2006 SUZUKI SX4 check engine light

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-8
2) Using special tool, install input shaft bearing to
flywheel (1).
Special tool
(B): 09925–98210
3) Aligning clutch disc to flywheel center using special
tool, install clutch cover (1) and bolts (2). Then
tighten bolts (2) to specification.
NOTE
• While tightening clutch cover bolts,
compress clutch disc with special tool
(clutch center guide) by hand so that disc
is centered.
• Tighten cover bolts little by little evenly in
diagonal order.

Special tool
(A): 09924–17811
(B): 09923–36320
Tightening torque
Clutch cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)4) Slightly apply grease to input shaft (1), then join
manual transaxle assembly with engine referring to
“Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
“A”: Grease 99000–25210 (SUZUKI Super
Grease I)
NOTE
When inserting transaxle input shaft to clutch
disc, turn crankshaft little by little to match
the splines.

Clutch Cover, Clutch Disc and Flywheel
Inspection
S6RW0D5306012
Input Shaft Bearing
Check bearing (1) for smooth rotation and replace it if
abnormality is found.
I4RS0A530016-01
I4RS0A530017-01
1
“A”I5RW0A530013-01
I3RM0A530014-01

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

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-6
3) Install steering column upper cover (1) and lower
cover (2).
CAUTION!
When installing covers, be careful so that
each lead wire is not caught between covers.
Otherwise, each lead wire is damaged.

4) Install steering wheel to steering column. Refer to
“Steering Wheel Removal and Installation”.
5) Connect negative (–) cable to battery.
6) Enable air bag system referring to “Enabling Air Bag
System in Section 8B”.
Centering Contact Coil Cable AssemblyS6RW0D6206004
1) Check that vehicle’s wheels (front tires) are set at
straight-ahead position.
2) Check that ignition switch is at LOCK position.
3) Turn contact coil counterclockwise slowly with a light
force till contact coil will not turn any further.
NOTE
Contact coil can turn about 5 turns at the
maximum, that is, if it is at the center
position, can turn about two and a half turns
both clockwise and counterclockwise.

4) From the position where contact coil became unable
to turn any further (it stopped), turn it back clockwise
about two and a half rotations and align center mark
with alignment mark (1).
Contact Coil Cable Assembly InspectionS6RW0D6206005
Refer to “Contact Coil Cable and Its Circuit Check in
Section 8B”.
Steering Column Removal and InstallationS6RW0D6206008
CAUTION!
Once the steering column is removed from
the vehicle, the column is extremely
susceptible to damage.
• Dropping the column assembly on its end
could collapse the steering shaft or loosen
the plastic shear pins which maintain
column length.
• Leaning on the column assembly could
cause it to bend or deform.
Any of the damage could impair the column’s
collapsible design.
Steering column mounting nuts should not
be loosened with steering shaft joint upper
side bolt tightened as this could cause
damage to shaft joint bearing.

NOTE
When servicing steering column or any
column-mounted component, remove
steering wheel. But when removing steering
column simply to gain access to instrument
panel components, leave steering wheel
installed on steering column.

3. Standard screw 4. Tapping screw
2
1
3
4
I6RW0B620003-01
I4RS0A620012-01
1
I4RS0A620013-01

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-8
3) Align flat part “a” of steering lower shaft (1) with bolt
hole “b” of shaft joint (2) of column as shown. Then
insert lower shaft into shaft joint of steering column.
4) Tighten lower shaft upper joint bolt (3) to specified
torque.
CAUTION!
After tightening column nuts, tighten steering
shaft upper joint bolt. Otherwise, shaft joint
bearing is damaged.

Tightening torque
Steering lower shaft assembly upper joint bolt
(a): 25 N·m (2.5 kgf-m, 18.5 lb-ft)
5) Install lighting switch and wiper switch to steering
column.
6) (Immobilizer model)
Install immobilizer control module from steering
column, referring to “ICM Removal and Installation in
Section 10C”.
7) Install contact coil cable assembly and steering
wheel referring to “Contact Coil Cable Assembly
Removal and Installation” and “Steering Wheel
Removal and Installation”.
8) Connect negative (–) cable to battery.
9) Enable air bag system referring to “Enabling Air Bag
System in Section 8B”.
Steering Column InspectionS6RW0D6206009
Check steering column for damage and operation
referring to “Checking Steering Column for Accident
Damage”.
Ignition Switch Cylinder Assembly Removal
and Installation (Non- Keyless Start Model)
S6RW0D6206010
Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air
Bag System in Section 8B”.
3) Remove steering column upper and lower covers.
4) (Immobilizer model)
Remove immobilizer control module referring to
“ICM Removal and Installation in Section 10C”.
5) Remove ignition switch cylinder assembly as follows.
a) Turn ignition key to “ACC” position.
b) Insert 2 mm (0.078 in.) rod (2) through hole (3)
and push ignition switch cylinder lock.
c) Detach ignition switch cylinder assembly (1) from
steering lock assembly (4).
Installation
1) Install ignition switch cylinder assembly as follows.
a) Turn ignition key to “ACC” position.
b) In this state, push ignition switch cylinder
assembly into steering lock assembly till it clicks.
2) (Immobilizer model)
Install immobilizer control module referring to “ICM
Removal and Installation in Section 10C”.
3) Install upper and lower cover and screws.
4) Connect negative (–) cable to battery.
5) Enabling air bag system referring to “Enabling Air
Bag System in Section 8B”.
6) (Immobilizer model)
If ignition switch cylinder assembly (that is ignition
key) has replaced, register ignition key transponder
code to ECM referring to “Registration of the Ignition
Key in Section 10C”.
1 2
“a”“b”
3, (a)
I5RW0A620007-01
2
3
1
4
I5JB0A620025-01

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-3
EPS Diagnosis General DescriptionS6RW0D6301002
The P/S system in this vehicle is controlled by the P/S control module. The P/S control module has an on-board
diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full
understanding of the outline of “On-Board Diagnostic System Description” and each item in “Precautions in
Diagnosing Troubles”, and then execute diagnosis according to “EPS System Check”.
On-Board Diagnostic System DescriptionS6RW0D6301003
The P/S control module performs the on-board diagnosis (self-diagnosis) on the system and operates the “EPS”
warning light (1) as follows.
• The “EPS” warning light lights when the ignition switch is turned to ON position (but the engine at stop) regardless
of the condition of the P/S control system. This is only to check if the “EPS” warning light is operated properly.
• If the areas monitored by the P/S control module is free from any trouble after the engine start (while engine is
running), the “EPS” warning light turns OFF.
• When the P/S control module detects a trouble which has occurred in the monitored areas the “EPS” warning light
comes ON while the engine is running to warn the driver of such occurrence of the trouble and at the same time it
stores the exact trouble area in memory inside of the P/S control module.
Driving Cycle
A “Driving Cycle” consists of engine startup and engine shutoff.
3 Driving Cycles Detection Logic
The malfunction detected in the first and second driving cycle is stored in P/S control module memory (in the form of
pending DTC) but the “EPS” warning light does not light at these time. It lights up at the third detection of same
malfunction also in the next driving cycle.
1
I7RW01632002-01

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-6 Power Assisted Steering System:
NOTE
• As execution of “DTC Clearance” will clear all DTCs, be sure to record all DTCs before service.
• DTC C1122 is indicated when ignition switch is at ON position and engine is not running, it means
that nothing is abnormal.
• Current DTC and history DTC can be identified by condition of the “EPS” warning light.
“EPS” warning light operates as follows.

8) Steering symptom diagnosis and P/S system
symptom diagnosis
1) Check and repair according to “Steering Symptom
Diagnosis in Section 6A” and “P/S System Symptom
Diagnosis”.
Are check and repair complete?Go to Step 11. Check and repair
malfunction part(s), and
go to Step 11.
9) Troubleshooting for DTC
1) Check and repair according to applicable DTC diag. flow.
Are check and repair complete?Go to Step 11. Check and repair
malfunction part(s), and
go to Step 11.
10) Intermittent problems check
1) Check for intermittent problems referring to “Intermittent
Problems Check”.
Is there any faulty condition?Repair or replace
malfunction part(s), and
go to Step 11.Go to Step 11.
11) Final confirmation test
1) Clear DTC if any.
2) Perform final confirmation test referring to “Final
Confirmation Test”.
Is there any problem symptom, DTC or abnormal condition?Go to Step 6. End. Step Action Yes No
Current DTC is set.
(Abnormality exists at
present.)Only history DTC is set.
(Faulty condition occurred once
in the past, but normal condition
is detected at present.)Current and history DTC
exist.
“EPS” warning light
after engine startedRemains ON. Turns OFF. Remains ON.

Downloaded from www.Manualslib.com manuals search engine 6C-8 Power Assisted Steering System:
Step 8: Steering Symptom Diagnosis and P/S
System Symptom Diagnosis
Perform basic steering system check according to
“Steering Symptom Diagnosis in Section 6A” first. When
the end of the flow has been reached, check the parts of
the system suspected as a possible cause referring to
“P/S System Symptom Diagnosis” and based on
symptoms appearing on the vehicle (symptoms obtained
through steps of customer complaint analysis, trouble
symptom confirmation and/or basic P/S system check)
and repair or replace faulty parts, if any.
Step 9: Troubleshooting for DTC (See each DTC
Diag. Flow)
Based on the DTC indicated in Step 6 or 7 and referring
to the applicable DTC diag. flow, locate the cause of the
trouble, namely in a sensor, switch, wire harness,
connector, actuator, P/S control module or other part and
repair or replace faulty parts.
Step 10: Intermittent Problems Check
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 P/
S system is free from any abnormal conditions. If what
has been repaired is related to the DTC, clear the DTC
once, perform DTC confirmation procedure and confirm
that no DTC is indicated.
“EPS” Warning Light CheckS6RW0D6304002
1) Turn ignition switch to ON position (but without
running engine) and check if the “EPS” warning light
(1) lights up. If the light dose not light up, go to
““EPS” Warning Light Does Not Come ON with
Ignition Switch Turned ON before Engine Starts” of
the diagnostic flows.
2) Start engine and check that “EPS” warning light turns
OFF. If light remains ON and no DTC is stored in P/S
control module, go to ““EPS” Warning Light Remains
ON Steady after Engine Starts” for troubleshooting.
DTC CheckS6RW0D6304003
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector
(DLC) (1) located on underside of instrument panel
at driver’s seat side.
Special tool
(A): SUZUKI scan tool
3) Start engine.
4) Read DTC according to the instructions displayed on
SUZUKI scan tool. For further details, refer to
operator’s manual for SUZUKI scan tool.
NOTE
• If communication between SUZUKI scan
tool and the vehicle can not be
established, perform “DLC and Its
Communication Check (No communication
to P/S Control Module)”.
• DTC C1122 (engine speed signal failure) is
indicated when ignition switch is at ON
position and engine is not running, but it
means there is nothing abnormal if
indication changes to a normal one when
engine is started.

5) After completing the check, turn ignition switch to
OFF position and disconnect SUZUKI scan tool from
DLC.
1
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(A)
1I5RW0A630004-01