Meter SUZUKI SWIFT 2000 1.G Transmission Service Workshop Manual

MANUAL TRANSMISSION 7A-15
[A] : GEAR SHIFTER 12. Reverse gear shift arm 25. Reverse gear shift lever bolt
: Apply thread lock 99000-32110 to all around
thread part of bolt.
[B] : DIFFERENTIAL 13. 5th gear shift fork 26. 5th gear shift fork plug
: Apply thread lock 99000-32110 to all around
thread part of plug.
1. Gear shift & select shaft 14. Side gear washer 27. Guide case
2. 5th & reverse gear shift cam 15. Differential side pinion gear 28. Select lever shaft bush
: Apply grease 99000-25010 to whole area of
bush.
3. Gear shift interlock plate 16. Differential side gear 29. Select lever boss
: Apply grease 99000-25010 to internal and exter-
nal diameter
4. Gear shift & select lever 17. Side gear washer 30. Final gear bolt
: Apply thread lock 99000-32110 to all around
thread part of bolt
5. Shift cable lever 18. Differential side oil seal
: Apply grease 99000- 25010 to oil
seal lip.31. Differential pinion shaft
6. Select cable lever 19. Differential side bearing 32. Differential pinion shaft pin
7. Low speed gear shift shaft 20. Speed sensor ring Tightening torque
8. High speed gear shift shaft 21. Differential case Do not reuse.
9. 5th & reverse gear shift shaft 22. Final gear Apply transmission oil.
10. Reverse gear shift lever 23. 5th to reverse interlock guide bolt
: Apply sealant 99000-31110 to bolt
thread.
11. 5th & reverse gear shift guide
shaft24. Gear shift interlock bolt
: Apply sealant 99000-31110 to bolt
thread.

7A-38 MANUAL TRANSMISSION
17) Clean mating surface of both left case (2) and side cover (1),
apply sealant to side cover (1) by using a nozzle as shown in
figure by such amount that its section is 1.5mm (0.059 in.) in
diameter, mate it with left case and then tighten bolts.
“B” : Sealant 99000-31110
Tightening torque
Side cover No.1 bolts (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
Side cover No.2 bolts (b) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
GEAR SHIFT AND SELECT SHAFT ASSEMBLY
1) Clean mating surface of guide case.
2) Apply grease to select lever shaft bush and select lever
boss, and install gear shift and select shaft assembly with
new gasket into transmission.
“A” : Grease 99000-25010
3) Apply sealant to gear shift guide case No. 2 bolt (5). Tighten
gear shift guide case No. 1 bolts (1) and No. 2 bolt (5) to
specified torque at the position that clearance “a” is within 1 -
1.5 mm (0.04 - 0.06 in.).
Tightening torque
Guide case bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
4) Install washer and gear shift interlock bolt (2) to which seal-
ant have been applied and them tighten it to specified
torque.
“B” : Sealant 99000-31110
Tightening torque
Gear shift inter lock bolt (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
5) Install washer and 5th to reverse interlock guide bolt (3) to
which sealant have been applied and then tighten it to speci-
fied torque.
“B” : Sealant 99000-31110
Tightening torque
5th to reverse interlock guide bolt (a) : 23 N·m (2.3 kg-m,
17.0 lb-ft)

MANUAL TRANSMISSION 7A-39
6) Tighten backup lamp switch (1) to specified torque.
Tightening torque
Backup lamp switch (b) : 19 N·m (1.9 kg-m, 14.0 lb-ft)
7) Check input shaft for rotation in each gear position.
8) Also confirm function of back up light switch in reverse posi-
tion by using ohmmeter.
TIGHTENING TORQUE SPECIFICATION
Fastening partTightening torque
Nm kg-m lb-ft
Transmission oil level/filler and drain plugs 21 2.1 15.5
Oil gutter bolt 10 1.0 7.5
Final gear bolts 90 9.0 65.0
Reverse gear shift lever bolts 23 2.3 17.0
Transmission case bolts 19 1.9 14.0
Reverse shaft bolt 23 2.3 17.0
Locating spring bolts 13 1.3 9.5
Left case plate screw 9 0.9 6.5
Countershaft nut 60 6.0 43.5
5th shift fork plug 10 1.0 7.5
Side cover No.1 bolts 10 1.0 7.5
Side cover No.2 bolts 23 2.3 17.0
Guide case bolts 23 2.3 17.0
Gear shift interlock bolt 23 2.3 17.0
5th to reverse interlock guide bolt 23 2.3 17.0
Backup lamp switch 19 1.9 14.0

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-7
TRANSMISSION CONTROL MODULE (TCM)
TCM is an electronic circuit component that controls gear shift, idle-up according to the signal from each sensor.
Also it has learning control function for performing optimum control. It is a microcomputer consisting of an IC,
transistor, diode, etc. It is installed behind glove box.
1.“O/D OFF” lamp (in combination meter) 11. Backup lamp 21. Dropping resistor
2.“O/D” off switch 12. Shift indicator (if equipped) 22. Output shaft speed sensor (A/T VSS)
3. Monitor connector No.2 13. A/T 23. Input shaft speed sensor (Turbine rev. sensor)
4. Brake lamp 14. Transmission temperature sensor
(A/T fluid temp. sensor)24. A/T power source relay
5. Brake lamp switch 15. Shift solenoid-A (Shift solenoid No.1) 25. Ignition switch
6. ECM 16. Shift solenoid-B (Shift solenoid No.2) 26. DLC
7. A/C clutch 17. Shift solenoid-C (Shift solenoid No.3) 27. Barometric pressure sensor
8. Transmission range sensor (Shift switch) 18. Shift solenoid-D (Shift solenoid No.4) 28. Solenoid power relay
9. Shift lock solenoid switch (if equipped) 19. Shift solenoid-E (Shift solenoid No.5) 29. Terminal arrangement of TCM coupler
(Viewed from harness side)
10. Shift lock solenoid (if equipped) 20. TCC solenoid (Lock-up solenoid)
C41-14
C41-21
C42-5
C41-23
G02-16
BLKBLKLT GRN/ RED/BLU BLU/ORN
PPL/YEL
3
45
+BB
GRN/WHT
LT BLU
PPL
WHT/BLK
BLK/WHT
BRN
PNK/BLK 6
7
8
C44-8
C43-8
C44-18
C44-20
C43-5
C44-5
910
ORN
RED
GRN/ORN RED/BLK
GRNC43-1
C43-2
C43-3
C43-9
C43-10
C43-11 GRN/YEL
BLU/WHT P
R
N
D
2
L11
12C44-21
C44-17
C43-4
C44-4
12V 12V
12V
12V
12V IG1
IG115V
5VC44-3
C44-16
C44-10
C44-23
C44-24
C44-25
C44-26
C44-22
C44-11
C44-12
C44-13
C43-6
C43-14
C43-13
C43-7
C43-15
C44-2
C44-15
C43-12
BLU BLUBLK
BLK BLK
BLU/YEL
YEL/BLK RED/WHT WHT BLU/ORN RED/BLU GRY/BLU
BLK/YEL WHT/BLU
BRN/WHT BRN/WHT BRN WHT/RED
BLK/YEL
BRN/YEL BLU/RED
GRY/RED13
14
15
16
17
19
20 BRN
21
22
23
+BB 24
25
26
12V
12V
12V
12V
18
12V
IG1
IG11
5V
1
2
28
27

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-16 AUTOMATIC TRANSMISSION (4 A/T)
2. DIAGNOSTIC TROUBLE CODE (DTC) CHECK, RECORD AND CLEARANCE
To check DTC, refer to “DTC CHECK” in this section. When a DTC exists, it means existence of a malfunction in
the system represented by that code but whether it still exists (current) or it occurred in the past and has gone
(history) is unknown. To know it, clear this DTC once (Refer to “DTC CLEARANCE” in this section.), perform
test drive and/or “TROUBLE SYMPTOM CONFIRMATION” in this section and then check DTC again as
described in “DTC CHECK”. Attempt to diagnose the trouble based on the DTC recorded in this step only or fail-
ure to clear the DTC in this step may mislead the diagnosis or make diagnosing difficult. Even after checking the
DTC with the SUZUKI scan tool, diagnosis should be performed according to this flow chart to check TCM for
proper self-diagnosis function.
3 and 4. VISUAL INSPECTION
As a preliminary step, perform visual check of the following items that support proper function of the automatic
transmission.
5.TROUBLE SYMPTOM CONFIRMATION
Check if what the customer claimed in “CUSTOMER COMPLAINT ANALYSIS” is actually found in the vehicle
and if that symptom is found, whether it is identified as a failure. (This step should be shared with the customer
if possible.)
When the symptom is not actually found, possibility is :
The symptom occurs under certain conditions.
----- Retry with the vehicle under different conditions.
The trouble occurred only temporarily and normal operation has been restored.
----- Perform “DTC CHECK” and if the diagnostic trouble code is indicated, inspect according to the flow
table for that DTC.
6 and 7. RECHECKING AND RECORD OF DTC
Refer to “DTC CHECK” in this section.INSPECTION ITEM REFERRING SECTION
Engine oil ----- level, leakage Section 0B
Engine coolant ----- level, leakage Section 0B
A/T fluid ----- level, leakage, color Section 0B
Battery ----- fluid level, corrosion of terminal
A/T fluid hoses ----- disconnection, looseness, deterioration
Connectors of electric wire harness ----- disconnection, friction Section 8
Fuses ----- burning Section 8
Parts ----- installation, bolt ----- looseness
Parts ----- deformation
Other parts that can be checked visually
Also add following items at engine start.
Indicator, warning lights in combination meter ----- ON
(indicating abnormality in system) or OFFSection 8C
Other parts that can be checked visually

7B-20 AUTOMATIC TRANSMISSION (4 A/T)
STALL TEST
This test is to check overall performance of automatic transmis-
sion and engine by measuring stall speed at “D” and “R” ranges.
Be sure to perform this test only when transmission fluid is at nor-
mal operating temperature and its level is between FULL and
LOW marks.
1) Apply parking brake and block wheels.
2) Install tachometer.
3) Start engine with select lever shifted to “P”.
4) Depress brake pedal fully.
5) Shift select lever to “D” and depress accelerator pedal fully
while watching tachometer. Read engine rpm quickly when it
has become constant (stall speed).
6) Release accelerator pedal immediately after stall speed is
checked.
7) In the same way, check stall speed in “R” range.
8) Stall speed should be within following specification.
Stall speed
: 2,750 – 3,150 r/min CAUTION:
 Do not run engine at stall more than 5 seconds contin-
uously, for fluid temperature may rise excessively
high.
 After performing stall test, be sure to leave engine run-
ning at idle for longer than 30 seconds before another
stall test.
Test result Possible cause
Lower than
standard levelLack of engine output
Defective torque converter
Higher than
standard level
in “D” rangeLow line pressure
Malfunctioning 1st & 2nd brake
Malfunctioning rear clutch
Malfunctioning stator one-way clutch
Higher than
standard level
in “R” rangeLow line pressure
Malfunctioning rear clutch
Malfunctioning reverse brake
Malfunctioning stator one-way clutch
Malfunctioning direct clutch

AUTOMATIC TRANSMISSION (4 A/T) 7B-25
[INTERMITTENT TROUBLES] and [NOTES ON SYSTEM CIR-
CUIT INSPECTION]
Refer to Section 0A.
DTC CHECK
[Check DTC with SUZUKI scan tool]
1) Turn ignition switch OFF.
2) After setting cartridge, connect SUZUKI scan tool to data link
connector (DLC) (1) located on underside of instrument
panel at driver’s seat side.
Special tool
(A) : 09931-76011 (SUZUKI scan tool)
(B) : Mass storage cartridge
(C) : 09931-76030 (16/14 pin DLC cable)
3) Turn ignition switch ON.
4) Read DTC according to instructions displayed on SUZUKI
scan tool and print it or write it down. Refer to SUZUKI scan
tool operator’s manual for further details.
5) After completing the check, turn ignition switch OFF and dis-
connect SUZUKI scan tool from data link connector (DLC)
(1).
[Check DTC without SUZUKI scan tool]
1) Turn ignition switch ON and make sure that O/D OFF lamp is
OFF in combination meter (O/D off switch OFF).
2) Turn ignition switch OFF.
3) Pull out clip (3) and remove glove box (2) from instrument
panel (1).

AUTOMATIC TRANSMISSION (4 A/T) 7B-53
INSPECTION OF TCM AND ITS CIRCUITS
TCM and its circuits can be checked at TCM wiring couplers by
measuring voltage and resistance.
INSPECTION
1) Remove TCM from vehicle referring to “TRANSMISSION
CONTROL MODULE” in this section.
2) Connect TCM couplers to TCM.
3) Check voltage at each terminal of couplers connected.CAUTION:
TCM cannot be checked by itself, it is strictly prohibited
to connect voltmeter or ohmmeter to TCM with coupler
disconnected from it.
NOTE:
As each terminal voltage is affected by the battery volt-
age, confirm that it is 11 V or more when ignition switch
is ON.
1. TCM 3. Body ground
2. Couplers
TERMINAL CIRCUITSTAN-
DARD
VOLTAGECONDITION
C431 Transmission range “P” switch10 – 14 V IG switch ON, selector lever at “P” range
0 – 1 V IG switch ON, selector lever other than “P” range
2 Transmission range “R” switch10 – 14 V IG switch ON, selector lever at “R” range
0 – 1 V IG switch ON, selector lever other than “R” range
3 Transmission range “N” switch10 – 14 V IG switch ON, selector lever at “N” range
0 – 1 V IG switch ON, selector lever other than “N” range
4 Diagnosis switch 10 – 14 VIG switch ON, diagnosis switch terminal not
grounded
5 Engine speed signal 0 – 1 V IG switch ON, leaving engine OFF
6 Output shaft speed sensor(+)––
7 Input shaft speed sensor(+)––
8 throttle opening signal––
9 Transmission range “D” switch10 – 14 V IG switch ON, selector lever at “D” range
0 – 1 V IG switch ON, selector lever other than “D” range
10 Transmission range “2” switch10 – 14 V IG switch ON, selector lever at “2” range
0 – 1 V IG switch ON, selector lever other than “2” range
11 Transmission range “L” switch10 – 14 V IG switch ON, selector lever at “L” range
0 – 1 V IG switch ON, selector lever other than “L” range