Tcm SUZUKI SX4 2006 1.G Service Owners Manual

Downloaded from www.Manualslib.com manuals search engine 5A-74 Automatic Transmission/Transaxle:
DTC P2764: Torque Converter Clutch (TCC) Circuit Pressure Control Solenoid Control Circuit LowS6RW0D5104043
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out with 2 persons, a driver and a tester, on a level road.

1) Connect scan tool to DLC with ignition switch OFF, if available.
2) Clear DTC in TCM memory.
3) Start engine.
4) Keep engine running at idle speed in “P” range for 20 seconds or more.
5) Check DTC.
12V
C06-5
C06-3
WHT/BLU
WHT/BLK
3
1
2
53
C06C07
[A]
I6RW0D510007-01
1. TCM 3. A/T
2. TCC solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side)
DTC detecting condition Trouble area
Voltage of TCC solenoid valve TCM terminal is low although
TCM is commanding TCC solenoid valve to turn ON.• TCC solenoid valve circuit shorted to ground
• Malfunction of TCC solenoid valve
•TCM

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-75
DTC Troubleshooting
Step Action Yes No
1Was “A/T System Check” performed?Go to Step 2. Go to “A/T System
Check”.
2Check TCC solenoid valve resistance
1) Turn ignition switch OFF.
2) Disconnect valve body harness connector (1), (2) on
automatic transaxle.
3) Check for proper connection to solenoid at “WHT/BLU”
and “WHT/BLK” circuits.
4) Check resistance of TCC solenoid valve.
TCC solenoid valve resistance
Between shift terminals of transaxle side valve body
harness connector: 5.0 – 5.6 Ω at 20 °C (68 °F)
Between shift terminals of transaxle side valve body
harness connector and transaxle: Infinity
Is check results satisfactory?Go to Step 3. Replace TCC solenoid
valve or valve body
harness.
3Check TCC solenoid valve circuit for ground short
1) Disconnect TCM connectors.
2) Check for proper connection to TCM at terminals “C06-
3” and “C06-5”.
3) If connection is OK, check continuity between terminal
“C06-5” of disconnected harness side TCM connector
and ground, between terminal “C06-3” of disconnected
harness side TCM connector and ground.
Are continuity indicated?“WHT/BLU” or “WHT/
BLK” circuit shorted to
ground.Intermittent trouble or
faulty TCM.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.
If OK, substitute a
known-good TCM and
recheck.
1
6 7 8 9
1054
32
2
1
I5RW0C510023-01

Downloaded from www.Manualslib.com manuals search engine 5A-76 Automatic Transmission/Transaxle:
DTC U0073: Control Module Communication Bus OffS6RW0D5104051
Refer to “Troubleshooting for CAN-DTC in Section 1A”.
DTC U0100: Lost Communication with ECM / PCM “A”S6RW0D5104052
Refer to “Troubleshooting for CAN-DTC in Section 1A”.
Inspection of TCM and Its CircuitsS6RW0D5104044
TCM and its circuits can be checked at TCM wiring connectors by measuring voltage, pulse signal and resistance.
CAUTION!
TCM cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmeter to TCM with
connector disconnected from it.

1) Remove TCM (1) from vehicle referring to “Transmission Control Module (TCM) Removal and Installation”.
2) Connect TCM connectors (2) to TCM.
3) Check voltage and/or pulse signal at each terminal of connectors connected using voltmeter (3) and oscilloscope
(4).
NOTE
• As each terminal voltage is affected by battery voltage, confirm that it is 11 V or more when ignition
switch is ON.
• Voltage with asterisk(*) cannot be measured by voltmeter because it is pulse signal. Check it with
oscilloscope if necessary.

Terminal arrangement of TCM coupler (Viewed from harness side)
3
4
12
I4RS0A510021-02
65
16 15 14 13 12 1143
24 23 212210 9 8 721
19 20 18 17 C06
17 16
26 2515 14 65 342
13 12
23 22 2411 10 9
21 20 1987
18 1 C07
I6RW0B510018-01

Downloaded from www.Manualslib.com manuals search engine 5A-80 Automatic Transmission/Transaxle:
Reference waveform No. 5
Output shaft speed sensor (VSS) signal at vehicle speed
60 km/h (37 mile/h).
TCM Power and Ground Circuit CheckS6RW0D5104045
Wiring DiagramMeasurement
terminalCH1: “C07-25” to “C06-1”
Oscilloscope
settingCH1: 5 V/DIV
TIME: 20 ms/DIV
Measurement
condition• After warmed up to normal
operating temperature
• Drive vehicle at 60 km/h (37
mile/h).
I3RM0B510028-01
BLK
BLK
BLK
C06-1
C06-23
C06-6YEL/BLKYEL/BLU
LT GRN/BLK
+BB
C06-24WHT/RED1
23
6
24 231
C06C07
[A]
I6RW0B510019-01
1. TCM 3. Ignition switch
2. A/T relay [A]: Terminal arrangement of TCM connector (viewed from harness side)

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-81
Troubleshooting
Brake Interlock System InspectionS6RW0D5104046
1) Check that select lever cannot be moved to any
other range from “P” range position when ignition
switch key is at ACC position, at LOCK position or it
is removed from keyhole of ignition switch, or brake
pedal is not depressed.2) Shift select lever to “P” range position, check for the
following.
• Ignition key can be turned between LOCK and
ACC positions back and forth and also it can be
removed from ignition switch. Step Action Yes No
1Check TCM back-up power circuit
1) Disconnect TCM connector with ignition switch OFF.
2) Check for proper connection to TCM at “C06-24”
terminal.
3) If OK, check voltage at terminal “C06-24” of
disconnected TCM connector.
Is it 10 – 14 V?Go to Step 2. “WHT/RED” circuit open
or shorted to ground.
2Check TCM power circuit
1) Disconnect TCM connector with ignition switch OFF.
2) Check for proper connection to TCM at “C06-6” terminal.
3) If OK, turn ignition switch ON and check voltage at
terminal “C06-6” of disconnected TCM connector.
Is it 10 – 14 V?Go to Step 4. Go to Step 3.
3Check A/T relay operation
1) Check A/T relay operation referring to “A/T Relay
Inspection”.
Is check result satisfactory?“YEL/BLK”, “YEL/BLU”,
“LT GRN/BLK” or “BLK”
circuit for power supply
open.Replace A/T relay.
4Check TCM ground circuit
1) Turn ignition switch OFF.
2) With TCM connectors disconnected, check for proper
connection to TCM at “C06-1” / “C06-23” terminal.
3) If OK, check resistance between “C06-1” / “C06-23”
terminal of disconnected TCM connector and body
ground.
Is continuity indicated?TCM power and ground
circuits are in good
condition.“BLK” circuit for TCM
ground open.
I4RS0A510047-01
I4RS0A510048-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-97
Transmission Control Module (TCM) Removal
and Installation
S6RW0D5106021
CAUTION!
• TCM and ECM consists of highly precise
parts, therefore when handling it, be
careful not to expose to excessive shock.
• When replacing TCM with used one, all
learned contents, which have been stored
in TCM memory by executing learning
control, should be initialized after
replacement.

Removal
1) Disconnect negative cable at battery.
2) If the vehicle is equipped with air bag system,
disable air bag system. Refer to “Disabling Air Bag
System in Section 8B”.
3) Disconnect connectors from TCM (1).
4) Remove TCM by removing its nuts.Installation
Reverse removal procedure noting the following.
• Connect TCM connectors securely.
• If the vehicle is equipped with air bag system, be sure
to enable air bag system after TCM is back in place.
Refer to “Enabling Air Bag System in Section 8B”.
A/T Relay InspectionS6RW0D5106022
1) Disconnect negative cable at battery.
2) Remove A/T relay (2) from fuse and relay box (1).
3) Check that there is no continuity between terminal
“C” and “D”.
If continuity is indicated, replace A/T relay.
4) Connect battery positive (+) terminal to terminal “A”
of A/T relay and battery negative (–) terminal to
terminal “B” of A/T relay.
Check continuity between terminal “C” and “D” of A/T
relay.
If continuity does not indicated, replace A/T relay.
I4RS0A510031-01
1
I5RW0C510040-01
“D” “B”“C”21
“A”
I5RW0C510041-02

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-109
36) Remove 2nd brake gasket (1).
37) Measure O/D and 2nd coast brake piston stroke.
If piston stroke exceeds specification, inspect and
replace plates and discs.
• Measure dimension “a” from mating surface of
transaxle case to O/D and 2nd coast brake rear
plate (1) using straightedge and micrometer
caliper.
• Measure dimension “b” from O/D and 2nd coast
brake piston (2) to rear cover assembly mating
surface using straightedge and micrometer
caliper.
• Calculate piston stroke from measured value of
dimensions “a” and “b”.
• Piston stroke = “a” – “b”
O/D and 2nd coast brake piston stroke
Standard: 0.65 – 1.05 mm (0.026 – 0.041 in.)
CAUTION!
When brake disc, retaining plate, separator
plate and/or rear plate of O/D and 2nd coast
brake have been replaced, all learned
contents, which have been stored in TCM
memory by executing learning control,
should be initialized referring to “Learning
Control Initialization”.
Neglecting this initialization may cause
excessive shift shock.

38) Remove forward and reverse clutch assembly (1).
39) Remove intermediate shaft thrust bearing front race
(1), thrust bearing (2) and rear race (3) from forward
and reverse clutch assembly (4).
NOTE
If intermediate shaft thrust bearing and/or
races are not found on forward and reverse
clutch assembly, they may have been left in
transaxle.

I2RH0B510109-01
I2RH0B510110-01
I2RH0B510111-01
I2RH0B510112-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-111
48) Remove O/D and 2nd coast brake retaining plate
snap ring (1).
49) Remove front planetary sun gear (1).
50) Remove front sun gear thrust bearing race (2) from
front planetary sun gear (1).
51) Before disassembling 2nd brake piston assembly
(4), check 2nd brake piston stroke by measuring
clearance between 2nd brake separator plate (1)
and piston (2) with feeler gauge (3).
If clearance, that is, piston stroke is out of
specification, replace brake discs and plates with
new ones.
CAUTION!
When brake disc, retaining plate and/or
separator plate of 2nd brake have been
replaced, all learned contents, which have
been stored in TCM memory by executing
learning control, should be initialized
referring to “Learning Control Initialization”.
Neglecting this initialization may cause
excessive shift shock.

2nd brake piston stroke
“a”: 0.40 – 1.25 mm (0.016 – 0.049 in.)
52) Using special tool and hydraulic press, remove 2nd
brake piston snap ring (1).
CAUTION!
Do not press 2nd brake piston assembly in
over 0.4 mm (0.016 in.).
Excessive compression may cause damage
to piston assembly, return spring, plates and/
or discs.

Special tool
(A): 09926–96050
I2RH0B510120-01
I2RH0B510121-01
I2RH0B510122-01
3
4 1 2
“a”4
I2RH0B510123-01
I2RH0B510124-01

Downloaded from www.Manualslib.com manuals search engine 5A-120 Automatic Transmission/Transaxle:
Direct Clutch Assembly Disassembly and
Reassembly
S6RW0D5106037
CAUTION!
When clutch disc, retaining plate and/or
separator plate of direct clutch have been
replaced, all learned contents, which have
been stored in TCM memory by executing
learning control, should be initialized
referring to “Learning Control Initialization”.
Neglecting this initialization may cause
excessive shift shock.

Disassembly
1) Remove plate snap ring (1) then remove direct
clutch retaining plate, discs and separator plates.
2) Using special tool and hydraulic press, remove shaft
snap ring (1).
Special tool
(A): 09926–98310
CAUTION!
Do not press direct clutch return spring
subassembly in over 0.7 mm (0.027 in.).
Excessive compression may cause damage
to direct clutch return spring subassembly
and/or piston.

3) Remove direct clutch return spring assembly (2).4) Using a finger to block oil hole (1), apply
compressed air (400 – 800 kPa, 4 – 8 kg/cm
2, 57 –
113 psi) to opposite hole, which will assist in removal
of the clutch piston.
5) Remove outer O-ring (1).
6) Remove inner O-ring (2).
7) Remove input shaft seal rings (1).
I2RH0B510162-01
I2RH0B510163-01
2. Direct clutch piston
1. Input shaft subassembly
I2RH0B510164-01
I2RH0B510165-01
I2RH0B510166-01
I2RH0B510167-01

Downloaded from www.Manualslib.com manuals search engine 5A-124 Automatic Transmission/Transaxle:
2) Blow compressed air (400 – 800 kPa, 4 – 8 kg/cm2,
57 – 113 psi) through oil hole (1) of transaxle rear
cover with the special tool attached on the upper
surface of forward clutch retaining plate, and
measure forward clutch piston stroke.
If piston stroke exceeds specified value,
disassemble, inspect and replace inner parts.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
Forward clutch piston stroke
1.30 – 1.50 mm (0.051 – 0.059 in.)
Forward and Reverse Clutch Assembly
Disassembly and Reassembly
S6RW0D5106041
CAUTION!
When clutch disc, retaining plate and/or
separator plate of forward clutch have been
replaced, all learned contents, which have
been stored in TCM memory by executing
learning control, should be initialized
referring to “Learning Control Initialization”.
Neglecting this initialization may cause
excessive shift shock.

Disassembly
1) Remove reverse clutch plate snap ring (1) and take
out reverse clutch retaining plate, discs, separator
plates and clutch cushion plate from intermediate
shaft subassembly.2) Remove forward clutch plate snap ring (1) and take
out forward clutch retaining plate, discs and
separator plates from forward clutch drum.
3) Remove balancer snap ring by using special tool and
hydraulic press.
Special tool
(A): 09926–97610
CAUTION!
Do not press forward clutch return spring
subassembly in over 1.5 mm (0.059 in.).
Excessive compression may cause damage
to return spring subassembly and/or
balancer.

4) Remove forward clutch balancer (1).
5) Remove forward clutch return spring subassembly
(1).
I2RH0B510177-02
I2RH0B510178-01
2. Intermediate shaft subassembly
I2RH0B510179-01
I2RH0B510180-01
I2RH0B510181-01