2006 SUZUKI SX4 AIR

Downloaded from www.Manualslib.com manuals search engine 5C-3 Clutch:
Repair Instructions
Clutch Pedal InspectionS6RW0D5306001
Cylinder Push Rod Play “a”
1) Press clutch pedal (1) gradually with finger, stop
when slight increase of resistance is felt and
measure how much pedal has moved (push rod
play) as represented by “a” as shown.
Push rod play
“a”: Max. 3 mm (0.12 in.)
2) If “a” is not within specification, replace master
cylinder (3) or pedal arm (2).
Clutch Pedal Free Travel “b”
1) Depress clutch pedal (1), stop the moment clutch
resistance is felt, and measure how much pedal has
moved (clutch pedal free travel) as represented by
“b” in the figure.
Clutch pedal free travel
“b”
: 2 – 8 mm (0.08 – 0.31 in.)
2) If “b” is not within specification, check pedal arm (2)
and master cylinder (3) and replace defective part.
Clutch Release Margin “c”
1) Pull up parking brake fully and block wheels.
2) Start engine and keep engine at idle with neutral
gear position.
3) Without clutch pedal (1) depressed, slightly push the
shift lever to reverse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress
clutch pedal (1), and at gear contact noise died
position (release point) stop depressing.
5) Measure distance between release point (4) and full
stroke point (5) on clutch pedal (1) which is shown by
“c” in the figure.
Clutch release margin
“c”: 25 – 55 mm (0.98 – 2.17 in.)6) If “c” is not within specification, it is possible that air
is trapped in this system. If suspected so, bleed air
referring to “Air Bleeding of Clutch System”.Upon
completion of above inspection, start engine and
check clutch for proper operation.
Clutch Fluid Level InspectionS6RW0D5306002
Refer to “Brake Fluid Level Inspection in Section 4A”.
Clutch fluid specification
: Refer to the reservoir cap of the brake master
cylinder.
Air Bleeding of Clutch SystemS6RW0D5306003
CAUTION!
When operating the pedal stroke for air
bleeding of clutch system, after releasing the
clutch pedal, be sure to wait 1 second or
more before depressing it again. Otherwise,
the oil seal of operating cylinder will be
damaged, resulting in oil leakage.

Bleed air from clutch system.
Refer to “Air Bleeding of Brake System in Section 4A”.
I5RW0A530002-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-4
Clutch Fluid Pipe and Hose LocationS6RW0D5306004
Clutch Fluid Pipe Removal and InstallationS6RW0D5306005
Removal
CAUTION!
Do not allow fluid to get on painted surface. It
may cause painted surface damage.

1) Remove dust and dirt from each joint of pipe to be
disconnected and clean around brake master
cylinder reservoir cap.
2) Take out fluid with syringe or such from brake master
cylinder reservoir.
3) Pull clamp (1) of clutch master cylinder (3) and pull
clamp (5) of fluid pipe joint (4), and then disconnect
clutch fluid pipe (2).
4) Pull clamp (6) of damper (7), and then disconnect
damper (7) from clutch fluid pipe (2).Installation
Reverse removal procedure for installation noting the
following.
CAUTION!
• Do not allow fluid to get on painted
surface.
• Do not allow pipe to contact hard against
vehicle body or other parts.

• Install each clamp securely.
• After installation, check clutch pedal free travel and
bleed air from clutch system referring to “Clutch Pedal
Inspection” and “Air Bleeding of Clutch System”.
• Check fluid leakage.
• Add fluid to MAX level of reservoir.
Clutch Fluid Pipe InspectionS6RW0D5306006
Check pipe (1) for damage, dirt and leak. Replace if
check result is not satisfactory.
4 [A]
3131
22
4
I5RW0A530003-02
[A]: RH steering vehicle 3. Clutch reservoir hose
1. Clutch master cylinder 4. Brake master cylinder reservoir
2. Clutch fluid pipe
2
6
5 74
3
1
2
I5RW0B530002-03
[A]: LH steering vehicle
[B]: RH steering vehicle
I5RW0A530005-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-6
Installation
1) Install clutch operating cylinder assembly (2) to
transaxle. Tighten new mounting bolts to specified
torque.
Tightening torque
Clutch operating cylinder assembly mounting
bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
2) Connect clutch fluid pipe (4) to clutch operating
cylinder assembly temporarily.
3) Install clutch pipe joint sleeve (3) to transaxle
securely and then tighten clutch fluid pipe flare nut
(1) to specified torque.
Tightening torque
Clutch fluid pipe flare nut (b): 16 N·m (1.6 kgf-
m, 11.5 lb-ft)4) Remount transaxle assembly referring to “Manual
Transaxle Unit Dismounting and Remounting in
Section 5B”.
5) Bleed air from system and check clutch pedal free
travel. Refer to “Air Bleeding of Clutch System” and
“Clutch Pedal Inspection”.
Clutch Operating Cylinder Assembly InspectionS6RW0D5306013
Check clutch fluid leakage, spring for damage and
bearing for smooth rotation. If malfunction is found,
replace clutch operating cylinder assembly.
Clutch Cover, Clutch Disc and Flywheel ComponentsS6RW0D5306010
3
4
(a)
2
1, (b)
I5RW0A530009-01
I5RW0B530005-03
2
1
3(a)
6
4
5
(b)
I6RW0C530001-01
1. Clutch cover 4. Flywheel : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
2. Clutch disc 5. Input shaft bearing : 70 N⋅m (7.0 kgf-m, 51.0 lb-ft)
3. Clutch cover bolt 6. Flywheel bolt : Do not reuse.

Downloaded from www.Manualslib.com manuals search engine 5C-9 Clutch:
Clutch Disc
Measure depth of rivet head depression, i.e. distance
between rivet head and facing surface.
If depression is found to have reached service limit at
any of rivet holes (2), replace clutch disc assembly (1).
Rivet head depth
Standard: 1.65 – 2.25 mm (0.06 – 0.09 in.)
Limit: 0.5 mm (0.02 in.)Clutch Cover
1) Check diaphragm spring (1) for abnormal wear or
damage.
2) Inspect pressure plate (2) for wear or heat spots.
3) If abnormality is found, replace clutch cover.
Do not disassemble it into diaphragm spring and
pressure plate.
Flywheel
Check surface contacting clutch disc for abnormal wear
or heat spots. Replace or repair as required.
Specifications
Tightening Torque SpecificationsS6RW0D5307001
NOTE
The specified tightening torque is also described in the following.
“Clutch Cover, Clutch Disc and Flywheel Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I4RS0A530019-01
I3RM0A530015-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Clutch master cylinder nut 13 1.3 9.5)
Clutch operating cylinder assembly mounting
bolt10 1.0 7.5)
Clutch fluid pipe flare nut 16 1.6 11.5)
Flywheel bolt 70 7.0 51.0)
Clutch cover bolt 23 2.3 17.0)

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 Precautions: 6-1
Ste eri ng
Precautions
Precautions
Precautions on SteeringS6RW0D6000001
Air Bag Warning
Refer to “Air Bag System Service Warning in Section 00”.
Precautions for Steering Diagnosis
Refer to “Precautions for Steering Diagnosis in Section 6A”.
Service Precautions of Steering Wheel and Column
Refer to “Service Precautions of Steering Wheel and Column in Section 6B”.
P/S System Note
Refer to “P/S System Note in Section 6C”.

Downloaded from www.Manualslib.com manuals search engine 6A-1 Steering General Diagnosis:
Ste eri ng
Steering General Diagnosis
Precautions
Precautions for Steering DiagnosisS6RW0D6100001
Since the problems in steering involve several systems, they must all be considered when diagnosing a complaint. To
avoid using the wrong symptom, always road test the vehicle first. Proceed with the following preliminary inspection
and correct any defects which are found.
1) Inspect tires for proper pressure and uneven wear.
2) Raise vehicle on a hoist and inspect steering system for loose or damaged parts.
3) Spin front wheels. Inspect for out-of-round tires, out-of-balance tires, bent rims, loosen and/or rough wheel
bearings.
Diagnostic Information and Procedures
Steering Symptom DiagnosisS6RW0D6104001
Condition Possible cause Correction / Reference Item
Hard steeringTire not adequately inflatedInflate tires to proper pressure.
Malfunction of power steering systemCheck and correct. Refer to “P/S System
Symptom Diagnosis in Section 6C”.
Bind in tie-rod end ball studs or lower
ball jointsReplace tie-rod end or front suspension control
arm.
Disturbed front wheel alignmentCheck and adjust front wheel alignment.
Bind in steering columnRepair or replace steering column assembly.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Too much play in steeringWheel bearings wornReplace wheel bearing.
Loose steering gear case boltsTighten gear case bolts.
Faulty steering gear case assemblyReplace steering gear case assembly.
Worn steering shaft jointsReplace steering lower shaft assembly.
Worn tie-rod ends or tie-rod inside ball
jointsReplace tie-rod end or tie-rod.
Worn lower ball jointsReplace front suspension control arm.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Poor return abilityBind in tie-rod end ball studsReplace tie-rod end.
Bind in ball jointsReplace front suspension control arm.
Bind in steering columnReplace steering column assembly.
Disturbed front end alignmentCheck and adjust front end alignment.
Faulty steering gear case assemblyReplace steering gear case assembly.
Tires not adequately inflatedAdjust tire pressure.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Rack and pinion noise
(Rattle or chuckle)Loose steering gear case boltsTighten steering gear case bolts.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Faulty steering gear case assemblyReplace steering gear case assembly.
Broken or otherwise damaged wheel
bearing(s)Replace wheel bearing(s).
Wander or poor steering
stabilityMismatched or uneven tiresReplace or inflate tires to proper pressure.
Loosen ball joints and tie-rod endsReplace suspension control arm or tie-rod end.
Faulty struts or mountingsReplace strut or repair mounting.
Loose stabilizer barTighten or replace stabilizer bar or bush.
Broken or sagging coil springsReplace coil spring.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Disturbed front wheel alignmentCheck and adjust front wheel alignment.
Faulty steering gear case assemblyReplace steering gear case assembly.

Downloaded from www.Manualslib.com manuals search engine Steering General Diagnosis: 6A-2
Steering System InspectionS6RW0D6104002
Check steering system referring to the following items.Erratic steering when
brakingWorn wheel bearingsReplace wheel bearing.
Broken or sagging coil springsReplace coil spring.
Wheel tires are inflated unequallyInflate tires to proper pressure.
Disturbed front wheel alignmentCheck and adjust front wheel alignment.
Brakes not working in unisonCheck and repair brake system.
Leaking wheel cylinder or caliperRepair or replace wheel cylinder or caliper.
Warped discsReplace brake disc.
Badly worn brake liningsReplace brake shoe lining.
Drum is out of round in some brakesReplace brake drum.
Defective wheel cylindersReplace or repair wheel cylinder. Condition Possible cause Correction / Reference Item
Inspection Item Referring section
Steering wheel Play, rattle “Steering Wheel Play Check in Section 6C”
Tie-rod end Looseness and damage “Tie-Rod End Inspection in Section 6C”
Wheel alignment “Front Wheel Alignment Inspection and Adjustment in
Section 2B”
Tie-rod end boot Damage “Tie-Rod End Boot On-Vehicle Inspection in Section 6C”
Steering rack boot Damage “Steering Rack Boot Inspection in Section 6C”
Steering shaft joint Rattle and damage “Steering Shaft Joint On-Vehicle Inspection in Section 6C”
EPS system Operation “EPS System Check in Section 6C”