2006 SUZUKI SX4 indicator

Downloaded from www.Manualslib.com manuals search engine 4A-5 Brake Control System and Diagnosis:
Brakes Symptom DiagnosisS6RW0D4104002
Condition Possible cause Correction / Reference Item
Not enough braking forceBrake oil leakage from brake linesLocate leaking point and repair.
Brake disc or pad stained with oilClean or replace.
Overheated brakesDetermine cause and repair.
Poor contact of shoes on brake drumRepair for proper contact.
Brake shoe stained with oil or wet with
waterReplace.
Badly worn brake padReplace.
Defective wheel cylindersRepair or replace.
Malfunctioning caliper assemblyRepair or replace.
Malfunctioning brake boosterCheck system and replace as necessary.
Malfunctioning brake master cylinderCheck system and replace as necessary.
Air in systemBleed system.
Malfunctioning ABSCheck system and replace as necessary.
Brake pull (Brakes not
working in unison)Pad, disc, shoe and/or drum are wet
with water or stained with oil in some
brakesClean or replace.
Drum-to-shoe clearance out of
adjustment in some brakes
(Malfunctioning auto adjusting
mechanism) Check for inoperative auto adjusting
mechanism.
Disc and/or drum are out of round in
some brakesReplace.
Tires are inflated unequallyInflate equally.
Malfunction in wheel cylinders (rear
drum brake model)Repair or replace.
Disturbed front wheel alignmentAdjust as prescribed.
Unmatched tires on same axleTires with approximately the same amount of
tread should be used on the same axle.
Restricted brake pipes or hosesCheck for soft hoses and damaged lines.
Replace with new hoses and new double-
walled steel brake tubing.
Malfunctioning caliper assemblyCheck for stuck or sluggish pistons and proper
lubrication of caliper slide pin.
Caliper should slide.
Loose suspension partsCheck all suspension mountings.
Loose calipersCheck and torque bolts to specifications.
Noise (high pitched
squeak without brake
applied)Contact wear indicator to brake discReplace brake pad.
Worn rear brake shoeReplace brake shoe.
Excessive pedal travel
(Pedal stroke too large)Partial brake system failureCheck brake systems and repair as necessary.
Brake fluid leakingRepair the leaking point, and bleed air.
Air in system (soft / spongy pedal)Bleed system.
Rear brake system not adjusted
(malfunctioning auto adjusting
mechanism)Repair auto adjusting mechanism.
Adjust rear brakes.
Bent brake shoesReplace brake shoes.
Brake locked Malfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-6
Dragging brakes (Without
a very light drag is
present in all brakes
immediately after pedal is
released)Master cylinder pistons not returning
correctlyReplace master cylinder.
Restricted brake pipes or hosesCheck for soft hoses or damaged pipes and
replace with new hoses and/or new brake
piping.
Incorrect parking brake adjustment on
rear brakesCheck and adjust to correct specifications.
Weakened or broken return springs in
the drum brakeReplace.
Sluggish parking brake cables or linkageRepair or replace.
Wheel cylinder or caliper piston stickingRepair as necessary.
Badly worn piston seal in caliperReplace piston seal.
Improper brake pedal free heightCheck brake pedal free height.
Pedal pulsation (Pedal
pulsates when depressed
for braking)Damaged wheel bearingsReplace wheel bearings.
Distorted steering knuckle or rear wheel
spindle or rear axle shaftReplace knuckle or rear wheel spindle or rear
axle shaft.
Excessive disc lateral runoutCheck per instructions. If not within
specifications, replace or machine disc.
Rear drums out of roundCheck runout.
Repair or replace drum as necessary.
Braking noiseGlazed brake pad and/or brake shoeRepair or replace brake pad and/or brake
shoe.
Worn or distorted brake shoeReplace brake shoe.
Loose front wheel bearingsReplace wheel hub.
Distorted backing plates or loose
mounting boltsReplace or retighten securing bolts.
Contact wear indicator to brake discReplace brake pads.
Brake warning light lights
after engine startParking brake appliedRelease parking brake and check that brake
warning light turns off.
Insufficient amount of brake fluidInvestigate leaky point, correct it and add
brake fluid.
Brake fluid leakingInvestigate leaky point, correct it and add
brake fluid.
Brake warning light circuit faultyRepair circuit.
Malfunctioning EBD systemCheck system referring to “EBD Warning Light
(Brake Warning Light) Comes ON Steady in
Section 4E”.
Brake warning light turns
on when brake is appliedBrake fluid leakingInvestigate leaky point, correct it and add
brake fluid.
Insufficient amount of brake fluidInvestigate leaky point, correct it and add
brake fluid.
Brake warning light fails
to turn on even when
parking brake is appliedBrake warning light circuit faultyReplace bulb or repair circuit.
ABS warning light turns
on after engine startMalfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light turns
on when brake is appliedMalfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light after
ignition switch has turned
ON Bulb burnt outReplace bulb.
Malfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light flashesNew ABS hydraulic unit / control module
assembly installed.Perform “ABS Hydraulic Unit Operation Check
in Section 4E”. Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Front Brakes: 4B-2
Front Disc Brake Pad On-Vehicle InspectionS6RW0D4206002
Inspect pad linings (1) periodically according to
maintenance schedule whenever wheels are removed
(for tire rotation or other reason). Take a look through
each end and inspection hole of caliper and check lining
thickness of outside and inside pads.
If lining is worn and its thickness (“a” in figure) is less
than limit, all pads must be replaced at the same time.
Front brake pad thickness “a” (lining thickness)
Standard: 10 mm (0.39 in.)
Limit: 2 mm (0.08 in.)
Front Disc Brake Pad Removal and InstallationS6RW0D4206003
NOTE
When replacing brake pad, replace it on the
right and left.

Removal
1) Hoist vehicle and remove front wheel.
2) Remove caliper pin bolts (1).
3) Remove caliper (1) from caliper carrier (2).
NOTE
Hang removed caliper (1) with a wire hook (4)
or the like so as to prevent brake hose from
bending and twisting excessively or being
pulled.
Don’t operate brake pedal with brake pads
removed.

4) Remove brake pads (3).
5) Remove brake pad spring (1) as show in figure.
Installation
1) Apply small amount of pad grease “a” (included in
spare parts) to pad spring and set brake pad spring
as shown in figure.
2) Set brake pad springs (1), and install brake pads (2)
and shim (4).
NOTE
Install the brake pad with wear indicator (3) to
the vehicle center side of front right brake
pad.

I7RW01420009-01
1
I7RW01420003-01
42
3
1
I7RW01420010-01
1
I7RW01420014-01
"a"
I7RW01420011-01
I7RW01420012-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 5- i
5
Section 5
CONTENTS
Transmission / Transaxle
Precautions ................................................. 5-1
Precautions............................................................. 5-1
Precautions on Transmission / Transaxle ............. 5-1
Automatic Transmission/Transaxle ....... 5A-1
Precautions........................................................... 5A-1
Precautions in Diagnosing Trouble ..................... 5A-1
Precautions for Disassembly and
Reassembly ...................................................... 5A-1
General Description ............................................. 5A-3
A/T Description ................................................... 5A-3
Clutch / Brake / Planetary Gear Function of
Automatic Transaxle ......................................... 5A-6
Table of Component Operation ........................... 5A-7
A/T Diagnosis General Description ..................... 5A-7
On-Board Diagnostic System Description ........... 5A-8
CAN Communication System Description........... 5A-9
Schematic and Routing Diagram ...................... 5A-10
Transmission Control Module (TCM) Wiring
Diagram .......................................................... 5A-10
Automatic Gear Shift Table ............................... 5A-12
Component Location ......................................... 5A-14
Electronic Shift Control System Components
Location .......................................................... 5A-14
Diagnostic Information and Procedures .......... 5A-16
A/T System Check ............................................ 5A-16
Visual Inspection ............................................... 5A-18
Malfunction Indicator Lamp (MIL) Check .......... 5A-19
Transmission Warning Light Check (Non-
Euro-OBD model) ........................................... 5A-19
DTC Table ......................................................... 5A-19
DTC Check ....................................................... 5A-21
DTC Clearance ................................................. 5A-22
Fail-Safe Table .................................................. 5A-22
Scan Tool Data ................................................. 5A-24
A/T Basic Check ............................................... 5A-27
Road Test ......................................................... 5A-27
Manual Road Test ............................................. 5A-30
Engine Brake Test ............................................ 5A-30
Stall Test ........................................................... 5A-31
Time Lag Test ................................................... 5A-32
Line Pressure Test ............................................ 5A-32
“P” Range Test.................................................. 5A-33
A/T Symptom Diagnosis ................................... 5A-34Transmission Warning Light Circuit Check –
Light Remains “ON” at Ignition Switch ON
(Non-Euro-OBD Model)................................... 5A-41
Transmission Warning Light Circuit Check –
Light Does Not Come “ON” at Ignition Switch
ON (Non-Euro-OBD Model)............................ 5A-41
DTC P0602: Control Module Programming
Error ................................................................ 5A-42
DTC P0705: Transmission Range Sensor
Circuit Malfunction (PRNDL Input) .................. 5A-42
DTC P0707: Transmission Range Sensor
Circuit Low ...................................................... 5A-44
DTC P0711: Transmission Fluid Temperature
Sensor “A” Control Range / Performance ....... 5A-46
DTC P0712: Transmission Fluid Temperature
Sensor Circuit Low .......................................... 5A-47
DTC P0713: Transmission Fluid Temperature
Sensor Circuit High ......................................... 5A-48
DTC P0717: Input / Turbine Speed Sensor
Circuit Malfunction........................................... 5A-50
DTC P0722: Output Speed Sensor (VSS)
Circuit No Signal ............................................. 5A-51
DTC P0741 / P0742: TCC Circuit
Performance or Stuck OFF / TCC Circuit
Stuck ON ......................................................... 5A-53
DTC P0751 / P0752 / P0756 / P0757: Shift
Solenoid Malfunction ....................................... 5A-54
DTC P0787: Shift / Timing Solenoid Control
Circuit Low ...................................................... 5A-55
DTC P0788: Shift / Timing Solenoid Control
Circuit High...................................................... 5A-57
DTC P0961: Pressure Control Solenoid “A”
Control Circuit Range / Performance .............. 5A-58
DTC P0962: Pressure Control Solenoid
Control Circuit Low .......................................... 5A-60
DTC P0963: Pressure Control Solenoid
Control Circuit High ......................................... 5A-62
DTC P0973 / P0976: Shift Solenoid-A (No.1)
Control Circuit Low / Shift Solenoid-B (No.2)
Control Circuit Low .......................................... 5A-64
DTC P0974 / P0977: Shift Solenoid-A (No.1)
/ Shift Solenoid-B (No.2) Control Circuit High .. 5A-66
DTC P1702: Internal Control Module Memory
Check Sum Error............................................. 5A-68

Downloaded from www.Manualslib.com manuals search engine 5A-14 Automatic Transmission/Transaxle:
Component Location
Electronic Shift Control System Components LocationS6RW0D5103001
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

5*
17
15
1
2
8
9
1011
12
13
16*18 19
14
7
6
3420
[B]
[A]5*
I6RW0D510004-01
[A]: Junction block with BCM model 7. Input shaft speed sensor 15. ECM
[B]: Junction block without BCM model 8. TCC solenoid valve 16. TCM
1. Engine 9. Transmission fluid temperature sensor 17. AT relay
2. Transaxle 10. Timing solenoid valve 18. “3” position switch
3. MIL 11. Pressure control solenoid valve 19. Select lever
4. Transaxle select position indicator 12. Shift solenoid valve-B (No.2) 20. Transmission warning light (non-Euro-OBD model)
5. Junction block assembly (included in BCM) 13. Shift solenoid valve-A (No.1)

Downloaded from www.Manualslib.com manuals search engine 5A-18 Automatic Transmission/Transaxle:
Step 2. DTC / Freeze Frame Data Check, Record and
Clearance
First, referring to “DTC Check”, check DTC and pending
DTC. If DTC exists, print or write down DTC and freeze
frame data and then clear malfunction DTC(s) by
referring to “DTC Clearance”. Malfunction DTC indicates
malfunction in the system but it is not possible to know
from it whether the malfunction is occurring now or it
occurred in the past and normal condition has been
restored. In order to know that, check symptom in
question according to Step 5 and then recheck DTC
according to Step 6.
Diagnosing a trouble based on the DTC in this step only
or failure to clear the DTC in this step may result in an
faulty diagnosis, trouble diagnosis of a normal circuit or
difficulty in troubleshooting which is otherwise
unnecessary.
Step 3 and 4. Visual Inspection
As a preliminary step, be sure to perform visual check of
the items that support proper function of the engine and
automatic transaxle referring to “Visual Inspection”.
Step 5. Trouble Symptom Confirmation
Check trouble symptoms based on information obtained
in “Step 1. Customer Complaint Analysis: ” and “Step 2.
DTC / Freeze Frame Data Check, Record and
Clearance: ”.
Also, reconfirm DTC according to “DTC Confirmation
Procedure” described in each DTC flow.
Step 6 and 7. Rechecking and Record of DTC and
Freeze Frame Data
Refer to “DTC Check” for checking procedure.Step 8. A/T Basic Check and A/T Symptom
Diagnosis
Perform basic check of A/T according to “A/T Basic
Check” first. When the end of the flow has been reached,
check the parts of the system suspected as a possible
cause referring to “A/T Symptom Diagnosis” and based
on symptoms appearing on the vehicle (symptoms
obtained through steps of customer complaint analysis,
trouble symptom confirmation and/or A/T basic check)
and repair or replace faulty parts, if any.
Step 9. Troubleshooting for DTC
Based on the DTC indicated in Step 6 / 7 and referring to
“applicable DTC flow”, locate the cause of the trouble,
namely in a sensor, switch, wire harness, connector,
actuator, TCM or other part and repair or replace faulty
parts.
Step 10. Check for Intermittent Problem
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
vehicle is free from any abnormal conditions. If what has
been repaired is related to the malfunction DTC, clear
the DTC once and check to ensure that no malfunction
DTC is indicated.
Visual InspectionS6RW0D5104002
Visually check the following parts and systems.
Inspection item Referring
• A/T fluid ----- level, leakage, color “Automatic Transaxle Fluid Level Inspection in
Section 0B”
• A/T fluid hoses ----- disconnection, looseness, deterioration “A/T Fluid Cooler Hoses Replacement”
• Throttle cable (if equipped) ----- play (under warm engine),
installation
• A/T select cable ----- installation “Select Cable Removal and Installation”
• Engine oil ----- level, leakage “Engine Oil and Filter Change in Section 0B”
• Engine coolant ----- level, leakage “Engine Coolant Change in Section 0B”
• Engine mountings ----- play, looseness, damage “Engine Assembly Removal and Installation in
Section 1D”
• Suspension ----- play, looseness “Suspension, Wheels and Tires Symptom
Diagnosis in Section 2A”
• Drive shafts ----- damage “Front Drive Shaft Assembly On-Vehicle Inspection
in Section 3A”
• Battery ----- indicator condition, corrosion of terminal “Battery Inspection in Section 1J”
• Connectors of electric wire harness ----- disconnection, friction “Electronic Shift Control System Components
Location”
• Fuses ----- burning
• Parts ----- installation, damage
• Bolts ----- looseness
• Other parts that can be checked visually

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-19
Malfunction Indicator Lamp (MIL) CheckS6RW0D5104003
Refer to the same item in “Malfunction Indicator Lamp (MIL) Check in Section 1A” for checking procedure.
Transmission Warning Light Check (Non-Euro-OBD model)S6RW0D5104053
1) Turn ignition switch ON.
2) Check that transmission warning light lights for about 2 – 4 sec. and then goes OFF.
If anything faulty is found, advance “Transmission Warning Light Circuit Check – Light Does Not Come “ON” at
Ignition Switch ON (Non-Euro-OBD Model)” or “Transmission Warning Light Circuit Check – Light Remains “ON”
at Ignition Switch ON (Non-Euro-OBD Model)”.
DTC TableS6RW0D5104004
NOTE
• There are two types of OBD system depending on the vehicle specification.For identification, refer
to “Precaution on On-Board Diagnostic (OBD) System in Section 1A”.
• For non-Euro-OBD model, some of DTC No. with (*) mark in the following table can not be detected
by TCM depending on vehicle specification and local regulation.
• With the CAN communication OBD generic scan tool, DTC No. with delta (U) mark in the following
table can not be read.
• A: Driving cycles when MIL lighting and storing DTC in TCM memory for Euro OBD model.
• B: Driving cycles when transmission warning light lighting and storing DTC in TCM memory for non-
Euro-OBD model.
• 1 driving cycle: MIL or transmission warning light lights up when DTC is detected during 1 driving
cycle.
• 2 driving cycles: MIL or transmission warning light lights up when the same DTC is detected also in
the next driving cycle after DTC is detected and stored temporarily in the first driving cycle.
• Driving cycle with (*): MIL or transmission warning light does not light up but TCM detects and
stores DTC.

Also check the following items at engine start, if possible.
• Malfunction indicator lamp ----- Operation “Malfunction Indicator Lamp (MIL) Check”
• Transmission warning light ----- Operation “Transmission Warning Light Check (Non-Euro-
OBD model)”
• Charge warning lamp ----- Operation “Generator Symptom Diagnosis in Section 1J”
• Engine oil pressure warning lamp ----- Operation “Oil Pressure Warning Light Symptom Diagnosis in
Section 9C”
• Engine coolant temp. meter ----- Operation “Engine Coolant Temperature (ECT) Meter
Symptom Diagnosis in Section 9C”
• Other parts that can be checked visuallyInspection item Referring
I5RW0C510009-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-27
MIL REQUEST
ON: Signal which TCM requires combination meter to
turn on malfunction indicator lamp.OFF: Signal which TCM does not require combination
meter to turn on malfunction indicator lamp.
A/T Basic CheckS6RW0D5104009
This check is important for troubleshooting when TCM has detected no DTC and no abnormality has been noted in
“Visual Inspection”. Follow the flow carefully.
Road TestS6RW0D5104010
This test is to check if upshift, downshift and lock-up take place at specified speeds while actually driving vehicle on a
level road.
WARNING!
• Carry out test in very little traffic area to prevent an accident.
• Test requires 2 persons, a driver and a tester.

1) Warm up engine.
2) With engine running at idle, shift select lever “D” range.
3) Accelerate vehicle speed by depressing accelerator pedal gradually.
4) While driving in “D” range, check if gear shift and lock-up occur properly as shown in “Automatic Gear Shift Table”. Step Action Yes No
1Was “A/T System Check” preformed?Go to Step 2. Go to “A/T System
Check”.
2 Perform “Road Test”.
Is it OK?Go to Step 3. Proceed to
“Troubleshooting” in
“Road Test”.
3 Perform “Manual Road Test”.
Is it OK?Go to Step 4. Proceed to
“Troubleshooting” in
“Manual Road Test”.
4 Perform “Engine Brake Test”.
Is it OK?Go to Step 5. Proceed to
“Troubleshooting” in
“Engine Brake Test”.
5 Perform “Stall Test”.
Is it OK?Go to Step 6. Proceed to
“Troubleshooting” in
“Stall Test”.
6 Perform “Time Lag Test”.
Is it OK?Go to Step 7. Proceed to
“Troubleshooting” in
“Time Lag Test”.
7 Perform “Line Pressure Test”.
Is it OK?Go to Step 8. Proceed to
“Troubleshooting” in
“Line Pressure Test”.
8 Proceed to “Trouble Diagnosis 1” in “A/T Symptom
Diagnosis”.
Is trouble identified?Repair or replace faulty
parts.Go to Step 9.
9 Proceed to “Trouble Diagnosis 2” in “A/T Symptom
Diagnosis”.
Is trouble identified?Repair or replace faulty
parts.Proceed to “Trouble
Diagnosis 3” in “A/T
Symptom Diagnosis”.