2006 SUZUKI SX4 Can

Downloaded from www.Manualslib.com manuals search engine 5B-4 Manual Transmission/Transaxle:
5th & Reverse Gear Shift Cam
5th & reverse gear shift cam, cam guide return spring
and 5th to reverse interlock guide bolt are provided to
prevent the gear from being directly shifted from 5th to
reverse.
1) When shift lever is at neutral position between 3rd
and 4th gear, shift cam (2) is under guide bolt and
can turn freely clockwise (to 3rd gear) and
counterclockwise (to 4th gear).
2) When shift lever is shifted toward the right from
neutral position, shift and select shaft (1) moves up
but shift cam (2) is restricted by guide bolt and return
spring is contracted.3) When shift lever is shifted to 5th gear, shift & select
shaft (1) turns clockwise letting shift cam (2) off from
guide bolt and pushed up by return spring. In this
state, movement of shift cam is restricted by guide
bolt and therefore, gearshift to reverse is not
attainable.
4) When shift lever is shifted from neutral position
between 5th gear and reverse gear to reverse gear,
shift cam (2) turns counterclockwise to attain reverse
gear.
1. Shift & select shaft
3. Return spring (expanded)
4. Reverse select spring (expanded)
3. Reverse select spring (contracted)
I2RH01520003-02
I2RH01520004-01
I2RH01520005-01
3. Reverse select spring (expanded)
1. Shift & select shaft
3. Return spring (contracted)
4. Reverse select spring (contracted)
I2RH01520006-01
I2RH01520007-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-5
Diagnostic Information and Procedures
Manual Transaxle Symptom DiagnosisS6RW0D5204001
Repair Instructions
Manual Transaxle Oil Level CheckS6RW0D5206001
1) Lift up vehicle and check oil leakage. Repair leaky
point, if any.
2) Remove oil level / filler plug (1) and check oil
contamination and oil level is lower end of oil level /
filler plug hole (2).
If oil is excessive dirty or insufficient, replace oil or
pour specified oil up to plug hole.
3) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil level / filler plug (a): 21 N·m (2.1
kgf-m, 15.5 lb-ft)Condition Possible cause Correction / Reference Item
Gears slipping out of
meshWorn shift fork shaftReplace
Worn shift fork or synchronizer sleeveReplace
Weak or damaged locating springsReplace
Worn bearings on input shaft or
countershaftReplace
Worn chamfered tooth on sleeve and
gearReplace sleeve and gear
Hard shiftingInadequate lubricantReplenish
Improper clutch pedal free travelReplace clutch arm or master cylinder
Distorted or broken clutch discReplace
Damaged clutch pressure plateReplace clutch cover
Worn synchronizer ringReplace
Worn chamfered tooth on sleeve or gearReplace sleeve or gear
Worn gear shift control shaft joint bushReplace
Distorted shift shaftReplace
Broken gear shift / select control cablesReplace
NoiseInadequate or insufficient lubricantReplenish
Damaged or worn bearing(s)Replace
Damaged or worn gear(s)Replace
Damaged or worn synchronizer partsReplace
I5RW0A520004-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-21
Reassembly
1) Install differential assembly into right case.
2) Join input shaft (5), countershaft (4), low speed gear
shift shaft (2) and high speed gear shift shaft (3)
assemblies all together, then install them into right
case (1) so as not to damage oil seal by input shaft
spline.
NOTE
• Input shaft right bearing on shaft can be
installed into right case (1) by tapping shaft
with plastic hammer.
• Make sure that countershaft is engaged
with final gear while installing.

3) Install 5th & reverse gear shift shaft (1) with 5th &
reverse gear shift guide shaft (2) into right case (5).
Reverse gear shift arm (4) has to be joined with
reverse gear shift lever (3) at the same time.4) Make reverse idler gear (1) with reverse gear shift
lever (2), insert reverse gear shaft (3) and washer (6)
into case (4) through idler gear and then align bolt
hole “a” in shaft with notch “b” in case.
5) Fasten reverse gear shift lever bolts (5) after
applying thread lock cement.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Reverse gear shift lever bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lb-ft)
NOTE
Check to confirm that reverse gear shift lever
end has clearance “c” to idler gear groove.

Distance between lever end and idler gear shaft
“c”: 0.5 – 1.0 mm (0.02 – 0.04 in.)
I2RH01520080-01
I3RH0A520013-01
I5RW0A520022-02

Downloaded from www.Manualslib.com manuals search engine 5B-24 Manual Transmission/Transaxle:
16) Place left case plate (2) inserting its end in groove of
shift guide shaft (4) and then tighten bolts (1) to
which thread lock cement has been applied.
NOTE
After tightening bolts, make sure that
countershaft can be rotated by hand feeling
certain load.

“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
Tightening torque
Left case plate bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
Right Case Disassembly and ReassemblyS6RW0D5206017
Disassembly
1) Remove differential side oil seal from right case
referring to “Differential Side Oil Seal Replacement”,
if necessary.
2) Remove differential side bearing outer race (1) using
brass bar (2), if necessary.3) Remove input shaft oil seal by using special tool, if
necessary.
Special tool
(A): 09913–75830
4) Pull out countershaft right bearing outer race by
using special tools, if necessary.
Special tool
(A): 09930–30104
(B): 09941–64511
Reassembly
1) Install input shaft oil seal facing its spring side
upward until it becomes flush with case surface. Use
special tool and hammer for installation and apply
grease to oil seal lip.
: Grease 99000–25011 (SUZUKI Super Grease A)
Special tool
(A): 09913–76010
3. Input shaft
5. Countershaft
I2RH01520087-01
2
1
I4RH01520024-01
(A)
I5RW0A520026-01
(A)
(B)
I5RW0A520027-01
(A)
I5RW0A520028-01

Downloaded from www.Manualslib.com manuals search engine 5B-32 Manual Transmission/Transaxle:
6) Disassemble synchronizer sleeve & hub assembly.
7) Take out 1st gear needle bearing from shaft.
8) In order to remove right bearing (1) from
countershaft, grind with a grinder (2) one part “a” of
right bearing (1) as illustrated till it becomes thin.
CAUTION!
Be careful not to grind too far not to damage
the shaft (3).

9) Break with a chisel (1) the thin ground right bearing
(2) and it can be removed.
Reassembly
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new one 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) Put the synchronizer outer ring (1), inner ring (3) and
the cone (2) together and then measure the step
difference between the outer ring and the inner ring.
And also check each chamfered tooth of gear and
synchronizer ring and replace with new one, if
necessary. Also, check gear tooth.
Difference between synchronizer outer ring and
inner ring (2nd)
Standard “b”: 0.95 – 1.25 mm (0.036 – 0.048 in.)
Service limit “b”: 0.5 mm (0.019 in.)
4) To ensure lubrication of countershaft (1), air blow oil
holes (2) and make sure that they are free from any
obstruction.
3
1
2
“a”31
I5RW0A520035-01
1
2I5RW0A520036-01
I5JB0A520079-01
I2RH01520059-01
I2RH01520060-01

Downloaded from www.Manualslib.com manuals search engine 5C-1 Clutch:
Transmission / Transaxle
Clutch
General Description
Clutch (Hydraulic Type) ConstructionS6RW0D5301001
The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type,
which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward.
The disc, carrying four torsional coil springs, is positioned on the transaxle input shaft with an involute spline fit.
The clutch cover is secured to the flywheel, and carries the diaphragm spring in such a way that the peripheral edge
part of the spring pushes on the pressure plate against the flywheel (with the disc in between), when the clutch release
bearing (incorporated in clutch operating cylinder) is held back. This is the engaged condition of the clutch.
Depressing the clutch pedal causes the release bearing (incorporated in clutch operating cylinder) to advance and
pushes on the tips of the tapered fingers of the diaphragm spring. When this happens, the diaphragm spring pulls the
pressure plate away from the flywheel, thereby interrupting the flow of drive from flywheel through clutch disc to
transaxle input shaft. Clutch fluid is supplied from brake fluid reservoir. Clutch fluid level can be checked by brake fluid
level of brake fluid reservoir.
I5RW0A530001-01
1. Crankshaft 4. Pressure plate 7. Operating cylinder assembly
2. Flywheel 5. Clutch cover 8. Input shaft bearing
3. Clutch disc 6. Diaphragm spring 9. Input shaft

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 6B-1 Steering Wheel and Column:
Ste eri ng
Steering Wheel and Column
Precautions
Service Precautions of Steering Wheel and ColumnS6RW0D6200001
For service precautions, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”.
Service and Diagnosis
For diagnosis and servicing, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”.
Disabling Air Bag System
For disabling air bag system, refer to “Disabling Air Bag System in Section 8B”.
Enabling Air Bag System
For enabling air bag system, refer to “Enabling Air Bag System in Section 8B”.
Handling and Storage
For handling and storage, refer to “Precautions on Handling and Storage of Air Bag System Components in Section
8B”.
Disposal
For disposal, refer to “Precautions on Disposal of Air Bag and Seat Belt Pretensioner in Section 8B”.
General Description
Steering Wheel and Column ConstructionS6RW0D6201001
This double tube type steering column has the following three important features in addition to the steering function:
• The column is energy absorbing, designed to compress in a front-end collision.
• The ignition switch and lock are mounted conveniently on this column.
• With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehicle.
To insure the energy absorbing action, it is important that only the specified screws, bolts and nuts be used as
designated, and that they are tightened to the specified torque. When the column assembly is removed from the
vehicle, special care must be taken in handling it. Use of a steering wheel puller other than the recommended puller in
this manual or a sharp blow on the end of the steering shaft, leaning on the assembly, or dropping the assembly could
shear the plastic shear pins which maintain column length and position.
The driver air bag (inflator) module is one of the supplemental restraint (air bag) system components and is mounted
to the center of the steering wheel. During certain frontal crashes, the air bag system supplements the restraint of the
driver’s and passenger’s seat belts by deploying the air bags. The air bag (inflator) module should be handled with
care to prevent accidental deployment. When servicing, be sure to observe “Precautions on Service and Diagnosis of
Air Bag System in Section 8B”.