2008 SUZUKI SWIFT Release

Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-25
Circuit Description
EBD warning lamp (brake warning lamp) is controlled by ESP® control module and BCM through lamp driver module
in combination meter.
If EBD system is in good condition, ESP ® control module turns EBD warning lamp ON at the ignition switch ON,
keeps it ON for 2 seconds and then turns it OFF.
EBD warning lamp is turned ON cont inuously at the following conditions.
• EBD system is an abnormality
• Connector of ESP ® control module is disconnected
• Parking brake switch is ON
• Brake fluid level is lower than minimum level
The information of parking brake switch and brake fluid leve l are transmitted from BCM to lamp driver module in
combination meter through CAN communication line.
Troubleshooting
Step Action Yes No 1 Check parking brake and brake fluid level
1) Make sure that:
• Parking brake is completely released.
• Brake fluid level is upper than the minimum level.
Are the check results OK? Go to Step 2. Release parking brake
completely and/or
replenish brake fluid.
2 Check ABS warning lamp
1) Turn ignition switch to ON position.
Does ABS warning lamp come on steady? Perform “ABS Warning
Lamp Does Not Come
ON at Ignition Switch
ON” previously outlined.Go to Step 3.
3 Check parking brake switch circuit and brake fluid level
switch circuit
1) Release parking brake completely, and replenish brake
fluid.
2) Disconnect BCM connectors with ignition switch turned OFF.
3) Measure resistance between each terminal of “L01-6”, “E46-5” and vehicle body ground.
Are resistance
∞ Ω? Go to Step 4. Check each applicable
circuit for short to
vehicle body ground. If
OK, then check parking
brake switch and/or
brake fluid level switch.
4 CAN communication circuit check
1) CAN communication circuit between combination meter,
ABS (ESP® ) control module and BCM referring to “DTC
U1073: Control Module Communication Bus Off”.
Is CAN communication circuit in good condition? Substitute a known-
good combination meter
and recheck. If EBD
warning lamp remains
ON, substitute a known-
good ESP
® hydraulic
unit / control module
assembly and recheck. Repair or replace.

Downloaded from www.Manualslib.com manuals search engine 4F-54 Electronic Stability Program:
Repair Instructions
ESP® Hydraulic Unit Operation CheckS7RS0B4606025
1) Check that basic brake system other than ESP ® is
in good condition.
2) Check that battery voltage is 11 V or higher.
3) Lift up vehicle.
4) Set transmission to neutral and release parking brake.
5) Turn each wheel gradually by hand to check if braked ragging occurs. If it does, correct.
6) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
7) Turn ignition switch to ON position and select menu press / depress in “HYDRAULIC CONTROL TEST”
under “miscellaneous test” (“MISC. TEST”) mode of
SUZUKI scan tool.
Refer to SUZUKI scan tool operator’s manual for
further details.
8) Perform the following checks with help of another person.
• Depressurization checkStep on brake pedal (1) and then select testing
wheel by SUZUKI scan tool and the wheel (2)
should be turned by another person’s hand. At this
time, check whether the wheel rotates freely due
to brake depressurization. • Pressurization check
Step off brake pedal (1) and then select testing
wheel by SUZUKI scan tool and the wheel (2)
should be turned by another person’s hand. At this
time, check whether the wheel locks due to brake
pressurization.
NOTE
Pressurization / Depressurization by SUZUKI
scan tool is available for 0.5 second.

9) Check for all 4-wheels condition respectively. If a faulty condition is found, replace hydraulic unit /
control module assembly.
10) After completing the check, turn ignition switch to OFF position and disconnect SUZUKI scan tool from
DLC.
Sensor CalibrationS7RS0B4606015
CAUTION!
If any DTC(s) other than C1075, C1076 or
C1078 are detected, sensor calibration can
not be completed. Repair the detected DTC
first.

NOTE
Steering angle sensor calibration is needed
when battery, “DOME” fuse or the steering
angle sensor is removed.
This sensor calibration can be done with/
without SUZUKI Scan Tool.
When ESP ® control module and/or yaw rate /
G sensor assembly is removed, sensor
calibration is needed with SUZUKI Scan Tool.

(A)
1
I4RS0B450003-01
I4RH01450021-01

Downloaded from www.Manualslib.com manuals search engine 4F-62 Electronic Stability Program:
4) Turn ignition switch to ON position and select menu “DATA LIST” mode of SUZUKI scan tool. Refer to
scan tool operator's manual for further derails.
5) When brake pedal is released, check “Master Cyl Press” under “DATA LIST” of SUZUKI scan tool.
If pressure is out of specification, replace ESP ®
hydraulic unit / cont rol module assembly.
Master cylinder pressure specification
Brake pedal released: 0 ± 0.8 MPa (0 ± 8 kg/cm2, 0
± 113 psi)
6) Hoist vehicle and remove right-side front wheel.
7) Connect special tool with rubber hose (1) to Front brake caliper bleeder plug (2).
Special tool
(A): 09956–02311
8) When bleeder plug loosen and depress brake pedal to make special tool gauge reading 10 MPa (100 kg/
cm
2, 1422 psi), check “Master Cyl Press” under
“DATA LIST” of SUZUKI scan tool.
If pressure displayed on SUZUKI scan tool is out of
specification, replace ESP ® hydraulic unit / control
module assembly.
Master cylinder pressure specification
Brake pedal depressed 10 MPa (100 kg/cm2, 1422
psi): 10 ± 1.2 MPa (100 ± 12 kg/cm2, 1422 ± 170
psi)
9) After completing the check, turn ignition switch to
OFF position and disconnect SUZUKI scan tool from
DLC.
10) Tighten bleeder plug and bleed air from brake system, referring to “Air Bleeding of Brake System in
Section 4A”.
Yaw Rate / G Sensor Assembly On-Vehicle
Inspection
S7RS0B4606017
Lateral G Inspection
1) Calibrate yaw rate / G sens or assembly referring to
“Sensor Calibration”.
2) Park and level the vehicle with parking brake and fix wheels with chokes.
3) Check yaw rate / G sensor assembly installation
condition. 4) Connect SUZUKI scan tool to data link connector
(DLC) (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
5) Turn ignition switch to ON position and select menu “DATA LIST” mode of SUZUKI scan tool. Refer to
scan tool operator's manual for further derails.
6) Check “G Sensor (lateral)” under “DATA LIST” of SUZUKI scan tool in the following vehicle conditions.
• Level condition
• Right-up condition
• Left-up condition
If Lateral G condition is ou t of specification, replace
yaw rate / G sensor assembly.
Lateral G sp ecification
2
(A)
1
I6JB01460025-01
Vehicle condition G Sensor (lateral)
Level condition 0 ± 0.1 G
Right-up condition 0.1 ± 0.1 G
Left-up condition –0.1 ± 0.1 G
[A]: Right-up condition “a”: Approx 350 mm (13.78 in.)
[B]: Left-up condition 1. Safety stand
(A)
1
I4RS0B450003-01
[A]
[B]“a”
1
“a”1
I6RS0B460039-02

Downloaded from www.Manualslib.com manuals search engine Table of Contents 5-iii
Gear Shift Control Lever and Cable Components...................................................... 5B-5
Gear Shift Control Le ver and Cable Removal
and Installation .................................................. 5B-6
Gear Select Control Cable Adjustment ............... 5B-6
Back Up Light Switch Removal and Installation ......................................................... 5B-7
Back Up Light Switch Inspection ......................... 5B-7
Manual Transaxle Unit Components ................... 5B-8
Manual Transaxle Unit Dismounting and Remounting....................................................... 5B-9
Gear Shift and Sele ct Shaft Assembly
Components.................................................... 5B-11
Gear Shift and Sele ct Shaft Assembly
Removal and Installation................................. 5B-11
Gear Shift and Select Shaft Disassembly and Assembly ........................................................ 5B-12
Manual Transaxle Assembly Components........ 5B-13
Fifth Gear Disassembly and Assembly ............. 5B-14
Manual Transaxle Assembly Disassembly and Reassembly ............................................. 5B-16
Transaxle Right Case Disassembly and Assembly ........................................................ 5B-23
Transaxle Left Case Disassembly and Assembly ........................................................ 5B-24
Input Shaft and Countershaft Components....... 5B-25
Input Shaft Assembly Disassembly and Reassembly .................................................... 5B-26
Countershaft Assembly Disassembly and Reassembly .................................................... 5B-28
Synchronizer Parts Inspec tion .......................... 5B-31
Gear Shift Shaft Components ........................... 5B-31
5th and Reverse Gear Shift Shafts Disassembly and Assembly ............................ 5B-32
Gear Shift Shaft and Fork Inspection ................ 5B-32
Differential Components ................................... 5B-33
Differential Disassembly and Assembly ............ 5B-33
Specifications ..................................................... 5B-35
Tightening Torque Specifications ...................... 5B-35
Special Tools and Equipmen t ........................... 5B-36
Recommended Service Material ....................... 5B-36 Special Tool ...................................................... 5B-36
Clutch ................
.............................. ......... 5C-1
General Description .............................................5C-1
Clutch Construction .............................................5C-1
Diagnostic Information and Procedures ............5C-2 Clutch System Symptom Diagnosis ....................5C-2
Repair Instructions ........... ...................................5C-2
Clutch Pedal Inspection ......................................5C-2
Clutch Fluid Level Inspection ..............................5C-3
Air Bleeding of Clutch System.............................5C-3
Clutch Pedal Position (CPP) Switch Removal and Installation ..................................................5C-4
Clutch Pedal Position (CPP) Switch Inspection and Adjustment ................................5C-5
Clutch Fluid Pipe and Hose Components ...........5C-5
Clutch Fluid Pipe Removal and Installation.........5C-6
Clutch Fluid Pipe Inspection................................5C-6
Clutch Master Cylinder Removal and Installation .........................................................5C-6
Clutch Operating Cylinder Removal and Installation .........................................................5C-7
Clutch Operating Cylinder Inspection..................5C-7
Clutch Pedal and Clutch Pedal Bracket Components ......................................................5C-7
Clutch Cover, Clutch Disc and Flywheel Components ......................................................5C-8
Clutch Cover, Clutch Disc and Flywheel Removal and Installation ...................................5C-8
Clutch Cover, Clutch Disc and Flywheel Inspection ........................................................5C-10
Clutch Release Syst em Removal and
Installation .......................................................5C-11
Clutch Release System Inspection ...................5C-13
Specifications .................... .................................5C-13
Tightening Torque Specifications ......................5C-13
Special Tools and Equipmen t ...........................5C-14
Recommended Service Material .......................5C-14
Special Tool ......................................................5C-14

Downloaded from www.Manualslib.com manuals search engine 5A-8 Automatic Transmission/Transaxle:
Brake Interlock System ConstructionS7RS0B5101004
Shift Lock Solenoid Control
This system consists of shift lock solenoid control
system and interlock cable control system.
The shift lock solenoid cont rol system is so designed
that the select lever can not be shifted from “P” range
position unless ignition switch is turned to “ON” or “ACC”
position and the brake pedal is depressed.
And interlock cable control system is so designed that
select lever cannot be shifted from “P” range position
unless ignition switch is turned to “ACC” or “ON”
position. Also, ignition key cannot be pulled out of key
slot unless select le ver is in “P” range.
Shift Lock Solenoid Manual Release
When push down shift lock solenoid valve release button
(1), select lever can be moved from “P” range position to
another range even without depressing the brake pedal.
(To shift select lever from “P” range to any other position,
turn ignition switch to ACC or ON position.)
A/T Diagnosis General DescriptionS7RS0B5101005
This vehicle is equipped with an electronic transaxle
control system, which controls the automatic shift up and
shift down timing, TCC operation, etc. suitably to vehicle
driving conditions.
TCM has an On-Board Diagnosis System which detects
a malfunction in this system.
When diagnosing a trouble in transaxle including this
system, be sure to have full understanding of the outline
of “On-Board Diagnostic System Description” and each
item in “Precautions in Diagnosing Trouble” and execute
diagnosis according to “A/T System Check” to obtain
correct result smoothly.
On-Board Diagnostic System DescriptionS7RS0B5101006
For automatic transaxle co ntrol system, TCM has the
following functions. Refer to “Inspection of TCM and Its
Circuits”.
• When ignition switch is turned ON with no malfunction in A/T control system is detected, transmission
warning light (1) lights for about 2 seconds after
ignition switch is turned ON and then goes OFF for
bulb check.
• When TCM detects a malfunction in A/T control system, it indicates transmission warning light (1) and
stores malfunction DTC in its memory.
• It is possible to communicate with TCM through data link connector (DLC) (3) by using SUZUKI scan tool
(2). Diagnostic information can be checked and
erased by using SUZUKI scan tool.
• For information about the following items, refer to “On- Board Diagnostic System De scription in Section 1A”
– Warm up cycle
– Driving cycle
– 2 Driving cycle detection logic
– Pending DTC
– Freeze frame data
1
I6RS0C510001-01
3
2
1
I6RS0C510002-01

Downloaded from www.Manualslib.com manuals search engine 5A-22 Automatic Transmission/Transaxle:
) P1702 Internal control module memory check
sum error • Power supply for all solenoid valves is cut.
• Gear position is fixed in 3rd gear.
• Line pressure control at gear shifting is inhibited.
• Lock-up function is inhibited to operate.
) P1703 CAN invalid data - TCM In case of throttle position signal malfunction:
• Throttle opening used for line pressure control is assumed
to be 100%.
• Throttle opening used for gear shifting control is assumed to be 0%.
• Upshifting to 4th gear is inhibited.
• Lock-up function is inhibited to operate. Line pressure control at gear shifting is inhibited.
• Garage shift control is inhibited.
• Learning control is inhibited.
In case of engine coolant temperature signal malfunction:
• Slip controlled lock-up function is inhibited to operate.
• After 15 minutes pass from detecting malfunction, engine coolant temperature is assumed to be normal operating
temperature, and controls of overdrive and lock-up is
released from inhibition.
In case of engine revolution signal malfunction:
• Upshifting to 4th gear is inhibited.
• Lock-up function is inhibited to operate.
• Line pressure control at gear shifting is inhibited.
• Torque reducing request to ECM (torque reduction control) is inhibited.
• Garage shift control is inhibited.
• Learning control is inhibited.
In case of engine torque signal malfunction:
• Line pressure control at gear shifting is inhibited.
• Torque reducing request to ECM (torque reduction control) is inhibited.
• Upshifting to 4th gear is inhibited.
• Learning control is inhibited.
) P1723 Range select switch malfunction “3” position switch is assumed to be OFF.
) P1774 Control module communication bus off • Throttle opening used for line pressure control is assumed
to be 100%.
• Throttle opening used for gear shifting control is assumed to be 0%.
• Engine revolution is assumed to be 0 RPM.
• After 15 minutes pass from detecting malfunction, engine coolant temperature is assumed to be 90 °C (194 °F).
• Lock-up function is inhibited to operate.
• Line pressure control at gear shifting is inhibited.
• Torque reducing request to ECM (torque reduction control) is inhibited.
• Upshifting to 4th gear is inhibited.
• Garage shift control is inhibited.
• Learning control is inhibited.
DTC No. Trouble area Fail-safe operation

Downloaded from www.Manualslib.com manuals search engine 5A-24 Automatic Transmission/Transaxle:
) ENGINE SPEED At engine idle spee d Engine idle speed is displayed
) INPUT SHAFT
REVOLUTION Ignition switch ON and engine stop 0 RPM
At 60 km/h (37.5 mile/h) constant speed, 20% or less
throttle opening and 3rd gear (“3” range)
2300 RPM
(displayed in increments of 50 rpm)
) OUTPUT SHAFT
REVOLUTION At vehicle stop 0 RPM
At 60 km/h (37.5 mile/h) constant speed, 20% or less
throttle opening and 3rd gear (“3” range)
2300 RPM
(displayed in increments of 50 rpm)
) BATTERY
VOLTAGE Ignition switch ON and engine stop Battery voltage is displayed
(8 – 16 V)
) AT F
TEMPERATURE After driving at 60 km/h (37.5 mile/h) for 15 minutes or
more, and A/T fluid temperature around sensor
reaches 70 – 80
°C (158 – 176 °F) 70 – 80
°C (158 – 176 °F)
) SHIFT SOLENOID-
A COMMAND At vehicle stop ON
At 60 km/h (37.5 mile/h) constant speed, 20% or less
throttle opening and 3rd gear (“3” range)
OFF
) SHIFT SOLENOID-
A MONITOR At vehicle stop ON
At 60 km/h (37.5 mile/h) constant speed, 20% or less
throttle opening and 3rd gear (“3” range)
OFF
) SHIFT SOLENOID-
B COMMAND At vehicle stop ON
At 60 km/h (37.5 mile/h) constant speed, 20% or less
throttle opening and 3rd gear (“3” range)
OFF
) SHIFT SOLENOID-
B MONITOR At vehicle stop ON
At 60 km/h (37.5 mile/h) constant speed, 20% or less
throttle opening and 3rd gear (“3” range)
OFF
) TIMING SOLENOID
COMMAND Ignition switch ON and sele
ct lever is in “N” range OFF
For about 0.5 sec. while on gear shifting between 3rd
and 4th or gear shifting “N” to “D” ON
) TIMING SOLENOID
MONITOR Ignition switch ON and sele
ct lever is in “N” range OFF
For about 0.5 sec. while on gear shifting between 3rd
and 4th or gear shifting “N” to “D” ON
) TCC SOLENOID At vehicle stop, closed throttle, engine idle speed and
1st gear 0%
) PRESSURE
CONTROL SOLENOID At vehicle stop, closed throttle, engine idle speed and
1st gear
0%
) VEHICLE SPEED At vehicle stop 0 km/h, 0 MPH
) O/D OFF SWITCH Ignition switch ON Shift select lever to “3” or “2”
range
ON
Shift select lever to other above
range OFF
) TRANSAXLE
RANGE Ignition switch ONSelect lever is in “P” position P
Select lever is in “R
” position R
Select lever is in “N” position N
Select lever is in “D” position D
Select lever is in “3” position D
Select lever is in “2” position 2
Select lever is in “L” position L
) D RANGE SIGNAL Ignition switch ON Select lever is in “P” position
OFF
Select lever is in “R” position ON
Select lever is in “N” position OFF
Select lever is in “D” position ON
Select lever is in “3” position ON
Select lever is in “2” position ON
Select lever is in “L” position ON
) THROTTLE
POSITION Ignition switch ONAccelerator peda
l is depressed 0 – 100% (Varies depending on
depressed value)
Accelerator peda l is released 0%
) BRAKE SWITCH Ignition switch ON Brake pedal is depressed
ON
Brake pedal is released OFF
Scan tool data
Vehicle condition Normal condition / reference
values

Downloaded from www.Manualslib.com manuals search engine 5A-26 Automatic Transmission/Transaxle:
TRANSAXLE RANGE
Transaxle range detected by signal fed from
transmission range sensor.
D RANGE SIGNAL
ON: Signal which TCM require ECM to increase idle
speed
OFF: Signal which TCM does not require ECM to
increase idle speed
THROTTLE POSITION (%)
Throttle opening ratio computed by CAN signal from
ECM.
BRAKE SWITCH
Inputted signal from brake light switch on pedal bracket.
ON: Brake pedal depressed
OFF: Brake pedal released
TORQUE REDUCTION SIGNAL
ON: Signal which TCM require ECM to reduce output
torque at shifting gear
OFF: Signal which TCM does not require ECM to reduce
output torque
ENGINE COOLANT TEMPERATURE ( °C, °F)
Engine coolant temperature computed by CAN signal
from ECM. AIR CONDITIONER SIGNAL
ON: Signal which inform that air conditioner compressor
is turned ON.
OFF: Signal which inform that air conditioner
compressor is not turned ON.
ENGINE TORQUE SIGNAL (N
⋅m)
Engine torque computed by duty pulse signal outputted
from ECM.
SLIP RPM (RPM)
This parameter indicates slip ping rotation in the torque
converter (difference between input shaft rotation and
engine rotation)
MIL REQUEST
ON: Signal which TCM requires combination meter to
turn on malfunction indicator lamp.
OFF: Signal which TCM does not require combination
meter to turn on malf unction indicator lamp.
FUEL CUT FLAG
ON: Signal which inform that fuel cut is operating.
OFF: Signal which inform that fuel cut is not operating.
A/T Basic CheckS7RS0B5104010
This check is important for troubleshooting when TCM has detected no DTC and no abnormality has been noted in
“Visual Inspection”. Fo llow the flow carefully.
Step Action YesNo
1 Was “A/T System Check” preformed? Go to Step 2.Go to “A/T System
Check”.
2 Perform “Road Test”.
Is it OK? Go to Step 3.
Proceed to
“Troubleshooting” in
“Road Test”.
3 Perform “Manual Road Test”.
Is it OK? Go to Step 4.
Proceed to
“Troubleshooting” in
“Manual Road Test”.
4 Perform “Engine Brake Test”.
Is it OK? Go to Step 5.
Proceed to
“Troubleshooting” in
“Engine Brake Test”.
5 Perform “Stall Test”.
Is it OK? Go to Step 6.
Proceed to
“Troubleshooting” in
“Stall Test”.
6 Perform “Time Lag Test”.
Is it OK? Go to Step 7.
Proceed to
“Troubleshooting” in
“Time Lag Test”.
7 Perform “Line Pressure Test”.
Is it OK? Go to Step 8.
Proceed to
“Troubleshooting” in
“Line Pressure Test”.
8 Proceed to “Trouble Diag nosis 1” in “A/T Symptom
Diagnosis”.
Is trouble identified? Repair or replace faulty
parts.
Go to Step 9.