2000 SUZUKI SWIFT ECO mode

MANUAL TRANSMISSION 7A-1
6F1
6F2
6G
6H
6K
7A1
7B1
7C1
7A
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 7A
MANUAL TRANSMISSION
CONTENTS

GENERAL DESCRIPTION .............................. 7A-2
CONSTRUCTION AND SERVICING ........... 7A-2
TRANSMISSION FOR 2WD MODEL....... 7A-3
TRANSMISSION FOR 4WD MODEL....... 7A-4
DIAGNOSIS ..................................................... 7A-5
ON-VEHICLE SERVICE .................................. 7A-5
OIL CHANGE ............................................... 7A-6
DIFFERENTIAL SIDE OIL SEAL ................. 7A-6
GEAR SHIFT CONTROL LEVER AND
CABLE ......................................................... 7A-8
VEHICLE SPEED SENSOR (VSS) ............ 7A-10
UNIT REPAIR OVERHAUL ........................... 7A-11
TRANSMISSION UNIT............................... 7A-11
TRASMISSION CASE ................................ 7A-12
INPUT & COUNTER SHAFT...................... 7A-13
GEAR SHIFTER & DIFFERENTIAL ........... 7A-14
TRANSMISSION UNIT............................... 7A-16
UNIT DISASSEMBLY ................................ 7A-17
FIFTH GEARS........................................ 7A-17GEAR SHIFTER, INPUT SHAFT AND
COUNTER SHAFT................................. 7A-19
RIGHT CASE ......................................... 7A-20
SUB ASSEMBLY SERVICE ...................... 7A-21
RIGHT CASE ......................................... 7A-21
LEFT CASE............................................ 7A-21
INPUT SHAFT ASSEMBLY ................... 7A-22
COUNTER SHAFT ASSEMBLY ............ 7A-25
GEAR SHIFTER..................................... 7A-29
DIFFERENTIAL ASSEMBLY ................. 7A-30
UNIT ASSEMBLY ...................................... 7A-33
DIFFERENTIAL TO LEFT CASE ........... 7A-33
FIFTH GEARS ....................................... 7A-35
GEAR SHIFT AND SELECT SHAFT
ASSEMBLY ............................................ 7A-38
TIGHTENING TORQUE SPECIFICATION.... 7A-39
REQUIRED SERVICE MATERIAL................ 7A-40
SPECIAL TOOL ............................................ 7A-40

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System :
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
 Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

7A-2 MANUAL TRANSMISSION
GENERAL DESCRIPTION
CONSTRUCTION AND SERVICING
The transmission provides five forward speeds and one reverse speed by means of three synchronizers and
three shafts-input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and
reverse uses a sliding idler gear arrangement.
The low speed synchronizer is mounted on counter shaft and engaged with counter shaft first gear or second
gear, while the high speed synchronizer is done on input shaft and engaged with input shaft third gear or fourth
gear.
The fifth speed synchronizer on input shaft is engaged with input shaft fifth gear mounted on the input shaft.
The double cone synchronizing mechanism is provided to 2nd gear synchromesh device for high performance
of shifting to 2nd gear.
The countershaft turns the final gear and differential assembly, thereby turning the front drive shafts which are
attached to the front wheels.
4WD model is equipped with transfer assembly on transmission being mated to right side of differential output in
transmission.
For servicing, it is necessary to use genuine sealant or its equivalent on mating surfaces of transmission case
which is made of aluminum. The case fastening bolts must be tightened to specified torque by means of torque
wrench. It is also important that all parts are thoroughly cleaned with cleaning fluid and air dried before reas-
sembling.
Further, care must be taken to adjust preload of counter shaft taper roller bearings. New synchronizer rings are
prohibited from being lapped with respective gear cones by using lapping compound before they are assembled.

8G-24 IMMOBILIZER CONTROL SYSTEM
5) Using SUZUKI scan tool, register Transponder code in
Immobilizer Control Module by executing “ENT. TRANS
COD (ENT. TP CODE)” command in SELECT MODE menu.
6) Make sure that immobilizer indicator lamp lights when igni-
tion switch is turned OFF once and then ON.
7) If any other Transponder code for ignition key with a built-in
transponder needs to be registered, repeat above steps 3),
5) and 6).
PROCEDURE AFTER IMMOBILIZER CONTROL MODULE
REPLACEMENT
When Immobilizer Control Module was replaced, including when replaced because rechecking by using a
known-good Immobilizer Control Module was necessary during trouble diagnosis, register Transponder code
and ECM/Immobilizer Control Module code in Immobilizer Control Module and ECM/Immobilizer Control Module
code in ECM by performing following procedure.
1) Perform steps 1) and 2) described in “How To Register Ignition Key”.
2) Prepare ignition key with a built-in transponder. And then turn ignition switch ON by using it.
3) Using SUZUKI scan tool, clear all transponder codes registered in Immobilizer Control Module by executing
“CLR. TRANS COD (CLEAR TP CODE)” command in SELECT MODE menu.
4) Using SUZUKI scan tool, register Transponder code in Immobilizer Control Module by executing “ENT.
TRANS COD (ENT. TP CODE)” command in SELECT MODE menu.
5) Using SUZUKI scan tool, register ECM/Immobilizer Control Module code in both Immobilizer Control Module
and ECM by executing “RECORD ECU (RECORD ECM/PCM/ICM)” command in SELECT MODE menu.
6) Make sure that immobilizer indicator lamp lights when ignition switch is turned OFF once and then ON.
7) If any other Transponder code for ignition key with a built-in transponder needs to be registered, repeat
above steps 2), 4) and 6).NOTE:
Up to 4 Transponder codes for ignition key with a built-
in transponder can be registered.
It is not possible to register the same Transponder
code for ignition key with a built-in transponder as the
one already registered in Immobilizer Control Module.
CAUTION:
When registering the ignition key including a transponder into the immobilizer control module by
using Suzuki scan tool, confirm that the knob color of the ignition key to be registered for the vehicle
is dark gray. The ignition key with wrong knob color cannot be registered.
NOTE:
When “CLR. TRANS COD (CLEAR TP CODE)” command is executed with the immobilizer indicator
lamp ON, it remains ON even after execution of that command is over. It will start flashing when the
ignition switch is turned OFF once and then turned ON after some seconds.

IMMOBILIZER CONTROL SYSTEM 8G-25
PROCEDURE AFTER ECM REPLACEMENT
When ECM was replaced, including when replaced because rechecking by using a known-good ECM was nec-
essary during trouble diagnosis, register ECM/Immobilizer Control Module code in ECM by performing following
procedure.
1) Perform steps 1) and 2) described in “How To Register Ignition Key”. And then turn ignition switch ON.
2) Using SUZUKI scan tool, register ECM/Immobilizer Control Module code in ECM by executing “RECORD
ECU (RECORD ECM/lCM)” command in SELECT MODE menu.
3) Make sure that malfunction indicator lamp lights when ignition switch is turned OFF once and then ON.
SPECIAL TOOL
NOTE:
Up to 4 Transponder codes for ignition key with a built-in transponder can be registered.
It is not possible to register the same Transponder code for ignition key with a built-in transponder
as the one already registered in Immobilizer Control Module.
NOTE:
For operation procedure of SUZUKI scan tool, refer to SUZUKI scan tool operator’s manual.
09931-76011 09931-76030
Tech 1A kit
See NOTE below.Immobilizer cartridge of
version 1.1 or more16/14 pin DLC cable Mass storage cartridge of
version 1.5 or more
NOTE:
This kit includs the following items.
1. Storage case, 2. Operator’s manual, 3. Tech 1A, 4. DLC cable, 5. Test lead/probe,
6. Power source cable, 7. DLC cable adaptor, 8. Self-test adaptor

BODY SERVICE 9-17
QUARTER WINDOW
REMOVAL AND INSTALLATION
Refer to “WINDSHIELD” in this section as removal and installa-
tion procedures are basically the same. However, note the follow-
ing.
Observe the following precautions when applying adhesive
(1) along glass (2) edge.
Adhesive (1) should be applied evenly especially in height.
Be careful not to damage primer (3).
Press glass against body quickly after adhesive (1) is
applied.
Adhesive amount specification and position for quarter
window
Height “a” : 13 mm (0.51 in.)
Width “b” : 6 mm (0.24 in.)
Width “c” : 14 mm (0.55 in.)
Position “d” : 5 mm (0.20 in.) for glass front section.
Position “e” : 11 mm (0.43 in.) for glass rear and upper
sections
Position “e” : 8 mm (0.31 in.) for 3 door model glass bot-
tom section
Position “e” : 10 mm (0.39 in.) for 5 door model glass bot-
tom section CAUTION:
Upon completion of installation, note the following.
Sudden closing of door before adhesive is completely
set may cause glass to become loose or to come off.
Therefore, if door is opened or closed before adhesive
is completely set, make sure to open all door glasses
and use proper care.
If molding is not securely in place, hold it down with a
tape until adhesive is completely set.
Each adhesive has its own setting time.
Be sure to refer to its maker’s instruction, check set-
ting time of adhesive to be used and observe precau-
tions to be taken before adhesive is set.
Refrain from driving till adhesive is completely set so
as to ensure proper and sufficient adhesion.
[A] : 3-door model
[B] : 5-door model
“A”
“A”“B”
“B”
“B”
“B”
“B”“B”
11
22
2
33 “d”
“c”“c”“e”
“a”“a”
“b”“b”
11
2 “A”“B”
[A]
[B]

AIR BAG SYSTEM 10B-13
Not Using SUZUKI Scan Tool
1) Turn ignition switch to ON position and wait about 6 seconds
or more.
2) Using service wire, repeat shorting and opening between
diagnosis switch terminal on “AIR BAG” monitor coupler and
body ground 5 times at about 1 second intervals.
3) Perform DTC CHECK and confirm that normal DTC (DTC
12) is displayed and not malfunction DTC.
DTC TABLE
NOTE:
If DTC B1051 or DTC B1071 is stored in SDM, it is not
possible to clear DTC.
1.“AIR BAG” monitor coupler (a) Open
2. Body ground (b) Short
3. Diagnosis switch terminal (c) About 10 seconds
4. Service wire (d) 1 sec.
1
4
2
DTC“AIR BAG” warning lamp
flashing pattern
Diagnosis
NO. MODE
–12Normal–
B1015 15
Passenger air
bag circuitResistance high
Diagnose trou-
ble according to
diagnostic flow
table corre-
sponding to
each code No. B1016 16 Resistance low
B1018 18 Short to ground
B1019 19 Short to power circuit
B1021 21
Driver air bag
circuitResistance high
B1022 22 Resistance low
B1024 24 Short to ground
B1025 25 Short to power circuit
B1032 32Power source
voltageToo low