2007 SUZUKI SWIFT Repair circuit

Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-51
DTC U1126: Lost Communication with Steering Angle Sensor (Reception Error)S7RS0B4604043
Wiring Diagram
Refer to “Wiring Diagram” under “DTC U1073: Control Module Communication Bus Off”.
DTC Detecting Condition and Trouble Area
DTC Troubleshooting4
Check each control module connectors
1) Check connection of connectors of all control modules
communicating by means of CAN.
2) Check DTC for ESP ®.
Is DTC U1100 detected? Go to Step 5. Check for intermittent
trouble referring to
“Intermittent and Poor
Connection Inspection
in Section 00”.
5 CAN communication circuit check
1) Turn ignition switch to OFF position.
2) Disconnect connectors of ESP ® control module and
ECM communicating by means of CAN.
3) Check CAN communication circuit between ESP®
control module and ECM for open, short and high
resistance.
Is each CAN communication circuit in good condition? Repair or replace the
CAN communication
line.
Go to Step 6.
6 CAN communication circuit check
1) Disconnect connectors of all control modules
communicating by means of CAN.
2) Check CAN communication circuit between control modules other than Step 5 for open, short and high
resistance.
Is each CAN communication circuit in good condition? Go to Step 7. Repair or replace the
CAN communication
line.
7 DTC check for ESP®
1) Connect connectors of disconnected control modules
communicating by means of CAN.
2) Disconnect each connector. •ECM
• Keyless start control module (if equipped)
• Combination meter
• Steering angle sensor
•BCM
3) Recheck DTC for ESP ®.
Is DTC U1100 detected? Check ESP
® control
module power and
ground circuit. If circuits
are OK, substitute a
known-good ESP ®
hydraulic unit / control
module assembly and
recheck. Check applicable
control module power
and ground circuit. If
circuit is OK, substitute
a known-good
applicable control
module and recheck.
Step Action Yes No
DTC Detecting Condition
Trouble Area
Steering angle sensor message data is missing from CAN
communication. • CAN communication circuit
• Steering angle sensor
• 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 DTC check for ESP®
1) Check DTC for ESP ®.
Is DTC U1126 and DTC U1073 detected together? Go to “DTC U1073:
Control Module
Communication Bus
Off”.Go to Step 3.

Downloaded from www.Manualslib.com manuals search engine 4F-52 Electronic Stability Program:
DTC U1140: Lost Communication with BCM (Reception Error)S7RS0B4604045
Wiring Diagram
Refer to “Wiring Diagram” under “DTC U1073: Control Module Communication Bus Off”.
DTC Detecting Condition and Trouble Area3
Check each control module connectors
1) Check connection of connectors of all control modules
communicating by means of CAN.
2) Check DTC for ESP ®.
Is DTC U1126 detected? Go to Step 4. Check for intermittent
trouble referring to
“Intermittent and Poor
Connection Inspection
in Section 00”.
4 CAN communication circuit check
1) Turn ignition switch to OFF position.
2) Disconnect connectors of ESP ® control module, BCM
and steering angle sensor communicating by means of
CAN.
3) Check CAN communication circuit for open, short and high resistance.
• Between ESP ® control module and BCM
• Between steering angle sensor and BCM
Is each CAN communication circuit in good condition? Repair or replace the
CAN communication
line.
Go to Step 5.
5 CAN communication circuit check
1) Disconnect connectors of all control modules
communicating by means of CAN.
2) Check CAN communication circuit between control modules other than Step 4 for open, short and high
resistance.
Is each CAN communication circuit in good condition? Go to Step 6. Repair or replace the
CAN communication
line.
6 DTC check for ESP®
1) Connect connectors of disconnected control modules
communicating by means of CAN.
2) Disconnect each connector. •ECM
• Keyless start control module
• Combination meter
• Steering angle sensor
•BCM
3) Check DTC for ESP ®.
Is DTC U1126 detected? Check ESP
® control
module power and
ground circuit. If circuits
are OK, substitute a
known-good ESP ®
hydraulic unit / control
module assembly and
recheck. Check applicable
control module power
and ground circuit. If
circuit is OK, substitute
a known-good
applicable control
module and recheck.
Step Action Yes No
DTC Detecting Condition
Trouble Area
BCM message data is missing from CAN communication. • CAN communication circuit
•BCM
• ESP® control module

Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-53
DTC TroubleshootingStep Action Yes No 1 Was “Electronic Stability Pr ogram Check” performed? Go to Step 2. Go to “Electronic
Stability Program
System Check”.
2 DTC check for ESP®
1) Check DTC for ESP ®.
Is DTC U1140 and DTC U1073 detected together? Go to “DTC U1073:
Control Module
Communication Bus
Off”.Go to Step 3.
3 DTC check for BCM
1) Check DTC for BCM.
Is DTC U1073 detected? Go to “DTC U1073 (No.
1073): Control Module
Communication Bus Off
in Section 10B”.Go to Step 4.
4 Check each control module connectors
1) Check connection of connectors of all control modules
communicating by means of CAN.
2) Check DTC for ESP ®.
Is DTC U1140 detected? Go to Step 4. Check for intermittent
trouble referring to
“Intermittent and Poor
Connection Inspection
in Section 00”.
5 CAN communication circuit check
1) Turn ignition switch to OFF position.
2) Disconnect connectors of ESP ® control module and
BCM communicating by means of CAN.
3) Check CAN communication circuit between ESP®
control module and BCM for open, short and high
resistance.
Is each CAN communication circuit in good condition? Repair or replace the
CAN communication
line.
Go to Step 6.
6 CAN communication circuit check
1) Disconnect connectors of all control modules
communicating by means of CAN.
2) Check CAN communication circuit between control modules other than Step 5 for open, short and high
resistance.
Is each CAN communication circuit in good condition? Go to Step 7. Repair or replace the
CAN communication
line.
7 DTC check for ESP®
1) Connect connectors of disconnected control modules
communicating by means of CAN.
2) Disconnect each connector. •ECM
• Keyless start control module
• Combination meter
• Steering angle sensor
•BCM
3) Check DTC for ESP ®.
Is DTC U1140 detected? Check ESP
® control
module power and
ground circuit. If circuits
are OK, substitute a
known-good ESP ®
hydraulic unit / control
module assembly and
recheck. Check applicable
control module power
and ground circuit. If
circuit is OK, substitute
a known-good
applicable control
module and recheck.

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-1
Transmission / Transaxle
Automatic Transmission/Transaxle
Precautions
Precautions in Diagnosing TroubleS7RS0B5100001
• Do not disconnect couplers from TCM, battery cable from battery, TCM ground wire harness from engine or
main fuse before checking the diagnostic information
(DTC, freeze frame data, etc.) stored in TCM memory.
Such disconnection will clea r memorized information
in TCM memory.
• Diagnostic information stored in TCM memory can be cleared as well as checked by using SUZUKI scan
tool or generic scan tool. Before using scan tool, read
its Operator’s (Instruction) Manual carefully to have
good understanding as to what functions are available
and how to use it.
It is indistinguishable wh ich module turns on MIL
because not only ECM but also TCM turns on MIL.
Therefore, check both ECM and TCM for DTC when
MIL lights on.
When checking TCM for DTC, keep in mind that DTC
is displayed on the scan tool as follows depending on
the scan tool used.
– SUZUKI scan tool displays DTC detected by TCM.
– Generic scan tool displays DTC detected by each of ECM and TCM simultaneously.
• Using SUZUKI scan tool the diagnostic information stored in TCM memory can be checked and cleared
as well. Before its use, be sure to read Operator’s
Manual supplied with it carefully to have good
understanding of its functions and usage.
• Be sure to read “Precautions for Electrical Circuit Service in Section 00” befo re inspection and observe
what is written there.
• TCM replacement
– When substituting a known-good TCM, check that all relays and actuators have resistance of
specified value.
Neglecting this check may result in damage to good
TCM.
• Communication of ECUs , ECM, TCM, ABS control
module, keyless start control module and BCM is
established by CAN (Controller Area Network).
Therefore, handle CAN communication line with care
referring to “Precaution for CAN Communication
System in Section 00”.
Precautions for Disassembly and ReassemblyS7RS0B5100002
When repairing automatic transaxle, it is necessary to
conduct the on-vehicle test to investigate where the
cause of the trouble lies first.
Then whether overhaul should be done or not is
determined. If the transaxle is disassembled without
such preliminary procedure, not only the cause of the
trouble would be unknown, but also a secondary trouble
may occur and often time would be wasted.
As the automatic transaxle consists of high precision
component, the following cautions should be strictly
observed when handling its parts in disassembly and
reassembly.
• Disassembling valve body assembly is prohibited
essentially. However, a few parts can be
disassembled. When disassembling valve body
component parts, confirm whether their parts are
allowed to disassemble or not referring to “Valve Body
Assembly Disassembly and Reassembly”.
• When component part of forward clutch, direct clutch, 2nd brake and/or O/D and 2nd coast brake, namely
clutch disc, brake disc, retaining plate and/or
separator plate, have been replaced, all learned
contents, which have been stored in TCM memory by
executing learning control, should be initialized
referring to “Learning Control Initialization”.
• Make sure to wash dirt off from the transaxle so that no such dirt will enter the transaxle during
dismounting and remounting.
• Select a clean place free from dust and dirt for overhauling.
• Place a rubber mat on the work bench to protect parts from damage.
• Work gloves or shop cloth should not be used. (Use a nylon cloth or a paper towel.)
• When separating the case joint, do not pry with a screwdriver or such but tap with a plastic hammer
lightly.
• Make sure to wash dirt off from the transaxle so that no such dirt will enter the transaxle during
disassembly and reassembly.
• Wash the disassembled parts in ATF (Automatic Transaxle Fluid) or kerosene (using care not to allow
ATF or kerosene to get on your face, etc.) and confirm
that each fluid passage is not clogged by blowing air
into it. But use kerosene to wash the discs, resin
washers and rubber parts.
• Replace each gasket, oil seal and O-ring with a new one.
• Apply ATF to sliding or rotating parts before
reassembly.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-17
Step 2. DTC / Freeze Frame Data Check, Record and Clearance
First, referring to “DTC Check”, check DTC and pending DTC. If DTC exists, print or write down DTC and freeze frame
data and then clear malfunction DTC(s) by referring to “DTC Clearance”. Malfunction DTC indicates malfunction in the
system but it is not possible to know from it whether the malfunction is occurring now or it occurred in the past and
normal condition has been restored. In order to know that, check symptom in question according to Step 5 and then
recheck DTC according to Step 6.
Diagnosing a trouble based on the DTC in this step only or fa ilure to clear the DTC in this step may result in an faulty
diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting which is otherwise unnecessary.
Step 3 and 4. Visual Inspection
As a preliminary step, be sure to perform visual check of the items that support proper function of the engine and
automatic transaxle referring to “Visual Inspection”.
Step 5. Trouble Symptom Confirmation
Check trouble symptoms based on information obtained in “Step 1. Customer Complaint Analysis: ” and “Step 2. DTC
/ Freeze Frame Data Check, Record and Clearance: ”.
Also, reconfirm DTC according to “DTC Confirmation Procedure” described in each DTC flow.
Step 6 and 7. Rechecking and Record of DTC and Freeze Frame Data
Refer to “DTC Check” for checking procedure.
Step 8. A/T Basic Check and A/T Symptom Diagnosis
Perform basic check of A/T according to “A/T Basic Check” first. When the end of the flow has been reached, check
the parts of the system suspected as a possible cause referring to “A/T Symptom Diagnosis” and based on symptoms
appearing on the vehicle (symptoms obtained through step s of customer complaint analysis, trouble symptom
confirmation and/or A/T basic check) and re pair or replace faulty parts, if any.
Step 9. Troubleshooting for DTC
Based on the DTC indicated in Step 6 / 7 and referring to “a pplicable DTC flow”, locate the cause of the trouble,
namely in a sensor, switch, wire harness, connector, actuator, TCM or other part and repair or replace faulty parts.
Step 10. Check for Intermittent Problem
Check parts where an intermittent trouble is easy to occur (e.g . wire harness, connector, etc.), referring to “Intermittent
and Poor Connection Inspection in Section 00” and related circuit of DTC recorded in Step 2.
Step 11. Final Confirmation Test
Confirm that the problem symptom has gone and the vehicl e is free from any abnormal conditions. If what has been
repaired is related to the malfunction DTC, clear the DTC once and check to ensure that no malfunction DTC is
indicated.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-31
Troubleshooting
Time Lag TestS7RS0B5104015
This test is to check conditions of clutch, brake and fluid pressure. “Time lag” means time elapsed since select lever is
shifted with engine idling till shock is felt.
1) With chocks placed before and behind front and rear wheels respectively, depress brake pedal.
2) Start engine.
3) With stop watch ready, shift select lever from “N” to “D” range an d measure time from that moment till shock is felt.
4) Similarly measure time lag by shifting select lever from “N” to “R” range.
Gear shifting time lag
“N” → “D”: Less than 0.7 sec.
“N” → “R”: Less than 1.2 sec.
NOTE
• When repeating this test, be sure to wait at least one minute after select lever is shifted back to “N”
range.
• Engine should be warmed up fully for this test.
• Repeat test 3 times and take average of those data for final time lag data.

Condition Possible cause Correction / Reference Item
Lower than standard level
in both “D” and “R” range Engine output torque failure
Inspect and repair engine.
Faulty one-way clutch of torque
converter Replace torque converter.
Higher than standard
level in “D” range Malfunction of pressure control solenoid
valve (Low line pressure) Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Slippery 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.
Higher than standard
level in “R” range Malfunction of pressure control solenoid
valve (Low line pressure) Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Slippery reverse clutch Inspect. If NG, replace.
Slippery 1st and reverse brake Inspect. If NG, replace.
Leakage from “R” range fluid pressure
circuit Replace valve body assembly.
Higher than standard
level in both “D” and “R”
range 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.
Leakage from both “D” and “R” range
fluid pressure circuit Replace valve body assembly.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-33
Troubleshooting
“P” Range TestS7RS0B5104017
1) Stop vehicle on a slope of 5 degrees or more, shift select lever to “P” range and at the same time apply parking brake.
2) After stopping engine, depress brake pedal and release parking brake.
3) Then, release brake pedal gradually and check that vehicle remains stationary.
4) Depress brake pedal and shift select lever to “N” range.
5) Then, release brake pedal gradually and check that vehicle moves.
WARNING!
Before test, make sure no one is around vehicle or down on a slope and keep watchful for safety
during test.

Troubleshooting Condition Possible cause Correction / Reference Item
Higher than standard
level in each range Malfunction of pressure control solenoid
valve (Low line pressure) Inspect. If NG, replace valve body assembly.
Faulty valve body component Replace valve body assembly.
Lower than standard level
in each range 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.
Leakage from both “D” and “R” range
fluid pressure circuit Replace valve body assembly.
Lower than standard level
only in “D” range Leakage from “D” range fluid pressure
circuit Replace valve body assembly.
Lower than standard level
only in “R” range Leakage from “R” range fluid pressure
circuit Replace valve body assembly.
Condition
Possible cause Correction / Reference Item
Vehicle moves at “P”
range or remains
stationary at “N” range Defective parking lock pawl or spring
Inspect. If NG, repair.