ECU SUZUKI SX4 2006 1.G Service Manual Online

Downloaded from www.Manualslib.com manuals search engine 5B-30 Manual Transmission/Transaxle:
6) Install 3rd gear needle bearing (4), apply oil to it,
then install 3rd gear (1) and synchronizer ring (2).
7) Drive in high speed sleeve & hub assembly (3) by
using special tool and hydraulic press.
NOTE
• While press-fitting sleeve & hub, make
sure that synchronizer ring key slots are
aligned with keys (5) in sleeve & hub
assembly.
• Check free rotation of 3rd gear after press-
fitting sleeve & hub assembly.
• Synchronizer rings for 3rd and 4th are
identical.

Special tool
(B): 09913–845108) Install circlip (1) and confirm that circlip is installed in
groove securely. Install needle bearing (2) of apply
oil to it and then install synchronizer ring (3) and 4th
gear (4).
9) Press-fit left bearing (2) by using special tool and
hydraulic press.
Special tool
(A): 09913–80113
10) Using the same special tool at step 9), drive in 5th
gear spacer (1).
CAUTION!
To prevent 5th gear spacer (1) from being
distorted because of excessive compression,
do not press-fit it with left bearing (2) at once.

[A]: 3rd gear side
A: Key way
B: Long boss
B
[A]3
(B)
4A 5
21
I5RW0A520034-02
5. Input shaft
I2RH01520052-01
I3RH0A520020-01

Downloaded from www.Manualslib.com manuals search engine 5B-34 Manual Transmission/Transaxle:
9) Install circlip (1) and confirm that circlip is installed in
groove securely.
Install needle bearing (2) and apply oil to needle
bearing.
With synchronizer outer ring (3), center cone (4) and
inner ring (5) put together and installed to 2nd gear
(6) as shown in figure.
10) Press-fit 3rd gear (2) and spacer (1) by using special
tools and hydraulic press.
NOTE
It is recommended to press-fit spacer and 3rd
gear first, and then 4th gear later separately
so that countershaft will not be compressed
excessively.

Special tool
(A): 09923–78210
(B): 09913–8521011) Press-fit 4th gear (2) by using the same procedure at
step 10).
12) Install left bearing cone (1) by using special tool and
hydraulic press.
NOTE
For protection of bearing cone (3), always
support shaft with special tool as shown in
figure.

Special tool
(A): 09923–78210
(E): 09913–80113
[A]: Section A – A
3. 2nd gear
I5RW0A520040-01
I4RH01520036-01
I2RH01520066-01

Downloaded from www.Manualslib.com manuals search engine 5C-1 Clutch:
Transmission / Transaxle
Clutch
General Description
Clutch (Hydraulic Type) ConstructionS6RW0D5301001
The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type,
which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward.
The disc, carrying four torsional coil springs, is positioned on the transaxle input shaft with an involute spline fit.
The clutch cover is secured to the flywheel, and carries the diaphragm spring in such a way that the peripheral edge
part of the spring pushes on the pressure plate against the flywheel (with the disc in between), when the clutch release
bearing (incorporated in clutch operating cylinder) is held back. This is the engaged condition of the clutch.
Depressing the clutch pedal causes the release bearing (incorporated in clutch operating cylinder) to advance and
pushes on the tips of the tapered fingers of the diaphragm spring. When this happens, the diaphragm spring pulls the
pressure plate away from the flywheel, thereby interrupting the flow of drive from flywheel through clutch disc to
transaxle input shaft. Clutch fluid is supplied from brake fluid reservoir. Clutch fluid level can be checked by brake fluid
level of brake fluid reservoir.
I5RW0A530001-01
1. Crankshaft 4. Pressure plate 7. Operating cylinder assembly
2. Flywheel 5. Clutch cover 8. Input shaft bearing
3. Clutch disc 6. Diaphragm spring 9. Input shaft

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-4
Clutch Fluid Pipe and Hose LocationS6RW0D5306004
Clutch Fluid Pipe Removal and InstallationS6RW0D5306005
Removal
CAUTION!
Do not allow fluid to get on painted surface. It
may cause painted surface damage.

1) Remove dust and dirt from each joint of pipe to be
disconnected and clean around brake master
cylinder reservoir cap.
2) Take out fluid with syringe or such from brake master
cylinder reservoir.
3) Pull clamp (1) of clutch master cylinder (3) and pull
clamp (5) of fluid pipe joint (4), and then disconnect
clutch fluid pipe (2).
4) Pull clamp (6) of damper (7), and then disconnect
damper (7) from clutch fluid pipe (2).Installation
Reverse removal procedure for installation noting the
following.
CAUTION!
• Do not allow fluid to get on painted
surface.
• Do not allow pipe to contact hard against
vehicle body or other parts.

• Install each clamp securely.
• After installation, check clutch pedal free travel and
bleed air from clutch system referring to “Clutch Pedal
Inspection” and “Air Bleeding of Clutch System”.
• Check fluid leakage.
• Add fluid to MAX level of reservoir.
Clutch Fluid Pipe InspectionS6RW0D5306006
Check pipe (1) for damage, dirt and leak. Replace if
check result is not satisfactory.
4 [A]
3131
22
4
I5RW0A530003-02
[A]: RH steering vehicle 3. Clutch reservoir hose
1. Clutch master cylinder 4. Brake master cylinder reservoir
2. Clutch fluid pipe
2
6
5 74
3
1
2
I5RW0B530002-03
[A]: LH steering vehicle
[B]: RH steering vehicle
I5RW0A530005-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-6
Installation
1) Install clutch operating cylinder assembly (2) to
transaxle. Tighten new mounting bolts to specified
torque.
Tightening torque
Clutch operating cylinder assembly mounting
bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
2) Connect clutch fluid pipe (4) to clutch operating
cylinder assembly temporarily.
3) Install clutch pipe joint sleeve (3) to transaxle
securely and then tighten clutch fluid pipe flare nut
(1) to specified torque.
Tightening torque
Clutch fluid pipe flare nut (b): 16 N·m (1.6 kgf-
m, 11.5 lb-ft)4) Remount transaxle assembly referring to “Manual
Transaxle Unit Dismounting and Remounting in
Section 5B”.
5) Bleed air from system and check clutch pedal free
travel. Refer to “Air Bleeding of Clutch System” and
“Clutch Pedal Inspection”.
Clutch Operating Cylinder Assembly InspectionS6RW0D5306013
Check clutch fluid leakage, spring for damage and
bearing for smooth rotation. If malfunction is found,
replace clutch operating cylinder assembly.
Clutch Cover, Clutch Disc and Flywheel ComponentsS6RW0D5306010
3
4
(a)
2
1, (b)
I5RW0A530009-01
I5RW0B530005-03
2
1
3(a)
6
4
5
(b)
I6RW0C530001-01
1. Clutch cover 4. Flywheel : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
2. Clutch disc 5. Input shaft bearing : 70 N⋅m (7.0 kgf-m, 51.0 lb-ft)
3. Clutch cover bolt 6. Flywheel bolt : Do not reuse.

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-2
Diagnostic Information and Procedures
Checking Steering Column for Accident
Damage
S6RW0D6204001
NOTE
Vehicles involved in accidents resulting in
body damage, where steering column has
been impacted or air bag deployed may have
a damaged or misaligned steering column.

• Check that two capsules (1) are attached to steering
column bracket securely. If found loose, replace
steering column assembly.
• Take measurement “a”, “b” and “c” as follows.
If it is shorter than specified length, replace steering
column assembly or steering lower shaft with new
one.
Steering column length
“a”: 339 ± 2 mm (13.3 ± 0.08 in.)
“b”: 59.5 ± 2.1 mm (2.4 ± 0.08 in.)
Steering lower shaft length
“c”: 348 ± 1 mm (13.7 ± 0.04 in.)• Check that there is no axial looseness “d” and no
axially-vertical looseness “e” for steering column
shaft.
If found defective, replace steering column assembly
with new one.
• Check steering shaft joints and shaft for any damages
such as crack, breakage, malfunction or excessive
play.
If anything is found faulty, replace as lower shaft
assembly or steering column assembly.
• Check steering shaft for smooth rotation.
If found defective, replace as steering column
assembly.
• Check steering shaft and steering column for bend,
cracks or deformation.
If found defective, replace.
1
1
I4RS0A620001-01
“a”
“d”
“e”“b”
“c”
I7RW01620002-01
I4RS0A620003-01

Downloaded from www.Manualslib.com manuals search engine 6B-5 Steering Wheel and Column:
4) Connect horn connector and audio control switch
connector, if necessary.
5) Install driver air bag (inflator) module to steering
wheel. Refer to “Driver Air Bag (Inflator) Module
Removal and Installation in Section 8B”.
6) Connect negative (–) cable to battery.
7) Enable air bag system referring to “Enabling Air Bag
System in Section 8B”.
Contact Coil Cable Assembly Removal and
Installation
S6RW0D6206003
CAUTION!
Do not turn contact coil more than allowable
number of turns (about two and a half turns
from the center position clockwise or
counterclockwise respectively), or coil will
break.

Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air
Bag System in Section 8B”.
3) Remove steering wheel from steering column
referring to “Steering Wheel Removal and
Installation”.
4) Remove steering column hole cover.
5) Remove steering column lower cover (2) and upper
cover (1).6) Remove contact coil cable assembly (1) from
steering column.
Installation
1) Check to make sure that vehicle’s front tires are set
at straight-ahead position and then ignition switch is
at LOCK position.
2) Install contact coil cable assembly to steering
column securely.
NOTE
New contact coil cable assembly is supplied
with contact coil set and held at its center
position with a lock pin (1). Remove this lock
pin after installing contact coil cable
assembly to steering column.

2
1
I6RW0B620005-01
1I6RW0B620009-02
I4RS0A620010-01

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 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 7B-20 Air Conditioning System: Manual Type
Charge
CAUTION!
• Because the sight glass is not used for this
A/C system, do not perform an additional
charge to the A/C system. To charge the
proper amount of refrigerant, recover and
evacuate the A/C system first. And then,
charge the proper amount of refrigerant
into the A/C system.
• Always charge refrigerant through low
pressure side of A/C system after the initial
charge is performed from the high
pressure side with the engine stopped.
• Never charge refrigerant through high
pressure side of A/C system with engine
running.
• Do not charge refrigerant while
compressor is hot.
• When installing tap valve to refrigerant
container to make a hole there through,
carefully follow directions given by
manufacturer.
• A pressure gauge should always be used
before and during refrigerant charge.
• The refrigerant container should be
emptied of refrigerant when discarding it.
• The refrigerant container should not be
heated up to 40 °C (104 °F) or over.
• Refrigerant container should not be
reversed in direction during refrigerant
charge. Reversing in direction causes
liquid refrigerant to enter compressor,
causing troubles, such as compression of
liquid refrigerant and the like.

NOTE
The air conditioning system contains HFC-
134a (R-134a).
Described here is a method to charge the air
conditioning system with refrigerant from the
refrigerant service container.
When charging refrigerant recovered by
using the refrigerant and recycling
equipment (when recycling refrigerant),
follow the procedure described in the
equipment manufacturer’s instruction
manual.

The initial charge of the A/C system is performed
through the high pressure side with the engine stopped.
And next, this method must be followed by charging from
the low pressure side with the engine running.
1) Check if hoses are routed properly after evacuating
the system.
2) Connect low charging hose (1) and high charging
hose (2) of the manifold gauge set (3) in position.
Then, open refrigerant container valve (4) to purge
the charging line.
3) Open the high pressure side valve (5) and charge
refrigerant to system.
4) After a while, open the low pressure side valve (6)
and close the high pressure side valve.
WARNING!
Make sure that high pressure side valve is
closed securely.

5) Start engine and keep engine speed at 1500 r/min,
and then operate A/C system.
6) Charge A/C system with refrigerant in vapor state. At
this time, refrigerant container should be held
upright.
4
3
6
2
1 5
I7RW01721012-01