brake sensor SUZUKI SWIFT 2005 2.G Service Manual PDF

Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-59
Installation
CAUTION!
Do not pull or twist wire harness more than
necessary when installing front wheel speed
sensor.

1) Check that no foreign material is attached to sensor(1) and mating encoder (2).
2) Install it by reversing removal procedure.
Tightening torque
Front wheel speed sensor bolt (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
Front wheel speed sensor harness clamp bolt
(b): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Check that there is no clearance between sensor and knuckle.
Front Wheel Speed Sensor InspectionS7RS0B4606030
Check sensor for damage.
If any malcondition is found, replace.
Rear Wheel Speed Sensor Removal and
Installation
S7RS0B4606031
CAUTION!
• Do not pull wire harness when removing rear wheel speed sensor.
• Do not cause damage to surface of rear wheel speed sensor and do not allow dust,
etc. to enter its installation hole.

Removal
1) Disconnect negative (–) cable from battery.
2) Remove quarter inner trim to brake referring to
“Floor Carpet Removal and Installation in Section
9H”.
3) Turn over floor carpet (2) and disconnect connector (1) of wheel speed sensor.
[A]: OK [B]: NG
(b)
1
[A][B]
11
2
(a)
I6RS0B460033-02
I5JB0A450031-01
2
2
1
I6RS0B460035-02

Downloaded from www.Manualslib.com manuals search engine 4F-60 Electronic Stability Program:
4) Hoist vehicle and remove wheel.
5) Remove harness clamp (1) and clamp bolts (2).
6) Remove rear wheel speed sensor (3) from knuckle.
Installation
CAUTION!
Do not pull or twist wi re harness more than
necessary when installing rear wheel speed
sensor.

Reverse removal procedure for installation noting the
following.
• Check that no foreign material is attached to sensor(1) and mating encoder (2).
• Be sure to install wheel speed sensor (1) and its bolt at the correct position as shown in figure.
Tighten sensor bolt and harness clamp bolts to
specified torque.
Tightening torque
Rear wheel speed sensor bolt (a): 11 N·m (1.1 kgf-
m, 8.0 lb-ft)
Rear wheel speed sensor harness clamp bolt (a):
11 N·m (1.1 kgf-m, 8.0 lb-ft)
• Check that there is no clearance between sensor and brake back plate.
Rear Wheel Speed Sensor InspectionS7RS0B4606032
Refer to “Front Wheel Speed Sensor Inspection” since
rear wheel speed sensor is the same as front wheel
speed sensor.
3
2
1
I6RS0B460036-02
[A]: OK [B]: NG
1
(b)
[A][B]
11
(a)
2
I6RS0B460037-02

Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-61
Front Wheel Encoder On-Vehicle InspectionS7RS0B4606033
Before inspect front wheel encoder, remove front drive
shaft or front wheel spindle referring to “Front Drive Shaft
Assembly Removal and Installation in Section 3A”.
• Check encoder (1) for being crack, damaged or deformed.
• Turn wheel and check if encoder rotation is free from eccentricity and looseness.
• Check that no foreign material is attached. If any faulty is found, cl ean encoder or replace wheel
bearing. Refer to “Front Wheel Hub, Steering Knuckle
and Wheel Bearing Removal and Installation in
Section 2B”.
Front Wheel Encoder Removal and InstallationS7RS0B4606034
CAUTION!
Front wheel encoder is included in front
wheel bearing. If front wheel encoder needs
to replaced, replace it as a front wheel
bearing.

For removal and installation of front wheel bearing,
referring to “Front Wheel Hub, Steering Knuckle and
Wheel Bearing Removal and Installation in Section 2B”.
Rear Wheel Encoder On-Vehicle InspectionS7RS0B4606035
Before inspect rear wheel encoder, hoist vehicle and
remove wheel.
• Check encoder (1) for being crack, damaged or deformed.
• Turn wheel and check if encoder rotation is free from eccentricity and looseness.
• Check that no foreign material is attached. If any faulty is found, cl ean encoder or replace rear
wheel hub assembly. Refer to “Rear Wheel Hub
Removal and Installati on in Section 2C”.
Rear Wheel Encoder Removal and InstallationS7RS0B4606036
CAUTION!
Rear wheel encoder is included in rear wheel
hub assembly. If rear wheel encoder needs to
replaced, replace it as a rear wheel hub
assembly.

For removal and installation of front wheel hub
assembly, referring to “Rear Wheel Hub Removal and
Installation in Section 2C”.
Master Cylinder Pressure Sensor On-Vehicle
Inspection
S7RS0B4606016
1) Calibrate yaw rate / G sens or assembly referring to
“Sensor Calibration”.
2) Check that basic brake system other than ESP ®
refer to “Brakes Diagnosi s Note in Section 4A”.
3) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
1
I5JB0A450034-01
1
I6RS0B460038-03
(A)
1
I4RS0B450003-01

Downloaded from www.Manualslib.com manuals search engine 4F-62 Electronic Stability Program:
4) Turn ignition switch to ON position and select menu “DATA LIST” mode of SUZUKI scan tool. Refer to
scan tool operator's manual for further derails.
5) When brake pedal is released, check “Master Cyl Press” under “DATA LIST” of SUZUKI scan tool.
If pressure is out of specification, replace ESP ®
hydraulic unit / cont rol module assembly.
Master cylinder pressure specification
Brake pedal released: 0 ± 0.8 MPa (0 ± 8 kg/cm2, 0
± 113 psi)
6) Hoist vehicle and remove right-side front wheel.
7) Connect special tool with rubber hose (1) to Front brake caliper bleeder plug (2).
Special tool
(A): 09956–02311
8) When bleeder plug loosen and depress brake pedal to make special tool gauge reading 10 MPa (100 kg/
cm
2, 1422 psi), check “Master Cyl Press” under
“DATA LIST” of SUZUKI scan tool.
If pressure displayed on SUZUKI scan tool is out of
specification, replace ESP ® hydraulic unit / control
module assembly.
Master cylinder pressure specification
Brake pedal depressed 10 MPa (100 kg/cm2, 1422
psi): 10 ± 1.2 MPa (100 ± 12 kg/cm2, 1422 ± 170
psi)
9) After completing the check, turn ignition switch to
OFF position and disconnect SUZUKI scan tool from
DLC.
10) Tighten bleeder plug and bleed air from brake system, referring to “Air Bleeding of Brake System in
Section 4A”.
Yaw Rate / G Sensor Assembly On-Vehicle
Inspection
S7RS0B4606017
Lateral G Inspection
1) Calibrate yaw rate / G sens or assembly referring to
“Sensor Calibration”.
2) Park and level the vehicle with parking brake and fix wheels with chokes.
3) Check yaw rate / G sensor assembly installation
condition. 4) Connect SUZUKI scan tool to data link connector
(DLC) (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
5) Turn ignition switch to ON position and select menu “DATA LIST” mode of SUZUKI scan tool. Refer to
scan tool operator's manual for further derails.
6) Check “G Sensor (lateral)” under “DATA LIST” of SUZUKI scan tool in the following vehicle conditions.
• Level condition
• Right-up condition
• Left-up condition
If Lateral G condition is ou t of specification, replace
yaw rate / G sensor assembly.
Lateral G sp ecification
2
(A)
1
I6JB01460025-01
Vehicle condition G Sensor (lateral)
Level condition 0 ± 0.1 G
Right-up condition 0.1 ± 0.1 G
Left-up condition –0.1 ± 0.1 G
[A]: Right-up condition “a”: Approx 350 mm (13.78 in.)
[B]: Left-up condition 1. Safety stand
(A)
1
I4RS0B450003-01
[A]
[B]“a”
1
“a”1
I6RS0B460039-02

Downloaded from www.Manualslib.com manuals search engine 4F-66 Electronic Stability Program:
Specifications
Tightening Torque SpecificationsS7RS0B4607001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
NOTE
The specified tightening torque is also described in the following.
“ESP® Hydraulic Unit / Control Module Assembly Removal and Installation”

Special Tools and Equipment
Special ToolS7RS0B4608001
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Brake pipe flare nut 16 1.6 11.5 )
ESP ® hydraulic unit / control module assembly
bolt 90.9 6.5)
ESP ® hydraulic unit / control module assembly
bracket bolt 25 2.5 18.0)
Front wheel speed sensor bolt 11 1.1 8.0 )
Front wheel speed sensor harness clamp bolt 11 1.1 8.0 )
Rear wheel speed sensor bolt 11 1.1 8.0 )
Rear wheel speed sensor har ness clamp bolt 11 1.1 8.0 )
Yaw rate / G sensor assembly nut 8 0.8 6.0 )
09956–02311SUZUKI scan tool
Brake pressure gauge —
) This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12.) / ) / ) /
) / ) / ) / )

Downloaded from www.Manualslib.com manuals search engine Table of Contents 5- i
5
Section 5
CONTENTS
Transmission / Transaxle
Precautions ................................................. 5-1
Precautions............................................................. 5-1
Precautions on Transmission / Transaxle ............. 5-1
Automatic Transmission/Transaxle ....... 5A-1
Precautions........................................................... 5A-1Precautions in Diagnosing Trouble ..................... 5A-1
Precautions for Disassembly and Reassembly ...................................................... 5A-1
General Description ............................................. 5A-3 A/T Description ................................................... 5A-3
Clutch / Brake / Planetary Gear Function of Automatic Transaxle ......................................... 5A-6
Table of Component Operation ........................... 5A-7
Brake Interlock System Construction .................. 5A-8
A/T Diagnosis General Description ..................... 5A-8
On-Board Diagnostic System Description ........... 5A-8
CAN Communication System Description........... 5A-9
Schematic and Routing Diagram ...................... 5A-10 Transmission Control Module (TCM) Wiring
Diagram .......................................................... 5A-10
Automatic Gear Shift Table ............................... 5A-12
Component Locatio n ......................................... 5A-13
Electronic Shift Cont rol System Components
Location .......................................................... 5A-13
Diagnostic Information and Procedures .......... 5A-15 A/T System Check ............................................ 5A-15
Visual Inspection ............................................... 5A-18
Malfunction Indicator Lamp (MIL) Check .......... 5A-18
Transmission Warning Ligh t Check .................. 5A-18
DTC Table ......................................................... 5A-19
DTC Check ....................................................... 5A-20
DTC Clearance ................................................. 5A-20
Fail-Safe Table ................ .................................. 5A-21
Scan Tool Data ................................................. 5A-23
A/T Basic Check ............................................... 5A-26
Road Test ......................................................... 5A-27
Manual Road Test ........... .................................. 5A-29
Engine Brake Test ............................................ 5A-30
Stall Test ........................................................... 5A-30
Time Lag Test ................................................... 5A-31
Line Pressure Test .......... .................................. 5A-32
“P” Range Test.................................................. 5A-33
A/T Symptom Diagnosis ..... .............................. 5A-34 No Gear Shift to 4th gear .................................. 5A-41
No Lock-Up Occurs ........................................... 5A-42
Transmission Warning Light Circuit Check –
Light Does Not Come “ON” at Ignition Switch
ON ................................................................... 5A-43
Transmission Warning Light Circuit Check – Light Remains “ON” at Ignition Switch ON ...... 5A-43
DTC P0602: Control Module Programming Error ................................................................ 5A-44
DTC P0705: Transmission Range Sensor Circuit Malfunction (PRNDL input) .................. 5A-44
DTC P0707: Transmission Range Sensor Circuit Low ...................................................... 5A-46
DTC P0712: Transmission Fluid Temperature Sensor “A” Circuit Low ... ................................. 5A-48
DTC P0713: Transmission Fluid Temperature Sensor “A” Circuit High .. ................................. 5A-49
DTC P0717: Input / Turbine Speed Sensor “A” Circuit Malfunction........................................... 5A-51
DTC P0722: Output Speed Sensor Circuit No Signal .............................................................. 5A-52
DTC P0787: Shift / Timing Solenoid Low .......... 5A-54
DTC P0788: Shift / Timing Solenoid High ......... 5A-56
DTC P0961: Pressure Control Solenoid “A”
Control Circuit Range / Performance .............. 5A-58
DTC P0962: Pressure Control Solenoid “A”
Control Circuit Low .......................................... 5A-60
DTC P0963: Pressure Control Solenoid “A”
Control Circuit High ......................................... 5A-62
DTC P0973 / P0976: Shift Solenoid “A” Control Circuit Low / Shift Solenoid “B”
Control Circuit Low .......................................... 5A-64
DTC P0974 / P0977: Shift Solenoid “A” / Shift Solenoid “B” Control Circuit High .................... 5A-66
DTC P1702: Internal Co ntrol Module Memory
Check Sum Error............................................. 5A-68
DTC P1703: Can Invalid Data - TCM ................ 5A-68
DTC P1723: Range Select Switch Malfunction ...................................................... 5A-69
DTC P1774: CAN Communication Bus Off ....... 5A-71
DTC P1777: TCM Lost Communication with ECM (Reception Error).................................... 5A-73
DTC P1778: TCM Lost Communication with BCM (Reception Error).................................... 5A-74

Downloaded from www.Manualslib.com manuals search engine 5-ii Table of Contents
DTC P1878: Torque Converter Clutch Shudder .......................................................... 5A-75
DTC P2762: Torque Converter Clutch (TCC) Pressure Control Sole noid Control Circuit
Range /Performance ....................................... 5A-76
DTC P2763: Torque Converter Clutch Pressure Control Sole noid Control Circuit
High ................................................................. 5A-78
DTC P2764: Torque Converter Clutch Circuit Pressure Control Sole noid Control Circuit
Low ................................................................. 5A-80
Inspection of TCM and Its Circuits .................... 5A-82
TCM Power and Ground Circuit Check ............. 5A-86
Brake Interlock System Inspection .................... 5A-87
Repair Instructions ........... .................................5A-88
Learning Control Initializat ion ............................ 5A-88
A/T Fluid Level Check ....................................... 5A-89
A/T Fluid Change .............................................. 5A-90
Select Lever Components ... .............................. 5A-90
Select Lever Assembly Removal and Installation ....................................................... 5A-90
Select Lever Knob Installa tion........................... 5A-90
Select Lever Inspection .... ................................. 5A-91
“3” Position Switch Inspec tion ........................... 5A-91
Shift Lock Solenoid Inspec tion .......................... 5A-91
Shift Lock Solenoid Replacement ..................... 5A-91
Select Cable Components ................................ 5A-92
Select Cable Removal and Installation ............. 5A-92
Select Cable Adjustment ................................... 5A-93
Key Interlock Cable Removal and Installation... 5A-93
Transmission Range Sensor (Shift Switch) Inspection and Adjustment .............................. 5A-95
Output Shaft Speed Sensor Removal and Installation ....................................................... 5A-96
Output Shaft Speed Sensor Inspection ............. 5A-96
Input Shaft Speed Sensor Removal and Installation ....................................................... 5A-96
Input Shaft Speed Sensor Inspection................ 5A-97
Transmission Fluid Temperature Sensor Removal and Installation ................................. 5A-97
Transmission Fluid Temperature Sensor Inspection ........................................................ 5A-98
Solenoid Valves (Shift Solenoid Valves and Timing Solenoid Valve) Removal and
Installation ....................................................... 5A-98
Solenoid Valves (Shift Solenoid Valves, and Timing Solenoid Valve) Inspection .................. 5A-99
Pressure Control Soleno id Valves (Pressure
Control Solenoid and TCC Pressure Control
Solenoid) Removal and Inst allation .............. 5A-101
Pressure Control Solenoid Valve Inspection ... 5A-101
Transmission Control Module (TCM) Removal and Installation ............................... 5A-102
A/T Relay Inspection ....................................... 5A-103
Differential Side Oil Seal Replacement ........... 5A-103
A/T Fluid Cooler Hoses Replacement ............. 5A-104
Automatic Transaxle Unit Components........... 5A-105
Automatic Transaxle Unit Dismounting and Remounting ................................................... 5A-106
Automatic Transaxle Asse mbly Components . 5A-108 Automatic Transaxle Unit
Disassembly........... 5A-110
Oil Pump Assembly Components ................... 5A-121
Oil Pump Assembly Disassembly and Reassembly .................................................. 5A-122
Oil Pump Assembly Inspection ....................... 5A-122
Direct Clutch Assembly Components.............. 5A-124
Direct Clutch Assembly Preliminary Check ..... 5A-124
Direct Clutch Assembly Disassembly and Reassembly .................................................. 5A-125
Direct Clutch Assembly Inspection.................. 5A-127
Forward and Reverse Clutch Assembly Components .................................................. 5A-128
Forward and Reverse Clutch Assembly Preliminary Check ......................................... 5A-129
Forward and Reverse Clutch Assembly Disassembly and Reassembly ...................... 5A-129
Forward and Reverse Clutch Assembly Inspection ...................................................... 5A-133
2nd Brake Piston Assembly Components ....... 5A-134
2nd Brake Piston Assembly Disassembly and Reassembly .................................................. 5A-134
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components........... 5A-135
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Disassembly and
Reassembly .................................................. 5A-136
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Inspection............... 5A-137
Countershaft Assembly Co mponents.............. 5A-138
Countershaft Assembly Disassembly and Reassembly .................................................. 5A-138
Valve Body Assembly Components ................ 5A-139
Valve Body Assembly Disassembly and Reassembly .................................................. 5A-140
Differential Assembly Components ................. 5A-141
Differential Assembly Disassembly and Reassembly .................................................. 5A-142
Differential Assembly Inspection ..................... 5A-143
Torque Converter Housing Disassembly and Reassembly .................................................. 5A-144
Transaxle Case Disassembly and Reassembly .................................................. 5A-146
Automatic Transaxle Unit Inspection and Adjus
tment .................................................... 5A-147
Automatic Transaxle Unit Assembly ............... 5A-150
Specifications .................. .................................5A-167
Tightening Torque Specifications .................... 5A-167
Special Tools and Equipmen t .........................5A-168
Recommended Service Material ..................... 5A-168
Special Tool .................................................... 5A-168
Manual Transmission/Tr ansaxle ............ 5B-1
General Description .............................................5B-1
Manual Transaxle Construction and Servicing .... 5B-1
Diagnostic Information and Procedures ............5B-3 Manual Transaxle Symptom Diagnosis............... 5B-3
Repair Instructions ............ ..................................5B-3
Manual Transaxle Oil Change............................. 5B-3
Differential Side Oil Seal Replacement ............... 5B-4

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 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