detected although output
speed sensor signal is inputted.
1 driving cycle
) P0722 Output speed sensor circuit no signal No sensor signal is inputted although input
speed sensor signal is inputted. 1 driving cycle
) P0787 Shift / Timing solenoid low Voltage of timing solenoid terminal is low
although TCM is commanding timing solenoid
to turn ON. 1 driving cycle
) P0788 Shift / Timing solenoid high Voltage of timing solenoid terminal is high
although TCM is commanding timing solenoid
to turn OFF. 1 driving cycle
) P0961 Pressure control solenoid “A” control
circuit range / performance Difference between target current of control
solenoid valve circuit and monitor current of
control solenoid valve circuit is more than
specification.
1 driving cycle
) P0962 Pressure control solenoid “A” control
circuit low No electric flow is detected on pressure control
solenoid circuit.
1 driving cycle
) P0963 Pressure control solenoid “A” control
circuit high Too much electric flow is detected on pressure
control solenoid circuit.
1 driving cycle
) P0973 Shift solenoid “A” control circuit low Voltage of shift solenoid terminal is low
although TCM is commanding shift solenoid to
turn ON. 1 driving cycle
) P0974 Shift solenoid “A” control circuit high Voltage of shift solenoid terminal is high
although TCM is commanding shift solenoid to
turn OFF. 1 driving cycle
) P0976 Shift solenoid “B” control circuit low Voltage of shift solenoid terminal is low
although TCM is commanding shift solenoid to
turn ON. 1 driving cycle
) P0977 Shift solenoid “B” control circuit high Voltage of shift solenoid terminal is high
although TCM is commanding shift solenoid to
turn OFF. 1 driving cycle
) P1702 Internal control module memory
check sum error Calculation of current data stored in TCM is not
correct comparing with pre-stored checking
data in TCM.
1 driving cycle
) P1703 CAN invalid data - TCM TCM receives malfunction signal of throttle
position

, engine coolan t temperature, engine
revolution and engine torque from ECM. *1, 1 driving cycle
) P1723 Range select switch malfunction “3” position switch ON signal is inputted
although transmission range switch signal is
inputted P, R, N or L. range. *1, 1 driving cycle
) P1774 Control module communication bus
off Transmitting and receiving error detected to
TCM for specified time continuously.
1 driving cycle

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-21
Fail-Safe TableS7RS0B5104008
This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sensor or
its circuit fails. The following table shows th e fail-safe function for each fail condition of sensor, solenoid or its circuit.
DTC No. Trouble area Fail-safe operation
) P0705 Transmission range sensor circuit
malfunction (PRNDL input) • Selected range is set in priority order shown below.
D> 2> L> R> N> P
• Slip controlled lock-up function is inhibited to operate.
• Learning control is inhibited.
) P0707 Transmission range sensor circuit low • Selected range is assumed to be “D” range.
• Slip controlled lock-up function is inhibited to operate.
• Learning control is inhibited.
) P0712 Transmission fluid temperature sensor “A”
circuit low • A/T fluid temperature is assumed to be 200
°C (392 °F).
• Upshifting to 4th gear is inhibited.
• Lock-up function is inhibited to operate.
• Garage shift control is inhibited.
• Learning control is inhibited.
)
P0713 Transmission fluid temperature sensor “A”
circuit high
) P0717 Input / Turbine speed sensor “A” circuit no
signal • Upshifting to 4th gear is inhibited.
• Lock-up function is inhibited to operate.
• Line pressure control at gear shifting is inhibited.
• Torque reducing request to ECM (torque reduction control)
is inhibited.
• Garage shift control is inhibited.
• Learning control is inhibited.
) P0722 Output speed sensor circuit no signal • Vehicle speed which is calculated by input shaft speed
sensor signal is used for gear shifting control instead of
vehicle speed calculated by output shaft speed sensor
signal.
• Upshifting to 4th gear is inhibited.
• Lock-up function is inhibited to operate.
• Line pressure control at gear shifting is inhibited.
• Torque reducing request to ECM (torque reduction control) is inhibited.
• Garage shift control is inhibited.
• Learning control is inhibited.
) P0787 Shift / Timing solenoid Low
• Power supply for all solenoid valves is cut.
• Gear position is fixed in 3rd gear.
• Line pressure control at gear shifting is inhibited.
• Look-up function is inhibited to operate.
• Garage shift control is inhibited.
• Torque reducing request to ECM (torque reduction control)
is inhibited.
)
P0788 Shift / Timing solenoid High
) P0962 Pressure control solenoid “A” control
circuit low
) P0963 Pressure control solenoid “A” control
circuit high
) P0973 Shift solenoid “A” control circuit low
) P0974 Shift solenoid “A” control circuit high
) P0976 Shift solenoid “B” control circuit low
) P0977 Shift solenoid “B” control circuit high
) P0961 Pressure control solenoid “A” control
circuit range / performance • Gear position is fixed in 3rd gear.
• Lock-up function is inhibited to operate.
• Slip controlled lock-up function is inhibited to operate.
• Line pressure control at gear shifting is inhibited.
• Torque reducing request to ECM (torque reduction control)
is inhibited.
• Garage shift control is inhibited.
• Leaning control is inhibited.

Downloaded from www.Manualslib.com manuals search engine 5A-24 Automatic Transmission/Transaxle:
) ENGINE SPEED At engine idle spee d Engine idle speed is displayed
) INPUT SHAFT
REVOLUTION Ignition switch ON and engine stop 0 RPM
At 60 km/h (37.5 mile/h) constant speed, 20% or less
throttle opening and 3rd gear (“3” range)
2300 RPM
(displayed in increments of 50 rpm)
) OUTPUT SHAFT
REVOLUTION At vehicle stop 0 RPM
At 60 km/h (37.5 mile/h) constant speed, 20% or less
throttle opening and 3rd gear (“3” range)
2300 RPM
(displayed in increments of 50 rpm)
) BATTERY
VOLTAGE Ignition switch ON and engine stop Battery voltage is displayed
(8 – 16 V)
) AT F
TEMPERATURE After driving at 60 km/h (37.5 mile/h) for 15 minutes or
more, and A/T fluid temperature around sensor
reaches 70 – 80
°C (158 – 176 °F) 70 – 80
°C (158 – 176 °F)
) SHIFT SOLENOID-
A COMMAND At vehicle stop ON
At 60 km/h (37.5 mile/h) constant speed, 20% or less
throttle opening and 3rd gear (“3” range)
OFF
) SHIFT SOLENOID-
A MONITOR At vehicle stop ON
At 60 km/h (37.5 mile/h) constant speed, 20% or less
throttle opening and 3rd gear (“3” range)
OFF
) SHIFT SOLENOID-
B COMMAND At vehicle stop ON
At 60 km/h (37.5 mile/h) constant speed, 20% or less
throttle opening and 3rd gear (“3” range)
OFF
) SHIFT SOLENOID-
B MONITOR At vehicle stop ON
At 60 km/h (37.5 mile/h) constant speed, 20% or less
throttle opening and 3rd gear (“3” range)
OFF
) TIMING SOLENOID
COMMAND Ignition switch ON and sele
ct lever is in “N” range OFF
For about 0.5 sec. while on gear shifting between 3rd
and 4th or gear shifting “N” to “D” ON
) TIMING SOLENOID
MONITOR Ignition switch ON and sele
ct lever is in “N” range OFF
For about 0.5 sec. while on gear shifting between 3rd
and 4th or gear shifting “N” to “D” ON
) TCC SOLENOID At vehicle stop, closed throttle, engine idle speed and
1st gear 0%
) PRESSURE
CONTROL SOLENOID At vehicle stop, closed throttle, engine idle speed and
1st gear
0%
) VEHICLE SPEED At vehicle stop 0 km/h, 0 MPH
) O/D OFF SWITCH Ignition switch ON Shift select lever to “3” or “2”
range
ON
Shift select lever to other above
range OFF
) TRANSAXLE
RANGE Ignition switch ONSelect lever is in “P” position P
Select lever is in “R
” position R
Select lever is in “N” position N
Select lever is in “D” position D
Select lever is in “3” position D
Select lever is in “2” position 2
Select lever is in “L” position L
) D RANGE SIGNAL Ignition switch ON Select lever is in “P” position
OFF
Select lever is in “R” position ON
Select lever is in “N” position OFF
Select lever is in “D” position ON
Select lever is in “3” position ON
Select lever is in “2” position ON
Select lever is in “L” position ON
) THROTTLE
POSITION Ignition switch ONAccelerator peda
l is depressed 0 – 100% (Varies depending on
depressed value)
Accelerator peda l is released 0%
) BRAKE SWITCH Ignition switch ON Brake pedal is depressed
ON
Brake pedal is released OFF
Scan tool data
Vehicle condition Normal condition / reference
values

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-25
Scan Tool Data Definitions:
GEAR POSITION
Current gear position computed by throttle position
coming from ECM and vehicle speed.
ENGINE SPEED (RPM)
Engine speed computed by reference pulses from
crankshaft position sensor.
INPUT SHAFT REVOLUTION (RPM)
Input shaft revolution computed by reference pulses
coming from input shaft speed sensor on transaxle case.
OUTPUT SHAFT REVOLUTION (RPM)
Output shaft revolution computed by reference pulses
coming from output shaft speed sensor on transaxle
case.
BATTERY VOLTAGE (V)
Battery voltage read by TCM as analog input signal by
TCM.
ATF TEMPERATURE (°C, °F)
ATF temperature decided by signal from transmission
fluid temperature sensor installed on valve body.
SHIFT SOLENOID-A COMMAND
ON: ON command being outputted to shift solenoid
valve-A (No.1)
OFF: ON command not being outputted to shift solenoid
valve-A (No.1)
SHIFT SOLENOID-A MONITOR
ON: Electricity being passed to shift solenoid valve-A
(No.1)
OFF: Electricity not being passed to shift solenoid valve-
A (No.1)
SHIFT SOLENOID-B COMMAND
ON: ON command being outputted to shift solenoid
valve-B (No.2) OFF: ON command not being outputted to shift solenoid
valve-B (No.2)
SHIFT SOLENOID-B MONITOR
ON: Electricity being passed to shift solenoid valve-B
(No.2)
OFF: Electricity not being passed to shift solenoid valve-
B (No.2)
TIMING SOLENOID COMMAND
ON: ON command being outputted to timing solenoid
valve
OFF: ON command not being outputted to timing
solenoid valve
TIMING SOLENOID MONITOR
ON: Electricity being passed to timing solenoid valve
OFF: Electricity not being passed to timing solenoid
valve
TCC SOLENOID
Electric current value ratio between electric current value
being outputted from TCM to solenoid and maximum
value can be outputted by TCM.
PRESSURE CONTROL SOLENOID
Electric current value ratio between electric current value
being outputted from TCM to solenoid and maximum
value can be outputted by TCM.
VEHICLE SPEED (KPH/MPH)
Vehicle speed computed by reference pulse signals
coming from vehicle speed sensor on transaxle case.
O/D OFF SWITCH (“3” position switch)
Inputted signal from “3” position switch in select lever
assembly.
ON: Shift select lever to “3” or “2” range
OFF: Shift select lever to other above range
)
TORQUE
REDUCTION SIGNAL While on gear upshifting with 25% or more throttle
opening
ON
Under condition of not shifting gear OFF
) ENGINE COOLANT
TEMPERATURE Ignition switch ON Engine coolant temperature is
displayed
) AIR CONDITIONER
SIGNAL Ignition switch ON and air conditioner switch OFF OFF
) ENGINE TORQUE
SIGNAL Ignition switch ON and engine stop 0 N
⋅m
) SLIP RPM Engine running at idle speed
and select lever is in “P”
range 0 RPM
Engine running, vehicle stop and select lever is in “D”
range Engine speed is displayed
) MIL REQUEST Ignition switch ON OFF
) FUEL CUT FLAG Ignition switch ON OFFScan tool data Vehicle condition
Normal condition / reference
values

Downloaded from www.Manualslib.com manuals search engine 5A-26 Automatic Transmission/Transaxle:
TRANSAXLE RANGE
Transaxle range detected by signal fed from
transmission range sensor.
D RANGE SIGNAL
ON: Signal which TCM require ECM to increase idle
speed
OFF: Signal which TCM does not require ECM to
increase idle speed
THROTTLE POSITION (%)
Throttle opening ratio computed by CAN signal from
ECM.
BRAKE SWITCH
Inputted signal from brake light switch on pedal bracket.
ON: Brake pedal depressed
OFF: Brake pedal released
TORQUE REDUCTION SIGNAL
ON: Signal which TCM require ECM to reduce output
torque at shifting gear
OFF: Signal which TCM does not require ECM to reduce
output torque
ENGINE COOLANT TEMPERATURE ( °C, °F)
Engine coolant temperature computed by CAN signal
from ECM. AIR CONDITIONER SIGNAL
ON: Signal which inform that air conditioner compressor
is turned ON.
OFF: Signal which inform that air conditioner
compressor is not turned ON.
ENGINE TORQUE SIGNAL (N
⋅m)
Engine torque computed by duty pulse signal outputted
from ECM.
SLIP RPM (RPM)
This parameter indicates slip ping rotation in the torque
converter (difference between input shaft rotation and
engine rotation)
MIL REQUEST
ON: Signal which TCM requires combination meter to
turn on malfunction indicator lamp.
OFF: Signal which TCM does not require combination
meter to turn on malf unction indicator lamp.
FUEL CUT FLAG
ON: Signal which inform that fuel cut is operating.
OFF: Signal which inform that fuel cut is not operating.
A/T Basic CheckS7RS0B5104010
This check is important for troubleshooting when TCM has detected no DTC and no abnormality has been noted in
“Visual Inspection”. Fo llow the flow carefully.
Step Action YesNo
1 Was “A/T System Check” preformed? Go to Step 2.Go to “A/T System
Check”.
2 Perform “Road Test”.
Is it OK? Go to Step 3.
Proceed to
“Troubleshooting” in
“Road Test”.
3 Perform “Manual Road Test”.
Is it OK? Go to Step 4.
Proceed to
“Troubleshooting” in
“Manual Road Test”.
4 Perform “Engine Brake Test”.
Is it OK? Go to Step 5.
Proceed to
“Troubleshooting” in
“Engine Brake Test”.
5 Perform “Stall Test”.
Is it OK? Go to Step 6.
Proceed to
“Troubleshooting” in
“Stall Test”.
6 Perform “Time Lag Test”.
Is it OK? Go to Step 7.
Proceed to
“Troubleshooting” in
“Time Lag Test”.
7 Perform “Line Pressure Test”.
Is it OK? Go to Step 8.
Proceed to
“Troubleshooting” in
“Line Pressure Test”.
8 Proceed to “Trouble Diag nosis 1” in “A/T Symptom
Diagnosis”.
Is trouble identified? Repair or replace faulty
parts.
Go to Step 9.