2006 SUZUKI SX4 PPL

Downloaded from www.Manualslib.com manuals search engine 5A-16 Automatic Transmission/Transaxle:
Diagnostic Information and Procedures
A/T System CheckS6RW0D5104001
Refer to the following items for the details of each step.
Step Action Yes No
1) Customer complaint analysis
1) Perform customer complaint analysis.
Was customer complaint analysis performed?Go to Step 2. Perform customer
complaint analysis.
2) DTC / freeze frame data check, record and clearance
1) Check for DTC.
Is there any DTC(s)?Print DTC or write them
down and clear them by
referring to “DTC
Clearance”. Go to Step
3.Go to Step 4.
3) Visual inspection
1) Perform visual inspection.
Is there any faulty condition?Repair or replace
malfunction part. Go to
St ep 11 .Go to Step 5.
4) Visual inspection
1) Perform visual inspection.
Is there any faulty condition?Repair or replace
malfunction part. Go to
St ep 11 .Go to Step 8.
5) Trouble symptom confirmation
1) Confirm trouble symptom.
Is trouble symptom identified?Go to Step 6. Go to Step 7.
6) Rechecking and record of DTC / freeze frame data
1) Recheck for DTC referring to “DTC Check”.
Is there any DTC(s)?Go to Step 9. Go to Step 8.
7) Rechecking and record of DTC / freeze frame data
1) Recheck for DTC referring to “DTC Check”.
Is there any DTC(s)?Go to Step 9. Go to Step 10.
8) A/T basic check and A/T symptom diagnosis
1) Check and repair according to “A/T Basic Check” and “A/
T Symptom Diagnosis”.
Are check and repair complete?Go to Step 11. Check and repair
malfunction part(s). Go
to Step 11.
9) Troubleshooting for DTC
1) Check and repair according to applicable DTC flow.
Are check and repair complete?Go to Step 11. Check and repair
malfunction part(s). Go
to Step 11.
10) Check for intermittent problems
1) Check for intermittent problems.
Is there any faulty condition?Repair or replace
malfunction part(s). Go
to Step 11.Go to Step 11.
11) Final confirmation test
1) Clear DTC if any.
2) Perform final confirmation test.
Is there any problem symptom, DTC or abnormal condition?Go to Step 6. End.

Downloaded from www.Manualslib.com manuals search engine 5A-18 Automatic Transmission/Transaxle:
Step 2. DTC / Freeze Frame Data Check, Record and
Clearance
First, referring to “DTC Check”, check DTC and pending
DTC. If DTC exists, print or write down DTC and freeze
frame data and then clear malfunction DTC(s) by
referring to “DTC Clearance”. Malfunction DTC indicates
malfunction in the system but it is not possible to know
from it whether the malfunction is occurring now or it
occurred in the past and normal condition has been
restored. In order to know that, check symptom in
question according to Step 5 and then recheck DTC
according to Step 6.
Diagnosing a trouble based on the DTC in this step only
or failure to clear the DTC in this step may result in an
faulty diagnosis, trouble diagnosis of a normal circuit or
difficulty in troubleshooting which is otherwise
unnecessary.
Step 3 and 4. Visual Inspection
As a preliminary step, be sure to perform visual check of
the items that support proper function of the engine and
automatic transaxle referring to “Visual Inspection”.
Step 5. Trouble Symptom Confirmation
Check trouble symptoms based on information obtained
in “Step 1. Customer Complaint Analysis: ” and “Step 2.
DTC / Freeze Frame Data Check, Record and
Clearance: ”.
Also, reconfirm DTC according to “DTC Confirmation
Procedure” described in each DTC flow.
Step 6 and 7. Rechecking and Record of DTC and
Freeze Frame Data
Refer to “DTC Check” for checking procedure.Step 8. A/T Basic Check and A/T Symptom
Diagnosis
Perform basic check of A/T according to “A/T Basic
Check” first. When the end of the flow has been reached,
check the parts of the system suspected as a possible
cause referring to “A/T Symptom Diagnosis” and based
on symptoms appearing on the vehicle (symptoms
obtained through steps of customer complaint analysis,
trouble symptom confirmation and/or A/T basic check)
and repair or replace faulty parts, if any.
Step 9. Troubleshooting for DTC
Based on the DTC indicated in Step 6 / 7 and referring to
“applicable DTC flow”, locate the cause of the trouble,
namely in a sensor, switch, wire harness, connector,
actuator, TCM or other part and repair or replace faulty
parts.
Step 10. Check for Intermittent Problem
Check parts where an intermittent trouble is easy to
occur (e.g. wire harness, connector, etc.), referring to
“Intermittent and Poor Connection Inspection in Section
00” and related circuit of DTC recorded in Step 2.
Step 11. Final Confirmation Test
Confirm that the problem symptom has gone and the
vehicle is free from any abnormal conditions. If what has
been repaired is related to the malfunction DTC, clear
the DTC once and check to ensure that no malfunction
DTC is indicated.
Visual InspectionS6RW0D5104002
Visually check the following parts and systems.
Inspection item Referring
• A/T fluid ----- level, leakage, color “Automatic Transaxle Fluid Level Inspection in
Section 0B”
• A/T fluid hoses ----- disconnection, looseness, deterioration “A/T Fluid Cooler Hoses Replacement”
• Throttle cable (if equipped) ----- play (under warm engine),
installation
• A/T select cable ----- installation “Select Cable Removal and Installation”
• Engine oil ----- level, leakage “Engine Oil and Filter Change in Section 0B”
• Engine coolant ----- level, leakage “Engine Coolant Change in Section 0B”
• Engine mountings ----- play, looseness, damage “Engine Assembly Removal and Installation in
Section 1D”
• Suspension ----- play, looseness “Suspension, Wheels and Tires Symptom
Diagnosis in Section 2A”
• Drive shafts ----- damage “Front Drive Shaft Assembly On-Vehicle Inspection
in Section 3A”
• Battery ----- indicator condition, corrosion of terminal “Battery Inspection in Section 1J”
• Connectors of electric wire harness ----- disconnection, friction “Electronic Shift Control System Components
Location”
• Fuses ----- burning
• Parts ----- installation, damage
• Bolts ----- looseness
• Other parts that can be checked visually

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-23
) P0787 Shift / Timing solenoid Control Circuit Low
• Power supply for all solenoid valves is cut.
• Gear position is fixed in 3rd gear.
• Line pressure control at gear shifting is inhibited.
• Look-up function is inhibited to operate. ) P0788 Shift / Timing solenoid Control Circuit High
) P0962Pressure control solenoid control circuit
low
) P0963Pressure control solenoid control circuit
high
) P0973 Shift solenoid-A (No.1) control circuit low
) P0974 Shift solenoid-A (No.1) control circuit high
) P0976 Shift solenoid-B (No.2) control circuit low
) P0977 Shift solenoid-B (No.2) control circuit high
) P0961Pressure Control Solenoid “A” Control
Circuit Range / Performance• Upshifting to 4th gear is inhibited.
• Lock-up function is inhibited to operate.
• Slip controlled lock-up function is inhibited to operate.
• Line pressure control at gear shifting is inhibited.
• Torque reducing request to ECM (torque reduction control)
is inhibited.
• Garage shift control is inhibited.
• Leaning control is inhibited.
) P1702Internal control module memory check
sum error• Power supply for all solenoid valves is cut.
• Gear position is fixed in 3rd gear.
• Line pressure control at gear shifting is inhibited.
• Lock-up function is inhibited to operate.
) P1723 Range select switch malfunction “3” position switch is assumed to be OFF.
) P1878 Torque converter clutch shudder Slip controlled lock-up function is inhibited to operate.
) P2762Torque Converter Clutch (TCC) Pressure
Control Solenoid Control Circuit Range /
Performance• Lock-up function is inhibited to operate.
• Slip controlled lock-up function is inhibited to operate.
• Upshifting to 4th gear is inhibited when Transmission Fluid
Temperature is 150 °C (302 °F) or more.
• Gear position is fixed in 1st gear when vehicle speed is 10
km/h (6 mile/h) or less.
) P2763Torque converter clutch pressure control
solenoid control circuit high• Lock-up function is inhibited to operate.
• Upshifting to 4th gear is inhibited when A/T fluid
temperature is more than 150 °C (302 °F).
• Vehicle speed is slower than 10 km/h (6 mile/h), gear
position is fixed in 1st gear for prevention of engine stall.
) P2764Torque converter clutch pressure control
solenoid control circuit low• Lock-up function is inhibited to operate.
• Upshifting to 4th gear is inhibited when A/T fluid
temperature is more than 150 °C (302 °F).
) U0073 Control module communication bus off• Throttle opening used for line pressure control is assumed
to be 100%.
• Throttle opening used for gear shifting control is assumed
to be 0%.
• Engine revolution is assumed to be 0 RPM.
• After 15 minutes pass from detecting malfunction, engine
coolant temperature is assumed to be 90 °C (194 °F).
• Lock-up function is inhibited to operate.
• Line pressure control at gear shifting is inhibited.
• Torque reducing request to ECM (torque reduction control)
is inhibited.
• Upshifting to 4th gear is inhibited.
• Garage shift control is inhibited.
• Learning control is inhibited. DTC No. Trouble area Fail-safe operation

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-31
Stall TestS6RW0D5104013
This test is to check overall performance of automatic transaxle and engine by measuring stall speed at “D” and “R”
ranges. Be sure to perform this test only when transaxle fluid is at normal operating temperature and its level is
between FULL and LOW marks.
CAUTION!
• Do not run engine at stall more than 5 seconds continuously, or fluid temperature may rise
excessively high.
• After performing stall test, be sure to leave engine running at idle for longer than 1 minute before
another stall test.

1) Apply parking brake and block wheels.
2) Install tachometer.
3) Start engine with select lever shifted to “P” range.
4) Depress brake pedal fully.
5) Shift select lever to “D” range and depress accelerator pedal fully while watching tachometer. Read engine rpm
quickly when it has become constant (stall speed).
6) Release accelerator pedal immediately after stall speed is checked.
7) In the same way, check stall speed in “R” range.
8) Stall speed should be within the following specification.
Engine stall speed
Standard: 2,200 – 2,600 rpm
Troubleshooting
Condition Possible cause Correction / Reference Item
Lower than standard level
in both “D” and “R” rangeEngine output torque failureInspect and repair engine.
Faulty one-way clutch of torque
converterReplace torque converter.
Higher than standard
level in “D” rangeMalfunction of pressure control solenoid
valve (Low line pressure)Inspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Slippery forward clutchInspect. If NG, replace.
Faulty one-way No.2 clutchInspect. If NG, replace.
Leakage from “D” range fluid pressure
circuitOverhaul or replace valve body assembly.
Higher than standard
level in “R” rangeMalfunction of pressure control solenoid
valve (Low line pressure)Inspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Slippery reverse clutchInspect. If NG, replace.
Slippery 1st and reverse brakeInspect. If NG, replace.
Leakage from “R” range fluid pressure
circuitOverhaul or replace valve body assembly.
Higher than standard
level in both “D” and “R”
rangeMalfunction of pressure control solenoid
valve (Low line pressure)Inspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Clogged oil strainerReplace.
Faulty oil pumpInspect. If NG, replace.
Leakage from both “D” and “R” range
fluid pressure circuitOverhaul or replace valve body assembly.

Downloaded from www.Manualslib.com manuals search engine 5A-32 Automatic Transmission/Transaxle:
Time Lag TestS6RW0D5104014
This test is to check conditions of clutch, brake and fluid pressure. “Time lag” means time elapsed since select lever is
shifted with engine idling till shock is felt.
1) With chocks placed before and behind front and rear wheels respectively, depress brake pedal.
2) Start engine.
3) With stop watch ready, shift select lever from “N” to “D” range and measure time from that moment till shock is felt.
4) Similarly measure time lag by shifting select lever from “N” to “R” range.
Gear shifting time lag
“N” → “D”: Less than 0.7 sec.
“N” → “R”: Less than 1.2 sec.
NOTE
• When repeating this test, be sure to wait at least one minute after select lever is shifted back to “N”
range.
• Engine should be warmed up fully for this test.
• Repeat test 3 times and take average of those data for final time lag data.

Troubleshooting
Line Pressure TestS6RW0D5104015
Purpose of this test is to check operating conditions of each part by measuring fluid pressure in fluid pressure line.
Line pressure test requires the following conditions.
• Automatic fluid is at normal operating temperature (70 – 80 °C / 158 – 176 °F).
• Fluid is replenished to proper level (between FULL and LOW on dipstick).
• Air conditioner switch is turned OFF.
1) Apply parking brake securely and place chocks against wheels.
2) Remove fluid pressure check hole plug bolt.
3) Attach oil pressure gauge to fluid pressure check hole in transaxle case.
Special tool
(A): 09925–37811–001Condition Possible cause Correction / Reference Item
“N”
→ “D” time lag
exceeds specificationMalfunction of transmission fluid
temperature sensorInspect. If NG, replace.
Malfunction of pressure control solenoid
valve (Low line pressure)Inspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Clogged oil strainerReplace.
Faulty oil pumpInspect. If NG, replace.
Faulty forward clutchInspect. If NG, replace.
Faulty one-way No.2 clutchInspect. If NG, replace.
Leakage from “D” range fluid pressure
circuitOverhaul or replace valve body assembly.
“N”
→ “R” time lag
exceeds specificationMalfunction of transmission fluid
temperature sensorInspect. If NG, replace.
Malfunction of pressure control solenoid
valve (Low line pressure)Inspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Clogged oil strainerReplace.
Faulty oil pumpInspect. If NG, replace.
Faulty reverse clutchInspect. If NG, replace.
Faulty 1st and reverse brakeInspect. If NG, replace.
Leakage from “R” range fluid pressure
circuitOverhaul or replace valve body assembly.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-33
CAUTION!
After attaching oil pressure gauge, check that no fluid leakage exists.

4) Depress foot brake fully, run engine at idle and stall then check fluid pressure in “D” or “R” range.
CAUTION!
• Do not continue running engine at stall speed longer than 5 seconds.
• After performing line pressure test, be sure to leave engine running at idle for longer than one
minute before performing another line pressure test.

Automatic transaxle line pressure
Troubleshooting
“P” Range TestS6RW0D5104016
1) Stop vehicle on a slope of 5 degrees or more, shift select lever to “P” range and at the same time apply parking
brake.
2) After stopping engine, depress brake pedal and release parking brake.
3) Then, release brake pedal gradually and check that vehicle remains stationary.
4) Depress brake pedal and shift select lever to “N” range.
5) Then, release brake pedal gradually and check that vehicle moves.
WARNING!
Before test, make sure no one is around vehicle or down on a slope and keep watchful for safety
during test.

Troubleshooting“D” range “R” range
At idle
speed3.7 – 4.1 kg/cm
2,
53 – 58psi5.9 – 6.8 kg/cm2,
84 – 97 psi
At stall
speed12.5 – 13.7 kg/cm
2,
178 – 195 psi16.5 – 19.0 kg/cm2,
235 – 270 psi
Condition Possible cause Correction / Reference Item
Higher than standard
level in each rangeMalfunction of pressure control solenoid
valve (Low line pressure)Inspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Lower than standard level
in each rangeMalfunction of pressure control solenoid
valve (Low line pressure)Inspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Clogged oil strainerReplace.
Faulty oil pumpInspect. If NG, replace.
Leakage from both “D” and “R” range
fluid pressure circuitOverhaul or replace valve body assembly.
Lower than standard level
only in “D” rangeLeakage from “D” range fluid pressure
circuitOverhaul or replace valve body assembly.
Lower than standard level
only in “R” rangeLeakage from “R” range fluid pressure
circuitOverhaul or replace valve body assembly.
Condition Possible cause Correction / Reference Item
Vehicle moves at “P”
range or remains
stationary at “N” rangeDefective parking lock pawl or springInspect. If NG, repair.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-41
Transmission Warning Light Circuit Check – Light Remains “ON” at Ignition Switch ON (Non-Euro-
OBD Model)
S6RW0D5104054
Troubleshooting
Transmission Warning Light Circuit Check – Light Does Not Come “ON” at Ignition Switch ON (Non-
Euro-OBD Model)
S6RW0D5104055
TroubleshootingNon operate TCC (lock-
up) systemFaulty torque converterReplace.
Excessive “N”
→ “D” time
lagFaulty oil pumpInspect. If NG, replace.
Faulty forward clutchInspect. If NG, replace.
Faulty one-way No.2 clutchInspect. If NG, replace.
Leakage from “D” range fluid pressure
circuitOverhaul or replace valve body assembly.
Excessive “N”
→ “R” time
lagFaulty oil pumpInspect. If NG, replace.
Faulty reverse clutchInspect. If NG, replace.
Faulty 1st and reverse brakeInspect. If NG, replace.
Leakage from “R” range fluid pressure
circuitOverhaul or replace valve body assembly.
Poor engine brake in
downshift to “2” rangeFaulty O/D and 2nd coast brakeInspect. If NG, replace.
Poor engine brake in
downshift to “L” rangeFaulty 1st and reverse brakeInspect. If NG, replace. Condition Possible cause Correction / Reference Item
Step Action Yes No
1Diagnostic Trouble Code (DTC) Check
1) Check DTC referring to “DTC Check”.
Is there any DTC(s)?Perform DTC Flow to
repair and retry.Substitute a known-
good TCM and recheck.
If OK, substitute a
known-good
combination meter and
recheck.
Step Action Yes No
1Combination Meter Power Supply Check
1) Turn ignition switch ON.
Does other indicator / warning lights in combination meter
comes ON?Go to Step 2. Repair combination
meter power supply
circuit referring to
“Combination Meter
Circuit Diagram in
Section 9C”.
2 1) TCM power and ground circuit check referring to “TCM
Power and Ground Circuit Check”.
Is it in good condition?Go to Step 3. Repair or replace.
3DTC check
1) Check DTC referring to “DTC Check”.
Is there DTC U0073 or U0100?Go to applicable DTC
diag. flow.Go to Step 4.
4Combination Meter Function Check
1) Turn ignition switch ON.
Does A/T selector position indicator show correct select
lever position?Replace combination
meter.Substitute a known-
good TCM and recheck.

Downloaded from www.Manualslib.com manuals search engine 5A-42 Automatic Transmission/Transaxle:
DTC P0602: Control Module Programming ErrorS6RW0D5104047
System Description
Internal control module is installed in ECM.
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
1) Connect scan tool to DLC with ignition switch turned OFF.
2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool.
3) Start engine and run it at idle if possible.
4) Check DTC and pending DTC by using scan tool.
DTC Troubleshooting
DTC P0705: Transmission Range Sensor Circuit Malfunction (PRNDL Input)S6RW0D5104020
Wiring DiagramDTC detecting condition Trouble area
Data programming error
(1 driving cycle detection logic)TCM
Step Action Yes No
1DTC check
1) Clear DTC referring to “DTC Clearance”.
2) Turn OFF ignition switch.
3) Turn ON ignition switch and check DTC.
Is DTC P0602 still indicated?Go to Step 2. Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.
2TCM power ground circuit check
1) Check that TCM power supply circuit and TCM ground
circuit is in good condition referring to “TCM Power and
Ground Circuit Check”.
Are check results OK?Substitute a known-
good TCM and recheck.Repair TCM power or
ground circuit.
2P
R
N
D
2
L3
1
PNK/BLK
RED
GRN
GRN/ORN
GRN/YEL
IG1
RED/BLK
LT GRN/BLK
C07-20
C07-1
C07-8
C07-7
C07-19
C07-18
C06
20 1987
18 1
C07
[A]
I6RW0B510008-01
1. TCM 3. Backup lamp
2. Transmission range sensor [A]: Terminal arrangement of TCM connector (viewed from harness side)