fluid table SUZUKI SWIFT 2006 2.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine 5A-132 Automatic Transmission/Transaxle:
• Measure forward clutch piston stroke in the same manner as “Forward and Reverse Clutch Assembly
Preliminary Check”.
When piston stroke is out of specification, select
forward clutch retaining plate with proper thickness
from among the following table and replace it.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
Forward clutch piston stroke
1.30 – 1.50 mm (0.051 – 0.059 in.)
Available forward clutch retaining plate thickness
• Install reverse clutch cushion plate (1) in correct direction as shown in figure.
• Apply A/T fluid to reverse clutch cushion plate (1),
reverse clutch separator plate (2), discs (3) and
retaining plate (4).
• Install reverse clutch cushio n plate (1), reverse clutch
separator plate (2), discs (3), retaining plate (4) and
then snap ring (5) to inte rmediate shaft subassembly. • Install reverse clutch plate snap ring so that its both
ends would be positioned in correct locations as
shown in figure.
• Measure reverse clutch piston stroke in the same manner as “Forward and Reverse Clutch Assembly
Preliminary Check”.
When piston stroke is out of specification, select
reverse clutch retaining plate with proper thickness
from among the following table and replace it.
Special tool
(A): 09900–20607
(B): 09900–20701
Reverse clutch piston stroke
1.20 – 1.60 mm (0.047 – 0.063 in.)
Available reverse clutch retaining plate thickness
Thickness Identification mark
3.0 mm (0.118 in.) 1
3.1 mm (0.122 in.) 5
3.2 mm (0.126 in.) 2
3.3 mm (0.130 in.) 6
3.4 mm (0.134 in.) 3
3.5 mm (0.138 in.) 7
3.6 mm (0.142 in.) 4
1. Oil hole
I2RH0B510177-02
I3RM0B510062-01
[A]: Correct[B]: Incorrect
ThicknessIdentification mark
3.0 mm (0.118 in.) 1
3.2 mm (0.126 in.) 2
3.4 mm (0.134 in.) 3
3.6 mm (0.142 in.) 4
I2RH0B510190-01
I2RH0B510191-01

Downloaded from www.Manualslib.com manuals search engine 5A-148 Automatic Transmission/Transaxle:
One-way clutch No.1 assembly1) Install one-way clutch No.1 assembly (2) to rear planetary sun gear subassembly (1).
2) Securing rear planetary sun gear subassembly, ensure that one-way clutch No.1 assembly rotates
only in one direction.
If the one-way clutch rotates in both directions or it
does not rotate in either direction, replace it with new
one.
Adjustment
Differential side bearing preload 1) After applying A/T fluid to differential assembly, fit it to transaxle case.
2) Install torque converter housing to transaxle case, then tighten bolts (1) to specified torque.
Tightening torque
Torque converter housing bolt (a): 29 N·m (2.9
kgf-m, 21 lb-ft) 3) Measure bearing preload (a) by using a special tool.
Special tool
(A): 09928–06050
Differential side bearing preload (a) measured as
starting torque
In the case of new bearing: 0.78 – 1.37 N ⋅m (7.9 –
13.9 kg-cm, 0.58 – 1.01 lb-ft)
In the case of reused bearing: 0.39 – 0.69 N ⋅m
(3.9 – 6.9 kg-cm, 0.29 – 0.51 lb-ft)
4) If bearing preload is out of specification, select shim with suitable thickness from among the list below
and replace it. Then adjust differential side bearing
preload within specification.
Available shim thickness
NOTE
Record measured differential side bearing,
because it is necessary to adjust
countershaft bearing preload.

5) Remove differential assembly.
I2RH0B510254-01
I2RH0B510255-01
Thickness Identification mark
1.80 mm (0.070 in.) A
1.85 mm (0.072 in.) B
1.90 mm (0.074 in.) C
1.95 mm (0.076 in.) D
2.00 mm (0.078 in.) E
2.05 mm (0.080 in.) F
2.08 mm (0.081 in.) G
2.11 mm (0.083 in.) H
2.14 mm (0.084 in.) J
2.17 mm (0.085 in.) K
2.20 mm (0.087 in.) L
2.23 mm (0.088 in.) M
2.26 mm (0.089 in.) N
2.29 mm (0.090 in.) P
2.32 mm (0.091 in.) Q
2.35 mm (0.092 in.) R
2.40 mm (0.094 in.) S
2.45 mm (0.096 in.) T
2.50 mm (0.098 in.) U
2.55 mm (0.100 in.) V
2.60 mm (0.102 in.) W
2.65 mm (0.104 in.) X
2.70 mm (0.106 in.) Y
I2RH0B510256-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-149
Countershaft bearing preload1) After applying A/T fluid to countershaft assembly (1) and differential assembly (2), fit them.
2) Install torque converter housing to transaxle case, then tighten bolts to specified torque.
Tightening torque
Torque converter housing bolt: 29 N·m (2.9 kgf-
m, 21 lb-ft)
3) Measure bearing preload (b) by using special tool. Special tool
(A): 09928–06050
Countershaft bearing preload (b) measured as
starting torque
In the case of new bearing: 0.33 – 0.96 N⋅ m (3.3 –
9.8 kg-cm, 0.24 – 0.69 lb-ft)
In the case of reused bearing: 0.17 – 0.38 N ⋅m
(1.7 – 3.8 kg-cm, 0.12 – 0.28 lb-ft) 4) If bearing preload is out of specification, select shim
with suitable thickness from among the list below
and replace it. Then adjust countershaft bearing
preload within specification.
Available shim thickness
5) Remove differential assembly and countershaft assembly.
Countershaft bearing
preload =(b) – Differential side bearing
preload (a)
I2RH0B510257-01
I3RM0B510067-01
Thickness Identification mark
1.70 (0.066 in.) 1
1.75 (0.068 in.) 2
1.80 (0.070 in.) 3
1.85 (0.072 in.) 4
1.90 (0.074 in.) 5
1.93 (0.075 in.) 6
1.96 (0.077 in.) 7
1.99 (0.078 in.) A
2.02 (0.079 in.) B
2.05 (0.080 in.) C
2.08 (0.081 in.) D
2.11 (0.083 in.) E
2.14 (0.084 in.) F
2.17 (0.085 in.) G
2.20 (0.086 in.) H
2.25 (0.088 in.) K
2.30 (0.090 in.) L
2.35 (0.092 in.) M
2.40 (0.094 in.) N
2.45 (0.096 in.) P
2.50 (0.098 in.) Q
2.55 (0.100 in.) R
2.60 (0.102 in.) S
2.65 (0.104 in.) U
2.70 (0.106 in.) W

Downloaded from www.Manualslib.com manuals search engine 5A-158 Automatic Transmission/Transaxle:
42) Measure O/D and 2nd coast brake piston stroke.• Measure dimension “a” from end face of transaxle case to O/D and 2nd coast brake rear plate (1)
using straightedge and micrometer caliper.
• Measure dimension “b” from O/D and 2nd coast brake piston (2) to rear cover assembly mating
surface using straightedge and micrometer
caliper.
• Calculate piston stroke from measured value of dimensions “a” and “b”.
• Piston stroke = “a” – “b”
O/D and 2nd coast brake piston stroke
Standard: 0.65 – 1.05 mm (0.026 – 0.041 in.)
When piston stroke is out of specification, select O/D
and 2nd coast brake rear plate with proper thickness
from among the following table and replace it.
Available O/D and 2nd coast brake rear plate
thickness
43) After applying A/T fluid to new 2nd brake gaskets (1), install them to transaxle case (2).
44) After applying A/T fluid to reverse clutch drum thrust bearing (1), install it to forward and reverse clutch
assembly (2).
45) Remove sealant attached to mating surface of transaxle rear cover (1) completely.
46) Apply sealant to mating surface of transaxle rear cover (1) by using a nozzle (2) as shown in figure by
such amount that its section is 1.2 mm (0.047 in.) in
diameter.
“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B)
Thickness Identification mark
1.8 mm (0.071 in.) 1
2.0 mm (0.079 in.) 2
2.2 mm (0.087 in.) 3
2.4 mm (0.094 in.) 4
2.6 mm (0.102 in.) 5
I2RH0B510298-01
I2RH0B510299-01
I2RH0B510300-01
“A” 2
1
I2RH0B510301-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-161
60) Measure input shaft thrust play.Apply dial gauge onto input shaft end (1) and
measure thrust play of input shaft.
Special tool
(A): 09900–20607
(B): 09900–20701
Input shaft thrust play
0.3 – 0.9 mm (0.012 – 0.035 in.)
When input shaft thrust play is out of specification,
select input shaft front th rust bearing with proper
thickness from among the following table and
replace it.
Available input shaft front thrust bearing
thickness
61) After applying A/T fluid to new O-ring, fit it to breather union (2). Then install breather union to
transaxle case.
62) Install breather hose (1). 63) Wipe off and clean mating surface between
transaxle case (1) and torque converter housing.
64) Apply sealant to torque converter housing by using a nozzle (2) as shown in figure by such amount that its
section is 1.2 mm (0.047 in.) in diameter.
“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B)
65) Install torque converter housing to transaxle case, tighten bolts to specified torque.
CAUTION!
Apply sealant to threads of four bolts shown
in figure before tightening.

“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B)
Tightening torque
Torque converter housing bolt (a): 29 N·m (2.9
kgf-m, 21 lb-ft)
Thickness
Outside
diameter Inside diameter
3.45 mm
(0.14 in.) 48.5 mm
(1.90 in.) 32.9 mm
(1.30 in.)
4.05 mm
(0.16 in.) 48.5 mm
(1.90 in.) 32.5 mm
(1.28 in.)
I2RH0B510313-01
I2RH0B510314-01
1 2
“A”
I2RH0B510315-01
I3RM0B510069-01

Downloaded from www.Manualslib.com manuals search engine 9-ii Table of Contents
List of Connectors ........................................... 9A-103
C Connector .................................................... 9A-103
D Connector (M16A engine) ........................... 9A-104
E Connector .................................................... 9A-104
G Connector .................................................... 9A-106
J Connector ..................................................... 9A-108
K Connector .................................................... 9A-109
L Connector..................................................... 9A-109
M Connector (SPORT model) ......................... 9A-111
O Connector .................................................... 9A-111
R Connector .................................................... 9A-111
Lighting Systems .................................... 9B-1
Component Location ........... ................................9B-1
Lighting System Component s Location............... 9B-1
Interior Light System Location............................. 9B-2
Diagnostic Information and Procedures ............ 9B-2 Headlight Symptom Diagnosis ............................ 9B-2
Headlight Leveling System Symptom Diagnosis (If Equipped) ..................................... 9B-2
Turn Signal and Hazard Warning Light Symptom Diagnosis .......................................... 9B-3
Clearance, Tail and License Plate Light Symptom Diagnosis .......................................... 9B-3
Back-Up Light Symptom Diagnosis..................... 9B-4
Brake Light Symptom Diagnosis ......................... 9B-4
Front Fog Light Symptom Diagnosis (If Equipped) .......................................................... 9B-4
Interior Light Symptom Diagnosis ....................... 9B-5
Repair Instructions ..............................................9B-5 Headlight Housing Removal and Installation ...... 9B-5
Headlight Bulb Replacemen t............................... 9B-6
Headlight Aiming Adjustment with Screen .......... 9B-6
Headlight Switch (in Lighting Switch) Removal and Installation ................................... 9B-8
Headlight Switch (in Lighting Switch) Inspection .......................................................... 9B-8
Hazard Warning Switch Removal and Installation ......................................................... 9B-8
Hazard Warning Switch Inspection ..................... 9B-9
Brake Light Switch Inspection ............................. 9B-9
Turn Signal Light Switch (in Lighting Switch) Removal and Installation ................................... 9B-9
Turn Signal Light Switch (in Lighting Switch) Inspection .......................................................... 9B-9
Turn Signal and Hazard Warning Relay Removal and Installation ................................... 9B-9
Turn Signal and Hazard Warning Relay Inspection ........................................................ 9B-10
License Light Removal and Installation............. 9B-10
Front Fog Light Removal and Installation (If Equipped) ........................................................ 9B-11
Front Fog Light Bulb Replacement (If Equipped) ........................................................ 9B-11
Front Fog Light Switch Inspection (If Equipped) ........................................................ 9B-11
Front Fog Light Relay Inspection (If Equipped) ........................................................ 9B-11
Front Fog Light Aiming Adjustment with Screen (If Equipped) ....................................... 9B-12 Headlight Leveling Switch Inspection (If
Equipped) ........................................................ 9B-13
Headlight Leveling Actuator Inspection (If Equipped) ........................................................ 9B-13
Instrumentation / Driver Info. / Horn ...... 9C-1
Precautions ...........................................................9C-1 Precautions in Diagnosing Troubles for Combination Meter ............................................9C-1
General Description .............................................9C-1 CAN Communication System Description...........9C-1
Auto Volume Co ntrol System Description (If
Equipped) ..........................................................9C-3
Schematic and Routing Diagram ........................9C-4 Combination Meter Circuit Diagram ....................9C-4
Component Location ............ ...............................9C-6
Audio System Component Location ....................9C-6
Diagnostic Information and Procedures ............9C-6 Speedometer and VSS Symp tom Diagnosis ......9C-6
Tachometer Symptom Diagnosis ........................9C-6
Engine Coolant Temperature (ECT) Meter Symptom Diagnosis ..........................................9C-7
Fuel Meter Symptom Diagnosis ..........................9C-7
Low Fuel Warning Light Symptom Diagnosis .....9C-7
Oil Pressure Warning Light Symptom Diagnosis ..........................................................9C-8
Brake and Parking Brake Warning Light Symptom Diagnosis ..........................................9C-8
Seat Belt Reminder Light Symptom Diagnosis (If Equipped)......................................................9C-8
A/T Shift Position Indicator Symptom Diagnosis (A/T Model).......................................9C-9
Charge Warning Light Sy mptom Diagnosis ........9C-9
Main Beam (High Beam) Indicator Symptom Diagnosis ..........................................................9C-9
Warning Buzzer Circuit Sy mptom Diagnosis ....9C-10
Cigarette Lighter Symptom Diagnosis (If Equipped) ........................................................9C-10
Horn Symptom Diagnosis .................................9C-10
Information Display Symptom Diagnosis (If Equipped) ........................................................9C-11
Clock Symptom Diagnosis (If Equipped)...........9C-12
Audio System Symptom Diagnosis (If Equipped) ........................................................9C-12
Remote Audio Control Switch Symptom Diagnosis (If Equipped) ...................................9C-13
Navigation Symptom Diagnosis (If Equipped)...9C-14
Repair Instructions ............ ................................9C-14
Ignition Switch Removal and Installation...........9C-14
Ignition Switch Inspection..................................9C-14
Combination Meter Removal and Installation ...9C-15
Fuel Level Sensor Removal and Installation .....9C-15
Fuel Level Sensor Inspection ............................9C-15
Oil Pressure Switch Remova l and Installation ..9C-15
Oil Pressure Switch Inspec tion .........................9C-16
Engine Coolant Temperature (ECT) Sensor Inspection ........................................................9C-16
Brake Fluid Level Switch Inspection .................9C-16
Parking Brake Switch Inspec tion.......................9C-16

Downloaded from www.Manualslib.com manuals search engine 10B-9 Body Electrical Control System:
Diagnostic Information and Procedures
BCM Self-Diagnosis FunctionS7RS0BA204001
• BCM monitors conditions of the system components and its circuit with ignition switch turned to ON position. When
an abnormality in the system oc curs, the area where that abnormality lies is stored in the memory of EEPROM in
BCM.
• DTC can be checked in either one of following ways. – DTC can be checked by SUZUKI scan tool (2) connected to DLC (1).
– DTC can be read from flashing pattern of theft deterrent light (3). Also, DTC is displayed on combination meter
(4) at the same time.
BCM input / output table
4. Oil pressure switch 15. Rear end door window defogger switch 26. Rear wiper relay
5. Outside air temperature sensor (if equipped) 16. A/C switch
27. Rear end door window defogger relay
6. Door lock actuator (incorporated in key cylinder switch) 17. Hazard warning switch
28. Turn signal and hazard warning relay
7. Door switch 18. Rear wiper switch 29. Key reminder switch (included in ignition switch)
8. Interior light 19. Lighting switch
9. Rear end door opener switch 20. Manual door lock switch
3
1
2
4I4RS0BA20004-03
Control
Input Output
Power door lock system • Key cylinder switch
• Manual door lock switch • Each door lock actuator
Keyless entry system • Key reminder switch
• Keyless entry receiver
• Driver side door switch • Each door lock actuator
• Turn signal and hazard warning relay
• Interior light
Keyless start system
(Door lock function) • Keyless start control module
• Each door lock actuator
• Turn signal and hazard warning relay
• Interior light
Rear wiper • Rear wiper INT switch
• Rear wiper LO switch • Rear wiper relay
Combination meter • Tail light switch
• Oil pressure switch
• Parking brake switch
• Driver side seat belt switch
• Brake fluid level switch
• Generator
• Each door switch • Combination meter