2008 SUZUKI SWIFT Adjustment

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-5
4) Pass parking brake cable (1) through bracket (3) of caliper.
5) Hang parking brake cable on lever (2) as follows.
NOTE
Make sure that lever (4) contacts pin (5).

6) Install brake pads and caliper referring to “Rear Disc Brake Pad Removal and Installation”.
7) Connect flexible hose (1) with new washers to caliper (2).
WARNING!
Make sure that flexible hose is not twisted
when tightening joint bolt. If it is twisted,
reconnect it using care not to twist it.

Tightening torque
Flexible hose joint bolt (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft) 8) Install brake cable clip (1) securely to bracket (2).
9) After reassembling brake lines, bleed air from them
referring to “Air Bleeding of Brake System in Section
4A”.
10) Check to make sure that system is free from fluid
leakage.
11) Start engine and then depress brake pedal with about 300 N (30 kg, 66 lbs) load 3 times or more so
as to obtain proper disc to pad clearance.
12) Check to make sure that parking brake lever stroke is as specified. Refer to “Parking Brake Inspection
and Adjustment in Section 4D”.
13) Tighten wheel nuts to specified torque.
Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
14) Remove vehicle from hoist and perform brake test (foot brake and parking brake).
1
23
45
I6RS0C430010-01
1 (a)2
I6RS0C430011-01
1
2
I6RS0C430012-01

Downloaded from www.Manualslib.com manuals search engine Parking Brake: 4D-2
Repair Instructions
Parking Brake Inspection and AdjustmentS7RS0B4406001
Inspection
Hold center of parking brake lever grip and pull it up with
200 N (20 kg, 44 lbs) force.
With parking brake lever pulled up as shown, count
ratchet notches. There should be 4 to 9 notches.
Also, check if both right and left rear wheels are locked
firmly.
To count number of notches easily, listen to click sounds
that ratchet makes while pulling parking brake lever
without pressing its button.
One click sound corresponds to one notch.
If number of notches is out of specification, adjust cable
referring to adjustment procedure so as to obtain
specified parking brake stroke.
NOTE
Check tooth tip of each notch for damage or
wear.
If any damage or wear is found, replace
parking brake lever.

Adjustment
NOTE
Make sure for the following conditions before
cable adjustment.
• No air is trapped in brake system.
• Brake pedal travel is proper.
• Start engine and then brake pedal has been depressed at least 3 times with about
160 N (16.0 kg, 35.3 lbs) load.
• Parking brake lever (1) has been pulled up a few times with about 200 N (20 kg, 44 lbs)
load.
If parking brake cable is replaced with new
one, pull up parking brake lever a few
times with about 500 N ⋅m (50 kg, 110 lbs)
force.

1) Release parking brake lever (1).
2) Loosen parking brake lever adjust nut (2) fully.
3) Make sure that lever (3) contacts pin (4).
4) Pull up parking brake lever 1 notch.
5) Rotate rear wheel by hand and fasten parking lever adjust nut until dragging rear wheel lightly.
I4RS0B440002-01
1. Parking brake cable 2. Brake caliper
I4RS0A440003-01
I6RS0C440001-01
I6RS0C440002-01

Downloaded from www.Manualslib.com manuals search engine 4D-3 Parking Brake:
6) Release parking brake lever and then make sure that there is no drag in rear wheel.
If there is, repeats go to step 2).
7) Make sure that the number of notch is between 4 and 9 when operating parking brake lever.
8) If the number of notch is not between 4 and 9, replace parking brake cable and/or inspect rear
brake caliper.
Parking brake stroke
When lever is pulled up at 200 N (20kg, 44lbs) : 4
to 9 notches
Parking Brake Cable Removal and InstallationS7RS0B4406002
Removal
NOTE
When it is necessary to remove both right
and left parking brake cables, repeat below
steps 2) and 5) on right and left wheels.

1) Hoist vehicle.
2) Remove wheel.
3) Disconnect parking brake cable from equalizer (parking brake lever) and clamps.
4) Disconnect parking brake cable from lever referring to “Rear Disc Brake Caliper Removal and Installation
in Section 4C”.
5) Remove parking brake cable and parking cable bracket.
Installation
Install it by reversing removal procedure, noting the
following points.
• Install clamps properly referring to “Parking Brake Cable Construction”.
• Tighten bolts and nuts to specified torque referring to “Parking Brake Cable Construction”.
Tightening torque
Parking brake lever bolt: 25 N·m (2.5 kgf-m, 18.0
lb-ft)
Parking cable clamp bolt: 11 N·m (1.1 kgf-m, 8.0
lb-ft)
Parking cable bracket bolt: 25 N·m (2.5 kgf-m,
18.0 lb-ft)
• Adjust parking brake cable. Refer to “Parking Brake Inspection and Adjustment”.
• Check brake disc for dragging and brake system for proper performance. Brake test should be performed.
Parking Brake Lever Removal and InstallationS7RS0B4406003
Removal
1) Remove console box.
2) Block vehicle wheels and release parking brake lever.
3) Disconnect lead wire of parking brake switch at coupler.
4) Loosen parking brake cable adjusting nut (1).
5) Remove parking brake lever bolts (1) and then remove parking brake lever assembly (2) with
equalizer (3).
NOTE
Don’t disassemble parking brake lever
switch. It must be removed and installed as a
complete switch assembly.

I4RS0A440004-01
I4RS0A440005-01

Downloaded from www.Manualslib.com manuals search engine Parking Brake: 4D-4
Installation1) Install in reverse order of removal procedure. Check equalizer inclined angle.
Tightening torque
Parking brake lever bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft) 2) After all parts are installed, parking brake lever
needs to be adjusted. Refer to “Parking Brake
Inspection and Adjustment”.
3) Check brake drum or disc for dragging and brake system for proper performance. After removing
vehicle from hoist, brake test should be performed.
Specifications
Tightening Torque SpecificationsS7RS0B4407001
NOTE
The specified tightening torque is also described in the following.
“Parking Brake Cable Construction”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I4RS0A440006-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Parking brake lever bolt 25 2.5 18.0 ) / )
Parking cable clamp bolt 11 1.1 8.0 )
Parking cable bracket bolt 25 2.5 18.0 )

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 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.

Downloaded from www.Manualslib.com manuals search engine 5A-46 Automatic Transmission/Transaxle:
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