Switch SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 5B-16 Manual Transmission/Transaxle:
Manual Transaxle Assembly ComponentsS6RW0D5206014
I5RW0A520018-03
1. Transaxle right case 22. Shift fork bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
2. Transaxle left case
: Apply sealant 99000-31260 to mating surface of left case and right
case.23. 5th gear shift fork
3. Gear shift and select shaft assembly
: Apply sealant 99000-31260 to mating surface of guide case and left
case.24. Needle bearing
4. Transaxle left case plate 25. Input shaft 5th gear
5. Transaxle side cover
: Apply sealant 99000-31260 to mating surface of side cover and left
case.26. Reverse gear shift lever
6. Back up light switch 27. Reverse gear shift lever bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
7. O-ring28. Reverse gear shaft
8. Differential assembly 29. Washer
9. Oil level / filler plug
: Apply sealant 99000-31260 to all around thread part of plug.30. Reverse idler gear

Downloaded from www.Manualslib.com manuals search engine 5B-38 Manual Transmission/Transaxle:
4) Press-fit right bearing (1) by using special tools and
hydraulic press.
Special tool
(A): 09925–15410
(B): 09924–07720
(C): 09913–852305) Hold differential assembly with soft jawed vise (3),
install final gear (2) and then tighten new final gear
bolts (1).
CAUTION!
Use of any other bolts than specified ones is
prohibited. Otherwise, bolts may loosen.

Tightening torque
Final gear bolt (a): 90 N·m (9.0 kgf-m, 65.0 lb-ft)
Specifications
Tightening Torque SpecificationsS6RW0D5207001
NOTE
The specified tightening torque is also described in the following.
“Gear Shift Control Lever and Cable Components”
“Manual Transaxle Unit Components”
“Gear Shift and Select Shaft Assembly Components”
“Manual Transaxle Assembly Components”
“Gear Shift Shaft Components”
“Differential Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
2. Differential case
3. Differential side left bearing
I5RW0A520048-01I5RW0A520049-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Transaxle oil level / filler plug 21 2.1 15.5) / )
Transaxle oil drain plug 21 2.1 15.5)
Back up light switch 23 2.3 17.0)
Guide case bolt No.1 23 2.3 17.0)
Guide case bolt No.2 23 2.3 17.0)
Gear shift interlock bolt 23 2.3 17.0)
5th to reverse interlock guide bolt 23 2.3 17.0)
Countershaft nut 100 10.0 75.0)
Shift fork shaft bolt 10 1.0 7.5)
Side cover bolt 10 1.0 7.5)
Reverse gear shift lever bolt 23 2.3 17.0)
Transaxle case bolt 23 2.3 17.0)
Reverse shaft bolt 23 2.3 17.0)
Gear shift locating bolt 13 1.3 9.5)
Left case plate bolt 23 2.3 17.0)
Oil gutter bolt 10 1.0 7.5)
Final gear bolt 90 9.0 65.0)

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 6B-1 Steering Wheel and Column:
Ste eri ng
Steering Wheel and Column
Precautions
Service Precautions of Steering Wheel and ColumnS6RW0D6200001
For service precautions, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”.
Service and Diagnosis
For diagnosis and servicing, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”.
Disabling Air Bag System
For disabling air bag system, refer to “Disabling Air Bag System in Section 8B”.
Enabling Air Bag System
For enabling air bag system, refer to “Enabling Air Bag System in Section 8B”.
Handling and Storage
For handling and storage, refer to “Precautions on Handling and Storage of Air Bag System Components in Section
8B”.
Disposal
For disposal, refer to “Precautions on Disposal of Air Bag and Seat Belt Pretensioner in Section 8B”.
General Description
Steering Wheel and Column ConstructionS6RW0D6201001
This double tube type steering column has the following three important features in addition to the steering function:
• The column is energy absorbing, designed to compress in a front-end collision.
• The ignition switch and lock are mounted conveniently on this column.
• With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehicle.
To insure the energy absorbing action, it is important that only the specified screws, bolts and nuts be used as
designated, and that they are tightened to the specified torque. When the column assembly is removed from the
vehicle, special care must be taken in handling it. Use of a steering wheel puller other than the recommended puller in
this manual or a sharp blow on the end of the steering shaft, leaning on the assembly, or dropping the assembly could
shear the plastic shear pins which maintain column length and position.
The driver air bag (inflator) module is one of the supplemental restraint (air bag) system components and is mounted
to the center of the steering wheel. During certain frontal crashes, the air bag system supplements the restraint of the
driver’s and passenger’s seat belts by deploying the air bags. The air bag (inflator) module should be handled with
care to prevent accidental deployment. When servicing, be sure to observe “Precautions on Service and Diagnosis of
Air Bag System in Section 8B”.

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-4
Steering Wheel Removal and InstallationS6RW0D6206002
CAUTION!
Do not turn the contact coil more than
allowable number of turns (about two and a
half turns from the center position clockwise
or counterclockwise respectively) with
steering wheel removed, or coil will break.

Removal
CAUTION!
Do not hammer the end of the shaft.
Hammering it will loosen the plastic shear
pins which maintain the column length and
impair the collapsible design of the column.

1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air
Bag System in Section 8B”.
3) Remove driver air bag (inflator) module from
steering wheel. Refer to “Driver Air Bag (Inflator)
Module Removal and Installation in Section 8B”.
4) Disconnect horn connector and audio control switch
connector, if equipped.
5) Remove steering shaft nut and then make alignment
marks (1) on steering wheel and shaft for a guide
during reinstallation.6) Remove steering wheel using special tool.
Special tool
(A): 09944–36011
InstallationCAUTION!
Following 2 Steps (Step 1) and 2)) are
prerequisite for installation of steering wheel.
If steering wheel has been installed without
these 2 Steps, contact coil will break when
steering wheel is turned.

1) Check that vehicle’s front tires are at straight-ahead
position and contact coil is centered. If contact coil is
turned after removing steering wheel, center contact
coil referring to “Centering Contact Coil Cable
Assembly”.
2) Install steering wheel to steering shaft with 2 grooves
(1) on contact coil fitted in 2 lugs (2) in the back of
steering wheel and also aligning marks (3) on
steering wheel and steering shaft.
3) Tighten steering shaft nut (4) to specified torque.
Tightening torque
Steering shaft nut (a): 33 N·m (3.3 kgf-m, 24.0 lb-
ft)
I4RS0A620005-01
(A)
I4RS0A620006-01
I4RS0A620007-01

Downloaded from www.Manualslib.com manuals search engine 6B-5 Steering Wheel and Column:
4) Connect horn connector and audio control switch
connector, if necessary.
5) Install driver air bag (inflator) module to steering
wheel. Refer to “Driver Air Bag (Inflator) Module
Removal and Installation in Section 8B”.
6) Connect negative (–) cable to battery.
7) Enable air bag system referring to “Enabling Air Bag
System in Section 8B”.
Contact Coil Cable Assembly Removal and
Installation
S6RW0D6206003
CAUTION!
Do not turn contact coil more than allowable
number of turns (about two and a half turns
from the center position clockwise or
counterclockwise respectively), or coil will
break.

Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air
Bag System in Section 8B”.
3) Remove steering wheel from steering column
referring to “Steering Wheel Removal and
Installation”.
4) Remove steering column hole cover.
5) Remove steering column lower cover (2) and upper
cover (1).6) Remove contact coil cable assembly (1) from
steering column.
Installation
1) Check to make sure that vehicle’s front tires are set
at straight-ahead position and then ignition switch is
at LOCK position.
2) Install contact coil cable assembly to steering
column securely.
NOTE
New contact coil cable assembly is supplied
with contact coil set and held at its center
position with a lock pin (1). Remove this lock
pin after installing contact coil cable
assembly to steering column.

2
1
I6RW0B620005-01
1I6RW0B620009-02
I4RS0A620010-01

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-6
3) Install steering column upper cover (1) and lower
cover (2).
CAUTION!
When installing covers, be careful so that
each lead wire is not caught between covers.
Otherwise, each lead wire is damaged.

4) Install steering wheel to steering column. Refer to
“Steering Wheel Removal and Installation”.
5) Connect negative (–) cable to battery.
6) Enable air bag system referring to “Enabling Air Bag
System in Section 8B”.
Centering Contact Coil Cable AssemblyS6RW0D6206004
1) Check that vehicle’s wheels (front tires) are set at
straight-ahead position.
2) Check that ignition switch is at LOCK position.
3) Turn contact coil counterclockwise slowly with a light
force till contact coil will not turn any further.
NOTE
Contact coil can turn about 5 turns at the
maximum, that is, if it is at the center
position, can turn about two and a half turns
both clockwise and counterclockwise.

4) From the position where contact coil became unable
to turn any further (it stopped), turn it back clockwise
about two and a half rotations and align center mark
with alignment mark (1).
Contact Coil Cable Assembly InspectionS6RW0D6206005
Refer to “Contact Coil Cable and Its Circuit Check in
Section 8B”.
Steering Column Removal and InstallationS6RW0D6206008
CAUTION!
Once the steering column is removed from
the vehicle, the column is extremely
susceptible to damage.
• Dropping the column assembly on its end
could collapse the steering shaft or loosen
the plastic shear pins which maintain
column length.
• Leaning on the column assembly could
cause it to bend or deform.
Any of the damage could impair the column’s
collapsible design.
Steering column mounting nuts should not
be loosened with steering shaft joint upper
side bolt tightened as this could cause
damage to shaft joint bearing.

NOTE
When servicing steering column or any
column-mounted component, remove
steering wheel. But when removing steering
column simply to gain access to instrument
panel components, leave steering wheel
installed on steering column.

3. Standard screw 4. Tapping screw
2
1
3
4
I6RW0B620003-01
I4RS0A620012-01
1
I4RS0A620013-01

Downloaded from www.Manualslib.com manuals search engine 6B-7 Steering Wheel and Column:
Removal
WARNING!
Never rest a steering column assembly on
the steering wheel with the air bag (inflator)
module face down and column vertical.
Otherwise, personal injury may result.

1) Disconnect negative (–) cable at battery.
2) Disable air bag system. Refer to “Disabling Air Bag
System in Section 8B”.
3) Remove steering wheel and contact coil cable
assembly referring to “Steering Wheel Removal and
Installation” and “Contact Coil Cable Assembly
Removal and Installation”.
4) (Immobilizer model)
Remove immobilizer control module from steering
column, referring to “ICM Removal and Installation in
Section 10C”.
5) Detach lighting switch and wiper switch from steering
column.
6) Remove lower shaft upper joint bolt (1).
7) Remove steering column mounting nuts (1), and
then remove steering column from vehicle.
NOTE
Do not move tilt lever until mounting bolts
and nuts are tightened to specified torque.

Installation
CAUTION!
After tightening steering column mounting
nuts, shaft joint bolts should be tightened.
Wrong tightening order could cause a
damage to shaft joint.

1) Be sure that front wheels are in straight.
2) Install steering column assembly to lower and upper
brackets. Tighten steering column mounting nuts
No.2 (1) first and then steering column mounting
nuts No.1 (2) to specifications as given below.
Tightening torque
Steering column mounting nut No.1 (a): 14 N·m (
1.4 kgf-m, 10.5 lb-ft)
Steering column mounting nut No.2 (b): 14 N·m (
1.4 kgf-m, 10.5 lb-ft)
NOTE
• When installing, make sure that clearance
“a” between bolt (3) and bracket (4) should
be 0 (zero).
• After installing tilt steering column, make
sure that steering column moves upwards
and downwards smoothly and stops when
tilt lever is fixed.

1
I5RW0A620005-01
1
1
I4RS0A620017-01
2, (a)
1, (b)
1, (b) 2, (a)
4
3“a” “a”
I5RW0A620006-02

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-8
3) Align flat part “a” of steering lower shaft (1) with bolt
hole “b” of shaft joint (2) of column as shown. Then
insert lower shaft into shaft joint of steering column.
4) Tighten lower shaft upper joint bolt (3) to specified
torque.
CAUTION!
After tightening column nuts, tighten steering
shaft upper joint bolt. Otherwise, shaft joint
bearing is damaged.

Tightening torque
Steering lower shaft assembly upper joint bolt
(a): 25 N·m (2.5 kgf-m, 18.5 lb-ft)
5) Install lighting switch and wiper switch to steering
column.
6) (Immobilizer model)
Install immobilizer control module from steering
column, referring to “ICM Removal and Installation in
Section 10C”.
7) Install contact coil cable assembly and steering
wheel referring to “Contact Coil Cable Assembly
Removal and Installation” and “Steering Wheel
Removal and Installation”.
8) Connect negative (–) cable to battery.
9) Enable air bag system referring to “Enabling Air Bag
System in Section 8B”.
Steering Column InspectionS6RW0D6206009
Check steering column for damage and operation
referring to “Checking Steering Column for Accident
Damage”.
Ignition Switch Cylinder Assembly Removal
and Installation (Non- Keyless Start Model)
S6RW0D6206010
Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air
Bag System in Section 8B”.
3) Remove steering column upper and lower covers.
4) (Immobilizer model)
Remove immobilizer control module referring to
“ICM Removal and Installation in Section 10C”.
5) Remove ignition switch cylinder assembly as follows.
a) Turn ignition key to “ACC” position.
b) Insert 2 mm (0.078 in.) rod (2) through hole (3)
and push ignition switch cylinder lock.
c) Detach ignition switch cylinder assembly (1) from
steering lock assembly (4).
Installation
1) Install ignition switch cylinder assembly as follows.
a) Turn ignition key to “ACC” position.
b) In this state, push ignition switch cylinder
assembly into steering lock assembly till it clicks.
2) (Immobilizer model)
Install immobilizer control module referring to “ICM
Removal and Installation in Section 10C”.
3) Install upper and lower cover and screws.
4) Connect negative (–) cable to battery.
5) Enabling air bag system referring to “Enabling Air
Bag System in Section 8B”.
6) (Immobilizer model)
If ignition switch cylinder assembly (that is ignition
key) has replaced, register ignition key transponder
code to ECM referring to “Registration of the Ignition
Key in Section 10C”.
1 2
“a”“b”
3, (a)
I5RW0A620007-01
2
3
1
4
I5JB0A620025-01

Downloaded from www.Manualslib.com manuals search engine 6B-9 Steering Wheel and Column:
Steering Lock Assembly (Ignition Switch)
Removal and Installation
S6RW0D6206011
Removal
1) Remove steering column. Refer to “Steering Column
Removal and Installation”.
2) Using center punch (1), loosen and remove steering
lock mounting bolts (2).
NOTE
Use care not to damage aluminum part of
steering lock body with center punch.

3) Turn ignition key to “ACC” or “ON” position and
remove steering lock assembly from steering
column.Installation
1) Position oblong hole (1) of steering shaft (2) in the
center of hole (3) in column (4).
2) Turn ignition key to “ACC” or “ON” position and
install steering lock assembly (5) onto column (4).
3) Now turn ignition key to “LOCK” position and pull it
out.
4) Align hub on lock with oblong hole (1) of steering
shaft (2) and rotate shaft to assure that steering shaft
is locked.
5) Tighten new bolts (1) until head of each bolt is
broken off.
6) Turn ignition key to “ACC” or “ON” position and
check to be sure that steering shaft (2) rotates
smoothly. Also check for lock operation.
7) Install steering column. Refer to “Steering Column
Removal and Installation”.
8) (Keyless start model)
If steering lock assembly has replaced, after
completing installation, register steering lock unit ID
code to keyless start control module as following.
• Immobilizer model:
Register ignition key transponder code in ECM
referring to “Registration of the Ignition Key in
Section 10C”.
• Non-immobilizer model:
Register steering lock unit ID code in keyless start
control module referring to “Keyless Start
Registration in Section 10E”.
I4RS0B620005-02
1
32
4
5
I4RS0B620006-02
I4RS0B620007-02