AUTO TRANS DIAGNOSIS - AW03-72LE

Article Text
1995 Suzuki Sidekick
For saer Nira Sakhalin Russia 693013
Copyright 1998 Mitchell Repair Information Company, LLC
Sunday, January 13, 2002 07:54PM

ARTICLE BEGINNING

1995 AUTOMATIC TRANSMISSIONS

AW03-72LE Electronic Controls (Except OBD-II)
Suzuki; Sidekick
APPLICATION

APPLICATION

Vehicle
1995 Sidekick

Transmission Model
..................................

AW03-72LE

DESCRIPTION

Automatic transmission is electronically controlled.

Transmission shifting and torque converter lock-up are controlled by
Transmission Control Module (TCM).
The TCM receives information from various input devices and
uses this information to control shift solenoids No. 1 and 2 on
transmission valve body for transmission shifting, and Torque
Converter Clutch (TCC) solenoid for torque converter lock-up.
An Overdrive (OD) switch is mounted on shift lever. When OD
switch is depressed to ON position, transmission will shift into 4th
gear when shift lever is in "D" position, and OD OFF light on
instrument panel will go off. When OD switch is released to OFF
position, transmission will shift into 3rd gear, and OD OFF light on
instrument panel will illuminate. The OD OFF light is located on
instrument panel.
OPERATION
TCM

The TCM receives information from various input devices and

uses this information to control shift solenoids No. 1 and 2 on
transmission valve body for transmission shifting, and TCC solenoid
for torque converter lock-up.
The TCM contains a self-diagnostic system, which will store a
trouble code if failures or problems are present in electronic control
system. Trouble code can be retrieved to determine problem area. See
SELF-DIAGNOSTIC SYSTEM. Note location of TCM. See Fig. 1.

TCM INPUT DEVICES

Brakelight Switch Signal

Brakelight switch delivers input signal to TCM, indicating
vehicle braking. Brakelight switch is located on brake pedal support.
Cruise Control Electronic Control Unit (ECU)
Cruise control unit delivers an input signal to control
overdrive operation in accordance with vehicle speed when cruise
control is operating. When in overdrive with cruise control on, if
vehicle speed drops 2 MPH less than the set speed, overdrive is
released to prevent reduction in vehicle speed. Once vehicle speed is
more than the set speed, the overdrive is resumed. If coolant
temperature is low, transmission will not shift into overdrive. Cruise
control unit is located next to TCM. See Fig. 1.
Engine Coolant Temperature (ECT) Sensor
ECT sensor delivers input signal to TCM, indicating engine
coolant temperature. ECT sensor is located on front of engine. See
Fig. 2.
Overdrive (OD) Switch
The OD switch provides an input signal to TCM to indicate
when overdrive is selected by operator. When OD switch is depressed to
ON position, transmission will shift into 4th gear when shift lever is
in "D" position, and OD OFF light on instrument panel will go off. The
OD OFF light is located on instrument panel. When OD switch is
released to OFF position, transmission will shift into 3rd gear, and
OD OFF light on instrument panel will illuminate. The OD switch is
mounted on shift lever.
Park/Neutral Position (PNP) Switch Signal
PNP switch delivers an input signal to TCM indicating shift
lever position. Switch is located on side of transmission.
Throttle Position (TP) Sensor
TP sensor delivers a variable throttle position input signal
to TCM. TP sensor is located on side of throttle body.
Vehicle Speed Sensor (VSS)
Vehicle speed signal is delivered to TCM by No. 1 and No. 2
speed sensors.

AUTO TRANS DIAGNOSIS - AW03-72LEArticle Text (p. 2)1995 Suzuki SidekickFor saer Nira Sakhalin Russia 69301

Fig. 1: Locating TCM Location

Courtesy of Suzuki of America Corp.

AUTO TRANS DIAGNOSIS - AW03-72LEArticle Text (p. 3)1995 Suzuki SidekickFor saer Nira Sakhalin Russia 69301
Fig. 2: Locating ECT Sensor
Courtesy of Suzuki of America Corp.

TCM OUTPUT DEVICES

No. 1 & No. 2 Shift Solenoids

The TCM controls transmission shifting by delivering an
output signal to operate proper shift solenoid. Shift solenoids are
located on transmission valve body. Shift solenoids are operated in
accordance with shift lever range. If a shift solenoid malfunctions,
TCM will select a gear. See FAIL SAFE GEAR POSITION table.
FAIL SAFE GEAR POSITION

Application

Solenoid
No. 1 Failure

"D"
1st Gear ......... 3rd
2nd Gear ......... 3rd
3rd Gear ......... 3rd
OD Gear ........... OD
"2"
1st Gear ......... 3rd
2nd Gear ......... 3rd
"L"
1st Gear ......... 1st

Solenoid
No. 2 Failure

Solenoid
No. 1 & 2
Failure

......... 1st
.......... OD
.......... OD
.......... OD

............
............
............
...........

OD
OD
OD
OD

.........
.........

1st
3rd

...........
...........

3rd
3rd

.........

1st

...........

1st

TCC Lock-Up Solenoid

The TCM controls torque converter lock-up by delivering an
output signal to TCC lock-up solenoid. Lock-up solenoid is activated
when shift lever is in "D" position, and vehicle is at a predetermined
specified speed.
SELF-DIAGNOSTIC SYSTEM
SYSTEM DIAGNOSIS

NOTE:

Before testing transmission, ensure fluid level is correct

and throttle and shift cables are properly adjusted. Ensure
engine starts with shift lever in Park and Neutral to ensure
proper adjustment of Park/Neutral Position (PNP) switch.
Transmission must first be tested for stored trouble codes.
See RETRIEVING TROUBLE CODES.

The TCM monitors transmission operation and contains a selfdiagnostic system which stores a trouble code if an electronic control
system
failure
or problem
is present.
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AUTO TRANS
DIAGNOSIS
- AW03-72LEArticle
Text

No. 1 or No. 2 shift solenoids and/or vehicle speed sensor, and a

trouble code is present, the TCM will deliver a signal to flash OD OFF
light on instrument panel to warn the driver.
RETRIEVING TROUBLE CODES

NOTE:

Before retrieving trouble codes, ensure battery is fully

charged for proper self-diagnostic system operation. Perform
diagnostic circuit check before retrieving trouble codes to
ensure operation of OD OFF light. See DIAGNOSTIC CIRCUIT
CHECK. Trouble codes must be cleared from TCM memory once
repairs have been performed. See CLEARING TROUBLE CODES.

Diagnostic Circuit Check

1) Turn ignition on. Release OD switch to OFF position.
Ensure OD OFF light on instrument panel illuminates. If OD OFF light
does not illuminate, check OD switch and wiring circuit. See wiring
diagram in WIRING DIAGRAM.
2) Depress OD switch to the ON position. Ensure OD OFF light
on instrument panel goes off. If OD OFF light remains on, check OD
switch and wiring circuit. If OD OFF light is blinking, check for
stored trouble codes. See TCM TROUBLE CODES.
TCM Trouble Codes
1) Turn ignition on. DO NOT start engine. Connect a jumper
wire between terminals on monitor coupler. See Fig. 3. Note number of
flashes from OD OFF light on instrument panel. If system operation is
normal, OD OFF light will flash trouble code 12. See Fig. 4.
2) If system is operating normally, and no trouble codes are
present, turn ignition off and remove jumper wire. Perform manual
shifting test to determine if problem is electrical or mechanical. See
MANUAL SHIFTING TEST under TRANSMISSION SHIFT TESTING. Check system by
symptom. See SYMPTOM TROUBLE SHOOTING.
3) If a trouble code is present, OD OFF light will flash a
trouble code. The number of flashes will equal first digit of trouble
code. After a one second pause, second digit will be displayed. See
Fig. 4.
4) If more than one trouble code is present, next trouble
code will be displayed after a 3 second pause. Smallest number trouble
code will be displayed first. Trouble codes will be repeated. Once
trouble code is obtained, determine probable cause. See
TROUBLE CODE IDENTIFICATION table.
NOTE:

Manufacturer does not provide diagnostic trouble code

testing information. Only symptom trouble shooting and
component testing procedures are given. For additional
component information, see appropriate ENGINE PERFORMANCE
article.

AUTO TRANS DIA

TROUBLE CODE IDENTIFICATION

Trouble Code
12
21
22
23
24
25
26
31
32
33
34
36

(1) Probable Cause

............................... System Operation Normal

..................... No. 1 Shift Solenoid Open Circuit
.................... No. 1 Shift Solenoid Short Circuit
..................... No. 2 Shift Solenoid Open Circuit
.................... No. 2 Shift Solenoid Short Circuit
............................. TCC Solenoid Open Circuit
............................ TCC Solenoid Short Circuit
............ Vehicle Speed Sensor Open Or Short Circuit
................ Throttle Position Sensor Short Circuit
................. Throttle Position Sensor Open Circuit
................ Defective Park/Neutral Position Switch
.............. (2) No Signal-Both Vehicle Speed Sensors

(1) - Check listed component for probable cause. Also check

wiring and connections of specified component.
(2) - No signal from both transmission and speedometer mounted
vehicle speed sensors.

Fig. 3: Identifying Monitor Coupler Terminals

Courtesy of Toyota Motor Sales, U.S.A., Inc.

AUTO TRANS DIAGNOSIS - AW03-72LEArticle Text (p. 6)1995 Suzuki SidekickFor saer N

Fig. 4: Identifying Trouble Code Displays

Courtesy of Toyota Motor Sales, U.S.A., Inc.
CLEARING TROUBLE CODES

Once repairs have been performed, trouble codes must be

cleared from TCM memory. To clear, disconnect negative battery cable
for at least 10 seconds.
TRANSMISSION SHIFT TESTING
MANUAL SHIFTING TEST

NOTE:

Perform manual shifting test if no trouble codes are

present. Manual shifting test determines if problem is an
electrical or mechanical related problem.

1) Start and operate vehicle until normal operating

temperature is achieved. Disconnect TCM harness connector. See Fig. 1.
Road test vehicle and ensure transmission gear changes correspond with
shift lever position. See GEAR APPLICATION table.
2) If an abnormality is present, problem is mechanically
related. If all gears are correct, perform trouble shooting in
accordance with symptom. See SYMPTOM TROUBLE SHOOTING. Turn ignition
off.
3) Reconnect TCM harness connector. Clear trouble codes from
TCM memory, as disconnecting electrical connector may set a trouble
code. See CLEARING TROUBLE CODES.

AUTO
TRANS DIAGNOSIS - AW03-72LEArticle Text (p. 7)1995 Suzuki SidekickFor saer Nira Sakhalin Russia 69301
GEAR APPLICATION

Shift Lever Position

"D"

............................................

Gear
Overdrive

"2"
"L"
"R"
"P"

............................................. 3rd Gear

............................................. 1st Gear
.............................................. Reverse
................................................. Park

SYMPTOM TROUBLE SHOOTING

DOES NOT SHIFT

1) Ensure engine and transmission are at normal operating

temperature. Retrieve trouble codes. See RETRIEVING TROUBLE CODES. If
a trouble code is present, repair as needed. Clear trouble codes. See
CLEARING TROUBLE CODES. If no trouble codes are present, go to next
step.
2) Perform manual shifting test. See MANUAL SHIFTING TEST
under TRANSMISSION SHIFT TESTING. Raise and support vehicle. Access
TCM harness connector (leave connected). See Fig. 1. Go to next step.
3) Using a DVOM, measure voltage (backprobe) between chassis
ground and TCM harness connector terminal S1, then terminal S2 while
operating vehicle through all gears with shift selector in "D"
position. See Fig. 5. Record readings and compare with table. See
SHIFT SOLENOID VOLTAGE table. Go to next step.
SHIFT SOLENOID VOLTAGE

Application
1st Gear
No. 1 Shift Solenoid
10-14 Volts .......
No. 2 Shift Solenoid
0 Volt ............

2nd Gear

3rd Gear

10-14 Volts

....

10-14 Volts

..

0 Volt

OD Gear

...........

10-14 Volts

........

0 Volt
0 Volt

4) If any reading is not as specified, go to next step. If

all readings are as specified, inspect shift solenoids. See SHIFT
SOLENOIDS under COMPONENT TESTING. If shift solenoids are okay,
inspect and repair circuits between TCM and shift solenoids as needed.
If circuits are okay, replace TCM and retest.
5) Repeat vehicle operation through all gears while
monitoring voltage between chassis ground and TCM harness connector
terminal "L", then terminal "2". Reading should be zero volts at each
terminal. If readings are not as specified, replace Park/Neutral
Position (PNP) switch and retest. If both readings are zero volts,
replace TCM and retest.

AUTO TRANS DIAGNOSIS -

Fig. 5: Identifying TCM Harness Connector Terminals

Courtesy of Suzuki of America Corp.
INCORRECT SHIFT SPEEDS

1) Ensure engine and transmission are at normal operating

temperature. Retrieve trouble codes. See RETRIEVING TROUBLE CODES. If
a trouble code is present, repair as needed. Clear trouble codes. See
CLEARING TROUBLE CODES. If no trouble codes are present, go to next
step.
2) Access TCM harness connector (leave connected). See
Fig. 1. Using a DVOM, measure voltage (backprobe) between chassis
ground and TCM harness connector terminal TH. See Fig. 5. Go to next
step.
3) Slowly depress accelerator pedal to Wide Open Throttle
(WOT). Monitor voltage while depressing throttle pedal. Voltage should
decrease as throttle is depressed. Voltage should be within the
following range: battery voltage multiplied by .95 (idle position) to
battery voltage multiplied by .39 (WOT). Go to next step.
4) If voltage is not within range in step 3), or changes
erratically, inspect Throttle Position (TP) sensor. See appropriate
ENGINE PERFORMANCE article. If voltage is within range, turn ignition
off and go to next step.
5) Disconnect TCM harness connector. Disconnect speedometer
cable from transmission. Using a DVOM, measure resistance between
chassis ground and TCM harness connector terminal SPM. See Fig. 5.
Monitor DVOM while turning speedometer cable. Go to next step.
6) If reading pulses between zero ohms and infinity 4 times
per revolution, go to next step. If reading is not as specified,
inspect for a broken speedometer cable, faulty sensor in speedometer
or faulty circuit between speedometer and TCM.
7) Ensure ignition is off. Reconnect TCM harness connector.
Turn ignition on. Using a DVOM, measure voltage (backprobe) between
chassis ground and TCM harness connector terminal PWR. See Fig. 5. If
reading is 5 volts with shift selector in "N" position, and zero volts
in "P" position, replace TCM and retest. If 1995
are not saer
as Nira Sakhalin Russia 69301
Suzuki SidekickFor
AUTO
TRANS DIAGNOSIS - AW03-72LEArticle Text (p. 9) readings
specified, replace PNP switch and retest. If problem is still present,

inspect and repair circuits between PNP switch and TCM.

NO UPSHIFT TO OVERDRIVE

1) Ensure engine and transmission are at normal operating

temperature. Retrieve trouble codes. See RETRIEVING TROUBLE CODES. If
a trouble code is present, repair as needed. Clear trouble codes. See
CLEARING TROUBLE CODES. If no trouble codes are present, go to next
step.
2) Perform manual shifting test. See MANUAL SHIFTING TEST
under TRANSMISSION SHIFT TESTING. Reconnect TCM harness connector.
Raise and support vehicle. Using a DVOM, measure voltage (backprobe)
between chassis ground and TCM harness connector terminal S1, then
terminal S2 while operating vehicle through all gears with shift
selector in "D" position. See Fig. 5. Record readings and compare with
table. See SHIFT SOLENOID VOLTAGE table. Go to next step.
SHIFT SOLENOID VOLTAGE

Application
1st Gear
No. 1 Shift Solenoid
10-14 Volts .......
No. 2 Shift Solenoid
0 Volt ............

2nd Gear

3rd Gear

OD Gear

10-14 Volts

...

0 Volt

............

10-14 Volts

...

10-14 Volts

0 Volt

........ 0 Volt

3) If any reading is not within specification, go to next

step. If all readings are within specification, inspect shift
solenoids. See SHIFT SOLENOIDS under COMPONENT TESTING. If shift
solenoids are okay, inspect and repair circuits between TCM and shift
solenoids as needed. If circuits are okay, replace TCM and retest.
4) Repeat vehicle operation through all gears while
monitoring voltage between chassis ground and TCM harness connector
terminal "L", then terminal "2". If reading is zero volts for both
circuits, go to next step. If reading is not as specified, replace
Park/Neutral Position (PNP) switch and retest.
5) Measure voltage (backprobe) between chassis ground and TCM
harness connector terminal OD. See Fig. 5. If reading is 5 volts with
OD switch in OFF position, and zero volts in ON position, go to next
step. If reading is not as specified, inspect OD switch and applicable
circuits. See wiring diagram in WIRING DIAGRAM. Repair as needed.
6) Measure voltage (backprobe) between chassis ground and TCM
harness connector terminal WT. See Fig. 5. If reading is zero volts
with engine coolant temperature below 77F (25C), and battery voltage
with engine coolant temperature above 86F (30C), go to step 8). If
reading is not as specified, go to next step.
AUTO TRANS

7) Inspect ECT sensor. See ENGINE COOLANT TEMPERATURE sensor

under COMPONENT TESTING. If ECT tests okay, see appropriate ENGINE
PERFORMANCE article for further diagnostic information.
8) Measure voltage (backprobe) between chassis ground and TCM
harness connector terminal L4. If reading is zero volts with transfer
case in 4WD position, and battery voltage in 2WD position, replace TCM
and retest. If reading is not as specified, replace 4WD switch
(located on side of transfer case).
NO TCC LOCK-UP

1) Ensure engine and transmission are at normal operating

temperature. Retrieve trouble codes. See RETRIEVING TROUBLE CODES. If
a trouble code is present, repair as needed. Clear trouble codes. See
CLEARING TROUBLE CODES. If no trouble codes are present, go to next
step.
2) Raise and support vehicle. Using a DVOM, measure voltage
(backprobe) between chassis ground and TCM harness connector terminal
S3 while operating vehicle through all forward gears with shift
selector in "D" position. See Fig. 5. Go to next step.
3) Ensure mode switch is in "N" (normal) position. Accelerate
to 35 MPH. If battery voltage is present, inspect TCC solenoid. See
SHIFT SOLENOIDS under COMPONENT TESTING. Replace as needed and retest.
If battery voltage is not present, measure voltage (backprobe) between
chassis ground and TCM harness connector terminal BK. See Fig. 5. Go
to next step.
4) Depress and release brake pedal while monitoring voltage.
If reading is zero volts with pedal released, and battery voltage with
pedal depressed, go to next step. If reading is not as specified,
inspect brake switch and circuit. Repair as needed.
5) Measure voltage (backprobe) between chassis ground and TCM
harness connector terminal WT. See Fig. 5. If reading is zero volts
with engine coolant temperature below 77F (25C), and battery voltage
with engine coolant temperature above 86F (30C), go to step 7). If
reading is not as specified, go to next step.
6) Inspect ECT sensor. See
ENGINE COOLANT TEMPERATURE (ECT) SENSOR under COMPONENT TESTING. If
ECT is okay, see appropriate ENGINE PERFORMANCE article for further
diagnostic information.
7) Measure voltage (backprobe) between chassis ground and TCM
harness connector terminal L4. If reading is zero volts with transfer
case in 4WD position, and battery voltage in 2WD position, replace TCM
and retest. If reading is not as specified, replace 4WD switch
(located on side of transfer case).
COMPONENT TESTING

AUTO TRANS DIAGNOSIS - AW03-72LEArticle

ENGINE COOLANT TEMPERATURE (ECT) SENSOR

Remove sensor from intake manifold and place in water with a

thermometer. Heat water to specified temperature and check resistance.
See ENGINE COOLANT TEMPERATURE (ECT) SENSOR RESISTANCE table. Replace
sensor if resistance is not within specification.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR RESISTANCE TABLE

Temp.
F (C)

Ohms

32 (0) .............................................. 5880

68 (20) ........................................ 2210-2690
104 (40) ............................................ 1140
140 (60) ............................................. 580
176 (80) ......................................... 290-350

SOLENOIDS

1) Obtain access to TCM. See Fig. 1. Ensure ignition is off.

Disconnect TCM harness connector. Turn ignition on. Using a fused
jumper wire, connect one end to TCM harness connector terminal +B.
With other end, probe terminals S1, S2 and S3, one at a time. See
Fig. 5. Ensure a "clicking" sound can be heard when battery voltage is
applied. Replace solenoid if no sound is heard.
2) To check solenoid seals, apply battery voltage to
solenoid. Apply ATF to solenoid with battery voltage connected. See
Fig. 6. ATF should pass through solenoid. Remove battery voltage.
Ensure ATF does not pass through solenoid. Replace solenoid if
defective.

AUTO TRANS DIAGNOSIS - AW03-72LEArticle Text (p. 12)1995 Suzuki SidekickFor saer Nira Sakhalin Russia 6930

Fig. 6: Checking Solenoids

Courtesy of Toyota Motor Sales, U.S.A., Inc.
PARK/NEUTRAL POSITION (PNP) SWITCH

SidekickFor saer Nira Sakhalin Russia 6930

AUTO TRANS
DIAGNOSISPNP
- AW03-72LEArticle
Textconnector.
(p. 13)1995 Suzuki
Disconnect
switch harness
Switch
is located on

side of transmission. Using a DVOM, check for continuity between

specified terminals in accordance with shift lever position. See
Fig. 7. Replace switch if defective.
PARK/NEUTRAL POSITION SWITCH CONTINUITY

Shift Lever Position

"P"
"R"
"N"
"D"
"2"
"L"

Continuity Between Terminals

......................................... 5 & 6,
................................................
......................................... 5 & 6,
................................................
................................................
................................................

8
4
7
3
2
1

&
&
&
&
&
&

9
9
9
9
9
9

Fig. 7: Identifying Park/Neutral Position (PNP) Switch Terminals

Courtesy of Toyota Motor Sales, U.S.A., Inc.
VEHICLE SPEED SENSOR

Ensure ignition is off. Disconnect TCM harness connector. See

Fig. 1. Using a DVOM, measure resistance between TCM harness connector
terminals SP and SPG. See Fig. 5. Resistance should be 387-473 ohms.
Replace as needed.
WIRING DIAGRAM

AUTO TRANS DIAGNOSIS -

AUTO TRANS DIAGNOSIS - AW03-72LEArticle Text (p. 15)1995 Suzuki SidekickFor saer Nira Sakhalin Russia 6930

Fig. 8:

Transmission Wiring Diagram (1995 Suzuki Sidekick)

END OF ARTICLE