2006 SUZUKI SX4 Output speed sensor

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-135
Reassembly
Reverse disassembly procedure for assembly, noting the
following points.
• Shift solenoid valve-A and -B are identical
• After applying A/T fluid to new O-rings, fit them to
solenoid valves, then install solenoid valves to valve
body.
• Tighten solenoid valve bolts to specified torque
Tightening torque
Solenoid valve bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Solenoid valve bolt specification
Differential Assembly ComponentsS6RW0D5106052
Bolt Length “a” Pieces
A (1) 49 mm (1.93 in.) 5
B (2) 20 mm (0.79 in.) 1
C (3) 60 mm (2.36 in.) 1
1
1 1
3
2
"a"
I4RS0A510046-01
I5RW0C510064-01
1. Differential side RH bearing 5. Side bearing shim : Apply automatic transaxle fluid.
2. Output shaft speed sensor (VSS) drive gear 6. Final gear bolt : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft)
3. Differential case subassembly 7. Side bearing cup : Do not reuse.
4. Final gear 8. Differential side LH bearing

Downloaded from www.Manualslib.com manuals search engine 5A-136 Automatic Transmission/Transaxle:
Differential Assembly Disassembly and
Reassembly
S6RW0D5106053
Disassembly
1) Remove final gear bolts (1), and then final gear (2).
2) Remove differential side RH bearing by using special
tools.
Special tool
(A): 09926–37610
(B): 09926–37610–001
(C): 09926–37610–003
(D): 09926–37610–002
3) Remove output shaft speed sensor (VSS) drive gear
(1).4) Remove differential side LH bearing by using special
tools.
Special tool
(A): 09926–37610
(B): 09926–37610–001
(C): 09926–37610–003
(D): 09926–37610–002
Reassembly
WARNING!
• When taking warmed final driven gear out
of vessel, use tongs or the like. Taking out
it with bare hand will cause severe burn.
• While installing warmed final driven gear,
use oven glove such as leather glove.
Picking up it with bare hand may cause
burn.

CAUTION!
Do not leave final driven gear in boiling water
for longer than 5 min. Overheating the gear
may cause strength reduction of gear.

1) Put final driven gear in water vessel, heat and
remove when it boils, then remove moisture.
NOTE
After removing moisture on final driven gear,
install final driven gear to differential case as
quickly as possible.

2. Differential case subassembly
I2RH0B510225-01
I2RH0B510226-01
I2RH0B510227-01
I2RH0B510228-01
I2RH0B510229-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-137
2) As shown in figure, facing groove (2) side upward,
install final driven gear (1) to differential case.
3) Tighten final gear bolts (1) to specified torque.
NOTE
To avoid rust, apply A/T fluid to final driven
gear after installation.

Tightening torque
Final gear bolt (a): 78 N·m (7.8 kgf-m, 56.5 lb-ft)
4) After applying A/T fluid to output shaft speed sensor
(VSS) drive gear (1), install output shaft speed
sensor drive gear.
5) Install new differential side RH bearing (1) by using
special tool and hydraulic press.
NOTE
Replace differential side RH bearing together
with bearing cup as a set.

Special tool
(A): 09913–701236) Install new differential side LH bearing (1) by using
special tool and hydraulic press.
NOTE
Replace differential side LH bearing together
with bearing cup as a set.

Special tool
(A): 09913–70123
Differential Assembly InspectionS6RW0D5106054
1) Hold differential case subassembly with soft jawed
vice and set special tools as shown.
Special tool
(A): 09900–20607
(B): 09900–20701
2) Measure differential gear thrust play.
Differential gear thrust play
Standard: 0.06 – 0.22 mm (0.002 – 0.009 in.)
3) If thrust play is out of specification, replace
differential case subassembly.
2. Final driven gear
I2RH0B510230-01
I2RH0B510231-01
I2RH0B510232-01
I2RH0B510233-01
I2RH0B510234-01
I2RH0B510235-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-159
83) Install select cable bracket (1).
Tightening torque
Select cable bracket bolt (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
84) Apply A/T fluid to O-rings of each sensor and install
input shaft speed sensor (1) and output shaft speed
sensor (VSS) (2).
Tightening torque
Input shaft speed sensor bolt (a): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
Output shaft speed sensor (VSS) bolt (b): 13
N·m (1.3 kgf-m, 9.5 lb-ft)
85) Install harness bracket and select cable clamp (3).
Tightening torque
Select cable clamp bolt (c): 13 N·m (1.3 kgf-m,
9.5 lb-ft)
86) Install transmission range sensor to transaxle case,
tighten bolts temporarily at this step.87) Install lock washer (1) and tighten lock nut (2) to
specified torque.
Tightening torque
Transmission range sensor lock nut (a): 7 N·m (
0.7 kgf-m, 5.0 lb-ft)
88) Install manual select lever (1) temporarily at this
step.
89) After shifting manual select lever counterclockwise
fully, select “N” range position by bringing it back 2
notches clockwise.
90) Remove manual select lever (1) at this step.
91) Loosen sensor bolts (4) and align needle direction
shaped on lock washer (2) with “N” reference line (3)
on transmission range sensor by moving sensor in
rotative direction.
92) Tighten sensor bolts to specified torque.
Tightening torque
Transmission range sensor bolt (b): 5.5 N·m (
0.55 kgf-m, 4.0 lb-ft)
93) Bend dents of lock washer (1) in order to prevent
displacement of lock washer.
1
(a)I5RW0C510069-02
(a)13
(c)
2(b)
I2RH0B510330-01
1I2RH0B510331-01
1
2, (a)
I2RH0B510332-01
132
4, (b)
4, (b)
I2RH0B510333-01
I2RH0B510334-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-161
Specifications
Tightening Torque SpecificationsS6RW0D5107001
NOTE
The specified tightening torque is also described in the following.
“Select Cable Components”
“Automatic Transaxle Unit Components”
“Automatic Transaxle Assembly Components”
“Oil Pump Assembly Components”
“Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components”
“Valve Body Assembly Components”
“Differential Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
A/T fluid drain plug 17 1.7 12.5) / ) / )
Transmission range sensor bolt 5.5 0.55 4.0) / )
Output shaft speed sensor (VSS) bolt 13 1.3 9.5) / )
Input shaft speed sensor bolt 5.5 0.55 4.0) / )
Valve body harness connector bolt 5.5 0.55 4.0) / )
Shift solenoid bolt 11 1.1 8.0)
Oil strainer bolt 10 1.0 7.5) / )
Oil pan bolt 7.0 0.7 5.0) / )
Engine oil pan bolt 55 5.5 40.0)
Transaxle and engine fastening bolt 85 8.5 61.5)
Transaxle and engine fastening nut 85 8.5 61.5)
Drive plate to torque converter bolt 19 1.9 14.0)
Transaxle housing lower plate bolt 11 1.1 8.0)
Oil pump subassembly bolt 10 1.0 7.5)
Rear cover plug 7.5 0.75 5.5)
Solenoid valve bolt 11 1.1 8.0)
Final gear bolt 78 7.8 56.5)
Torque converter housing plug 7.5 0.75 5.5)
Lubrication tube clamp bolt 5.5 0.55 4.0)
Fluid reservoir RH plate bolt 5.5 0.55 4.0)
Torque converter housing bolt 33 3.3 24.0) / ) / )
Manual detent spring bolt 10 1.0 7.5)
Parking lock pawl bracket bolt 7.5 0.75 5.5)
Rear cover bolt 25 2.5 18.0)
Fluid reservoir LH plate bolt 10 1.0 7.5)
Oil pump assembly bolt 25 2.5 18.0)
Transaxle case plug 7.5 0.75 5.5)
Valve body bolt 11 1.1 8.0)
Fluid cooler pipe union 25 2.5 18.0)
Fluid cooler pipe union bolt 35 3.5 25.5)
Fluid cooler pipe bracket bolt 10 1.0 7.5)
Fluid filler tube bolt 10 1.0 7.5)
Select cable bracket bolt 23 2.3 17.0)
Select cable clamp bolt 13 1.3 9.5)
Transmission range sensor lock nut 7 0.7 5.0)
Manual select lever nut 13 1.3 9.5)

Downloaded from www.Manualslib.com manuals search engine 6C-4 Power Assisted Steering System:
Schematic and Routing Diagram
EPS System Wiring Circuit DiagramS6RW0D6302001
[A]
123
45
3 21
4
567
8
9 11
10 12 13
141516
17 18 19201
2
[B]
1
2
[C] [D]
10 9 8 7654 3 21
16 15 14 13 12 11
26 25 24 2322 21 20 19 18 17
32 31 30 29 28 27
[F][E]
12
BRN RED/
BLU GRY LT GRN/
BLK
BLK
RED
WHT GRN
BLK
E11-1
E11-5
E11-14
E11-12
[J]:E01-44E01-4
[J]:E01-27E01-26
E12-1
E12-2
E11-10E11-8
E11-9
E11-19
E13-1 GRN
GRY
GRN
WHT
G241-25G241-31
RED/BLK
11
12
1314 3 18
20
21
7 19
4 12
22
12V
E13-2BLK
9V
REDE11-20
12V
12V
E61-2
E61-1
610
55
5V
8
E11-115V
PPL
E11-4
9
23
+BB
BLU/
WHTE04-9
1524YELE11-18E31-5
E31-2
E31-39V
3V
E31-4
E31-1IG11617
C07-25
[H]
[G]
G04-15
[I]:G04-22
25L313-3
[I]
I6RW0D630001-01
[A]: P/S control module connector No.1 “E11” (viewed from harness side) 3. Junction block assembly 15. BCM
[B]: P/S control module connector No.2 “E13” (viewed from harness side) 4. Main fuse 16. Output shaft speed sensor
[C]: P/S control module connector No.3 “E12” (viewed from harness side) 5. Front (left/right) wheel speed sensor 17. TCM
[D]: Combination meter connector “G241” (viewed from harness side) 6. ABS control module 18. Individual circuit fuse box No.1
[E]: Torque sensor connector “E31” (viewed from harness side) 7. Combination meter 19. “IGN” fuse
[F]: Motor connector “E61” (viewed from harness side) 8. “EPS” warning light 20. “P/S” fuse
[G]: M/T model 9. Data link connector (DLC) 21. “IG1 SIG” fuse
[H]: A/T model 10. ECM 22. “MTR” fuse
[I]: Junction block without BCM model (Taiwan model) 11. P/S control module 23. To ABS control module
[J]: M15A engine with 4A/T equipped with slip control model (Hong Kong
model)12. P/S motor 24. To HVAC control module
1. Main fuse box 13. Shield 25. To SDM
2. Ignition switch 14. Torque sensor (built into steering gear case)

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-5
Terminal Arrangement of P/S Control Module Coupler (Viewed from Harness Side)
Diagnostic Information and Procedures
EPS System CheckS6RW0D6304001
WARNING!
Carry out test drive in light traffic area to prevent an accident.

Refer to the following items for the details of each step.Terminal Circuit Terminal Circuit
E11-1Ignition switch signal for P/S control
moduleE11-13 —
E11-2 — E11-14 P/S active signal (idle up signal)
E11-3 — E11-15 —
E11-4 Vehicle speed signal E11-16 —
E11-5 “EPS” warning Light E11-17 —
E11-6 — E11-18 Torque sensor signal (Main)
E11-7 — E11-19 Ground for shield wire
E11-8 9 V power supply for torque sensor E11-20Reference sensor power supply for
torque sensor
E11-9 Ground for torque sensors E12-1 Motor output 1
E11-10 Torque sensor signal (Sub) E12-2 Motor output 2
E11-11Serial communication circuit for data
link connectorE13-1Main power supply for internal
memory and EPS motor
E11-12 Engine speed signal E13-2 Ground for P/S control module
Step Action Yes No
1) Customer complaint analysis
1) Perform customer complaint analysis referring to
“Customer Complaint Analysis”.
Was customer complaint analysis performed?Go to Step 2. Perform customer
complaint analysis.
2) DTC check, record and clearance
1) Check for DTC (including pending DTC) referring to
“DTC Check, Record and Clearance”.
Is there any DTC(s)?Print DTC or write them
down and clear them by
referring to “DTC
Clearance”, and go to
St ep 3 .Go to Step 4.
3) Visual inspection
1) Perform visual inspection referring to “Visual Inspection”.
Is there any faulty condition?Repair or replace
malfunction part, and go
to Step 11.Go to Step 5.
4) Visual inspection
1) Perform visual inspection referring to “Visual Inspection”.
Is there any faulty condition?Repair or replace
malfunction part, and go
to Step 11.Go to Step 8.
5) Trouble symptom confirmation
1) Confirm trouble symptom referring to “Trouble Symptom
Confirmation”.
Is trouble symptom identified?Go to Step 6. Go to Step 7.
6) Rechecking and record of DTC
1) Recheck for DTC referring to “DTC Check”.
Is there any DTC(s)?Go to Step 9. Go to Step 8.
7) Rechecking and record of DTC
1) Recheck for DTC referring to “DTC Check”.
Is there any DTC(s)?Go to Step 9. Go to Step 10.

Downloaded from www.Manualslib.com manuals search engine 6C-12 Power Assisted Steering System:
Scan Tool DataS6RW0D6304007
NOTE
When P/S motor is cold condition (that is, armature coil of P/S motor is not heated), normal value with
asterisk (*) mark in the following table is displayed on scan tool

Scan Tool Data Definitions
Power Supply Voltage
This parameter indicates battery positive voltage.
Sensor Power Supply (Torque Sensor Power Supply,
V)
This parameter indicates the power supply voltage which
the P/S control module supplies to the torque sensor.
Sensor (Main) Torque (Torque Sensor Main Torque,
N⋅m)
The torque sensor is installed to detect the steering force
and the steering direction. It consists of two
potentiometers and the main torque sensor is one of
these.
Sensor (Sub) Torque (Torque Sensor Sub Torque,
N⋅m)
The torque sensor is installed to detect the steering force
and the steering direction. It consists of two
potentiometers and the sub-torque sensor is one of
these. Its output characteristics are compared with those
of the main torque sensor.Control Torque (N⋅m)
This parameter is an internal parameter of the P/S
control module. It is obtained by computing the torque
sensor input signal.
Target Motor Current (Motor Control Current, A)
Based on the input signal, the P/S control module
determines the assist amount and controls the current to
the motor suitable for that assist amount. This parameter
indicates that control value.
Measured MOT Current (Motor Monitor Current, A)
This parameter indicates the actually measured value of
the current flowing to the motor. The motor circuit
condition is diagnosed by comparing this parameter with
“Motor Control” parameter described previously.
Vehicle Speed (km/h, MPH)
Vehicle speed signal is fed from BCM. P/S control
module determines the amount of power assist based on
this vehicle speed signal and the torque sensor signal.
Engine Speed (rpm)
Engine speed signal is fed from the ECM so that it can
be used for trouble diagnosis of the electric power
steering system. Scan tool data Vehicle condition Normal condition
) Power Supply Voltage
Ignition switch ON10 – 14 V
) Sensor Power Supply7.4 – 10 V
) Sensor (Main) TorqueEngine running at idle
speedSteering wheel at fully turned to left –10.5 – 0 N⋅m
Steering wheel at free 0 N⋅m
Steering wheel at fully turned to right 0 – 12.85 N⋅m
) Sensor (Sub) Torque Engine running at idle
speedSteering wheel at fully turned to left 0 – 10.65 N⋅m
Steering wheel at free 0 N⋅m
Steering wheel at fully turned to right –12.85 – 0 N⋅m
) Control TorqueEngine running at idle
speedSteering wheel at fully turned to left –7.22 – 0 N⋅m
Steering wheel at free 0 N⋅m
Steering wheel at fully turned to right 0 – 7.16 N⋅m
) Target Motor CurrentEngine running at idle
speedSteering wheel at free 0 A
Steering wheel at fully turned to left or
right*45 – 60 A
) Measured MOT
Current
Engine running at idle
speedSteering wheel at free 0 A
Steering wheel at fully turned to left or
right*45 – 60 A
) Vehicle Speed Engine running and vehicle at stop 0 km/h
) Engine Speed Engine running at idle speed after warming up 700 ± 50 rpm
) Motor Drive VoltageEngine running at idle
speedSteering wheel at free 0.8 – 1 V
Steering wheel at fully turned to right *5.5 – 8.5 V
) System Power Status
Ignition switch ONON
) IGN switch StatusON
) Torque sensor Status
Engine running at idle speedON
) Fail Safe FET StatusON