MIL SUZUKI SWIFT 2007 2.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 5A-86 Automatic Transmission/Transaxle:
Reference waveform No. 5
Output shaft speed sensor signal at vehicle speed 60
km/h (37 mile/h).
TCM Power and Ground Circuit CheckS7RS0B5104046
Wiring DiagramMeasurement
terminal
CH1: “C35-25” to “C34-1”
Oscilloscope
setting CH1: 5 V/DIV
TIME: 2 ms/DIV
Measurement
condition • After warmed up to normal
operating temperature
• Drive vehicle at 60 km/h (37 mile/h).
I3RM0B510028-01
BLK
BLK
BLK
C34-1
C34-23
C34-6YEL/BLKYEL/BLU
LT GRN/BLK
+BB
C34-24WHT/RED1
23
6
24 23 1
C34C35
[A]
I4RS0A510023-01
1. TCM
3. Ignition switch
2. A/T relay [A]: Terminal arrangement of TCM connector (viewed from harness side)

Downloaded from www.Manualslib.com manuals search engine 5A-150 Automatic Transmission/Transaxle:
Automatic Transaxle Unit AssemblyS7RS0B5106060
CAUTION!
• Automatic transaxle consists of highly precise parts. As even flaw in small part
may cause oil leakage or decrease in
function, check each part carefully before
installation.
• Clean all parts with compressed air. Never use wiping cloths or rags.
• Before assembling new clutch or brake discs, soak them in automatic transaxle
fluid for at least 2 hours.
• Be sure to use new gaskets and O-rings.
• Lubricate O-rings with automatic transaxle
fluid.
• Apply automatic transaxle fluid on sliding or rotating surfaces of the parts before
assembly.
• Use Suzuki Super Grease “C” to retain parts in place.
• Be sure to install thrust bearings and races in correct direction and position.
• Make sure that snap ring ends are not aligned with one of cut outs and are
installed in groove correctly.
• Do not use adhesive cements on gaskets and similar parts.
• Be sure to torque each bolt and nut to specification.

1) Install new manual shift sh aft oil seal to transaxle
case.
Use special tool and hammer to install it, and then
apply grease to its lip.
Special tool
(A): 09925–98210
“A”: Grease 99000–25030 (SUZUKI Super
Grease C)
Manual shift shaft oil seal installing depth
“a”: 0.5 – 1.5 mm (0.02 – 0.06 in.) 2) Install manual detent spring (1) to transaxle case
and tighten manual detent spring bolt to specified
torque.
Tightening torque
Manual detent spring bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)
3) Install parking lock pawl ro d (2) to manual valve lever
(1).
4) After applying A/T fluid to new manual valve lever (1), install new manual shift shaft (4), new spacer (3)
and manual valve lever to transaxle case.
5) After installing manual valve lever pin (2) by using spring pin remover with 3.5 mm (0.14 in.) in diameter
(5) and hammer, turn spacer to set the position as
shown in figure. Then caulk spacer with a punch.
“a”
(A)
“A”
I2RH0B510258-01
I2RH0B510259-01
I2RH0B510260-01
I2RH0B510261-01

Downloaded from www.Manualslib.com manuals search engine 5B-34 Manual Transmission/Transaxle:
Assembly
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
after disassembly, prepare replacing parts and proceed
to reassembly. Make sure that all parts are clean.
1) Assemble differential gear and measure thrust play
of differential gear as follows.
Special tool
(A): 09900–20607
(B): 09900–20701
Differential gear thrust play
0.03 – 0.31 mm (0.001 – 0.012 in.)
Left side
1. Hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to top
surface of gear (2).
2. Using 2 screwdrivers (1), move gear up and down and read movement of dial gauge pointer.
Right side
1. Using similar procedure to the left side, set dial gauge tip to gear (2) shoulder.
2. Move gear up and down by hand and read dial gauge.
2) If thrust play is out of sp ecification, select suitable
thrust washer from among the following available
size, install it and check again that specified gear
play is obtained.
Available thrust washer thickness
3) Drive in new differential pinion shaft pin (2) till the depth from differential case (3) surface is about 1
mm (0.04 in.).
4) Press-fit left bearing (2) using special tool and copper hammer.
Special tool
(A): 09913–76010
5) Support differential assembly (1) as illustrated so as to left bearing is floating , and then press-fit right
bearing (3) using special tools.
Special tool
(A): 09913–76010
(B): 09951–16060
0.85 mm (0.033 in.) 1.05 mm (0.041 in.)
0.90 mm (0.035 in.) 1.10 mm (0.043 in.)
0.95 mm (0.037 in.) 1.15 mm (0.045 in.)
1.00 mm (0.039 in.)
[A]: Left side
[B]: Right side
I3RH0A520083-01
1
(A)
3
2 (B)
I6RS0C520008-01

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-9
3) Start engine.
4) Read DTC according to the instructions displayed on
SUZUKI scan tool. For further details, refer to
operator’s manual for SUZUKI scan tool.
NOTE
• If communication between SUZUKI scan tool and the vehicle can not be
established, perform “Serial Data Link
Circuit Check”.
• DTC C1122 (engine speed signal failure) is indicated when ignition switch is at ON
position and engine is not running, but it
means there is nothing abnormal if
indication changes to a normal one when
engine is started.

5) After completing the check, turn ignition switch to
OFF position and disconnect SUZUKI scan tool from
DLC.
DTC ClearanceS7RS0B6304004
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector (DLC) (1) located on underside of instrument panel
at driver’s seat side.
Special tool
(A): SUZUKI scan tool
3) Turn ignition switch to ON position.
4) Erase DTC according to the instructions displayed on SUZUKI scan tool. For further details, refer to
operator’s manual for SUZUKI scan tool.
5) After completing the clearance, turn ignition switch to OFF position and disconnect SUZUKI scan tool from
DLC.
DTC TableS7RS0B6304005
CAUTION!
Be sure to perform the “EPS Syst em Check” before starting troubleshooting corresponding to each
DTC.

(A)
1
I4RS0B450003-01
DTC No. Detecting item Detecting condition
(DTC will set when detecting) Trouble area MIL
No
CODES Normal — — —
) C1113 Steering torque sensor (Main
and Sub) circuit correlation Voltage difference between torque
sensor main signal and sub signal
is more than 0.6 V for 1 second
continuously. • Torque sensor signal circuit
• Torque sensor
• P/S control module
1 driving
cycle
) C1114 Steering torque sensor
reference power supply
circuit Circuit voltage of torque sensor 5
V reference power supply voltage
is more than 5.7 V or less than 4.3
V for 1 second continuously. • Torque sensor circuit
• Torque sensor
• P/S control module
1 driving
cycle
) C1117 Steering torque sensor
failure signal circuit low Torque sensor internal failure
signal circuit voltage is less than
1.7 V when ignition switch turned
ON.
• Torque sensor signal circuit
• Torque sensor
• P/S control module1 driving
cycle
) C1118 Steering torque sensor
failure signal circuit high Torque sensor internal failure
signal circuit voltage is more than
3.7 V for 1 second continuously. 1 driving
cycle
) C1119 Steering torque sensor
power supply circuit Circuit voltage of torque sensor
main power supply
is less than
7.5 V for 1 second continuously. • Torque sensor circuit
• Torque sensor
• P/S control module
1 driving
cycle

Downloaded from www.Manualslib.com manuals search engine 6C-10 Power Assisted Steering System:
) C1121 No vehicle speed signal
(60 seconds or more) Vehicle speed signal is 0 km/h
even though engine speed is
more than 4000 rpm for more than
60 seconds continuously (before
elapse of 5 min from engine start)
or vehicle speed signal is 0 km/h
even though engine speed is
more than 2500 rpm for more than
60 seconds continuously (after
elapse of 5 min for engine start). • Vehicle speed signal circuit
• Wheel speed sensor
•ECM
• P/S control module
• ABS control module
• CAN communication circuit
Not
applicable
) C1122 Engine speed signal Engine speed signal is less than
220 rpm for more than 0.8
seconds.
or
Engine speed signal is less than
220 rpm for more than 20
seconds continuously even
though vehicle speed signal is
more than 50 km/h.• Engine speed signal circuit
•ECM
• P/S control module
• Vehicle speed signal
1 driving
cycle
) C1123 No vehicle speed signal
(30 seconds or more) Vehicle speed signal is 0 km/h
with continuously more than 3
driving cycles even though engine
speed is more than 4000 rpm for
more than 30 seconds
continuously (before elapse of 5
min from engine start).
or
vehicle speed signal is 0 km/h
with continuously more than 3
driving cycles even though engine
speed is more than 2500 rpm for
more than 30 seconds
continuously (after elapse of 5 min
for engine start). • Vehicle speed signal circuit
• Wheel speed sensor
•ECM
• P/S control module
• ABS control module
• CAN communication circuit
3 driving
cycles
) C1124 Vehicle speed performance
(Impossible deceleration) Vehicle speed signal is less than 5
km/h for more
than 5 seconds
continuously with more than
specified deceleration speed (–20
m/s
2) from over 20 km/h. Not
applicable
) C1141 P/S motor circuit voltage Voltage between both motor drive
circuits is more than 8.5 V or less
than 0.2 V for 0.5 seconds
continuously while motor is not
drived.
• P/S motor circuit
• P/S motor
• P/S control module1 driving
cycle
) C1142 P/S motor circuit range /
performance Measured motor drive current is
more than 10 A as compared with
target motor drive current. 1 driving
cycle
DTC No. Detecting item
Detecting condition
(DTC will set when detecting) Trouble area MIL

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-11
Scan Tool DataS7RS0B6304006
NOTE
When P/S motor is cold condition (that is, armature coil of P/S motor is not heated), normal value with
asterisk (*) mark in the following table is displayed on scan tool.

) C1143 P/S motor circuit current too
high Measured motor drive current is
more than 50 A.
• P/S motor circuit
• P/S motor
• P/S control module1 driving
cycle
) C1145 P/S motor circuit current too
low Measured motor drive current is
less than 2 A continuously for
more than 3 seconds even though
target motor drive current is more
than 4 A.
or
Measured motor drive current is
less than 0.8 A for total 1 second
even though motor control duty is
more than 90% while target motor
drive current is less than 8 A. 1 driving
cycle
) C1153 P/S control module power
supply circuit Power supply voltage of P/S
control module is less than 9 V for
5 seconds continuously. • P/S control module power
supply circuit
• Undercharged Battery
• P/S control module 1 driving
cycle
) C1155 P/S control module internal
failure Internal memory (EEPROM) is
data error.
• P/S control moduleNot
applicable
Internal circuit is faulty.
or
Power supply voltage of P/S
control module exceeded 17.5 V. • Overcharged Battery
• P/S control module
1 driving
cycle
DTC No. Detecting item
Detecting condition
(DTC will set when detecting) Trouble area MIL
Scan tool data
Vehicle conditionNormal condition
) Battery Voltage
Ignition switch ON 10 – 14 V
) TQS Power Supply 10 – 14 V
) TQS Main Torque Engine running at idle speed Steering wheel at fully turned to left –9.4 – 0 N
⋅m
Steering wheel at free 0 N⋅m
Steering wheel at fully turned to right 0 – 9.4 N ⋅m
) TQS Sub Torque Engine running at idle speed Steering wheel at fully turned to left –9.4 – 0 N
⋅m
Steering wheel at free 0 N⋅m
Steering wheel at fully turned to right 0 – 9.4 N ⋅m
) Assist Torque Engine running at idle speed Steering wheel at fully turned to left –9.4 – 0 N
⋅m
Steering wheel at free 0 N⋅m
Steering wheel at fully turned to right 0 – 9.4 N ⋅m
) Motor Control Engine running at idle speed Steering wheel at free
0 A
Steering wheel at fully turned to left or right *35 – 45 A
) Motor Monitor Engine running at idle speed Steering wheel at free
0 A
Steering wheel at fully turned to left or right *35 – 45 A
) Vehicle Speed Engine running and vehicle at stop 0 km/h
) Engine Speed Engine running at idle speed after warming up 700 ± 50 rpm
) Motor Volt Engine running at idle speed Steering wheel at free
0.8 – 1 V
Steering wheel at fully turned to right About 5 V
) Ignition switch Ignition switch ON ON

Downloaded from www.Manualslib.com manuals search engine 6C-26 Power Assisted Steering System:
DTC C1121 / C1123 / C1124: VSS Circuit FailureS7RS0B6304017
DTC C1121: No Vehicle Speed Signal (60 Seconds or More)
DTC C1123: No Vehicle Speed Signal (30 Seconds or More)
DTC C1124: Vehicle Speed Performance (Impossible Deceleration)
Wiring Diagram
DTC Detecting Condition and Trouble Area
M
BRNRED/
BLU
BLK
RED
E52-14
E52-12
E23-4
E23-26
E23-25 E51-1
E51-2
[A ]
12
3
4 5 67
89
11
10
12 13
141516
17 18 19 20
5V
PPL
E52-4
8
5
12V
E49-2BLK
12V
12V
6REDRED/ BLKWHT
7WHTWHT/BLKWHTBLK BLK
111
2
[B ]
9
LT GRN
/BLKE52-1 E49-1
GRNGRNWHTBLK
WHY
10
3
4
4
4
4
1 2
12
I7RS0B630009-01
[A]: Connector “E52” (viewed from harness side)
4. Fuse9. ABS/ESP® control module
[B]: Connector “E49” (viewed from harness si de)5. ECM 10. Individual circuit fuse box No.1
1. Main fuse box 6. Left-front wheel speed sensor11. Vehicle speed signal circuit
2. Ignition switch 7. Right-front wheel speed sensor 12. Engine speed signal circuit
3. Junction block assembly 8. P/S control module
DTC detecting condition Trouble area
DTC C1121:
Vehicle speed signal is 0 km/h even though engine speed
is more than 4000 rpm for more than 60 seconds
continuously (before elapse of 5 min from engine start) or
vehicle speed signal is 0 km/h even though engine speed
is more than 2500 rpm for more than 60 seconds
continuously (after elapse of 5 min for engine start).
(1 driving cycle detection logic but MIL does not light up)
DTC C1123:
Vehicle speed signal is 0 km/h with continuously more
than 3 driving cycles even though engine speed is more
than 4000 rpm for more than 30 seconds continuously
(before elapse of 5 min from engine start) or vehicle speed
signal is 0 km/h with continuously more than 3 driving
cycles even though engine speed is more than 2500 rpm
for more than 30 seconds continuously (after elapse of 5
min for engine start).
(3 driving cycle detection logic)
DTC C1124:
Vehicle speed signal is less than 5 km/h for more than 5
seconds continuously with more than specified
deceleration speed (–20 m/s
2) from over 20 km/h.
(1 driving cycle detection logic but MIL does not light up) • Vehicle speed signal circuit
• Wheel speed sensor
•ECM
• P/S control module
• ABS/ESP®
control module
• CAN communication circuit

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-33
DTC C1155: P/S Control Module FailureS7RS0B6304021
Wiring Diagram
Refer to “DTC C1153: P/S Control Module Power Supply Circuit Voltage Low”.
DTC Detecting Condition and Trouble Area
DTC Troubleshooting DTC detecting condition Trouble area
Internal memory (EEPROM) is data error.
(In this case, MIL does not light up)
or
Internal circuit is faulty.
or
Power supply voltage of P/S control module exceeded
17.5 V.
(1 driving cycle detection logic) • Overcharged Battery
• P/S control module
Step
Action YesNo
1 Was “EPS System Check” performed? Go to Step 2.Go to “EPS System
Check”.
2 P/S control module power supply and ground circuit
check
Check power supply circuit and ground circuit for P/S control
module referring to “P/S Control Module Power Supply and
Ground Circuit Check”.
Is check result in good condition? Go to Step 3.
Repair or replace
defective circuit.
3 Battery voltage check
1) Check voltage between positive (+) battery terminal and
vehicle body ground with engine speed at 3000 rpm.
Is voltage 15.5 V or less? Replace P/S control
module.
Check charging system
referring to “Generator
Test (Overcharged
Battery Check) in
Section 1J”.

Downloaded from www.Manualslib.com manuals search engine 8A-1 Seat Belts:
Restraint
Seat Belts
Precautions
Precautions on Service and Diagnosis of Seat
Belt
S7RS0B8100001
WARNING!
If replacing seat belt is necessary, replace
buckle and seat belt assembly together as a
set. This is for the reason of ensuring locking
of tongue plate with buckle. If these parts are
replaced individually, such a locking
condition may become unreliable. For this
reason, SUZUKI will supply only the spare
buckle and seat belt assembly in a set part.

Before servicing or replacing seat belts, refer to the
following precautionary items.
• Seat belts should be normal relative to strap retractor and buckle portions. • Keep sharp edges and damaging objects away from
belts.
• Avoid bending or damaging any portion of belt buckle or latch plate.
• Do not bleach or dye belt webbing. (Use only mild soap and lukewarm water to clean it.)
• When installing a seat belt anchor bolt, it should be tightened by hand at first to prevent cross-threading
and then to specified torque.
• Do not attempt any repair s on retractor mechanisms
or retractor covers. Replace defective assemblies with
new replacement parts.
• Keep belts dry and clean at all times.
• If there exist any parts in question, replace such parts.
• Replace belts whose webbing is cut or otherwise damaged.
• Do not put anything into trim panel opening which seat belt webbing passes through.
General Description
Seat Belt ConstructionS7RS0B8101001
1
1
6
6
6
5
5
7
6
6
2
2
3
4
I4RS0A810001-02
1. Front seat belt assembly (with ELR and pretensioner) 4. Buckle for front seat belt assembly7. Buckle for rear center seat belt
2. Rear seat belt assembly (with A-ELR or ELR) 5. Buckle for rear seat belt assembly
3. Rear center seat belt (with A-ELR or ELR) 6. Retractor assembly

Downloaded from www.Manualslib.com manuals search engine 8B-4 Air Bag System:
WARNING!
Never attempt to measure the resistance of
the seat belt pretensioners. It is very
dangerous as the electric current from the
tester may activate pretensioner.

• Never attempt to disassemble the seat belt
pretensioners (retractor assembly).
• If any abnormality is found, be sure to replace it with
new one as an assembly.
• When an abnormality is noted as existing in the live (inactivated) seat belt preten sioner, be sure to activate
it before discarding it.
• When grease, cleaning agent oil, water, etc., got on the seat belt pretensioners (r etractor assembly), wipe
it off immediately with a dry cloth.
• If seat belt pretensioner was dropped from a height of 30 cm (1 ft) or more, it should be replaced with a new
one as an assembly.
WARNING!
• For handling and storage of a live seat belt pretensioner, select a place where the
ambient temperature below 65 °C (150 ° F),
without high humidity and away from
electric noise.
• Never carry the seat belt pretensioner by webbing.
• When placing a live seat belt pretensioner on the workbench or other surface, be sure
not to lay it with its exhaust hole (1)
provided side facing down. It is also
prohibited to put something on its face
with an exhaust hole (1) or to put a seat
belt pretensioner on top of another.
Otherwise, personal injury may result.

Deployed Air Bag (Inflator) Module and Activated
Seat Belt Pretensioner
WARNING!
• The air bag (inflator) module and seat belt
pretensioner immediately after
deployment/activation is very hot. Wait for
at least 30 minutes to cool it off before
proceeding the work.
• Do not apply water, oil, etc. to deployed air bag (inflator) module and to activate seat
belt pretensioner.
• After an air bag (inflator) module has been deployed, the surface of the air bag may
contain a powdery residue. This powder
consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by-
products of the chemical reaction. As with
many service procedures, gloves and
safety glasses should be worn.
• Wash your hands with mild soap and water after completing the work.

Refer to the procedure described under “Deployed Air
Bag (Inflator) Module and Activated Seat Belt
Pretensioner Disposal” for disposal.
Air Bag Wire Harness and Connector
Air bag wire harness is includ ed in main harness (1),
instrument panel harness (4), floor harness (3) and seat
harness (5). Air bag wire harness can be identified easily
as the part of connector side wire harness is covered
with a yellow protection tube. Be very careful when
handling it.
I2RH01820047-01
1
I2RH01820048-01