valve body SUZUKI SX4 2006 1.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-67
DTC Troubleshooting
Step Action Yes No
1Was “A/T System Check” performed?Go to Step 2. Go to “A/T System
Check”.
2Check shift solenoid valve circuit for IG short
1) Connect valve body harness connector.
2) Disconnect TCM connectors.
3) Check for proper connection to TCM at terminal “C06-
16” (for shift solenoid valve-A (No.1)) or “C06-15” (for
shift solenoid valve-B (No.2)).
4) If connection is OK, turn ignition switch ON and measure
voltage between terminal “C06-16” (for shift solenoid
valve-A (No.1)) or “C06-15” (for shift solenoid valve-B
(No.2)) of disconnected harness side TCM connector
and ground.
Is it 0 – 2 V?Go to Step 3. DTC P0974: “BRN”
circuit shorted to power
circuit.
DTC P0977: “BLK/YEL”
circuit shorted to power
circuit.
3Check shift solenoid valve resistance
1) Turn ignition switch OFF.
2) Disconnect valve body harness connector (1), (2) on
automatic transaxle.
3) Check for proper connection to solenoid at “BRN” (for
shift solenoid valve-A (No.1)) or “BLK/YEL” (for shift
solenoid valve-B (No.2)) circuit.
Check resistance of solenoid valve.
Shift solenoid valve resistance
Between shift solenoid valve-A (No.1) terminal (3)
and transaxle: 11 – 15 Ω at 20 °C (68 °F)
Between shift solenoid valve-B (No.2) terminal (4)
and transaxle: 11 – 15 Ω at 20 °C (68 °F)
Is check results satisfactory?Intermittent trouble or
faulty TCM. Check for
intermittent referring to
“Intermittent and Poor
Connection Inspection
in Section 00”. If OK,
substitute a known-
good TCM and recheck.Replace applicable shift
solenoid valve or valve
body harness.
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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 Automatic Transmission/Transaxle: 5A-71
DTC Troubleshooting
Step Action Yes No
1Was “A/T System Check” performed?Go to Step 2. Go to “A/T System
Check”.
2Check TCC solenoid valve resistance
1) Turn ignition switch OFF.
2) Disconnect valve body harness connector (1), (2) on
automatic transaxle.
3) Check for proper connection to terminal at “WHT/BLU”
and “WHT/BLK” circuit.
4) Check resistance of TCC solenoid valve.
TCC solenoid valve resistance
Between terminals of transaxle side valve body
harness connector: 5.0 – 5.6 Ω at 20 °C (68 °F)
Between terminals of transaxle valve body harness
connector and transaxle: Infinity
Is check results satisfactory?Go to Step 3. Replace TCC solenoid
valve or valve body
harness.
3Check for pressure control solenoid valve circuit
1) Disconnect TCM connectors
2) Check for proper connection to TCM at terminals “C06-
3” and “C06-5”. If connection is OK, check circuit for
open, short and high resistance for the following circuit.
• Between “C06-3” terminal of TCM connector and
“WHT/BLK” terminal of valve body harness connector.
• Between “C06-4” terminal of TCM connector and
“WHT/BLU” terminal of valve body harness connector.
Are they in good condition?Intermittent trouble or
faulty TCM. Check for
intermittent referring to
“Intermittent and Poor
Connection Inspection
in Section 00”. If OK,
substitute a known-
good TCM and recheck.Repair “WHT/BLU” and/
or “WHT/BLK” circuit.
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-73
DTC Troubleshooting
Step Action Yes No
1Was “A/T System Check” performed?Go to Step 2. Go to “A/T System
Check”.
2Check TCC solenoid valve circuit for IG short
1) Connect valve body harness connector.
2) Disconnect TCM connectors.
3) Check for proper connection to TCM at terminal “C06-3”
and “C06-5”.
4) If connection is OK, turn ignition switch ON and measure
voltage between terminal “C06-3” of disconnected
harness side TCM connector and ground between
terminal “C06-5” of disconnected harness side TCM
connector and ground.
Are voltage 1 V or less?Go to Step 3. “WHT/BLU” or “WHT/
BLK” circuit shorted to
power circuit.
3Check TCC solenoid valve resistance
1) Turn ignition switch OFF.
2) Disconnect valve body harness connector (1), (2) on
automatic transaxle.
3) Check for proper connection to solenoid at “WHT/BLU”
and “WHT/BLK” circuits.
4) Check resistance of TCC solenoid valve.
TCC solenoid valve resistance
Between terminals of transaxle side valve body
harness connector: 5.0 – 5.6 Ω at 20 °C (68 °F)
Between terminals of transaxle side valve body
harness connector and transaxle: Infinity
Is check results satisfactory?Intermittent trouble or
faulty TCM.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.
If OK, substitute a
known-good TCM and
recheck.Replace TCC solenoid
valve or lead wire.
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Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-75
DTC Troubleshooting
Step Action Yes No
1Was “A/T System Check” performed?Go to Step 2. Go to “A/T System
Check”.
2Check TCC solenoid valve resistance
1) Turn ignition switch OFF.
2) Disconnect valve body harness connector (1), (2) on
automatic transaxle.
3) Check for proper connection to solenoid at “WHT/BLU”
and “WHT/BLK” circuits.
4) Check resistance of TCC solenoid valve.
TCC solenoid valve resistance
Between shift terminals of transaxle side valve body
harness connector: 5.0 – 5.6 Ω at 20 °C (68 °F)
Between shift terminals of transaxle side valve body
harness connector and transaxle: Infinity
Is check results satisfactory?Go to Step 3. Replace TCC solenoid
valve or valve body
harness.
3Check TCC solenoid valve circuit for ground short
1) Disconnect TCM connectors.
2) Check for proper connection to TCM at terminals “C06-
3” and “C06-5”.
3) If connection is OK, check continuity between terminal
“C06-5” of disconnected harness side TCM connector
and ground, between terminal “C06-3” of disconnected
harness side TCM connector and ground.
Are continuity indicated?“WHT/BLU” or “WHT/
BLK” circuit shorted to
ground.Intermittent trouble or
faulty TCM.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.
If OK, substitute a
known-good TCM and
recheck.
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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).
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Downloaded from www.Manualslib.com manuals search engine 5A-92 Automatic Transmission/Transaxle:
Installation
Reverse removal procedure to install valve body
harness and valve body assembly noting the following
points.
• For details of valve body assembly and their
connectors installation, refer to “Automatic Transaxle
Unit Assembly”.
• For details of A/T oil pan installation, refer to
“Automatic Transaxle Unit Assembly”. Use new oil
pan gasket.
• Tighten valve body harness connector bolt to
specified torque.
Tightening torque
Valve body harness connector bolt (a): 5.5 N·m (
0.55 kgf-m, 4.0 lb-ft)
• 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.Transmission Fluid Temperature Sensor
Inspection
S6RW0D5106015
Warm up transmission fluid temperature sensor (2).
Check resistance between terminals of valve body
harness connector (1). Thus make sure its resistance
decrease as its temperature increase.
Transmission fluid temperature sensor resistance
10 °C (50 °F): 5.8 – 7.1 kΩ
11 0 °C (230 °F): 231 – 263 Ω
145 °C (293 °F): 105 – 117 Ω
Solenoid Valves (Shift Solenoid Valves and
Timing Solenoid Valve) Removal and
Installation
S6RW0D5106061
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).
I2RH0B510051-01
I2RH0B510052-01

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.

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I2RH01510071-01
I2RH0B510064-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-103
1. Torque converter 37. Transmission range sensor 73. Rear planetary sun gear subassembly
2. Torque converter housing
: Apply sealant 99000-31230 to mating
surface to transaxle case.38. Cooler check valve 74. Rear sun gear thrust bearing race
3. Oil strainer assembly
: Replace oil strainer when overhauling.39. Spring 75. Rear sun gear thrust bearing
4. Parking lock pawl shaft 40. Transaxle case plug 76. Forward clutch hub
5. Parking lock pawl 41. Fluid filler tube 77. Intermediate shaft thrust bearing race
6. Parking lock pawl return spring 42. Fluid level gauge 78. Intermediate shaft thrust bearing
7. Parking lock pawl rod 43. Fluid cooler inlet pipe 79. 2nd brake piston snap ring
8. Parking lock pawl bracket 44. Fluid cooler outlet pipe 80. O/D and 2nd coast brake retaining
plate snap ring
9. Manual detent spring 45. 2nd brake gasket 81. O/D and 2nd coast brake retaining
plate
10. Manual valve lever 46. Brake drum gasket 82. O/D and 2nd coast brake disc
11. Manual valve lever pin 47. Pipe union 83. O/D and 2nd coast brake separator
plate
12. Manual shift shaft 48. Reduction drive gear nut
: After tightening nut so as rotational
torque of reduction drive gear to be in
specified value, caulk nut securely.84. O/D and 2nd coast brake rear plate
13. Manual shift shaft oil seal
: Apply grease 99000-25030 to oil seal
lip.49. Reduction drive gear 85. Rear cover seal ring
14. Differential side oil seal
: Apply grease 99000-25030 to oil seal
lip.50. Planetary ring gear subassembly 86. Reverse clutch drum thrust bearing
15. Torque converter housing plug 51. Breather hose 87. Rear cover plug
16. Lubrication LH tube 52. Breather union 88. Transaxle rear cover
: Apply sealant 99000-31230 to mating
surface.
17. Lubrication RH tube 53. Input shaft speed sensor 89. Harness bracket
18. Fluid reservoir RH plate 54. Valve body harness 90. Select cable clamp
19. Input shaft front thrust bearing 55. 1st and reverse brake piston 91. Governor apply No.1 gasket
20. Input shaft rear thrust bearing 56. O-ring 92. Output shaft speed sensor (VSS)
21. Input shaft rear thrust bearing race 57. 1st and reverse brake return spring
subassembly93. One-way clutch outer race retainer
22. Direct clutch hub 58. 1st and reverse brake disc 94. Select cable bracket
23. Lubrication tube clamp 59. 1st and reverse brake separator plate : Do not reuse.
24. Fluid reservoir LH plate 60. 1st and reverse brake retaining plate : Apply automatic transaxle fluid.
25. Governor apply No.2 gasket 61. 1st and reverse brake snap ring : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
26. Automatic transaxle case 62. Planetary gear assembly : 7.0 N⋅m (0.7 kgf-m, 5.0 lb-ft)
27. Accumulator piston O-ring 63. Planetary carrier thrust washer
: Apply grease 99000-25030 to slide
contact face.: 7.5 N⋅m (0.75 kgf-m, 5.5 lb-ft)
28. Accumulator spring 64. One-way clutch No.2 assembly : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
29. C2 accumulator piston 65. 2nd brake retaining plate : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
30. C1 accumulator piston 66. 2nd brake disc : 17 N⋅m (1.7 kgf-m, 12.5 lb-ft)
31. B1 accumulator piston 67. 2nd brake separator plate : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft)
32. Oil pan gasket 68. 2nd brake return spring subassembly : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
33. Oil pan 69. Front sun gear thrust bearing race : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
34. A/T fluid drain plug 70. Front planetary sun gear : 33 N⋅m (3.3 kgf-m, 24.0 lb-ft)
35. Manual select lever 71. Planetary gear thrust bearing
36. Lock washer 72. One-way clutch No.1 assembly

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-105
9) Remove fluid cooler pipes (1) and pipe unions (2).
10) Remove fluid level gauge (3) and fluid filler tube (4).
11) Remove oil pan (1) and oil pan gasket (2).
NOTE
• For removal of oil pan, do not turn
transaxle over as this will contaminate
valve body with foreign materials in
bottom of oil pan.
• When removing oil pan, tap around it
lightly with plastic hammer. Do not force it
off by using screwdriver or the like.

12) Remove oil strainer assembly (1).13) Disconnect connectors (2) from solenoid valves and
transmission fluid temperature sensor (1).
14) Remove valve body assembly bolts.
CAUTION!
Be careful not to let manual valve fall off
when removing valve body assembly.

NOTE
There are five kinds of bolts (bolts A (1), B (2),
C (3), D (4) and E (5)) fixing valve body
assembly.

15) Remove manual valve rod (1) from manual valve
lever (2), then remove valve body assembly (3).
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