air line SUZUKI SWIFT 2006 2.G Service Repair Manual

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-2 Automatic Transmission/Transaxle:
CAUTION!
• Keep component parts in group for each subassembly and avoid mixing them up.
• Clean all parts with cleaning solvent thoroughly and air dry them.
• Use kerosene or automatic transaxle fluid as cleaning solvent.
• Do not use wiping cloths or rags to clean or dry parts.
• All oil passages should be blown out and checked to make sure that they are not
obstructed.
• Keep face and eyes away from solvent spray while air blowing parts.
• Check mating surface for irregularities and remove them, if any, and clean it again.
• Soak new clutch discs and brake discs in transaxle fluid for at least 2 hours before
assembly.
• Replace all gaskets and O-ring with new ones.
• Apply automatic transaxle fluid to all O- rings.
• When installing seal ring, be careful so that it is not expanded excessively, extruded or
caught.
• Replace oil seals that are removed and apply grease to their lips.
• Before installing, be sure to apply automatic transaxle fluid to sliding, rolling
and thrusting surface of all component
part. Also after installation, make sure to
check each part for proper operation.
• Always use torque wrench when tightening bolts.

• A new discs should be soaked in ATF at least 2 hours before use.
Part Inspection and Correction Table Part Inspect for Correction
Casted part,
machined part Small flaw, burr
Remove with oil
stone.
Deep or grooved
flaw Replace part.
Clogged fluid
passage Clean with air or
wire.
Flaw on installing
surface, residual
gasket Remove with oil
stone or replace
part.
Crack Replace part.
Bearing Unsmooth rotation Replace.
Streak, pitting, flaw,
crack
Replace.
Bushing, thrust
washer Flaw, burr, wear,
burning
Replace.
Oil seal, gasket Flawed or
hardened seal ring
Replace.
Worn seal ring on
its periphery or side Replace.
Piston seal ring, oil
seal, gasket, etc. Replace.
Gear Flaw, burr Replace.
Worn gear tooth Replace.
Splined part Burr, flaw, torsion Correct with oil
stone or replace.
Snap ring Wear, flaw,
distortion
Replace.
No interference Replace.
Thread Burr Replace.
Damage Replace.
Sp rin g Settling, sign of
burning Replace.
Friction plate Wear, burning,
distortion,
damaged claw Replace.
Separator plate,
retaining plate Wear, burning,
distortion,
damaged claw
Replace.
Sealing surface
(where lip
contacts) Flaw, rough
surface, stepped
wear, foreign
material
Replace.

Downloaded from www.Manualslib.com manuals search engine 5A-26 Automatic Transmission/Transaxle:
TRANSAXLE RANGE
Transaxle range detected by signal fed from
transmission range sensor.
D RANGE SIGNAL
ON: Signal which TCM require ECM to increase idle
speed
OFF: Signal which TCM does not require ECM to
increase idle speed
THROTTLE POSITION (%)
Throttle opening ratio computed by CAN signal from
ECM.
BRAKE SWITCH
Inputted signal from brake light switch on pedal bracket.
ON: Brake pedal depressed
OFF: Brake pedal released
TORQUE REDUCTION SIGNAL
ON: Signal which TCM require ECM to reduce output
torque at shifting gear
OFF: Signal which TCM does not require ECM to reduce
output torque
ENGINE COOLANT TEMPERATURE ( °C, °F)
Engine coolant temperature computed by CAN signal
from ECM. AIR CONDITIONER SIGNAL
ON: Signal which inform that air conditioner compressor
is turned ON.
OFF: Signal which inform that air conditioner
compressor is not turned ON.
ENGINE TORQUE SIGNAL (N
⋅m)
Engine torque computed by duty pulse signal outputted
from ECM.
SLIP RPM (RPM)
This parameter indicates slip ping rotation in the torque
converter (difference between input shaft rotation and
engine rotation)
MIL REQUEST
ON: Signal which TCM requires combination meter to
turn on malfunction indicator lamp.
OFF: Signal which TCM does not require combination
meter to turn on malf unction indicator lamp.
FUEL CUT FLAG
ON: Signal which inform that fuel cut is operating.
OFF: Signal which inform that fuel cut is not operating.
A/T Basic CheckS7RS0B5104010
This check is important for troubleshooting when TCM has detected no DTC and no abnormality has been noted in
“Visual Inspection”. Fo llow the flow carefully.
Step Action YesNo
1 Was “A/T System Check” preformed? Go to Step 2.Go to “A/T System
Check”.
2 Perform “Road Test”.
Is it OK? Go to Step 3.
Proceed to
“Troubleshooting” in
“Road Test”.
3 Perform “Manual Road Test”.
Is it OK? Go to Step 4.
Proceed to
“Troubleshooting” in
“Manual Road Test”.
4 Perform “Engine Brake Test”.
Is it OK? Go to Step 5.
Proceed to
“Troubleshooting” in
“Engine Brake Test”.
5 Perform “Stall Test”.
Is it OK? Go to Step 6.
Proceed to
“Troubleshooting” in
“Stall Test”.
6 Perform “Time Lag Test”.
Is it OK? Go to Step 7.
Proceed to
“Troubleshooting” in
“Time Lag Test”.
7 Perform “Line Pressure Test”.
Is it OK? Go to Step 8.
Proceed to
“Troubleshooting” in
“Line Pressure Test”.
8 Proceed to “Trouble Diag nosis 1” in “A/T Symptom
Diagnosis”.
Is trouble identified? Repair or replace faulty
parts.
Go to Step 9.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-31
Troubleshooting
Time Lag TestS7RS0B5104015
This test is to check conditions of clutch, brake and fluid pressure. “Time lag” means time elapsed since select lever is
shifted with engine idling till shock is felt.
1) With chocks placed before and behind front and rear wheels respectively, depress brake pedal.
2) Start engine.
3) With stop watch ready, shift select lever from “N” to “D” range an d measure time from that moment till shock is felt.
4) Similarly measure time lag by shifting select lever from “N” to “R” range.
Gear shifting time lag
“N” → “D”: Less than 0.7 sec.
“N” → “R”: Less than 1.2 sec.
NOTE
• When repeating this test, be sure to wait at least one minute after select lever is shifted back to “N”
range.
• Engine should be warmed up fully for this test.
• Repeat test 3 times and take average of those data for final time lag data.

Condition Possible cause Correction / Reference Item
Lower than standard level
in both “D” and “R” range Engine output torque failure
Inspect and repair engine.
Faulty one-way clutch of torque
converter Replace torque converter.
Higher than standard
level in “D” range Malfunction of pressure control solenoid
valve (Low line pressure) Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Slippery forward clutch Inspect. If NG, replace.
Faulty one-way No.2 clutch Inspect. If NG, replace.
Leakage from “D” range fluid pressure
circuit Replace valve body assembly.
Higher than standard
level in “R” range Malfunction of pressure control solenoid
valve (Low line pressure) Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Slippery reverse clutch Inspect. If NG, replace.
Slippery 1st and reverse brake Inspect. If NG, replace.
Leakage from “R” range fluid pressure
circuit Replace valve body assembly.
Higher than standard
level in both “D” and “R”
range Malfunction of pressure control solenoid
valve (Low line pressure)
Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Clogged oil strainer Replace.
Faulty oil pump Inspect. If NG, replace.
Leakage from both “D” and “R” range
fluid pressure circuit Replace valve body assembly.

Downloaded from www.Manualslib.com manuals search engine 5A-32 Automatic Transmission/Transaxle:
Troubleshooting
Line Pressure TestS7RS0B5104016
Purpose of this test is to check operat ing conditions of each part by measuring fluid pressure in fluid pressure line.
Line pressure test requires the following conditions.
• Automatic fluid is at normal operating temperature (70 – 80 °C / 158 – 176 °F).
• Fluid is replenished to proper level (between FULL and LOW on dipstick).
• Air conditioner switch is turned OFF.
1) Apply parking brake securely and place chocks against wheels.
2) Remove fluid pressure check hole plug bolt.
3) Attach oil pressure gauge to fluid pr essure check hole in transaxle case.
Special tool
(A): 09925-37811-001
CAUTION!
After attaching oil pressure gauge, check that no fluid leakage exists.

4) Depress foot brake fully, run engine at idle and stall then check fluid pressure in “D” or “R” range.
CAUTION!
• Do not continue running engine at stall speed longer than 5 seconds.
• After performing line pressure test, be sure to leave engine running at idle for longer than one minute before performing another line pressure test.

Automatic transaxle line pressure
Condition Possible cause Correction / Reference Item
“N”
→ “D” time lag
exceeds specification Malfunction of transmission fluid
temperature sensor Inspect. If NG, replace.
Malfunction of pressure control solenoid
valve (Low line pressure) Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Clogged oil strainer Replace.
Faulty oil pump Inspect. If NG, replace.
Faulty forward clutch Inspect. If NG, replace.
Faulty one-way No.2 clutch Inspect. If NG, replace.
Leakage from “D” range fluid pressure
circuit Replace valve body assembly.
“N”
→ “R” time lag
exceeds specification Malfunction of transmission fluid
temperature sensor Inspect. If NG, replace.
Malfunction of pressure control solenoid
valve (Low line pressure) Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Clogged oil strainer Replace.
Faulty oil pump Inspect. If NG, replace.
Faulty reverse clutch Inspect. If NG, replace.
Faulty 1st and reverse brake Inspect. If NG, replace.
Leakage from “R” range fluid pressure
circuit Replace valve body assembly.
“D” range
“R” range
At idle speed 3.8 – 4.2 kg/cm2, 54 – 60psi 5.9 – 6.9 kg/cm2, 84 – 98 psi
At stall speed 12.1 – 13.4 kg/cm2, 172 – 191 psi 16.8 – 19.5 kg/cm2, 239 – 277 psi

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-33
Troubleshooting
“P” Range TestS7RS0B5104017
1) Stop vehicle on a slope of 5 degrees or more, shift select lever to “P” range and at the same time apply parking brake.
2) After stopping engine, depress brake pedal and release parking brake.
3) Then, release brake pedal gradually and check that vehicle remains stationary.
4) Depress brake pedal and shift select lever to “N” range.
5) Then, release brake pedal gradually and check that vehicle moves.
WARNING!
Before test, make sure no one is around vehicle or down on a slope and keep watchful for safety
during test.

Troubleshooting Condition Possible cause Correction / Reference Item
Higher than standard
level in each range Malfunction of pressure control solenoid
valve (Low line pressure) Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Lower than standard level
in each range Malfunction of pressure control solenoid
valve (Low line pressure) Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Clogged oil strainer Replace.
Faulty oil pump Inspect. If NG, replace.
Leakage from both “D” and “R” range
fluid pressure circuit Replace valve body assembly.
Lower than standard level
only in “D” range Leakage from “D” range fluid pressure
circuit Replace valve body assembly.
Lower than standard level
only in “R” range Leakage from “R” range fluid pressure
circuit Replace valve body assembly.
Condition
Possible cause Correction / Reference Item
Vehicle moves at “P”
range or remains
stationary at “N” range Defective parking lock pawl or spring
Inspect. If NG, repair.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-37
Non operate TCC (lock-
up) systemTCC pressure control solenoid valve
circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Shift solenoid valve-A and/or-B circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Pressure control solenoid valve circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Output shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Input shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Transmission range sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Transmission fluid temperature sensor
circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
CAN communication circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Throttle position sensor circuit faulty Inspect circuit for open, short and intermittent
referring to “Electric Throttle Body Assembly
On-Vehicle Inspection in Section 1C”. If NG,
repair.
Engine coolant temperature sensor
circuit faulty Inspect circuit for open, short and intermittent
referring to “DTC P0117: Engine Coolant
Temperature Circuit Low
in Section 1A” and/or
“DTC P0118: Engine Coolant Temperature
Circuit High in Section 1A”. If NG, repair.
Brake light switch circuit faulty Refer to “No Lock-Up Occurs”.
TCM Substitute a known-good TCM and recheck.
ECM Substitute a known-good ECM and recheck.
Higher or lower stall
speed Pressure control solenoid valve circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
TCM Substitute a known-good TCM and recheck.
Excessive “N”
→ “D” or
“N”
→ “R” time lag Pressure control solenoid valve circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Transmission fluid temperature sensor
circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
TCM Substitute a known-good TCM and recheck.
Higher or lower line
pressure Pressure control solenoid valve circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
TCM Substitute a known-good TCM and recheck.
Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-95
5) Shift select lever to “N” position.
NOTE
If select lever is in “P” position, shift select
lever referring to “Select Lever Inspection”.

6) Install cable casing cap (3) to selector bracket (4).
7) Connect cable end (1) to interlock cam (2) with ignition switch turned to ACC position.
8) Drive lock button (5) in cable end until it locks cable expansion and contraction.
9) With select lever set at “P ” position, turn ignition key
to ACC position and then check for the following
conditions.
• With knob button released, ignition key can be turned from ACC position to LOCK position.
• With knob button pressed, ignition key cannot be
turned from ACC position to LOCK position.
10) Install steering column cover. 11) If the vehicle is equipped with air bag system, connect negative cable at battery and enable air bag
system, referring to “Enabling Air Bag System in
Section 8B”.
Transmission Range Sensor (Shift Switch)
Inspection and Adjustment
S7RS0B5106015
1) Shift manual select lever (4) to “N” range.
2) Check that needle direction shaped on lock washer (2) and “N” reference line (1) on transmission range
sensor are aligned. If not, loosen sensor bolts (3)
and align them.
Tightening torque
Transmission range sensor bolt (a): 5.5 N·m (
0.55 kgf-m, 4.0 lb-ft)
3) Check that engine starts in “N” and “P” ranges but it doesn’t start in “D”, “2”, “L” or “R” range. Also, check
that back-up lamp lights in “R” range.
If faulty condition cannot be corrected by adjustment,
disconnect transmission range sensor connector
and check that continuity ex ists as shown by moving
manual select lever.
3
4 1
2
3 5
I4RS0A510055-01
I3RM0B510038-01
4
3
2
1
98 76 5
12 345
6789
P
R N
D 2
L
I3RM0B510039-01

Downloaded from www.Manualslib.com manuals search engine 5C-2 Clutch:
Diagnostic Information and Procedures
Clutch System Symptom DiagnosisS7RS0B5304001
Repair Instructions
Clutch Pedal InspectionS7RS0B5306001
Cylinder Push Rod Play “A”1) Press clutch pedal (1) gradually with finger, stop when slight increase of resistance is felt and
measure how much pedal has moved (push rod
play) as represented by “A” as shown.
Push rod play
“A”: Max. 3 mm (0.12 in.)
2) If “A” is not within specification, replace master cylinder (3) or pedal arm (2). Clutch Pedal Free Travel “B”
1) Depress clutch pedal (1), stop the moment clutch resistance is felt, and measure how much pedal has
moved (clutch pedal free travel) as represented by
“B” in figure.
Clutch pedal free travel
“B”
: 2 – 8 mm (0.08 – 0.31 in.)
2) If “B” is not within specification, check pedal arm (2) and master cylinder (3) and replace defective part.
Condition Possible cause Correction / Reference Item
Slipping Improper clutch pedal free travel Replace master cylinder or clutch pedal arm.
Worn or oily clutch disc facing Replace disc.
Warped disc, pressure plate or flywheel
surface Replace disc, clutch cover or flywheel.
Weakened diaphragm spring Replace clutch cover.
Master cylinder piston or seal cup not
returning Replace master cylinder.
Dragging clutch Improper clutch pedal free travel Replace master cylinder or clutch pedal arm.
Weakened diaphragm spring, or worn
spring tip Replace clutch cover.
Rusted input shaft splines Lubricate.
Damaged or worn splines of transaxle
input shaft Replace input shaft.
Excessively wobbly clutch disc Replace disc.
Clutch facings broken or dirty with oil Replace disc.
Fluid leakage Repair or replace.
Clutch vibration Glazed (glass-like) clutch facings Repair or replace disc.
Clutch facings dirty with oil Replace disc.
Release bearing slides unsmoothly on
input shaft bearing retainer Lubricate or replace input shaft bearing
retainer.
Wobbly clutch disc, or poor facing
contact Replace disc.
Weakened torsion springs in clutch disc Replace disc.
Clutch disc rivets loose Replace disc.
Distorted pressure plate or flywheel
surface Replace clutch cover or flywheel.
Weakened engine mounting Replace engine mounting.
Loosened engine mounting bolt or nut Retighten engine mounting bolt or nut.
Noisy clutch Worn or broken release bearing Replace release bearing.
Input shaft front bearing worn down Replace input shaft bearing.
Excessive rattle of clutch disc hub Replace disc.
Cracked clutch disc Replace disc.
Pressure plate and diaphragm spring
rattling Replace clutch cover.
Grabbing clutch Clutch disc facings soaked with oil Replace disc.
Clutch disc facings excessively worn Replace disc.
Rivet heads showing out of facing Replace disc.
Weakened torsion springs Replace disc.

Downloaded from www.Manualslib.com manuals search engine 5C-4 Clutch:
3) Depress clutch pedal several times, and then release clutch pedal, push snap ring (2) and pull pipe
connector (1) one notch.
4) When fluid pressure in cylinder is almost depleted, push pipe connector.
5) Repeat this operation until there are no more air bubbles in hydraulic line.
6) When bubbles stop, depress and hold clutch pedal, push pipe connector, and pull snap ring.
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 clutch pedal for sponginess. If found spongy, repeat entire procedure of bleeding.Clutch Pedal Position (CPP) Switch Removal
and Installation
S7RS0B5306004
Removal
1) Disconnect connector of C PP switch (1) with ignition
switch OFF.
2) Remove CPP switch (1 ) from pedal bracket.
Installation 1) Instal CPP switch to pedal bracket.
2) Adjust switch position re ferring to “Clutch Pedal
Position (CPP) Switch Inspection and Adjustment”.
3) Connect connector to CPP switch securely.
2
1
I4RS0A530004-01
I4RS0A530023-01
1
I6RS0C530001-02