AIR SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 5B-12 Manual Transmission/Transaxle:
Manual Transaxle Unit Dismounting and
Remounting
S6RW0D5206010
Dismounting
1) Drain coolant.
2) Remove battery and tray with ECM.
3) Remove air cleaner case and resonator.
4) Remove clutch fluid pipe referring to “Clutch Fluid
Pipe Removal and Installation in Section 5C”.
5) Disconnect back up light switch coupler and undo
wiring harness clamps.
6) Disconnect gear shift and gear select control cables
(1) from transaxle.
7) Remove earth cable from transaxle.
8) Remove water inlet pipe.
9) Remove starting motor referring to “Starting Motor
Dismounting and Remounting in Section 1I”.
10) Remove transaxle to engine bolts (1) of upper side.
11) Drain transaxle oil and transfer oil, if equipped.
12) Remove engine under covers.
13) Remove drive shaft assembly and center shaft
referring to “Front Drive Shaft Assembly Removal
and Installation in Section 3A”.
14) Remove exhaust No.1, No.2 and No.3 pipes
referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
15) Remove suspension frame, engine front mounting
member and engine mounting member referring to
“Front Suspension Frame, Stabilizer Bar and/or
Bushing Removal and Installation in Section 2B” and
“Engine Mountings Components in Section 1D”.16) Remove transfer referring to “Transfer Dismounting
and Remounting in Section 3C”, if equipped.
17) Remove clutch housing lower plate.
18) Support transaxle with transmission jack.
19) Remove left mounting (1) and left mounting bracket
(2).
20) Remove stiffener bolts (2), transaxle to engine bolts
(1) and nut of lower side, and then lower transaxle.
Remounting
CAUTION!
• Care should be taken not to scratch oil
seal lip with drive shaft while raising
transaxle.
• Do not hit drive shaft joint with hammer
when installing it into differential gear.

Reverse dismounting procedure for remounting of
transaxle, noting the following points.
• Tighten each bolts and nuts to specified torque
referring to “Manual Transaxle Unit Components” and
“Engine Mountings Components in Section 1D”.
• Set each clamp for wiring securely.
• Fill transaxle oil and transfer oil referring to “Manual
Transaxle Oil Change” and “Transfer Oil Change in
Section 3C”.
• Connect battery and check function of engine, clutch
and transaxle.
1
I5RW0A520011-01
1
I5RW0A520012-01
1
2
I5RW0A520013-01
1
2I5RW0A520014-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-29
Reassembly
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new ones as
necessary.
2) Check clearance “a” between synchronizer ring (2)
and gear (1), key slot width “b” in synchronizer ring
and each chamfered tooth of gear and synchronizer
ring and replace with new one, if necessary. Also,
check gear tooth.
Clearance “a” between synchronizer ring and
gear
Standard: 1.0 – 1.4 mm (0.040 – 0.055 in.)
Service limit: 0.5 mm (0.020 in.)
Key slot width “b”
Standard: 10.0 – 10.2 mm (0.394 – 0.401 in.)
Limit: 10.45 mm (0.411 in.)
3) To ensure lubrication of input shaft (1), air blow oil
holes (2) and make sure that they are free from any
obstruction.4) Fit high speed synchronizer sleeve (4) to hub (3),
insert 3 keys (2) in it and then set springs (1) as
shown in figure.
NOTE
• No specific direction is assigned to high
speed synchronizer sleeve or each key but
it is assigned as assembly.
• Size of high speed synchronizer sleeve,
hub, keys and springs are the smaller than
those of low speed one.

Synchronizer key installation position
A = B
5) Drive in right bering (1) to input shaft (2) using
special tool and hydraulic press.
Special tool
(A): 09913–80113
I5JB0A520054-01
I2RH01520049-01
[A]: 4th gear side
C: Left side (Short flange)
D: Key way
E: Projecting end
I5RW0A520033-01
I3RH0A520019-01

Downloaded from www.Manualslib.com manuals search engine 5B-32 Manual Transmission/Transaxle:
6) Disassemble synchronizer sleeve & hub assembly.
7) Take out 1st gear needle bearing from shaft.
8) In order to remove right bearing (1) from
countershaft, grind with a grinder (2) one part “a” of
right bearing (1) as illustrated till it becomes thin.
CAUTION!
Be careful not to grind too far not to damage
the shaft (3).

9) Break with a chisel (1) the thin ground right bearing
(2) and it can be removed.
Reassembly
1) Clean all components thoroughly, inspect them for
any abnormality and replace with new one as
necessary.
2) Check clearance “a” between synchronizer ring (2)
and gear (1), key slot width “b” in synchronizer ring
and each chamfered tooth of gear and synchronizer
ring and replace with new one, if necessary. Also,
check gear tooth.
Clearance “a” between synchronizer ring and
gear
Standard: 1.0 – 1.4 mm (0.040 – 0.055 in.)
Service limit: 0.5 mm (0.020 in.)
Key slot width “b”
Standard: 10.0 – 10.2 mm (0.394 – 0.401 in.)
Limit: 10.45 mm (0.411 in.)3) Put the synchronizer outer ring (1), inner ring (3) and
the cone (2) together and then measure the step
difference between the outer ring and the inner ring.
And also check each chamfered tooth of gear and
synchronizer ring and replace with new one, if
necessary. Also, check gear tooth.
Difference between synchronizer outer ring and
inner ring (2nd)
Standard “b”: 0.95 – 1.25 mm (0.036 – 0.048 in.)
Service limit “b”: 0.5 mm (0.019 in.)
4) To ensure lubrication of countershaft (1), air blow oil
holes (2) and make sure that they are free from any
obstruction.
3
1
2
“a”31
I5RW0A520035-01
1
2I5RW0A520036-01
I5JB0A520079-01
I2RH01520059-01
I2RH01520060-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-2
Diagnostic Information and Procedures
Clutch System Symptom DiagnosisS6RW0D5304001
Condition Possible cause Correction / Reference Item
SlippingImproper clutch pedal free travelBleed air or replace master cylinder.
Worn or oily clutch disc facingReplace disc.
Warped disc, pressure plate or flywheel
surfaceReplace disc, clutch cover or flywheel.
Weakened diaphragm springReplace clutch cover.
Master cylinder piston or seal cup not
returningReplace master cylinder.
Dragging clutchImproper clutch pedal free travelBleed air or replace master cylinder.
Weakened diaphragm spring, or worn
spring tipReplace clutch cover.
Rusted input shaft splinesLubricate.
Damaged or worn splines of transaxle
input shaftReplace input shaft.
Excessively wobbly clutch discReplace disc.
Clutch facings broken or dirty with oilReplace disc.
Fluid leakageRepair or replace.
Clutch vibrationGlazed (glass-like) clutch facingsRepair or replace disc.
Clutch facings dirty with oilReplace disc.
Release bearing slides unsmoothlyReplace clutch operating cylinder assembly.
Wobbly clutch disc, or poor facing
contactReplace disc.
Weakened torsion springs in clutch discReplace disc.
Clutch disc rivets looseReplace disc.
Distorted pressure plate or flywheel
surfaceReplace clutch cover or flywheel.
Weakened engine mountingReplace engine mounting.
Loosened engine mounting bolt or nutRetighten engine mounting bolt or nut.
Noisy clutchWorn or broken release bearingReplace clutch operating cylinder assembly.
Input shaft front bearing worn downReplace input shaft bearing.
Excessive rattle of clutch disc hubReplace disc.
Cracked clutch discReplace disc.
Pressure plate and diaphragm spring
rattlingReplace clutch cover.
Grabbing clutchClutch disc facings soaked with oilReplace disc.
Clutch disc facings excessively wornReplace disc.
Rivet heads showing out of facingReplace disc.
Weakened torsion springsReplace disc.

Downloaded from www.Manualslib.com manuals search engine 5C-3 Clutch:
Repair Instructions
Clutch Pedal InspectionS6RW0D5306001
Cylinder Push Rod Play “a”
1) Press clutch pedal (1) gradually with finger, stop
when slight increase of resistance is felt and
measure how much pedal has moved (push rod
play) as represented by “a” as shown.
Push rod play
“a”: Max. 3 mm (0.12 in.)
2) If “a” is not within specification, replace master
cylinder (3) or pedal arm (2).
Clutch Pedal Free Travel “b”
1) Depress clutch pedal (1), stop the moment clutch
resistance is felt, and measure how much pedal has
moved (clutch pedal free travel) as represented by
“b” in the figure.
Clutch pedal free travel
“b”
: 2 – 8 mm (0.08 – 0.31 in.)
2) If “b” is not within specification, check pedal arm (2)
and master cylinder (3) and replace defective part.
Clutch Release Margin “c”
1) Pull up parking brake fully and block wheels.
2) Start engine and keep engine at idle with neutral
gear position.
3) Without clutch pedal (1) depressed, slightly push the
shift lever to reverse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress
clutch pedal (1), and at gear contact noise died
position (release point) stop depressing.
5) Measure distance between release point (4) and full
stroke point (5) on clutch pedal (1) which is shown by
“c” in the figure.
Clutch release margin
“c”: 25 – 55 mm (0.98 – 2.17 in.)6) If “c” is not within specification, it is possible that air
is trapped in this system. If suspected so, bleed air
referring to “Air Bleeding of Clutch System”.Upon
completion of above inspection, start engine and
check clutch for proper operation.
Clutch Fluid Level InspectionS6RW0D5306002
Refer to “Brake Fluid Level Inspection in Section 4A”.
Clutch fluid specification
: Refer to the reservoir cap of the brake master
cylinder.
Air Bleeding of Clutch SystemS6RW0D5306003
CAUTION!
When operating the pedal stroke for air
bleeding of clutch system, after releasing the
clutch pedal, be sure to wait 1 second or
more before depressing it again. Otherwise,
the oil seal of operating cylinder will be
damaged, resulting in oil leakage.

Bleed air from clutch system.
Refer to “Air Bleeding of Brake System in Section 4A”.
I5RW0A530002-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-4
Clutch Fluid Pipe and Hose LocationS6RW0D5306004
Clutch Fluid Pipe Removal and InstallationS6RW0D5306005
Removal
CAUTION!
Do not allow fluid to get on painted surface. It
may cause painted surface damage.

1) Remove dust and dirt from each joint of pipe to be
disconnected and clean around brake master
cylinder reservoir cap.
2) Take out fluid with syringe or such from brake master
cylinder reservoir.
3) Pull clamp (1) of clutch master cylinder (3) and pull
clamp (5) of fluid pipe joint (4), and then disconnect
clutch fluid pipe (2).
4) Pull clamp (6) of damper (7), and then disconnect
damper (7) from clutch fluid pipe (2).Installation
Reverse removal procedure for installation noting the
following.
CAUTION!
• Do not allow fluid to get on painted
surface.
• Do not allow pipe to contact hard against
vehicle body or other parts.

• Install each clamp securely.
• After installation, check clutch pedal free travel and
bleed air from clutch system referring to “Clutch Pedal
Inspection” and “Air Bleeding of Clutch System”.
• Check fluid leakage.
• Add fluid to MAX level of reservoir.
Clutch Fluid Pipe InspectionS6RW0D5306006
Check pipe (1) for damage, dirt and leak. Replace if
check result is not satisfactory.
4 [A]
3131
22
4
I5RW0A530003-02
[A]: RH steering vehicle 3. Clutch reservoir hose
1. Clutch master cylinder 4. Brake master cylinder reservoir
2. Clutch fluid pipe
2
6
5 74
3
1
2
I5RW0B530002-03
[A]: LH steering vehicle
[B]: RH steering vehicle
I5RW0A530005-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-6
Installation
1) Install clutch operating cylinder assembly (2) to
transaxle. Tighten new mounting bolts to specified
torque.
Tightening torque
Clutch operating cylinder assembly mounting
bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
2) Connect clutch fluid pipe (4) to clutch operating
cylinder assembly temporarily.
3) Install clutch pipe joint sleeve (3) to transaxle
securely and then tighten clutch fluid pipe flare nut
(1) to specified torque.
Tightening torque
Clutch fluid pipe flare nut (b): 16 N·m (1.6 kgf-
m, 11.5 lb-ft)4) Remount transaxle assembly referring to “Manual
Transaxle Unit Dismounting and Remounting in
Section 5B”.
5) Bleed air from system and check clutch pedal free
travel. Refer to “Air Bleeding of Clutch System” and
“Clutch Pedal Inspection”.
Clutch Operating Cylinder Assembly InspectionS6RW0D5306013
Check clutch fluid leakage, spring for damage and
bearing for smooth rotation. If malfunction is found,
replace clutch operating cylinder assembly.
Clutch Cover, Clutch Disc and Flywheel ComponentsS6RW0D5306010
3
4
(a)
2
1, (b)
I5RW0A530009-01
I5RW0B530005-03
2
1
3(a)
6
4
5
(b)
I6RW0C530001-01
1. Clutch cover 4. Flywheel : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
2. Clutch disc 5. Input shaft bearing : 70 N⋅m (7.0 kgf-m, 51.0 lb-ft)
3. Clutch cover bolt 6. Flywheel bolt : Do not reuse.

Downloaded from www.Manualslib.com manuals search engine 5C-9 Clutch:
Clutch Disc
Measure depth of rivet head depression, i.e. distance
between rivet head and facing surface.
If depression is found to have reached service limit at
any of rivet holes (2), replace clutch disc assembly (1).
Rivet head depth
Standard: 1.65 – 2.25 mm (0.06 – 0.09 in.)
Limit: 0.5 mm (0.02 in.)Clutch Cover
1) Check diaphragm spring (1) for abnormal wear or
damage.
2) Inspect pressure plate (2) for wear or heat spots.
3) If abnormality is found, replace clutch cover.
Do not disassemble it into diaphragm spring and
pressure plate.
Flywheel
Check surface contacting clutch disc for abnormal wear
or heat spots. Replace or repair as required.
Specifications
Tightening Torque SpecificationsS6RW0D5307001
NOTE
The specified tightening torque is also described in the following.
“Clutch Cover, Clutch Disc and Flywheel Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I4RS0A530019-01
I3RM0A530015-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Clutch master cylinder nut 13 1.3 9.5)
Clutch operating cylinder assembly mounting
bolt10 1.0 7.5)
Clutch fluid pipe flare nut 16 1.6 11.5)
Flywheel bolt 70 7.0 51.0)
Clutch cover bolt 23 2.3 17.0)

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 Precautions: 6-1
Ste eri ng
Precautions
Precautions
Precautions on SteeringS6RW0D6000001
Air Bag Warning
Refer to “Air Bag System Service Warning in Section 00”.
Precautions for Steering Diagnosis
Refer to “Precautions for Steering Diagnosis in Section 6A”.
Service Precautions of Steering Wheel and Column
Refer to “Service Precautions of Steering Wheel and Column in Section 6B”.
P/S System Note
Refer to “P/S System Note in Section 6C”.