2006 SUZUKI SX4 Precautions

Downloaded from www.Manualslib.com manuals search engine 5-1 Precautions:
Transmission / Transaxle
Precautions
Precautions
Precautions on Transmission / TransaxleS6RW0D5000001
Air Bag Warning
Refer to “Air Bag Warning in Section 00”.
Precautions in Diagnosing Trouble
Refer to “Precautions in Diagnosing Trouble in Section 5A”.
Precautions for Disassembly and Reassembly
Refer to “Precautions for Disassembly and Reassembly in Section 5A”.
Precaution on CAN Troubleshooting
Refer to “Precaution on CAN Troubleshooting in Section 1A”.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-1
Transmission / Transaxle
Automatic Transmission/Transaxle
Precautions
Precautions in Diagnosing TroubleS6RW0D5100001
• Do not disconnect couplers from TCM, battery cable
from battery, TCM ground wire harness from engine or
main fuse before checking the diagnostic information
(DTC, freeze frame data, etc.) stored in TCM memory.
Such disconnection will clear memorized information
in TCM memory.
• Diagnostic information stored in TCM memory can be
cleared as well as checked by using SUZUKI scan
tool or CAN communication OBD generic scan tool.
Before using scan tool, read its Operator’s
(Instruction) Manual carefully to have good
understanding as to what functions are available and
how to use it.
It is indistinguishable which module turns on MIL
because not only ECM but also TCM turns on MIL.
Therefore, check both ECM and TCM for DTC when
MIL lights on.
When checking TCM for DTC, keep in mind that DTC
is displayed on the scan tool as follows depending on
the scan tool used.
– SUZUKI scan tool displays DTC detected by TCM.
– CAN communication OBD generic scan tool
displays DTC detected by each of ECM and TCM
simultaneously.
• Be sure to read “Precautions for Electrical Circuit
Service in Section 00” before inspection and observe
what is written there.
• TCM replacement
– When substituting a known-good TCM, check that
all relays and actuators have resistance of
specified value.
Neglecting this check may result in damage to good
TCM.
• Communication of ECM, BCM, combination meter,
keyless start control module (if equipped), ABS
control module, 4WD control module (if equipped),
TCM and DLC, is established by CAN (Controller
Area Network). (For more detail of CAN
communication for ECM, refer to “CAN
Communication System Description”). Therefore,
handle CAN communication line with care referring to
“Precaution for CAN Communication System in
Section 00”.
Precautions for Disassembly and ReassemblyS6RW0D5100002
When repairing automatic transaxle, it is necessary to
conduct the on-vehicle test to investigate where the
cause of the trouble lies first.
Then whether overhaul should be done or not is
determined. If the transaxle is disassembled without
such preliminary procedure, not only the cause of the
trouble would be unknown, but also a secondary trouble
may occur and often time would be wasted.
As the automatic transaxle consists of high precision
component, the following cautions should be strictly
observed when handling its parts in disassembly and
reassembly.
• Disassembling valve body assembly is prohibited
essentially. However, a few parts can be
disassembled. When disassembling valve body
component parts, confirm whether their parts are
allowed to disassemble or not referring to “Valve Body
Assembly Disassembly and Reassembly”.
• When component part of forward clutch, direct clutch,
2nd brake and/or O/D and 2nd coast brake, namely
clutch disc, brake disc, retaining plate and/or
separator plate, have been replaced, all learned
contents, which have been stored in TCM memory by
executing learning control, should be initialized
referring to “Learning Control Initialization”.
• Make sure to wash dirt off from the transaxle so that
no such dirt will enter the transaxle during
dismounting and remounting.
• Select a clean place free from dust and dirt for
overhauling.
• Place a rubber mat on the work bench to protect parts
from damage.
• Work gloves or shop cloth should not be used. (Use a
nylon cloth or a paper towel.)
• When separating the case joint, do not pry with a
screwdriver or such but tap with a plastic hammer
lightly.
• Make sure to wash dirt off from the transaxle so that
no such dirt will enter the transaxle during
disassembly and reassembly.
• Wash the disassembled parts in ATF (Automatic
Transaxle Fluid) or kerosene (using care not to allow
ATF or kerosene to get on your face, etc.) and confirm
that each fluid passage is not clogged by blowing air
into it. But use kerosene to wash the discs, resin
washers and rubber parts.
• Replace each gasket, oil seal and O-ring with a new
one.
• Apply ATF to sliding or rotating parts before
reassembly.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-7
Table of Component OperationS6RW0D5101003
{: ON
×: OFF
U: ON only when TCC is operating
A/T Diagnosis General DescriptionS6RW0D5101004
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.
NOTE
There are two type of On-Board Diagnostic System, Euro OBD system and non-Euro-OBD system
depending on the vehicle specification.For identification, refer to “Precaution on On-Board Diagnostic
(OBD) System in Section 1A”.

Selector
positionGear
positionPart
Shift solenoid
valve-A (No.1)Shift solenoid
valve-B (No.2)TCC solenoid
valveForward
clutchDirect clutchReverse
clutch
PParking{{× ×××
R Reverse{{×××{
N Neutral{{× ×××
D1st{{×{××
2nd{××{××
3rd××U{{×
4th×{U×{×
21st{{×{××
2nd{××{××
L1st{{×{××
Selector
positionGear
positionPart
O/D and 2nd
coast brake2nd brake1st and
reverse brakeOne-way No.1
clutchOne-way No.2
clutch
PParking×××××
R Reverse××{××
N Neutral×××××
D1st××××{
2nd×{×{×
3rd×{×××
4th{{×××
21st××××{
2nd{{×{×
L1st××{×{

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 Precautions: 6-1
Ste eri ng
Precautions
Precautions
Precautions on SteeringS6RW0D6000001
Air Bag Warning
Refer to “Air Bag System Service Warning in Section 00”.
Precautions for Steering Diagnosis
Refer to “Precautions for Steering Diagnosis in Section 6A”.
Service Precautions of Steering Wheel and Column
Refer to “Service Precautions of Steering Wheel and Column in Section 6B”.
P/S System Note
Refer to “P/S System Note in Section 6C”.

Downloaded from www.Manualslib.com manuals search engine 6A-1 Steering General Diagnosis:
Ste eri ng
Steering General Diagnosis
Precautions
Precautions for Steering DiagnosisS6RW0D6100001
Since the problems in steering involve several systems, they must all be considered when diagnosing a complaint. To
avoid using the wrong symptom, always road test the vehicle first. Proceed with the following preliminary inspection
and correct any defects which are found.
1) Inspect tires for proper pressure and uneven wear.
2) Raise vehicle on a hoist and inspect steering system for loose or damaged parts.
3) Spin front wheels. Inspect for out-of-round tires, out-of-balance tires, bent rims, loosen and/or rough wheel
bearings.
Diagnostic Information and Procedures
Steering Symptom DiagnosisS6RW0D6104001
Condition Possible cause Correction / Reference Item
Hard steeringTire not adequately inflatedInflate tires to proper pressure.
Malfunction of power steering systemCheck and correct. Refer to “P/S System
Symptom Diagnosis in Section 6C”.
Bind in tie-rod end ball studs or lower
ball jointsReplace tie-rod end or front suspension control
arm.
Disturbed front wheel alignmentCheck and adjust front wheel alignment.
Bind in steering columnRepair or replace steering column assembly.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Too much play in steeringWheel bearings wornReplace wheel bearing.
Loose steering gear case boltsTighten gear case bolts.
Faulty steering gear case assemblyReplace steering gear case assembly.
Worn steering shaft jointsReplace steering lower shaft assembly.
Worn tie-rod ends or tie-rod inside ball
jointsReplace tie-rod end or tie-rod.
Worn lower ball jointsReplace front suspension control arm.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Poor return abilityBind in tie-rod end ball studsReplace tie-rod end.
Bind in ball jointsReplace front suspension control arm.
Bind in steering columnReplace steering column assembly.
Disturbed front end alignmentCheck and adjust front end alignment.
Faulty steering gear case assemblyReplace steering gear case assembly.
Tires not adequately inflatedAdjust tire pressure.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Rack and pinion noise
(Rattle or chuckle)Loose steering gear case boltsTighten steering gear case bolts.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Faulty steering gear case assemblyReplace steering gear case assembly.
Broken or otherwise damaged wheel
bearing(s)Replace wheel bearing(s).
Wander or poor steering
stabilityMismatched or uneven tiresReplace or inflate tires to proper pressure.
Loosen ball joints and tie-rod endsReplace suspension control arm or tie-rod end.
Faulty struts or mountingsReplace strut or repair mounting.
Loose stabilizer barTighten or replace stabilizer bar or bush.
Broken or sagging coil springsReplace coil spring.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Disturbed front wheel alignmentCheck and adjust front wheel alignment.
Faulty steering gear case assemblyReplace steering gear case assembly.

Downloaded from www.Manualslib.com manuals search engine 6B-1 Steering Wheel and Column:
Ste eri ng
Steering Wheel and Column
Precautions
Service Precautions of Steering Wheel and ColumnS6RW0D6200001
For service precautions, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”.
Service and Diagnosis
For diagnosis and servicing, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”.
Disabling Air Bag System
For disabling air bag system, refer to “Disabling Air Bag System in Section 8B”.
Enabling Air Bag System
For enabling air bag system, refer to “Enabling Air Bag System in Section 8B”.
Handling and Storage
For handling and storage, refer to “Precautions on Handling and Storage of Air Bag System Components in Section
8B”.
Disposal
For disposal, refer to “Precautions on Disposal of Air Bag and Seat Belt Pretensioner in Section 8B”.
General Description
Steering Wheel and Column ConstructionS6RW0D6201001
This double tube type steering column has the following three important features in addition to the steering function:
• The column is energy absorbing, designed to compress in a front-end collision.
• The ignition switch and lock are mounted conveniently on this column.
• With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehicle.
To insure the energy absorbing action, it is important that only the specified screws, bolts and nuts be used as
designated, and that they are tightened to the specified torque. When the column assembly is removed from the
vehicle, special care must be taken in handling it. Use of a steering wheel puller other than the recommended puller in
this manual or a sharp blow on the end of the steering shaft, leaning on the assembly, or dropping the assembly could
shear the plastic shear pins which maintain column length and position.
The driver air bag (inflator) module is one of the supplemental restraint (air bag) system components and is mounted
to the center of the steering wheel. During certain frontal crashes, the air bag system supplements the restraint of the
driver’s and passenger’s seat belts by deploying the air bags. The air bag (inflator) module should be handled with
care to prevent accidental deployment. When servicing, be sure to observe “Precautions on Service and Diagnosis of
Air Bag System in Section 8B”.

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-1
Ste eri ng
Power Assisted Steering System
Precautions
P/S System NoteS6RW0D6300001
NOTE
All steering gear fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with one of
the same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to assure proper retention of these parts.

Precautions in Diagnosing TroublesS6RW0D6300002
• Take a note of DTC indicated on the SUZUKI scan tool.
• Before inspection, be sure to read “Precautions for Electrical Circuit Service in Section 00” and understand what is
written there.
• DTC C1122 (engine speed signal failure) is indicated when ignition switch is at ON position and engine is not
running, but it means there is nothing abnormal if indication changes to a normal one when engine is started.
• As DTC is stored in memory of the P/S control module, be sure to clear memory after repair by performing the
procedure described in “DTC Clearance”.