2006 SUZUKI SX4 battery

Downloaded from www.Manualslib.com manuals search engine 5A-94 Automatic Transmission/Transaxle:
4) Install oil strainer assembly (1).
Tightening torque
Oil strainer bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
5) Install new oil pan gasket (1) and oil pan (2).
6) Tighten oil pan bolts to specified torque diagonally
and little by little.
Tightening torque
Oil pan bolt (b): 7.0 N·m (0.7 kgf-m, 5.0 lb-ft)
7) Install left side engine under cover.
8) Lower vehicle.
9) Connect negative cable at battery.
Solenoid Valves (Shift Solenoid Valves and
Timing Solenoid Valve) Inspection
S6RW0D5106062
Resistance Check
Check shift solenoid valves and timing solenoid valve.
Shift solenoid valves and timing solenoid valve
resistance
Standard: 11 – 15 Ω at 20 °C (68 °F)Operation Check
Shift solenoid valve-A (No.1) and -B (No.2)
CAUTION!
• Do not insert air gun against strainer
installed on inlet of solenoid valve too
deeply, when blowing air into solenoid
valve. If not, the strainer will be damaged.
• Be very careful as dust etc. does not enter
when solenoid valves are inspected.

• Check that solenoid valve (1) actuate with click sound
when battery voltage is conducted.
• When solenoid valve (1) is connected to battery (2),
confirm that solenoid valve is close condition by
blowing air (50 – 200 kPa, 0.5 – 2.0 kg/cm
2, 7 – 28.5
psi) into solenoid valve as shown in figure.
• When solenoid valve (1) is not connected to battery
(2), confirm that solenoid valve is open condition by
blowing air (50 – 200 kPa, 0.5 – 2.0 kg/cm
2, 7 – 28.5
psi) into solenoid valve as shown in figure.
NOTE
Do not fail to inspect with air to prevent
mistaken checking because return spring for
valve is not installed into solenoid valve.

I2RH0B510059-01
I2RH0B510060-01
I2RH0B510061-01
I2RH0B510062-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-95
Timing solenoid valve
CAUTION!
• Do not insert air gun against strainer
installed on inlet of solenoid valve too
deeply, when blowing air into solenoid
valve. If not, the strainer will be damaged.
• Be very careful as dust etc. does not enter
when solenoid valves are inspected.

• Check that solenoid valve (1) actuate with click sound
when battery voltage is conducted.
• When timing solenoid valve (1) is connected to battery
(2), confirm that timing solenoid valve is open
condition by blowing air (50 – 200 kPa, 0.5 – 2.0 kg/
cm
2, 7 – 28.5 psi) into solenoid valve as shown in
figure.
• When timing solenoid valve (1) is not connected to
battery (2), confirm that timing solenoid valve is close
condition by blowing air (50 – 200 kPa, 0.5 – 2.0 kg/
cm
2, 7 – 28.5 psi) into solenoid valve as shown in
figure.
NOTE
Do not fail to inspect with air to prevent
mistaken checking because return spring for
valve is not installed into solenoid valve.

Pressure Control Solenoid Valves (Pressure
Control Solenoid and TCC Solenoid) Removal
and Installation
S6RW0D5106063
Removal
1) Disconnect negative cable at battery.
2) Lift up vehicle.
3) Remove left side engine under cover.
4) Remove drain plug and drain A/T fluid.
5) Install drain plug.
Tightening torque
A/T fluid drain plug: 17 N·m (1.7 kgf-m, 12.5 lb-ft)
6) Remove A/T oil pan (1) and oil pan gasket (2).
7) Remove oil strainer assembly (3).
8) Remove transmission fluid temperature sensor (1)
from sensor clamp.
9) Disconnect solenoid connectors (2).
I2RH0B510063-01
I2RH0B510054-01
2
1
I5RW0C510038-02

Downloaded from www.Manualslib.com manuals search engine 5A-96 Automatic Transmission/Transaxle:
10) Remove valve body assembly referring to
“Automatic Transaxle Unit Disassembly”.
11) Remove pressure control solenoid valve and TCC
pressure control solenoid valve referring to “Valve
Body Assembly Disassembly and Reassembly”.
Installation
Reverse removal procedure to install pressure control
solenoid valve and valve body assembly noting the
following points.
• For detail of pressure control solenoid valve and TCC
pressure control solenoid valve installation, refer to
“Valve Body Assembly Disassembly and
Reassembly”.
• For detail of valve body assembly installation, refer to
“Automatic Transaxle Unit Assembly”.
• For detail of installing wire harness for solenoid valves
and sensor, refer to “Automatic Transaxle Unit
Assembly”. Use new O-rings.
• For detail of A/T oil pan and oil strainer assembly
installation, refer to “Automatic Transaxle Unit
Assembly”. Use new oil pan gasket.
• Pour A/T fluid and check fluid level according to
procedure described in “A/T Fluid Change”.
• Check for fluid leakage after warming up A/T.
Pressure Control Solenoid Valves InspectionS6RW0D5106020
CAUTION!
• Be very careful as dust etc. does enter
when pressure control solenoid valves are
inspected.

Resistance Check
Measure resistance between pressure control solenoid
valves (Pressure control solenoid and TCC pressure
control solenoid) (1) terminals.
Pressure control solenoid valve and TCC pressure
control solenoid valve resistance
Standard: 5.0 – 5.6 Ω at 20 °C (68 °F)Operation Check
Check pressure control solenoid valves (Pressure
control solenoid and TCC pressure control solenoid)
operation in the either manner of the following.
Using regulated DC power supply
1) Connect pressure control solenoid valve (1) with
regulated DC power supply (2) as shown in figure.
2) Turn regulated DC power supply switch ON and
increase voltage of power supply keeping current
within 1.0 A.
3) Check for gradual movement of valve (3) in the
direction of arrow “A” as voltage is increased.
4) Check movement of valve (3) in the direction of
arrow “B” as voltage is decreased.
5) Turn power supply switch OFF.
CAUTION!
Do not pass current 1.0 A or more, or
pressure control solenoid is burned out.

Not using regulated DC power supply
1) Connect pressure control solenoid valve (1) to
battery (2) setting 21 W bulb (4) on the way as
shown in figure.
2) Check for movement of valve (3) in the direction of
arrow “A”.
3) Disconnect pressure control solenoid valve (1) from
battery (2) and check movement of valve (3) in the
direction of arrow “B” as shown in figure.
CAUTION!
Set 21 W bulb on the way, or pressure control
solenoid valve is burned out.

1
I2RH01510071-01
I2RH0B510064-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-97
Transmission Control Module (TCM) Removal
and Installation
S6RW0D5106021
CAUTION!
• TCM and ECM consists of highly precise
parts, therefore when handling it, be
careful not to expose to excessive shock.
• When replacing TCM with used one, all
learned contents, which have been stored
in TCM memory by executing learning
control, should be initialized after
replacement.

Removal
1) Disconnect negative cable at battery.
2) If the vehicle is equipped with air bag system,
disable air bag system. Refer to “Disabling Air Bag
System in Section 8B”.
3) Disconnect connectors from TCM (1).
4) Remove TCM by removing its nuts.Installation
Reverse removal procedure noting the following.
• Connect TCM connectors securely.
• If the vehicle is equipped with air bag system, be sure
to enable air bag system after TCM is back in place.
Refer to “Enabling Air Bag System in Section 8B”.
A/T Relay InspectionS6RW0D5106022
1) Disconnect negative cable at battery.
2) Remove A/T relay (2) from fuse and relay box (1).
3) Check that there is no continuity between terminal
“C” and “D”.
If continuity is indicated, replace A/T relay.
4) Connect battery positive (+) terminal to terminal “A”
of A/T relay and battery negative (–) terminal to
terminal “B” of A/T relay.
Check continuity between terminal “C” and “D” of A/T
relay.
If continuity does not indicated, replace A/T relay.
I4RS0A510031-01
1
I5RW0C510040-01
“D” “B”“C”21
“A”
I5RW0C510041-02

Downloaded from www.Manualslib.com manuals search engine 5B-10 Manual Transmission/Transaxle:
3) Apply grease to pin (5) of gear shift control lever, and
then install adjuster (1) into pin of gear shift control
lever securely.
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
4) Push cable end holder (2) in the direction of A.
NOTE
At this time, do not apply force in the cable
operation direction B to adjuster.

5) Slide lock plate (3) in the direction of C, until it gets
over the claw (4) of cable end holder.
Back Up Light Switch Removal and InstallationS6RW0D5206007
Removal
1) Remove battery and tray with ECM.
2) Disconnect back up light switch coupler (1).
3) Remove back up light switch.
Installation
1) Apply oil to new O-ring (1) and tighten back up light
switch (2) to specified torque.
Tightening torque
Back up light switch (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
2) Connect back up light switch coupler.
3) Install battery and tray with ECM.
Back Up Light Switch InspectionS6RW0D5206008
Check back up light switch for function using ohmmeter.
Switch ON (Push): Continuity
Switch OFF (Release): No continuity
3
3
41
2
A C
1
B
5, “A”
I4RS0A520005-01
2. Gear shift and select shaft assembly
2
1I5RW0A520009-01
1 2, (a)
I3RH0A520006-01
I5RW0A520050-01

Downloaded from www.Manualslib.com manuals search engine 5B-12 Manual Transmission/Transaxle:
Manual Transaxle Unit Dismounting and
Remounting
S6RW0D5206010
Dismounting
1) Drain coolant.
2) Remove battery and tray with ECM.
3) Remove air cleaner case and resonator.
4) Remove clutch fluid pipe referring to “Clutch Fluid
Pipe Removal and Installation in Section 5C”.
5) Disconnect back up light switch coupler and undo
wiring harness clamps.
6) Disconnect gear shift and gear select control cables
(1) from transaxle.
7) Remove earth cable from transaxle.
8) Remove water inlet pipe.
9) Remove starting motor referring to “Starting Motor
Dismounting and Remounting in Section 1I”.
10) Remove transaxle to engine bolts (1) of upper side.
11) Drain transaxle oil and transfer oil, if equipped.
12) Remove engine under covers.
13) Remove drive shaft assembly and center shaft
referring to “Front Drive Shaft Assembly Removal
and Installation in Section 3A”.
14) Remove exhaust No.1, No.2 and No.3 pipes
referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
15) Remove suspension frame, engine front mounting
member and engine mounting member referring to
“Front Suspension Frame, Stabilizer Bar and/or
Bushing Removal and Installation in Section 2B” and
“Engine Mountings Components in Section 1D”.16) Remove transfer referring to “Transfer Dismounting
and Remounting in Section 3C”, if equipped.
17) Remove clutch housing lower plate.
18) Support transaxle with transmission jack.
19) Remove left mounting (1) and left mounting bracket
(2).
20) Remove stiffener bolts (2), transaxle to engine bolts
(1) and nut of lower side, and then lower transaxle.
Remounting
CAUTION!
• Care should be taken not to scratch oil
seal lip with drive shaft while raising
transaxle.
• Do not hit drive shaft joint with hammer
when installing it into differential gear.

Reverse dismounting procedure for remounting of
transaxle, noting the following points.
• Tighten each bolts and nuts to specified torque
referring to “Manual Transaxle Unit Components” and
“Engine Mountings Components in Section 1D”.
• Set each clamp for wiring securely.
• Fill transaxle oil and transfer oil referring to “Manual
Transaxle Oil Change” and “Transfer Oil Change in
Section 3C”.
• Connect battery and check function of engine, clutch
and transaxle.
1
I5RW0A520011-01
1
I5RW0A520012-01
1
2
I5RW0A520013-01
1
2I5RW0A520014-01

Downloaded from www.Manualslib.com manuals search engine 5B-14 Manual Transmission/Transaxle:
Gear Shift and Select Shaft Assembly Removal
and Installation
S6RW0D5206012
Removal
1) Remove battery and tray with ECM.
2) Disconnect gear shift and gear select control cables
from transaxle.
3) Remove gear shift interlock bolt (1) and 5th to
reverse interlock guide bolt (2) from transaxle case.
4) Remove gear shift & select shaft assembly (3).
Installation
1) Clean mating surface of guide case (1) and left case
(5), apply sealant to left case as shown in figure by
such amount that its section is 1.5 mm (0.059 in.) in
diameter, mate guide case with left case.
“B”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
2) Install guide case bolts No.1 to which sealant has
been applied and guide case bolts No.2 (2), and
tighten them to specified torque.
: Sealant 99000–31260 (SUZUKI Bond No.1217G)
Tightening torque
Guide case bolt No.1: 23 N·m (2.3 kgf-m, 17.0 lb-
ft)
Guide case bolt No.2 (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)3) Install washer and gear shift interlock bolt (3) to
which sealant has been applied and then tighten it to
specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Gear shift interlock bolt (b): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
4) Install washer and 5th to reverse interlock guide bolt
(4) to which sealant has been applied and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
5th to reverse interlock guide bolt (c): 23 N·m (
2.3 kgf-m, 17.0 lb-ft)
5) Connect gear shift and gear select control cables to
transaxle.
6) Install battery and tray with ECM.
7) Check input shaft for rotation in each gear position.
4. Transaxle side cover
3
1
2
4
I5RW0A520016-01
I5RW0A520017-02

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-4
Steering Wheel Removal and InstallationS6RW0D6206002
CAUTION!
Do not turn the contact coil more than
allowable number of turns (about two and a
half turns from the center position clockwise
or counterclockwise respectively) with
steering wheel removed, or coil will break.

Removal
CAUTION!
Do not hammer the end of the shaft.
Hammering it will loosen the plastic shear
pins which maintain the column length and
impair the collapsible design of the column.

1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air
Bag System in Section 8B”.
3) Remove driver air bag (inflator) module from
steering wheel. Refer to “Driver Air Bag (Inflator)
Module Removal and Installation in Section 8B”.
4) Disconnect horn connector and audio control switch
connector, if equipped.
5) Remove steering shaft nut and then make alignment
marks (1) on steering wheel and shaft for a guide
during reinstallation.6) Remove steering wheel using special tool.
Special tool
(A): 09944–36011
InstallationCAUTION!
Following 2 Steps (Step 1) and 2)) are
prerequisite for installation of steering wheel.
If steering wheel has been installed without
these 2 Steps, contact coil will break when
steering wheel is turned.

1) Check that vehicle’s front tires are at straight-ahead
position and contact coil is centered. If contact coil is
turned after removing steering wheel, center contact
coil referring to “Centering Contact Coil Cable
Assembly”.
2) Install steering wheel to steering shaft with 2 grooves
(1) on contact coil fitted in 2 lugs (2) in the back of
steering wheel and also aligning marks (3) on
steering wheel and steering shaft.
3) Tighten steering shaft nut (4) to specified torque.
Tightening torque
Steering shaft nut (a): 33 N·m (3.3 kgf-m, 24.0 lb-
ft)
I4RS0A620005-01
(A)
I4RS0A620006-01
I4RS0A620007-01