2006 SUZUKI SX4 shaft

Downloaded from www.Manualslib.com manuals search engine 6B-9 Steering Wheel and Column:
Steering Lock Assembly (Ignition Switch)
Removal and Installation
S6RW0D6206011
Removal
1) Remove steering column. Refer to “Steering Column
Removal and Installation”.
2) Using center punch (1), loosen and remove steering
lock mounting bolts (2).
NOTE
Use care not to damage aluminum part of
steering lock body with center punch.

3) Turn ignition key to “ACC” or “ON” position and
remove steering lock assembly from steering
column.Installation
1) Position oblong hole (1) of steering shaft (2) in the
center of hole (3) in column (4).
2) Turn ignition key to “ACC” or “ON” position and
install steering lock assembly (5) onto column (4).
3) Now turn ignition key to “LOCK” position and pull it
out.
4) Align hub on lock with oblong hole (1) of steering
shaft (2) and rotate shaft to assure that steering shaft
is locked.
5) Tighten new bolts (1) until head of each bolt is
broken off.
6) Turn ignition key to “ACC” or “ON” position and
check to be sure that steering shaft (2) rotates
smoothly. Also check for lock operation.
7) Install steering column. Refer to “Steering Column
Removal and Installation”.
8) (Keyless start model)
If steering lock assembly has replaced, after
completing installation, register steering lock unit ID
code to keyless start control module as following.
• Immobilizer model:
Register ignition key transponder code in ECM
referring to “Registration of the Ignition Key in
Section 10C”.
• Non-immobilizer model:
Register steering lock unit ID code in keyless start
control module referring to “Keyless Start
Registration in Section 10E”.
I4RS0B620005-02
1
32
4
5
I4RS0B620006-02
I4RS0B620007-02

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-10
Steering Lower Shaft Removal and InstallationS6RW0D6206012
CAUTION!
Never turn steering wheel while steering
lower shaft is removed.
Should it have been turned and contact coil
have got out of its centered position, it needs
to be centered again. Also, turning steering
wheel more than about two and a half turns
will break contact coil.

Removal
1) Turn steering wheel so that vehicle’s front tires are at
straight-ahead position.
2) Turn ignition switch to LOCK position and remove
key.
3) Remove steering joint cover.
4) Make alignment marks (4) on lower shaft (1) and
pinion shaft (3) for a guide during reinstallation.
5) Remove lower shaft upper and lower joint bolts (2).
6) Remove steering lower shaft (1).Installation
1) Be sure that front wheels are in straight forward
state.
2) Align flat part “a” of steering lower shaft (1) with bolt
hole “b” of shaft joint (2) of column as shown. Then
insert lower shaft into shaft joint of steering column.
3) Insert lower shaft (1) into pinion shaft (3) with
matching marks (4).
4) Tighten lower joint bolt (6) to specified torque first
and then upper joint bolt (5) to specified torque.
Tightening torque
Steering lower shaft assembly upper joint bolt
(a): 25 N·m (2.5 kgf-m, 18.5 lb-ft)
Steering lower shaft assembly lower joint bolt
(b): 25 N·m (2.5 kgf-m, 18.5 lb-ft)
1
2
1
3
2
4
I5RW0A620008-01
“a”“b”
1 2
6, (a)
4
3
5, (a)
I5RW0A620009-02

Downloaded from www.Manualslib.com manuals search engine 6B-11 Steering Wheel and Column:
Specifications
Tightening Torque SpecificationsS6RW0D6207001
NOTE
The specified tightening torque is also described in the following.
“Steering Wheel and Column Construction”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Special ToolS6RW0D6208001
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Steering shaft nut 33 3.3 24.0)
Steering column mounting nut No.1 14 1.4 10.5)
Steering column mounting nut No.2 14 1.4 10.5)
Steering lower shaft assembly upper joint bolt 25 2.5 18.5) / )
Steering lower shaft assembly lower joint bolt 25 2.5 18.5)
09944–36011
Steering wheel remover
)

Downloaded from www.Manualslib.com manuals search engine 6C-4 Power Assisted Steering System:
Schematic and Routing Diagram
EPS System Wiring Circuit DiagramS6RW0D6302001
[A]
123
45
3 21
4
567
8
9 11
10 12 13
141516
17 18 19201
2
[B]
1
2
[C] [D]
10 9 8 7654 3 21
16 15 14 13 12 11
26 25 24 2322 21 20 19 18 17
32 31 30 29 28 27
[F][E]
12
BRN RED/
BLU GRY LT GRN/
BLK
BLK
RED
WHT GRN
BLK
E11-1
E11-5
E11-14
E11-12
[J]:E01-44E01-4
[J]:E01-27E01-26
E12-1
E12-2
E11-10E11-8
E11-9
E11-19
E13-1 GRN
GRY
GRN
WHT
G241-25G241-31
RED/BLK
11
12
1314 3 18
20
21
7 19
4 12
22
12V
E13-2BLK
9V
REDE11-20
12V
12V
E61-2
E61-1
610
55
5V
8
E11-115V
PPL
E11-4
9
23
+BB
BLU/
WHTE04-9
1524YELE11-18E31-5
E31-2
E31-39V
3V
E31-4
E31-1IG11617
C07-25
[H]
[G]
G04-15
[I]:G04-22
25L313-3
[I]
I6RW0D630001-01
[A]: P/S control module connector No.1 “E11” (viewed from harness side) 3. Junction block assembly 15. BCM
[B]: P/S control module connector No.2 “E13” (viewed from harness side) 4. Main fuse 16. Output shaft speed sensor
[C]: P/S control module connector No.3 “E12” (viewed from harness side) 5. Front (left/right) wheel speed sensor 17. TCM
[D]: Combination meter connector “G241” (viewed from harness side) 6. ABS control module 18. Individual circuit fuse box No.1
[E]: Torque sensor connector “E31” (viewed from harness side) 7. Combination meter 19. “IGN” fuse
[F]: Motor connector “E61” (viewed from harness side) 8. “EPS” warning light 20. “P/S” fuse
[G]: M/T model 9. Data link connector (DLC) 21. “IG1 SIG” fuse
[H]: A/T model 10. ECM 22. “MTR” fuse
[I]: Junction block without BCM model (Taiwan model) 11. P/S control module 23. To ABS control module
[J]: M15A engine with 4A/T equipped with slip control model (Hong Kong
model)12. P/S motor 24. To HVAC control module
1. Main fuse box 13. Shield 25. To SDM
2. Ignition switch 14. Torque sensor (built into steering gear case)

Downloaded from www.Manualslib.com manuals search engine 6C-22 Power Assisted Steering System:
DTC C1121 / C1123 / C1124: Vehicle Speed Signal Circuit FailureS6RW0D6304014
DTC C1121: No Vehicle Speed Signal (60 Seconds or More)
DTC C1123: No Vehicle Speed Signal (30 Seconds or More)
DTC C1124: Vehicle Speed Performance (Impossible Deceleration)
Wiring Diagram5Torque sensor power supply circuit check
1) Check that torque sensor power supply circuit is as
follows.
• Insulation resistance of wire harness is infinity
between “Torque sensor power supply circuit” terminal
and each other terminal at torque sensor connector.
• Wiring harness resistance of “Torque sensor power
supply circuit” is less than 1 Ω.
• Insulation between “Torque sensor power supply
circuit” and vehicle body ground is infinity.
Is circuit in good condition?Replace P/S control
module.Repair or replace
defective circuit. Step Action Yes No
[A]
123
4567
8
9 11
10 12 13
141516
17 18 1920
1
2
[B]
BRN RED/
BLU LT GRN/
BLK
E11-1
E11-14
E11-12
E13-1 GRN
GRN
WHT
8
3 10
12
13
11
4 1
2
12V
E13-2BLK
12V
12V
9 5
77
E11-11
G04-15
[E]G04-22
5V
PPL
E11-4
BLU/
WHTE04-9
6
14
IG11615
C07-25
[D][C]
[F]E01-44E01-4
[F]E01-27E01-26
I6RW0D630003-01
[A]: P/S control module connector No.1 “E11” (viewed from harness side) 3. Junction block assembly 11. “IGN” fuse
[B]: P/S control module connector No.2 “E13” (viewed from harness side) 4. Main fuse 12. “P/S” fuse
[C]: M/T model 5. ECM 13. “IG1 SIG” fuse
[D]: A/T model 6. BCM 14. Vehicle speed signal
[E]: Junction block without BCM model (Taiwan model) 7. Front left/right wheel speed sensor 15. TCM
[F]: M15A engine with 4A/T equipped with slip control model (Hong Kong model) 8. P/S control module 16. Output shaft speed sensor
1. Main fuse box 9. ABS control module
2. Ignition switch 10. Individual circuit fuse box No.1

Downloaded from www.Manualslib.com manuals search engine 6C-34 Power Assisted Steering System:
Steering Wheel Play CheckS6RW0D6304021
• Check steering wheel for looseness or rattle by
moving it in its shaft direction and lateral direction.
If found defective, repair or replace.
• Check steering wheel for play, holding vehicle in
straight forward condition on the ground with engine
stopped.
If steering wheel play is not within specification,
inspect as follows and replace if found defective.
– Tie-rod end ball stud for wear (Ball stud should
move when more than 0.2 N⋅m (2 kg-cm, 0.44 lb-ft)
torque is applied.)
– Lower ball joint for wear
– Steering shaft joint for wear
– Steering pinion or rack gear for wear or breakage
– Each part for looseness
Steering wheel play
“a”
: 0 – 30 mm (0 – 1.18 in.)
Steering Force CheckS6RW0D6304022
1) Place vehicle on level road and set steering wheel at
straight-ahead position.
2) Check if tire inflation pressure is as specified
referring to the tire placard.
3) Remove driver air bag (inflator) module referring to
“Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
4) Start engine.
5) With engine idling, measure steering force by turning
torque wrench.
Steering force
: Less than 6.4 N⋅m (0.64 kgf-m, 4.6 lb-ft)
6) Install driver air bag (inflator) module referring to
“Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
I3RM0A630021-01
I3RM0A630022-01

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-37
3) Inspect for proper toe referring to “Front Wheel
Alignment Inspection and Adjustment in Section 2B”.
4) After confirming proper toe, tighten tie-rod end lock
nut to specified torque.
Tightening torque
Tie-rod end lock nut (a): 45 N·m (4.5 kgf-m, 32.5
lb-ft)
5) Tighten wheel bolts to specified torque and lower
hoist.
Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
Tie-Rod End InspectionS6RW0D6306004
• Inspect for play in ball joint.
• Inspect for play in rack end ball joint.
In either case, if found defective, replace.
Steering Shaft Joint On-Vehicle InspectionS6RW0D6306005
Check shaft joint for wear, breakage and any other
damage and replace if any defect exists.
Steering Gear Case Assembly Removal and
Installation
S6RW0D6306006
Removal
CAUTION!
Be sure to set front wheels (tires) in straight
direction and remove ignition key from key
cylinder before performing the following
steps, otherwise, contact coil of air bag
system may get damaged.

1) Remove steering joint cover.
2) Make alignment marks (1) on pinion shaft (2) and
joint of steering lower shaft (3) for a guide during
reinstallation.
3) Loosen joint bolt (steering column side) (4) and
remove joint bolt (pinion shaft side) (5) and
disconnect steering lower shaft (3) from pinion shaft
(2).
4) Disconnect torque sensor connector and P/S motor
connector from steering gear case.
5) Remove front suspension frame referring to “Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation in Section 2B”, and then
remove steering gear case.
Installation
1) Install grommet (1) as shown in figure.
I3RM0A630030-01
I4RS0A630043-01
I4RS0B630012-01
2. Protrusion
5
2
1
5
34
3
I4RS0B630013-01
1
2
1
2
I5RW0A630018-02

Downloaded from www.Manualslib.com manuals search engine 6C-38 Power Assisted Steering System:
2) Install steering gear case to vehicle, and then install
front suspension frame referring to “Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation in Section 2B”.
3) Install steering gear case to suspension frame (3) as
follows.
a) Set member bracket (2) to steering gear case
(1).
b) Install all steering gear case mounting bolts by
hand.
c) Tighten steering mounting bolts in numerical
order and specified torque.
Tightening torque
Steering gear case mounting bolt (a): 70 N·m (
7.0 kgf-m, 51.0 lb-ft)
4) Connect torque sensor connector and P/S motor
connector to steering gear case.
5) Be sure that steering wheel and brake discs (right &
left) are all straight-ahead position and then insert
steering lower shaft (5) into steering pinion shaft (3)
with matching marks (4).
6) Tighten steering shaft joint lower bolt (1) and upper
bolt (2) to specified torque (tighten lower side first
and then tighten upper side).
Tightening torque
Steering lower shaft assembly upper joint bolt
(a): 25 N·m (2.5 kgf-m, 18.5 lb-ft)
Steering lower shaft assembly lower joint bolt
(b): 25 N·m (2.5 kgf-m, 18.5 lb-ft)
7) Install steering joint cover.Steering Rack Boot InspectionS6RW0D6306007
Hoist vehicle.
Inspect each boot for tear. A torn boot allows entry of
dust and water which can cause wear to steering rack
and pinion to produce noise as well as rust to result in
malfunction of steering system.
Even if boot tear is small, replace with new one.
Also, check each boot for dent. If there is a dent, keep
boot in most compressed state for some seconds to
correct dent.
Boots should be visually inspected for any damage, dent
and tear during every periodical inspection at specified
intervals and whenever vehicle is hoisted for any other
purpose.
Tie-Rod / Rack Boot Removal and InstallationS6RW0D6306008
Removal
1) Remove steering gear case assembly referring to
“Steering Gear Case Assembly Removal and
Installation”.
2) Remove member bracket from steering gear case
assembly.
3) For ease of adjustment after installation, make
marking (1) of tie-rod end lock nut position of tie-rod
thread.
4) Loosen tie-rod end lock nut and remove tie-rod end.
5) Remove boot band (2) and clip (1).
6) Remove boot from tie-rod.I7RW01632009-01
5
4 1, (b)
3
2, (a)
1, (b)5
I5RW0A630020-01
I2RH01630012-01
I4RS0A630044-01
IYSQ01630034-01