2006 SUZUKI SX4 light

Downloaded from www.Manualslib.com manuals search engine 5B-38 Manual Transmission/Transaxle:
4) Press-fit right bearing (1) by using special tools and
hydraulic press.
Special tool
(A): 09925–15410
(B): 09924–07720
(C): 09913–852305) Hold differential assembly with soft jawed vise (3),
install final gear (2) and then tighten new final gear
bolts (1).
CAUTION!
Use of any other bolts than specified ones is
prohibited. Otherwise, bolts may loosen.

Tightening torque
Final gear bolt (a): 90 N·m (9.0 kgf-m, 65.0 lb-ft)
Specifications
Tightening Torque SpecificationsS6RW0D5207001
NOTE
The specified tightening torque is also described in the following.
“Gear Shift Control Lever and Cable Components”
“Manual Transaxle Unit Components”
“Gear Shift and Select Shaft Assembly Components”
“Manual Transaxle Assembly Components”
“Gear Shift Shaft Components”
“Differential Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
2. Differential case
3. Differential side left bearing
I5RW0A520048-01I5RW0A520049-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Transaxle oil level / filler plug 21 2.1 15.5) / )
Transaxle oil drain plug 21 2.1 15.5)
Back up light switch 23 2.3 17.0)
Guide case bolt No.1 23 2.3 17.0)
Guide case bolt No.2 23 2.3 17.0)
Gear shift interlock bolt 23 2.3 17.0)
5th to reverse interlock guide bolt 23 2.3 17.0)
Countershaft nut 100 10.0 75.0)
Shift fork shaft bolt 10 1.0 7.5)
Side cover bolt 10 1.0 7.5)
Reverse gear shift lever bolt 23 2.3 17.0)
Transaxle case bolt 23 2.3 17.0)
Reverse shaft bolt 23 2.3 17.0)
Gear shift locating bolt 13 1.3 9.5)
Left case plate bolt 23 2.3 17.0)
Oil gutter bolt 10 1.0 7.5)
Final gear bolt 90 9.0 65.0)

Downloaded from www.Manualslib.com manuals search engine 5C-3 Clutch:
Repair Instructions
Clutch Pedal InspectionS6RW0D5306001
Cylinder Push Rod Play “a”
1) Press clutch pedal (1) gradually with finger, stop
when slight increase of resistance is felt and
measure how much pedal has moved (push rod
play) as represented by “a” as shown.
Push rod play
“a”: Max. 3 mm (0.12 in.)
2) If “a” is not within specification, replace master
cylinder (3) or pedal arm (2).
Clutch Pedal Free Travel “b”
1) Depress clutch pedal (1), stop the moment clutch
resistance is felt, and measure how much pedal has
moved (clutch pedal free travel) as represented by
“b” in the figure.
Clutch pedal free travel
“b”
: 2 – 8 mm (0.08 – 0.31 in.)
2) If “b” is not within specification, check pedal arm (2)
and master cylinder (3) and replace defective part.
Clutch Release Margin “c”
1) Pull up parking brake fully and block wheels.
2) Start engine and keep engine at idle with neutral
gear position.
3) Without clutch pedal (1) depressed, slightly push the
shift lever to reverse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress
clutch pedal (1), and at gear contact noise died
position (release point) stop depressing.
5) Measure distance between release point (4) and full
stroke point (5) on clutch pedal (1) which is shown by
“c” in the figure.
Clutch release margin
“c”: 25 – 55 mm (0.98 – 2.17 in.)6) If “c” is not within specification, it is possible that air
is trapped in this system. If suspected so, bleed air
referring to “Air Bleeding of Clutch System”.Upon
completion of above inspection, start engine and
check clutch for proper operation.
Clutch Fluid Level InspectionS6RW0D5306002
Refer to “Brake Fluid Level Inspection in Section 4A”.
Clutch fluid specification
: Refer to the reservoir cap of the brake master
cylinder.
Air Bleeding of Clutch SystemS6RW0D5306003
CAUTION!
When operating the pedal stroke for air
bleeding of clutch system, after releasing the
clutch pedal, be sure to wait 1 second or
more before depressing it again. Otherwise,
the oil seal of operating cylinder will be
damaged, resulting in oil leakage.

Bleed air from clutch system.
Refer to “Air Bleeding of Brake System in Section 4A”.
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Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-8
2) Using special tool, install input shaft bearing to
flywheel (1).
Special tool
(B): 09925–98210
3) Aligning clutch disc to flywheel center using special
tool, install clutch cover (1) and bolts (2). Then
tighten bolts (2) to specification.
NOTE
• While tightening clutch cover bolts,
compress clutch disc with special tool
(clutch center guide) by hand so that disc
is centered.
• Tighten cover bolts little by little evenly in
diagonal order.

Special tool
(A): 09924–17811
(B): 09923–36320
Tightening torque
Clutch cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)4) Slightly apply grease to input shaft (1), then join
manual transaxle assembly with engine referring to
“Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
“A”: Grease 99000–25210 (SUZUKI Super
Grease I)
NOTE
When inserting transaxle input shaft to clutch
disc, turn crankshaft little by little to match
the splines.

Clutch Cover, Clutch Disc and Flywheel
Inspection
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Input Shaft Bearing
Check bearing (1) for smooth rotation and replace it if
abnormality is found.
I4RS0A530016-01
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1
“A”I5RW0A530013-01
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Downloaded from www.Manualslib.com manuals search engine Table of Contents 6- i
6
Section 6
CONTENTS
Steering
Precautions ................................................. 6-1
Precautions............................................................. 6-1
Precautions on Steering........................................ 6-1
Steering General Diagnosis.................... 6A-1
Precautions........................................................... 6A-1
Precautions for Steering Diagnosis ..................... 6A-1
Diagnostic Information and Procedures ............ 6A-1
Steering Symptom Diagnosis .............................. 6A-1
Steering System Inspection ................................ 6A-2
Steering Wheel and Column................... 6B-1
Precautions........................................................... 6B-1
Service Precautions of Steering Wheel and
Column.............................................................. 6B-1
General Description ............................................. 6B-1
Steering Wheel and Column Construction .......... 6B-1
Diagnostic Information and Procedures ............ 6B-2
Checking Steering Column for Accident
Damage ............................................................ 6B-2
Repair Instructions .............................................. 6B-3
Steering Wheel and Column Construction .......... 6B-3
Steering Wheel Removal and Installation ........... 6B-4
Contact Coil Cable Assembly Removal and
Installation ......................................................... 6B-5
Centering Contact Coil Cable Assembly ............. 6B-6
Contact Coil Cable Assembly Inspection ............ 6B-6
Steering Column Removal and Installation ......... 6B-6
Steering Column Inspection ................................ 6B-8
Ignition Switch Cylinder Assembly Removal
and Installation (Non- Keyless Start Model)...... 6B-8
Steering Lock Assembly (Ignition Switch)
Removal and Installation................................... 6B-9
Steering Lower Shaft Removal and
Installation ....................................................... 6B-10
Specifications..................................................... 6B-11
Tightening Torque Specifications ...................... 6B-11
Special Tools and Equipment ........................... 6B-11
Special Tool ...................................................... 6B-11
Power Assisted Steering System........... 6C-1
Precautions........................................................... 6C-1
P/S System Note ................................................. 6C-1
Precautions in Diagnosing Troubles ................... 6C-1General Description .............................................6C-2
P/S System Description ......................................6C-2
EPS Diagnosis General Description ...................6C-3
On-Board Diagnostic System Description ...........6C-3
Schematic and Routing Diagram ........................6C-4
EPS System Wiring Circuit Diagram ...................6C-4
Diagnostic Information and Procedures ............6C-5
EPS System Check .............................................6C-5
“EPS” Warning Light Check ................................6C-8
DTC Check..........................................................6C-8
DTC Clearance ...................................................6C-9
DTC Table ...........................................................6C-9
Visual Inspection ...............................................6C-11
Scan Tool Data .................................................6C-12
P/S System Symptom Diagnosis ......................6C-13
DLC and Its Communication Check (No
communication to P/S Control Module)...........6C-14
“EPS” Warning Light Does Not Come ON with
Ignition Switch Turned ON before Engine
Starts ...............................................................6C-16
“EPS” Warning Light Remains ON Steady
after Engine Starts ..........................................6C-18
DTC C1111 / C1113 / C1115: Torque Sensor
Circuit Failure ..................................................6C-19
DTC C1116: Steering Torque Sensor Power
Supply Circuit ..................................................6C-21
DTC C1121 / C1123 / C1124: Vehicle Speed
Signal Circuit Failure .......................................6C-22
DTC C1122: Engine Speed Signal....................6C-24
DTC C1141 / C1142 / C1143 / C1145: Motor
Circuit Failure ..................................................6C-26
DTC C1153: P/S Control Module Power
Supply Circuit ..................................................6C-27
DTC C1155: P/S Control Module Internal
Failure .............................................................6C-28
P/S Control Module Power Supply and
Ground Circuit Check ......................................6C-29
Inspection of P/S Control Module and Its
Circuits ............................................................6C-30
Steering Wheel Play Check ..............................6C-34
Steering Force Check .......................................6C-34
Repair Instructions ............................................6C-35
Steering Gear Case Assembly Components ....6C-35
Tie-Rod End Boot On-Vehicle Inspection .........6C-36
Tie-Rod End Removal and Installation..............6C-36

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-6
3) Install steering column upper cover (1) and lower
cover (2).
CAUTION!
When installing covers, be careful so that
each lead wire is not caught between covers.
Otherwise, each lead wire is damaged.

4) Install steering wheel to steering column. Refer to
“Steering Wheel Removal and Installation”.
5) Connect negative (–) cable to battery.
6) Enable air bag system referring to “Enabling Air Bag
System in Section 8B”.
Centering Contact Coil Cable AssemblyS6RW0D6206004
1) Check that vehicle’s wheels (front tires) are set at
straight-ahead position.
2) Check that ignition switch is at LOCK position.
3) Turn contact coil counterclockwise slowly with a light
force till contact coil will not turn any further.
NOTE
Contact coil can turn about 5 turns at the
maximum, that is, if it is at the center
position, can turn about two and a half turns
both clockwise and counterclockwise.

4) From the position where contact coil became unable
to turn any further (it stopped), turn it back clockwise
about two and a half rotations and align center mark
with alignment mark (1).
Contact Coil Cable Assembly InspectionS6RW0D6206005
Refer to “Contact Coil Cable and Its Circuit Check in
Section 8B”.
Steering Column Removal and InstallationS6RW0D6206008
CAUTION!
Once the steering column is removed from
the vehicle, the column is extremely
susceptible to damage.
• Dropping the column assembly on its end
could collapse the steering shaft or loosen
the plastic shear pins which maintain
column length.
• Leaning on the column assembly could
cause it to bend or deform.
Any of the damage could impair the column’s
collapsible design.
Steering column mounting nuts should not
be loosened with steering shaft joint upper
side bolt tightened as this could cause
damage to shaft joint bearing.

NOTE
When servicing steering column or any
column-mounted component, remove
steering wheel. But when removing steering
column simply to gain access to instrument
panel components, leave steering wheel
installed on steering column.

3. Standard screw 4. Tapping screw
2
1
3
4
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I4RS0A620012-01
1
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Downloaded from www.Manualslib.com manuals search engine 6B-7 Steering Wheel and Column:
Removal
WARNING!
Never rest a steering column assembly on
the steering wheel with the air bag (inflator)
module face down and column vertical.
Otherwise, personal injury may result.

1) Disconnect negative (–) cable at battery.
2) Disable air bag system. Refer to “Disabling Air Bag
System in Section 8B”.
3) Remove steering wheel and contact coil cable
assembly referring to “Steering Wheel Removal and
Installation” and “Contact Coil Cable Assembly
Removal and Installation”.
4) (Immobilizer model)
Remove immobilizer control module from steering
column, referring to “ICM Removal and Installation in
Section 10C”.
5) Detach lighting switch and wiper switch from steering
column.
6) Remove lower shaft upper joint bolt (1).
7) Remove steering column mounting nuts (1), and
then remove steering column from vehicle.
NOTE
Do not move tilt lever until mounting bolts
and nuts are tightened to specified torque.

Installation
CAUTION!
After tightening steering column mounting
nuts, shaft joint bolts should be tightened.
Wrong tightening order could cause a
damage to shaft joint.

1) Be sure that front wheels are in straight.
2) Install steering column assembly to lower and upper
brackets. Tighten steering column mounting nuts
No.2 (1) first and then steering column mounting
nuts No.1 (2) to specifications as given below.
Tightening torque
Steering column mounting nut No.1 (a): 14 N·m (
1.4 kgf-m, 10.5 lb-ft)
Steering column mounting nut No.2 (b): 14 N·m (
1.4 kgf-m, 10.5 lb-ft)
NOTE
• When installing, make sure that clearance
“a” between bolt (3) and bracket (4) should
be 0 (zero).
• After installing tilt steering column, make
sure that steering column moves upwards
and downwards smoothly and stops when
tilt lever is fixed.

1
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1
1
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2, (a)
1, (b)
1, (b) 2, (a)
4
3“a” “a”
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Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-8
3) Align flat part “a” of steering lower shaft (1) with bolt
hole “b” of shaft joint (2) of column as shown. Then
insert lower shaft into shaft joint of steering column.
4) Tighten lower shaft upper joint bolt (3) to specified
torque.
CAUTION!
After tightening column nuts, tighten steering
shaft upper joint bolt. Otherwise, shaft joint
bearing is damaged.

Tightening torque
Steering lower shaft assembly upper joint bolt
(a): 25 N·m (2.5 kgf-m, 18.5 lb-ft)
5) Install lighting switch and wiper switch to steering
column.
6) (Immobilizer model)
Install immobilizer control module from steering
column, referring to “ICM Removal and Installation in
Section 10C”.
7) Install contact coil cable assembly and steering
wheel referring to “Contact Coil Cable Assembly
Removal and Installation” and “Steering Wheel
Removal and Installation”.
8) Connect negative (–) cable to battery.
9) Enable air bag system referring to “Enabling Air Bag
System in Section 8B”.
Steering Column InspectionS6RW0D6206009
Check steering column for damage and operation
referring to “Checking Steering Column for Accident
Damage”.
Ignition Switch Cylinder Assembly Removal
and Installation (Non- Keyless Start Model)
S6RW0D6206010
Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air
Bag System in Section 8B”.
3) Remove steering column upper and lower covers.
4) (Immobilizer model)
Remove immobilizer control module referring to
“ICM Removal and Installation in Section 10C”.
5) Remove ignition switch cylinder assembly as follows.
a) Turn ignition key to “ACC” position.
b) Insert 2 mm (0.078 in.) rod (2) through hole (3)
and push ignition switch cylinder lock.
c) Detach ignition switch cylinder assembly (1) from
steering lock assembly (4).
Installation
1) Install ignition switch cylinder assembly as follows.
a) Turn ignition key to “ACC” position.
b) In this state, push ignition switch cylinder
assembly into steering lock assembly till it clicks.
2) (Immobilizer model)
Install immobilizer control module referring to “ICM
Removal and Installation in Section 10C”.
3) Install upper and lower cover and screws.
4) Connect negative (–) cable to battery.
5) Enabling air bag system referring to “Enabling Air
Bag System in Section 8B”.
6) (Immobilizer model)
If ignition switch cylinder assembly (that is ignition
key) has replaced, register ignition key transponder
code to ECM referring to “Registration of the Ignition
Key in Section 10C”.
1 2
“a”“b”
3, (a)
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2
3
1
4
I5JB0A620025-01

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-3
EPS Diagnosis General DescriptionS6RW0D6301002
The P/S system in this vehicle is controlled by the P/S control module. The P/S control module has an on-board
diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full
understanding of the outline of “On-Board Diagnostic System Description” and each item in “Precautions in
Diagnosing Troubles”, and then execute diagnosis according to “EPS System Check”.
On-Board Diagnostic System DescriptionS6RW0D6301003
The P/S control module performs the on-board diagnosis (self-diagnosis) on the system and operates the “EPS”
warning light (1) as follows.
• The “EPS” warning light lights when the ignition switch is turned to ON position (but the engine at stop) regardless
of the condition of the P/S control system. This is only to check if the “EPS” warning light is operated properly.
• If the areas monitored by the P/S control module is free from any trouble after the engine start (while engine is
running), the “EPS” warning light turns OFF.
• When the P/S control module detects a trouble which has occurred in the monitored areas the “EPS” warning light
comes ON while the engine is running to warn the driver of such occurrence of the trouble and at the same time it
stores the exact trouble area in memory inside of the P/S control module.
Driving Cycle
A “Driving Cycle” consists of engine startup and engine shutoff.
3 Driving Cycles Detection Logic
The malfunction detected in the first and second driving cycle is stored in P/S control module memory (in the form of
pending DTC) but the “EPS” warning light does not light at these time. It lights up at the third detection of same
malfunction also in the next driving cycle.
1
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