2006 SUZUKI SWIFT oil pressure sensor

Downloaded from www.Manualslib.com manuals search engine 1D-53 Engine Mechanical:
Main Bearings, Crankshaft and Cylinder Block ComponentsS7RS0B1406035
(a)
(c)
(d)(e)
(b)
(f)
(f)
(f)
(g)
(h)
12
3
4
5 67
8910
11 15
12 13
14 16
17
18 19
2021
22
23 24
25
26
OIL
OIL
OIL
OILOIL
I6RS0C140025-02
1. CKP sensor : See “A” 12. Input shaft bearing 23. Sensor plate bolt
2. Knock sensor 13. Flywheel or drive plate 24. Oil pressure switch 3. Cylinder block 14. Main bearing cap 25. Piston cooling nozzle
4. Venturi plug 15. Flywheel or drive plate bolt 26. Piston cooling valve
5. Main bearing : See “B” 16. Rear oil seal housing mounting bolt : 22 N
⋅m (2.2 kgf-m, 16.0 lb-ft)
6. Sensor plate 17. Main bearing cap No.2 bolt : 5 N ⋅m (0.5 kgf-m, 4.0 lb-ft)
7. Crankshaft timing sprocket key 18. Main bearing cap No.1 bolt : See “D”:70 N
⋅m (7.0 kgf-m, 51.0 lb-ft)
8. Crankshaft 19. O-ring : Tighten 25 N ⋅m (2.5 kgf-m, 18.0 lb-ft) by the specified
procedure.
9. Thrust bearing 20. Oil filter adapter case : Tighten 30 N ⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N⋅m (5.0
kgf-m, 36.5 lb-ft) and 60 ° by the specified procedure.
10. Rear oil seal housing : See “C” 21. Oil filter adapter bolt : 11 N
⋅m (1.1 kgf-m, 8.0 lb-ft)
11. Rear oil seal 22. Spring pin : 13 N ⋅m (1.3 kgf-m, 9.5 lb-ft)

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 Automatic Transmission/Transaxle: 5A-27
Road TestS7RS0B5104011
This test is to check if upshift, downshift and lock-up take place at specified speeds while actually driving vehicle on a
level road.
WARNING!
• Carry out test in very little traffic area to prevent an accident.
• Test requires 2 persons, a driver and a tester.

1) Warm up engine.
2) With engine running at idle, shift select lever “D” range.
3) Accelerate vehicle speed by depressing accelerator pedal gradually.
4) While driving in “D” range, check if gear shift and lock-up occur properly as shown in “Automatic Gear Shift Table”.
Troubleshooting 9 Proceed to “Trouble Diag
nosis 2” in “A/T Symptom
Diagnosis”.
Is trouble identified? Repair or replace faulty
parts.
Proceed to “Trouble
Diagnosis 3” in “A/T
Symptom Diagnosis”.
Step Action Yes No
Condition
Possible cause Correction / Reference Item
Unable to run in all range Faulty valve body component Replace valve body assembly.
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.
Faulty forward clutch Inspect. If NG, replace.
Faulty reverse clutch Inspect. If NG, replace.
Faulty 1st and reverse brake Inspect. If NG, replace.
Damaged drive plate Inspect. If NG, replace.
Faulty torque converter Replace.
No gear shift as 3rd gear Malfunction of shift solenoid valve-A
and/or -B Inspect. If NG, replace.
Malfunction of timing solenoid valve Inspect. If NG, replace.
Malfunction of pressure control solenoid
valve Inspect. If NG, replace valve body assembly.
1
→ 2 upshift fails to
occur Malfunction of shif
t solenoid valve-B Inspect. If NG, replace.
Malfunction of output shaft speed
sensor Inspect. If NG, replace.
Malfunction of throttle position sensor Inspect. If NG, replace.
Malfunction of transmission range
sensor Inspect. If NG, replace.
Faulty valve body component Replace valve body assembly.
Faulty 2nd brake Inspect. If NG, replace.
Faulty one-way No.1 clutch Inspect. If NG, replace.
2
→ 3 upshift fails to
occur Malfunction of shif
t solenoid valve-A Inspect. If NG, replace.
Malfunction of output shaft speed
sensor Inspect. If NG, replace.
Malfunction of throttle position sensor Inspect. If NG, replace.
Malfunction of transmission range
sensor Inspect. If NG, replace.
Faulty valve body component Replace valve body assembly.
Faulty direct clutch Inspect. If NG, replace.

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 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 Automatic Transmission/Transaxle: 5A-99
Installation1) Install shift solenoid valve- A (No.1) (1), shift solenoid
valve-B (No.2) (2) and timing solenoid valve (3).
Tightening torque
Shift solenoid bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-
ft)
2) Connect solenoid connectors identifying their installing positions by wire color.
3) Install transmission fluid sensor (6) and sensor wire to clamp. 4) Install oil strain
er assembly (1).
Tightening torque
Oil strainer bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
5) Install new oil pan gasket (1) and oil pan (2).
6) Tighten oil pan bolts to specified torque diagonally and little by little.
Tightening torque
Oil pan bolt (b): 7.0 N·m (0.7 kgf-m, 5.0 lb-ft)
Solenoid Valves (Shift Solenoid Valves, and
Timing Solenoid Valve) Inspection
S7RS0B5106023
Resistance Check
Check shift solenoid valves and timing solenoid valve.
Shift solenoid valves and timing solenoid valve
resistance
Standard: 11 – 15 Ω at 20 °C (68 ° F)
Solenoid coupler Wire color
Shift solenoid valv e-A (No.1) (2) White
Shift solenoid valv e-B (No.2) (3) Black
Timing solenoid valve (1) Yellow
TCC pressure control solenoid
valve (4) Light green / Brown
Pressure control solenoid valve (5) Green / Gray
1 2
3
(a)
I4RS0A510029-01
1
2
3 5
4
6
I4RS0A510030-01
I2RH0B510059-01
I2RH0B510060-01
I2RH0B510061-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-101
Pressure Control Solenoid Valves (Pressure
Control Solenoid and TCC Pressure Control
Solenoid) Removal and Installation
S7RS0B5106024
Removal1) Disconnect negative cable at battery.
2) Lift up vehicle.
3) Remove drain plug and drain A/T fluid.
4) Install drain plug.
Tightening torque
A/T fluid drain plug: 17 N·m (1.7 kgf-m, 12.5 lb-ft)
5) Remove A/T oil pan (1) and oil pan gasket (2).
6) Remove oil strain er assembly (3).
7) Remove transmission fluid temperature sensor (1) from sensor clamp.
8) Disconnect solenoid connectors (2). 9) Remove valve body assembly referring to
“Automatic Transaxl e Unit Disassembly”.
10) Remove pressure control solenoid valve and TCC pressure control solenoid valve referring to “Valve
Body Assembly Disassembly and Reassembly”.
Installation
Reverse removal procedure to install pressure control
solenoid valve and valve body assembly noting the
following points.
• For detail of pressure control solenoid valve and TCC pressure control solenoid va lve installation, refer to
“Valve Body Assembly Disassembly and
Reassembly”.
• For detail of valve body asse mbly installation, refer to
“Automatic Transaxle Unit Assembly”.
• For detail of installing wire harness for solenoid valves and sensor, refer to “Automatic Transaxle Unit
Assembly”. Use new O-rings.
• For detail of A/T oil pan and oil strainer assembly
installation, refer to “A utomatic Transaxle Unit
Assembly”. Use new oil pan gasket.
• Pour A/T fluid and check fluid level according to procedure described in “A/T Fluid Change”.
• Check for fluid leakage after warming up A/T.
Pressure Control Solenoid Valve InspectionS7RS0B5106025
CAUTION!
• Be very careful as dust etc. does enter when pressure control solenoid valves are
inspected.

Resistance Check
Measure resistance between pressure control solenoid
valves (Pressure control solenoid and TCC pressure
control solenoid) (1) terminals.
Pressure control solenoid valve and TCC pressure
control solenoid valve resistance
Standard: 5.0 – 5.6 Ω at 20 °C (68 °F)
I2RH0B510054-01
1 2I4RS0A510027-01
1
I2RH01510071-01

Downloaded from www.Manualslib.com manuals search engine 5A-164 Automatic Transmission/Transaxle:
74) Connect solenoid connectors to solenoid valves identifying their installing positions by wire colors,
and install transmission fluid temperature sensor to
its clamp.
Solenoid valve coupler specification
75) Install oil strainer assembly (1).
Tightening torque
Oil strainer bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft) 76) Install oil cleaner magnets (1) in oil pan (2).
NOTE
If metal particles are attached to the magnets,
clean them before installing.

77) Install new oil pan gasket (1) between transaxle case
and oil pan (2).
78) Tighten oil pan bolts to specified torque diagonally and little by little.
Tightening torque
Oil pan bolt (a): 7.0 N·m (0.7 kgf-m, 5.0 lb-ft)
79) After applying A/T fluid to new O-rings, fit it to fluid inlet union (1). Then inst all fluid outlet union to
transaxle case.
Tightening torque
Fluid outlet union (a): 25 N·m (2.5 kgf-m, 18.0 lb-
ft)
80) Install new gaskets (2) and then install fluid cooler pipes.
Tightening torque
Fluid cooler pipe union bolt (b): 22 N·m (2.2 kgf-
m, 16.0 lb-ft)
Fluid cooler pipe bracket bolt (c): 10 N·m (1.0
kgf-m, 7.5 lb-ft)
Solenoid valve coupler Wire color
Shift solenoid valve-A (No.1) (2) White
Shift solenoid val ve-B (No.2) (3) Black
Timing solenoid valve (1) Yellow
TCC pressure control solenoid
valve (4) Light green /
Brown
Pressure control solenoid valve (5) Gray / Green
Transmission fluid temperature
sensor (6) Orange
12
3 5
4
6
I4RS0A510030-01
I2RH0B510325-01
I2RH0B510326-01
I2RH0B510327-01