Sas SUZUKI SX4 2006 1.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 5-ii Table of Contents
DTC P1723: Range Select Switch
Malfunction ...................................................... 5A-68
DTC P1878: Torque Converter Clutch
Shudder .......................................................... 5A-69
DTC P2762: Torque Converter Clutch (TCC)
Pressure Control Solenoid Control Circuit
Range / Performance ...................................... 5A-70
DTC P2763: Torque Converter Clutch (TCC)
Pressure Control Solenoid Control Circuit
High ................................................................. 5A-72
DTC P2764: Torque Converter Clutch (TCC)
Circuit Pressure Control Solenoid Control
Circuit Low ...................................................... 5A-74
DTC U0073: Control Module Communication
Bus Off ............................................................ 5A-76
DTC U0100: Lost Communication with ECM /
PCM “A” .......................................................... 5A-76
Inspection of TCM and Its Circuits .................... 5A-76
TCM Power and Ground Circuit Check ............. 5A-80
Brake Interlock System Inspection .................... 5A-81
Repair Instructions ............................................5A-82
Learning Control Initialization ............................ 5A-82
A/T Fluid Level Check ....................................... 5A-82
A/T Fluid Change .............................................. 5A-83
Select Lever Components ................................. 5A-84
Select Lever Assembly Removal and
Installation ....................................................... 5A-84
Select Lever Knob Installation........................... 5A-84
Select Lever Inspection ..................................... 5A-85
“3” Position Switch Inspection ........................... 5A-85
Shift Lock Solenoid Inspection .......................... 5A-85
Shift Lock Solenoid Replacement ..................... 5A-85
Select Cable Components ................................ 5A-86
Select Cable Removal and Installation ............. 5A-86
Select Cable Adjustment ................................... 5A-86
Key Interlock Cable Removal and Installation... 5A-87
Transmission Range Sensor Inspection and
Adjustment ...................................................... 5A-89
Output Shaft Speed Sensor (VSS) Removal
and Installation ................................................ 5A-90
Output Shaft Speed Sensor (VSS) Inspection .. 5A-90
Input Shaft Speed Sensor Removal and
Installation ....................................................... 5A-91
Input Shaft Speed Sensor Inspection................ 5A-91
Transmission Fluid Temperature Sensor
Removal and Installation ................................. 5A-91
Transmission Fluid Temperature Sensor
Inspection ........................................................ 5A-92
Solenoid Valves (Shift Solenoid Valves and
Timing Solenoid Valve) Removal and
Installation ....................................................... 5A-92
Solenoid Valves (Shift Solenoid Valves and
Timing Solenoid Valve) Inspection .................. 5A-94
Pressure Control Solenoid Valves (Pressure
Control Solenoid and TCC Solenoid)
Removal and Installation ................................. 5A-95
Pressure Control Solenoid Valves Inspection ... 5A-96
Transmission Control Module (TCM)
Removal and Installation ................................. 5A-97
A/T Relay Inspection ......................................... 5A-97Differential Side Oil Seal Replacement ............. 5A-98
A/T Fluid Cooler Hoses Replacement ............... 5A-98
Automatic Transaxle Unit Components............. 5A-99
Automatic Transaxle Unit Dismounting and
Remounting ................................................... 5A-100
Automatic Transaxle Assembly Components . 5A-102
Automatic Transaxle Unit Disassembly........... 5A-104
Oil Pump Assembly Components ................... 5A-116
Oil Pump Assembly Disassembly and
Reassembly .................................................. 5A-116
Oil Pump Assembly Inspection ....................... 5A-117
Direct Clutch Assembly Components.............. 5A-119
Direct Clutch Assembly Preliminary Check ..... 5A-119
Direct Clutch Assembly Disassembly and
Reassembly .................................................. 5A-120
Direct Clutch Assembly Inspection.................. 5A-122
Forward and Reverse Clutch Assembly
Components .................................................. 5A-123
Forward and Reverse Clutch Assembly
Preliminary Check ......................................... 5A-123
Forward and Reverse Clutch Assembly
Disassembly and Reassembly ...................... 5A-124
Forward and Reverse Clutch Assembly
Inspection ...................................................... 5A-127
2nd Brake Piston Assembly Components ....... 5A-128
2nd Brake Piston Assembly Disassembly and
Reassembly .................................................. 5A-128
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Components........... 5A-129
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Disassembly and
Reassembly .................................................. 5A-130
Transaxle Rear Cover (O/D and 2nd Coast
Brake Piston) Assembly Inspection............... 5A-131
Countershaft Assembly Components.............. 5A-132
Countershaft Assembly Disassembly and
Reassembly .................................................. 5A-132
Valve Body Assembly Components ................ 5A-133
Valve Body Assembly Disassembly and
Reassembly .................................................. 5A-134
Differential Assembly Components ................. 5A-135
Differential Assembly Disassembly and
Reassembly .................................................. 5A-136
Differential Assembly Inspection ..................... 5A-137
Torque Converter Housing Disassembly and
Reassembly .................................................. 5A-138
Transaxle Case Disassembly and
Reassembly .................................................. 5A-140
Automatic Transaxle Unit Inspection and
Adjustment .................................................... 5A-141
Automatic Transaxle Unit Assembly ............... 5A-144
Specifications ...................................................5A-161
Tightening Torque Specifications .................... 5A-161
Special Tools and Equipment .........................5A-162
Recommended Service Material ..................... 5A-162
Special Tool .................................................... 5A-162
Manual Transmission/Transaxle ............ 5B-1
General Description .............................................5B-1
Manual Transaxle Construction .......................... 5B-1

Downloaded from www.Manualslib.com manuals search engine Table of Contents 5-iii
Diagnostic Information and Procedures ............ 5B-5
Manual Transaxle Symptom Diagnosis............... 5B-5
Repair Instructions .............................................. 5B-5
Manual Transaxle Oil Level Check ..................... 5B-5
Manual Transaxle Oil Change ............................ 5B-6
Differential Side Oil Seal Replacement ............... 5B-7
Gear Shift Control Lever and Cable
Components...................................................... 5B-8
Gear Shift Control Lever and Cable Removal
and Installation .................................................. 5B-9
Gear Select Control Cable Adjustment ............... 5B-9
Back Up Light Switch Removal and
Installation ....................................................... 5B-10
Back Up Light Switch Inspection ....................... 5B-10
Manual Transaxle Unit Components ................. 5B-11
Manual Transaxle Unit Dismounting and
Remounting..................................................... 5B-12
Gear Shift and Select Shaft Assembly
Components.................................................... 5B-13
Gear Shift and Select Shaft Assembly
Removal and Installation................................. 5B-14
Gear Shift and Select Shaft Assembly
Disassembly and Reassembly ........................ 5B-15
Manual Transaxle Assembly Components........ 5B-16
Fifth Gear Disassembly and Reassembly ......... 5B-17
Manual Transaxle Assembly Disassembly
and Reassembly ............................................. 5B-19
Right Case Disassembly and Reassembly ....... 5B-24
Left Case Disassembly and Reassembly.......... 5B-25
Input Shaft and Countershaft Components....... 5B-27
Input Shaft Disassembly and Reassembly........ 5B-28
Countershaft Disassembly and Reassembly .... 5B-31
Gear Shift Shaft Components ........................... 5B-35
5th and Reverse Gear Shift Shafts
Disassembly and Reassembly ........................ 5B-35
Gear Shift Shaft and Fork Inspection ................ 5B-35
Differential Components ................................... 5B-36Differential Disassembly and Reassembly ........ 5B-36
Specifications .....................................................5B-38
Tightening Torque Specifications ...................... 5B-38
Special Tools and Equipment ...........................5B-39
Recommended Service Material ....................... 5B-39
Special Tool ...................................................... 5B-39
Clutch ....................................................... 5C-1
General Description .............................................5C-1
Clutch (Hydraulic Type) Construction .................5C-1
Diagnostic Information and Procedures ............5C-2
Clutch System Symptom Diagnosis ....................5C-2
Repair Instructions ..............................................5C-3
Clutch Pedal Inspection ......................................5C-3
Clutch Fluid Level Inspection ..............................5C-3
Air Bleeding of Clutch System.............................5C-3
Clutch Fluid Pipe and Hose Location ..................5C-4
Clutch Fluid Pipe Removal and Installation.........5C-4
Clutch Fluid Pipe Inspection................................5C-4
Clutch Master Cylinder Removal and
Installation .........................................................5C-5
Clutch Operating Cylinder Assembly
Removal and Installation ...................................5C-5
Clutch Operating Cylinder Assembly
Inspection ..........................................................5C-6
Clutch Cover, Clutch Disc and Flywheel
Components ......................................................5C-6
Clutch Cover, Clutch Disc and Flywheel
Removal and Installation ...................................5C-7
Clutch Cover, Clutch Disc and Flywheel
Inspection ..........................................................5C-8
Specifications .......................................................5C-9
Tightening Torque Specifications ........................5C-9
Special Tools and Equipment ...........................5C-10
Recommended Service Material .......................5C-10
Special Tool ......................................................5C-10

Downloaded from www.Manualslib.com manuals search engine 5-1 Precautions:
Transmission / Transaxle
Precautions
Precautions
Precautions on Transmission / TransaxleS6RW0D5000001
Air Bag Warning
Refer to “Air Bag Warning in Section 00”.
Precautions in Diagnosing Trouble
Refer to “Precautions in Diagnosing Trouble in Section 5A”.
Precautions for Disassembly and Reassembly
Refer to “Precautions for Disassembly and Reassembly in Section 5A”.
Precaution on CAN Troubleshooting
Refer to “Precaution on CAN Troubleshooting in Section 1A”.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-1
Transmission / Transaxle
Automatic Transmission/Transaxle
Precautions
Precautions in Diagnosing TroubleS6RW0D5100001
• Do not disconnect couplers from TCM, battery cable
from battery, TCM ground wire harness from engine or
main fuse before checking the diagnostic information
(DTC, freeze frame data, etc.) stored in TCM memory.
Such disconnection will clear memorized information
in TCM memory.
• Diagnostic information stored in TCM memory can be
cleared as well as checked by using SUZUKI scan
tool or CAN communication OBD generic scan tool.
Before using scan tool, read its Operator’s
(Instruction) Manual carefully to have good
understanding as to what functions are available and
how to use it.
It is indistinguishable which module turns on MIL
because not only ECM but also TCM turns on MIL.
Therefore, check both ECM and TCM for DTC when
MIL lights on.
When checking TCM for DTC, keep in mind that DTC
is displayed on the scan tool as follows depending on
the scan tool used.
– SUZUKI scan tool displays DTC detected by TCM.
– CAN communication OBD generic scan tool
displays DTC detected by each of ECM and TCM
simultaneously.
• Be sure to read “Precautions for Electrical Circuit
Service in Section 00” before inspection and observe
what is written there.
• TCM replacement
– When substituting a known-good TCM, check that
all relays and actuators have resistance of
specified value.
Neglecting this check may result in damage to good
TCM.
• Communication of ECM, BCM, combination meter,
keyless start control module (if equipped), ABS
control module, 4WD control module (if equipped),
TCM and DLC, is established by CAN (Controller
Area Network). (For more detail of CAN
communication for ECM, refer to “CAN
Communication System Description”). Therefore,
handle CAN communication line with care referring to
“Precaution for CAN Communication System in
Section 00”.
Precautions for Disassembly and ReassemblyS6RW0D5100002
When repairing automatic transaxle, it is necessary to
conduct the on-vehicle test to investigate where the
cause of the trouble lies first.
Then whether overhaul should be done or not is
determined. If the transaxle is disassembled without
such preliminary procedure, not only the cause of the
trouble would be unknown, but also a secondary trouble
may occur and often time would be wasted.
As the automatic transaxle consists of high precision
component, the following cautions should be strictly
observed when handling its parts in disassembly and
reassembly.
• Disassembling valve body assembly is prohibited
essentially. However, a few parts can be
disassembled. When disassembling valve body
component parts, confirm whether their parts are
allowed to disassemble or not referring to “Valve Body
Assembly Disassembly and Reassembly”.
• When component part of forward clutch, direct clutch,
2nd brake and/or O/D and 2nd coast brake, namely
clutch disc, brake disc, retaining plate and/or
separator plate, have been replaced, all learned
contents, which have been stored in TCM memory by
executing learning control, should be initialized
referring to “Learning Control Initialization”.
• Make sure to wash dirt off from the transaxle so that
no such dirt will enter the transaxle during
dismounting and remounting.
• Select a clean place free from dust and dirt for
overhauling.
• Place a rubber mat on the work bench to protect parts
from damage.
• Work gloves or shop cloth should not be used. (Use a
nylon cloth or a paper towel.)
• When separating the case joint, do not pry with a
screwdriver or such but tap with a plastic hammer
lightly.
• Make sure to wash dirt off from the transaxle so that
no such dirt will enter the transaxle during
disassembly and reassembly.
• Wash the disassembled parts in ATF (Automatic
Transaxle Fluid) or kerosene (using care not to allow
ATF or kerosene to get on your face, etc.) and confirm
that each fluid passage is not clogged by blowing air
into it. But use kerosene to wash the discs, resin
washers and rubber parts.
• Replace each gasket, oil seal and O-ring with a new
one.
• Apply ATF to sliding or rotating parts before
reassembly.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-91
Input Shaft Speed Sensor Removal and
Installation
S6RW0D5106012
Removal
1) Disconnect negative cable at battery.
2) Disconnect input shaft speed sensor connector (2).
3) Remove input shaft speed sensor (1) by removing its
bolt.
Installation
1) Apply A/T fluid to input shaft speed sensor O-ring.
2) Install input shaft speed sensor (1) to A/T case and
tighten bolt to specified torque.
Tightening torque
Input shaft speed sensor bolt (a): 5.5 N·m (0.55
kgf-m, 4.0 lb-ft)
3) Connect input shaft speed sensor connector (2) to
input shaft speed sensor (1).
4) Connect negative cable to battery.
Input Shaft Speed Sensor InspectionS6RW0D5106013
1) Disconnect negative cable at battery.
2) Disconnect input shaft speed sensor connector (2).
3) Check resistance between input shaft speed sensor
(1) terminals.
Input shaft speed sensor resistance
Standard: 560 – 680 Ω at 20 °C (68 °F)
Transmission Fluid Temperature Sensor
Removal and Installation
S6RW0D5106014
Removal
1) Disconnect negative cable at battery.
2) Lift up vehicle.
3) Remove left side engine under cover.
4) With engine is cool, remove drain plug and drain A/T
fluid.
5) Install drain plug. Refer to “A/T Fluid Change”.
6) Remove A/T oil pan.
7) Remove oil strainer assembly.
8) Remove valve body assembly referring to
“Automatic Transaxle Unit Disassembly”.
CAUTION!
When pulling valve body harness out of
transaxle case, take care not to damage
transmission fluid temperature sensor at
narrow exit of case.
Careless sensor treatment might cause
sensor malfunction.

9) Remove valve body harness (1).
12
I5RW0C510034-01
12
(a)I5RW0C510035-01
12I5RW0C510036-01
I2RH0B510050-01

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
I2RH01510071-01
I2RH0B510064-01

Downloaded from www.Manualslib.com manuals search engine 5A-104 Automatic Transmission/Transaxle:
Automatic Transaxle Unit DisassemblyS6RW0D5106031
CAUTION!
• Thoroughly clean transaxle exterior before
overhauling it.
• Keep working table, tools and hands clean
while overhauling.
• Use special care to handle aluminum parts
so as not to damage them.
• Do not expose removed parts to dust.
Keep them always clean.

1) Remove torque converter (1).
CAUTION!
Remove torque converter as much straight
as possible. Leaning it may cause to damage
oil seal lip.

2) Remove engine mounting LH bracket (1).
3) Remove manual select lever (1).4) Uncaulk lock washer (1), then remove lock nut (2)
and lock washer.
5) Remove transmission range sensor (1).
6) Remove output shaft speed sensor (VSS) (2) and
input shaft speed sensor (1).
7) Remove harness bracket and select cable clamp (3).
8) Remove select cable bracket (1).
I2RH0B510078-01
1
I5RW0C510058-01
1I2RH0B510080-01
I2RH0B510081-01
1I2RH0B510082-01
2 3
1
I2RH0B510083-01
1
I5RW0C510059-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-111
48) Remove O/D and 2nd coast brake retaining plate
snap ring (1).
49) Remove front planetary sun gear (1).
50) Remove front sun gear thrust bearing race (2) from
front planetary sun gear (1).
51) Before disassembling 2nd brake piston assembly
(4), check 2nd brake piston stroke by measuring
clearance between 2nd brake separator plate (1)
and piston (2) with feeler gauge (3).
If clearance, that is, piston stroke is out of
specification, replace brake discs and plates with
new ones.
CAUTION!
When brake disc, retaining plate and/or
separator plate of 2nd brake have been
replaced, all learned contents, which have
been stored in TCM memory by executing
learning control, should be initialized
referring to “Learning Control Initialization”.
Neglecting this initialization may cause
excessive shift shock.

2nd brake piston stroke
“a”: 0.40 – 1.25 mm (0.016 – 0.049 in.)
52) Using special tool and hydraulic press, remove 2nd
brake piston snap ring (1).
CAUTION!
Do not press 2nd brake piston assembly in
over 0.4 mm (0.016 in.).
Excessive compression may cause damage
to piston assembly, return spring, plates and/
or discs.

Special tool
(A): 09926–96050
I2RH0B510120-01
I2RH0B510121-01
I2RH0B510122-01
3
4 1 2
“a”4
I2RH0B510123-01
I2RH0B510124-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-113
61) Measure 1st and reverse brake piston stroke.
If piston stroke exceeds specified value,
disassemble, inspect and replace discs and plates.
• Using special tool, measure 1st and reserve brake
piston stroke when compressed air (400 – 800
kPa, 4 – 8 kg/cm
2, 57 – 113 psi) is blown through
oil hole.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06020
1st and reverse brake piston stroke
Standard: 0.79 – 1.49 mm (0.031 – 0.059 in.)
62) Remove snap ring while the 1st and reverse brake
piston return springs are compressed using special
tool and hydraulic press.
CAUTION!
Do not press 1st and reverse brake return
spring subassembly in over 0.8 mm (0.031
in.).
Excessive compression may cause damage
to return spring subassembly, discs, plates
and/or piston.

Special tool
(A): 09926–9762063) Remove 1st and reverse brake retaining plate, discs
and separator plates.
64) Remove 1st and reverse brake return spring
subassembly (1).
65) Turn over transaxle and uncaulk reduction drive gear
nut (1).
66) Secure reduction drive gear (1) with parking lock
pawl, then remove reduction drive gear nut.
CAUTION!
• It is recommended that this operation
should be carried out on rubber mat to
prevent damaging transaxle case.
• Never reuse removed nut.

I2RH0B510133-01
I2RH0B510134-01
I2RH0B510135-01
I2RH0B510136-01
I2RH0B510137-02

Downloaded from www.Manualslib.com manuals search engine 5A-116 Automatic Transmission/Transaxle:
Oil Pump Assembly ComponentsS6RW0D5106032
Oil Pump Assembly Disassembly and
Reassembly
S6RW0D5106033
Disassembly
1) Remove O-ring from pump body.
2) Remove 8 oil pump subassembly bolts (1) and stator
shaft assembly (2).3) Remove oil seal (1) using special tool.
Special tool
(A): 09913–50121
I5RW0C510061-01
1. Oil seal
: Apply grease 99000-25030 to oil seal lip.5. Oil pump drive gear : Apply automatic transaxle fluid.
2. O-ring 6. Stator shaft assembly : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
3. Oil pump body 7. Oil pump subassembly bolts : Do not reuse.
4. Oil pump driven gear
2
1
I4RS0A510041-01
2. Oil pump body
I2RH0B510150-01