2006 SUZUKI SWIFT Engine removal

Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-63
Yaw Rate Inspection1) Calibrate yaw rate / G sens or assembly referring to
“Sensor Calibration”.
2) Check yaw rate / G sensor assembly installation
condition.
3) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
4) Turn ignition switch to ON position and select menu
“DATA LIST” mode of SUZUKI scan tool. Refer to
scan tool operator's manual for further derails.
5) Check “Yaw rate sensor” under “DATA LIST” of SUZUKI scan tool in the following vehicle conditions.
• Parking condition
• Drive vehicle in right turning condition with steering wheel fully turned
• Drive vehicle in left tu rning condition with steering
wheel fully turned
If yaw rate condition is ou t of specification, replace
yaw rate / G sensor assembly.
Yaw rate specification
NOTE
• Drive the vehicle on level ground and at 10 km/h (6.2 mph).
• Minimum turning radius is 5.2 m (17.1 ft).

Yaw Rate / G Sensor Assembly Removal and
Installation
S7RS0B4606018
CAUTION!
• When yaw rate / G sensor assembly is replaced, ESP ® control module needs zero
calibration. Perform zero calibration by
SUZUKI scan tool referring to “Sensor
Calibration”.
• Regarding yaw rate / G sensor assembly removal/installation, confirm specified
torque and never use impact wrench to
avoid damage.
• When handling the yaw rate / G sensor assembly, be careful not to drop it or apply
an impact to it.
If an excessive impact was applied, never
attempt disassembly or repair but replace
it with a new one.

Vehicle condition Yaw rate
Parking 0 ± 4 deg/s
Right turning 30 ± 4 deg/s
Left turning –30 ± 4 deg/s
(A)
1
I4RS0B450003-01
[A]: Right turning“a”: Approx 5.2 m (17.1 ft.)
[B]: Left turning
[A]
[B] “a”
“a”
I6RS0B460040-02

Downloaded from www.Manualslib.com manuals search engine 4F-64 Electronic Stability Program:
Removal1) Disconnect negative (–) cable at battery.
2) Remove front console box referring to “Console Box Components in Section 9H”.
3) Disconnect connector from yaw rate / G sensor
assembly.
4) Remove yaw rate / G sens or assembly from sensor
bracket.
Installation 1) Before installing yaw rate / G sensor assembly (1),
check installing condition as follows.
• Deformations around sensor installation area (2) (in sensor bracket).
• Foreign matters on mating surface between sensor and sensor bracket.
2) Install yaw rate / G sensor assembly (1) to floor panel.
Tightening torque
Yaw rate / G sensor assembly nut (a): 8 N·m (0.8
kgf-m, 6.0 lb-ft)
3) Connect connector to yaw rate / G sensor assembly.
4) Install console box referring to “Console Box Components in Section 9H”.
5) Connect negative (–) cable to battery.
6) After completing installation, calibrate yaw rate / G
sensor assembly referring to “Sensor Calibration”.Yaw Rate / G Sensor InspectionS7RS0B4606019
• Check sensor for dents, cracks or deformation.
• Check sensor connector (sensor side and harness
side) and sensor connector lock mechanism for
damage or crack.
• Check connector terminals for bend, corrosion or rust.
If it is found faulty, replace yaw rate / G sensor assembly.
Steering Angle Sensor On-Vehicle InspectionS7RS0B4606020
CAUTION!
Before each inspection, confirm steering
angle sensor calibration is completed.
If calibration is incompleted, calibrate sensor
referring to “Sensor Calibration”.

1) Connect SUZUKI scan tool to data link connector
(DLC) (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
(a)
1
(a)
2I6RS0B460041-02
I6JB01460031-01
(A)
1
I4RS0B450003-01

Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-65
2) Turn ignition switch to ON position and select menu
“DATA LIST” mode of SUZUKI scan tool.
Refer to scan tool operator's manual for further
derails.
3) Check “Steering angle Sen” under “DATA LIST” of SUZUKI scan tool in th e following steering wheel
conditions.
• Front wheels in straight-ahead position
• Rotate steering wheel a round in clockwise (counter clockwise) from straight-ahead position
If steering angle condition is out of specification,
replace steering angle sensor.
Steering angle Specification
Steering Angle Sensor Removal and InstallationS7RS0B4606021
Refer to “Steering Angle Sensor Removal and
Installation in Section 6B”.
Steering Angle Sensor InspectionS7RS0B4606022
• Check sensor for dents, cracks or deformation.
• Check sensor connector (sensor side and harness
side) and sensor connector lock mechanism for
damage or crack.
• Check connector terminals for bend, corrosion or rust.
If it is found faulty, replace steering angle sensor (1).
ESP ® OFF Switch Removal and InstallationS7RS0B4606023
Removal
1) Disconnect negative (–) cable at battery.
2) Remove rear console box referring to “Console Box Components in Section 9H”.
3) Disconnect ESP ® OFF switch coupler.
4) Remove ESP ® OFF switch (1) from rear console
box (2).
Installation
Reverse removal procedure.
ESP ® OFF Switch InspectionS7RS0B4606024
Check for continuity between terminals at each switch
position.
If check result is not as specified, replace ESP ® OFF
switch.
Vehicle condition Steering angle
Front wheels in straight-
ahead position 0
± 3 °
Rotate steering wheel a
round in clockwise 360
± 3°
Rotate steering wheel a
round in counterclockwise –360
± 3 °
I6JB01460032-01
1
I6JB01460033-01
[A]: Free [B]: Push
1
I6RS0B460042-02
[A]
[B]2345
2
3
4
1
5
I6RS0B460043-02

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 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 5A-18 Automatic Transmission/Transaxle:
Visual InspectionS7RS0B5104002
Visually check the following parts and systems.
Malfunction Indicator Lamp (MIL) CheckS7RS0B5104003
Refer to the same item in “Malfunction Indicator Lam p (MIL) Check in Section 1A” for checking procedure.
Transmission Warning Light CheckS7RS0B5104004
1) Turn ignition switch ON.
2) Check that transmission warning light lights for about 2 – 4 sec. and then goes OFF.
If anything faulty is found, advance “Transmission Warn ing Light Circuit Check – Light Does Not Come “ON” at
Ignition Switch ON” or “Transmission Warning Light Circu it Check – Light Remains “ON” at Ignition Switch ON”.
Inspection item Referring
• A/T fluid ----- level, leakage, color “Automatic Transaxle Fluid Level Inspection in Section 0B”
• A/T fluid hoses ----- disconnection, looseness, deterioration “A/T Fluid Cooler Hoses Replacement”
• A/T select cable ----- installation “S elect Cable Removal and Installation”
• Engine oil ----- level, leakage “Engine Oil and Filter Change in Section 0B”
• Engine coolant ----- level, leakage “Engine Coolant Change in Section 0B”
• Engine mountings ----- play, looseness, damage “Engine Assembly Removal and Installation in Section 1D”
• Suspension ----- play, looseness “Suspension, Wheels and Tires Symptom Diagnosis in Section 2A”
• Drive shafts ----- damage “Front Drive Shaft Assembly On-Vehicle Inspection in Section 3A”
• Battery ----- indicator condition, corrosion of terminal “Battery Inspection in Section 1J”
• Connectors of electric wire harness ----- disconnection, friction “Electronic Shift Control System Components
Location”
• Fuses ----- burning
• Parts ----- installation, damage
• Bolts ----- looseness
• Other parts that can be checked visually
Also check the following items at engine start, if possible.
• Transmission warning light (if equipped) ----- Operation “Transmission Warning Light Check”
• Malfunction indicator lamp ----- Operation “Malfunction Indicator Lamp (MIL) Check”
• Charge warning lamp ----- Operation “Generator Symptom Diagnosis in Section 1J”
• Engine oil pressure warning lamp ----- Operation “Oil Pressure Warning Ligh t Symptom Diagnosis in
Section 9C”
• Engine coolant temp. meter ----- Operation “Engine Coolant Temperature (ECT) Meter
Symptom Diagnosis in Section 9C”
• Other parts that can be checked visually
I4RS0A510008-01

Downloaded from www.Manualslib.com manuals search engine 5A-82 Automatic Transmission/Transaxle:
Inspection of TCM and Its CircuitsS7RS0B5104045
TCM and its circuits can be checked at TCM wiring connec tors by measuring voltage, pulse signal and resistance.
CAUTION!
TCM cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmeter to TCM with
connector disconnected from it.

1) Remove TCM (1) from vehicle referring to “Transmission Control Module (TCM) Removal and Installation”.
2) Connect TCM connectors (2) to TCM.
3) Check voltage and/or pulse signal at each terminal of connectors connected using voltmeter (3) and oscilloscope
(4).
NOTE
• As each terminal voltage is affected by battery voltag e, confirm that it is 11 V or more when ignition
switch is ON.
• Voltage with asterisk(*) cannot be measured by voltmeter because it is pulse signal. Check it with oscilloscope if necessary.

Terminal arrangement of TCM coupler (Viewed from harness side)
5. Body ground
3
5 4
12
I6RS0C510009-01
65
16 15 14 13 12 11 43
24 23 2122 10 9 8 721
1920 18 17
C34
17 16
26 25
15 14
65 3
42
13 12
23 2224 11 10 9
21 20 19 87
18
1
C35
I4RS0A510022-01