Cool SUZUKI SWIFT 2006 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Wheels and Tires: 2D-2
Lower than recommended pressure can cause:
• Tire squeal on turns
• Hard Steering
• Rapid and uneven wear on the edges of the tread
• Tire rim bruises and rupture
• Tire cord breakage
• High tire temperature
• Reduced handling
• High fuel consumption
Replacement Tires
When replacement is necessary, the original equipment
type tire should be used. Refer to the Tire Placard.
Replacement tires should be of the same size, load
range and construction as those originally on the vehicle.
Use of any other size or type tire may affect ride,
handling, speedometer / odometer calibration, vehicle
ground clearance and tire or snow chain clearance to the
body and chassis.
It is recommended that new tires be installed in pairs on
the same axle. If necessary to replace only one tire, it
should be paired with the tire having the most tread, to
equalize braking traction.
WARNING!
Do not mix different types of tires on the
same vehicle such as radial, bias and bias-
belted tires except in emergencies, because
handling may be seriously affected and may
result in loss of control.

The metric term for tire infl ation pressure is the kilo
pascal (kPa). Tire pressures is usually printed in both
kPa and kgf/cm
2 on the “Tire Placard”.
Metric tire gauges are available from tool suppliers.
The chart, shown the table, converts commonly used
inflation pressures from kPa to kgf/cm
2 and psi.
Wheels DescriptionS7RS0B2401002
Wheel Maintenance
Wheel repairs that use welding, heating, or peening are
not approved. All damaged wheels should be replaced.
Replacement Wheels
Wheels must be replaced if they are bent, dented, have
excessive lateral or radial runout, air leak through welds,
have elongated bolt holes, if lug wheel bolts won’t stay
tight, or if they are heavily rusted. Wheels with greater
runout than shown in the following may cause
objectional vibrations.
Replacement wheels must be equivalent to the original
equipment wheels in load capacity, diameter, rim with
offset and mounting configuration. A wheel of improper
size or type may affect wheel and bearing life, brake
cooling, speedometer / odometer calibration, vehicle
ground clearance and tire clearance to body and
chassis.
How to Measure Wheel Runout
To measure the wheel runout, it is necessary to use an
accurate dial indicator. The tire may be on or off the
wheel. The wheel should be installed to the wheel
balancer of the like for proper measurement.
Take measurements of both lateral runout “a” and radial
runout “b” at both inside an d outside of the rim flange.
With the dial indicator set in place securely, turn the
wheel one full revolution slowly and record every reading
of the indicator.
When the measured runout exceeds the specification
and correction by the balancer adjustment is impossible,
replace the wheel. If the reading is affected by welding,
paint or scratch, it should be ignored.
Lateral runout limit “a”
: 0.3 mm (0.012 in.)
Radial runout limit “b”
: 0.3 mm (0.012 in.)
kPa kgf/cm2psi
Conversion: 1 psi =
6.895 kPa 1 kgf/cm
2 =
98.066 kPa 160 1.6 23
180 1.8 26
200 2.0 29
220 2.2 32
240 2.4 35
260 2.6 38
280 2.8 41
300 3.0 44
I4RS0A240001-01

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2) Check tire if it can be repaired, referring to “Tire
Repair”. If it cannot be repaired, replace it with new
one.
3) Replace valve core of flat tire with new one if tire is reused after repairing.CAUTION!
Be sure to use new valve core. Otherwise, air
leak may occur due to sealant attached to
valve core.

4) Install tire to ri m of wheel, check that there is no air
leakage and adjust it to specified pressure shown on
tire placard.
Specifications
Wheels and Tires SpecificationsS7RS0B2407001
Tire size (Standard)
: 195/50R16 87V
Wheel size (Standard)
: 16x 6 J
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
NOTE
• Tire inflation pressure should be checked when tires are cool.
• Specified tire inflation pressure should be found on tire placard or in owner’s manual which came
with the vehicle.

Tightening Torque SpecificationsS7RS0B2407002
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
Wheel nut 858.5 61.5 ) / )

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

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SpecificationsItem Specifications
Torque converter Ty p e
Stall torque ratio 3-element, 1-step, 2-phase type (with TCC (lock-up)
mechanism)
2.0 – 2.2
Oil pump Ty p e
Drive system Internal involute gear type oil pump (non crescent type)
Engine driven
Gear change
device Type 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
Forward 1st
↔ 2nd ↔ 3rd ↔ 4th automatic gear
change
“3” range Forward 1st
↔ 2nd ↔ 3rd ← 4th automatic gear
change
“2” range Forward 1st ↔ 2nd ← 3rd automatic gear change
“L” range Forward 1st
← 2nd ← 3rd reduction, and fixed at 1st
gear
Gear
ratio 1st 2.875 Number of teeth Front sun gear: 24
2nd 1.568 Rear sun gear: 30
3rd 1.000 Long planet pinion: 20
4th (overdrive gear) 0.697 Short planet pinion: 19
Reverse (reverse gear) 2.300 Ring gear: 69
Control elements Wet type multiple-disc clutch... 3 sets
Wet type multiple-d
isc brake... 3 sets
One-way clutch... 2 sets
Reduction gear ratio 1.023
Final gear reduction ratio 4.277
Lubrication Lubrication system Force feed system by oil pump
Cooling Cooling system Radiator assisted cooling (water-cooled)
Fluid used SUZUKI ATF 3317 or Mobil ATF 3309

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CAN Communication System DescriptionS7RS0B5101007
Refer to “CAN Communication System Description in Section 1A” for CAN communication System description. TCM
communicates control data with each control module as follows.
TCM Transmission Data
TCM Reception Data
DATA
TCM
Transmit
Transmission oil temperarure
signal
Torque request signal
Vehicle speed pulse signal
Transmission warning light
signal
Transmission actual gear position
signal
A/T select lever position signal
ECMCombination
meterBCM
I7RS0B510001-03
Engine torque signal
Engine speed signal
Throttle position signal
A/C compressor clutch signal
Engine coolant temperature signal
Brake pedal switch signal
Reception data from ECM
Accelerator pedal position signalI7RS0B510002-03

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

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Visual InspectionS7RS0B5104002
Visually check the following parts and systems.
Malfunction Indicator Lamp (MIL) CheckS7RS0B5104003
Refer to the same item in “Malfunction Indicator Lam p (MIL) Check in Section 1A” for checking procedure.
Transmission Warning Light CheckS7RS0B5104004
1) Turn ignition switch ON.
2) Check that transmission warning light lights for about 2 – 4 sec. and then goes OFF.
If anything faulty is found, advance “Transmission Warn ing Light Circuit Check – Light Does Not Come “ON” at
Ignition Switch ON” or “Transmission Warning Light Circu it Check – Light Remains “ON” at Ignition Switch ON”.
Inspection item Referring
• A/T fluid ----- level, leakage, color “Automatic Transaxle Fluid Level Inspection in Section 0B”
• A/T fluid hoses ----- disconnection, looseness, deterioration “A/T Fluid Cooler Hoses Replacement”
• A/T select cable ----- installation “S elect Cable Removal and Installation”
• Engine oil ----- level, leakage “Engine Oil and Filter Change in Section 0B”
• Engine coolant ----- level, leakage “Engine Coolant Change in Section 0B”
• Engine mountings ----- play, looseness, damage “Engine Assembly Removal and Installation in Section 1D”
• Suspension ----- play, looseness “Suspension, Wheels and Tires Symptom Diagnosis in Section 2A”
• Drive shafts ----- damage “Front Drive Shaft Assembly On-Vehicle Inspection in Section 3A”
• Battery ----- indicator condition, corrosion of terminal “Battery Inspection in Section 1J”
• Connectors of electric wire harness ----- disconnection, friction “Electronic Shift Control System Components
Location”
• Fuses ----- burning
• Parts ----- installation, damage
• Bolts ----- looseness
• Other parts that can be checked visually
Also check the following items at engine start, if possible.
• Transmission warning light (if equipped) ----- Operation “Transmission Warning Light Check”
• Malfunction indicator lamp ----- Operation “Malfunction Indicator Lamp (MIL) Check”
• Charge warning lamp ----- Operation “Generator Symptom Diagnosis in Section 1J”
• Engine oil pressure warning lamp ----- Operation “Oil Pressure Warning Ligh t Symptom Diagnosis in
Section 9C”
• Engine coolant temp. meter ----- Operation “Engine Coolant Temperature (ECT) Meter
Symptom Diagnosis in Section 9C”
• Other parts that can be checked visually
I4RS0A510008-01

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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 5A-22 Automatic Transmission/Transaxle:
) P1702 Internal control module memory check
sum error • Power supply for all solenoid valves is cut.
• Gear position is fixed in 3rd gear.
• Line pressure control at gear shifting is inhibited.
• Lock-up function is inhibited to operate.
) P1703 CAN invalid data - TCM In case of throttle position signal malfunction:
• Throttle opening used for line pressure control is assumed
to be 100%.
• Throttle opening used for gear shifting control is assumed to be 0%.
• Upshifting to 4th gear is inhibited.
• Lock-up function is inhibited to operate. Line pressure control at gear shifting is inhibited.
• Garage shift control is inhibited.
• Learning control is inhibited.
In case of engine coolant temperature signal malfunction:
• Slip controlled lock-up function is inhibited to operate.
• After 15 minutes pass from detecting malfunction, engine coolant temperature is assumed to be normal operating
temperature, and controls of overdrive and lock-up is
released from inhibition.
In case of engine revolution signal malfunction:
• 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.
In case of engine torque signal malfunction:
• Line pressure control at gear shifting is inhibited.
• Torque reducing request to ECM (torque reduction control) is inhibited.
• Upshifting to 4th gear is inhibited.
• Learning control is inhibited.
) P1723 Range select switch malfunction “3” position switch is assumed to be OFF.
) P1774 Control module communication bus off • Throttle opening used for line pressure control is assumed
to be 100%.
• Throttle opening used for gear shifting control is assumed to be 0%.
• Engine revolution is assumed to be 0 RPM.
• After 15 minutes pass from detecting malfunction, engine coolant temperature is assumed to be 90 °C (194 °F).
• 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.
• Upshifting to 4th gear is inhibited.
• Garage shift control is inhibited.
• Learning control is inhibited.
DTC No. Trouble area Fail-safe operation

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Scan Tool DataS7RS0B5104009
As the data values given in the following table are standard values estimated on the basis of values obtained from the
normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good
condition, there may be cases where the checked value does not fall within each specified data range. Therefore,
judgment as abnormal should not be made by checking with these data alone.
Also, condition in the following table that can be checked by the scan tool are those detected by TCM and output from
TCM as commands and there may be cases where the auto matic transaxle or actuator is not operating (in the
condition) as indicated by the scan tool.
NOTE
The following scan tool data related to automatic transaxle can be checked only by communicating
with TCM.

) P1777 TCM lost communication with ECM
(Reception error) • Throttle opening used for line pressure control is assumed
to be 100%.
• Throttle opening used for gear shifting control is assumed to be 0%.
• Engine revolution is assumed to be 0 RPM.
• After 15 minutes pass from detecting malfunction, engine coolant temperature is assumed to be 90 °C (194 °F).
• 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.
• Upshifting to 4th gear is inhibited.
• Garage shift control is inhibited.
• Learning control is inhibited.
) P1778 TCM lost communication with BCM
(Reception error) “3” position switch is assumed to be OFF.
) P1878 Torque converter clutch shudder Slip contro lled lock-up function is inhibited to operate.
) P2762 Torque converter clutch pressure control
solenoid control circuit range /
performance • Lock-up function is inhibited to operate.
• Slip controlled lock-up function is inhibited to operate.
• Upshifting to 4th gear is inhibited when transmission fluid
temperature is 150 °C (302 ° F) or more.
• Gear position is fixed in 1st gear when vehicle speed is 10 km/h (6 mile/h) or less.
) P2763 Torque converter clutch pressure control
solenoid control circuit high • Lock-up function is inhibited to operate.
• Upshifting to 4th gear is inhibited when A/T fluid
temperature is more than 150 °C (302 °F).
• Vehicle speed is slower than 10 km/h (6 mile/h), gear position is fixed in 1st gear for prevention of engine stall.
) P2764 Torque converter clutch pressure control
solenoid control circuit low • Lock-up function is inhibited to operate.
• Upshifting to 4th gear is inhibited when A/T fluid
temperature is more than 150 °C (302 °F).
DTC No. Trouble area Fail-safe operation
Scan tool data
Vehicle condition Normal condition / reference
values
) GEAR POSITION Ignition switch ON Select lever is in “P” position
P or N
Select lever is in “R” position R
Select lever is in “N” position P or N
Select lever is in “D” position 1
Select lever is in “3” position 1
Select lever is in “2” position 1
Select lever is in “L” position 1