low oil pressure SUZUKI SX4 2006 1.G Service Service Manual

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CAUTION!
After attaching oil pressure gauge, check that no fluid leakage exists.

4) Depress foot brake fully, run engine at idle and stall then check fluid pressure in “D” or “R” range.
CAUTION!
• Do not continue running engine at stall speed longer than 5 seconds.
• After performing line pressure test, be sure to leave engine running at idle for longer than one
minute before performing another line pressure test.

Automatic transaxle line pressure
Troubleshooting
“P” Range TestS6RW0D5104016
1) Stop vehicle on a slope of 5 degrees or more, shift select lever to “P” range and at the same time apply parking
brake.
2) After stopping engine, depress brake pedal and release parking brake.
3) Then, release brake pedal gradually and check that vehicle remains stationary.
4) Depress brake pedal and shift select lever to “N” range.
5) Then, release brake pedal gradually and check that vehicle moves.
WARNING!
Before test, make sure no one is around vehicle or down on a slope and keep watchful for safety
during test.

Troubleshooting“D” range “R” range
At idle
speed3.7 – 4.1 kg/cm
2,
53 – 58psi5.9 – 6.8 kg/cm2,
84 – 97 psi
At stall
speed12.5 – 13.7 kg/cm
2,
178 – 195 psi16.5 – 19.0 kg/cm2,
235 – 270 psi
Condition Possible cause Correction / Reference Item
Higher than standard
level in each rangeMalfunction of pressure control solenoid
valve (Low line pressure)Inspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Lower than standard level
in each rangeMalfunction of pressure control solenoid
valve (Low line pressure)Inspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Clogged oil strainerReplace.
Faulty oil pumpInspect. If NG, replace.
Leakage from both “D” and “R” range
fluid pressure circuitOverhaul or replace valve body assembly.
Lower than standard level
only in “D” rangeLeakage from “D” range fluid pressure
circuitOverhaul or replace valve body assembly.
Lower than standard level
only in “R” rangeLeakage from “R” range fluid pressure
circuitOverhaul or replace valve body assembly.
Condition Possible cause Correction / Reference Item
Vehicle moves at “P”
range or remains
stationary at “N” rangeDefective parking lock pawl or springInspect. If NG, repair.

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Transmission Warning Light Circuit Check – Light Remains “ON” at Ignition Switch ON (Non-Euro-
OBD Model)
S6RW0D5104054
Troubleshooting
Transmission Warning Light Circuit Check – Light Does Not Come “ON” at Ignition Switch ON (Non-
Euro-OBD Model)
S6RW0D5104055
TroubleshootingNon operate TCC (lock-
up) systemFaulty torque converterReplace.
Excessive “N”
→ “D” time
lagFaulty oil pumpInspect. If NG, replace.
Faulty forward clutchInspect. If NG, replace.
Faulty one-way No.2 clutchInspect. If NG, replace.
Leakage from “D” range fluid pressure
circuitOverhaul or replace valve body assembly.
Excessive “N”
→ “R” time
lagFaulty oil pumpInspect. If NG, replace.
Faulty reverse clutchInspect. If NG, replace.
Faulty 1st and reverse brakeInspect. If NG, replace.
Leakage from “R” range fluid pressure
circuitOverhaul or replace valve body assembly.
Poor engine brake in
downshift to “2” rangeFaulty O/D and 2nd coast brakeInspect. If NG, replace.
Poor engine brake in
downshift to “L” rangeFaulty 1st and reverse brakeInspect. If NG, replace. Condition Possible cause Correction / Reference Item
Step Action Yes No
1Diagnostic Trouble Code (DTC) Check
1) Check DTC referring to “DTC Check”.
Is there any DTC(s)?Perform DTC Flow to
repair and retry.Substitute a known-
good TCM and recheck.
If OK, substitute a
known-good
combination meter and
recheck.
Step Action Yes No
1Combination Meter Power Supply Check
1) Turn ignition switch ON.
Does other indicator / warning lights in combination meter
comes ON?Go to Step 2. Repair combination
meter power supply
circuit referring to
“Combination Meter
Circuit Diagram in
Section 9C”.
2 1) TCM power and ground circuit check referring to “TCM
Power and Ground Circuit Check”.
Is it in good condition?Go to Step 3. Repair or replace.
3DTC check
1) Check DTC referring to “DTC Check”.
Is there DTC U0073 or U0100?Go to applicable DTC
diag. flow.Go to Step 4.
4Combination Meter Function Check
1) Turn ignition switch ON.
Does A/T selector position indicator show correct select
lever position?Replace combination
meter.Substitute a known-
good TCM and recheck.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-93
7) Remove oil strainer assembly (3).
8) Remove transmission fluid temperature sensor (1)
from sensor clamp.
9) Disconnect solenoid connectors (2).
10) Remove shift solenoid valve-A (No.1) (1), shift
solenoid valve-B (No.2) (2) and timing solenoid valve
(3) by removing bolts.Installation
1) Install shift solenoid valve-A (No.1) (1), shift solenoid
valve-B (No.2) (2) and timing solenoid valve (3).
Tightening torque
Shift solenoid bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-
ft)
2) Connect solenoid connectors identifying their
installing positions by wire color.
3) Install transmission fluid sensor (6) and sensor wire
to clamp.
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2
1
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12
3
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Solenoid coupler Wire color
Shift solenoid valve-A (No.1) (2) White
Shift solenoid valve-B (No.2) (3) Black
Timing solenoid valve (1) Yellow
TCC pressure control solenoid
valve (4)Light green / Brown
Pressure control solenoid valve
(5)Green / Gray
12
3 (a)
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2 4
6
1
3
5
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Timing solenoid valve
CAUTION!
• Do not insert air gun against strainer
installed on inlet of solenoid valve too
deeply, when blowing air into solenoid
valve. If not, the strainer will be damaged.
• Be very careful as dust etc. does not enter
when solenoid valves are inspected.

• Check that solenoid valve (1) actuate with click sound
when battery voltage is conducted.
• When timing solenoid valve (1) is connected to battery
(2), confirm that timing solenoid valve is open
condition by blowing air (50 – 200 kPa, 0.5 – 2.0 kg/
cm
2, 7 – 28.5 psi) into solenoid valve as shown in
figure.
• When timing solenoid valve (1) is not connected to
battery (2), confirm that timing solenoid valve is close
condition by blowing air (50 – 200 kPa, 0.5 – 2.0 kg/
cm
2, 7 – 28.5 psi) into solenoid valve as shown in
figure.
NOTE
Do not fail to inspect with air to prevent
mistaken checking because return spring for
valve is not installed into solenoid valve.

Pressure Control Solenoid Valves (Pressure
Control Solenoid and TCC Solenoid) Removal
and Installation
S6RW0D5106063
Removal
1) Disconnect negative cable at battery.
2) Lift up vehicle.
3) Remove left side engine under cover.
4) Remove drain plug and drain A/T fluid.
5) Install drain plug.
Tightening torque
A/T fluid drain plug: 17 N·m (1.7 kgf-m, 12.5 lb-ft)
6) Remove A/T oil pan (1) and oil pan gasket (2).
7) Remove oil strainer assembly (3).
8) Remove transmission fluid temperature sensor (1)
from sensor clamp.
9) Disconnect solenoid connectors (2).
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2
1
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Downloaded from www.Manualslib.com manuals search engine 5A-96 Automatic Transmission/Transaxle:
10) Remove valve body assembly referring to
“Automatic Transaxle Unit Disassembly”.
11) Remove pressure control solenoid valve and TCC
pressure control solenoid valve referring to “Valve
Body Assembly Disassembly and Reassembly”.
Installation
Reverse removal procedure to install pressure control
solenoid valve and valve body assembly noting the
following points.
• For detail of pressure control solenoid valve and TCC
pressure control solenoid valve installation, refer to
“Valve Body Assembly Disassembly and
Reassembly”.
• For detail of valve body assembly installation, refer to
“Automatic Transaxle Unit Assembly”.
• For detail of installing wire harness for solenoid valves
and sensor, refer to “Automatic Transaxle Unit
Assembly”. Use new O-rings.
• For detail of A/T oil pan and oil strainer assembly
installation, refer to “Automatic Transaxle Unit
Assembly”. Use new oil pan gasket.
• Pour A/T fluid and check fluid level according to
procedure described in “A/T Fluid Change”.
• Check for fluid leakage after warming up A/T.
Pressure Control Solenoid Valves InspectionS6RW0D5106020
CAUTION!
• Be very careful as dust etc. does enter
when pressure control solenoid valves are
inspected.

Resistance Check
Measure resistance between pressure control solenoid
valves (Pressure control solenoid and TCC pressure
control solenoid) (1) terminals.
Pressure control solenoid valve and TCC pressure
control solenoid valve resistance
Standard: 5.0 – 5.6 Ω at 20 °C (68 °F)Operation Check
Check pressure control solenoid valves (Pressure
control solenoid and TCC pressure control solenoid)
operation in the either manner of the following.
Using regulated DC power supply
1) Connect pressure control solenoid valve (1) with
regulated DC power supply (2) as shown in figure.
2) Turn regulated DC power supply switch ON and
increase voltage of power supply keeping current
within 1.0 A.
3) Check for gradual movement of valve (3) in the
direction of arrow “A” as voltage is increased.
4) Check movement of valve (3) in the direction of
arrow “B” as voltage is decreased.
5) Turn power supply switch OFF.
CAUTION!
Do not pass current 1.0 A or more, or
pressure control solenoid is burned out.

Not using regulated DC power supply
1) Connect pressure control solenoid valve (1) to
battery (2) setting 21 W bulb (4) on the way as
shown in figure.
2) Check for movement of valve (3) in the direction of
arrow “A”.
3) Disconnect pressure control solenoid valve (1) from
battery (2) and check movement of valve (3) in the
direction of arrow “B” as shown in figure.
CAUTION!
Set 21 W bulb on the way, or pressure control
solenoid valve is burned out.

1
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Diagnostic Information and Procedures
Manual Transaxle Symptom DiagnosisS6RW0D5204001
Repair Instructions
Manual Transaxle Oil Level CheckS6RW0D5206001
1) Lift up vehicle and check oil leakage. Repair leaky
point, if any.
2) Remove oil level / filler plug (1) and check oil
contamination and oil level is lower end of oil level /
filler plug hole (2).
If oil is excessive dirty or insufficient, replace oil or
pour specified oil up to plug hole.
3) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil level / filler plug (a): 21 N·m (2.1
kgf-m, 15.5 lb-ft)Condition Possible cause Correction / Reference Item
Gears slipping out of
meshWorn shift fork shaftReplace
Worn shift fork or synchronizer sleeveReplace
Weak or damaged locating springsReplace
Worn bearings on input shaft or
countershaftReplace
Worn chamfered tooth on sleeve and
gearReplace sleeve and gear
Hard shiftingInadequate lubricantReplenish
Improper clutch pedal free travelReplace clutch arm or master cylinder
Distorted or broken clutch discReplace
Damaged clutch pressure plateReplace clutch cover
Worn synchronizer ringReplace
Worn chamfered tooth on sleeve or gearReplace sleeve or gear
Worn gear shift control shaft joint bushReplace
Distorted shift shaftReplace
Broken gear shift / select control cablesReplace
NoiseInadequate or insufficient lubricantReplenish
Damaged or worn bearing(s)Replace
Damaged or worn gear(s)Replace
Damaged or worn synchronizer partsReplace
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Downloaded from www.Manualslib.com manuals search engine 5C-1 Clutch:
Transmission / Transaxle
Clutch
General Description
Clutch (Hydraulic Type) ConstructionS6RW0D5301001
The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type,
which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward.
The disc, carrying four torsional coil springs, is positioned on the transaxle input shaft with an involute spline fit.
The clutch cover is secured to the flywheel, and carries the diaphragm spring in such a way that the peripheral edge
part of the spring pushes on the pressure plate against the flywheel (with the disc in between), when the clutch release
bearing (incorporated in clutch operating cylinder) is held back. This is the engaged condition of the clutch.
Depressing the clutch pedal causes the release bearing (incorporated in clutch operating cylinder) to advance and
pushes on the tips of the tapered fingers of the diaphragm spring. When this happens, the diaphragm spring pulls the
pressure plate away from the flywheel, thereby interrupting the flow of drive from flywheel through clutch disc to
transaxle input shaft. Clutch fluid is supplied from brake fluid reservoir. Clutch fluid level can be checked by brake fluid
level of brake fluid reservoir.
I5RW0A530001-01
1. Crankshaft 4. Pressure plate 7. Operating cylinder assembly
2. Flywheel 5. Clutch cover 8. Input shaft bearing
3. Clutch disc 6. Diaphragm spring 9. Input shaft

Downloaded from www.Manualslib.com manuals search engine 6A-1 Steering General Diagnosis:
Ste eri ng
Steering General Diagnosis
Precautions
Precautions for Steering DiagnosisS6RW0D6100001
Since the problems in steering involve several systems, they must all be considered when diagnosing a complaint. To
avoid using the wrong symptom, always road test the vehicle first. Proceed with the following preliminary inspection
and correct any defects which are found.
1) Inspect tires for proper pressure and uneven wear.
2) Raise vehicle on a hoist and inspect steering system for loose or damaged parts.
3) Spin front wheels. Inspect for out-of-round tires, out-of-balance tires, bent rims, loosen and/or rough wheel
bearings.
Diagnostic Information and Procedures
Steering Symptom DiagnosisS6RW0D6104001
Condition Possible cause Correction / Reference Item
Hard steeringTire not adequately inflatedInflate tires to proper pressure.
Malfunction of power steering systemCheck and correct. Refer to “P/S System
Symptom Diagnosis in Section 6C”.
Bind in tie-rod end ball studs or lower
ball jointsReplace tie-rod end or front suspension control
arm.
Disturbed front wheel alignmentCheck and adjust front wheel alignment.
Bind in steering columnRepair or replace steering column assembly.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Too much play in steeringWheel bearings wornReplace wheel bearing.
Loose steering gear case boltsTighten gear case bolts.
Faulty steering gear case assemblyReplace steering gear case assembly.
Worn steering shaft jointsReplace steering lower shaft assembly.
Worn tie-rod ends or tie-rod inside ball
jointsReplace tie-rod end or tie-rod.
Worn lower ball jointsReplace front suspension control arm.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Poor return abilityBind in tie-rod end ball studsReplace tie-rod end.
Bind in ball jointsReplace front suspension control arm.
Bind in steering columnReplace steering column assembly.
Disturbed front end alignmentCheck and adjust front end alignment.
Faulty steering gear case assemblyReplace steering gear case assembly.
Tires not adequately inflatedAdjust tire pressure.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Rack and pinion noise
(Rattle or chuckle)Loose steering gear case boltsTighten steering gear case bolts.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Faulty steering gear case assemblyReplace steering gear case assembly.
Broken or otherwise damaged wheel
bearing(s)Replace wheel bearing(s).
Wander or poor steering
stabilityMismatched or uneven tiresReplace or inflate tires to proper pressure.
Loosen ball joints and tie-rod endsReplace suspension control arm or tie-rod end.
Faulty struts or mountingsReplace strut or repair mounting.
Loose stabilizer barTighten or replace stabilizer bar or bush.
Broken or sagging coil springsReplace coil spring.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Disturbed front wheel alignmentCheck and adjust front wheel alignment.
Faulty steering gear case assemblyReplace steering gear case assembly.

Downloaded from www.Manualslib.com manuals search engine Steering General Diagnosis: 6A-2
Steering System InspectionS6RW0D6104002
Check steering system referring to the following items.Erratic steering when
brakingWorn wheel bearingsReplace wheel bearing.
Broken or sagging coil springsReplace coil spring.
Wheel tires are inflated unequallyInflate tires to proper pressure.
Disturbed front wheel alignmentCheck and adjust front wheel alignment.
Brakes not working in unisonCheck and repair brake system.
Leaking wheel cylinder or caliperRepair or replace wheel cylinder or caliper.
Warped discsReplace brake disc.
Badly worn brake liningsReplace brake shoe lining.
Drum is out of round in some brakesReplace brake drum.
Defective wheel cylindersReplace or repair wheel cylinder. Condition Possible cause Correction / Reference Item
Inspection Item Referring section
Steering wheel Play, rattle “Steering Wheel Play Check in Section 6C”
Tie-rod end Looseness and damage “Tie-Rod End Inspection in Section 6C”
Wheel alignment “Front Wheel Alignment Inspection and Adjustment in
Section 2B”
Tie-rod end boot Damage “Tie-Rod End Boot On-Vehicle Inspection in Section 6C”
Steering rack boot Damage “Steering Rack Boot Inspection in Section 6C”
Steering shaft joint Rattle and damage “Steering Shaft Joint On-Vehicle Inspection in Section 6C”
EPS system Operation “EPS System Check in Section 6C”

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10) Check for each pressure of low side and high side if it is within shaded range of graph. If each gauge reading is out
of specified pressure, correct defective part referring to the following table.
When diagnosing troubles of abnormal pressure on the low side and high side for each pressure more specifically,
refer to “Trouble Diagnosis for Abnormal Pressure”.
NOTE
Pressure registered on gauge varies with ambient temperature. Therefore, use the graphs when
determining if pressures are normal or not.

Low side and high side pressure example, Gauges should read as follows when ambient temperature is 30
°C (86 °F)
Pressure on high pressure gauge (HI): 1130 – 1560 kPa (11.4 – 15.6 kgf/cm2)
Pressure on low pressure gauge (LO): 270 – 390 kPa (2.7 – 3.9 kgf/cm2)
High pressure gauge
[A]: Pressure of high pressure gauge [C]: Ambient temperature [E]: Acceptable range
[B]: Pressure of low pressure gauge [D]: Humidity
Condition Possible cause Correction
Pressure is higher than
acceptable range
(“A” area)Refrigerant overcharged Recharge.
Expansion valve frozen or clogged Check expansion valve.
Clogged refrigerant passage of high pressure side Clean or replace.
Condenser cooling fan malfunction (Insufficient
cooling of condenser)Check condenser cooling fan.
Dirty or bent condenser fins (Insufficient cooling of
condenser)Clean or repair.
Compressor malfunction (Insufficient oil etc.) Check compressor.
Engine overheat Check engine cooling system
referring to “Engine Cooling Symptom
Diagnosis in Section 1F”.
22 312.9 2200
0 1 2 3
30 70 30 70%
4 5 6 7 8 9 10
11 12 13
14
15
16
17
18
19 21 298.7 2100
20
14.2 28.4 42.7 56.9 71.1 85.3 99.5 113.8 128.0
142.2
151.4 170.6 184.9
199.1
213.3
227.5
241.7
256.0
270.2
284.4
100 200 300 400 500 600 700 800 900 1000
1100 1200 1300
1400
1500
1600
1700
1800
1900
2000
25 30 35
77 86 95 psi kPa kgf/cm
2
[C] [B] [A]
C
F
“A”
“B”
“C”
[E]
[E]
“D”[D]
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