2006 SUZUKI SWIFT Adjust

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DTC Detecting Condition and Trouble Area
DTC Troubleshooting
DTC C1028: Master Cylinder Pressure Sensor Circuit FailureS7RS0B4604031
DTC Detecting Condition and Trouble Area
DTC TroubleshootingDTC Detecting Condition Trouble Area
Mechanical switch failure, fa ilure in switch wiring is
shorted to ground. • ESP
® OFF switch
• ESP ® OFF switch circuit
• ESP ® control module
Step Action YesNo
1 Was “Electronic Stability Pr ogram Check” performed? Go to Step 2.Go to “Electronic
Stability Program
System Check”.
2 Check ESP ® OFF switch condition
Is ESP
® OFF switch is OFF condition? Go to Step 3. ESP
® OFF switch
turned OFF condition
and recheck.
3 Check ESP ® OFF switch
1) Turn ignition switch to OFF position.
2) Remove ESP® OFF switch referring to “ESP ® OFF
Switch Removal and Installation”.
3) Check for proper connection at each terminal of ESP ®
OFF switch.
4) If OK, then check ESP ® OFF switch referring to “ESP ®
OFF Switch Inspection”.
Is it good condition? Go to Step 4. Replace ESP
® OFF
switch.
4 Check ESP ® OFF switch circuit
1) Disconnect ESP ® control module connector.
2) Check for proper connection to ESP ® control module
connector at “E85-7” terminal.
3) If OK, then check resistance between “E85-7” terminal and vehicle body ground.
Is resistance infinity? Substitute a known-
good ESP
® hydraulic
unit / control module
assembly and recheck. “LT GRN/RED” wire
circuit is shorted to
ground.
DTC Detecting Condition
Trouble Area
Input signal voltage from master cylinder pressure sensor
in ESP ® control module is too high or low. • Leakage or air in the hydraulic brake system
• Clearance between brake pad and disc too high
Step
Action YesNo
1 Was “Electronic Stability Pr ogram Check” performed? Go to Step 2.Go to “Electronic
Stability Program
System Check”.
2 Check brake system
1) Check brake system as follows.
• Leakage or air in the hydraulic brake system
• Clearance between brake pad and disc too high
Are they in good condition? Go to Step 3.
Repair, replace or
adjust.
3 Check sensor calibration
1) Calibrate master cylinder pressure sensor referring to
“Sensor Calibration”.
2) Clear all DTC(s) and recheck DTC.
Is DTC C1028 still detected? Substitute a known-
good ESP
® hydraulic
unit / control module
assembly recheck. Master cylinder
pressure sensor
calibration was
incompleted.

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

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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 Automatic Transmission/Transaxle: 5A-3
General Description
A/T DescriptionS7RS0B5101001
This automatic transaxle is electronic control full automatic transaxle with forward 4-speed and reverse 1-speed.
The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an automatically controlled lock-up
mechanism.
The gear change device consists of a ravigneau type planet ary gear unit, 3 multiple disc type clutches, 3 multiple disc
type brakes and 2 one-way clutches.
The hydraulic pressure control device consists of a valve body assembly, pressure control solenoid valve (linear
solenoid), 2 shift solenoid va lves, TCC pressure control solenoid valve (lin ear solenoid) and a timing solenoid valve.
Optimum line pressure complying with engine torque is produced by the pressure control solenoid valve in
dependence upon control signal from transmission control module (TCM). This makes it possible to control the line
pressure with high accuracy in accordance with the engine power and running conditions to achieve smooth shifting
characteristics and high efficiency.
A clutch-to-clutch control system is prov ided for shifting between 3rd gear and 4th gear. This clutch-to-clutch control
system is made to function optimally , so that hydraulic pressure controls such as shown below are conducted.
• When upshifting from 3rd gear to 4th gear, to adjust the drain hydraulic pressure at releasing the forward clutch, a
timing solenoid valve is used to switch a hydraulic passage with an orifice to another during shifting.
• When downshifting from 4th gear to 3rd gear, to adjust the line pressure applied to the forward clutch at engaging the forward clutch, a timing solenoid valve is used to s witch a hydraulic passage with an orifice to another during
shifting.
• When upshifting from 3rd gear to 4th gear with engine throttle opened, to optimize the line pressure applied to the forward clutch at releasing the forward clutch, the learning control is processed to compensate the switching timing
of the timing solenoid at every shifting.
• When downshifting from 4th gear to 3rd gear with engine throttle opened, to optimize the line pressure applied to
the forward clutch at engaging the forw ard clutch, the learning control is processed to compensate the line pressure
at every shifting.
Employing the ravigneau type planetary gear unit and this clutch-to-clutch control system greatly simplifies the
construction to make possible a lightweight and compact transaxle.
A line pressure learning control is conducted to provide opti mum shifting time at every upshifting with engine throttle
opened. If long upshifting time is detected, the subsequent line pressure applied during upshifting is intensified. On the
contrary, if short upshifting time is detected, the subs equent line pressure applied during upshifting is weakened.
Slip controlled lock-up function
Even at a lower speed than when the TCC gets engaged completely, control over the TCC pressure control solenoid
works to cause the TCC to slip (be engaged slightly), ther eby improving the transmission efficiency. While such slip
control is being executed, the oil pressure applied to the TCC is controlled by the TCC pressure control solenoid so
that the difference between the engine speed and the input shaft speed becomes close to the specified value.
Also, during deceleration, the TCC is made to slip (be enga ged slightly) to raise the engine speed and enlarge the fuel
cut operation range so that better fuel consumption is achieved.
Due to this reason, it is absolutely necessary for the automati c transmission to use ATF suitable for slip control. Use of
any fluid other than the specified ATF may cause j uddering or some other faulty condition to occur.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-43
Transmission Warning Light Circuit Check – Light Does Not Come “ON” at Ignition Switch ONS7RS0B5104021
Troubleshooting
Transmission Warning Light Circuit Check – Light Remains “ON” at Ignition Switch ONS7RS0B5104022
TroubleshootingStep Action Yes No
1 Was “A/T System Check” performed? Go to Step 2. Go to “A/T System
Check”.
2 Check DTC
Is DTC P0705, P0707, P0712, P0713, P0717, P0722,
P0787, P0788, P0961, P0962, P0963, P0973, P0974,
P0976, P0977, P1702, P1703, P1774, P1777, P2762,
P2763 and/or P2764 detected? Go to applicable DTC
diag. flow.
Go to Step 3.
3 Brake light switch signal inspection
1) With ignition switch turned ON, check voltage between
terminal “C35-20” of ECM connector and ground.
Brake light switch signal specification
Brake pedal is released: 0 – 1 V
Brake pedal is depressed: 8 – 14 V
Is result as specified? Substitute a known-
good TCM and recheck.
Mis-adjusted brake light
switch or faulty brake
light switch.
Step
Action YesNo
1 Combination meter power supply check
1) Turn ignition switch ON.
Does other indicator / warnin g lights in combination meter
comes ON? Go to Step 2.
Repair combination
meter power supply
circuit referring to “C-1
Combination Meter
Circuit Diagram (Meter)
in Section 9A”.
2 TCM power and ground circuit check
1) Check referring to “TCM Power and Ground Circuit
Check”.
Is it in good condition? Go to Step 3.
Repair or replace.
3 DTC check
1) Check DTC referring to “DTC Check”.
Is there DTC P1774? Go to applicable DTC
diag. flow.
Go to Step 4.
4 Combination meter function check
1) Turn ignition switch ON.
Does A/T selector position in dicator show correct select
lever position? Replace combination
meter.
Substitute a known-
good TCM and recheck.
Step
Action YesNo
1 Diagnostic Trouble Code (DTC) Check
1) Check DTC referring to “DTC Check”.
Is there any DTC(s)? Perform DTC Flow to
repair and retry.
Substitute a known-
good TCM and recheck.
If OK, substitute a
known-good
combination meter and
recheck.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-45
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure1) Connect scan tool to DLC with ignition switch OFF.
2) Clear DTCs in TCM memo ry by using scan tool.
3) Start engine and shift select lever to “D” range.
4) Keep engine running at idle speed for 25 seconds or more.
5) Stop vehicle and check DTC.
DTC Troubleshooting DTC detecting condition Trouble area
Multiple or more signals are inputted simultaneously for 10
seconds. • Select cable maladjusted
• Transmission range sensor (switch) maladjusted
• Transmission range sensor (switch) or its circuit
malfunction
•TCM
Step Action YesNo
1 Was “A/T System Check” performed? Go to Step 2.Go to “A/T System
Check”.
2 Do you have SUZUKI scan tool? Go to Step 3.Go to Step 4.
3 Check transmission range sensor (switch) circuit for
operation
Check by using SUZUKI scan tool:
1) Connect SUZUKI scan tool to DLC with ignition switch
OFF.
2) Turn ignition switch ON and check transmission range signal (“P”, “R”, “N”, “D”, “3”, “2” or “L”) on display when
shifting select lever to each range.
Is applicable range indicated? Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.
Go to Step 5.
4 Check transmission range sensor (switch) circuit for
operation
Check by not using SUZUKI scan tool:
1) Turn ignition switch ON.
2) Check voltage at terminals “C35-1”, “C35-7”, “C35-8”,
“C35-18”, “C35-19” and “C35-20” respectively with
select lever shifted to each range.
Taking terminal “C35-19” as an example, is battery
voltage indicated only when se lect lever is shifted to “2”
range and 0 V for other ranges as shown in the following
table.
Check voltage at other terminals likewise, referring to the
following table.
Are check results satisfactory? Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.
Go to Step 5.
5 1) Check select cable for adjustment referring to “Select Cable Adjustment”.
Is it adjusted correctly? Go to Step 6.
Adjust.
6 Check transmission range sensor (switch) for
installation position
1) Shift select lever to “N” range.
2) Check that “N” reference line on sensor and needle
direction shaped on lock washer are aligned.
Are they aligned? Go to Step 7.
Adjust.

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Table for Step 4
DTC P0707: Transmission Range Sensor Circuit LowS7RS0B5104024
Wiring Diagram
DTC Detecting Condition and Trouble Area7 1) Check transmission range sensor (switch) referring to
“Transmission Range Sensor (Shift Switch) Inspection
and Adjustment”.
Are check results satisfactory? “RED/BLK”, “PNK/BLK”,
“RED”, “GRN/ORN”,
“GRN”, “GRN/YEL” or
“LT GRN/BLK” circuit
shorted to power circuit
or shorted each other. If
wires and connections
are OK, substitute a
know-good TCM and
recheck.Replace transmission
range sensor.
Step Action Yes No
Terminal
C35-20 C35-1 C35-8 C35-7 C35-19 C35-18
Select lever position P 8 – 14 V 0 V 0 V 0 V 0 V 0 V
R 0 V 8 – 14 V 0 V 0 V 0 V 0 V
N 0 V 0 V 8 – 14 V 0 V 0 V 0 V
D or 3 0 V 0 V 0 V 8 – 14 V 0 V 0 V 2 0 V 0 V 0 V 0 V 8 – 14 V 0 V
L0 V0 V0 V0 V0 V8 – 14 V
1. TCM 3. Backup lamp
2. Transmission range sensor [A]: Terminal arrangem ent of TCM connector (viewed from harness side)
DTC detecting condition Trouble area
Transmission range switch signal (P, R, N, D, 2, or L) is not
inputted for more than 30 seconds when vehicle speed is
faster than 30 km/h (19 mile/h) and engine speed is faster
than 1500 rpm. • Select cable maladjusted
• Transmission range sensor (switch) maladjusted
• Transmission range sensor (switch) or its circuit
malfunction
•TCM
2P
R
N
D 2 L 3
1
PNK/BLK
RED
GRN
GRN/ORN
GRN/YEL
IG11
RED/BLK
LT GRN/BLK
C35-20
C35-1
C35-8
C35-7
C35-19
C35-18
C34
20 19
87
18
1
C35
[A]
I4RS0A510010-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-47
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out with 2 persons, a driver and a tester, on a level road.

1) Connect scan tool to DLC with ignition switch OFF.
2) Clear DTCs in TCM memo ry by using scan tool.
3) Start engine and shift select lever to “D” range.
4) Start vehicle and increase vehicle speed to 40 km/h (25 mile/h) or more for 1 minutes.
5) Stop vehicle and turn ignition switch OFF.
6) Repeat Step 3) to 4) one time.
7) Stop vehicle and check DTC.
DTC Troubleshooting Step Action YesNo
1 Was “A/T System Check” performed? Go to Step 2.Go to “A/T System
Check”.
2 Do you have SUZUKI scan tool? Go to Step 3.Go to Step 4.
3 Check transmission range sensor (switch) circuit for
operation
Check by using SUZUKI scan tool:
1) Connect SUZUKI scan tool to DLC with ignition switch
OFF.
2) Turn ignition switch ON and check transmission range signal (P, R, N, D, 3, 2 or L) on display when shifting
select lever to each range.
Is applicable range indicated? Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”
Go to Step 5.
4 Check transmission range sensor (switch) circuit for
operation
Check by not using SUZUKI scan tool:
1) Turn ignition switch ON.
2) Check voltage at terminals “C35-1”, “C35-7”, “C35-8”,
“C35-18”, “C35-19” and “C35-20” respectively with
select lever shifted to each range.
Taking terminal “C35-19” as an example, is battery
voltage indicated only when se lect lever is shifted to “2”
range and 0 V for other ranges as shown in the following
table.
Check voltage at other terminals likewise, referring to the
following table.
Are check results satisfactory? Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.
Go to Step 5.
5 1) Check select cable for adjustment referring to “Select Cable Adjustment”.
Is it adjusted correctly? Go to Step 6.
Adjust.
6 Check transmission range sensor (switch) for
installation position
1) Shift select lever to “N” range.
2) Check that “N” reference line on sensor and needle
direction shaped on lock washer are aligned.
Are they aligned? Go to Step 7.
Adjust.