BCM SUZUKI SX4 2006 1.G Service Service Manual

Downloaded from www.Manualslib.com manuals search engine 5A-10 Automatic Transmission/Transaxle:
Schematic and Routing Diagram
Transmission Control Module (TCM) Wiring DiagramS6RW0D5102001
12V
12V
12V
IG1
118
9
10
P
R
N
D
2
L12
2.5V
5V
12V
5V
12V
12V
12V
WHT
BLK
BLK
BLK
BLK
PPLBLK/WHT
BLK/ORN
IG11
RED/BLK
YEL/BLKYEL/BLU
LT GRN/BLK
+BB
WHT/RED
14
20 15
16
17
19
12V18
1 2
3
132126
24 27
28
29
30
65
16 15 14 13 12 1143
24 23 212210 9 8 721
19 20 18 17 C06
17 16
26 2515 14 65 342
13 12
23 22 2411 10 9
21 20 1987
18 1 C07
[A]
22
25
YELYEL/GRN
WHT
P
N
BRN LT/GRN
ORN
BLK/YEL
BLU/BLK
GRY
LT GRN/BLKWHT/BLU
WHT/BLK
C06-11
C06-12
C06-16
C06-15
C06-14
C06-4
C06-2
C06-1
C06-23C06-6 C06-24C06-5
C06-3
RED
GRN GRN/ORNPNK/BLK
GRN/YEL
LT GRN/BLKC07-6
C07-16
C07-23 C07-25
C07-20
C07-1
C07-8
C07-7
C07-19
C07-18
4IG11 23
C07-9
YEL
RED
WHTBLU35 34
3637
5REDWHT
7
WHT
RED
33
4
6
C06-7C06-17WHT
REDREDWHT
WHT
12V12V
WHTRED
WHTREDREDWHT
31
32
RED
WHTRED[B]
[C]
I6RW0D510003-02
1. TCM 15. Shift solenoid valve-A (No.1) 29. “ST SIG” fuse
2. Input shaft speed sensor 16. Shift solenoid valve-B (No.2) 30. “ST” fuse
3. Output shaft speed sensor / VSS 17. Timing solenoid valve 31. MIL
4. ECM 18. TCC solenoid valve 32. Transmission warning light (non-Euro-OBD model)
5. Combination meter 19. Pressure control solenoid valve 33. ABS control module
6. BCM 20. A/T 34. To Data link connector
7. 4WD control module (if equipped) 21. A/T relay 35. To BCM
8. “3” position switch 22. Inhibitor switch (including transmission range
sensor)36. Junction connector
9. Shift lock solenoid 23. Starter motor relay 37. Keyless start control module (if equipped)
10. Brake light switch 24. Ignition switch [A]: Terminal arrangement of TCM connector (viewed
from harness side)
11. Transmission range sensor 25. Starter motor [B]: Junction block with BCM model
12. Backup lamp 26. “DOME” fuse [C]: Junction block without BCM model
13. Data link connector (DLC) 27. “AT” fuse
14. Transmission fluid temperature sensor 28. “IG1 SIG” fuse

Downloaded from www.Manualslib.com manuals search engine 5A-14 Automatic Transmission/Transaxle:
Component Location
Electronic Shift Control System Components LocationS6RW0D5103001
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

5*
17
15
1
2
8
9
1011
12
13
16*18 19
14
7
6
3420
[B]
[A]5*
I6RW0D510004-01
[A]: Junction block with BCM model 7. Input shaft speed sensor 15. ECM
[B]: Junction block without BCM model 8. TCC solenoid valve 16. TCM
1. Engine 9. Transmission fluid temperature sensor 17. AT relay
2. Transaxle 10. Timing solenoid valve 18. “3” position switch
3. MIL 11. Pressure control solenoid valve 19. Select lever
4. Transaxle select position indicator 12. Shift solenoid valve-B (No.2) 20. Transmission warning light (non-Euro-OBD model)
5. Junction block assembly (included in BCM) 13. Shift solenoid valve-A (No.1)

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-15
6. Output shaft speed sensor (VSS) 14. Transmission range sensor
EngineTorque converter with
torque converter clutch
Oil pumpRegulator valves
in valve body
Planetary gear
unit
Clutches and
brakes
Control valves
in valve body
Shift solenoid valves,
TCC solenoid valve and
Timing solenoid valve Pressure control
solenoid valve
Final gear
reduction unit
Engine control module (ECM)
Body control module (BCM)
Combination meter
· Engine torque signal
· Engine speed signal
Transmission control module (TCM)
· Torque request signal
· Throttle position signal
· Accelerator pedal position signal
· Engine coolant temperature signal
· Brake pedal switch signal
· Driving cycle active
· Warm up cycle active
Accelerator pedal
position sensor
Crank shaft
position sensor
Engine coolant
temperature sensor
Input shaft speed sensor
Brake light switch
“3” position switch
Transmission range sensor
Transmission fluid
temperature sensor
Output shaft speed
sensor (VSS)
Power transmission
Fluid pressure circuit
Electric signal
Data link connector
· Transmission diagnostic trouble code (DTC) · Vehicle speed pulse signal
· Transmission warning light signal
· A/T select lever position signal
· Transmission actual gear position signal
· Transmission oil temperature signal · MIL control signal
ABS control module
· A/C compressor clutch signal
I6RW0D510005-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-69
DTC Troubleshooting
DTC P1878: Torque Converter Clutch ShudderS6RW0D5104041
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out with 2 persons, a driver and tester, on a level road.

1) Connect scan tool to DLC with ignition switch OFF.
2) Clear DTCs in TCM and ECM memories by using scan tool.
3) Start engine and warm it up to normal operating temperature.
4) Drive vehicle with 3rd or 4th gear in “D” range and slip controlled lock-up ON for 20 seconds or longer referring to
“Automatic Gear Shift Table”.
5) Stop vehicle.
6) Check DTC, pending DTC and freeze-frame data.
DTC TroubleshootingStep Action Yes No
1Was “A/T System Check” performed?Go to Step 2. Go to “A/T System
Check”.
2“3” position switch circuit for operation
1) Connect SUZUKI scan tool to DLC with ignition switch
OFF.
2) Turn ignition switch ON and check “3” position switch
signal on scan tool data display when shifting select
lever to each range.
Does indicate “3” position switch condition OFF when
shifting select lever to “P”, “R”, “N” and “L” range?Substitute a known-
good TCM and recheck.Go to Step 3.
3“3” position switch signal inspection
With ignition switch ON, check voltage between “C07-9”
terminal of TCM coupler and ground.
“3” position switch specifications
Shift select lever to “3” or “2” range: Battery voltage
Shift select lever to other above range: 0 V
Is the result as specified?Substitute a known-
good BCM and recheck.Go to Step 4.
4Check “3” position switch operation
Is it in good condition?“YEL” wire shorted to
ground.Replace “3” position
switch.
DTC detecting condition Trouble area
The acceleration slip control function stops when the variation in the
output revolution speed of the specified amplitude and specified cycle
is detected within a specified period of time. When the specified
variation is not detected after the acceleration slip control stops.•Mismatching ATF
• Torque converter clutch malfunction
• Valve body
Step Action Yes No
1Was “A/T System Check” performed?Go to Step 2. Go to “A/T System
Check”.
2 Change A/T fluid referring to “A/T Fluid Change”.
Check DTC after performing “DTC Confirmation Procedure”.
Is DTC P1878 still indicated?Faulty torque converter
clutch.
Replace torque
converter.System is in good
condition.

Downloaded from www.Manualslib.com manuals search engine 6C-2 Power Assisted Steering System:
General Description
P/S System DescriptionS6RW0D6301001
This electronic power steering (EPS) system consists of a power steering (P/S) control module (3), a torque sensor
(4), a P/S motor (5). In this system, the P/S control module determines the level and direction of the assist force for the
steering wheel (1) according to the signal from the torque sensor and the vehicle speed signal from BCM (9). The P/S
control module runs the motor so as to assist the operation of the steering wheel.
The P/S control module diagnoses troubles which may occur in the area including the following components when the
ignition switch is ON and the engine is running. When the P/S control module detects any malfunction, it stops the
motor operation.
• Torque sensor
• Vehicle speed signal circuit
• Engine speed signal circuit
• P/S Motor
• P/S control module.
1
32
4
6
7
5
8
9
I7RW01632001-01
2. Steering column 7. Battery
6. Steering gear case assembly 8. ECM

Downloaded from www.Manualslib.com manuals search engine 6C-4 Power Assisted Steering System:
Schematic and Routing Diagram
EPS System Wiring Circuit DiagramS6RW0D6302001
[A]
123
45
3 21
4
567
8
9 11
10 12 13
141516
17 18 19201
2
[B]
1
2
[C] [D]
10 9 8 7654 3 21
16 15 14 13 12 11
26 25 24 2322 21 20 19 18 17
32 31 30 29 28 27
[F][E]
12
BRN RED/
BLU GRY LT GRN/
BLK
BLK
RED
WHT GRN
BLK
E11-1
E11-5
E11-14
E11-12
[J]:E01-44E01-4
[J]:E01-27E01-26
E12-1
E12-2
E11-10E11-8
E11-9
E11-19
E13-1 GRN
GRY
GRN
WHT
G241-25G241-31
RED/BLK
11
12
1314 3 18
20
21
7 19
4 12
22
12V
E13-2BLK
9V
REDE11-20
12V
12V
E61-2
E61-1
610
55
5V
8
E11-115V
PPL
E11-4
9
23
+BB
BLU/
WHTE04-9
1524YELE11-18E31-5
E31-2
E31-39V
3V
E31-4
E31-1IG11617
C07-25
[H]
[G]
G04-15
[I]:G04-22
25L313-3
[I]
I6RW0D630001-01
[A]: P/S control module connector No.1 “E11” (viewed from harness side) 3. Junction block assembly 15. BCM
[B]: P/S control module connector No.2 “E13” (viewed from harness side) 4. Main fuse 16. Output shaft speed sensor
[C]: P/S control module connector No.3 “E12” (viewed from harness side) 5. Front (left/right) wheel speed sensor 17. TCM
[D]: Combination meter connector “G241” (viewed from harness side) 6. ABS control module 18. Individual circuit fuse box No.1
[E]: Torque sensor connector “E31” (viewed from harness side) 7. Combination meter 19. “IGN” fuse
[F]: Motor connector “E61” (viewed from harness side) 8. “EPS” warning light 20. “P/S” fuse
[G]: M/T model 9. Data link connector (DLC) 21. “IG1 SIG” fuse
[H]: A/T model 10. ECM 22. “MTR” fuse
[I]: Junction block without BCM model (Taiwan model) 11. P/S control module 23. To ABS control module
[J]: M15A engine with 4A/T equipped with slip control model (Hong Kong
model)12. P/S motor 24. To HVAC control module
1. Main fuse box 13. Shield 25. To SDM
2. Ignition switch 14. Torque sensor (built into steering gear case)

Downloaded from www.Manualslib.com manuals search engine 6C-10 Power Assisted Steering System:
)
C1121No vehicle speed signal
(60 Seconds or More)Vehicle speed signal is 0 km/h
even though engine speed is
more than 4000 rpm for more
than 60 seconds continuously
(before elapse of 5 min from
engine start)
or
vehicle speed signal is 0 km/h
even though engine speed is
more than 2500 rpm for more
than 60 seconds continuously
(after elapse of 5 min for engine
start).• Vehicle speed signal
circuit
•BCM
•ECM
• TCM (A/T model)
• ABS control module (M/
T model)
• P/S control module
• CAN communication
line circuit1 driving
cycleDoes not
light up
)
C1122Engine speed signalEngine speed signal is less than
220 rpm for more than 0.8
seconds.
or
Engine speed signal is less than
220 rpm for more than 20
seconds continuously even
though vehicle speed signal is
more than 50 km/h.• Engine speed signal
circuit
•ECM
• P/S control module1 driving
cycle1 driving
cycle
)
C1123No vehicle speed signal
(30 seconds or more)Vehicle speed signal is 0 km/h
with continuously more than 3
driving cycles even though
engine speed is more than 4000
rpm for more than 30 seconds
continuously (before elapse of 5
min from engine start)
or
vehicle speed signal is 0 km/h
with continuously more than 3
driving cycles even though
engine speed is more than 2500
rpm for more than 30 seconds
continuously (after elapse of 5
min for engine start).• Vehicle speed signal
circuit
•BCM
•ECM
• TCM (A/T model)
• ABS control module (M/
T model)
• P/S control module
• CAN communication
line circuit3 driving
cycle3 driving
cycle
)
C1124Vehicle speed
performance
(impossible
deceleration) Vehicle speed signal is less than
5 km/h for more than 5 seconds
continuously with more than
specified deceleration speed (–
20 m/s
2) from over 20 km/h.1 driving
cycleDoes not
light up DTC No. Detecting itemDetecting condition
(DTC will set when detecting)Trouble area DTC“EPS”
warning
light

Downloaded from www.Manualslib.com manuals search engine 6C-12 Power Assisted Steering System:
Scan Tool DataS6RW0D6304007
NOTE
When P/S motor is cold condition (that is, armature coil of P/S motor is not heated), normal value with
asterisk (*) mark in the following table is displayed on scan tool

Scan Tool Data Definitions
Power Supply Voltage
This parameter indicates battery positive voltage.
Sensor Power Supply (Torque Sensor Power Supply,
V)
This parameter indicates the power supply voltage which
the P/S control module supplies to the torque sensor.
Sensor (Main) Torque (Torque Sensor Main Torque,
N⋅m)
The torque sensor is installed to detect the steering force
and the steering direction. It consists of two
potentiometers and the main torque sensor is one of
these.
Sensor (Sub) Torque (Torque Sensor Sub Torque,
N⋅m)
The torque sensor is installed to detect the steering force
and the steering direction. It consists of two
potentiometers and the sub-torque sensor is one of
these. Its output characteristics are compared with those
of the main torque sensor.Control Torque (N⋅m)
This parameter is an internal parameter of the P/S
control module. It is obtained by computing the torque
sensor input signal.
Target Motor Current (Motor Control Current, A)
Based on the input signal, the P/S control module
determines the assist amount and controls the current to
the motor suitable for that assist amount. This parameter
indicates that control value.
Measured MOT Current (Motor Monitor Current, A)
This parameter indicates the actually measured value of
the current flowing to the motor. The motor circuit
condition is diagnosed by comparing this parameter with
“Motor Control” parameter described previously.
Vehicle Speed (km/h, MPH)
Vehicle speed signal is fed from BCM. P/S control
module determines the amount of power assist based on
this vehicle speed signal and the torque sensor signal.
Engine Speed (rpm)
Engine speed signal is fed from the ECM so that it can
be used for trouble diagnosis of the electric power
steering system. Scan tool data Vehicle condition Normal condition
) Power Supply Voltage
Ignition switch ON10 – 14 V
) Sensor Power Supply7.4 – 10 V
) Sensor (Main) TorqueEngine running at idle
speedSteering wheel at fully turned to left –10.5 – 0 N⋅m
Steering wheel at free 0 N⋅m
Steering wheel at fully turned to right 0 – 12.85 N⋅m
) Sensor (Sub) Torque Engine running at idle
speedSteering wheel at fully turned to left 0 – 10.65 N⋅m
Steering wheel at free 0 N⋅m
Steering wheel at fully turned to right –12.85 – 0 N⋅m
) Control TorqueEngine running at idle
speedSteering wheel at fully turned to left –7.22 – 0 N⋅m
Steering wheel at free 0 N⋅m
Steering wheel at fully turned to right 0 – 7.16 N⋅m
) Target Motor CurrentEngine running at idle
speedSteering wheel at free 0 A
Steering wheel at fully turned to left or
right*45 – 60 A
) Measured MOT
Current
Engine running at idle
speedSteering wheel at free 0 A
Steering wheel at fully turned to left or
right*45 – 60 A
) Vehicle Speed Engine running and vehicle at stop 0 km/h
) Engine Speed Engine running at idle speed after warming up 700 ± 50 rpm
) Motor Drive VoltageEngine running at idle
speedSteering wheel at free 0.8 – 1 V
Steering wheel at fully turned to right *5.5 – 8.5 V
) System Power Status
Ignition switch ONON
) IGN switch StatusON
) Torque sensor Status
Engine running at idle speedON
) Fail Safe FET StatusON

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-13
Motor Drive Voltage (V)
This parameter indicates the voltage between motor
terminals.
System Power Status (EPS System Power, ON, OFF)
This parameter indicates input status of EPS system
power supply.
IGN switch Status (ON, OFF)
This parameter indicates the condition of the power
supply through the ignition switch.Torque sensor Status (ON, OFF)
This parameter indicates the output status of the torque
sensor power supply.
Fail Safe FET Status (ON, OFF)
This parameter indicates the status of the motor drive
power supply circuit.
P/S System Symptom DiagnosisS6RW0D6304008
This section describes trouble diagnosis of the P/S system parts whose trouble is not indicated by the on-board
diagnostic system (self-diagnostic function). When no malfunction is indicated by the on-board diagnostic system
(self-diagnosis function) and assuredly those steering basic parts as described in “Steering Symptom Diagnosis in
Section 6A” are all in good condition, check the following power steering system parts which may be a possible cause
for each symptom of the steering.
Condition Possible cause Correction / Reference Item
Steering wheel feels
heavy (Perform “Steering
Force Check:” before
diagnosis.)Steering wheel installed improperly
(twisted)Install steering wheel correctly.
Poor performance of P/S motorCheck P/S motor referring to “P/S Motor and
Its Circuit Inspection”.
Poor performance of torque sensorCheck torque sensor referring to “Torque
Sensor and Its Circuit Inspection”.
Steering gear case assembly
malfunctionReplace steering gear case assembly.
Poor performance of vehicle speed
signal from BCMCheck vehicle speed signal circuit referring to
“DTC C1121 / C1123 / C1124: Vehicle Speed
Signal Circuit Failure”.
Steering wheel feels
heavy momentarily when
turning it to the left or
rightSteering gear case assembly
malfunctionReplace steering gear case assembly.
Poor recovery from turnsPoor performance of torque sensorCheck torque sensor referring to “Torque
Sensor and Its Circuit Inspection”.
Steering gear case assembly
malfunctionReplace steering gear case assembly.
Vehicle pulls to one side
during straight drivingPoor performance of torque sensorCheck torque sensor referring to “Torque
Sensor and Its Circuit Inspection”.
Steering gear case assembly
malfunctionReplace steering gear case assembly.
Abnormal noiseP/S motor (built in steering gear case
assembly) malfunctionReplace steering gear case assembly.
No idle upP/S control module faultyCheck P/S control module referring to
“Inspection of P/S Control Module and Its
Circuits”.

Downloaded from www.Manualslib.com manuals search engine 6C-14 Power Assisted Steering System:
DLC and Its Communication Check (No communication to P/S Control Module)S6RW0D6304009
Wiring Diagram
Troubleshooting
[A]
123
4567
8
9 11
10 12 13
141516
17 18 1920
1
2
[B]
10 9 8 7654 3 21
16 15 14 13 12 11
26 25 24 2322 21 20 19 18 17
32 31 30 29 28 27
[C]
LT GRN/BLKE11-1
E11-11
E13-1 GRN
GRN
WHT
8
13
318
19
20
5
6 17
4
12
712V
E13-2BLK
9
G241-31
+BB
BLU/
WHTE04-9
10
11
RED/BLK
G241-25E11-5GRY
L313-312
BLKBLK/
ORN
16
16
15
14[D]
I6RW0D630002-01
[A]: P/S control module connector No.1 “E11” (viewed from harness side) 5. Combination meter 13. Individual circuit fuse box No.1
[B]: P/S control module connector No2 “E13” (viewed from harness side) 6. “EPS” warning light 14. Serial data circuit
[C]: Combination meter connector “G241” (viewed from harness side) 7. Data link connector (DLC) 15. DLC power supply circuit
[D]: Junction block without BCM model (Taiwan model) 8. P/S control module 16. DLC ground circuit
1. Main fuse box 9. BCM 17. “IGN” fuse
2. Ignition switch 10. To HVAC control module 18. “P/S” fuse
3. Junction block assembly 11. To ABS control module 19. “IG1 SIG” fuse
4. Main fuse 12. To SDM 20. “MTR” fuse
Step Action Yes No
1“EPS” warning light check
1) Turn ignition switch to ON position.
Does “EPS” warning light turn on?Go to step 2. Go to ““EPS” Warning
Light Does Not Come
ON with Ignition Switch
Turned ON before
Engine Starts”.
2Scan tool condition check
1) Make sure that SUZUKI scan tool is as follows.
• Correct PCMCIA card (software) is used.
• There are no deformation and wear for DLC cable
terminals.
• Connection for DLC cable terminals is in good
condition.
Are they OK?Go to step 3. Repair or replace
defective part.