Information SUZUKI SWIFT 2006 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 4F-66 Electronic Stability Program:
Specifications
Tightening Torque SpecificationsS7RS0B4607001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
NOTE
The specified tightening torque is also described in the following.
“ESP® Hydraulic Unit / Control Module Assembly Removal and Installation”

Special Tools and Equipment
Special ToolS7RS0B4608001
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Brake pipe flare nut 16 1.6 11.5 )
ESP ® hydraulic unit / control module assembly
bolt 90.9 6.5)
ESP ® hydraulic unit / control module assembly
bracket bolt 25 2.5 18.0)
Front wheel speed sensor bolt 11 1.1 8.0 )
Front wheel speed sensor harness clamp bolt 11 1.1 8.0 )
Rear wheel speed sensor bolt 11 1.1 8.0 )
Rear wheel speed sensor har ness clamp bolt 11 1.1 8.0 )
Yaw rate / G sensor assembly nut 8 0.8 6.0 )
09956–02311SUZUKI scan tool
Brake pressure gauge —
) 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.) / ) / ) /
) / ) / ) / )

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

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 Table of Contents 5-iii
Gear Shift Control Lever and Cable Components...................................................... 5B-5
Gear Shift Control Le ver and Cable Removal
and Installation .................................................. 5B-6
Gear Select Control Cable Adjustment ............... 5B-6
Back Up Light Switch Removal and Installation ......................................................... 5B-7
Back Up Light Switch Inspection ......................... 5B-7
Manual Transaxle Unit Components ................... 5B-8
Manual Transaxle Unit Dismounting and Remounting....................................................... 5B-9
Gear Shift and Sele ct Shaft Assembly
Components.................................................... 5B-11
Gear Shift and Sele ct Shaft Assembly
Removal and Installation................................. 5B-11
Gear Shift and Select Shaft Disassembly and Assembly ........................................................ 5B-12
Manual Transaxle Assembly Components........ 5B-13
Fifth Gear Disassembly and Assembly ............. 5B-14
Manual Transaxle Assembly Disassembly and Reassembly ............................................. 5B-16
Transaxle Right Case Disassembly and Assembly ........................................................ 5B-23
Transaxle Left Case Disassembly and Assembly ........................................................ 5B-24
Input Shaft and Countershaft Components....... 5B-25
Input Shaft Assembly Disassembly and Reassembly .................................................... 5B-26
Countershaft Assembly Disassembly and Reassembly .................................................... 5B-28
Synchronizer Parts Inspec tion .......................... 5B-31
Gear Shift Shaft Components ........................... 5B-31
5th and Reverse Gear Shift Shafts Disassembly and Assembly ............................ 5B-32
Gear Shift Shaft and Fork Inspection ................ 5B-32
Differential Components ................................... 5B-33
Differential Disassembly and Assembly ............ 5B-33
Specifications ..................................................... 5B-35
Tightening Torque Specifications ...................... 5B-35
Special Tools and Equipmen t ........................... 5B-36
Recommended Service Material ....................... 5B-36 Special Tool ...................................................... 5B-36
Clutch ................
.............................. ......... 5C-1
General Description .............................................5C-1
Clutch Construction .............................................5C-1
Diagnostic Information and Procedures ............5C-2 Clutch System Symptom Diagnosis ....................5C-2
Repair Instructions ........... ...................................5C-2
Clutch Pedal Inspection ......................................5C-2
Clutch Fluid Level Inspection ..............................5C-3
Air Bleeding of Clutch System.............................5C-3
Clutch Pedal Position (CPP) Switch Removal and Installation ..................................................5C-4
Clutch Pedal Position (CPP) Switch Inspection and Adjustment ................................5C-5
Clutch Fluid Pipe and Hose Components ...........5C-5
Clutch Fluid Pipe Removal and Installation.........5C-6
Clutch Fluid Pipe Inspection................................5C-6
Clutch Master Cylinder Removal and Installation .........................................................5C-6
Clutch Operating Cylinder Removal and Installation .........................................................5C-7
Clutch Operating Cylinder Inspection..................5C-7
Clutch Pedal and Clutch Pedal Bracket Components ......................................................5C-7
Clutch Cover, Clutch Disc and Flywheel Components ......................................................5C-8
Clutch Cover, Clutch Disc and Flywheel Removal and Installation ...................................5C-8
Clutch Cover, Clutch Disc and Flywheel Inspection ........................................................5C-10
Clutch Release Syst em Removal and
Installation .......................................................5C-11
Clutch Release System Inspection ...................5C-13
Specifications .................... .................................5C-13
Tightening Torque Specifications ......................5C-13
Special Tools and Equipmen t ...........................5C-14
Recommended Service Material .......................5C-14
Special Tool ......................................................5C-14

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 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

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-15
Diagnostic Information and Procedures
A/T System CheckS7RS0B5104001
Refer to the following items for the details of each step.Step Action Yes No 1 ) Customer complaint analysis
1) Perform customer complaint analysis.
Was customer complaint analysis performed? Go to Step 2. Perform customer
complaint analysis.
2 ) DTC / freeze frame data check, record and clearance
1) Check for DTC.
Is there any DTC(s)? Print DTC or write them
down and clear them by
referring to “DTC
Clearance”. Go to Step
3.Go to Step 4.
3 ) Visual inspection
1) Perform visual inspection.
Is there any faulty condition? Repair or replace
malfunction part. Go to
St ep 11 .
Go to Step 5.
4 ) Visual inspection
1) Perform visual inspection.
Is there any faulty condition? Repair or replace
malfunction part. Go to
St ep 11 .
Go to Step 8.
5 ) Trouble symptom confirmation
1) Confirm trouble symptom.
Is trouble symptom identified? Go to Step 6.
Go to Step 7.
6 ) Rechecking and record of DTC / freeze frame data
1) Recheck for DTC referring to “DTC Check”.
Is there any DTC(s)? Go to Step 9.
Go to Step 8.
7 ) Rechecking and record of DTC / freeze frame data
1) Recheck for DTC referring to “DTC Check”.
Is there any DTC(s)? Go to Step 9.
Go to Step 10.
8 ) A/T basic check and A/T symptom diagnosis
1) Check and repair according to “A/T Basic Check” and “A/
T Symptom Diagnosis”.
Are check and repair complete? Go to Step 11. Check and repair
malfunction part(s). Go
to Step 11.
9 ) Troubleshooting for DTC
1) Check and repair according to applicable DTC flow.
Are check and repair complete? Go to Step 11. Check and repair
malfunction part(s). Go
to Step 11.
10 ) Check for intermittent problems
1) Check for interm ittent problems.
Is there any faulty condition? Repair or replace
malfunction part(s). Go
to Step 11.
Go to Step 11.
11 ) Final confirmation test
1) Clear DTC if any.
2) Perform final confirmation test.
Is there any problem symptom, DTC or abnormal condition? Go to Step 6.
End.

Downloaded from www.Manualslib.com manuals search engine 5A-16 Automatic Transmission/Transaxle:
Step 1. Customer Complaint Analysis
Record details of the problem such as failure, complaint and how it occurred as described by the customer.
For this purpose, use of such an inspec tion form will facilitate collecting information to the point required for proper
analysis and diagnosis. Customer problem inspection form (Example)
NOTE
The form is a standard sample. It should be modified according to conditions characteristic of each
market.

I6RS0C510015-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-17
Step 2. DTC / Freeze Frame Data Check, Record and Clearance
First, referring to “DTC Check”, check DTC and pending DTC. If DTC exists, print or write down DTC and freeze frame
data and then clear malfunction DTC(s) by referring to “DTC Clearance”. Malfunction DTC indicates malfunction in the
system but it is not possible to know from it whether the malfunction is occurring now or it occurred in the past and
normal condition has been restored. In order to know that, check symptom in question according to Step 5 and then
recheck DTC according to Step 6.
Diagnosing a trouble based on the DTC in this step only or fa ilure to clear the DTC in this step may result in an faulty
diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting which is otherwise unnecessary.
Step 3 and 4. Visual Inspection
As a preliminary step, be sure to perform visual check of the items that support proper function of the engine and
automatic transaxle referring to “Visual Inspection”.
Step 5. Trouble Symptom Confirmation
Check trouble symptoms based on information obtained in “Step 1. Customer Complaint Analysis: ” and “Step 2. DTC
/ Freeze Frame Data Check, Record and Clearance: ”.
Also, reconfirm DTC according to “DTC Confirmation Procedure” described in each DTC flow.
Step 6 and 7. Rechecking and Record of DTC and Freeze Frame Data
Refer to “DTC Check” for checking procedure.
Step 8. A/T Basic Check and A/T Symptom Diagnosis
Perform basic check of A/T according to “A/T Basic Check” first. When the end of the flow has been reached, check
the parts of the system suspected as a possible cause referring to “A/T Symptom Diagnosis” and based on symptoms
appearing on the vehicle (symptoms obtained through step s of customer complaint analysis, trouble symptom
confirmation and/or A/T basic check) and re pair or replace faulty parts, if any.
Step 9. Troubleshooting for DTC
Based on the DTC indicated in Step 6 / 7 and referring to “a pplicable DTC flow”, locate the cause of the trouble,
namely in a sensor, switch, wire harness, connector, actuator, TCM or other part and repair or replace faulty parts.
Step 10. Check for Intermittent Problem
Check parts where an intermittent trouble is easy to occur (e.g . wire harness, connector, etc.), referring to “Intermittent
and Poor Connection Inspection in Section 00” and related circuit of DTC recorded in Step 2.
Step 11. Final Confirmation Test
Confirm that the problem symptom has gone and the vehicl e is free from any abnormal conditions. If what has been
repaired is related to the malfunction DTC, clear the DTC once and check to ensure that no malfunction DTC is
indicated.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-167
Specifications
Tightening Torque SpecificationsS7RS0B5107001
NOTE
The specified tightening torque is also described in the following.
“Select Cable Components”
“Automatic Transaxle Unit Components”
“Automatic Transaxle Assembly Components”
“Oil Pump Assembly Components”
“Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components”
“Valve Body Assembly Components”
“Differential Assembly Components”

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
A/T fluid drain plug 171.7 12.5 ) / ) / )
Transmission range sensor bolt 5.5 0.55 4.0) / )
Output shaft speed sensor bolt 131.3 9.5 ) / )
Input shaft speed sensor bolt 5.5 0.55 4.0)
Valve body harness connector bolt 7.00.7 5.0 )
Shift solenoid bolt 111.1 8.0 )
Oil strainer bolt 101.0 7.5 ) / )
Oil pan bolt 7.00.7 5.0 ) / )
Transaxle and engine fastening bolt and nut 85 8.5 61.5)
Drive plate to torque converter bolt 252.5 18.0 )
Transaxle stiffener bolt 555.5 40)
Starter motor bolt and nut 505.0 36.5 )
Oil pump subassembly bolt 101.0 7.5 )
Rear cover plug 7.5 0.75 5.5)
Solenoid valve bolt 111.1 8.0 )
Final gear bolt 787.8 56.5 )
Torque converter housing plug 7.5 0.75 5.5)
Lubrication tube clamp bolt 5.5 0.55 4.0)
Fluid reservoir RH plate bolt 5.5 0.55 4.0)
Torque converter housing bolt 292.9 21) / ) / )
Manual detent spring bolt 101.0 7.5 )
Parking lock pawl bracket bolt 7.5 0.75 5.5)
Rear cover bolt 252.5 18.0 )
Fluid reservoir LH plate bolt 101.0 7.5 )
Oil pump assembly bolt 252.5 18.0 )
Transaxle case plug 7.5 0.75 5.5)
Valve body harness connector bolt 5.5 0.55 4.0)
Valve body bolt 111.1 8.0 )
Fluid outlet union 252.5 18.0 )
Fluid cooler pipe union bolt 222.2 16.0 )
Fluid cooler pipe bracket bolt 101.0 7.5 )
Fluid filler tube bolt 101.0 7.5 )
Input shaft speed sensor bolt 111.1 8.0 )
Harness bracket bolt 232.3 17.0 )
Select cable clamp bolt 101.0 7.5 )
Transmission range sensor lock nut 70.7 5.0 )
Manual select lever nut 131.3 9.5 )
Engine mounting LH bracket bolt 555.5 40.0
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