2006 SUZUKI SX4 Ac panel

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-9
Gear Shift Control Lever and Cable Removal
and Installation
S6RW0D5206005
Removal
1) Remove console box.
2) Disconnect cable ends (5) from pivot (6) of gear shift
control lever assembly by removing clip.
3) Disconnect gear shift and select control cables (1)
from gear shift control lever assembly (2) while
pulling quick joint (4) as shown in figure.
4) Remove gear shift control lever assembly mounting
nuts (3) and gear shift lever assembly from floor
panel.
5) Disconnect gear shift and select control cables from
transaxle.
6) Remove cable grommet bolt, and then remove gear
shift and select control cables from floor panel.
Installation
Reverse removal procedure for installation nothing the
following.
• Tighten each bolts and nuts to specified torque
referring to “Gear Shift Control Lever and Cable
Components”.
• Adjust gear select control cable referring to “Gear
Select Control Cable Adjustment”.
Gear Select Control Cable AdjustmentS6RW0D5206006
1) Release lock plate (1) which restricts moving of
cable end holder (2).
2) Push cable end holder (2) out from adjuster (4) using
appropriate tool (3) to disengage cable.
36
5
2
3
41
I4RS0A520003-01
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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 6C-8 Power Assisted Steering System:
Step 8: Steering Symptom Diagnosis and P/S
System Symptom Diagnosis
Perform basic steering system check according to
“Steering Symptom Diagnosis in Section 6A” first. When
the end of the flow has been reached, check the parts of
the system suspected as a possible cause referring to
“P/S System Symptom Diagnosis” and based on
symptoms appearing on the vehicle (symptoms obtained
through steps of customer complaint analysis, trouble
symptom confirmation and/or basic P/S system check)
and repair or replace faulty parts, if any.
Step 9: Troubleshooting for DTC (See each DTC
Diag. Flow)
Based on the DTC indicated in Step 6 or 7 and referring
to the applicable DTC diag. flow, locate the cause of the
trouble, namely in a sensor, switch, wire harness,
connector, actuator, P/S control module or other part and
repair or replace faulty parts.
Step 10: Intermittent Problems Check
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 P/
S system is free from any abnormal conditions. If what
has been repaired is related to the DTC, clear the DTC
once, perform DTC confirmation procedure and confirm
that no DTC is indicated.
“EPS” Warning Light CheckS6RW0D6304002
1) Turn ignition switch to ON position (but without
running engine) and check if the “EPS” warning light
(1) lights up. If the light dose not light up, go to
““EPS” Warning Light Does Not Come ON with
Ignition Switch Turned ON before Engine Starts” of
the diagnostic flows.
2) Start engine and check that “EPS” warning light turns
OFF. If light remains ON and no DTC is stored in P/S
control module, go to ““EPS” Warning Light Remains
ON Steady after Engine Starts” for troubleshooting.
DTC CheckS6RW0D6304003
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector
(DLC) (1) located on underside of instrument panel
at driver’s seat side.
Special tool
(A): SUZUKI scan tool
3) Start engine.
4) Read DTC according to the instructions displayed on
SUZUKI scan tool. For further details, refer to
operator’s manual for SUZUKI scan tool.
NOTE
• If communication between SUZUKI scan
tool and the vehicle can not be
established, perform “DLC and Its
Communication Check (No communication
to P/S Control Module)”.
• 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.

5) After completing the check, turn ignition switch to
OFF position and disconnect SUZUKI scan tool from
DLC.
1
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(A)
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Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-9
DTC ClearanceS6RW0D6304004
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector
(DLC) (1) located on underside of instrument panel
at driver’s seat side.
Special tool
(A): SUZUKI scan tool3) Turn ignition switch to ON position.
4) Erase DTC according to the instructions displayed
on SUZUKI scan tool. For further details, refer to
operator’s manual for SUZUKI scan tool.
5) After completing the clearance, turn ignition switch to
OFF position and disconnect SUZUKI scan tool from
DLC.
DTC TableS6RW0D6304005
CAUTION!
Be sure to perform the “EPS System Check” before starting troubleshooting corresponding to each
DTC.

(A)
1I5RW0A630004-01
DTC No. Detecting itemDetecting condition
(DTC will set when detecting)Trouble area DTC“EPS”
warning
light
No
CODESNormal — — — —
) C1111Steering torque sensor
(Main) circuit voltageCircuit voltage of sensor main is
more than 4.5 V or less than 0.5
V
• Torque sensor signal
circuit
• Torque sensor
• P/S control module1 driving
cycle1 driving
cycle
)
C1113Steering torque sensor
(Main and Sub) circuit
correlationDifference between steering
torque calculated based on
sensor main signal and steering
torque calculated based on
sensor sub signal is more than
4.9 N⋅m
or
Difference between
instantaneous value and average
value of steering torque
calculated based on sensor main
signal and steering torque
calculated based on sensor sub
signal is more than 2.94 N⋅m1 driving
cycle1 driving
cycle
)
C1115Steering torque sensor
(Sub) circuit voltageCircuit voltage of sensor sub
signal is more than 4.5 V or less
than 0.5 V1 driving
cycle1 driving
cycle
)
C1116Steering torque sensor
power supply circuit Circuit voltage of torque sensor 9
V power supply is less than 7 V• Torque sensor 9 V
power supply circuit
• Torque sensor
• P/S control module1 driving
cycle1 driving
cycle

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-41
P/S Control Module Removal and InstallationS6RW0D6306011
Removal
1) Disconnect negative cable at battery.
2) Remove console box.
3) Disconnect connectors (1) from P/S control module.
4) Remove P/S control module and bracket (2) from
floor panel.
5) Separate P/S control module and bracket.
Installation
Reverse removal procedure.
Torque Sensor and Its Circuit InspectionS6RW0D6306012
1) Check that torque sensor circuit is in good condition
referring to Step 2 to 3 of “DTC C1111 / C1113 /
C1115: Torque Sensor Circuit Failure”. If check result
is not satisfactory, repair torque sensor circuit.
2) Remove console box.
3) With ignition switch turned OFF, connect scan tool to
DLC or connect voltage tester between “E11-18” –
“E11-9” (main sensor) or “E11-10” – “E11-9” (sub
sensor) with connected connector to P/S control
module.
4) Set torque wrench to steering wheel referring to
“Steering Force Check” for checking steering force.
1
2
I5RW0A630027-01
[A]: Main sensor [B]: Sub sensor
E11
1818
E11
10
[A]
[B]
9 9
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I3RM0A630022-01

Downloaded from www.Manualslib.com manuals search engine 7A-4 Heater and Ventilation:
Repair Instructions
HVAC Unit ComponentsS6RW0D7106001
For non-A/C and manual A/C, refer to “HVAC Unit
Components in Section 7B”.
For auto A/C, refer to “HVAC Unit Components in
Section 7B”.
HVAC Unit Removal and Installation (Non-A/C)S6RW0D7106002
For manual A/C and auto A/C, refer to “HVAC Unit
Removal and Installation in Section 7B”.
Removal
1) Drain engine coolant referring to “Cooling System
Draining in Section 1F”, and then disconnect heater
hoses from HVAC unit.
2) Remove cowl top cover from vehicle body referring
to “Cowl Top and Front Lower Crossmember
Components in Section 9K”.
3) Remove instrument panel from vehicle body
referring to “Instrument Panel Removal and
Installation in Section 9C”.
4) Remove HVAC unit (1) from vehicle body by
removing nuts (2).Installation
Reverse removal procedure noting the following
instructions.
• Be careful not to catch any cable and wiring harness
in inappropriate position.
• Adjust control cables of HVAC control unit referring to
“HVAC Control Unit Removal and Installation”.
• Refill cooling system with coolant referring to “Cooling
System Flush and Refill in Section 1F”.
Blower Motor Removal and InstallationS6RW0D7106003
Removal
1) Disconnect negative (–) cable from battery.
2) Disconnect connector (1) from blower motor (2).
3) Remove blower motor (2) from HVAC unit as follows.
a) Remove screws (4).
b) Release tub (3) to arrow direction.
c) Hold Step b) and turn blower motor (2) to arrow
direction.
Installation
Reverse removal procedure.
Blower Motor InspectionS6RW0D7106004
• Check blower motor for resistance between two
terminals as shown.
If there is no continuity, replace blower motor.
2
2
2
1
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3
2
b)
c)
1
4
4I7RW01710004-02
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Downloaded from www.Manualslib.com manuals search engine Heater and Ventilation: 7A-5
• Check for operation and current.
a. Put blower motor (1) in a soft-jawed vise.
b. Connect battery to blower motor as shown.
c. Check if blower motor operates smoothly without
noise.
d. Check if ammeter indicates the specified current.
If measured current is out of specification, replace
blower motor.
Blower motor specified current at 12 V
18.5 A maximum at 20 – 25 °C (68 – 77 °F)
Blower Motor Resistor Removal and InstallationS6RW0D7106005
Removal
1) Disconnect negative (–) cable from battery.
2) Remove glove box from instrument panel.
3) Remove passenger side foot duct (1) from HVAC
unit by removing screw (2).4) Disconnect connector (1) from blower motor resistor
(2), and then remove blower motor resistor from
HVAC unit by removing screws (3).
Installation
Reverse removal procedure.
Blower Motor Resistor InspectionS6RW0D7106006
Measure each terminal-to-terminal resistance. If
measured resistance is out of specification, replace
blower motor resistor.
Blower motor resistor resistance
“H” – “MH”: Approx. 0.43 Ω at 20 – 25 °C (68 – 77 °F)
“MH” – “ML”: Approx. 0.6 Ω at 20 – 25 °C (68 – 77 °F)
“ML” – “L”: Approx. 2.0 Ω at 20 – 25 °C (68 – 77 °F)
1
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1
2
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2
3
1
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Downloaded from www.Manualslib.com manuals search engine Heater and Ventilation: 7A-7
HVAC Control Unit Removal and InstallationS6RW0D7106009
Removal
1) Disconnect negative (–) cable at battery.
2) Remove steering column hole cover from instrument
panel.
3) Remove audio unit from instrument panel referring to
“Audio Unit Removal and Installation (If Equipped) in
Section 9C”.
4) Remove driver side foot duct (1) from HVAC unit by
removing screw (2).
5) Disconnect temperature control cable (1) and air
flow control cable (2) from HVAC unit (3).
LH steering vehicleRH steering vehicle
6) Remove center garnish from instrument panel.
7) Remove HVAC control unit from instrument panel.
8) Disconnect connectors from HVAC control unit.
Installation
Reverse removal procedure noting the following
instructions.
• Connect temperature control cable and air flow control
cable of HVAC control unit to links of HVAC unit.
a. For LH steering vehicle, set airflow selector (1) to
“DEF” position and temperature selector (2) to
“MAX HOT” position.
For RH steering vehicle, set airflow selector (1) to
“VENT” position and temperature selector (2) to
“MAX COOL” position.
1
2
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I7RW01710012-02
F: Vehicle forward
I6RW0C710005-01
12I4RS0B710013-01
12I4RS0A710016-01