speed SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 5A-10 Automatic Transmission/Transaxle:
Schematic and Routing Diagram
Transmission Control Module (TCM) Wiring DiagramS6RW0D5102001
12V
12V
12V
IG1
118
9
10
P
R
N
D
2
L12
2.5V
5V
12V
5V
12V
12V
12V
WHT
BLK
BLK
BLK
BLK
PPLBLK/WHT
BLK/ORN
IG11
RED/BLK
YEL/BLKYEL/BLU
LT GRN/BLK
+BB
WHT/RED
14
20 15
16
17
19
12V18
1 2
3
132126
24 27
28
29
30
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
[A]
22
25
YELYEL/GRN
WHT
P
N
BRN LT/GRN
ORN
BLK/YEL
BLU/BLK
GRY
LT GRN/BLKWHT/BLU
WHT/BLK
C06-11
C06-12
C06-16
C06-15
C06-14
C06-4
C06-2
C06-1
C06-23C06-6 C06-24C06-5
C06-3
RED
GRN GRN/ORNPNK/BLK
GRN/YEL
LT GRN/BLKC07-6
C07-16
C07-23 C07-25
C07-20
C07-1
C07-8
C07-7
C07-19
C07-18
4IG11 23
C07-9
YEL
RED
WHTBLU35 34
3637
5REDWHT
7
WHT
RED
33
4
6
C06-7C06-17WHT
REDREDWHT
WHT
12V12V
WHTRED
WHTREDREDWHT
31
32
RED
WHTRED[B]
[C]
I6RW0D510003-02
1. TCM 15. Shift solenoid valve-A (No.1) 29. “ST SIG” fuse
2. Input shaft speed sensor 16. Shift solenoid valve-B (No.2) 30. “ST” fuse
3. Output shaft speed sensor / VSS 17. Timing solenoid valve 31. MIL
4. ECM 18. TCC solenoid valve 32. Transmission warning light (non-Euro-OBD model)
5. Combination meter 19. Pressure control solenoid valve 33. ABS control module
6. BCM 20. A/T 34. To Data link connector
7. 4WD control module (if equipped) 21. A/T relay 35. To BCM
8. “3” position switch 22. Inhibitor switch (including transmission range
sensor)36. Junction connector
9. Shift lock solenoid 23. Starter motor relay 37. Keyless start control module (if equipped)
10. Brake light switch 24. Ignition switch [A]: Terminal arrangement of TCM connector (viewed
from harness side)
11. Transmission range sensor 25. Starter motor [B]: Junction block with BCM model
12. Backup lamp 26. “DOME” fuse [C]: Junction block without BCM model
13. Data link connector (DLC) 27. “AT” fuse
14. Transmission fluid temperature sensor 28. “IG1 SIG” fuse

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-11
Operation of Shift Solenoid Valves, Timing Solenoid Valve and TCC Solenoid Valve
{: ON (Turn power ON)
×: OFF (Turn power OFF)
U: ON only when TCC is operating Selector
positionGear
positionSolenoid
Condition Shift
solenoid
valve-A
(No.1)Shift
solenoid
valve-B
(No. 2)Timing
solenoid
valveTCC
solenoid
valve
PParking{{××
RReverse{{××When vehicle is traveling forwards in
less than 9 km/h, 6 mile/h vehicle speed
{{{×When vehicle is traveling forwards in 9
km/h, 6 mile/h or more vehicle speed
(Reverse)××××When fail-safe function is operating
N Neutral{{××
DNeutral →
1st——{—Timing solenoid is turned ON for about
0.5 sec. while on gear shifting
1st{{××
2nd{×××
3rd×××U
3rd ↔ 4th — —{—Timing solenoid is turned ON for about
0.5 sec. while on gear shifting
4th×{×U
(3rd)××××When fail-safe function is operating
21st{{××
2nd{×××
(3rd)××××When fail-safe function is operating
L1st{{××
(3rd)××××When fail-safe function is operating
Valve status
Turn power ON Turn power OFF
Shift solenoid valve-A (No.1) Close Open
Shift solenoid valve-B (No.2) Close Open
Timing solenoid valve Open Close
TCC solenoid valve Close Open

Downloaded from www.Manualslib.com manuals search engine 5A-12 Automatic Transmission/Transaxle:
Automatic Gear Shift TableS6RW0D5102002
Automatic gear shift schedule is shown in the following table. Test-drive the vehicle on a flat road in the D position.
M16A Engine Model
1.Shift Point in D, 3 and/or 2 position
2. Lock-up point in D and/or 3 positionThrottle opening (%) Shift Vehicle speed km/h (mph) Remark
UP shiftOver 85%1st → 2nd 48 – 53 (30 – 33) D, 3, 2 range
2nd → 3rd 98 – 103 (61 – 64) D, 3 range
3rd → 4th 158 – 163 (98 – 101) D range
50%1st → 2nd 35 – 40 (22 – 25) D, 3, 2 range
2nd → 3rd 69 – 74 (43 – 46) D, 3 range
3rd → 4th 106 – 111 (66 – 69) D range
10%1st → 2nd 11 – 16 (7 – 10) D, 3, 2 range
2nd → 3rd 23 – 28 (14 – 17) D, 3 range
3rd → 4th 51 – 56 (32 – 35) D range
DOWN shiftOver 85%4th → 3rd 144 – 149 (89 – 93) D range
3rd → 2nd 91 – 96 (57 – 60) D, 3 range
2nd → 1st 42 – 47 (26 – 29) D, 3, 2 range
50%4th → 3rd 73 – 78 (45 – 48) D range
3rd → 2nd 36 – 41 (22 – 25) D, 3 range
2nd → 1st 11 – 16 (7 – 10) D, 3, 2 range
10%4th → 3rd 30 – 35 (19 – 22) D range
3rd → 2nd 15 – 20 (9 – 12) D, 3 range
2nd → 1st 6 – 11 (4 –7) D, 3, 2 range
Lock-up
clutch statusThrottle
opening (%)Vehicle speed km/h (mph) Remark
3rd gear lock-upONOver 85% 123 – 128 (76 – 80) D, 3 range
50% 90 – 95 (56 – 59) D, 3 range
OFFOver 90% 105 – 110 (65 – 68) D, 3 range
50% 76 – 81 (47 – 50) D, 3 range
4th gear lock-upONOver 85% 158 – 163 (98 – 101)•D range
• Except throttle opening shift from low
to high at vehicle speed 160 km/h
(100 mph) or more with Lock-up ON
condition.
50% 132 – 137 (82 – 85) D range
OFFOver 90% 144 – 149 (89 – 93) D range
50% 122 – 127 (76 – 79) D range

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-13
M15A Engine Model
1.Shift Point in D, 3 and/or 2 position
2. Lock-up point in D and/or 3 positionThrottle opening (%) Shift Vehicle speed km/h (mph) Remark
UP shiftOver 90%1st → 2nd 50 – 55 (31 - 34) D, 3, 2 range
2nd → 3rd 100 – 105 (62 - 65) D, 3 range
3rd → 4th 162 – 167 (101 - 104) D range
50%1st → 2nd 34 – 39 (21 - 24) D, 3, 2 range
2nd → 3rd 76 – 81 (47 - 50) D, 3 range
3rd → 4th 120 – 125 (75 - 78) D range
10%1st → 2nd 15 – 20 (9 - 12) D, 3, 2 range
2nd → 3rd 45 – 50 (28 - 31) D, 3 range
3rd → 4th 66 – 71 (41 - 44) D range
DOWN shiftOver 95%4th → 3rd 144 – 149 (89 – 93) D range
3rd → 2nd 87 – 92 (54 – 57) D, 3 range
2nd → 1st 44 – 49 (27 – 30) D, 3, 2 range
50%4th → 3rd 66 – 71 (41 – 44) D range
3rd → 2nd 26 – 31 (16 – 19) D, 3 range
2nd → 1st 6 – 11 (4 – 7) D, 3, 2 range
10%4th → 3rd 53 – 58 (33 – 36) D range
3rd → 2nd 15 – 20 (9 – 12) D, 3 range
2nd → 1st 6 – 11 (4 – 7) D, 3, 2 range
Lock-up
clutch statusThrottle
opening (%)Vehicle speed km/h (mph) Remark
3rd gear lock-upONOver 90% 138 – 143 (86 – 89) D, 3 range
50% 118 – 123 (73 – 76) 3 range
OFFOver 95% 128 – 133 (80 – 83) D, 3 range
50% 108 – 113 (67 – 70) 3 range
4th gear lock-upONOver 90% 162 – 167 (101 – 104)•D range
• Except throttle opening shift from low
to high at vehicle speed 160 km/h
(100 mph) or more with Lock-up ON
condition.
50% 132 – 137 (82 – 85) D range
OFFOver 95% 152 – 157 (94 – 98) D range
50% 113 – 118 (70 – 73) D range

Downloaded from www.Manualslib.com manuals search engine 5A-14 Automatic Transmission/Transaxle:
Component Location
Electronic Shift Control System Components LocationS6RW0D5103001
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

5*
17
15
1
2
8
9
1011
12
13
16*18 19
14
7
6
3420
[B]
[A]5*
I6RW0D510004-01
[A]: Junction block with BCM model 7. Input shaft speed sensor 15. ECM
[B]: Junction block without BCM model 8. TCC solenoid valve 16. TCM
1. Engine 9. Transmission fluid temperature sensor 17. AT relay
2. Transaxle 10. Timing solenoid valve 18. “3” position switch
3. MIL 11. Pressure control solenoid valve 19. Select lever
4. Transaxle select position indicator 12. Shift solenoid valve-B (No.2) 20. Transmission warning light (non-Euro-OBD model)
5. Junction block assembly (included in BCM) 13. Shift solenoid valve-A (No.1)

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-15
6. Output shaft speed sensor (VSS) 14. Transmission range sensor
EngineTorque converter with
torque converter clutch
Oil pumpRegulator valves
in valve body
Planetary gear
unit
Clutches and
brakes
Control valves
in valve body
Shift solenoid valves,
TCC solenoid valve and
Timing solenoid valve Pressure control
solenoid valve
Final gear
reduction unit
Engine control module (ECM)
Body control module (BCM)
Combination meter
· Engine torque signal
· Engine speed signal
Transmission control module (TCM)
· Torque request signal
· Throttle position signal
· Accelerator pedal position signal
· Engine coolant temperature signal
· Brake pedal switch signal
· Driving cycle active
· Warm up cycle active
Accelerator pedal
position sensor
Crank shaft
position sensor
Engine coolant
temperature sensor
Input shaft speed sensor
Brake light switch
“3” position switch
Transmission range sensor
Transmission fluid
temperature sensor
Output shaft speed
sensor (VSS)
Power transmission
Fluid pressure circuit
Electric signal
Data link connector
· Transmission diagnostic trouble code (DTC) · Vehicle speed pulse signal
· Transmission warning light signal
· A/T select lever position signal
· Transmission actual gear position signal
· Transmission oil temperature signal · MIL control signal
ABS control module
· A/C compressor clutch signal
I6RW0D510005-01

Downloaded from www.Manualslib.com manuals search engine 5A-20 Automatic Transmission/Transaxle:
DTC No. Detecting itemDetecting condition
(DTC will set when detecting)AB
) UP0602Control module Programming
ErrorData programming error. — —
) P0705Transmission range sensor circuit
malfunction (PRNDL input)Multiple signals are inputted simultaneously.1 driving
cycle1 driving
cycle
) P0707Transmission range sensor circuit
lowNo sensor signal is inputted.2 driving
cycles2 driving
cycles
) *P0711Transmission Fluid Temperature
Sensor “A” circuit Range /
PerformanceTransmission temperature sensor signal is no
change for specified time continuously.2 driving
cycles2 driving
cycles*
) P0712Transmission fluid temperature
sensor circuit lowSensor output voltage is too low.1 driving
cycle1 driving
cycle
) P0713Transmission fluid temperature
sensor circuit highSensor output voltage is too high.1 driving
cycle1 driving
cycle
) P0717Input / Turbine speed sensor
circuit no signalNo sensor signal is detected although output
speed sensor signal is inputted.1 driving
cycle1 driving
cycle
) P0722Output speed sensor circuit no
signalNo sensor signal is inputted although input
speed sensor signal is inputted.1 driving
cycle1 driving
cycle
) *P0741Torque converter clutch circuit
performance or stuck offDifference in revolution between engine and
input shaft is too large although TCM is
commanding TCC solenoid valve to turn ON.2 driving
cycles2 driving
cycles*
) *P0742Torque converter clutch circuit
stuck onDifference in revolution between engine and
input shaft is too small although TCM is
commanding TCC solenoid valve to turn OFF.2 driving
cycles2 driving
cycles*
) *P0751
Shift solenoid-A (No.1)
performance or stuck offActual gear position is 3rd gear although TCM
command is for 2nd gear.2 driving
cycles2 driving
cycles*
) *P0752 Shift solenoid-A (No.1) stuck onActual gear position is 2nd gear although TCM
command is for 3rd gear.2 driving
cycles2 driving
cycles*
) *P0756Shift solenoid-B (No.2)
performance or stuck offActual gear position is 3rd gear although TCM
command is for 4th gear.2 driving
cycles2 driving
cycles*
) *P0757 Shift solenoid-B (No.2) stuck onActual gear position is 4th gear although TCM
command is for 3rd gear.2 driving
cycles2 driving
cycles*
) P0787Shift / Timing solenoid control
circuit lowVoltage of timing solenoid terminal is low
although TCM is commanding timing solenoid to
turn ON.1 driving
cycle1 driving
cycle
) P0788Shift / Timing solenoid control
circuit highVoltage of timing solenoid terminal is high
although TCM is commanding timing solenoid to
turn OFF.1 driving
cycle1 driving
cycle
) P0961Pressure Control Solenoid “A”
Control Circuit Range /
PerformanceDifference between actual current of control
solenoid valve circuit and current of control
solenoid valve circuit calculated by ECM is more
than specification.1 driving
cycle1 driving
cycle
) P0962Pressure control solenoid control
circuit lowNo electric flow is detected on pressure control
solenoid circuit.1 driving
cycle1 driving
cycle
) P0963Pressure control solenoid control
circuit highToo much electric flow is detected on pressure
control solenoid circuit.1 driving
cycle1 driving
cycle
) P0973Shift solenoid-A (No.1) control
circuit lowVoltage of shift solenoid terminal is low although
TCM is commanding shift solenoid to turn ON.1 driving
cycle1 driving
cycle
) P0974
Shift solenoid-A (No.1) control
circuit highVoltage of shift solenoid terminal is high
although TCM is commanding shift solenoid to
turn OFF.1 driving
cycle1 driving
cycle
) P0976Shift solenoid-B (No.2) control
circuit lowVoltage of shift solenoid terminal is low although
TCM is commanding shift solenoid to turn ON.1 driving
cycle1 driving
cycle
) P0977Shift solenoid-B (No.2) control
circuit highVoltage of shift solenoid terminal is high
although TCM is commanding shift solenoid to
turn OFF.1 driving
cycle1 driving
cycle
) P1702Internal control module memory
check sum errorCalculation of current data stored in TCM is not
correct comparing with pre-stored checking data
in TCM.1 driving
cycle1 driving
cycle

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-21
DTC CheckS6RW0D5104005
NOTE
• There are two types of OBD system
depending on the vehicle specification.For
identification, refer to “Precaution on On-
Board Diagnostic (OBD) System in Section
1A”.
• For Euro-OBD model, the MIL is turned on
when the ECM and/or TCM detect
malfunction(s). Each control module
stores diagnostic information as the
diagnostic trouble code (DTC) in its
memory and outputs the DTC to the scan
tool. Therefore, check both of the control
modules for any DTC with the SUZUKI
scan tool because the DTC stored in ECM
and TCM is not read and displayed at a
time. However, each of the control
modules needs not to be checked with the
CAN communication OBD generic scan
tool because the DTC stored in ECM and
TCM is read and displayed at a time. In
case using CAN communication OBD
generic scan tool, refer to “DTC Table in
Section 1A”.

1) Turn ignition switch to OFF position.
2) Connect scan tool to data link connector (DLC) (1).
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
3) Turn ignition switch ON.
4) Read DTC, pending DTC and freeze frame data
according to instructions displayed on scan tool and
print it down. Refer to scan tool operator’s manual
for further details.
If communication between scan tool and TCM is not
possible, check if scan tool is communicable by
connecting it to TCM in another vehicle. If
communication is possible in this case, scan tool is
in good condition. Then check data link connector
and serial data line (circuit) in the vehicle with which
communication was not possible.
5) After completing the check, turn ignition switch off
and disconnect scan tool from data link connector. ) UP1723 Range select switch malfunction“3” position switch ON signal is inputted
although transmission range switch signal is
inputted P, R, N or L. range.1 driving
cycle*1 driving
cycle*
)
U*P1878Torque converter clutch shudderVariation in the output revolution speed of the
specified amplitude and specified cycle is
detected under slip lock-up condition.20 driving
cycles*20 driving
cycles*
) P2762Torque Converter Clutch (TCC)
Pressure Control Solenoid Control
Circuit Range / PerformanceDifference between actual current of TCC
solenoid valve circuit and current of TCC
solenoid valve circuit calculated by ECM is more
than specification.1 driving
cycle1 driving
cycle
) P2763Torque converter clutch pressure
control solenoid control circuit highToo much electric flow is detected on TCC
solenoid valve circuit.1 driving
cycle1 driving
cycle
) P2764Torque converter clutch pressure
control solenoid control circuit lowNo electric flow is detected on TCC solenoid
valve circuit.1 driving
cycle1 driving
cycle
) U0073Control Module Communication
Bus OffTransmission error that is inconsistent between
transmission data and transmission monitor
(CAN bus monitor) data is detected more than
specified time continuously.1 driving
cycle1 driving
cycle
) U0100Lost Communication with ECM /
PCM “A”Receiving error from ECM detected to TCM for
specified time continuously.1 driving
cycle1 driving
cycle DTC No. Detecting itemDetecting condition
(DTC will set when detecting)AB
(A) 1I5RW0C510072-01

Downloaded from www.Manualslib.com manuals search engine 5A-22 Automatic Transmission/Transaxle:
DTC ClearanceS6RW0D5104006
WARNING!
When performing a driving test, select a safe
place where there is neither any traffic nor
any traffic accident possibility and be very
careful during testing to avoid occurrence of
an accident.

After repair or replace malfunction part(s), clear all DTCs
by performing the following procedure.
1) Connect SUZUKI scan tool to data link connector in
the same manner as when making this connection
for “DTC Check”.
2) Turn ignition switch ON.3) Erase DTC and pending DTC according to
instructions displayed on scan tool. Refer to scan
tool operator’s manual for further details.
4) After completing the clearance, turn ignition switch
OFF and disconnect scan tool from data link
connector (DLC).
NOTE
DTC and freeze frame data stored in TCM
memory are also cleared in the following
cases. Be careful not to clear them before
keeping their record.
• When the same malfunction (DTC) is not
detected again during 40 engine warm-up
cycles.

Fail-Safe TableS6RW0D5104007
This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sensor or
its circuit fails. The following table shows the fail-safe function for each fail condition of sensor, solenoid or its circuit.
DTC No. Trouble area Fail-safe operation
) P0705Transmission range sensor circuit
malfunction (PRNDL input)• Selected range is set in priority order shown below.
D> 2> L> R> N> P
• Slip controlled lock-up function is inhibited to operate.
• Learning control is inhibited.
) P0707 Transmission range sensor circuit low• Selected range is assumed to be “D” range.
• Slip controlled lock-up function is inhibited to operate.
• Learning control is inhibited.
) P0712
) P0713Transmission fluid temperature sensor
circuit low• A/T fluid temperature is assumed to be 200 °C (392 °F).
• Upshifting to 4th gear is inhibited.
• Lock-up function is inhibited to operate.
• Garage shift control is inhibited.
• Learning control is inhibited.
) P0717Input / Turbine speed sensor circuit no
signal• Upshifting to 4th gear is inhibited.
• Lock-up function is inhibited to operate.
• Line pressure control at gear shifting is inhibited.
• Torque reducing request to ECM (torque reduction control)
is inhibited.
• Garage shift control is inhibited.
• Learning control is inhibited.
) P0722 Output speed sensor circuit no signal• Vehicle speed which is calculated by input shaft speed
sensor signal is used for gear shifting control instead of
vehicle speed calculated by output shaft speed sensor
(VSS) signal.
• Upshifting to 4th gear is inhibited.
• Lock-up function is inhibited to operate.
• Line pressure control at gear shifting is inhibited.
• Torque reducing request to ECM (torque reduction control)
is inhibited.
• Garage shift control is inhibited.
• Learning control is inhibited.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-23
) P0787 Shift / Timing solenoid Control Circuit Low
• Power supply for all solenoid valves is cut.
• Gear position is fixed in 3rd gear.
• Line pressure control at gear shifting is inhibited.
• Look-up function is inhibited to operate. ) P0788 Shift / Timing solenoid Control Circuit High
) P0962Pressure control solenoid control circuit
low
) P0963Pressure control solenoid control circuit
high
) P0973 Shift solenoid-A (No.1) control circuit low
) P0974 Shift solenoid-A (No.1) control circuit high
) P0976 Shift solenoid-B (No.2) control circuit low
) P0977 Shift solenoid-B (No.2) control circuit high
) P0961Pressure Control Solenoid “A” Control
Circuit Range / Performance• Upshifting to 4th gear is inhibited.
• Lock-up function is inhibited to operate.
• Slip controlled lock-up function is inhibited to operate.
• Line pressure control at gear shifting is inhibited.
• Torque reducing request to ECM (torque reduction control)
is inhibited.
• Garage shift control is inhibited.
• Leaning control is inhibited.
) P1702Internal control module memory check
sum error• Power supply for all solenoid valves is cut.
• Gear position is fixed in 3rd gear.
• Line pressure control at gear shifting is inhibited.
• Lock-up function is inhibited to operate.
) P1723 Range select switch malfunction “3” position switch is assumed to be OFF.
) P1878 Torque converter clutch shudder Slip controlled lock-up function is inhibited to operate.
) P2762Torque Converter Clutch (TCC) Pressure
Control Solenoid Control Circuit Range /
Performance• Lock-up function is inhibited to operate.
• Slip controlled lock-up function is inhibited to operate.
• Upshifting to 4th gear is inhibited when Transmission Fluid
Temperature is 150 °C (302 °F) or more.
• Gear position is fixed in 1st gear when vehicle speed is 10
km/h (6 mile/h) or less.
) P2763Torque converter clutch pressure control
solenoid control circuit high• Lock-up function is inhibited to operate.
• Upshifting to 4th gear is inhibited when A/T fluid
temperature is more than 150 °C (302 °F).
• Vehicle speed is slower than 10 km/h (6 mile/h), gear
position is fixed in 1st gear for prevention of engine stall.
) P2764Torque converter clutch pressure control
solenoid control circuit low• Lock-up function is inhibited to operate.
• Upshifting to 4th gear is inhibited when A/T fluid
temperature is more than 150 °C (302 °F).
) U0073 Control module communication bus off• Throttle opening used for line pressure control is assumed
to be 100%.
• Throttle opening used for gear shifting control is assumed
to be 0%.
• Engine revolution is assumed to be 0 RPM.
• After 15 minutes pass from detecting malfunction, engine
coolant temperature is assumed to be 90 °C (194 °F).
• Lock-up function is inhibited to operate.
• Line pressure control at gear shifting is inhibited.
• Torque reducing request to ECM (torque reduction control)
is inhibited.
• Upshifting to 4th gear is inhibited.
• Garage shift control is inhibited.
• Learning control is inhibited. DTC No. Trouble area Fail-safe operation