602 SUZUKI SX4 2006 1.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine Table of Contents 5- i
5
Section 5
CONTENTS
Transmission / Transaxle
Precautions ................................................. 5-1
Precautions............................................................. 5-1
Precautions on Transmission / Transaxle ............. 5-1
Automatic Transmission/Transaxle ....... 5A-1
Precautions........................................................... 5A-1
Precautions in Diagnosing Trouble ..................... 5A-1
Precautions for Disassembly and
Reassembly ...................................................... 5A-1
General Description ............................................. 5A-3
A/T Description ................................................... 5A-3
Clutch / Brake / Planetary Gear Function of
Automatic Transaxle ......................................... 5A-6
Table of Component Operation ........................... 5A-7
A/T Diagnosis General Description ..................... 5A-7
On-Board Diagnostic System Description ........... 5A-8
CAN Communication System Description........... 5A-9
Schematic and Routing Diagram ...................... 5A-10
Transmission Control Module (TCM) Wiring
Diagram .......................................................... 5A-10
Automatic Gear Shift Table ............................... 5A-12
Component Location ......................................... 5A-14
Electronic Shift Control System Components
Location .......................................................... 5A-14
Diagnostic Information and Procedures .......... 5A-16
A/T System Check ............................................ 5A-16
Visual Inspection ............................................... 5A-18
Malfunction Indicator Lamp (MIL) Check .......... 5A-19
Transmission Warning Light Check (Non-
Euro-OBD model) ........................................... 5A-19
DTC Table ......................................................... 5A-19
DTC Check ....................................................... 5A-21
DTC Clearance ................................................. 5A-22
Fail-Safe Table .................................................. 5A-22
Scan Tool Data ................................................. 5A-24
A/T Basic Check ............................................... 5A-27
Road Test ......................................................... 5A-27
Manual Road Test ............................................. 5A-30
Engine Brake Test ............................................ 5A-30
Stall Test ........................................................... 5A-31
Time Lag Test ................................................... 5A-32
Line Pressure Test ............................................ 5A-32
“P” Range Test.................................................. 5A-33
A/T Symptom Diagnosis ................................... 5A-34Transmission Warning Light Circuit Check –
Light Remains “ON” at Ignition Switch ON
(Non-Euro-OBD Model)................................... 5A-41
Transmission Warning Light Circuit Check –
Light Does Not Come “ON” at Ignition Switch
ON (Non-Euro-OBD Model)............................ 5A-41
DTC P0602: Control Module Programming
Error ................................................................ 5A-42
DTC P0705: Transmission Range Sensor
Circuit Malfunction (PRNDL Input) .................. 5A-42
DTC P0707: Transmission Range Sensor
Circuit Low ...................................................... 5A-44
DTC P0711: Transmission Fluid Temperature
Sensor “A” Control Range / Performance ....... 5A-46
DTC P0712: Transmission Fluid Temperature
Sensor Circuit Low .......................................... 5A-47
DTC P0713: Transmission Fluid Temperature
Sensor Circuit High ......................................... 5A-48
DTC P0717: Input / Turbine Speed Sensor
Circuit Malfunction........................................... 5A-50
DTC P0722: Output Speed Sensor (VSS)
Circuit No Signal ............................................. 5A-51
DTC P0741 / P0742: TCC Circuit
Performance or Stuck OFF / TCC Circuit
Stuck ON ......................................................... 5A-53
DTC P0751 / P0752 / P0756 / P0757: Shift
Solenoid Malfunction ....................................... 5A-54
DTC P0787: Shift / Timing Solenoid Control
Circuit Low ...................................................... 5A-55
DTC P0788: Shift / Timing Solenoid Control
Circuit High...................................................... 5A-57
DTC P0961: Pressure Control Solenoid “A”
Control Circuit Range / Performance .............. 5A-58
DTC P0962: Pressure Control Solenoid
Control Circuit Low .......................................... 5A-60
DTC P0963: Pressure Control Solenoid
Control Circuit High ......................................... 5A-62
DTC P0973 / P0976: Shift Solenoid-A (No.1)
Control Circuit Low / Shift Solenoid-B (No.2)
Control Circuit Low .......................................... 5A-64
DTC P0974 / P0977: Shift Solenoid-A (No.1)
/ Shift Solenoid-B (No.2) Control Circuit High .. 5A-66
DTC P1702: Internal Control Module Memory
Check Sum Error............................................. 5A-68

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 5A-42 Automatic Transmission/Transaxle:
DTC P0602: Control Module Programming ErrorS6RW0D5104047
System Description
Internal control module is installed in ECM.
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
1) Connect scan tool to DLC with ignition switch turned OFF.
2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool.
3) Start engine and run it at idle if possible.
4) Check DTC and pending DTC by using scan tool.
DTC Troubleshooting
DTC P0705: Transmission Range Sensor Circuit Malfunction (PRNDL Input)S6RW0D5104020
Wiring DiagramDTC detecting condition Trouble area
Data programming error
(1 driving cycle detection logic)TCM
Step Action Yes No
1DTC check
1) Clear DTC referring to “DTC Clearance”.
2) Turn OFF ignition switch.
3) Turn ON ignition switch and check DTC.
Is DTC P0602 still indicated?Go to Step 2. Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.
2TCM power ground circuit check
1) Check that TCM power supply circuit and TCM ground
circuit is in good condition referring to “TCM Power and
Ground Circuit Check”.
Are check results OK?Substitute a known-
good TCM and recheck.Repair TCM power or
ground circuit.
2P
R
N
D
2
L3
1
PNK/BLK
RED
GRN
GRN/ORN
GRN/YEL
IG1
RED/BLK
LT GRN/BLK
C07-20
C07-1
C07-8
C07-7
C07-19
C07-18
C06
20 1987
18 1
C07
[A]
I6RW0B510008-01
1. TCM 3. Backup lamp
2. Transmission range sensor [A]: Terminal arrangement of TCM connector (viewed from harness side)

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-85
Select Lever InspectionS6RW0D5106005
Check select lever for smooth and clear-cut movement
individually. If a malfunction is found, replace select lever
assembly.
“3” Position Switch InspectionS6RW0D5106016
1) Remove console box referring to “Console Box
Components in Section 9H”.
2) Disconnect “3” position switch connector (1).
3) Check continuity between “3” position switch
terminals.
“3” position switch specification
Shift select lever to “3” or “2” range: Continuity
Shift other above range: No continuity
Shift Lock Solenoid InspectionS6RW0D5106024
Check that shift lock solenoid (1) actuate when battery
voltage is conducted.
Shift Lock Solenoid ReplacementS6RW0D5106025
1) Remove console box referring to “Console Box
Components in Section 9H”.
2) Replace shift lock solenoid (1) using flat head or like.
3) Install covers as they were.1
I5RW0C510037-02
1
I5RW0C510043-02
1
I5RW0C510044-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-87
2) Remove adjuster (cable end) from select lever pin of
select lever assembly.
3) Remove adjuster (cable end) from select lever pin of
select lever assembly.
4) Release lock plate (1) which restrict moving of cable
end holder (2).
5) Push cable end holder (1) out from eye-end (2) using
an appropriate tool (3) to disengage cable.
6) Shift select lever to “N” position.
7) Apply grease to select lever pin and install adjuster
(cable end) to it.
: Grease 99000–25011 (SUZUKI Super Grease
A)
8) With both select lever and transmission range
sensor kept each “N” position, drive cable end holder
(1) in until it locks cable.
9) Slide lock plate (2) to secure cable end holder in
position.
10) After select cable was installed, check for the
following.
• Push vehicle with select lever shifted to “P” range.
Vehicle should not move.
• Vehicle can not be driven in “N” range.• Vehicle can be driven in “D”, “3”, “2” and “L”
ranges.
• Vehicle can be backed in “R” range.
Key Interlock Cable Removal and InstallationS6RW0D5106026
NOTE
Don’t bend interlock cable excessively when
removing and installing it, or system will not
operate correctly.

Removal
1) If the vehicle is equipped with air bag system,
disconnect negative cable at battery and disable air
bag system, referring to “Disabling Air Bag System in
Section 8B”.
2) Remove steering column cover.
3) Turn ignition switch to ACC position.
4) Pull out key interlock cable (1) from key cylinder
cover (2) while pressing checkhook with slotted
screwdriver (3) or the like.
5) Turn ignition switch to LOCK position.
6) Remove console box referring to “Console Box
Components in Section 9H”.
7) Detach cable end (1) from interlock cam (2) while
pressing claws (3) of interlock cam boss.
At this time, be careful not to cause damage to its
claws.
Detach cable casing cap (4) from bracket (5) while
pressing checkhook.
8) Remove interlock cable.
I2RH01510046-01
I2RH01510047-01
I3RM0B510037-01
2
13I5RW0C510045-01
4
5 3 12
4
I5RW0C510046-01

Downloaded from www.Manualslib.com manuals search engine 5A-96 Automatic Transmission/Transaxle:
10) Remove valve body assembly referring to
“Automatic Transaxle Unit Disassembly”.
11) Remove pressure control solenoid valve and TCC
pressure control solenoid valve referring to “Valve
Body Assembly Disassembly and Reassembly”.
Installation
Reverse removal procedure to install pressure control
solenoid valve and valve body assembly noting the
following points.
• For detail of pressure control solenoid valve and TCC
pressure control solenoid valve installation, refer to
“Valve Body Assembly Disassembly and
Reassembly”.
• For detail of valve body assembly installation, refer to
“Automatic Transaxle Unit Assembly”.
• For detail of installing wire harness for solenoid valves
and sensor, refer to “Automatic Transaxle Unit
Assembly”. Use new O-rings.
• For detail of A/T oil pan and oil strainer assembly
installation, refer to “Automatic Transaxle Unit
Assembly”. Use new oil pan gasket.
• Pour A/T fluid and check fluid level according to
procedure described in “A/T Fluid Change”.
• Check for fluid leakage after warming up A/T.
Pressure Control Solenoid Valves InspectionS6RW0D5106020
CAUTION!
• Be very careful as dust etc. does enter
when pressure control solenoid valves are
inspected.

Resistance Check
Measure resistance between pressure control solenoid
valves (Pressure control solenoid and TCC pressure
control solenoid) (1) terminals.
Pressure control solenoid valve and TCC pressure
control solenoid valve resistance
Standard: 5.0 – 5.6 Ω at 20 °C (68 °F)Operation Check
Check pressure control solenoid valves (Pressure
control solenoid and TCC pressure control solenoid)
operation in the either manner of the following.
Using regulated DC power supply
1) Connect pressure control solenoid valve (1) with
regulated DC power supply (2) as shown in figure.
2) Turn regulated DC power supply switch ON and
increase voltage of power supply keeping current
within 1.0 A.
3) Check for gradual movement of valve (3) in the
direction of arrow “A” as voltage is increased.
4) Check movement of valve (3) in the direction of
arrow “B” as voltage is decreased.
5) Turn power supply switch OFF.
CAUTION!
Do not pass current 1.0 A or more, or
pressure control solenoid is burned out.

Not using regulated DC power supply
1) Connect pressure control solenoid valve (1) to
battery (2) setting 21 W bulb (4) on the way as
shown in figure.
2) Check for movement of valve (3) in the direction of
arrow “A”.
3) Disconnect pressure control solenoid valve (1) from
battery (2) and check movement of valve (3) in the
direction of arrow “B” as shown in figure.
CAUTION!
Set 21 W bulb on the way, or pressure control
solenoid valve is burned out.

1
I2RH01510071-01
I2RH0B510064-01

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 5A-98 Automatic Transmission/Transaxle:
Differential Side Oil Seal ReplacementS6RW0D5106023
1) Lift up vehicle and drain automatic transaxle fluid.
2) Remove drive shaft assembly and center shaft
referring to “Front Drive Shaft Assembly Removal
and Installation in Section 3A”.
3) Remove differential side oil seal (1) by using special
tool.
Special tool
(A): 09913–50121
4) Apply grease to new differential side oil seal lips.
: Grease 99000–25030 (SUZUKI Super Grease C)
5) Install new differential side oil seals (1) by using
special tool.
Special tool
(A): 09913–75510
(B): 09913–75810
Differential side oil seal installing depth
Right side “a”: 13.2 – 14.2 mm (0.52 – 0.56 in.)
Left side “b”: 3.8 – 4.8 mm (0.15 – 0.19 in.)
6) Insert drive shaft assembly and center shaft referring
to “Front Drive Shaft Assembly Removal and
Installation in Section 3A”.
7) Pour A/T fluid referring to “A/T Fluid Change”.
A/T Fluid Cooler Hoses ReplacementS6RW0D5106027
The rubber hoses for the A/T fluid cooler should be
checked at specified interval. If replacing them, be sure
to note the following.
• to replace clamps at the same time
• to insert hose as far as its limit mark
• to clamp clamps securely
[A]: Right side [B]: Left side
(A)
1I5RW0A520006-02
“a” “b”
(B)[B] [A]
1
(A)
I5RW0C510042-01
1. Inlet hose (Outlet from A/T fluid cooler)
2. Outlet hose (Inlet to A/T fluid cooler)
2
1I5RW0C510049-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-99
Automatic Transaxle Unit ComponentsS6RW0D5106028
I5RW0C510050-01
1. Drive plate 6. Transaxle and engine fastening bolt : 19 N⋅m (1.9 kgf-m, 14.0 lb-ft)
2. Drive plate bolt 7. Transaxle and engine fastening nut : 69 N⋅m (6.9 kgf-m, 50.0 lb-ft)
3. Drive plate to torque converter bolt 8. Transaxle housing lower plate : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
4. Torque converter 9. Transaxle housing lower plate bolt : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)
5. Engine oil pan bolt : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 5A-100 Automatic Transmission/Transaxle:
Automatic Transaxle Unit Dismounting and
Remounting
S6RW0D5106029
Dismounting
1) Take down transaxle with engine. For its procedure,
refer to “Engine Assembly Removal and Installation
in Section 1D”.
2) Remove transaxle housing lower plate (1).
3) Remove drive plate to torque converter bolts (1)
engage flat head rod or the like (2) with drive plate
ring gear.4) Remove starting motor.
5) Remove bolts and nut fastening engine and
transaxle, then detach transaxle from engine.WARNING!
Be sure to keep transaxle with torque
converter horizontal or facing up throughout
the work. Should it be tilted with torque
converter down, converter may fall off and
cause personal injury.

NOTE
When detaching transaxle from engine, move
it in parallel with crankshaft and use care so
as not to apply excessive force to drive plate
and torque converter.

1
I5RW0C510051-01
1
2I5RW0C510052-01
I5RW0C510053-01