wheel SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-34
Installation
1) Install hydraulic unit / control module assembly by
reversing removal procedure noting the following.
Install ABS hydraulic unit / control module assembly
bracket bolt as follows.
a) Tighten bracket bolt (1) and (2) by hand.
b) Then tighten bracket bolt to specified torque.
Tightening order (1) → (2)
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft)
ABS hydraulic unit / control module assembly
bolt (b): 9 N·m (0.9 kgf-m, 6.5 lb-ft)
ABS hydraulic unit / control module assembly
bracket bolt (c): 26 N·m (2.6 kgf-m, 19.0 lb-ft)2) Bleed air from brake system referring to “Air
Bleeding of Brake System in Section 4A”.
3) Check each installed part for fluid leakage and
perform “ABS Hydraulic Unit Operation Check”.
NOTE
For new ABS hydraulic unit / control module
assembly, if “ABS Hydraulic Unit Operation
Check” has not been performed, ABS
warning light may flash when ignition switch
is turned ON position.
Accordingly preform “ABS Hydraulic Unit
Operation Check” to stop flashing of ABS
warning light.

Front and Rear Wheel Speed Sensor On-Vehicle
Inspection
S6RW0D4506005
Output Voltage Inspection
1) Disconnect negative (–) cable from battery.
2) Hoist vehicle a little.
3) Disconnect wheel speed sensor connector.
4) Set up measuring device as shown in figure, the
resistance to 115 Ω and the power supply voltage to
12 V.
CAUTION!
Incorrect voltage and/or wrong connection
cause damage to wheel speed sensor.

I6RW0C450011-01
1. Wheel speed sensor connector 4. “BLK” wire terminal
2. Resistance (115Ω) 5. Power supply (12 V)
3. “WHT” wire terminal
V
41
3
2
5
I5JB0A450026-03

Downloaded from www.Manualslib.com manuals search engine 4E-35 ABS:
5) Measure voltage at resistance without wheel
rotation.If voltage is out of specification, check
sensor, mating encoder and their installation
conditions.
Voltage at the resistance (115
Ω) without wheel
rotation
680 – 960 mV
6) Measure voltage at resistance with wheel rotation
and confirm voltage alternately changes between
high and low voltages.If voltage does not change
with wheel rotation, check sensor, mating encoder
and their installation conditions.
Voltage at the resistance (115
Ω) with wheel
rotation
High voltage “a”: 1360 – 1930 mV
Low voltage “b”: 680 – 960 mV
Reference
When using oscilloscope for this check, check if peak-to-
peak voltage and waveform meet specification.
Peak-to-peak voltage at the resistance (115
Ω) with
wheel rotation
High voltage “a”: 1360 to 1930 mV
Low voltage “b”: 680 to 960 mV
Front Wheel Speed Sensor Removal and
Installation
S6RW0D4506006
CAUTION!
• Do not pull wire harness when removing
and installing front wheel speed sensor.
• Do not cause damage to surface of front
wheel speed sensor and do not allow dust,
etc. to enter its installation hole.

Removal
1) Disconnect negative (–) cable from battery.
2) Disconnect front wheel speed sensor connector (1).
3) Hoist vehicle and remove wheel.
4) Remove harness clamp, clamp bolt (2).
5) Remove front wheel speed sensor (3) from knuckle.
[A]: Voltage [B]: Time
I5JB0A450027-01
I5JB0A450028-02
3
1
2
I5RW0A450023-01

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-36
Installation
1) Check that no foreign material is attached to sensor
(1) and wheel speed sensor encoder (included in
wheel hub assembly).
2) Install it by reversing removal procedure.
NOTE
Before fitting wheel speed sensor, be sure to
silicon grease to its O-ring.

Tightening torque
Front wheel speed sensor bolt (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
Front wheel speed sensor harness clamp bolt
(b): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Check that there is no clearance between sensor
and knuckle.
Front and Rear Wheel Speed Sensor InspectionS6RW0D4506007
Check sensor for damage.
If any malcondition is found, replace.
Rear Wheel Speed Sensor Removal and
Installation (4WD Model)
S6RW0D4506008
CAUTION!
Rear wheel speed sensor is included in rear
wheel hub assembly. If rear wheel speed
sensor needs to be replaced, replace it as a
rear wheel hub assembly.

For removal and Installation of rear wheel speed sensor
(included in rear wheel hub), refer to “Rear Wheel Hub
Assembly Removal and Installation in Section 2C”.
Rear Wheel Speed Sensor Removal and
Installation (2WD Model)
S6RW0D4506009
CAUTION!
• Do not pull wire harness when removing
and installing rear wheel speed sensor.
• Do not cause damage to surface of rear
wheel speed sensor and do not allow dust,
etc. to enter its installation hole.

Removal
1) Disconnect negative (–) cable from battery.
2) Hoist vehicle, and remove wheel.
3) Disconnect rear wheel speed sensor connector.
4) Remove harness clamp.
5) Remove rear wheel speed sensor from wheel hub.
Installation
1) Check that no foreign material is attached to sensor
and encoder (included in wheel hub assembly).
2) Install it by reversing removal procedure.
NOTE
Before fitting wheel speed sensor, be sure to
silicon grease to its O-ring.

Tightening torque
Rear wheel speed sensor bolt: 11 N·m (1.1 kgf-
m, 8.0 lb-ft)
3) Check that there is no clearance between sensor
and wheel hub.[A]: OK [B]: NG
1
2
(b)
(a)
I5RW0A450025-01
[A][B]
11
I5RW0A450024-01
I5JB0A450031-01
[A]: OK [B]: NG
[A][B]
11
I5RW0A450024-01

Downloaded from www.Manualslib.com manuals search engine 4E-37 ABS:
Front Wheel Speed Sensor Encoder On-Vehicle
Inspection
S6RW0D4506010
Before inspecting front wheel speed sensor encoder,
remove front drive shaft referring to “Front Drive Shaft
Assembly Removal and Installation in Section 3A”.
• Check sensor encoder (1) for crack, damage or
deformation.
• Turn wheel and check if sensor encoder rotation is
free from eccentricity and looseness.
• Check that no foreign material is attached.
If any faulty is found, clean or replace. Refer to “Front
Wheel Hub, Steering Knuckle and Wheel Bearing
Removal and Installation in Section 2B”.
Front Wheel Speed Sensor Encoder Removal
and Installation
S6RW0D4506011
CAUTION!
Front wheel speed sensor encoder is
included in front wheel hub assembly. If front
wheel speed sensor encoder needs to be
replaced, replace it as a front wheel hub
assembly.

For removal and installation of front wheel hub
assembly, referring to “Front Wheel Hub, Steering
Knuckle and Wheel Bearing Removal and Installation in
Section 2B”.
Rear Wheel Speed Sensor Encoder On-Vehicle
Inspection
S6RW0D4506012
For 4WD model
Refer to “Rear Wheel Speed Sensor On-Vehicle
Inspection”.
For 2WD model
Before inspecting rear wheel speed sensor encoder,
remove rear wheel speed sensor referring to “Rear
Wheel Speed Sensor Removal and Installation (2WD
Model)”.
• Check encoder (1) for crack, damage or deformation.
• Turn wheel and check if encoder rotation is free from
eccentricity and looseness.
• Check that no foreign material is attached.
If any faulty is found, clean or replace. Refer to “Rear
Wheel Hub Assembly Removal and Installation in
Section 2C”.
Rear Wheel Speed Sensor Encoder Removal
and Installation
S6RW0D4506013
CAUTION!
Rear wheel speed sensor encoder is included
in rear wheel hub assembly. If rear wheel
speed sensor encoder needs to be replaced,
replace it as a rear wheel hub assembly.

For removal and installation of front wheel hub
assembly, referring to “Rear Wheel Hub Assembly
Removal and Installation in Section 2C”.
1
I5RW0A450026-01

Downloaded from www.Manualslib.com manuals search engine 4E-39 ABS:
Specifications
Tightening Torque SpecificationsS6RW0D4507001
NOTE
The specified tightening torque is also described in the following.
“ABS Hydraulic Unit / Control Module Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Special ToolS6RW0D4508001
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Brake pipe flare nut 16 1.6 11.5)
ABS hydraulic unit / control module assembly
bolt90.9 6.5)
ABS hydraulic unit / control module assembly
bracket bolt26 2.6 19.0)
Front wheel speed sensor bolt 11 1.1 8.0)
Front wheel speed sensor harness clamp bolt 11 1.1 8.0)
Rear wheel speed sensor bolt 11 1.1 8.0)
G sensor bolt 3.0 0.3 2.2)
09950–78220 SUZUKI scan tool
Flare nut wrench (10 mm) —
)This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12. ) / )

Downloaded from www.Manualslib.com manuals search engine Table of Contents 5-iii
Diagnostic Information and Procedures ............ 5B-5
Manual Transaxle Symptom Diagnosis............... 5B-5
Repair Instructions .............................................. 5B-5
Manual Transaxle Oil Level Check ..................... 5B-5
Manual Transaxle Oil Change ............................ 5B-6
Differential Side Oil Seal Replacement ............... 5B-7
Gear Shift Control Lever and Cable
Components...................................................... 5B-8
Gear Shift Control Lever and Cable Removal
and Installation .................................................. 5B-9
Gear Select Control Cable Adjustment ............... 5B-9
Back Up Light Switch Removal and
Installation ....................................................... 5B-10
Back Up Light Switch Inspection ....................... 5B-10
Manual Transaxle Unit Components ................. 5B-11
Manual Transaxle Unit Dismounting and
Remounting..................................................... 5B-12
Gear Shift and Select Shaft Assembly
Components.................................................... 5B-13
Gear Shift and Select Shaft Assembly
Removal and Installation................................. 5B-14
Gear Shift and Select Shaft Assembly
Disassembly and Reassembly ........................ 5B-15
Manual Transaxle Assembly Components........ 5B-16
Fifth Gear Disassembly and Reassembly ......... 5B-17
Manual Transaxle Assembly Disassembly
and Reassembly ............................................. 5B-19
Right Case Disassembly and Reassembly ....... 5B-24
Left Case Disassembly and Reassembly.......... 5B-25
Input Shaft and Countershaft Components....... 5B-27
Input Shaft Disassembly and Reassembly........ 5B-28
Countershaft Disassembly and Reassembly .... 5B-31
Gear Shift Shaft Components ........................... 5B-35
5th and Reverse Gear Shift Shafts
Disassembly and Reassembly ........................ 5B-35
Gear Shift Shaft and Fork Inspection ................ 5B-35
Differential Components ................................... 5B-36Differential Disassembly and Reassembly ........ 5B-36
Specifications .....................................................5B-38
Tightening Torque Specifications ...................... 5B-38
Special Tools and Equipment ...........................5B-39
Recommended Service Material ....................... 5B-39
Special Tool ...................................................... 5B-39
Clutch ....................................................... 5C-1
General Description .............................................5C-1
Clutch (Hydraulic Type) Construction .................5C-1
Diagnostic Information and Procedures ............5C-2
Clutch System Symptom Diagnosis ....................5C-2
Repair Instructions ..............................................5C-3
Clutch Pedal Inspection ......................................5C-3
Clutch Fluid Level Inspection ..............................5C-3
Air Bleeding of Clutch System.............................5C-3
Clutch Fluid Pipe and Hose Location ..................5C-4
Clutch Fluid Pipe Removal and Installation.........5C-4
Clutch Fluid Pipe Inspection................................5C-4
Clutch Master Cylinder Removal and
Installation .........................................................5C-5
Clutch Operating Cylinder Assembly
Removal and Installation ...................................5C-5
Clutch Operating Cylinder Assembly
Inspection ..........................................................5C-6
Clutch Cover, Clutch Disc and Flywheel
Components ......................................................5C-6
Clutch Cover, Clutch Disc and Flywheel
Removal and Installation ...................................5C-7
Clutch Cover, Clutch Disc and Flywheel
Inspection ..........................................................5C-8
Specifications .......................................................5C-9
Tightening Torque Specifications ........................5C-9
Special Tools and Equipment ...........................5C-10
Recommended Service Material .......................5C-10
Special Tool ......................................................5C-10

Downloaded from www.Manualslib.com manuals search engine 5A-18 Automatic Transmission/Transaxle:
Step 2. DTC / Freeze Frame Data Check, Record and
Clearance
First, referring to “DTC Check”, check DTC and pending
DTC. If DTC exists, print or write down DTC and freeze
frame data and then clear malfunction DTC(s) by
referring to “DTC Clearance”. Malfunction DTC indicates
malfunction in the system but it is not possible to know
from it whether the malfunction is occurring now or it
occurred in the past and normal condition has been
restored. In order to know that, check symptom in
question according to Step 5 and then recheck DTC
according to Step 6.
Diagnosing a trouble based on the DTC in this step only
or failure to clear the DTC in this step may result in an
faulty diagnosis, trouble diagnosis of a normal circuit or
difficulty in troubleshooting which is otherwise
unnecessary.
Step 3 and 4. Visual Inspection
As a preliminary step, be sure to perform visual check of
the items that support proper function of the engine and
automatic transaxle referring to “Visual Inspection”.
Step 5. Trouble Symptom Confirmation
Check trouble symptoms based on information obtained
in “Step 1. Customer Complaint Analysis: ” and “Step 2.
DTC / Freeze Frame Data Check, Record and
Clearance: ”.
Also, reconfirm DTC according to “DTC Confirmation
Procedure” described in each DTC flow.
Step 6 and 7. Rechecking and Record of DTC and
Freeze Frame Data
Refer to “DTC Check” for checking procedure.Step 8. A/T Basic Check and A/T Symptom
Diagnosis
Perform basic check of A/T according to “A/T Basic
Check” first. When the end of the flow has been reached,
check the parts of the system suspected as a possible
cause referring to “A/T Symptom Diagnosis” and based
on symptoms appearing on the vehicle (symptoms
obtained through steps of customer complaint analysis,
trouble symptom confirmation and/or A/T basic check)
and repair or replace faulty parts, if any.
Step 9. Troubleshooting for DTC
Based on the DTC indicated in Step 6 / 7 and referring to
“applicable DTC flow”, locate the cause of the trouble,
namely in a sensor, switch, wire harness, connector,
actuator, TCM or other part and repair or replace faulty
parts.
Step 10. Check for Intermittent Problem
Check parts where an intermittent trouble is easy to
occur (e.g. wire harness, connector, etc.), referring to
“Intermittent and Poor Connection Inspection in Section
00” and related circuit of DTC recorded in Step 2.
Step 11. Final Confirmation Test
Confirm that the problem symptom has gone and the
vehicle is free from any abnormal conditions. If what has
been repaired is related to the malfunction DTC, clear
the DTC once and check to ensure that no malfunction
DTC is indicated.
Visual InspectionS6RW0D5104002
Visually check the following parts and systems.
Inspection item Referring
• A/T fluid ----- level, leakage, color “Automatic Transaxle Fluid Level Inspection in
Section 0B”
• A/T fluid hoses ----- disconnection, looseness, deterioration “A/T Fluid Cooler Hoses Replacement”
• Throttle cable (if equipped) ----- play (under warm engine),
installation
• A/T select cable ----- installation “Select Cable Removal and Installation”
• Engine oil ----- level, leakage “Engine Oil and Filter Change in Section 0B”
• Engine coolant ----- level, leakage “Engine Coolant Change in Section 0B”
• Engine mountings ----- play, looseness, damage “Engine Assembly Removal and Installation in
Section 1D”
• Suspension ----- play, looseness “Suspension, Wheels and Tires Symptom
Diagnosis in Section 2A”
• Drive shafts ----- damage “Front Drive Shaft Assembly On-Vehicle Inspection
in Section 3A”
• Battery ----- indicator condition, corrosion of terminal “Battery Inspection in Section 1J”
• Connectors of electric wire harness ----- disconnection, friction “Electronic Shift Control System Components
Location”
• Fuses ----- burning
• Parts ----- installation, damage
• Bolts ----- looseness
• Other parts that can be checked visually

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-31
Stall TestS6RW0D5104013
This test is to check overall performance of automatic transaxle and engine by measuring stall speed at “D” and “R”
ranges. Be sure to perform this test only when transaxle fluid is at normal operating temperature and its level is
between FULL and LOW marks.
CAUTION!
• Do not run engine at stall more than 5 seconds continuously, or fluid temperature may rise
excessively high.
• After performing stall test, be sure to leave engine running at idle for longer than 1 minute before
another stall test.

1) Apply parking brake and block wheels.
2) Install tachometer.
3) Start engine with select lever shifted to “P” range.
4) Depress brake pedal fully.
5) Shift select lever to “D” range and depress accelerator pedal fully while watching tachometer. Read engine rpm
quickly when it has become constant (stall speed).
6) Release accelerator pedal immediately after stall speed is checked.
7) In the same way, check stall speed in “R” range.
8) Stall speed should be within the following specification.
Engine stall speed
Standard: 2,200 – 2,600 rpm
Troubleshooting
Condition Possible cause Correction / Reference Item
Lower than standard level
in both “D” and “R” rangeEngine output torque failureInspect and repair engine.
Faulty one-way clutch of torque
converterReplace torque converter.
Higher than standard
level in “D” rangeMalfunction of pressure control solenoid
valve (Low line pressure)Inspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Slippery forward clutchInspect. If NG, replace.
Faulty one-way No.2 clutchInspect. If NG, replace.
Leakage from “D” range fluid pressure
circuitOverhaul or replace valve body assembly.
Higher than standard
level in “R” rangeMalfunction of pressure control solenoid
valve (Low line pressure)Inspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Slippery reverse clutchInspect. If NG, replace.
Slippery 1st and reverse brakeInspect. If NG, replace.
Leakage from “R” range fluid pressure
circuitOverhaul or replace valve body assembly.
Higher than standard
level in both “D” and “R”
rangeMalfunction of pressure control solenoid
valve (Low line pressure)Inspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Clogged oil strainerReplace.
Faulty oil pumpInspect. If NG, replace.
Leakage from both “D” and “R” range
fluid pressure circuitOverhaul or replace valve body assembly.

Downloaded from www.Manualslib.com manuals search engine 5A-32 Automatic Transmission/Transaxle:
Time Lag TestS6RW0D5104014
This test is to check conditions of clutch, brake and fluid pressure. “Time lag” means time elapsed since select lever is
shifted with engine idling till shock is felt.
1) With chocks placed before and behind front and rear wheels respectively, depress brake pedal.
2) Start engine.
3) With stop watch ready, shift select lever from “N” to “D” range and measure time from that moment till shock is felt.
4) Similarly measure time lag by shifting select lever from “N” to “R” range.
Gear shifting time lag
“N” → “D”: Less than 0.7 sec.
“N” → “R”: Less than 1.2 sec.
NOTE
• When repeating this test, be sure to wait at least one minute after select lever is shifted back to “N”
range.
• Engine should be warmed up fully for this test.
• Repeat test 3 times and take average of those data for final time lag data.

Troubleshooting
Line Pressure TestS6RW0D5104015
Purpose of this test is to check operating conditions of each part by measuring fluid pressure in fluid pressure line.
Line pressure test requires the following conditions.
• Automatic fluid is at normal operating temperature (70 – 80 °C / 158 – 176 °F).
• Fluid is replenished to proper level (between FULL and LOW on dipstick).
• Air conditioner switch is turned OFF.
1) Apply parking brake securely and place chocks against wheels.
2) Remove fluid pressure check hole plug bolt.
3) Attach oil pressure gauge to fluid pressure check hole in transaxle case.
Special tool
(A): 09925–37811–001Condition Possible cause Correction / Reference Item
“N”
→ “D” time lag
exceeds specificationMalfunction of transmission fluid
temperature sensorInspect. If NG, replace.
Malfunction of pressure control solenoid
valve (Low line pressure)Inspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Clogged oil strainerReplace.
Faulty oil pumpInspect. If NG, replace.
Faulty forward clutchInspect. If NG, replace.
Faulty one-way No.2 clutchInspect. If NG, replace.
Leakage from “D” range fluid pressure
circuitOverhaul or replace valve body assembly.
“N”
→ “R” time lag
exceeds specificationMalfunction of transmission fluid
temperature sensorInspect. If NG, replace.
Malfunction of pressure control solenoid
valve (Low line pressure)Inspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Clogged oil strainerReplace.
Faulty oil pumpInspect. If NG, replace.
Faulty reverse clutchInspect. If NG, replace.
Faulty 1st and reverse brakeInspect. If NG, replace.
Leakage from “R” range fluid pressure
circuitOverhaul or replace valve body assembly.

Downloaded from www.Manualslib.com manuals search engine 5A-82 Automatic Transmission/Transaxle:
• With shift lock solenoid release button (1) pushed
and ignition key turned to ACC position, select
lever can be shifted from “P” range position to any
other range.
• With shift lock solenoid release button (1) pushed
and ignition key turned to LOCK position, select
lever can not be shifted from “P” range position to
any other range.• When ignition switch is turned ON and brake
pedal is depressed, select lever can be shifted
from “P” range position to any other range.
3) With ignition lever shifted to any position other than
“P” range, check that ignition key cannot be turned
LOCK position and it cannot be removed from
ignition switch unless it is at LOCK position.
Repair Instructions
Learning Control InitializationS6RW0D5106001
1) Connect san tool to DLC (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
2) Start engine and shift select lever to “P” range.
3) Select “Misc Test” mode on scan tool.
4) Perform “AT learned initialize” on scan tool.
A/T Fluid Level CheckS6RW0D5106002
CAUTION!
Do not use any fluid other than the specified
ATF. Use of any fluid other than the specified
ATF may cause juddering or some other
faulty condition to occur.

Level Check at Normal Operating (Hot) Temperature
– Hot Check
1) Stop vehicle and place it level.
2) Apply parking brake and place chocks against
wheels.
3) With select lever at “P” position, start engine.
4) Warm up engine till fluid temperature reaches
normal operating temperature (70 – 80 °C / 158 –
176 °F). As a guide to check fluid temperature, warm
up engine to normal operating.
5) Keep engine idling and shift select lever slowly to “L”
and back to “P” position.
6) With engine idling, pull out fluid level gauge, wipe it
off with a clean cloth and put it back into place.
1
I4RS0A510049-01
I4RS0A510050-01
I4RS0A510051-01
(A) 1I5RW0C510072-01