2006 SUZUKI SX4 speed

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-29
Reassembly
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new ones as
necessary.
2) Check clearance “a” between synchronizer ring (2)
and gear (1), key slot width “b” in synchronizer ring
and each chamfered tooth of gear and synchronizer
ring and replace with new one, if necessary. Also,
check gear tooth.
Clearance “a” between synchronizer ring and
gear
Standard: 1.0 – 1.4 mm (0.040 – 0.055 in.)
Service limit: 0.5 mm (0.020 in.)
Key slot width “b”
Standard: 10.0 – 10.2 mm (0.394 – 0.401 in.)
Limit: 10.45 mm (0.411 in.)
3) To ensure lubrication of input shaft (1), air blow oil
holes (2) and make sure that they are free from any
obstruction.4) Fit high speed synchronizer sleeve (4) to hub (3),
insert 3 keys (2) in it and then set springs (1) as
shown in figure.
NOTE
• No specific direction is assigned to high
speed synchronizer sleeve or each key but
it is assigned as assembly.
• Size of high speed synchronizer sleeve,
hub, keys and springs are the smaller than
those of low speed one.

Synchronizer key installation position
A = B
5) Drive in right bering (1) to input shaft (2) using
special tool and hydraulic press.
Special tool
(A): 09913–80113
I5JB0A520054-01
I2RH01520049-01
[A]: 4th gear side
C: Left side (Short flange)
D: Key way
E: Projecting end
I5RW0A520033-01
I3RH0A520019-01

Downloaded from www.Manualslib.com manuals search engine 5B-30 Manual Transmission/Transaxle:
6) Install 3rd gear needle bearing (4), apply oil to it,
then install 3rd gear (1) and synchronizer ring (2).
7) Drive in high speed sleeve & hub assembly (3) by
using special tool and hydraulic press.
NOTE
• While press-fitting sleeve & hub, make
sure that synchronizer ring key slots are
aligned with keys (5) in sleeve & hub
assembly.
• Check free rotation of 3rd gear after press-
fitting sleeve & hub assembly.
• Synchronizer rings for 3rd and 4th are
identical.

Special tool
(B): 09913–845108) Install circlip (1) and confirm that circlip is installed in
groove securely. Install needle bearing (2) of apply
oil to it and then install synchronizer ring (3) and 4th
gear (4).
9) Press-fit left bearing (2) by using special tool and
hydraulic press.
Special tool
(A): 09913–80113
10) Using the same special tool at step 9), drive in 5th
gear spacer (1).
CAUTION!
To prevent 5th gear spacer (1) from being
distorted because of excessive compression,
do not press-fit it with left bearing (2) at once.

[A]: 3rd gear side
A: Key way
B: Long boss
B
[A]3
(B)
4A 5
21
I5RW0A520034-02
5. Input shaft
I2RH01520052-01
I3RH0A520020-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-31
Countershaft Disassembly and ReassemblyS6RW0D5206021
Disassembly
1) Drive out left bearing cone (2) with 4th gear (3) by
using puller (4) and hydraulic press.
CAUTION!
• Use puller and hydraulic press that will
bear at least 5 ton (11,000 lb) safely.
• To avoid tooth damage, support 4th gear
(3) at flat side of puller.

2) Apply puller (5) to 2nd gear (4) and drive out 3rd &
4th gear spacer (2) and 3rd gear (3) together with
2nd gear by using hydraulic press. Needle bearing
would come out with 2nd gear.
CAUTION!
• If compression exceeds 5 ton (11,000 lb),
release compression once, reset bearing
puller and then continue press work again.
• To avoid gear tooth from being damaged,
support it at flat side of bearing puller.

3) Take out 2nd synchronizer outer ring, center cone
and inner ring.
4) Using special tool, remove circlip (1).
NOTE
Correct tool tips to be flat to facilitate
removal of circlip.

Special tool
(A): 09900–06107
5) Apply puller (3) to 1st gear (2) and drive out low
speed synchronizer sleeve & hub assembly (1) with
1st gear by using hydraulic press.
CAUTION!
To avoid gear tooth from damage, support it
at flat side of bearing puller.

1. Countershaft
1. Countershaft
I2RH01520054-01
I2RH01520055-01
2. Low speed synchronizer sleeve
I2RH01520056-01
I2RH01520057-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-33
5) Fit low speed synchronizer sleeve (4) to hub (3),
insert 3 keys (2) in it and then set springs (1) as
shown in figure.
NOTE
• No specific direction is assigned to each
key but it is assigned as sleeve & hub
assembly.
• Size of low speed synchronizer keys and
springs are the larger than those of high
speed one.

Synchronizer key installation position
A = B
6) Install right bearing cone (1) to counter shaft (2) by
using special tools and hydraulic press.
Special tool
(A): 09913–76010
(B): 09924–077207) Install needle bearing (4), apply oil to it, then install
1st gear and 1st gear synchronizer ring (2).
8) Drive in low speed sleeve & hub assembly (1) by
using special tools and hammer.
NOTE
• Support shaft with special tool as shown in
figure so that retainer of bearing cone (4)
will be free from compression.
• Make sure that synchronizer ring key slots
are aligned with keys (5) while press-fitting
sleeve & hub assembly.
• Check free rotation of 1st gear (3) after
press-fitting sleeve & hub assembly.

Special tool
(A): 09923–78210
(B): 09913–85210
(C): 09940–54910
(D): 09924–07710
[A]: 1st gear side
C: Key way
I5RW0A520037-01
(A)
(B)
2
1
I5RW0A520038-01
[A]: 1st gear side
A: Key slots
B: Short flange
I5RW0A520039-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-35
Gear Shift Shaft ComponentsS6RW0D5206022
5th and Reverse Gear Shift Shafts Disassembly
and Reassembly
S6RW0D5206023
Disassembly
Disassemble component parts by using special tool and
hammer.
Special tool
: 09922–85811
Reassembly
Replace or correct parts as required and assemble
shafts making sure that component parts are in proper
order as shown in figure.
NOTE
Install 2 steel balls (3) in reverse gear shift
arm (1) without fail.

Gear Shift Shaft and Fork InspectionS6RW0D5206024
1) Using feeler gauge, check clearance between fork
(1) and sleeve (2) and replace those parts if it
exceeds limit of 1.0 mm (0.039 in.).
NOTE
For correct judgement of parts replacement,
carefully inspect contact portion of fork and
sleeve.

Clearance “a” between fork and sleeve
Service limit: 1.0 mm (0.039 in.)
2) Insert each gear shift shaft into case and check that
it moves smoothly. If it doesn’t, correct by using
oilstone, reamer or the like.
I5RW0A520041-01
1. Low speed gear shift shaft 4. 5th & reverse gear shift guide shaft 7. 5th & reverse gear shift yoke
2. High speed gear shift shaft 5. Reverse gear shift arm : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
3. 5th & reverse gear shift shaft 6. Gear shift locating bolt
: Apply sealant 99000-31260 to bolt thread.
2. Spring 6. 5th & reverse gear shift yoke
4. Spring pin 7. 5th & reverse gear shift guide shaft
5. 5th & reverse gear shift shaft
I5RW0A520042-01
I2RH01520068-01

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 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”.

Downloaded from www.Manualslib.com manuals search engine 6C-2 Power Assisted Steering System:
General Description
P/S System DescriptionS6RW0D6301001
This electronic power steering (EPS) system consists of a power steering (P/S) control module (3), a torque sensor
(4), a P/S motor (5). In this system, the P/S control module determines the level and direction of the assist force for the
steering wheel (1) according to the signal from the torque sensor and the vehicle speed signal from BCM (9). The P/S
control module runs the motor so as to assist the operation of the steering wheel.
The P/S control module diagnoses troubles which may occur in the area including the following components when the
ignition switch is ON and the engine is running. When the P/S control module detects any malfunction, it stops the
motor operation.
• Torque sensor
• Vehicle speed signal circuit
• Engine speed signal circuit
• P/S Motor
• P/S control module.
1
32
4
6
7
5
8
9
I7RW01632001-01
2. Steering column 7. Battery
6. Steering gear case assembly 8. ECM