2004 SUZUKI SWIFT electric

Downloaded from www.Manualslib.com manuals search engine 5A-40 Automatic Transmission/Transaxle:
Trouble Diagnosis 3
Off-vehicle repairNon operate TCC (lock-
up) system
Malfunction of TCC solenoid valve
Inspect. If NG, replace.
Malfunction of shift solenoid valve-A
and/or -B Inspect. If NG, replace.
Malfunction of output shaft speed
sensor Inspect. If NG, replace.
Malfunction of input shaft speed sensor Inspect. If NG, replace.
Malfunction of transmission range
sensor Inspect. If NG, replace.
Malfunction of transmission fluid
temperature sensor Inspect. If NG, replace.
Malfunction of pressure control solenoid
valve Inspect. If NG, replace valve body assembly.
Malfunction of throttle position sensor Inspect referring to “Electric Throttle Body
Assembly On-Vehicle Inspection in Section
1C”. If NG, replace.
Malfunction of engine coolant
temperature sensor Inspect referring to “ECT Sensor Inspection in
Section 1C”. If NG, replace.
Malfunction of brake light switch Inspect referring to “Brake Light Switch
Inspection in Section 9B”. If NG, replace.
Faulty valve body component Replace valve body assembly.
Excessive “N”
→ “D” or
“N”
→ “R” time lag Malfunction of transmission fluid
temperature sensor Inspect. If NG, replace.
Pressure control solenoid valve circuit
faulty Inspect. If NG, replace valve body assembly.
Clogged oil strainer Replace.
Faulty valve body component Replace valve body assembly.
Condition Possible cause Correction / Reference Item
Condition
Possible cause Correction / Reference Item
Unable to run in all range Faulty oil pump Inspect. If NG, replace.
Seized or broken planetary gear Inspect. If NG, replace.
Faulty one-way No.2 clutch Inspect. If NG, replace.
Damaged drive plate Inspect. If NG, replace.
Faulty forward clutch Inspect. If NG, replace.
Faulty reverse clutch Inspect. If NG, replace.
Faulty 1st and reverse brake Inspect. If NG, replace.
Faulty torque converter Replace.
Excessive “N”
→ “D” shift
shock Faulty forward clutch
Inspect. If NG, replace.
Excessive “N”
→ “R” shift
shock Faulty reverse clutch
Inspect. If NG, replace.
Faulty 1st and reverse brake Inspect. If NG, replace.
Poor 1
→ 2 shift,
excessive shock or
slippage Faulty 2nd brake
Inspect. If NG, replace.
Faulty one-way No.1 clutch Inspect. If NG, replace.
Poor 2
→ 3 shift,
excessive shock or
slippage Faulty direct clutch
Inspect. If NG, replace.
Poor 3
↔ O/D shift,
excessive shock or
slippage Faulty forward clutch
Inspect. If NG, replace.
Faulty O/D and 2nd coast brake Inspect. If NG, replace.
Poor 3
→ 2 shift,
excessive shock or
slippage Faulty direct clutch
Inspect. If NG, replace.
Faulty one-way No.1 clutch Inspect. If NG, replace.
Poor 2
→ 1 shift,
excessive shock or
slippage Faulty 2nd brake
Inspect. If NG, replace.
Faulty one-way No.2 clutch Inspect. If NG, replace.

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-1
Steeri ng
Power Assisted Steering System
Precautions
Steering System NoteS7RS0B6300001
NOTE
All steering gear fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with one of
the same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to assure proper retention of these parts.

Precautions in Diagnosing TroublesS7RS0B6300002
• Take a note of DTC indicated on the SUZUKI scan tool.
• Before inspection, be sure to read “Pre cautions for Electrical Circuit Service in Section 00” and understand what is
written there.
• 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 indica tion changes to a normal one when engine is started.
• As DTC is stored in memory of the P/S control module, be sure to clear memory after repair by performing the
procedure described in “DTC Clearance”.

Downloaded from www.Manualslib.com manuals search engine 6C-12 Power Assisted Steering System:
Scan Tool Data Definitions
Battery Voltage
This parameter indicates battery positive voltage.
TQS Power Supply (Torque Sensor Power Supply, V)
This parameter indicates the power supply voltage which
the P/S control module supplies to the torque sensor.
TQS Main Torque (Torque Sensor Main Torque, N ⋅m)
The torque sensor is installed to detect the steering force
and the steering directio n. It consists of two
potentiometers and the main torque sensor is one of
these.
TQS Sub Torque (Torque Sensor Sub Torque, N ⋅m)
The torque sensor is installed to detect the steering force
and the steering directio n. It consists of two
potentiometers and the sub-torque sensor is one of
these. Its output characteristics are compared with those
of the main torque sensor.
Assist Torque (N ⋅m)
This parameter is an internal parameter of the P/S
control module. It is obtained by computing the torque
sensor input signal. Motor Control (Motor Control Current, A)
Based on the input signal, the P/S control module
determines the assist amount
and controls the current to
the motor suitable for that a ssist amount. This parameter
indicates that control value.
Motor Monitor (Motor Monitor Current, A)
This parameter indicates the actually measured value of
the current flowing to the motor. The motor circuit
condition is diagnosed by co mparing this parameter with
“Motor Control” parameter described previously.
Vehicle Speed (km/h, MPH)
Vehicle speed signal is fed from BCM. P/S control
module determines the amount of power assist based on
this vehicle speed signal and the torque sensor signal.
Engine Speed (rpm)
Engine speed signal is fed from the ECM so that it can
be used for trouble diagnos is of the electric power
steering system.
Motor Volt (V)
This parameter indicates the voltage between motor
terminals.
Ignition switch (ON, OFF)
This parameter indicates the condition of the power
supply through the ignition switch.
Visual InspectionS7RS0B6304007
Visually check the following pats and system.
P/S System Symptom DiagnosisS7RS0B6304008
This section describes trouble diagnosis of the P/S system parts whose trouble is not indicated by the on-board
diagnostic system (self-diagnostic functi on). When no malfunction is indicated by the on-board diagnostic system
(self-diagnosis function) and those stee ring basic parts as described in “Steering Symptom Diagnosis in Section 6A”
are all in good condition, check the following power steer ing system parts which may be a possible cause for each
symptom of the steering. Inspection Item Referring section
Battery Level, leakage, color “Batte ry Description in Section 1J”
Connectors of electric wire
harness Disconnection friction “Intermittent and Poor
Connection Inspection in Section 00”
Fuses Burning “Cautions in Body Electric al System Servicing in Section 9A”
Parts Installation, damage
Other parts that can be checked visually
Condition Possible cause Correction / Reference Item
Steering wheel feels
heavy (Perform “Steering
Force Check” before
diagnosis.) Steering wheel installed improperly
(twisted)
Install steering wheel correctly.
Poor performance of torque sensor Check torque sensor referring to “Torque
Sensor and Its Circuit Inspection”.
Poor performance of P/S motor Check motor referring to “P/S Motor and Its
Circuit Inspection”.
Steering gear case assembly faulty Replace.
Poor performance of vehicle speed
signal from ECM Check vehicle speed signal circuit referring to
“DTC C1121 / C1123 / C1124: VSS Circuit
Failure”.

Downloaded from www.Manualslib.com manuals search engine 7B-34 Air Conditioning System: Automatic Type
Automatic Type
Precautions
A/C System CautionS7RS0B7220001
Refer to “A/C System Caution”.
Precautions in Diagnosing TroubleS7RS0B7220002
• Do not disconnect couplers from HVAC control module, battery cable from battery, HVAC control module ground
wire harness from body or main fuse before confirming diagnostic information (diagnostic trouble code) stored in
HVAC control module memory.
• Diagnostic information (diagnostic trouble code) stored in HVAC control module can be checked by display of HVAC
control module. Also, it can be checked by using SU ZUKI scan tool. Before checking diagnostic information
(diagnostic trouble code), read this manual and operator's manual for SUZUKI scan tool to know how to read
diagnostic information (diagnostic trouble code).
• When trouble is diagnosed using diagnostic information (diagnostic trouble code) on display of HVAC control
module, keep in your mind that each diagnostic inform ation (diagnostic trouble code) has priority, and only
diagnostic information (diagnostic troub le code) which has the highest priority is indicated. Therefore, after
troubleshooting the malfunction, make sure if there exists any other diagnostic information (diagnostic trouble
code).
• Be sure to read “Precautions for Electrical Circuit Service in Section 00” before inspection.
Precautions on Servicing A/C SystemS7RS0B7220003
Refer to “Precautions on Servicing A/C System”.
General Description
Auto A/C System DescriptionS7RS0B7221001
The automatic type air conditioning system (auto A/C) is pr ovided with the function to automatically control the inside
air temperature, fan speed, air flow outl et direction and air intake position by HVAC control module in addition to
functions of the manual type air conditioning system (manua l A/C). Once the inside air temperature is set using the
temperature selector, HVAC control module automatically controls the inside air temperature at the constant level at all
times based on the inside air temperature, outside ai r temperature, amount of sunlight and engine coolant
temperature detected respectively by the inside air te mperature sensor, outside air temperature sensor, sunload
sensor and ECT sensor. At this time, “FULL AUTO A/ C” appears on the display of HVAC control module.
With the air intake selector pushed in the above state, it is possible to select any position of the air intake actuator.
Then, “FULL AUTO A/C” on the display changes to “AUTO A/C”.

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-49
Step 7. Final confirmation test
Confirm if the problem symptom is troubleshoot and the A/C system is free from any abnormal conditions. If there
existed DTC, clear the DTC. Then , check if the DTC is still detected and if there is any other DTC.
Visual InspectionS7RS0B7224009
Check visually the following parts and systems.
DTC B1502: Inside Air Temperature Sensor and/or Its Circuit MalfunctionS7RS0B7224010
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Troubleshooting
NOTE
When DTC B1503, B1513 and B1514 are indicated together, it is possible that “ORN” wire circuit open.

Inspection item Correction
• Refrigerant ---- leakage and amount
• A/C pipe or hose ---- disconnection, looseness and deterioration
• A/C compressor drive belt ---- looseness and damage Refer to “Compressor Drive Belt Inspection and
Adjustment”.
• Battery ---- fluid level and corrosion of terminal
• Connectors of electric wire harn ess ---- disconnection and friction
• Fuses ---- burning
• Parts ---- installation and damage
• Other parts that can be checked visually
5V
PNK/BLK
ORN G52-6
G52-3
2
1
3
7812910
65 431516 14 13 12 11
G52
789101920121112
65 431718 16 15 14 13
G51
I5RS0A722010-01
1. HVAC control module
2. Inside air temperature sensor 3. To other sensors
DTC Detecting Condition Trouble Area
Inside air temperature sensor signal voltage is higher than or lower than
specified value for specified time continuously. • Inside air temperature sensor circuit
• Inside air temperature sensor
• HVAC control module
Step
Action YesNo
1 Inside air temperature sensor signal circuit check
1) Disconnect inside air temperature sensor connector.
2) Check for proper connection to inside air temperature
sensor at “PNK/BLK” and “ORN” wire terminals.
3) If OK, measure voltage between “PNK/BLK” wire terminal of inside air temp erature sensor connector and
vehicle body ground with ignition switch turned ON.
Is voltage 4 – 6 V? Go to Step 5.
Go to Step 2.

Downloaded from www.Manualslib.com manuals search engine 7B-68 Air Conditioning System: Automatic Type
G51-8 BLU/REDBlower motor control
voltage feedback 10 – 14 V Ignition switch turned ON, blower speed selector OFF
About 8.5 V Ignition switch turned ON, blower speed selector 1st
position
About 6.5 V Ignition switch turned ON, blower speed selector 2nd
position
About 5.5 V Ignition switch turned ON, blower speed selector 3rd
position
About 4.0 V Ignition switch turned ON, blower speed selector 4th
position
About 3.0 V Ignition switch turned ON, blower speed selector 5th
position
About 2.0 V Ignition switch turned ON, blower speed selector 6th
position
About 1.0 V Ignition switch turned ON, blower speed selector 7th
position
Below 1.0 V Ignition switch turned ON, blower speed selector HIGH
position
G51-9 GRY Blower motor controller 0 – 1 V
Ignition switch turned ON, blower speed selector OFF
position
2 – 3 V Ignition switch turned ON, blower speed selector
between 1st and HIGH position
G51-10 BLK/RED Rear defogger indicator 0 – 1 V Ignition switch turned ON, rear defogger switch OFF
10 – 14 V Ignition switch turned ON, rear defogger switch ON
G51-11 RED/YEL Illumination switch 0 – 1 V Ignition switch turned ON, lighting switch OFF position
10 – 14 V Ignition switch turned ON, lighting switch ON position
G51-12 BLK/YEL Illumination ground 0 – 1 V Full-time
G51-13 — — — —
G51-14 — — — —
G51-15 RED Air intake actuator
(RECIRCULATION AIR) 0 – 1 VIgnition switch turned ON, air intake selector is
recirculation air mode or air intake actuator is working
in operation to recirculation air position or fresh air
position.
10 – 14 V Ignition switch turned ON, ai
r intake selector is fresh
air mode (air intake actuator fresh air position).
G51-16 GRN/RED Air intake actuator
(MIX AIR) 10 – 14 V
Ignition switch turned ON, air intake actuator is
recirculation air or fresh air position.
0 – 1 V Ignition switch turned ON, air intake actuator is mix air
position or air intake actuator is working in operation to
recirculation air position or fresh air position.
G51-17 GRN Air intake actuator
(FRESH AIR) 0 – 1 V
Ignition switch turned ON, ai
r intake selector is fresh
air mode or air intake actuator is working in operation
to recirculation air position or fresh air position.
10 – 14 V Ignition switch turned ON, air intake selector is
recirculation air mode (air intake actuator recirculation
air position).
G51-18 GRN/WHT A/C switch signal Refer to “Inspe ction of BCM and its Circuits in Section 10B”
G51-19 BLU/WHT Electric load signal for
blower motor 10 – 14 V
Ignition switch turned ON, blower speed selector OFF
or between 1st and 5th position
0 – 2 V Ignition switch turned ON, blower speed selector
between 6th and HIGH position
G51-20 BRN Rear defogger switch 0 – 1 V
Ignition switch turned ON, rear defogger switch ON
(rear defogger switch is kept in push) position
4 – 6 V Ignition switch turned ON, rear defogger switch OFF
position
Terminal Wire Color Circuit
Normal
Vo l ta g e Condition

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-69
Terminal Wire Color CircuitNormal
Vo l ta g e Condition
G52-1 WHT Output of 5 V power
source for air flow control
actuator position sensor
and temperature control
actuator position sensor 4 – 6 V Ignition switch turned ON
G52-2 PNK Output of 5 V power
source for sunload sensor 4 – 6 V Ignition switch turned ON
G52-3 ORN Ground for sensors Below 0.3 V Ignition switch turned ON
G52-4 WHT/BLK Evaporator temperature
sensor signal 3.45 – 3.65 V
Ignition switch turned ON, evaporator temperature 0
°
C (32 °F)
2.55 – 2.85 V Ignition switch turned ON, evaporator temperature
15
°C (59 ° F)
1.7 – 2.1 V Ignition switch turned ON, evaporator temperature
30
°C (86 ° F)
G52-5 YEL/BLK Sunload sensor signal
G52-6 PNK/BLK Inside air temperature
sensor signal About 2.0 V
Ignition switch turned ON, room temperature 25
°C
(77 °F)
About 2.8 V Ignition switch turned ON, room temperature 0
°C
(32 °F)
G52-7 — — — —
G52-8 RED/BLK Electric power source 10 – 14 V Ignition switch turned ON
G52-9 — — — —
G52-10 — — — —
G52-11 BLK/ORN Ground for HVAC control
module Below 0.3 V Ignition
switch turned ON
G52-12 — — — —
G52-13 YEL Temperature control
actuator position sensor
signal About 4.0 V
Ignition switch turned ON, temperature selector MAX
COOL position
About 2.0 V Ignition switch turned ON, temperature selector MAX
HOT position
G52-14 WHT/BLU Air flow control actuator
position sensor signal About 4.0 V
Ignition switch turned ON
, air flow selector VENT
position
About 1.6 V Ignition switch ON, air flow selector DEF position
G52-15 — — — —
G52-16 WHT/RED Electric power source for
back-up 10 – 14 V Full-time

Downloaded from www.Manualslib.com manuals search engine 7B-70 Air Conditioning System: Automatic Type
A/C System Performance InspectionS7RS0B7224027
Refer to “A/C System Performance Inspection”.
A/C System Inspection at ECMS7RS0B7224028
Voltage Check
ECM and its circuits can be checked by measuring voltage with special tool connected.
CAUTION!
• ECM connectors are waterproofed. Each terminal of the ECM connectors is sealed up with the
grommet. Therefore, do not measure circuit voltage and resistance by inserting the tester’s probe
into the sealed terminal at the harness side. Or, ECM and its circuits may be damaged by water.
• ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with couplers disconnected from ECM.

1) Remove ECM (1) from its bracket by referring to “Electric Throttle Body System Calibration in Section 1C”.
2) Connect special tool (2) between ECM and ECM connectors securely.
3) Check voltage at each terminal.
NOTE
As each terminal voltage is affected by the battery voltage, confirm that the battery voltage is 11 V or
more when ignition sw itch is ON position.

Terminal arrangement of ECM coupler (Viewed from harness side)
1
2
I5RS0A722018-01
E23 C37
34
1819
567
1011
17
20
47 46
495051
2122
52 16
25 9
24
14
29
55
57 54 53
59
60 58 2
262728
15
30
56 4832 31
34353637
40
42 39 38
44
45 43 41 331
1213
238
34
1819
567
1011
17
20
47 46
495051
2122
52 16
25 9
24
14
29
55
57 54 53
59
60 58 2
262728
15
30
56 4832 31
34353637
40
42 39 38
44
45 43 41 331
1213
238
I4RS0A720010-01