2006 SUZUKI SX4 Crankshaft

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-2
Condition Possible cause Correction / Reference Item
Motor not running (No
operating sound of
magnetic switch)Transmission range sensor is not in P or
N, or not adjusted (A/T model)Shift in P or N, or adjust sensor. (A/T model)
Battery run downRecharge battery.
Battery voltage too low due to battery
deteriorationReplace battery.
Poor contact in battery terminal
connectionRetighten or replace.
Loose grounding cable connectionRetighten.
Fuse set loose or blown offTighten or replace.
Poor contacting action of ignition switch
and magnetic switchReplace.
Lead wire coupler loose in placeRetighten.
Open-circuit between ignition switch and
magnetic switchRepair.
Open-circuit in pull-in coilReplace magnetic switch.
Brushes are seating poorly or worn
downRepair or replace.
Poor sliding of plunger and/or pinionRepair.
Faulty starting motor control relay“Main Relay, Fuel Pump Relay, Starting Motor
Control Relay, Throttle Actuator Control Relay
and Radiator Cooling Fan Relay Inspection in
Section 1C”.
Faulty ECM and its circuit“Inspection of ECM and Its Circuits in Section
1A”.
Motor not running
(Operating sound of
magnetic switch heard)Battery run downRecharge battery.
Battery voltage too low due to battery
deteriorationReplace battery.
Loose battery cable connectionsRetighten.
Burnt main contact point, or poor
contacting action of magnetic switchReplace magnetic switch.
Brushes are seating poorly or worn
downRepair or replace.
Weakened brush springReplace.
Burnt commutatorReplace armature.
Layer short-circuit of armatureReplace.
Crankshaft rotation obstructedRepair.
Starting motor running
but too slow (small
torque) (If battery and
wiring are satisfactory,
inspect starting motor)Insufficient contact of magnetic switch
main contactsReplace magnetic switch.
Layer short-circuit of armatureReplace.
Disconnected, burnt or worn
commutatorRepair commutator or replace armature.
Worn brushesReplace brush.
Weakened brush springsReplace spring.
Burnt or abnormally worn end bushReplace bush.
Starting motor running,
but not cranking engineWorn pinion tipReplace over-running clutch.
Poor sliding of over-running clutchRepair.
Over-running clutch slippingReplace over-running clutch.
Worn teeth of ring gearReplace flywheel (M/T model) or drive plate (A/
T model).
NoiseAbnormally worn bushReplace bush.
Worn pinion or worn teeth of ring gearReplace over-running clutch, flywheel (M/T
model) or drive plate (A/T model).
Poor sliding of pinion (failure in return
movement)Repair or replace.
Worn internal or planetary gear teethReplace.
Lack of oil in each partLubricate.

Downloaded from www.Manualslib.com manuals search engine 1J-8 Charging System:
3) After loosening generator bracket bolts (2) and pivot
bolt (3), adjust belt tension to specification described
at step 2) by loosening / tightening generator adjust
bolt (1).
4) Tighten generator bracket bolts and pivot bolt as
specified torque.
Tightening torque
Generator bracket bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Generator pivot bolt (b): 50 N·m (5.0 kgf-m, 36.0
lb-ft)
5) Check belt tension for specification after turning
crankshaft two rotations clockwise.
6) Tighten generator adjusting bolt (1) as specified
torque.
Tightening torque
Generator adjusting bolt (c): Tighten 7.0 N·m (
0.7 kgf-m, 5.0 lb-ft) by the specified procedure.
7) Connect negative cable at battery.
Water Pump / Generator Drive Belt Removal and
Installation
S6RW0D1A06007
Removal
1) Disconnect negative cable at battery.
2) If vehicle equipped with A/C, remove compressor
drive belt before removing water pump belt (1).
Refer to “Compressor Drive Belt Removal and
Installation in Section 7B” or “Compressor Drive Belt
Removal and Installation in Section 7B”.
3) Loosen generator bracket bolts (2) and generator
pivot bolt (3).
4) Loosen generator adjusting bolt (4), and then
remove water pump belt.
installation
1) Install belt (1) to water pump pulley (2), crankshaft
pulley (3) and generator pulley (4).
2) Adjust belt tension referring to “Water Pump /
Generator Drive Belt Tension Inspection and
Adjustment”.
3) If vehicle equipped with A/C, install compressor drive
belt referring to “Compressor Drive Belt Removal
and Installation in Section 7B” or “Compressor Drive
Belt Removal and Installation in Section 7B”.
4) Connect negative cable at battery.
a
I5RW0C160006-01
1, (c)
2, (a)
3, (b)
I5RW0C160007-01
4
23
1
I5RW0C160008-01
2
1
34I5RW0C160009-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-22
Special Tools and Equipment
Recommended Service MaterialS6RW0D2208001
Special ToolS6RW0D2208002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease H P/No.: 99000–25121)
09913–65810 09913–75510
Crankshaft bearing puller Bearing installer
)) / ) / )
09913–75821 09913–85230
Bearing installer attachment Bearing remover tool
) / ))
09925–14520 09942–15511
Bearing and oil seal installer
(80 x 50 mm)Sliding hammer
))
09943–17912 09943–25010
Wheel hub remover Spring compressor
))
09943–37910 09943–76310
Bearing installer & remover Bush remover
)) / )
09944–78220
Bearing installer support
)

Downloaded from www.Manualslib.com manuals search engine 5A-26 Automatic Transmission/Transaxle:
Scan Tool Data Definitions:
GEAR POSITION
Current gear position computed by throttle position
coming from ECM and vehicle speed.
ENGINE SPEED (RPM)
Engine speed computed by reference pulses from
crankshaft position sensor.
INPUT SHAFT REVOLUTION (RPM)
Input shaft revolution computed by reference pulses
coming from input shaft speed sensor on transaxle case.
OUTPUT SHAFT REVOLUTION (RPM)
Output shaft revolution computed by reference pulses
coming from output shaft speed sensor (VSS) on
transaxle case.
BATTERY VOLTAGE (V)
Battery voltage read by TCM as analog input signal by
TCM.
ATF TEMPERATURE (°C, °F)
ATF temperature decided by signal from transmission
fluid temperature sensor installed on valve body.
SHIFT SOLENOID-A COMMAND
ON: ON command being outputted to shift solenoid
valve-A (No.1)
OFF: ON command not being outputted to shift solenoid
valve-A (No.1)
SHIFT SOLENOID-A MONITOR
ON: Electricity being passed to shift solenoid valve-A
(No.1)
OFF: Electricity not being passed to shift solenoid valve-
A (No.1)
SHIFT SOLENOID-B COMMAND
ON: ON command being outputted to shift solenoid
valve-B (No.2)
OFF: ON command not being outputted to shift solenoid
valve-B (No.2)
SHIFT SOLENOID-B MONITOR
ON: Electricity being passed to shift solenoid valve-B
(No.2)
OFF: Electricity not being passed to shift solenoid valve-
B (No.2)
TIMING SOLENOID COMMAND
ON: ON command being outputted to timing solenoid
valve
OFF: ON command not being outputted to timing
solenoid valve
TIMING SOLENOID MONITOR
ON: Electricity being passed to timing solenoid valve
OFF: Electricity not being passed to timing solenoid
valveTCC SOLENOID
Electric current value ratio between electric current value
being outputted from TCM to solenoid and maximum
value can be outputted by TCM.
PRESSURE CONTROL SOLENOID
Electric current value ratio between electric current value
being outputted from TCM to solenoid and maximum
value can be outputted by TCM.
VEHICLE SPEED (KPH/MPH)
Vehicle speed computed by reference pulse signals
coming from vehicle speed sensor on transaxle case.
“3” POSITION SWITCH
Inputted signal from “3” position switch in select lever
assembly.
ON: Shift select lever to “3” or “2” range
OFF: Shift select lever to other above range
TRANSAXLE RANGE
Transaxle range detected by signal fed from
transmission range sensor.
D RANGE SIGNAL
ON: Signal which TCM require ECM to increase idle
speed
OFF: Signal which TCM does not require ECM to
increase idle speed
THROTTLE POSITION (%)
Throttle opening ratio computed by duty signal from
ECM.
BRAKE SWITCH
Inputted signal from brake light switch on pedal bracket.
ON: Brake pedal depressed
OFF: Brake pedal released
TORQUE REDUCTION SIGNAL
ON: Signal which TCM require ECM to reduce output
torque at shifting gear
OFF: Signal which TCM does not require ECM to reduce
output torque
ENGINE COOLANT TEMPERATURE (°C, °F)
Engine coolant temperature computed by duty signal
from ECM.
AIR CONDITIONER SIGNAL
ON: Signal which inform that air conditioner compressor
is turned ON.
OFF: Signal which inform that air conditioner
compressor is not turned ON.
SLIP RPM (RPM)
This parameter indicates slipping rotation in the torque
converter (difference between input shaft rotation and
engine rotation)

Downloaded from www.Manualslib.com manuals search engine 5A-28 Automatic Transmission/Transaxle:
Troubleshooting
Condition Possible cause Correction / Reference Item
Unable to run in all rangeFaulty valve body componentReplace valve body assembly.
Faulty oil pumpInspect. If NG, replace.
Seized or broken planetary gearInspect. If NG, replace.
Faulty one-way No.2 clutchInspect. If NG, replace.
Faulty forward clutchInspect. If NG, replace.
Faulty reverse clutchInspect. If NG, replace.
Faulty 1st and reverse brakeInspect. If NG, replace.
Damaged drive plateInspect. If NG, replace.
Faulty torque converterReplace.
No gear shift as 3rd gearMalfunction of shift solenoid valve-A
and/or -BInspect. If NG, replace.
Malfunction of timing solenoid valveInspect. If NG, replace.
Malfunction of pressure control solenoid
valveInspect. If NG, replace valve body assembly.
1
→ 2 upshift fails to
occurMalfunction of shift solenoid valve-BInspect. If NG, replace.
Malfunction of output shaft speed
sensor (VSS)Inspect. If NG, replace.
Malfunction of throttle position sensorInspect. If NG, replace.
Malfunction of transmission range
sensorInspect. If NG, replace.
Faulty valve body componentReplace valve body assembly.
Faulty 2nd brakeInspect. If NG, replace.
Faulty one-way No.1 clutchInspect. If NG, replace.
2
→ 3 upshift fails to
occurMalfunction of shift solenoid valve-AInspect. If NG, replace.
Malfunction of output shaft speed
sensor (VSS)Inspect. If NG, replace.
Malfunction of throttle position sensorInspect. If NG, replace.
Malfunction of transmission range
sensorInspect. If NG, replace.
Faulty valve body componentReplace valve body assembly.
Faulty direct clutchInspect. If NG, replace.
3
→ 4 upshift fails to
occurMalfunction of shift solenoid valve-BInspect. If NG, replace.
Malfunction of “3” position switchInspect. If NG, replace.
Malfunction of engine coolant
temperature sensorInspect. If NG, replace.
Malfunction of output shaft speed
sensor (VSS)Inspect. If NG, replace.
Malfunction of input shaft speed sensorInspect. If NG, replace.
Malfunction of throttle position sensorInspect. If NG, replace.
Malfunction of transmission range
sensorInspect. If NG, replace.
Malfunction of crankshaft position
sensorInspect. If NG, replace.
Malfunction of timing solenoid valveInspect. If NG, replace.
Malfunction of transmission fluid
temperature sensorInspect. If NG, replace.
Malfunction of pressure control solenoid
valveInspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Faulty O/D and 2nd coast brakeInspect. If NG, replace.
Gear shift point is
incorrectAbnormal engine conditionInspect and repair engine.
Malfunction of output shaft speed
sensor (VSS)Inspect. If NG, replace.
Malfunction of throttle position sensorInspect. If NG, replace.
Malfunction of pressure control solenoid
valveInspect. If NG, replace valve body assembly.

Downloaded from www.Manualslib.com manuals search engine 5A-34 Automatic Transmission/Transaxle:
A/T Symptom DiagnosisS6RW0D5104017
Trouble Diagnosis 1
Electrical repair
Condition Possible cause Correction / Reference Item
Excessive shift shockShift solenoid valve-A and/or -B circuit
faultyInspect circuit for open, short and intermittent.
If NG, repair.
Pressure control solenoid valve circuit
faultyInspect circuit for open, short and intermittent.
If NG, repair.
Timing solenoid valve circuit faulty only
when N → D or 3 ↔ 4 shiftingInspect circuit for open, short and intermittent.
If NG, repair.
Output shaft speed sensor (VSS) circuit
faultyInspect circuit for open, short and intermittent.
If NG, repair.
Input shaft speed sensor circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Transmission fluid temperature sensor
circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
CAN communication circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Throttle position sensor circuit faultyInspect circuit for open, short and intermittent
referring to “DTC P0122: Throttle Position
Sensor (Main) Circuit Low in Section 1A” and/
or “DTC P0123: Throttle Position Sensor
(Main) Circuit High in Section 1A”. If NG, repair.
Crankshaft position sensor circuit faultyInspect circuit for open, short and intermittent
referring to “DTC P0335: Crankshaft Position
(CKP) Sensor Circuit in Section 1A”. If NG,
repair.
TCMSubstitute a known-good TCM and recheck.
ECMSubstitute a known-good ECM and recheck.
No gear shift as 3rd gearShift solenoid valve-A and/or -B circuit
faultyInspect circuit for open, short and intermittent.
If NG, repair.
Pressure control solenoid valve circuit
faultyInspect circuit for open, short and intermittent.
If NG, repair.
Timing solenoid valve circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
TCMSubstitute a known-good TCM and recheck.
Poor 1
→ 2 shiftShift solenoid valve-B circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Output shaft speed sensor (VSS) circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Transmission range sensor circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
CAN communication circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Throttle position sensor circuit faultyInspect circuit for open, short and intermittent
referring to “DTC P0122: Throttle Position
Sensor (Main) Circuit Low in Section 1A” and/
or “DTC P0123: Throttle Position Sensor
(Main) Circuit High in Section 1A”. If NG, repair.
TCMSubstitute a known-good TCM and recheck.
ECMSubstitute a known-good ECM and recheck.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-35
Poor 2 → 3 shiftShift solenoid valve-A circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Output shaft speed sensor (VSS) circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Transmission range sensor circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
CAN communication circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Throttle position sensor circuit faultyInspect circuit for open, short and intermittent
referring to “DTC P0122: Throttle Position
Sensor (Main) Circuit Low in Section 1A” and/
or “DTC P0123: Throttle Position Sensor
(Main) Circuit High in Section 1A”. If NG, repair.
TCMSubstitute a known-good TCM and recheck.
ECMSubstitute a known-good ECM and recheck.
Poor 3
→ 4 shiftShift solenoid valve-B circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Pressure control solenoid valve circuit
faultyInspect circuit for open, short and intermittent.
If NG, repair.
Timing solenoid valve circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Output shaft speed sensor (VSS) circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Input shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Transmission range sensor circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Transmission fluid temperature sensor
circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
CAN communication circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Throttle position sensor circuit faultyInspect circuit for open, short and intermittent
referring to “DTC P0122: Throttle Position
Sensor (Main) Circuit Low in Section 1A” and/
or “DTC P0123: Throttle Position Sensor
(Main) Circuit High in Section 1A”. If NG, repair.
Engine coolant temperature sensor
circuit faultyInspect circuit for open, short and intermittent
referring to “DTC P0117: Engine Coolant
Temperature Circuit Low in Section 1A” and/or
“DTC P0118: Engine Coolant Temperature
Circuit High in Section 1A”. If NG, repair.
Crankshaft position sensor circuit faultyInspect circuit for open, short and intermittent
referring to “DTC P0335: Crankshaft Position
(CKP) Sensor Circuit in Section 1A”. If NG,
repair.
“3” position switch circuit faultyInspect. If NG, repair.
TCMSubstitute a known-good TCM and recheck.
ECMSubstitute a known-good ECM and recheck. Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 5A-38 Automatic Transmission/Transaxle:
Trouble Diagnosis 2
On-vehicle repair
Condition Possible cause Correction / Reference Item
Unable to run in all rangeFaulty valve body componentReplace valve body assembly.
Excessive shift shockEngine abnormal conditionInspect and repair engine.
Malfunction of shift solenoid valve-A
and/or -BInspect. If NG, replace.
Malfunction of output shaft speed
sensor (VSS)Inspect. If NG, replace.
Malfunction of input shaft speed sensorInspect. If NG, replace.
Malfunction of transmission range
sensorInspect. If NG, replace.
Malfunction of transmission fluid
temperature sensorInspect. If NG, replace.
Malfunction of timing solenoid valve only
when N → D or 3 ↔ 4 shiftingInspect. If NG, replace.
Malfunction of pressure control solenoid
valveInspect. If NG, replace valve body assembly.
Malfunction of brake light switch except
N → D or N → R shiftingInspect referring to “Brake Light Switch
Inspection in Section 9B”. If NG, replace.
Malfunction of crankshaft position
sensorInspect referring to “Camshaft Position (CMP)
Sensor Inspection in Section 1C”. If NG,
replace.
Malfunction of Accelerator pedal
position (APP) sensorInspect referring to “Accelerator Pedal Position
(APP) Sensor Assembly On-Vehicle Inspection
in Section 1C”. If NG, replace.
Faulty valve body componentReplace valve body assembly.
Poor 1
→ 2 shiftMalfunction of shift solenoid valve-BInspect. If NG, replace.
Malfunction of output shaft speed
sensor (VSS)Inspect. If NG, replace.
Malfunction of transmission range
sensorInspect. If NG, replace.
Malfunction of Accelerator pedal
position (APP) sensorInspect referring to “Accelerator Pedal Position
(APP) Sensor Assembly On-Vehicle Inspection
in Section 1C”. If NG, replace.
Faulty valve body componentReplace valve body assembly.
Poor 2
→ 3 shiftMalfunction of shift solenoid valve-AInspect. If NG, replace.
Malfunction of output shaft speed
sensor (VSS)Inspect. If NG, replace.
Malfunction of transmission range
sensorInspect. If NG, replace.
Malfunction of Accelerator pedal
position (APP) sensorInspect referring to “Accelerator Pedal Position
(APP) Sensor Assembly On-Vehicle Inspection
in Section 1C”. If NG, replace.
Faulty valve body componentReplace valve body assembly.