2006 SUZUKI SX4 Washer

Downloaded from www.Manualslib.com manuals search engine 4B-1 Front Brakes:
Brakes
Front Brakes
Repair Instructions
Front Disc Brake ComponentsS6RW0D4206001
I7RW01420001-05
1. Caliper 9. Disk brake piston
: Apply rubber grease included in piston
seal set or brake fluid to contact surface of
cylinder.17. Brake flexible hose
: Be sure to direct mark (18) to
inside of vehicle “I” as shown in
figure.
2. Caliper pin bolt 10. Pad spring
: Apply grease included in brake pad spare
parts to inside.: 26 N⋅m (2.6 kgf-m, 19.0 lb-ft)
3. Boot 11. Brake disc : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Slide pin No.1
: Apply rubber grease included in slide pin / boot
set.12. Brake caliper carrier : 9 N⋅m (0.9 kgf-m, 6.5 lb-ft)
5. Brake pad 13. Caliper carrier bolt : 85 N⋅m (8.5kgf-m, 61.5 lb-ft)
6. Shim 14. Bleeder plug : Do not reuse.
7. Cylinder boot
: Apply small amount of rubber grease included
in piston seal set or brake fluid.15. Flexible hose joint bolt
8. Piston seal
: Apply small amount of rubber grease included
in piston seal set or brake fluid.16. Hose washer

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 5A-2 Automatic Transmission/Transaxle:
CAUTION!
• Keep component parts in group for each
subassembly and avoid mixing them up.
• Clean all parts with cleaning solvent
thoroughly and air dry them.
• Use kerosene or automatic transaxle fluid
as cleaning solvent.
• Do not use wiping cloths or rags to clean
or dry parts.
• All oil passages should be blown out and
checked to make sure that they are not
obstructed.
• Keep face and eyes away from solvent
spray while air blowing parts.
• Check mating surface for irregularities and
remove them, if any, and clean it again.
• Soak new clutch discs and brake discs in
transaxle fluid for at least 2 hours before
assembly.
• Replace all gaskets and O-ring with new
ones.
• Apply automatic transaxle fluid to all O-
rings.
• When installing seal ring, be careful so that
it is not expanded excessively, extruded or
caught.
• Replace oil seals that are removed and
apply grease to their lips.
• Before installing, be sure to apply
automatic transaxle fluid to sliding, rolling
and thrusting surface of all component
part. Also after installation, make sure to
check each part for proper operation.
• Always use torque wrench when
tightening bolts.

• A new discs should be soaked in ATF at least 2 hours
before use.Part Inspection and Correction Table
Part Inspect for Correction
Casted part,
machined partSmall flaw, burr Remove with oil
stone.
Deep or grooved
flawReplace part.
Clogged fluid
passageClean with air or
wire.
Flaw on installing
surface, residual
gasketRemove with oil
stone or replace
part.
Crack Replace part.
Bearing Unsmooth rotation Replace.
Streak, pitting, flaw,
crackReplace.
Bushing, thrust
washerFlaw, burr, wear,
burningReplace.
Oil seal, gasket Flawed or
hardened seal ringReplace.
Worn seal ring on
its periphery or sideReplace.
Piston seal ring, oil
seal, gasket, etc.Replace.
Gear Flaw, burr Replace.
Worn gear tooth Replace.
Splined part Burr, flaw, torsion Correct with oil
stone or replace.
Snap ring Wear, flaw,
distortionReplace.
No interference Replace.
Thread Burr Replace.
Damage Replace.
Spring Settling, sign of
burningReplace.
Friction plate Wear, burning,
distortion,
damaged clawReplace.
Separator
plate, retaining
plateWear, burning,
distortion,
damaged clawReplace.
Sealing
surface (where
lip contacts)Flaw, rough
surface, stepped
wear, foreign
materialReplace.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-43
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
1) Connect scan tool to DLC with ignition switch OFF.
2) Clear DTCs in TCM memory by using scan tool.
3) Start engine and shift select lever to “D” range.
4) Keep engine running at idle speed for 25 seconds or more.
5) Stop vehicle and check DTC.
DTC TroubleshootingDTC detecting condition Trouble area
Multiple or more signals are inputted simultaneously for 10
seconds.• Select cable maladjusted
• Transmission range sensor maladjusted
• Transmission range sensor or its circuit malfunction
•TCM
Step Action Yes No
1Was “A/T System Check” performed?Go to Step 2. Go to “A/T System
Check”.
2Do you have SUZUKI scan tool?Go to Step 3. Go to Step 4.
3Check transmission range sensor circuit for operation
Check by using SUZUKI scan tool:
1) Connect SUZUKI scan tool to DLC with ignition switch
OFF.
2) Turn ignition switch ON and check transmission range
signal (“P”, “R”, “N”, “D”, “2” or “L”) on display when
shifting select lever to each range.
Is applicable range indicated?Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.Go to Step 5.
4Check transmission range sensor circuit for operation
Check by not using SUZUKI scan tool:
1) Turn ignition switch ON.
2) Check voltage at terminals “C07-1”, “C07-7”, “C07-8”,
“C07-18”, “C07-19” and “C07-20” respectively with
select lever shifted to each range.
Taking terminal “C07-19” as an example, is battery
voltage indicated only when select lever is shifted to “2”
range and 0 V for other ranges as shown in the following
table.
Check voltage at other terminals likewise, referring to the
following table.
Are check results satisfactory?Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.Go to Step 5.
5 1) Check select cable for adjustment referring to “Select
Cable Adjustment”.
Is it adjusted correctly?Go to Step 6. Adjust.
6Check transmission range sensor for installation
position
1) Shift select lever to “N” range.
2) Check that “N” reference line on sensor and needle
direction shaped on lock washer are aligned.
Are they aligned?Go to Step 7. Adjust.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-45
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out with 2 persons, a driver and a tester, on a level road.

1) Connect scan tool to DLC with ignition switch OFF.
2) Clear DTCs in TCM memory by using scan tool.
3) Start engine and shift select lever to “D” range.
4) Start vehicle and increase vehicle speed to 40 km/h (25 mile/h) or more for 1 minutes.
5) Stop vehicle and turn ignition switch OFF.
6) Repeat Step 3) to 4) one time.
7) Stop vehicle and check DTC.
DTC Troubleshooting
Step Action Yes No
1Was “A/T System Check” performed?Go to Step 2. Go to “A/T System
Check”.
2Do you have SUZUKI scan tool?Go to Step 3. Go to Step 4.
3Check transmission range sensor circuit for operation
Check by using SUZUKI scan tool:
1) Connect SUZUKI scan tool to DLC with ignition switch
OFF.
2) Turn ignition switch ON and check transmission range
signal (P, R, N, D, 2 or L) on display when shifting select
lever to each range.
Is applicable range indicated?Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.Go to Step 5.
4Check transmission range sensor circuit for operation
Check by not using SUZUKI scan tool:
1) Turn ignition switch ON.
2) Check voltage at terminals “C07-1”, “C07-7”, “C07-8”,
“C07-18”, “C07-19” and “C07-20” respectively with
select lever shifted to each range.
Taking terminal “C07-19” as an example, is battery
voltage indicated only when select lever is shifted to “2”
range and 0 V for other ranges as shown in the following
table.
Check voltage at other terminals likewise, referring to the
following table.
Are check results satisfactory?Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.Go to Step 5.
5 1) Check select cable for adjustment referring to “Select
Cable Adjustment”.
Is it adjusted correctly?Go to Step 6. Adjust.
6Check transmission range sensor for installation
position
1) Shift select lever to “N” range.
2) Check that “N” reference line on sensor and needle
direction shaped on lock washer are aligned.
Are they aligned?Go to Step 7. Adjust.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-89
2) Turn ignition switch to ACC position.
3) Insert cable casing cap (1) into key cylinder cover (2)
securely.
4) Pull out lock button (1) of select lever side cable end
(2).
5) Shift select lever to “N” position.
NOTE
If select lever is in “P” position, shift select
lever referring to “Select Lever Inspection”.

6) Install cable casing cap (3) to bracket (4).
7) Connect cable end (1) to interlock cam (2) with
ignition switch turned to ACC position.
8) Drive lock button (5) in cable end until it locks cable
expansion and contraction.9) With select lever set at “P” position, turn ignition key
to ACC position and then check for the following
conditions.
• With knob button released, ignition key can be
turned from ACC position to LOCK position.
• With knob button pressed, ignition key cannot be
turned from ACC position to LOCK position.
10) Install knee protector to steering column.
11) Install steering column cover.
12) If the vehicle is equipped with air bag system,
connect negative cable at battery and enable air bag
system, referring to “Enabling Air Bag System in
Section 8B”.
Transmission Range Sensor Inspection and
Adjustment
S6RW0D5106009
1) Shift manual select lever (4) to “N” range.
2) Check that needle direction shaped on lock washer
(2) and “N” reference line (1) on transmission range
sensor are aligned. If not, loosen sensor bolts (3)
and align them.
Tightening torque
Transmission range sensor bolt (a): 5.5 N·m (
0.55 kgf-m, 4.0 lb-ft)
2
1I5RW0C510047-01
1 1
2
I2RH01510086-01
3
4 12
3 5
I5RW0C510048-01
1
3, (a) 4
2
I2RH0B510041-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-103
1. Torque converter 37. Transmission range sensor 73. Rear planetary sun gear subassembly
2. Torque converter housing
: Apply sealant 99000-31230 to mating
surface to transaxle case.38. Cooler check valve 74. Rear sun gear thrust bearing race
3. Oil strainer assembly
: Replace oil strainer when overhauling.39. Spring 75. Rear sun gear thrust bearing
4. Parking lock pawl shaft 40. Transaxle case plug 76. Forward clutch hub
5. Parking lock pawl 41. Fluid filler tube 77. Intermediate shaft thrust bearing race
6. Parking lock pawl return spring 42. Fluid level gauge 78. Intermediate shaft thrust bearing
7. Parking lock pawl rod 43. Fluid cooler inlet pipe 79. 2nd brake piston snap ring
8. Parking lock pawl bracket 44. Fluid cooler outlet pipe 80. O/D and 2nd coast brake retaining
plate snap ring
9. Manual detent spring 45. 2nd brake gasket 81. O/D and 2nd coast brake retaining
plate
10. Manual valve lever 46. Brake drum gasket 82. O/D and 2nd coast brake disc
11. Manual valve lever pin 47. Pipe union 83. O/D and 2nd coast brake separator
plate
12. Manual shift shaft 48. Reduction drive gear nut
: After tightening nut so as rotational
torque of reduction drive gear to be in
specified value, caulk nut securely.84. O/D and 2nd coast brake rear plate
13. Manual shift shaft oil seal
: Apply grease 99000-25030 to oil seal
lip.49. Reduction drive gear 85. Rear cover seal ring
14. Differential side oil seal
: Apply grease 99000-25030 to oil seal
lip.50. Planetary ring gear subassembly 86. Reverse clutch drum thrust bearing
15. Torque converter housing plug 51. Breather hose 87. Rear cover plug
16. Lubrication LH tube 52. Breather union 88. Transaxle rear cover
: Apply sealant 99000-31230 to mating
surface.
17. Lubrication RH tube 53. Input shaft speed sensor 89. Harness bracket
18. Fluid reservoir RH plate 54. Valve body harness 90. Select cable clamp
19. Input shaft front thrust bearing 55. 1st and reverse brake piston 91. Governor apply No.1 gasket
20. Input shaft rear thrust bearing 56. O-ring 92. Output shaft speed sensor (VSS)
21. Input shaft rear thrust bearing race 57. 1st and reverse brake return spring
subassembly93. One-way clutch outer race retainer
22. Direct clutch hub 58. 1st and reverse brake disc 94. Select cable bracket
23. Lubrication tube clamp 59. 1st and reverse brake separator plate : Do not reuse.
24. Fluid reservoir LH plate 60. 1st and reverse brake retaining plate : Apply automatic transaxle fluid.
25. Governor apply No.2 gasket 61. 1st and reverse brake snap ring : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
26. Automatic transaxle case 62. Planetary gear assembly : 7.0 N⋅m (0.7 kgf-m, 5.0 lb-ft)
27. Accumulator piston O-ring 63. Planetary carrier thrust washer
: Apply grease 99000-25030 to slide
contact face.: 7.5 N⋅m (0.75 kgf-m, 5.5 lb-ft)
28. Accumulator spring 64. One-way clutch No.2 assembly : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
29. C2 accumulator piston 65. 2nd brake retaining plate : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
30. C1 accumulator piston 66. 2nd brake disc : 17 N⋅m (1.7 kgf-m, 12.5 lb-ft)
31. B1 accumulator piston 67. 2nd brake separator plate : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft)
32. Oil pan gasket 68. 2nd brake return spring subassembly : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
33. Oil pan 69. Front sun gear thrust bearing race : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
34. A/T fluid drain plug 70. Front planetary sun gear : 33 N⋅m (3.3 kgf-m, 24.0 lb-ft)
35. Manual select lever 71. Planetary gear thrust bearing
36. Lock washer 72. One-way clutch No.1 assembly

Downloaded from www.Manualslib.com manuals search engine 5A-104 Automatic Transmission/Transaxle:
Automatic Transaxle Unit DisassemblyS6RW0D5106031
CAUTION!
• Thoroughly clean transaxle exterior before
overhauling it.
• Keep working table, tools and hands clean
while overhauling.
• Use special care to handle aluminum parts
so as not to damage them.
• Do not expose removed parts to dust.
Keep them always clean.

1) Remove torque converter (1).
CAUTION!
Remove torque converter as much straight
as possible. Leaning it may cause to damage
oil seal lip.

2) Remove engine mounting LH bracket (1).
3) Remove manual select lever (1).4) Uncaulk lock washer (1), then remove lock nut (2)
and lock washer.
5) Remove transmission range sensor (1).
6) Remove output shaft speed sensor (VSS) (2) and
input shaft speed sensor (1).
7) Remove harness bracket and select cable clamp (3).
8) Remove select cable bracket (1).
I2RH0B510078-01
1
I5RW0C510058-01
1I2RH0B510080-01
I2RH0B510081-01
1I2RH0B510082-01
2 3
1
I2RH0B510083-01
1
I5RW0C510059-01