2006 SUZUKI SX4 temperature sensor

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-32
Coupling Air Temperature Sensor InspectionS6RW0D3206007
CAUTION!
Do not heat up coupling air temperature
sensor more than 100 °C (212 °F). Otherwise,
coupling air temperature sensor will be
damaged.

• Blow hot air to temperature sensing part (2) of
coupling air temperature sensor (3) using hot air drier
(4) and measure resistance between sensor terminals
while heating air gradually.
If measured resistance does not show such
characteristic as shown, replace air temperature
sensor.
Coupling Assembly InspectionS6RW0D3206008
• Check coupling assembly for oil leakage. If leakage
exists, replace it.
• Measure resistance between “a” terminal and “b”
terminal of coupling connector (1).
If measured resistance is out of specification, check
harness for open or short.
If OK, replace coupling assembly.
Coupling assembly resistance
: 2 – 3 Ω
[A]: Lower limit [D]: Resistance
[B]: Normal [E]: Temperature
[C]: Upper limit 1. Temperature gauge
020
32 68 17680 (6.00)
(0.34) (2.56)
1
4
23
[D]
[C]
[B]
[A]
[E]
I5RW0A320021-01
1
“a” “b”I5RW0A320064-01

Downloaded from www.Manualslib.com manuals search engine 3B-35 Differential:
Rear Differential ComponentsS6RW0D3206013
4 5
9
2
30
6
(a)13
12
(a)
3
A
3A
141617 2118
29
3A
1(b)
22
1217G
101217G
11
8OIL
15OIL
19 20OIL
23OIL
25OIL27OIL
27OIL
25OIL
19OIL18
26 28
OIL
26OIL23OIL
24OIL
(c)
14
7
I5RW0A320026-02
1. Flange nut 13. Differential cover bolt 25. Differential gear
2. Companion flange 14. Spacer 26. Spring washer
3. Oil seal
: Apply grease 99000-25010 to oil seal lip.15. Rear bearing 27. Thrust washer
4. Coupling front bearing 16. Shim 28. Pinion shaft
5. Coupling case
: Apply sealant 99000-31260 to mating surface of carrier and coupling
case.17. Bevel pinion 29. Pinion shaft pin
6. Coupling assembly
: Never disassemble.18. Shim 30. Coupling case bolt
7. Snap ring 19. Differential side bearing : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
8. Bevel pinion nut
: Tighten nut so as rotation torque of bevel pinion to be in specified value.20. Bevel gear : 125 N⋅m (12.5 kgf-m, 90.5 lb-ft)
9. Front bearing 21. Differential case : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft)
10. Differential carrier
: Apply sealant 99000-31260 to mating surface of carrier and rear cover.22. Bevel gear bolt : Do not reuse.
11. Coupling air temperature sensor 23. Pinion washer : Apply differential oil.
12. Differential cover 24. Pinion

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-48
Specifications
Tightening Torque SpecificationsS6RW0D3207001
NOTE
The specified tightening torque is also described in the following.
“Rear Differential Mountings Components”
“Rear Differential Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS6RW0D3208001
NOTE
Required service material is also described in the following.
“Rear Differential Components”

Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Differential oil level / filler plug 23 2.3 17.0) / )
Differential oil drain plug 23 2.3 17.0)
Coupling air temperature sensor 18 1.8 13.0)
Bevel gear bolt 73 7.3 52.0)
Bevel pinion nut 230 – 340 23.0 – 34.0 166.5 – 246.0)
Differential cover bolt 23 2.3 17.0)
Flange nut 110 11.0 79.5)
Coupling case bolt 23 2.3 17.0)
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25010) / ) / )
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260) / ) / ) / ) / )

Downloaded from www.Manualslib.com manuals search engine Table of Contents 5- i
5
Section 5
CONTENTS
Transmission / Transaxle
Precautions ................................................. 5-1
Precautions............................................................. 5-1
Precautions on Transmission / Transaxle ............. 5-1
Automatic Transmission/Transaxle ....... 5A-1
Precautions........................................................... 5A-1
Precautions in Diagnosing Trouble ..................... 5A-1
Precautions for Disassembly and
Reassembly ...................................................... 5A-1
General Description ............................................. 5A-3
A/T Description ................................................... 5A-3
Clutch / Brake / Planetary Gear Function of
Automatic Transaxle ......................................... 5A-6
Table of Component Operation ........................... 5A-7
A/T Diagnosis General Description ..................... 5A-7
On-Board Diagnostic System Description ........... 5A-8
CAN Communication System Description........... 5A-9
Schematic and Routing Diagram ...................... 5A-10
Transmission Control Module (TCM) Wiring
Diagram .......................................................... 5A-10
Automatic Gear Shift Table ............................... 5A-12
Component Location ......................................... 5A-14
Electronic Shift Control System Components
Location .......................................................... 5A-14
Diagnostic Information and Procedures .......... 5A-16
A/T System Check ............................................ 5A-16
Visual Inspection ............................................... 5A-18
Malfunction Indicator Lamp (MIL) Check .......... 5A-19
Transmission Warning Light Check (Non-
Euro-OBD model) ........................................... 5A-19
DTC Table ......................................................... 5A-19
DTC Check ....................................................... 5A-21
DTC Clearance ................................................. 5A-22
Fail-Safe Table .................................................. 5A-22
Scan Tool Data ................................................. 5A-24
A/T Basic Check ............................................... 5A-27
Road Test ......................................................... 5A-27
Manual Road Test ............................................. 5A-30
Engine Brake Test ............................................ 5A-30
Stall Test ........................................................... 5A-31
Time Lag Test ................................................... 5A-32
Line Pressure Test ............................................ 5A-32
“P” Range Test.................................................. 5A-33
A/T Symptom Diagnosis ................................... 5A-34Transmission Warning Light Circuit Check –
Light Remains “ON” at Ignition Switch ON
(Non-Euro-OBD Model)................................... 5A-41
Transmission Warning Light Circuit Check –
Light Does Not Come “ON” at Ignition Switch
ON (Non-Euro-OBD Model)............................ 5A-41
DTC P0602: Control Module Programming
Error ................................................................ 5A-42
DTC P0705: Transmission Range Sensor
Circuit Malfunction (PRNDL Input) .................. 5A-42
DTC P0707: Transmission Range Sensor
Circuit Low ...................................................... 5A-44
DTC P0711: Transmission Fluid Temperature
Sensor “A” Control Range / Performance ....... 5A-46
DTC P0712: Transmission Fluid Temperature
Sensor Circuit Low .......................................... 5A-47
DTC P0713: Transmission Fluid Temperature
Sensor Circuit High ......................................... 5A-48
DTC P0717: Input / Turbine Speed Sensor
Circuit Malfunction........................................... 5A-50
DTC P0722: Output Speed Sensor (VSS)
Circuit No Signal ............................................. 5A-51
DTC P0741 / P0742: TCC Circuit
Performance or Stuck OFF / TCC Circuit
Stuck ON ......................................................... 5A-53
DTC P0751 / P0752 / P0756 / P0757: Shift
Solenoid Malfunction ....................................... 5A-54
DTC P0787: Shift / Timing Solenoid Control
Circuit Low ...................................................... 5A-55
DTC P0788: Shift / Timing Solenoid Control
Circuit High...................................................... 5A-57
DTC P0961: Pressure Control Solenoid “A”
Control Circuit Range / Performance .............. 5A-58
DTC P0962: Pressure Control Solenoid
Control Circuit Low .......................................... 5A-60
DTC P0963: Pressure Control Solenoid
Control Circuit High ......................................... 5A-62
DTC P0973 / P0976: Shift Solenoid-A (No.1)
Control Circuit Low / Shift Solenoid-B (No.2)
Control Circuit Low .......................................... 5A-64
DTC P0974 / P0977: Shift Solenoid-A (No.1)
/ Shift Solenoid-B (No.2) Control Circuit High .. 5A-66
DTC P1702: Internal Control Module Memory
Check Sum Error............................................. 5A-68

Downloaded from www.Manualslib.com manuals search engine 5-ii Table of Contents
DTC P1723: Range Select Switch
Malfunction ...................................................... 5A-68
DTC P1878: Torque Converter Clutch
Shudder .......................................................... 5A-69
DTC P2762: Torque Converter Clutch (TCC)
Pressure Control Solenoid Control Circuit
Range / Performance ...................................... 5A-70
DTC P2763: Torque Converter Clutch (TCC)
Pressure Control Solenoid Control Circuit
High ................................................................. 5A-72
DTC P2764: Torque Converter Clutch (TCC)
Circuit Pressure Control Solenoid Control
Circuit Low ...................................................... 5A-74
DTC U0073: Control Module Communication
Bus Off ............................................................ 5A-76
DTC U0100: Lost Communication with ECM /
PCM “A” .......................................................... 5A-76
Inspection of TCM and Its Circuits .................... 5A-76
TCM Power and Ground Circuit Check ............. 5A-80
Brake Interlock System Inspection .................... 5A-81
Repair Instructions ............................................5A-82
Learning Control Initialization ............................ 5A-82
A/T Fluid Level Check ....................................... 5A-82
A/T Fluid Change .............................................. 5A-83
Select Lever Components ................................. 5A-84
Select Lever Assembly Removal and
Installation ....................................................... 5A-84
Select Lever Knob Installation........................... 5A-84
Select Lever Inspection ..................................... 5A-85
“3” Position Switch Inspection ........................... 5A-85
Shift Lock Solenoid Inspection .......................... 5A-85
Shift Lock Solenoid Replacement ..................... 5A-85
Select Cable Components ................................ 5A-86
Select Cable Removal and Installation ............. 5A-86
Select Cable Adjustment ................................... 5A-86
Key Interlock Cable Removal and Installation... 5A-87
Transmission Range Sensor Inspection and
Adjustment ...................................................... 5A-89
Output Shaft Speed Sensor (VSS) Removal
and Installation ................................................ 5A-90
Output Shaft Speed Sensor (VSS) Inspection .. 5A-90
Input Shaft Speed Sensor Removal and
Installation ....................................................... 5A-91
Input Shaft Speed Sensor Inspection................ 5A-91
Transmission Fluid Temperature Sensor
Removal and Installation ................................. 5A-91
Transmission Fluid Temperature Sensor
Inspection ........................................................ 5A-92
Solenoid Valves (Shift Solenoid Valves and
Timing Solenoid Valve) Removal and
Installation ....................................................... 5A-92
Solenoid Valves (Shift Solenoid Valves and
Timing Solenoid Valve) Inspection .................. 5A-94
Pressure Control Solenoid Valves (Pressure
Control Solenoid and TCC Solenoid)
Removal and Installation ................................. 5A-95
Pressure Control Solenoid Valves Inspection ... 5A-96
Transmission Control Module (TCM)
Removal and Installation ................................. 5A-97
A/T Relay Inspection ......................................... 5A-97Differential Side Oil Seal Replacement ............. 5A-98
A/T Fluid Cooler Hoses Replacement ............... 5A-98
Automatic Transaxle Unit Components............. 5A-99
Automatic Transaxle Unit Dismounting and
Remounting ................................................... 5A-100
Automatic Transaxle Assembly Components . 5A-102
Automatic Transaxle Unit Disassembly........... 5A-104
Oil Pump Assembly Components ................... 5A-116
Oil Pump Assembly Disassembly and
Reassembly .................................................. 5A-116
Oil Pump Assembly Inspection ....................... 5A-117
Direct Clutch Assembly Components.............. 5A-119
Direct Clutch Assembly Preliminary Check ..... 5A-119
Direct Clutch Assembly Disassembly and
Reassembly .................................................. 5A-120
Direct Clutch Assembly Inspection.................. 5A-122
Forward and Reverse Clutch Assembly
Components .................................................. 5A-123
Forward and Reverse Clutch Assembly
Preliminary Check ......................................... 5A-123
Forward and Reverse Clutch Assembly
Disassembly and Reassembly ...................... 5A-124
Forward and Reverse Clutch Assembly
Inspection ...................................................... 5A-127
2nd Brake Piston Assembly Components ....... 5A-128
2nd Brake Piston Assembly Disassembly and
Reassembly .................................................. 5A-128
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Components........... 5A-129
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Disassembly and
Reassembly .................................................. 5A-130
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Inspection............... 5A-131
Countershaft Assembly Components.............. 5A-132
Countershaft Assembly Disassembly and
Reassembly .................................................. 5A-132
Valve Body Assembly Components ................ 5A-133
Valve Body Assembly Disassembly and
Reassembly .................................................. 5A-134
Differential Assembly Components ................. 5A-135
Differential Assembly Disassembly and
Reassembly .................................................. 5A-136
Differential Assembly Inspection ..................... 5A-137
Torque Converter Housing Disassembly and
Reassembly .................................................. 5A-138
Transaxle Case Disassembly and
Reassembly .................................................. 5A-140
Automatic Transaxle Unit Inspection and
Adjustment .................................................... 5A-141
Automatic Transaxle Unit Assembly ............... 5A-144
Specifications ...................................................5A-161
Tightening Torque Specifications .................... 5A-161
Special Tools and Equipment .........................5A-162
Recommended Service Material ..................... 5A-162
Special Tool .................................................... 5A-162
Manual Transmission/Transaxle ............ 5B-1
General Description .............................................5B-1
Manual Transaxle Construction .......................... 5B-1

Downloaded from www.Manualslib.com manuals search engine 5A-10 Automatic Transmission/Transaxle:
Schematic and Routing Diagram
Transmission Control Module (TCM) Wiring DiagramS6RW0D5102001
12V
12V
12V
IG1
118
9
10
P
R
N
D
2
L12
2.5V
5V
12V
5V
12V
12V
12V
WHT
BLK
BLK
BLK
BLK
PPLBLK/WHT
BLK/ORN
IG11
RED/BLK
YEL/BLKYEL/BLU
LT GRN/BLK
+BB
WHT/RED
14
20 15
16
17
19
12V18
1 2
3
132126
24 27
28
29
30
65
16 15 14 13 12 1143
24 23 212210 9 8 721
19 20 18 17 C06
17 16
26 2515 14 65 342
13 12
23 22 2411 10 9
21 20 1987
18 1 C07
[A]
22
25
YELYEL/GRN
WHT
P
N
BRN LT/GRN
ORN
BLK/YEL
BLU/BLK
GRY
LT GRN/BLKWHT/BLU
WHT/BLK
C06-11
C06-12
C06-16
C06-15
C06-14
C06-4
C06-2
C06-1
C06-23C06-6 C06-24C06-5
C06-3
RED
GRN GRN/ORNPNK/BLK
GRN/YEL
LT GRN/BLKC07-6
C07-16
C07-23 C07-25
C07-20
C07-1
C07-8
C07-7
C07-19
C07-18
4IG11 23
C07-9
YEL
RED
WHTBLU35 34
3637
5REDWHT
7
WHT
RED
33
4
6
C06-7C06-17WHT
REDREDWHT
WHT
12V12V
WHTRED
WHTREDREDWHT
31
32
RED
WHTRED[B]
[C]
I6RW0D510003-02
1. TCM 15. Shift solenoid valve-A (No.1) 29. “ST SIG” fuse
2. Input shaft speed sensor 16. Shift solenoid valve-B (No.2) 30. “ST” fuse
3. Output shaft speed sensor / VSS 17. Timing solenoid valve 31. MIL
4. ECM 18. TCC solenoid valve 32. Transmission warning light (non-Euro-OBD model)
5. Combination meter 19. Pressure control solenoid valve 33. ABS control module
6. BCM 20. A/T 34. To Data link connector
7. 4WD control module (if equipped) 21. A/T relay 35. To BCM
8. “3” position switch 22. Inhibitor switch (including transmission range
sensor)36. Junction connector
9. Shift lock solenoid 23. Starter motor relay 37. Keyless start control module (if equipped)
10. Brake light switch 24. Ignition switch [A]: Terminal arrangement of TCM connector (viewed
from harness side)
11. Transmission range sensor 25. Starter motor [B]: Junction block with BCM model
12. Backup lamp 26. “DOME” fuse [C]: Junction block without BCM model
13. Data link connector (DLC) 27. “AT” fuse
14. Transmission fluid temperature sensor 28. “IG1 SIG” fuse

Downloaded from www.Manualslib.com manuals search engine 5A-14 Automatic Transmission/Transaxle:
Component Location
Electronic Shift Control System Components LocationS6RW0D5103001
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

5*
17
15
1
2
8
9
1011
12
13
16*18 19
14
7
6
3420
[B]
[A]5*
I6RW0D510004-01
[A]: Junction block with BCM model 7. Input shaft speed sensor 15. ECM
[B]: Junction block without BCM model 8. TCC solenoid valve 16. TCM
1. Engine 9. Transmission fluid temperature sensor 17. AT relay
2. Transaxle 10. Timing solenoid valve 18. “3” position switch
3. MIL 11. Pressure control solenoid valve 19. Select lever
4. Transaxle select position indicator 12. Shift solenoid valve-B (No.2) 20. Transmission warning light (non-Euro-OBD model)
5. Junction block assembly (included in BCM) 13. Shift solenoid valve-A (No.1)

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-15
6. Output shaft speed sensor (VSS) 14. Transmission range sensor
EngineTorque converter with
torque converter clutch
Oil pumpRegulator valves
in valve body
Planetary gear
unit
Clutches and
brakes
Control valves
in valve body
Shift solenoid valves,
TCC solenoid valve and
Timing solenoid valve Pressure control
solenoid valve
Final gear
reduction unit
Engine control module (ECM)
Body control module (BCM)
Combination meter
· Engine torque signal
· Engine speed signal
Transmission control module (TCM)
· Torque request signal
· Throttle position signal
· Accelerator pedal position signal
· Engine coolant temperature signal
· Brake pedal switch signal
· Driving cycle active
· Warm up cycle active
Accelerator pedal
position sensor
Crank shaft
position sensor
Engine coolant
temperature sensor
Input shaft speed sensor
Brake light switch
“3” position switch
Transmission range sensor
Transmission fluid
temperature sensor
Output shaft speed
sensor (VSS)
Power transmission
Fluid pressure circuit
Electric signal
Data link connector
· Transmission diagnostic trouble code (DTC) · Vehicle speed pulse signal
· Transmission warning light signal
· A/T select lever position signal
· Transmission actual gear position signal
· Transmission oil temperature signal · MIL control signal
ABS control module
· A/C compressor clutch signal
I6RW0D510005-01