Power steer SUZUKI SX4 2006 1.G Service Service Manual

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Terminal Wire color Circuit Normal voltage Condition
E11-1 LT GRN/BLKIgnition switch signal for P/S
control module10 – 14 V Ignition switch ON
E11-2 — — — —
E11-3 — — — —
E11-4 PPL Vehicle speed signal*0 – 1 V
↑↓
8 – 14 V
(“Reference
waveform No.7”
under “Inspection
of BCM and Its
Circuits in
Section 10B”)• Ignition switch ON
• Front left tire turned quickly with right
tire locked
E11-5 GRY “EPS” warning light0 V Ignition switch ON
0 – 14 V Engine running
E11-6 — — — —
E11-7 — — — —
E11-8 GRN9 V power supply for torque
sensorAbout 9 V• Ignition switch ON
• Voltage between “E11-8” and “E11-9”
terminals
E11-9 BLK Ground for torque sensors — —
E11-10 WHT Torque sensor signal (Sub)About 2.5 – 4.0 V• Steering wheel with left turn
• Out put voltage varies linearly
depending on steering force
About 2.5 V Steering wheel at free
About 1.0 – 2.5 V• Steering wheel with right turn
• Out put voltage varies linearly
depending on steering force
E11-11 BLUSerial communication circuit for
data link connector——
E11-12 BRN Engine speed signal*0 – 1 V
↑↓
8 – 14 V
(“Reference
waveform No.24
and No.25” under
“Inspection of
ECM and Its
Circuits in
Section 1A”)Engine idling
E11-13 — — — —
E11-14 RED/BLU P/S active signal (idle up signal)About 12 V Ignition switch ON
0 – 1 VEngine idling and turned steering wheel
to the right or left until it stops
E11-15 — — — —
E11-16 — — — —
E11-17 — — — —
E11-18 YEL Torque sensor signal (Main)About 1.0 – 2.5 V• Steering wheel with left turn
• Out put voltage varies linearly
depending on steering force
About 2.5 V Steering wheel at free
About 2.5 – 4.0 V• Steering wheel with right turn
• Out put voltage varies linearly
depending on steering force
E11-19 GRY Ground for shield wire — —

Downloaded from www.Manualslib.com manuals search engine 6C-32 Power Assisted Steering System:
NOTE
*: The voltage of this circuit may not be checked by voltmeter. If so, use oscilloscope.

Reference waveform No.1
Motor output signal 1(1), Motor output signal 2(2), with
engine idlingE11-20 REDReference sensor power supply
for torque sensorAbout 3.0 – 3.5 V• Ignition switch ON
• Check voltage between “E11-20” and
“E11-9” terminals
E12-1 BLK Motor output 1*0 – 1 V
↑↓
10 – 14 V
(“Reference
waveform No.1: ”,
“Reference
waveform No.2: ”
and “Reference
waveform No.3: ”)• Engine idling and steering wheel at
straight position
• Voltage between “E12-1” and vehicle
body ground
E12-2 RED Motor output 2*0 – 1 V
↑↓
10 – 14 V
(“Reference
waveform No.1: ”,
“Reference
waveform No.2: ”
and “Reference
waveform No.3: ”)• Engine idling and steering wheel at
straight position
• Voltage between “E12-2” and vehicle
body ground
E13-1 GRNMain power supply for internal
memory and P/S motor10 – 14 V —
E13-2 BLK Ground for P/S control module Below 0.3 V — Terminal Wire color Circuit Normal voltage Condition
Measurement
terminalCH1: “E12-1” to vehicle body ground
CH1: “E12-2” to vehicle body ground
Oscilloscope
settingCH1: 5 V/DIV, CH2: 5 V/DIV
TIME: 20 µs/DIV
Measurement
condition• Engine is idling and steering
wheel at straight position
I6RS0B630017-01

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Reference waveform No.2
Motor output signal 1(1), Motor output signal 2(2), with
engine idlingReference waveform No.3
Motor output signal 1(1), Motor output signal 2(2), with
engine idling
Measurement
terminalCH1: “E12-1” to vehicle body ground
CH1: “E12-2” to vehicle body ground
Oscilloscope
settingCH1: 5 V/DIV, CH2: 5 V/DIV
TIME: 20 µs/DIV
Measurement
condition• Engine is idling and steering
wheel is turned to left or right at
turning speed of 90° /sec
[A]: Steering wheel is turned left at turning speed of 90° /sec
[B]: Steering wheel is turned right at turning speed of 90° /sec
[C]: 12 V ON
[D]: GND ON
[E]: 1 duty cycle
I6RS0B630018-01
Measurement
terminalCH1: “E12-1” to vehicle body ground
CH1: “E12-2” to vehicle body ground
Oscilloscope
settingCH1: 5 V/DIV, CH2: 5 V/DIV
TIME: 20 µs/DIV
Measurement
condition• Engine is idling and steering
wheel is kept fully turned to left or
right until it stops
[A]: Steering wheel is kept fully turned left unit it stops
[B]: Steering wheel is kept fully turned right unit it stops
[C]: 12 V ON
[D]: GND ON
I6RS0B630019-01

Downloaded from www.Manualslib.com manuals search engine 6C-34 Power Assisted Steering System:
Steering Wheel Play CheckS6RW0D6304021
• Check steering wheel for looseness or rattle by
moving it in its shaft direction and lateral direction.
If found defective, repair or replace.
• Check steering wheel for play, holding vehicle in
straight forward condition on the ground with engine
stopped.
If steering wheel play is not within specification,
inspect as follows and replace if found defective.
– Tie-rod end ball stud for wear (Ball stud should
move when more than 0.2 N⋅m (2 kg-cm, 0.44 lb-ft)
torque is applied.)
– Lower ball joint for wear
– Steering shaft joint for wear
– Steering pinion or rack gear for wear or breakage
– Each part for looseness
Steering wheel play
“a”
: 0 – 30 mm (0 – 1.18 in.)
Steering Force CheckS6RW0D6304022
1) Place vehicle on level road and set steering wheel at
straight-ahead position.
2) Check if tire inflation pressure is as specified
referring to the tire placard.
3) Remove driver air bag (inflator) module referring to
“Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
4) Start engine.
5) With engine idling, measure steering force by turning
torque wrench.
Steering force
: Less than 6.4 N⋅m (0.64 kgf-m, 4.6 lb-ft)
6) Install driver air bag (inflator) module referring to
“Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
I3RM0A630021-01
I3RM0A630022-01

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Repair Instructions
Steering Gear Case Assembly ComponentsS6RW0D6306001
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle the figure is symmetrical.

8
6
5
9
13
18
17
3
12
7(b)
(b)
(a)
(c)2
1
(e)
(d)
3
(a)
25
6
8
7
9
(b)
(b)
1621
1920
15
1207F
14
4
4
10
11
12(c)
12
(c)
10
11
I6RW0C630010-01
1. Steering gear case 11. Clip 21. O-ring
2. Tie-rod lock washer 12. Steering gear case mounting bolt
: Refer to “Steering Gear Case Assembly Removal and
Installation”. : 75 N⋅m (7.5 kgf-m, 54.5 lb-ft)
3. Tie-rod 13. Steering gear case grommet : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft)
4. Wire 14. Member bracket : 70 N⋅m (7.0 kgf-m, 51.0 lb-ft)
5. Boot 15. Steering rack plunger : Refer to “Steering Rack Plunger Removal and
Installation”.
6. Rack boot clip 16. Steering rack plunger spring : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)
7. Tie-rod end lock nut 17. Steering rack damper screw
: Apply sealant 99000-31250 to all around thread part of rack
damper screw.: Do not reuse.
8. Tie-rod end 18. Steering rack damper lock nut
9. Tie-rod end nut 19. Washer
10. Boot 20. Spring washer
: Make sure of the direction of installation referring to “Steering
Rack Plunger Removal and Installation”.

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Tie-Rod End Boot On-Vehicle InspectionS6RW0D6306002
Check boot for crack and damage. If any defect is found,
replace it with a new one.
Tie-Rod End Removal and InstallationS6RW0D6306003
Removal
1) Hoist vehicle, and then remove front wheel.
2) Remove tie-rod end nut (1) from steering knuckle.
3) Disconnect tie-rod end (1) from knuckle (2) using
puller (3).4) For ease of adjustment after installation, make
marking (1) of tie-rod end lock nut (2) position on tie-
rod end thread. Then, loosen lock nut and remove
tie-rod end (3) from tie-rod (4).
Installation
1) Install tie-rod end lock nut (1) and tie-rod end (2) to
tie-rod (3). Align lock nut with mark (4) on tie-rod
thread.
2) Connect tie-rod end to knuckle. Tighten tie-rod end
nut (1) to specified torque.
Tightening torque
Tie-rod end nut (a): 45 N·m (4.5 kgf-m, 32.5 lb-ft)
I3RM0A630024-01
I3RM0A630025-01
21
3
I4RS0A630040-01
I4RS0A630041-01
I4RS0A630042-01
I3RM0A630029-01

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3) Inspect for proper toe referring to “Front Wheel
Alignment Inspection and Adjustment in Section 2B”.
4) After confirming proper toe, tighten tie-rod end lock
nut to specified torque.
Tightening torque
Tie-rod end lock nut (a): 45 N·m (4.5 kgf-m, 32.5
lb-ft)
5) Tighten wheel bolts to specified torque and lower
hoist.
Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
Tie-Rod End InspectionS6RW0D6306004
• Inspect for play in ball joint.
• Inspect for play in rack end ball joint.
In either case, if found defective, replace.
Steering Shaft Joint On-Vehicle InspectionS6RW0D6306005
Check shaft joint for wear, breakage and any other
damage and replace if any defect exists.
Steering Gear Case Assembly Removal and
Installation
S6RW0D6306006
Removal
CAUTION!
Be sure to set front wheels (tires) in straight
direction and remove ignition key from key
cylinder before performing the following
steps, otherwise, contact coil of air bag
system may get damaged.

1) Remove steering joint cover.
2) Make alignment marks (1) on pinion shaft (2) and
joint of steering lower shaft (3) for a guide during
reinstallation.
3) Loosen joint bolt (steering column side) (4) and
remove joint bolt (pinion shaft side) (5) and
disconnect steering lower shaft (3) from pinion shaft
(2).
4) Disconnect torque sensor connector and P/S motor
connector from steering gear case.
5) Remove front suspension frame referring to “Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation in Section 2B”, and then
remove steering gear case.
Installation
1) Install grommet (1) as shown in figure.
I3RM0A630030-01
I4RS0A630043-01
I4RS0B630012-01
2. Protrusion
5
2
1
5
34
3
I4RS0B630013-01
1
2
1
2
I5RW0A630018-02

Downloaded from www.Manualslib.com manuals search engine 6C-38 Power Assisted Steering System:
2) Install steering gear case to vehicle, and then install
front suspension frame referring to “Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation in Section 2B”.
3) Install steering gear case to suspension frame (3) as
follows.
a) Set member bracket (2) to steering gear case
(1).
b) Install all steering gear case mounting bolts by
hand.
c) Tighten steering mounting bolts in numerical
order and specified torque.
Tightening torque
Steering gear case mounting bolt (a): 70 N·m (
7.0 kgf-m, 51.0 lb-ft)
4) Connect torque sensor connector and P/S motor
connector to steering gear case.
5) Be sure that steering wheel and brake discs (right &
left) are all straight-ahead position and then insert
steering lower shaft (5) into steering pinion shaft (3)
with matching marks (4).
6) Tighten steering shaft joint lower bolt (1) and upper
bolt (2) to specified torque (tighten lower side first
and then tighten upper side).
Tightening torque
Steering lower shaft assembly upper joint bolt
(a): 25 N·m (2.5 kgf-m, 18.5 lb-ft)
Steering lower shaft assembly lower joint bolt
(b): 25 N·m (2.5 kgf-m, 18.5 lb-ft)
7) Install steering joint cover.Steering Rack Boot InspectionS6RW0D6306007
Hoist vehicle.
Inspect each boot for tear. A torn boot allows entry of
dust and water which can cause wear to steering rack
and pinion to produce noise as well as rust to result in
malfunction of steering system.
Even if boot tear is small, replace with new one.
Also, check each boot for dent. If there is a dent, keep
boot in most compressed state for some seconds to
correct dent.
Boots should be visually inspected for any damage, dent
and tear during every periodical inspection at specified
intervals and whenever vehicle is hoisted for any other
purpose.
Tie-Rod / Rack Boot Removal and InstallationS6RW0D6306008
Removal
1) Remove steering gear case assembly referring to
“Steering Gear Case Assembly Removal and
Installation”.
2) Remove member bracket from steering gear case
assembly.
3) For ease of adjustment after installation, make
marking (1) of tie-rod end lock nut position of tie-rod
thread.
4) Loosen tie-rod end lock nut and remove tie-rod end.
5) Remove boot band (2) and clip (1).
6) Remove boot from tie-rod.I7RW01632009-01
5
4 1, (b)
3
2, (a)
1, (b)5
I5RW0A630020-01
I2RH01630012-01
I4RS0A630044-01
IYSQ01630034-01

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7) Unbend bent part of tie-rod lock washer (1).
8) Remove tie-rod (3) from rack (2).
Installation
1) Install tie-rod (1) and new tie-rod lock washer (3) to
rack (2).
2) Hold rack with soft jawed vise and tighten tie-rod to
specified torque.
Tightening torque
Tie-rod (a): 75 N·m (7.5 kgf-m, 54.5 lb-ft)
3) Bend lock washer at 2 places (1) as shown in figure.
4) Apply grease “A” to boot inside as shown in figure.
Position boot properly in grooves of gear case (or
rack side mount) and tie-rod.
After this, check to ensure that boot is free from twist
and dent.
“A”: Grease 99000–25050 (SUZUKI Super
Grease E) 5) Clamp boot with clip and wire. Wire should be new
and should go around the boot twice.
Pull its both ends together by screwdriver or such
and make sure that the wire won’t be crossed. Then
twist the ends 4 – 5 times, the twisted ends should
be bent in the circumferential direction.
NOTE
After clamping, make sure that the boot
installation part is fixed.
If the boot turns easily by hand, tighten with
higher torque to fix it firmly.

6) Install tie-rod end lock nut and tie-rod end to tie-rod.
Position lock nut to marking (1) made in removal.
NOTE
When tie-rod was replaced, measure length
“a” on removed tie-rod and use it on new
replacement tie-rod so as to position lock nut
properly.

7) Install member bracket (1), and then install earth
cable (2) as shown in figure.
Angle “a”
: Within 20°
Tightening torque
Earth cable bolt (a): 4.0 N·m (0.4 kgf-m, 2.8 lb-ft)
3
2
1I5RW0A630021-01
31, (a)
2
I6RW0B630019-01
I4RS0A630035-01
“A”
I7RW01632010-01
IYSQ01630035-01
I3RM0A630052-01
“a”
1
(a)
2
I6RW0C630011-01

Downloaded from www.Manualslib.com manuals search engine 6C-40 Power Assisted Steering System:
Steering Rack Plunger Removal and InstallationS6RW0D6306009
Removal
1) Loosen lock nut (1) with holding damper screw (2).
2) Remove lock nut (1), rack damper screw (2), rack
plunger spring (3), washer (5), spring washers (6),
O-ring (7) and rack plunger (4).
Installation
1) Install plunger (1), new O-ring (6), washer (4), spring
washers (5) and spring (2) as shown.
NOTE
Do not wipe off grease previously applied to
new plunger.

2) Apply sealant to rack damper screw (3) and tighten
them as follows.
a) Tighten damper screw to 25 N⋅m (2.5 kgf-m, 18.0
lb-ft).
b) Loosen damper screw until 180°.
c) Retighten damper screw to 3.9 N⋅m (0.39 kgf-m,
3.0 lb-ft).
d) After tightening rack damper screw to specified
torque, turn it back by 10° or less.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F)
Tightening torque
Rack damper screw (a): Tighten 25 N⋅m (2.5
kgf-m, 18.0 lb-ft) and loosen 180° and then
tighten 3.9 N⋅m (0.39 kgf-m, 3.0 lb-ft) and turn
it back by 10° or less by the specified
procedure.3) Pinion rotation torque should be checked with rack
position centered.
Also, check if rack as a whole moves smoothly.
Special tool
(A): 09944–18220
Tightening torque
Rotation torque of pinion (a): 2.2 N·m (0.22 kgf-
m, 1.5 lb-ft)
4) After adjustment, tighten lock nut to specified torque
with holding damper screw at the position.
Tightening torque
Steering rack damper lock nut: 60 N·m (6.0 kgf-
m, 43.5 lb-ft)Steering Rack Plunger InspectionS6RW0D6306010
NOTE
Do not wipe off grease applied to rack
plunger which is removed.

• Inspect rack plunger (1) for wear or damage.
• Inspect rack plunger spring (2) for deterioration.
If any abnormality is found, replace.
I5RW0A630024-02
I5RW0A630025-03
I3RM0A630055-02
I5RW0A630026-02