meter SUZUKI SX4 2006 1.G Service Workshop Manual

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 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-12 Power Assisted Steering System:
Scan Tool DataS6RW0D6304007
NOTE
When P/S motor is cold condition (that is, armature coil of P/S motor is not heated), normal value with
asterisk (*) mark in the following table is displayed on scan tool

Scan Tool Data Definitions
Power Supply Voltage
This parameter indicates battery positive voltage.
Sensor Power Supply (Torque Sensor Power Supply,
V)
This parameter indicates the power supply voltage which
the P/S control module supplies to the torque sensor.
Sensor (Main) Torque (Torque Sensor Main Torque,
N⋅m)
The torque sensor is installed to detect the steering force
and the steering direction. It consists of two
potentiometers and the main torque sensor is one of
these.
Sensor (Sub) Torque (Torque Sensor Sub Torque,
N⋅m)
The torque sensor is installed to detect the steering force
and the steering direction. It consists of two
potentiometers and the sub-torque sensor is one of
these. Its output characteristics are compared with those
of the main torque sensor.Control Torque (N⋅m)
This parameter is an internal parameter of the P/S
control module. It is obtained by computing the torque
sensor input signal.
Target Motor Current (Motor Control Current, A)
Based on the input signal, the P/S control module
determines the assist amount and controls the current to
the motor suitable for that assist amount. This parameter
indicates that control value.
Measured MOT Current (Motor Monitor Current, A)
This parameter indicates the actually measured value of
the current flowing to the motor. The motor circuit
condition is diagnosed by comparing this parameter with
“Motor Control” parameter described previously.
Vehicle Speed (km/h, MPH)
Vehicle speed signal is fed from BCM. P/S control
module determines the amount of power assist based on
this vehicle speed signal and the torque sensor signal.
Engine Speed (rpm)
Engine speed signal is fed from the ECM so that it can
be used for trouble diagnosis of the electric power
steering system. Scan tool data Vehicle condition Normal condition
) Power Supply Voltage
Ignition switch ON10 – 14 V
) Sensor Power Supply7.4 – 10 V
) Sensor (Main) TorqueEngine running at idle
speedSteering wheel at fully turned to left –10.5 – 0 N⋅m
Steering wheel at free 0 N⋅m
Steering wheel at fully turned to right 0 – 12.85 N⋅m
) Sensor (Sub) Torque Engine running at idle
speedSteering wheel at fully turned to left 0 – 10.65 N⋅m
Steering wheel at free 0 N⋅m
Steering wheel at fully turned to right –12.85 – 0 N⋅m
) Control TorqueEngine running at idle
speedSteering wheel at fully turned to left –7.22 – 0 N⋅m
Steering wheel at free 0 N⋅m
Steering wheel at fully turned to right 0 – 7.16 N⋅m
) Target Motor CurrentEngine running at idle
speedSteering wheel at free 0 A
Steering wheel at fully turned to left or
right*45 – 60 A
) Measured MOT
Current
Engine running at idle
speedSteering wheel at free 0 A
Steering wheel at fully turned to left or
right*45 – 60 A
) Vehicle Speed Engine running and vehicle at stop 0 km/h
) Engine Speed Engine running at idle speed after warming up 700 ± 50 rpm
) Motor Drive VoltageEngine running at idle
speedSteering wheel at free 0.8 – 1 V
Steering wheel at fully turned to right *5.5 – 8.5 V
) System Power Status
Ignition switch ONON
) IGN switch StatusON
) Torque sensor Status
Engine running at idle speedON
) Fail Safe FET StatusON

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-13
Motor Drive Voltage (V)
This parameter indicates the voltage between motor
terminals.
System Power Status (EPS System Power, ON, OFF)
This parameter indicates input status of EPS system
power supply.
IGN switch Status (ON, OFF)
This parameter indicates the condition of the power
supply through the ignition switch.Torque sensor Status (ON, OFF)
This parameter indicates the output status of the torque
sensor power supply.
Fail Safe FET Status (ON, OFF)
This parameter indicates the status of the motor drive
power supply circuit.
P/S System Symptom DiagnosisS6RW0D6304008
This section describes trouble diagnosis of the P/S system parts whose trouble is not indicated by the on-board
diagnostic system (self-diagnostic function). When no malfunction is indicated by the on-board diagnostic system
(self-diagnosis function) and assuredly those steering basic parts as described in “Steering Symptom Diagnosis in
Section 6A” are all in good condition, check the following power steering system parts which may be a possible cause
for each symptom of the steering.
Condition Possible cause Correction / Reference Item
Steering wheel feels
heavy (Perform “Steering
Force Check:” before
diagnosis.)Steering wheel installed improperly
(twisted)Install steering wheel correctly.
Poor performance of P/S motorCheck P/S motor referring to “P/S Motor and
Its Circuit Inspection”.
Poor performance of torque sensorCheck torque sensor referring to “Torque
Sensor and Its Circuit Inspection”.
Steering gear case assembly
malfunctionReplace steering gear case assembly.
Poor performance of vehicle speed
signal from BCMCheck vehicle speed signal circuit referring to
“DTC C1121 / C1123 / C1124: Vehicle Speed
Signal Circuit Failure”.
Steering wheel feels
heavy momentarily when
turning it to the left or
rightSteering gear case assembly
malfunctionReplace steering gear case assembly.
Poor recovery from turnsPoor performance of torque sensorCheck torque sensor referring to “Torque
Sensor and Its Circuit Inspection”.
Steering gear case assembly
malfunctionReplace steering gear case assembly.
Vehicle pulls to one side
during straight drivingPoor performance of torque sensorCheck torque sensor referring to “Torque
Sensor and Its Circuit Inspection”.
Steering gear case assembly
malfunctionReplace steering gear case assembly.
Abnormal noiseP/S motor (built in steering gear case
assembly) malfunctionReplace steering gear case assembly.
No idle upP/S control module faultyCheck P/S control module referring to
“Inspection of P/S Control Module and Its
Circuits”.

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 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 6C-30 Power Assisted Steering System:
Inspection of P/S Control Module and Its CircuitsS6RW0D6304020
The P/S control module and its circuits can be checked at the P/S control module wiring couplers by measuring
voltage and resistance.
CAUTION!
P/S control module cannot be checked by itself. It is strictly prohibited to connect voltmeter or
ohmmeter to the P/S control module with connectors disconnected from the P/S control module.

Voltage Check
1) Remove console box.
2) Check for voltage at each terminal with connectors connected to the P/S control module.
NOTE
As each terminal voltage is affected by the battery voltage, confirm if the battery voltage is 11 V or
more when ignition switch is ON.

[C]
[A]
123
4567
8
9 11
10 12 13
141516
17 18 1920
1
2
[B]
1
2
I7RW01632020-01
[A]: P/S control module connector No.1 “E11” (viewed from harness side)
[B]: P/S control module connector No.2 “E13” (viewed from harness side)
[C]: P/S control module connector No.3 “E12” (viewed from harness side)

Downloaded from www.Manualslib.com manuals search engine 6C-32 Power Assisted Steering System:
NOTE
*: The voltage of this circuit may not be checked by voltmeter. If so, use oscilloscope.

Reference waveform No.1
Motor output signal 1(1), Motor output signal 2(2), with
engine idlingE11-20 REDReference sensor power supply
for torque sensorAbout 3.0 – 3.5 V• Ignition switch ON
• Check voltage between “E11-20” and
“E11-9” terminals
E12-1 BLK Motor output 1*0 – 1 V
↑↓
10 – 14 V
(“Reference
waveform No.1: ”,
“Reference
waveform No.2: ”
and “Reference
waveform No.3: ”)• Engine idling and steering wheel at
straight position
• Voltage between “E12-1” and vehicle
body ground
E12-2 RED Motor output 2*0 – 1 V
↑↓
10 – 14 V
(“Reference
waveform No.1: ”,
“Reference
waveform No.2: ”
and “Reference
waveform No.3: ”)• Engine idling and steering wheel at
straight position
• Voltage between “E12-2” and vehicle
body ground
E13-1 GRNMain power supply for internal
memory and P/S motor10 – 14 V —
E13-2 BLK Ground for P/S control module Below 0.3 V — Terminal Wire color Circuit Normal voltage Condition
Measurement
terminalCH1: “E12-1” to vehicle body ground
CH1: “E12-2” to vehicle body ground
Oscilloscope
settingCH1: 5 V/DIV, CH2: 5 V/DIV
TIME: 20 µs/DIV
Measurement
condition• Engine is idling and steering
wheel at straight position
I6RS0B630017-01