timing SUZUKI SWIFT 2005 2.G Service Repair Manual
[x] Cancel search | Manufacturer: SUZUKI, Model Year: 2005, Model line: SWIFT, Model: SUZUKI SWIFT 2005 2.GPages: 1496, PDF Size: 34.44 MB
Page 401 of 1496

Downloaded from www.Manualslib.com manuals search engine Ignition System:  1H-9
6) Set timing light (1) to high-tension cord for No.1 cylinder and check that ignition timing is within 
specification.
Initial ignition timing
Fixed with SUZUKI scan tool: 5  ± 3° BTDC (at 
specified idle speed)
Ignition order
1 – 3 – 4 – 2
Special tool
(A):  09930–76420 7) If ignition timing is out 
of specification, check the 
followings.
• CKP sensor
• CKP sensor plate
• CMP sensor
• CMP sensor rotor tooth of camshaft
• VSS
• Timing chain cover installation
8) After checking initial igniti on timing, release ignition 
timing fixation by using scan tool.
9) With engine idling (throttl e opening at closed position 
and vehicle stopped), check that ignition timing is 
about 3 ° – 13°  BTDC. (Constant variation within a 
few degrees from 3 ° – 13°  BTDC indicates no 
abnormality but proves operation of electronic timing 
control system.) Also, check that increasing engine 
speed advances ignition timing.
If the check results are not satisfactory, check CKP 
sensor and ECM.
Specifications
Tightening Torque SpecificationsS7RS0B1807001
Reference:
For the tightening torque of fastener not specified in this  section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Special ToolS7RS0B1808001
1, (A)10
0I3RB0A180004-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Spark plug 25 2.5  18.0  )
Ignition coil bolt 10 1.0  7.5  )
09930–76420SUZUKI scan tool
Timing-light (dry cell type) —
 ) 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.  )  
Page 641 of 1496

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  
Page 642 of 1496

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  
Page 647 of 1496

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.  
Page 652 of 1496

Downloaded from www.Manualslib.com manuals search engine 5A-8 Automatic Transmission/Transaxle: 
Brake Interlock System ConstructionS7RS0B5101004
Shift Lock Solenoid Control
This system consists of shift lock solenoid control 
system and interlock cable control system.
The shift lock solenoid cont rol system is so designed 
that the select lever can not be shifted from “P” range 
position unless ignition switch is turned to “ON” or “ACC” 
position and the brake pedal is depressed.
And interlock cable control system is so designed that 
select lever cannot be shifted from “P” range position 
unless ignition switch is turned to “ACC” or “ON” 
position. Also, ignition key cannot be pulled out of key 
slot unless select le ver is in “P” range.
Shift Lock Solenoid Manual Release
When push down shift lock solenoid valve release button 
(1), select lever can be moved from “P” range position to 
another range even without depressing the brake pedal. 
(To shift select lever from “P” range to any other position, 
turn ignition switch to ACC or ON position.)
A/T Diagnosis General DescriptionS7RS0B5101005
This vehicle is equipped with an electronic transaxle 
control system, which controls the automatic shift up and 
shift down timing, TCC operation, etc. suitably to vehicle 
driving conditions.
TCM has an On-Board Diagnosis System which detects 
a malfunction in this system.
When diagnosing a trouble in transaxle including this 
system, be sure to have full understanding of the outline 
of “On-Board Diagnostic System Description” and each 
item in “Precautions in Diagnosing Trouble” and execute 
diagnosis according to “A/T System Check” to obtain 
correct result smoothly.
On-Board Diagnostic System DescriptionS7RS0B5101006
For automatic transaxle co ntrol system, TCM has the 
following functions. Refer to “Inspection of TCM and Its 
Circuits”.
• When ignition switch is turned ON with no malfunction  in A/T control system is detected, transmission 
warning light (1) lights for about 2 seconds after 
ignition switch is turned ON and then goes OFF for 
bulb check.
• When TCM detects a malfunction in A/T control  system, it indicates  transmission warning light (1) and 
stores malfunction DTC in its memory.
• It is possible to communicate with TCM through data  link connector (DLC) (3) by using SUZUKI scan tool 
(2). Diagnostic information can be checked and 
erased by using SUZUKI scan tool.
• For information about the following items, refer to “On- Board Diagnostic System De scription in Section 1A”
– Warm up cycle
– Driving cycle
– 2 Driving cycle detection logic
– Pending DTC
– Freeze frame data
1
I6RS0C510001-01
3
2
1
I6RS0C510002-01  
Page 654 of 1496

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)