2006 SUZUKI SX4 wiring system

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 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 6C-14 Power Assisted Steering System:
DLC and Its Communication Check (No communication to P/S Control Module)S6RW0D6304009
Wiring Diagram
Troubleshooting
[A]
123
4567
8
9 11
10 12 13
141516
17 18 1920
1
2
[B]
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
[C]
LT GRN/BLKE11-1
E11-11
E13-1 GRN
GRN
WHT
8
13
318
19
20
5
6 17
4
12
712V
E13-2BLK
9
G241-31
+BB
BLU/
WHTE04-9
10
11
RED/BLK
G241-25E11-5GRY
L313-312
BLKBLK/
ORN
16
16
15
14[D]
I6RW0D630002-01
[A]: P/S control module connector No.1 “E11” (viewed from harness side) 5. Combination meter 13. Individual circuit fuse box No.1
[B]: P/S control module connector No2 “E13” (viewed from harness side) 6. “EPS” warning light 14. Serial data circuit
[C]: Combination meter connector “G241” (viewed from harness side) 7. Data link connector (DLC) 15. DLC power supply circuit
[D]: Junction block without BCM model (Taiwan model) 8. P/S control module 16. DLC ground circuit
1. Main fuse box 9. BCM 17. “IGN” fuse
2. Ignition switch 10. To HVAC control module 18. “P/S” fuse
3. Junction block assembly 11. To ABS control module 19. “IG1 SIG” fuse
4. Main fuse 12. To SDM 20. “MTR” fuse
Step Action Yes No
1“EPS” warning light check
1) Turn ignition switch to ON position.
Does “EPS” warning light turn on?Go to step 2. Go to ““EPS” Warning
Light Does Not Come
ON with Ignition Switch
Turned ON before
Engine Starts”.
2Scan tool condition check
1) Make sure that SUZUKI scan tool is as follows.
• Correct PCMCIA card (software) is used.
• There are no deformation and wear for DLC cable
terminals.
• Connection for DLC cable terminals is in good
condition.
Are they OK?Go to step 3. Repair or replace
defective part.

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-15
3Communication check
1) Check DLC terminal for deformation and wear.
2) If it is in good condition, connect SUZUKI scan tool to
DLC with ignition switch tuned OFF.
3) Check if communication is possible by making
communication with other control modules (BCM, ABS,
HVAC control module or SDM).
Is it possible to communicate with the other control
modules?Go to Step 4. Go to Step 6.
4Serial communication circuit check
1) With ignition switch turned OFF, disconnect “E11”
connector from P/S control module and check for proper
connection at P/S control module connector terminal.
2) If connections are OK, check that “Serial data circuit” is
as follows.
• Wiring resistance of “Serial data circuit” wire between
DLC connector and P/S control module connector is
less than 1 Ω.
Is it resistance less than 1
Ω?Go to Step 5. “Serial data circuit” is
open or high resistance.
5P/S control module power and ground circuit check
1) Check power supply circuit and ground circuit for P/S
control module referring to “P/S Control Module Power
Supply and Ground Circuit Check”.
Is check result in good condition?Substitute a known-
good P/S control
module and recheck.Repair or replace
defective circuit.
6DLC power and ground circuit check
1) Check power supply circuit and ground circuit for DLC
connector as follows.
• Voltage of “DLC connector power supply circuit”
between DLC connector terminal and vehicle body
ground is 10 –14 V with ignition switch turned ON.
• Wire resistance of each “DLC connector ground
circuit” between DLC connector terminal and vehicle
body ground is less than 1 Ω.
Is check result in good condition?Go to Step 7. Repair or replace
defective circuit.
7Serial communication circuit check
1) With ignition switch turned OFF, disconnect “E11”
connector from P/S control module and check for
terminal to P/S control module connector.
2) If connections are OK, check that “Serial data circuit” is
as follows.
• Insulation resistance of “Serial data circuit” wire is
infinity between its terminal and other terminals at P/S
control module connector.
• Insulation resistance of “Serial data circuit” wire is
infinity between its terminal and vehicle body ground.
Is circuit in good condition?Go to Step 8. Repair or replace
defective circuit. Step Action Yes No

Downloaded from www.Manualslib.com manuals search engine 6C-16 Power Assisted Steering System:
“EPS” Warning Light Does Not Come ON with Ignition Switch Turned ON before Engine StartsS6RW0D6304010
Wiring Diagram8Scan tool operation check
1) Check if communication is possible by making
communication with other vehicles.
Is it possible to communicate with the other vehicle?Scan tool is in good
condition, check
intermittent trouble
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.Recheck PCMCIA card
and DLC cable for faulty
condition. If they are
OK, scan tool is faulty. Step Action Yes No
[A]
123
4567
8
9 11
10 12 13
141516
17 18 1920
1
2
[B]
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
[C]
LT GRN/BLKE11-1E13-1 GRNGRN
WHT
7
8
311
12
13
5
6 10
4 12
12V
E13-2BLK
G241-31
RED/BLK
G241-25E11-5GRY
9
I6RW0C630003-01
[A]: P/S control module connector No.1 “E11” (viewed from harness side) 4. Main fuse 10. “IGN” fuse
[B]: P/S control module connector No.2 “E13” (viewed from harness side) 5. Combination meter 11. “P/S” fuse
[C]: Combination meter connector “G241” (viewed from harness side) 6. “EPS” warning light 12. “IG1 SIG” fuse
1. Main fuse box 7. P/S control module 13. “MTR” fuse
2. Ignition switch 8. Individual circuit fuse box No.1
3. Junction block assembly 9. “EPS” warning light circuit

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-17
Circuit Description
Operation (ON/OFF) of “EPS” warning light is controlled by P/S control module through combination meter.
If the P/S system is in good condition, P/S control module turns “EPS” warning light ON at the ignition switch ON, and
then turns it OFF at the engine start. If an abnormality in the system is detected, “EPS” warning light is turned ON
continuously by P/S control module. If P/S control module is disconnected, “EPS” warning light is not turned ON.
Troubleshooting
Step Action Yes No
1“EPS” warning light power supply check
1) Turn ignition switch ON.
Do the other warning light come on?Go to Step 2. “GRN”, “RED/BLK” wire
circuit or circuit fuse for
combination meter is
open or short to ground.
2Fuse check
1) Turn ignition switch OFF.
2) Remove and inspect circuit fuse for P/S control module.
Is fuse in good condition?Reinstall fuse, and then
go to Step 3.Check “GRN” wire
circuit for short to
ground.
If OK, replace fuse.
3P/S control module power supply and ground circuit
check
Check power supply circuit and ground circuit for P/S control
module referring to “P/S Control Module Power Supply and
Ground Circuit Check”.
Is check result in good condition?Go to Step 4. Repair or replace
defective circuit.
4Combination meter power supply circuit check
1) Remove combination meter and disconnect combination
meter connector (“G241”) with ignition switch turned
OFF.
2) Check for proper connection to the combination meter at
“G241-31” terminal.
3) If OK, check voltage between “G241-31” (“RED/BLK”
wire) terminal and body ground with ignition switch ON.
Is it 10 – 14 V?Go to Step 5. “RED/BLK” wire circuit
is open or short to
ground.
5“EPS” warning light circuit resistance check
1) Check for proper connection to the combination meter at
“G241-25” terminal and P/S control module at “E11-5”
terminal.
2) Check that “EPS warning light circuit” is as follows.
• Insulation resistance of “EPS warning light circuit”
wire is infinity between its terminal and each terminal
at combination meter connector.
• Wiring resistance of “EPS warning light circuit” wire is
less than 1 Ω.
• Insulation resistance of “EPS warning light circuit”
wire is infinity between its terminal and vehicle body
ground.
Is circuit in good condition?“GRY” wire circuit is
open.Go to Step 6.
6“EPS” warning light circuit voltage check
1) Connect combination meter connector (“G241”) with
ignition switch turned OFF.
2) Check for voltage between “E11-5” (“GRY” wire) terminal
and body ground with ignition switch ON.
Is it 10 – 14 V?Replace the P/S control
module.Replace the
combination meter.

Downloaded from www.Manualslib.com manuals search engine 6C-18 Power Assisted Steering System:
“EPS” Warning Light Remains ON Steady after Engine StartsS6RW0D6304011
Wiring Diagram
Refer to ““EPS” Warning Light Does Not Come ON with Ignition Switch Turned ON before Engine Starts”.
Circuit Description
Operation (ON/OFF) of “EPS” warning light is controlled by P/S control module through combination meter.
If the P/S system is in good condition, P/S control module turns “EPS” warning light ON at the ignition switch ON, and
then turns it OFF at the engine start. If an abnormality in the system is detected, “EPS” warning light is turned ON
continuously by P/S control module. If P/S control module is disconnected, “EPS” warning light is not turned ON.
Troubleshooting
Step Action Yes No
1 Check DTC referring to “DTC Check”.
Is there any DTC(s) (NO CODES on SUZUKI scan tool)?Go to applicable DTC
diag. flow.Go to Step 2.
2“EPS” warning light circuit check
1) With ignition switch turned OFF, disconnect P/S control
module connector.
2) Check for proper connection to the P/S control module at
“E11-5” terminal.
3) If OK, then turn ignition switch to ON position.
Does “EPS” warning light turn ON?Go to Step 3. Replace P/S control
module.
3Combination meter ground circuit check
1) Remove combination meter and disconnect combination
meter connector with ignition switch turned OFF.
2) Check combination meter connector for proper
connection.
3) If connections are OK, check that “EPS warning light
circuit” is as follows.
• Insulation resistance of “EPS warning light circuit”
wire is infinity between its terminal and each terminal
at combination meter connector.
• Insulation resistance of “EPS warning light circuit”
wire is infinity between its terminal and vehicle body
ground.
Is circuit in good condition?Replace combination
meter.Repair defective circuit.

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-19
DTC C1111 / C1113 / C1115: Torque Sensor Circuit FailureS6RW0D6304012
DTC C1111: Steering Torque Sensor (Main) Circuit Voltage
DTC C1113: Steering Torque Sensor (Main and Sub) Circuit Correlation
DTC C1115: Steering Torque Sensor (Sub) Circuit Voltage
Wiring Diagram
DTC Detecting Condition and Trouble Area
[A]
123
453 21
4
5
67
8
9 11
10 12 13
141516
17 18 1920
1
2
[B]
[C]
LT GRN/
BLK
WHT GRN
BLK
E11-1
E11-10E11-8
E11-9
E11-19
E13-1 GRN
GRY
GRN
WHT
5
6
37
10
11
9
4 12
12V
E13-2BLK
9V
REDE11-20
5VYELE11-18E31-5
E31-2
E31-39V
E31-43V
E31-1
8
8
I6RW0C630004-02
[A]: P/S control module connector No.1 “E11” (viewed from harness side) 3. Junction block assembly 8. Torque sensor signal circuit
[B]: P/S control module connector No.2 “E13” (viewed from harness side) 4. Main fuse 9. “IGN” fuse
[C]: Torque sensor connector “E31” (viewed from harness side) 5. P/S control module 10. “P/S” fuse
1. Main fuse box 6. Torque sensor 11. “IG1 SIG” fuse
2. Ignition switch 7. Individual circuit fuse box No.1
DTC detecting condition Trouble area
DTC C1111:
Circuit voltage of sensor main is more than 4.5 V or less
than 0.5 V
(1 driving cycle detection logic)
DTC C1113:
Difference between steering torque calculated based on
sensor main signal and steering torque calculated based
on sensor sub signal is more than 4.9 N⋅m
or
Difference between instantaneous value and average
value of steering torque calculated based on sensor main
signal and steering torque calculated based on sensor sub
signal is more than 2.94 N⋅m
(1 driving cycle detection logic)
DTC C1115:
Circuit voltage of sensor sub signal is more than 4.5 V or
less than 0.5 V
(1 driving cycle detection logic)• Torque sensor signal circuit
• Torque sensor
• P/S control module