forward SUZUKI SWIFT 2005 2.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine 3A-12 Drive Shaft / Axle:
10) Set new differential side (or center shaft side) small band and new differential side (or center shaft side)
boot on shaft temporarily.
11) Drive in the cage (1) by using special tool.
Special tool
(A): 09913–84510
12) Install circlip (1) by using snap ring pliers (2).
13) Apply grease to entire su rface of cage. Use specified
grease in tube included in spare parts.
14) Insert cage into joint housing (2) and fit snap ring (1) into groove of joint housing (2).
CAUTION!
Position opening of snap ring “c” so that it
will not be lined up with a ball.

15) Apply grease (including in spare parts) to inside of joint housing (1).
Grease color
“A”: Dark gray
Amount
“A”: 70 – 90 g (2.5 – 3.2 oz) 16) Fit boot (1) to grooves of shaft and housing (2) adjust
length to specification below.
17) Inset screw driver into boot and allow air to enter boot so that air pressure in boot becomes the same
as atmospheric pressure.
Drive shaft boot fixing position (distance
between boot end (housing side) and small boot
band center)
Left side and right side drive shafts “a”: 89.5 mm
(3.52 in.)
CAUTION!
• Band each boot band against forward rotation.
• Do not squeeze or distort boot when fastening it with bands. Distorted boot
caused by squeezing air may reduce its
durability.

(A)
1
I5RS0B310009-01
I5RS0B310010-01
I2RH01310036-01
[A]: Drive shaft inserted into differential side
[B]: Drive shaft inserted into center shaft side
I5RS0B310011-02
I5RS0B310012-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: 3A-13
18) Place differential side boot (or center shaft side) new
big band (3) and new small band (4) onto boot
putting band outer end (1) against forward rotation
(2) as shown in figure.
19) Fasten differential side (or center shaft side) boot band.
• For differential side (or center shaft side) boot big band
Fasten band (1) by drawing hooks (2) with special
tool and engage hooks (3) in slot and window (4).
Special tool
(A): 09943–57021
• For differential side (or center shaft side) boot small band
Fasten band (5) using special tool as shown in
figure.
Distance “a”
: 2.6 ± 1.4 mm (0.102 ± 0.055 in.)
Special tool
(B): 09943–57010
I5JB0A311006-01
(A)
1 4
2 3
(B)
5 “a”
I5RS0B310013-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-1
Brakes
Brake Control System and Diagnosis
Precautions
Precautions on BrakeS7RS0B4100001
Air Bag Warning
Refer to “Air Bag System Service Warning in Section 00”.
Brakes Diagnosis Note
Refer to “Brakes Diagnosis Note”.
General Description
Brakes ConstructionS7RS0B4101001
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two
in front and two in rear).
The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make two
independent circuits. One connects front right & rear left brakes and the other connects front left & rear right brakes.
In this brake system, the disc brake type is used for the front wheel brake and the rear wheel brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and
mechanical linkage system. The same brake shoes or pads are used for both parking and foot brakes.
A
5
3
2
1
4
8
8
6
7
I6RS0C410001-01
1. Brake booster 4. Primary side 7. Parking brake lever
2. Master cylinder 5. 4 way joint 8. Parking brake cable
3. Secondary side 6. ABS or ESP® hydraulic unit / control module assembly A: Forward

Downloaded from www.Manualslib.com manuals search engine 4A-10 Brake Control System and Diagnosis:
7) Then attach bleeder plug cap.
8) After completing bleeding operation, apply fluid pressure to pipe line and check for leakage.
9) Replenish fluid into reserv oir up to specified level.
10) Check brake pedal for sponginess. If found spongy, repeat entire procedure of bleeding.
Front Brake Hose / Pipe Removal and
Installation
S7RS0B4106007
“Front Brake Hose / Pipe Construction”
CAUTION!
Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid, flush it with water immediately
if any fluid is spilled.

Removal
1) Raise and support vehicle properly. Remove tire and wheel.
NOTE
This operation is not necessary when
removing pipes connecting master cylinder.

2) Clean dirt and foreign mate rial from both flexible
hose end and pipe end fittings.
3) Drain brake fluid in reservoir.
4) Remove brake flexible hose or pipe.
Installation
Reverse brake flexible hose removal procedure, noting
the following.
• Make sure that steering wh eel is in straight-forward
position and flexible hose has not twist or kink.
• Check to make sure that flexible hose doesn’t contact any part of suspension, both in extreme right and
extreme left turn conditions. If it does at any point,
remove and correct. Fill and maintain brake fluid level
in reservoir.
• Bleed brake system. Refer to “Air Bleeding of Brake System”.
• Perform brake test and check installed part for fluid leakage.
Rear Brake Hose / Pipe Removal and
Installation
S7RS0B4106008
CAUTION!
Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid, flush it with water immediately
if any fluid is spilled.

Removal
1) Raise and support vehicle properly. Remove tire and wheel.
2) Clean dirt and foreign material from both flexible hose end and pipe end fittings.
3) Drain brake fluid in reservoir.
4) Remove brake flexible hose or pipe.
Installation
Reverse brake flexible hose removal procedure, noting
the following.
• Fill and maintain brake fluid level in reservoir.
• Bleed brake system. Refer to “Air Bleeding of Brake System”.
• Perform brake test and check each installed part for fluid leakage.
• Never reuse protector nut once removed. Be sure to use a new one.
• Install clamps properly referring to the figure and tighten bolts.
• When installing hose, make sure that it has no twist or
kink.
I4RS0B410006-01

Downloaded from www.Manualslib.com manuals search engine 4F-2 Electronic Stability Program:
Perform sensor calibration according to “Sensor Calibration”.
Precautions in Speedometer Test or Other TestsS7RS0B4600005
When performing speedometer or other tests using speedometer tester or chassis dynamometer, ESP® function must
be deactivated by ESP ® OFF switch or using SUZUKI scan to ol to complete the tests correctly.
When using SUZUKI scan tool, set to the “MISC. TEST” mode to stop the ESP ® function. Refer to SUZUKI scan tool
operator's manual for further details.
General Description
Electronic Stability Program DescriptionS7RS0B4601006
Electronic Stability Program (ESP ®) is an auxiliary function to enable the vehicle to av oid a danger safely while the
vehicle is running, stopping or turning.
Electronic Stability Program (ESP ®) consists of following functions.
ESP ® is a registered trademark of Daimler Chrysler AG.
Antilock Brake System (ABS)
This system prevents tire locking which may occur when br ake is applied suddenly or on slippery roads. With this
function, as the vehicle body is kept in the stable state an d tires unlocked, the driver can avoid any obstacle by turning
the steering wheel.
Electronic Brake force Distribution (EBD)
This function distributes braking force of front and rear wheels properly according to the vehicle load condition.
With this function, the braking force of the front and rear wheels is controlled for the optimum effect to secure the
maximum braking force regardless of the loadage.
Traction Control System (TCS)
This system controls the engine and brake to prevent the dr iving wheels from spinning at the time of starting and
accelerating. Particularly, this fu nction is helpful for safe driving on muddy or icy roads. When ESP ® control module
detects wheel spinning using information from the yaw rate sensor and wheel speed sensor, it lower the engine torque
by closing the electronic controlled thro ttle and controlling ignition. At the same time, brake is applied to the spinning
tire.
Stability Control
This function controls the vehicle body in the stable state by controlling the engine and braking so as to prevent the
vehicle from over-steering or under-steering while turning.
When under-steering occurs, this function lowers the engine torque and applies brake to the inner rear wheel in the
vehicle forward direction so as to pr event the vehicle from moving outward.
When over-steering occurs, this function applies brake to the outer front wheel in the vehicle forward direction so as to
prevent the vehicle from moving inward. Sensor Procedures required calibration
Steering angle sensor • Power is not su pplied to steering angle sensor. (battery, fuse and/or connector is
removed.)
• Steering angle sensor is replaced.
• Power is not supplied to ESP ® control module. (battery, fuse and/or connector is
removed.)
• ESP® hydraulic unit / control module assembly is replaced.
Master cylinder pressure sensor • ESP® hydraulic unit / control module assembly is removed or replaced.
Yaw rate / G sensor assembly • Yaw rate / G sensor assembly is removed or replaced.
• ESP® hydraulic unit / control module assembly is replaced.

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 Automatic Transmission/Transaxle: 5A-1
Transmission / Transaxle
Automatic Transmission/Transaxle
Precautions
Precautions in Diagnosing TroubleS7RS0B5100001
• Do not disconnect couplers from TCM, battery cable from battery, TCM ground wire harness from engine or
main fuse before checking the diagnostic information
(DTC, freeze frame data, etc.) stored in TCM memory.
Such disconnection will clea r memorized information
in TCM memory.
• Diagnostic information stored in TCM memory can be cleared as well as checked by using SUZUKI scan
tool or generic scan tool. Before using scan tool, read
its Operator’s (Instruction) Manual carefully to have
good understanding as to what functions are available
and how to use it.
It is indistinguishable wh ich module turns on MIL
because not only ECM but also TCM turns on MIL.
Therefore, check both ECM and TCM for DTC when
MIL lights on.
When checking TCM for DTC, keep in mind that DTC
is displayed on the scan tool as follows depending on
the scan tool used.
– SUZUKI scan tool displays DTC detected by TCM.
– Generic scan tool displays DTC detected by each of ECM and TCM simultaneously.
• Using SUZUKI scan tool the diagnostic information stored in TCM memory can be checked and cleared
as well. Before its use, be sure to read Operator’s
Manual supplied with it carefully to have good
understanding of its functions and usage.
• Be sure to read “Precautions for Electrical Circuit Service in Section 00” befo re inspection and observe
what is written there.
• TCM replacement
– When substituting a known-good TCM, check that all relays and actuators have resistance of
specified value.
Neglecting this check may result in damage to good
TCM.
• Communication of ECUs , ECM, TCM, ABS control
module, keyless start control module and BCM is
established by CAN (Controller Area Network).
Therefore, handle CAN communication line with care
referring to “Precaution for CAN Communication
System in Section 00”.
Precautions for Disassembly and ReassemblyS7RS0B5100002
When repairing automatic transaxle, it is necessary to
conduct the on-vehicle test to investigate where the
cause of the trouble lies first.
Then whether overhaul should be done or not is
determined. If the transaxle is disassembled without
such preliminary procedure, not only the cause of the
trouble would be unknown, but also a secondary trouble
may occur and often time would be wasted.
As the automatic transaxle consists of high precision
component, the following cautions should be strictly
observed when handling its parts in disassembly and
reassembly.
• Disassembling valve body assembly is prohibited
essentially. However, a few parts can be
disassembled. When disassembling valve body
component parts, confirm whether their parts are
allowed to disassemble or not referring to “Valve Body
Assembly Disassembly and Reassembly”.
• When component part of forward clutch, direct clutch, 2nd brake and/or O/D and 2nd coast brake, namely
clutch disc, brake disc, retaining plate and/or
separator plate, have been replaced, all learned
contents, which have been stored in TCM memory by
executing learning control, should be initialized
referring to “Learning Control Initialization”.
• Make sure to wash dirt off from the transaxle so that no such dirt will enter the transaxle during
dismounting and remounting.
• Select a clean place free from dust and dirt for overhauling.
• Place a rubber mat on the work bench to protect parts from damage.
• Work gloves or shop cloth should not be used. (Use a nylon cloth or a paper towel.)
• When separating the case joint, do not pry with a screwdriver or such but tap with a plastic hammer
lightly.
• Make sure to wash dirt off from the transaxle so that no such dirt will enter the transaxle during
disassembly and reassembly.
• Wash the disassembled parts in ATF (Automatic Transaxle Fluid) or kerosene (using care not to allow
ATF or kerosene to get on your face, etc.) and confirm
that each fluid passage is not clogged by blowing air
into it. But use kerosene to wash the discs, resin
washers and rubber parts.
• Replace each gasket, oil seal and O-ring with a new one.
• Apply ATF to sliding or rotating parts before
reassembly.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-3
General Description
A/T DescriptionS7RS0B5101001
This automatic transaxle is electronic control full automatic transaxle with forward 4-speed and reverse 1-speed.
The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an automatically controlled lock-up
mechanism.
The gear change device consists of a ravigneau type planet ary gear unit, 3 multiple disc type clutches, 3 multiple disc
type brakes and 2 one-way clutches.
The hydraulic pressure control device consists of a valve body assembly, pressure control solenoid valve (linear
solenoid), 2 shift solenoid va lves, TCC pressure control solenoid valve (lin ear solenoid) and a timing solenoid valve.
Optimum line pressure complying with engine torque is produced by the pressure control solenoid valve in
dependence upon control signal from transmission control module (TCM). This makes it possible to control the line
pressure with high accuracy in accordance with the engine power and running conditions to achieve smooth shifting
characteristics and high efficiency.
A clutch-to-clutch control system is prov ided for shifting between 3rd gear and 4th gear. This clutch-to-clutch control
system is made to function optimally , so that hydraulic pressure controls such as shown below are conducted.
• When upshifting from 3rd gear to 4th gear, to adjust the drain hydraulic pressure at releasing the forward clutch, a
timing solenoid valve is used to switch a hydraulic passage with an orifice to another during shifting.
• When downshifting from 4th gear to 3rd gear, to adjust the line pressure applied to the forward clutch at engaging the forward clutch, a timing solenoid valve is used to s witch a hydraulic passage with an orifice to another during
shifting.
• When upshifting from 3rd gear to 4th gear with engine throttle opened, to optimize the line pressure applied to the forward clutch at releasing the forward clutch, the learning control is processed to compensate the switching timing
of the timing solenoid at every shifting.
• When downshifting from 4th gear to 3rd gear with engine throttle opened, to optimize the line pressure applied to
the forward clutch at engaging the forw ard clutch, the learning control is processed to compensate the line pressure
at every shifting.
Employing the ravigneau type planetary gear unit and this clutch-to-clutch control system greatly simplifies the
construction to make possible a lightweight and compact transaxle.
A line pressure learning control is conducted to provide opti mum shifting time at every upshifting with engine throttle
opened. If long upshifting time is detected, the subsequent line pressure applied during upshifting is intensified. On the
contrary, if short upshifting time is detected, the subs equent line pressure applied during upshifting is weakened.
Slip controlled lock-up function
Even at a lower speed than when the TCC gets engaged completely, control over the TCC pressure control solenoid
works to cause the TCC to slip (be engaged slightly), ther eby improving the transmission efficiency. While such slip
control is being executed, the oil pressure applied to the TCC is controlled by the TCC pressure control solenoid so
that the difference between the engine speed and the input shaft speed becomes close to the specified value.
Also, during deceleration, the TCC is made to slip (be enga ged slightly) to raise the engine speed and enlarge the fuel
cut operation range so that better fuel consumption is achieved.
Due to this reason, it is absolutely necessary for the automati c transmission to use ATF suitable for slip control. Use of
any fluid other than the specified ATF may cause j uddering or some other faulty condition to occur.

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 Automatic Transmission/Transaxle: 5A-5
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