2006 SUZUKI SX4 rear assembly

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-24
DTC Troubleshooting
Step Action Yes No
1Was “ABS Check” performed?Go to Step 2. Go to “ABS Check”.
2Check tire condition
1) Check that tire pressure is specifications.
Are they in good condition?Go to Step 3. Replace tire or adjust
tire pressure and
recheck.
3Wheel speed sensor circuit check
1) Disconnect ABS hydraulic unit / control module
connector and applicable wheel speed sensor connector
with ignition switch turned OFF.
2) Check for proper connection to ABS hydraulic unit /
control module connector at applicable terminals and
terminals of applicable wheel speed sensor.
3) If OK then check applicable wheel speed sensor circuit
for open, short and high resistance.
Is each applicable wheel speed sensor circuit in good
condition?Go to Step 4. Repair circuit and
recheck
4Wheel speed sensor check
1) Inspection applicable wheel speed sensor referring to
“Front and Rear Wheel Speed Sensor Inspection”.
Is it in good condition?Go to Step 5. Clean or replace.
5Wheel speed sensor encoder check
1) Inspection applicable wheel speed sensor encoder
referring to “Front Wheel Speed Sensor Encoder On-
Vehicle Inspection” and/or “Rear Wheel Speed Sensor
Encoder On-Vehicle Inspection”.
Is it in good condition?Go to Step 6. Clean or replace wheel
hub assembly.
6Wheel speed sensor signal check
1) Inspection applicable wheel speed sensor referring to
“Front and Rear Wheel Speed Sensor On-Vehicle
Inspection”.
Is it in good condition?Substitute a known-
good wheel hub
assembly and recheck.
If DTC detected,
substitute a known-
good ABS hydraulic unit
/ control module and
recheck.Replace wheel speed
sensor and recheck.

Downloaded from www.Manualslib.com manuals search engine 4E-25 ABS:
DTC C1033: Wheel Speed Sensor DeviationS6RW0D4504016
Wiring Diagram
Refer to “Wiring Diagram” under “DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel
Speed Sensor Circuit / Sensor or Encoder”.
DTC Detecting Condition and Trouble Area
DTC Troubleshooting DTC Detecting Condition Trouble Area
• Three or more sensor signals seem to be effected by
temporary failure suspicion at the same time.
• One wheel or more are controlled by ABS for more than
specified time.• Wheel speed sensor
• Wheel speed sensor circuit
• Wheel encoder
• ABS control module
• Tire (flat tire)
Step Action Yes No
1Was “ABS Check” performed?Go to Step 2. Go to “ABS Check”.
2Check DTC for ABS
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Turn ignition switch ON and check DTC for ABS.
Is DTC C1021, C1022, C1025, C1026, C1031, C1032,
C1035 and/or C1036 detected together?Go to “DTC C1021 /
C1022 / C1025 / C1026
/ C1031 / C1032 /
C1035 / C1036: Wheel
Speed Sensor Circuit /
Sensor or Encoder” and
recheck.Go to Step 3.
3Check tire condition
1) Check that tire pressure is specifications.
Are they in good condition?Go to Step 4. Replace tire or adjust
tire pressure and
recheck.
4Wheel speed sensor circuit check
1) Disconnect ABS hydraulic unit / control module
connector and all wheel speed sensor connectors with
ignition switch turned OFF.
2) Check for proper connection to ABS hydraulic unit /
control module connector and terminals of wheel speed
sensor.
3) If OK then check all wheel speed sensors circuit for
open, short and high resistance.
Are wheel speed sensor circuits in good condition?Go to Step 5. Repair circuit and
recheck.
5Wheel speed sensor check
1) Inspection all wheel speed sensors referring to “Front
and Rear Wheel Speed Sensor Inspection”.
Are they in good condition?Go to Step 6. Clean or replace.
6Wheel speed sensor encoder check
1) Inspection all wheel speed sensor encoders referring to
“Front Wheel Speed Sensor Encoder On-Vehicle
Inspection” and “Rear Wheel Speed Sensor Encoder
On-Vehicle Inspection”.
Are they in good condition?Go to Step 7. Clean or replace wheel
hub assembly.
7Wheel speed sensor signal check
1) Inspection all wheel speed sensors referring to “Front
and Rear Wheel Speed Sensor On-Vehicle Inspection”.
Are they in good condition?Substitute a known-
good wheel hub
assembly and recheck.
If DTC detected,
substitute a known-
good ABS hydraulic unit
/ control module and
recheck.Replace wheel speed
sensor and recheck.

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-26
DTC C1041 / C1042 / C1045 / C1046 / C1051 / C1052 / C1055 / C1056: Inlet / Outlet SolenoidS6RW0D4504017
DTC C1041 / C1045 / C1051 / C1055: Right-Front / Left-Front / Right-Rear / Left- Rear Inlet Solenoid
DTC C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / Left- Rear Outlet Solenoid
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Troubleshooting
WHT/BLU
1 2
5
3
BLK
E08-24
E08-23
6 4
E08 [A]
1
2
3
4
5
6
7 12
13
14
15
16
17
18
19
20
21
228
9
10
11
23
24
25
26
I7RW01450008-02
[A]: ABS control module assembly connector (viewed from terminal side) 4. ABS hydraulic unit / control module assembly
1. Battery5. Solenoid valve power supply driver (transistor)
2. Main fuse box6. Solenoid valve driver
3. Solenoid valve
DTC Detecting Condition Trouble Area
DTC C1041, C1042, C1045, C1046, C1051, C1052,
C1055, C1056:
• Solenoid valve circuit is opened, shorted to power,
ground and/or each valve in ABS hydraulic unit / control
module assembly.
• Mismatching solenoid output and solenoid monitor is
detected.• ABS control module
Step Action Yes No
1Was “ABS Check” performed?Go to Step 2. Go to “ABS Check”.
2ABS hydraulic unit / control module power source
circuit check
1) Turn ignition switch to OFF position.
2) Disconnect ABS hydraulic unit / control module
connector.
3) Check for proper connection to ABS hydraulic unit /
control module connector at terminal “E08-24” and “E08-
23”.
4) If OK, then measure voltage between terminal “E08-24”
of module connector and “E08-23”.
Is it 10 – 14 V?Substitute a known-
good ABS hydraulic unit
/ control module
assembly and recheck.“WHT/BLU” or “BLK”
circuit open or high
resistance.

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-34
Installation
1) Install hydraulic unit / control module assembly by
reversing removal procedure noting the following.
Install ABS hydraulic unit / control module assembly
bracket bolt as follows.
a) Tighten bracket bolt (1) and (2) by hand.
b) Then tighten bracket bolt to specified torque.
Tightening order (1) → (2)
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft)
ABS hydraulic unit / control module assembly
bolt (b): 9 N·m (0.9 kgf-m, 6.5 lb-ft)
ABS hydraulic unit / control module assembly
bracket bolt (c): 26 N·m (2.6 kgf-m, 19.0 lb-ft)2) Bleed air from brake system referring to “Air
Bleeding of Brake System in Section 4A”.
3) Check each installed part for fluid leakage and
perform “ABS Hydraulic Unit Operation Check”.
NOTE
For new ABS hydraulic unit / control module
assembly, if “ABS Hydraulic Unit Operation
Check” has not been performed, ABS
warning light may flash when ignition switch
is turned ON position.
Accordingly preform “ABS Hydraulic Unit
Operation Check” to stop flashing of ABS
warning light.

Front and Rear Wheel Speed Sensor On-Vehicle
Inspection
S6RW0D4506005
Output Voltage Inspection
1) Disconnect negative (–) cable from battery.
2) Hoist vehicle a little.
3) Disconnect wheel speed sensor connector.
4) Set up measuring device as shown in figure, the
resistance to 115 Ω and the power supply voltage to
12 V.
CAUTION!
Incorrect voltage and/or wrong connection
cause damage to wheel speed sensor.

I6RW0C450011-01
1. Wheel speed sensor connector 4. “BLK” wire terminal
2. Resistance (115Ω) 5. Power supply (12 V)
3. “WHT” wire terminal
V
41
3
2
5
I5JB0A450026-03

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-36
Installation
1) Check that no foreign material is attached to sensor
(1) and wheel speed sensor encoder (included in
wheel hub assembly).
2) Install it by reversing removal procedure.
NOTE
Before fitting wheel speed sensor, be sure to
silicon grease to its O-ring.

Tightening torque
Front wheel speed sensor bolt (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
Front wheel speed sensor harness clamp bolt
(b): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Check that there is no clearance between sensor
and knuckle.
Front and Rear Wheel Speed Sensor InspectionS6RW0D4506007
Check sensor for damage.
If any malcondition is found, replace.
Rear Wheel Speed Sensor Removal and
Installation (4WD Model)
S6RW0D4506008
CAUTION!
Rear wheel speed sensor is included in rear
wheel hub assembly. If rear wheel speed
sensor needs to be replaced, replace it as a
rear wheel hub assembly.

For removal and Installation of rear wheel speed sensor
(included in rear wheel hub), refer to “Rear Wheel Hub
Assembly Removal and Installation in Section 2C”.
Rear Wheel Speed Sensor Removal and
Installation (2WD Model)
S6RW0D4506009
CAUTION!
• Do not pull wire harness when removing
and installing rear wheel speed sensor.
• Do not cause damage to surface of rear
wheel speed sensor and do not allow dust,
etc. to enter its installation hole.

Removal
1) Disconnect negative (–) cable from battery.
2) Hoist vehicle, and remove wheel.
3) Disconnect rear wheel speed sensor connector.
4) Remove harness clamp.
5) Remove rear wheel speed sensor from wheel hub.
Installation
1) Check that no foreign material is attached to sensor
and encoder (included in wheel hub assembly).
2) Install it by reversing removal procedure.
NOTE
Before fitting wheel speed sensor, be sure to
silicon grease to its O-ring.

Tightening torque
Rear wheel speed sensor bolt: 11 N·m (1.1 kgf-
m, 8.0 lb-ft)
3) Check that there is no clearance between sensor
and wheel hub.[A]: OK [B]: NG
1
2
(b)
(a)
I5RW0A450025-01
[A][B]
11
I5RW0A450024-01
I5JB0A450031-01
[A]: OK [B]: NG
[A][B]
11
I5RW0A450024-01

Downloaded from www.Manualslib.com manuals search engine 4E-37 ABS:
Front Wheel Speed Sensor Encoder On-Vehicle
Inspection
S6RW0D4506010
Before inspecting front wheel speed sensor encoder,
remove front drive shaft referring to “Front Drive Shaft
Assembly Removal and Installation in Section 3A”.
• Check sensor encoder (1) for crack, damage or
deformation.
• Turn wheel and check if sensor encoder rotation is
free from eccentricity and looseness.
• Check that no foreign material is attached.
If any faulty is found, clean or replace. Refer to “Front
Wheel Hub, Steering Knuckle and Wheel Bearing
Removal and Installation in Section 2B”.
Front Wheel Speed Sensor Encoder Removal
and Installation
S6RW0D4506011
CAUTION!
Front wheel speed sensor encoder is
included in front wheel hub assembly. If front
wheel speed sensor encoder needs to be
replaced, replace it as a front wheel hub
assembly.

For removal and installation of front wheel hub
assembly, referring to “Front Wheel Hub, Steering
Knuckle and Wheel Bearing Removal and Installation in
Section 2B”.
Rear Wheel Speed Sensor Encoder On-Vehicle
Inspection
S6RW0D4506012
For 4WD model
Refer to “Rear Wheel Speed Sensor On-Vehicle
Inspection”.
For 2WD model
Before inspecting rear wheel speed sensor encoder,
remove rear wheel speed sensor referring to “Rear
Wheel Speed Sensor Removal and Installation (2WD
Model)”.
• Check encoder (1) for crack, damage or deformation.
• Turn wheel and check if encoder rotation is free from
eccentricity and looseness.
• Check that no foreign material is attached.
If any faulty is found, clean or replace. Refer to “Rear
Wheel Hub Assembly Removal and Installation in
Section 2C”.
Rear Wheel Speed Sensor Encoder Removal
and Installation
S6RW0D4506013
CAUTION!
Rear wheel speed sensor encoder is included
in rear wheel hub assembly. If rear wheel
speed sensor encoder needs to be replaced,
replace it as a rear wheel hub assembly.

For removal and installation of front wheel hub
assembly, referring to “Rear Wheel Hub Assembly
Removal and Installation in Section 2C”.
1
I5RW0A450026-01

Downloaded from www.Manualslib.com manuals search engine 4E-39 ABS:
Specifications
Tightening Torque SpecificationsS6RW0D4507001
NOTE
The specified tightening torque is also described in the following.
“ABS Hydraulic Unit / Control Module Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Special ToolS6RW0D4508001
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Brake pipe flare nut 16 1.6 11.5)
ABS hydraulic unit / control module assembly
bolt90.9 6.5)
ABS hydraulic unit / control module assembly
bracket bolt26 2.6 19.0)
Front wheel speed sensor bolt 11 1.1 8.0)
Front wheel speed sensor harness clamp bolt 11 1.1 8.0)
Rear wheel speed sensor bolt 11 1.1 8.0)
G sensor bolt 3.0 0.3 2.2)
09950–78220 SUZUKI scan tool
Flare nut wrench (10 mm) —
)This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12. ) / )

Downloaded from www.Manualslib.com manuals search engine 5-ii Table of Contents
DTC P1723: Range Select Switch
Malfunction ...................................................... 5A-68
DTC P1878: Torque Converter Clutch
Shudder .......................................................... 5A-69
DTC P2762: Torque Converter Clutch (TCC)
Pressure Control Solenoid Control Circuit
Range / Performance ...................................... 5A-70
DTC P2763: Torque Converter Clutch (TCC)
Pressure Control Solenoid Control Circuit
High ................................................................. 5A-72
DTC P2764: Torque Converter Clutch (TCC)
Circuit Pressure Control Solenoid Control
Circuit Low ...................................................... 5A-74
DTC U0073: Control Module Communication
Bus Off ............................................................ 5A-76
DTC U0100: Lost Communication with ECM /
PCM “A” .......................................................... 5A-76
Inspection of TCM and Its Circuits .................... 5A-76
TCM Power and Ground Circuit Check ............. 5A-80
Brake Interlock System Inspection .................... 5A-81
Repair Instructions ............................................5A-82
Learning Control Initialization ............................ 5A-82
A/T Fluid Level Check ....................................... 5A-82
A/T Fluid Change .............................................. 5A-83
Select Lever Components ................................. 5A-84
Select Lever Assembly Removal and
Installation ....................................................... 5A-84
Select Lever Knob Installation........................... 5A-84
Select Lever Inspection ..................................... 5A-85
“3” Position Switch Inspection ........................... 5A-85
Shift Lock Solenoid Inspection .......................... 5A-85
Shift Lock Solenoid Replacement ..................... 5A-85
Select Cable Components ................................ 5A-86
Select Cable Removal and Installation ............. 5A-86
Select Cable Adjustment ................................... 5A-86
Key Interlock Cable Removal and Installation... 5A-87
Transmission Range Sensor Inspection and
Adjustment ...................................................... 5A-89
Output Shaft Speed Sensor (VSS) Removal
and Installation ................................................ 5A-90
Output Shaft Speed Sensor (VSS) Inspection .. 5A-90
Input Shaft Speed Sensor Removal and
Installation ....................................................... 5A-91
Input Shaft Speed Sensor Inspection................ 5A-91
Transmission Fluid Temperature Sensor
Removal and Installation ................................. 5A-91
Transmission Fluid Temperature Sensor
Inspection ........................................................ 5A-92
Solenoid Valves (Shift Solenoid Valves and
Timing Solenoid Valve) Removal and
Installation ....................................................... 5A-92
Solenoid Valves (Shift Solenoid Valves and
Timing Solenoid Valve) Inspection .................. 5A-94
Pressure Control Solenoid Valves (Pressure
Control Solenoid and TCC Solenoid)
Removal and Installation ................................. 5A-95
Pressure Control Solenoid Valves Inspection ... 5A-96
Transmission Control Module (TCM)
Removal and Installation ................................. 5A-97
A/T Relay Inspection ......................................... 5A-97Differential Side Oil Seal Replacement ............. 5A-98
A/T Fluid Cooler Hoses Replacement ............... 5A-98
Automatic Transaxle Unit Components............. 5A-99
Automatic Transaxle Unit Dismounting and
Remounting ................................................... 5A-100
Automatic Transaxle Assembly Components . 5A-102
Automatic Transaxle Unit Disassembly........... 5A-104
Oil Pump Assembly Components ................... 5A-116
Oil Pump Assembly Disassembly and
Reassembly .................................................. 5A-116
Oil Pump Assembly Inspection ....................... 5A-117
Direct Clutch Assembly Components.............. 5A-119
Direct Clutch Assembly Preliminary Check ..... 5A-119
Direct Clutch Assembly Disassembly and
Reassembly .................................................. 5A-120
Direct Clutch Assembly Inspection.................. 5A-122
Forward and Reverse Clutch Assembly
Components .................................................. 5A-123
Forward and Reverse Clutch Assembly
Preliminary Check ......................................... 5A-123
Forward and Reverse Clutch Assembly
Disassembly and Reassembly ...................... 5A-124
Forward and Reverse Clutch Assembly
Inspection ...................................................... 5A-127
2nd Brake Piston Assembly Components ....... 5A-128
2nd Brake Piston Assembly Disassembly and
Reassembly .................................................. 5A-128
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Components........... 5A-129
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Disassembly and
Reassembly .................................................. 5A-130
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Inspection............... 5A-131
Countershaft Assembly Components.............. 5A-132
Countershaft Assembly Disassembly and
Reassembly .................................................. 5A-132
Valve Body Assembly Components ................ 5A-133
Valve Body Assembly Disassembly and
Reassembly .................................................. 5A-134
Differential Assembly Components ................. 5A-135
Differential Assembly Disassembly and
Reassembly .................................................. 5A-136
Differential Assembly Inspection ..................... 5A-137
Torque Converter Housing Disassembly and
Reassembly .................................................. 5A-138
Transaxle Case Disassembly and
Reassembly .................................................. 5A-140
Automatic Transaxle Unit Inspection and
Adjustment .................................................... 5A-141
Automatic Transaxle Unit Assembly ............... 5A-144
Specifications ...................................................5A-161
Tightening Torque Specifications .................... 5A-161
Special Tools and Equipment .........................5A-162
Recommended Service Material ..................... 5A-162
Special Tool .................................................... 5A-162
Manual Transmission/Transaxle ............ 5B-1
General Description .............................................5B-1
Manual Transaxle Construction .......................... 5B-1