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

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

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-149
26) Apply A/T fluid to 2nd brake piston assembly (1), and
align the projection of 2nd brake piston assembly
with the groove of transaxle case, then put together.
27) Install 2nd brake piston snap ring (1) by using
special tool and hydraulic press.
CAUTION!
Do not damage 2nd brake piston assembly,
return spring subassembly, plates and discs
by pressing in 2nd brake assembly passing
through its original installing position over
0.4 mm (0.016 in.).

Special tool
(A): 09926–96050
28) 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 clutch 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
Standard: 0.40 – 1.25 mm (0.016 – 0.049 in.)
29) After applying A/T fluid to front sun gear thrust
bearing race (2), install it to front planetary sun gear
(1).
30) Apply A/T fluid to front planetary sun gear (1) and
install it to planetary gear assembly (2).
I2RH0B510282-01
I2RH0B510283-01
32
1
I2RH0B510284-01
I2RH0B510285-01
I2RH0B510286-01

Downloaded from www.Manualslib.com manuals search engine 5A-152 Automatic Transmission/Transaxle:
43) Measure O/D and 2nd coast brake piston stroke.
• Measure dimension “a” from end face 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.)
When piston stroke is out of specification, select O/D
and 2nd coast brake rear plate with proper thickness
from among the following table and replace it.
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.

Available O/D and 2nd coast brake rear plate
thickness
44) After applying A/T fluid to new 2nd brake gaskets (1),
install them to transaxle case (2).
45) After applying A/T fluid to reverse clutch drum thrust
bearing (1), install it to forward and reverse clutch
assembly (2).
46) Remove sealant attached to mating surface of
transaxle rear cover (1) completely.
47) Apply sealant to mating surface of transaxle rear
cover (1) by using a nozzle (2) as shown in figure by
such amount that its section is 1.2 mm (0.047 in.) in
diameter.
“A”: Sealant 99000–31230 (SUZUKI Bond
No.1216B) Thickness Identification mark
1.8 mm (0.071 in.) 1
2.0 mm (0.079 in.) 2
2.2 mm (0.087 in.) 3
2.4 mm (0.094 in.) 4
2.6 mm (0.102 in.) 5
I2RH0B510298-01
I2RH0B510299-01
I2RH0B510300-01
“A”2
1
I2RH0B510301-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 6- i
6
Section 6
CONTENTS
Steering
Precautions ................................................. 6-1
Precautions............................................................. 6-1
Precautions on Steering........................................ 6-1
Steering General Diagnosis.................... 6A-1
Precautions........................................................... 6A-1
Precautions for Steering Diagnosis ..................... 6A-1
Diagnostic Information and Procedures ............ 6A-1
Steering Symptom Diagnosis .............................. 6A-1
Steering System Inspection ................................ 6A-2
Steering Wheel and Column................... 6B-1
Precautions........................................................... 6B-1
Service Precautions of Steering Wheel and
Column.............................................................. 6B-1
General Description ............................................. 6B-1
Steering Wheel and Column Construction .......... 6B-1
Diagnostic Information and Procedures ............ 6B-2
Checking Steering Column for Accident
Damage ............................................................ 6B-2
Repair Instructions .............................................. 6B-3
Steering Wheel and Column Construction .......... 6B-3
Steering Wheel Removal and Installation ........... 6B-4
Contact Coil Cable Assembly Removal and
Installation ......................................................... 6B-5
Centering Contact Coil Cable Assembly ............. 6B-6
Contact Coil Cable Assembly Inspection ............ 6B-6
Steering Column Removal and Installation ......... 6B-6
Steering Column Inspection ................................ 6B-8
Ignition Switch Cylinder Assembly Removal
and Installation (Non- Keyless Start Model)...... 6B-8
Steering Lock Assembly (Ignition Switch)
Removal and Installation................................... 6B-9
Steering Lower Shaft Removal and
Installation ....................................................... 6B-10
Specifications..................................................... 6B-11
Tightening Torque Specifications ...................... 6B-11
Special Tools and Equipment ........................... 6B-11
Special Tool ...................................................... 6B-11
Power Assisted Steering System........... 6C-1
Precautions........................................................... 6C-1
P/S System Note ................................................. 6C-1
Precautions in Diagnosing Troubles ................... 6C-1General Description .............................................6C-2
P/S System Description ......................................6C-2
EPS Diagnosis General Description ...................6C-3
On-Board Diagnostic System Description ...........6C-3
Schematic and Routing Diagram ........................6C-4
EPS System Wiring Circuit Diagram ...................6C-4
Diagnostic Information and Procedures ............6C-5
EPS System Check .............................................6C-5
“EPS” Warning Light Check ................................6C-8
DTC Check..........................................................6C-8
DTC Clearance ...................................................6C-9
DTC Table ...........................................................6C-9
Visual Inspection ...............................................6C-11
Scan Tool Data .................................................6C-12
P/S System Symptom Diagnosis ......................6C-13
DLC and Its Communication Check (No
communication to P/S Control Module)...........6C-14
“EPS” Warning Light Does Not Come ON with
Ignition Switch Turned ON before Engine
Starts ...............................................................6C-16
“EPS” Warning Light Remains ON Steady
after Engine Starts ..........................................6C-18
DTC C1111 / C1113 / C1115: Torque Sensor
Circuit Failure ..................................................6C-19
DTC C1116: Steering Torque Sensor Power
Supply Circuit ..................................................6C-21
DTC C1121 / C1123 / C1124: Vehicle Speed
Signal Circuit Failure .......................................6C-22
DTC C1122: Engine Speed Signal....................6C-24
DTC C1141 / C1142 / C1143 / C1145: Motor
Circuit Failure ..................................................6C-26
DTC C1153: P/S Control Module Power
Supply Circuit ..................................................6C-27
DTC C1155: P/S Control Module Internal
Failure .............................................................6C-28
P/S Control Module Power Supply and
Ground Circuit Check ......................................6C-29
Inspection of P/S Control Module and Its
Circuits ............................................................6C-30
Steering Wheel Play Check ..............................6C-34
Steering Force Check .......................................6C-34
Repair Instructions ............................................6C-35
Steering Gear Case Assembly Components ....6C-35
Tie-Rod End Boot On-Vehicle Inspection .........6C-36
Tie-Rod End Removal and Installation..............6C-36

Downloaded from www.Manualslib.com manuals search engine 6-ii Table of Contents
Tie-Rod End Inspection.....................................6C-37
Steering Shaft Joint On-Vehicle Inspection.......6C-37
Steering Gear Case Assembly Removal and
Installation .......................................................6C-37
Steering Rack Boot Inspection ..........................6C-38
Tie-Rod / Rack Boot Removal and Installation ..6C-38
Steering Rack Plunger Removal and
Installation .......................................................6C-40
Steering Rack Plunger Inspection .....................6C-40P/S Control Module Removal and Installation...6C-41
Torque Sensor and Its Circuit Inspection ..........6C-41
P/S Motor and Its Circuit Inspection ..................6C-42
Specifications .....................................................6C-43
Tightening Torque Specifications ......................6C-43
Special Tools and Equipment ...........................6C-44
Recommended Service Material .......................6C-44
Special Tool ......................................................6C-44

Downloaded from www.Manualslib.com manuals search engine Table of Contents 7- i
7
Section 7
CONTENTS
HVAC
Precautions ................................................. 7-1
Precautions............................................................. 7-1
Precautions on HVAC ........................................... 7-1
Heater and Ventilation............................. 7A-1
General Description ............................................. 7A-1
Heater and Ventilation Construction ................... 7A-1
Schematic and Routing Diagram ........................ 7A-2
Heater and Ventilation Wiring Circuit Diagram .... 7A-2
Component Location ........................................... 7A-2
Electronic Control System Components
Location ............................................................ 7A-2
Diagnostic Information and Procedures ............ 7A-3
Heater and Ventilation Symptom Diagnosis........ 7A-3
Repair Instructions .............................................. 7A-4
HVAC Unit Components ..................................... 7A-4
HVAC Unit Removal and Installation (Non-A/
C) ...................................................................... 7A-4
Blower Motor Removal and Installation............... 7A-4
Blower Motor Inspection ..................................... 7A-4
Blower Motor Resistor Removal and
Installation ......................................................... 7A-5
Blower Motor Resistor Inspection ....................... 7A-5
Blower Motor Relay Inspection ........................... 7A-6
HVAC Control Unit Components ......................... 7A-6
HVAC Control Unit Removal and Installation ...... 7A-7
Blower Speed Selector Inspection ...................... 7A-9
Air Intake Selector Inspection ............................. 7A-9
Air Intake Control Actuator Removal and
Installation ......................................................... 7A-9
Air Intake Control Actuator Inspection .............. 7A-10
Center Ventilation Louver Removal and
Installation ....................................................... 7A-11
Side Ventilation Louver Removal and
Installation ....................................................... 7A-11
Rear Duct Removal and Installation (If
Equipped)........................................................ 7A-12
HVAC Air Filter Removal and Installation (If
Equipped)........................................................ 7A-12
HVAC Air Filter Inspection (If Equipped) ........... 7A-12
Air Conditioning System......................... 7B-1
Manual Type ............................................................ 7B-1
Precautions........................................................... 7B-1A/C System Caution ............................................ 7B-1
Precautions on Servicing A/C System ................ 7B-1
General Description .............................................7B-2
Sub-Cool A/C System Description ...................... 7B-2
Manual A/C Electronic Input Output Table .......... 7B-3
A/C Operation Description at ECM ..................... 7B-3
Schematic and Routing Diagram ........................7B-4
A/C System Air Flow Diagram............................. 7B-4
A/C System Wiring Diagram ............................... 7B-5
Component Location ...........................................7B-6
A/C System Major Components Location ........... 7B-6
Electronic Control System Components
Location............................................................. 7B-7
Diagnostic Information and Procedures ............7B-8
A/C System Performance Inspection .................. 7B-8
Trouble Diagnosis for Abnormal Pressure ........ 7B-11
A/C System Inspection at ECM ......................... 7B-12
A/C System Symptom Diagnosis ...................... 7B-13
Abnormal Noise Symptom Diagnosis of A/C
System ............................................................ 7B-15
Repair Instructions ............................................7B-17
Operation Procedure for Refrigerant Charge .... 7B-17
Condenser Cooling Fan Removal and
Installation ....................................................... 7B-22
Condenser Cooling Fan Inspection ................... 7B-23
Condenser Assembly On-Vehicle Inspection .... 7B-23
Condenser Assembly Removal and
Installation ....................................................... 7B-23
Desiccant Removal and Installation .................. 7B-24
HVAC Unit Components ................................... 7B-25
HVAC Unit Removal and Installation ................ 7B-26
Evaporator Inspection ....................................... 7B-27
Evaporator Temperature Sensor Removal
and Installation ................................................ 7B-27
Evaporator Temperature Sensor Inspection ..... 7B-28
Expansion Valve Removal and Installation ....... 7B-28
Expansion Valve Inspection .............................. 7B-28
A/C Refrigerant Pressure Sensor and Its
Circuit Inspection............................................. 7B-29
A/C Refrigerant Pressure Sensor Removal
and Installation ................................................ 7B-29
A/C Switch Inspection ....................................... 7B-29
A/C System Relay Inspection............................ 7B-30
Compressor Drive Belt Inspection and
Adjustment ...................................................... 7B-30

Downloaded from www.Manualslib.com manuals search engine 7-ii Table of Contents
Compressor Drive Belt Removal and
Installation ....................................................... 7B-31
Compressor Assembly Removal and
Installation ....................................................... 7B-31
Compressor Assembly Components................. 7B-32
Magnet Clutch Inspection.................................. 7B-32
Magnet Clutch Removal and Installation........... 7B-33
Thermal Switch Inspection ................................ 7B-35
Thermal Switch Removal and Installation ......... 7B-35
Relief Valve Inspection...................................... 7B-36
Relief valve Removal and Installation ............... 7B-36
Specifications .....................................................7B-37
Tightening Torque Specifications ...................... 7B-37
Special Tools and Equipment ...........................7B-37
Recommended Service Material ....................... 7B-37
Special Tool ...................................................... 7B-37
Automatic Type .....................................................7B-38
Precautions.........................................................7B-38
A/C System Caution .......................................... 7B-38
Precautions in Diagnosing Trouble ................... 7B-38
Precautions on Servicing A/C System .............. 7B-38
General Description ...........................................7B-39
Auto A/C System Description ............................ 7B-39
HVAC Control Description................................. 7B-40
Sub-Cool A/C System Description .................... 7B-40
On-Board Diagnostic System Description ......... 7B-41
Schematic and Routing Diagram ......................7B-41
A/C System Air Flow Diagram........................... 7B-41
A/C System Wiring Diagram ............................. 7B-42
Component Location .........................................7B-43
A/C System Major Components Location ......... 7B-43
Electronic Control System Components
Location .......................................................... 7B-44
Diagnostic Information and Procedures ..........7B-45
Air Conditioning System Check......................... 7B-45
A/C System Symptom Diagnosis ...................... 7B-47
Abnormal Noise Symptom Diagnosis of A/C
System ............................................................ 7B-49
DTC Check........................................................ 7B-49
DTC Clearance ................................................. 7B-51
DTC Table ......................................................... 7B-52
Fail-Safe Table .................................................. 7B-54
Scan Tool Data ................................................. 7B-55
Visual Inspection ............................................... 7B-57
DTC B1502: Inside Air Temperature Sensor
Circuit Malfunction .......................................... 7B-57
DTC B1503: Evaporator Temperature Sensor
Circuit Malfunction .......................................... 7B-59
DTC B1504: Sunload Sensor Circuit
Malfunction ...................................................... 7B-60
DTC B1511: Temperature Control Actuator
(Position Sensor) and/or Its Circuit
Malfunction ...................................................... 7B-61
DTC B1512: Air flow Control Actuator
(Position Sensor) and/or Its Circuit
Malfunction ...................................................... 7B-63
DTC B1513: Temperature Control Actuator
(Motor) and/or Its Circuit Malfunction .............. 7B-65DTC B1514: Air Flow Control Actuator (Motor)
and/or Its Circuit Malfunction........................... 7B-67
DTC B1520 / B1521 / B1522: Temperature /
Blower Speed / Air Flow Selector
Malfunction ...................................................... 7B-68
DTC B1541: Back-Up Power Supply Circuit
Malfunction ...................................................... 7B-69
DTC B1546: A/C Refrigerant Pressure
Malfunction ...................................................... 7B-70
DTC B1551: Serial Communication Circuit
Malfunction ...................................................... 7B-70
DTC B1552: HVAC Control Module Check
Sum Error ........................................................ 7B-72
DTC B1553: CAN Communication Circuit
Malfunction ...................................................... 7B-72
DTC B1557: VSS Signal Failure ....................... 7B-73
DTC B1561: ECT Signal Failure ....................... 7B-73
DTC B1562: Outside Air Temperature Signal
Failure ............................................................. 7B-74
DTC B1563: A/C Refrigerant Pressure Signal
Failure ............................................................. 7B-74
DTC B1570: Engine Type Signal Failure .......... 7B-75
DTC B1571: Combination Meter Spec Signal
Failure ............................................................. 7B-75
Inspection of HVAC Control Module and Its
Circuit .............................................................. 7B-76
A/C System Inspection at ECM ......................... 7B-79
Repair Instructions ............................................7B-79
Operation Procedure for Refrigerant Charge .... 7B-79
HVAC Unit Components ................................... 7B-80
HVAC Unit Removal and Installation ................ 7B-81
Temperature Control Actuator Removal and
Installation ....................................................... 7B-81
Temperature Control Actuator and Its Circuit
Inspection ........................................................ 7B-81
Air Flow Control Actuator Removal and
Installation ....................................................... 7B-83
Air Flow Control Actuator and Its Circuit
Inspection ........................................................ 7B-83
Air Intake Actuator Removal and Installation .... 7B-84
Air Intake Actuator Inspection ........................... 7B-84
Actuator Linkage Inspection.............................. 7B-84
Blower Motor Controller Removal and
Installation ....................................................... 7B-84
Blower Motor Controller Inspection ................... 7B-85
HVAC Control Module Removal and
Installation ....................................................... 7B-85
Sunload Sensor Removal and Installation ........ 7B-85
Sunload Sensor Inspection ............................... 7B-86
Outside Air Temperature Sensor Removal
and Installation ................................................ 7B-86
Outside Air Temperature Sensor Inspection ..... 7B-86
Inside Air Temperature Sensor Removal and
Installation ....................................................... 7B-86
Inside Air Temperature Sensor Inspection ........ 7B-86
Condenser Cooling Fan Relay Inspection......... 7B-87
Condenser Cooling Fan Removal and
Installation ....................................................... 7B-87
Condenser Cooling Fan Inspection ................... 7B-87
Condenser Assembly On-Vehicle Inspection .... 7B-87