2006 SUZUKI SX4 key

Downloaded from www.Manualslib.com manuals search engine 5A-88 Automatic Transmission/Transaxle:
Installation
1) Lay interlock cable to its original cabling route.
C
1 2
3
4
5
61
9 [C] [A]
7
12
3
4
567
8
2 [B]
I5RW0C510073-01
[A]: LH steering vehicle 2. Clamp 6. EPS control module
[B]: RH steering vehicle 3. Steering lock assembly / Steering lock unit (if equipped with Keyless
start system)7. Brake switch bracket
[C]: View C 4. Key cylinder cover 8. Wiring harness
1. Key interlock cable 5. Select lever assembly 9. Marking

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 Manual Transmission/Transaxle: 5B-27
Input Shaft and Countershaft ComponentsS6RW0D5206019
I3RH0A520017-01
1. Input shaft 12. Input shaft left bearing 23. 2nd gear synchronizer center cone
2. Oil seal
: Apply grease 99000-25010 to oil seal lip.13. Circlip 24. 2nd gear synchronizer inner ring
3. Input shaft right bearing 14. 5th gear spacer 25. Circlip
4. Input shaft 3rd gear 15. Countershaft right bearing 26. Countershaft 2nd gear
5. Needle bearing 16. Countershaft 27. Countershaft 3rd gear
6. High speed synchronizer ring 17. Countershaft 1st gear 28. 3rd & 4th gear spacer
7. High speed synchronizer spring 18. Low speed synchronizer ring 29. Countershaft 4th gear
8. High speed synchronizer sleeve & hub 19. Low speed synchronizer spring 30. Countershaft left bearing
9. High speed synchronizer key 20. Low speed synchronizer sleeve & hub : Do not reuse.
10. Circlip 21. Low speed synchronizer key : Apply transaxle oil.
11. Input shaft 4th gear 22. 2nd gear synchronizer outer ring

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-29
Reassembly
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new ones 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) To ensure lubrication of input shaft (1), air blow oil
holes (2) and make sure that they are free from any
obstruction.4) Fit high speed synchronizer sleeve (4) to hub (3),
insert 3 keys (2) in it and then set springs (1) as
shown in figure.
NOTE
• No specific direction is assigned to high
speed synchronizer sleeve or each key but
it is assigned as assembly.
• Size of high speed synchronizer sleeve,
hub, keys and springs are the smaller than
those of low speed one.

Synchronizer key installation position
A = B
5) Drive in right bering (1) to input shaft (2) using
special tool and hydraulic press.
Special tool
(A): 09913–80113
I5JB0A520054-01
I2RH01520049-01
[A]: 4th gear side
C: Left side (Short flange)
D: Key way
E: Projecting end
I5RW0A520033-01
I3RH0A520019-01

Downloaded from www.Manualslib.com manuals search engine 5B-30 Manual Transmission/Transaxle:
6) Install 3rd gear needle bearing (4), apply oil to it,
then install 3rd gear (1) and synchronizer ring (2).
7) Drive in high speed sleeve & hub assembly (3) by
using special tool and hydraulic press.
NOTE
• While press-fitting sleeve & hub, make
sure that synchronizer ring key slots are
aligned with keys (5) in sleeve & hub
assembly.
• Check free rotation of 3rd gear after press-
fitting sleeve & hub assembly.
• Synchronizer rings for 3rd and 4th are
identical.

Special tool
(B): 09913–845108) Install circlip (1) and confirm that circlip is installed in
groove securely. Install needle bearing (2) of apply
oil to it and then install synchronizer ring (3) and 4th
gear (4).
9) Press-fit left bearing (2) by using special tool and
hydraulic press.
Special tool
(A): 09913–80113
10) Using the same special tool at step 9), drive in 5th
gear spacer (1).
CAUTION!
To prevent 5th gear spacer (1) from being
distorted because of excessive compression,
do not press-fit it with left bearing (2) at once.

[A]: 3rd gear side
A: Key way
B: Long boss
B
[A]3
(B)
4A 5
21
I5RW0A520034-02
5. Input shaft
I2RH01520052-01
I3RH0A520020-01

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 Manual Transmission/Transaxle: 5B-33
5) Fit low speed synchronizer sleeve (4) to hub (3),
insert 3 keys (2) in it and then set springs (1) as
shown in figure.
NOTE
• No specific direction is assigned to each
key but it is assigned as sleeve & hub
assembly.
• Size of low speed synchronizer keys and
springs are the larger than those of high
speed one.

Synchronizer key installation position
A = B
6) Install right bearing cone (1) to counter shaft (2) by
using special tools and hydraulic press.
Special tool
(A): 09913–76010
(B): 09924–077207) Install needle bearing (4), apply oil to it, then install
1st gear and 1st gear synchronizer ring (2).
8) Drive in low speed sleeve & hub assembly (1) by
using special tools and hammer.
NOTE
• Support shaft with special tool as shown in
figure so that retainer of bearing cone (4)
will be free from compression.
• Make sure that synchronizer ring key slots
are aligned with keys (5) while press-fitting
sleeve & hub assembly.
• Check free rotation of 1st gear (3) after
press-fitting sleeve & hub assembly.

Special tool
(A): 09923–78210
(B): 09913–85210
(C): 09940–54910
(D): 09924–07710
[A]: 1st gear side
C: Key way
I5RW0A520037-01
(A)
(B)
2
1
I5RW0A520038-01
[A]: 1st gear side
A: Key slots
B: Short flange
I5RW0A520039-01

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