coolant SUZUKI SX4 2006 1.G Service Manual Online

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-35
Poor 2 → 3 shiftShift solenoid valve-A circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Output shaft speed sensor (VSS) circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Transmission range sensor circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
CAN communication circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Throttle position sensor circuit faultyInspect circuit for open, short and intermittent
referring to “DTC P0122: Throttle Position
Sensor (Main) Circuit Low in Section 1A” and/
or “DTC P0123: Throttle Position Sensor
(Main) Circuit High in Section 1A”. If NG, repair.
TCMSubstitute a known-good TCM and recheck.
ECMSubstitute a known-good ECM and recheck.
Poor 3
→ 4 shiftShift solenoid valve-B circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Pressure control solenoid valve circuit
faultyInspect circuit for open, short and intermittent.
If NG, repair.
Timing solenoid valve circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Output shaft speed sensor (VSS) circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Input shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Transmission range sensor circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Transmission fluid temperature sensor
circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
CAN communication circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Throttle position sensor circuit faultyInspect circuit for open, short and intermittent
referring to “DTC P0122: Throttle Position
Sensor (Main) Circuit Low in Section 1A” and/
or “DTC P0123: Throttle Position Sensor
(Main) Circuit High in Section 1A”. If NG, repair.
Engine coolant temperature sensor
circuit faultyInspect circuit for open, short and intermittent
referring to “DTC P0117: Engine Coolant
Temperature Circuit Low in Section 1A” and/or
“DTC P0118: Engine Coolant Temperature
Circuit High in Section 1A”. If NG, repair.
Crankshaft position sensor circuit faultyInspect circuit for open, short and intermittent
referring to “DTC P0335: Crankshaft Position
(CKP) Sensor Circuit in Section 1A”. If NG,
repair.
“3” position switch circuit faultyInspect. If NG, repair.
TCMSubstitute a known-good TCM and recheck.
ECMSubstitute a known-good ECM and recheck. Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-37
Non operate TCC (lock-
up) systemTCC solenoid valve circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Shift solenoid valve-A and/or-B circuit
faultyInspect circuit for open, short and intermittent.
If NG, repair.
Pressure control solenoid valve circuit
faultyInspect circuit for open, short and intermittent.
If NG, repair.
Output shaft speed sensor (VSS) circuit
faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Input shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent.
If NG, repair.
Transmission range sensor circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Transmission fluid temperature sensor
circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
CAN communication circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
Throttle position sensor circuit faultyInspect circuit for open, short and intermittent
referring to “DTC P0122: Throttle Position
Sensor (Main) Circuit Low in Section 1A” and/
or “DTC P0123: Throttle Position Sensor
(Main) Circuit High in Section 1A”. If NG, repair.
Engine coolant temperature sensor
circuit faultyInspect circuit for open, short and intermittent
referring to “DTC P0117: Engine Coolant
Temperature Circuit Low in Section 1A” and/or
“DTC P0118: Engine Coolant Temperature
Circuit High in Section 1A”. If NG, repair.
Brake light switch circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
TCMSubstitute a known-good TCM and recheck.
ECMSubstitute a known-good ECM and recheck.
Higher or lower stall
speedPressure control solenoid valve circuit
faultyInspect circuit for open, short and intermittent.
If NG, repair.
TCMSubstitute a known-good TCM and recheck.
Excessive “N”
→ “D” or
“N”
→ “R” time lagPressure control solenoid valve circuit
faultyInspect circuit for open, short and intermittent.
If NG, repair.
Transmission fluid temperature sensor
circuit faultyInspect circuit for open, short and intermittent.
If NG, repair.
TCMSubstitute a known-good TCM and recheck.
Higher or lower line
pressurePressure control solenoid valve circuit
faultyInspect circuit for open, short and intermittent.
If NG, repair.
TCMSubstitute a known-good TCM and recheck. Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-39
Poor 3 → 4 shiftMalfunction of shift solenoid valve-BInspect. If NG, replace.
Malfunction of timing solenoid valveInspect. If NG, replace.
Malfunction of output shaft speed
sensor (VSS)Inspect. If NG, replace.
Malfunction of input shaft speed sensorInspect. If NG, replace.
Malfunction of transmission range
sensorInspect. If NG, replace.
Malfunction of transmission fluid
temperature sensorInspect. If NG, replace.
Malfunction of “3” position switchInspect. If NG, replace.
Malfunction of engine coolant
temperature sensorInspect referring to “Engine Coolant
Temperature (ECT) Sensor Inspection in
Section 1C”. If NG, replace.
Malfunction of Accelerator pedal
position (APP) sensorInspect referring to “Accelerator Pedal Position
(APP) Sensor Assembly On-Vehicle Inspection
in Section 1C”. If NG, replace.
Malfunction of pressure control solenoid
valveInspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Poor 4
→ 3 shiftMalfunction of shift solenoid valve-BInspect. If NG, replace.
Malfunction of timing solenoid valveInspect. If NG, replace.
Malfunction of output shaft speed
sensor (VSS)Inspect. If NG, replace.
Malfunction of input shaft speed sensorInspect. If NG, replace.
Malfunction of “3” position off switchInspect. If NG, replace.
Malfunction of Accelerator pedal
position (APP) sensorInspect referring to “Accelerator Pedal Position
(APP) Sensor Assembly On-Vehicle Inspection
in Section 1C”. If NG, replace.
Malfunction of pressure control solenoid
valveInspect. If NG, replace valve body assembly.
Faulty valve body componentReplace valve body assembly.
Poor 3
→ 2 shiftMalfunction of shift solenoid valve-AInspect. If NG, replace.
Malfunction of output shaft speed
sensor (VSS)Inspect. If NG, replace.
Malfunction of Accelerator pedal
position (APP) sensorInspect referring to “Accelerator Pedal Position
(APP) Sensor Assembly On-Vehicle Inspection
in Section 1C”. If NG, replace.
Faulty valve body componentReplace valve body assembly.
Poor 2
→ 1 shiftMalfunction of shift solenoid valve-BInspect. If NG, replace.
Malfunction of output shaft speed
sensor (VSS)Inspect. If NG, replace.
Malfunction of Accelerator pedal
position (APP) sensorInspect referring to “Accelerator Pedal Position
(APP) Sensor Assembly On-Vehicle Inspection
in Section 1C”. If NG, replace.
Faulty valve body componentReplace valve body assembly.
Incorrect shift pointEngine abnormal conditionInspect and repair engine.
Malfunction of output shaft speed
sensor (VSS)Inspect. If NG, replace.
Malfunction of Accelerator pedal
position (APP) sensorInspect referring to “Accelerator Pedal Position
(APP) Sensor Assembly On-Vehicle Inspection
in Section 1C”. If NG, replace. Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 5A-40 Automatic Transmission/Transaxle:
Trouble Diagnosis 3
Off-vehicle repairNon operate TCC (lock-
up) systemMalfunction of TCC solenoid valveInspect. If NG, replace.
Malfunction of shift solenoid valve-A
and/or -BInspect. If NG, replace.
Malfunction of output shaft speed
sensor (VSS)Inspect. If NG, replace.
Malfunction of input shaft speed sensorInspect. If NG, replace.
Malfunction of transmission range
sensorInspect. If NG, replace.
Malfunction of transmission fluid
temperature sensorInspect. If NG, replace.
Malfunction of pressure control solenoid
valveInspect. If NG, replace valve body assembly.
Malfunction of Accelerator pedal
position (APP) sensorInspect referring to “Accelerator Pedal Position
(APP) Sensor Assembly On-Vehicle Inspection
in Section 1C”. If NG, replace.
Malfunction of engine coolant
temperature sensorInspect referring to “Engine Coolant
Temperature (ECT) Sensor Inspection in
Section 1C”. If NG, replace.
Malfunction of brake light switchInspect referring to “Brake Light Switch
Inspection in Section 9B”. If NG, replace.
Faulty valve body componentReplace valve body assembly.
Excessive “N”
→ “D” or
“N”
→ “R” time lagMalfunction of transmission fluid
temperature sensorInspect. If NG, replace.
Pressure control solenoid valve circuit
faultyInspect. If NG, replace valve body assembly.
Clogged oil strainerReplace.
Faulty valve body componentReplace valve body assembly. Condition Possible cause Correction / Reference Item
Condition Possible cause Correction / Reference Item
Unable to run in all rangeFaulty oil pumpInspect. If NG, replace.
Seized or broken planetary gearInspect. If NG, replace.
Faulty one-way No.2 clutchInspect. If NG, replace.
Damaged drive plateInspect. If NG, replace.
Faulty forward clutchInspect. If NG, replace.
Faulty reverse clutchInspect. If NG, replace.
Faulty 1st and reverse brakeInspect. If NG, replace.
Faulty torque converterReplace.
Excessive “N”
→ “D” shift
shockFaulty forward clutchInspect. If NG, replace.
Excessive “N”
→ “R” shift
shockFaulty reverse clutchInspect. If NG, replace.
Faulty 1st and reverse brakeInspect. If NG, replace.
Poor 1
→ 2 shift,
excessive shock or
slippageFaulty 2nd brakeInspect. If NG, replace.
Faulty one-way No.1 clutchInspect. If NG, replace.
Poor 2
→ 3 shift,
excessive shock or
slippageFaulty direct clutchInspect. If NG, replace.
Poor 3
↔ O/D shift,
excessive shock or
slippageFaulty forward clutchInspect. If NG, replace.
Faulty O/D and 2nd coast brakeInspect. If NG, replace.
Poor 3
→ 2 shift,
excessive shock or
slippageFaulty direct clutchInspect. If NG, replace.
Faulty one-way No.1 clutchInspect. If NG, replace.
Poor 2
→ 1 shift,
excessive shock or
slippageFaulty 2nd brakeInspect. If NG, replace.
Faulty one-way No.2 clutchInspect. If NG, replace.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-49
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 a tester, on a level road.

1) Connect scan tool to DLC with ignition switch OFF, if available.
2) Clear DTC in TCM memory and start engine.
3) Increase engine coolant temperature to about 50 °C (122 °F) and more.
4) Start vehicle and increase vehicle speed to about 20 km/h (12 mile/h) for 10 minutes or more.
5) Stop vehicle and check DTC.
DTC Troubleshooting
Step Action Yes No
1Was “A/T System Check” performed?Go to Step 2. Go to “A/T System
Check”.
2Check transmission fluid temperature circuit for open
1) Turn ignition switch OFF.
2) Disconnect TCM connectors from TCM.
3) Check for proper connection to transmission fluid
temperature sensor at terminals “C06-11” and “C06-12”.
4) If OK, check continuity between terminals “C06-11” and
“C06-12” of disconnected harness side TCM connector.
Is continuity indicated?Go to Step 3. “LT GRN” or “ORN”
circuit open.
3Check transmission fluid temperature circuit for IG
short
1) Cool down A/T fluid temperature under ambient
temperature.
2) Connect TCM connectors to TCM with ignition switch
OFF.
3) Turn ignition switch ON.
4) Measure voltage between terminal “C06-11” of TCM
connector and ground.
Is it 4.6 V or more?“LT GRN” circuit shorted
to power circuit.
If circuit is OK, go to
St ep 4 .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.
4Inspect transmission fluid temperature sensor
1) Inspect transmission fluid temperature sensor referring
to “Transmission Fluid Temperature Sensor Inspection”.
Is result 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 transmission
fluid temperature
sensor.

Downloaded from www.Manualslib.com manuals search engine 5B-12 Manual Transmission/Transaxle:
Manual Transaxle Unit Dismounting and
Remounting
S6RW0D5206010
Dismounting
1) Drain coolant.
2) Remove battery and tray with ECM.
3) Remove air cleaner case and resonator.
4) Remove clutch fluid pipe referring to “Clutch Fluid
Pipe Removal and Installation in Section 5C”.
5) Disconnect back up light switch coupler and undo
wiring harness clamps.
6) Disconnect gear shift and gear select control cables
(1) from transaxle.
7) Remove earth cable from transaxle.
8) Remove water inlet pipe.
9) Remove starting motor referring to “Starting Motor
Dismounting and Remounting in Section 1I”.
10) Remove transaxle to engine bolts (1) of upper side.
11) Drain transaxle oil and transfer oil, if equipped.
12) Remove engine under covers.
13) Remove drive shaft assembly and center shaft
referring to “Front Drive Shaft Assembly Removal
and Installation in Section 3A”.
14) Remove exhaust No.1, No.2 and No.3 pipes
referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
15) Remove suspension frame, engine front mounting
member and engine mounting member referring to
“Front Suspension Frame, Stabilizer Bar and/or
Bushing Removal and Installation in Section 2B” and
“Engine Mountings Components in Section 1D”.16) Remove transfer referring to “Transfer Dismounting
and Remounting in Section 3C”, if equipped.
17) Remove clutch housing lower plate.
18) Support transaxle with transmission jack.
19) Remove left mounting (1) and left mounting bracket
(2).
20) Remove stiffener bolts (2), transaxle to engine bolts
(1) and nut of lower side, and then lower transaxle.
Remounting
CAUTION!
• Care should be taken not to scratch oil
seal lip with drive shaft while raising
transaxle.
• Do not hit drive shaft joint with hammer
when installing it into differential gear.

Reverse dismounting procedure for remounting of
transaxle, noting the following points.
• Tighten each bolts and nuts to specified torque
referring to “Manual Transaxle Unit Components” and
“Engine Mountings Components in Section 1D”.
• Set each clamp for wiring securely.
• Fill transaxle oil and transfer oil referring to “Manual
Transaxle Oil Change” and “Transfer Oil Change in
Section 3C”.
• Connect battery and check function of engine, clutch
and transaxle.
1
I5RW0A520011-01
1
I5RW0A520012-01
1
2
I5RW0A520013-01
1
2I5RW0A520014-01

Downloaded from www.Manualslib.com manuals search engine 7A-4 Heater and Ventilation:
Repair Instructions
HVAC Unit ComponentsS6RW0D7106001
For non-A/C and manual A/C, refer to “HVAC Unit
Components in Section 7B”.
For auto A/C, refer to “HVAC Unit Components in
Section 7B”.
HVAC Unit Removal and Installation (Non-A/C)S6RW0D7106002
For manual A/C and auto A/C, refer to “HVAC Unit
Removal and Installation in Section 7B”.
Removal
1) Drain engine coolant referring to “Cooling System
Draining in Section 1F”, and then disconnect heater
hoses from HVAC unit.
2) Remove cowl top cover from vehicle body referring
to “Cowl Top and Front Lower Crossmember
Components in Section 9K”.
3) Remove instrument panel from vehicle body
referring to “Instrument Panel Removal and
Installation in Section 9C”.
4) Remove HVAC unit (1) from vehicle body by
removing nuts (2).Installation
Reverse removal procedure noting the following
instructions.
• Be careful not to catch any cable and wiring harness
in inappropriate position.
• Adjust control cables of HVAC control unit referring to
“HVAC Control Unit Removal and Installation”.
• Refill cooling system with coolant referring to “Cooling
System Flush and Refill in Section 1F”.
Blower Motor Removal and InstallationS6RW0D7106003
Removal
1) Disconnect negative (–) cable from battery.
2) Disconnect connector (1) from blower motor (2).
3) Remove blower motor (2) from HVAC unit as follows.
a) Remove screws (4).
b) Release tub (3) to arrow direction.
c) Hold Step b) and turn blower motor (2) to arrow
direction.
Installation
Reverse removal procedure.
Blower Motor InspectionS6RW0D7106004
• Check blower motor for resistance between two
terminals as shown.
If there is no continuity, replace blower motor.
2
2
2
1
I7RW01710003-01
3
2
b)
c)
1
4
4I7RW01710004-02
I7RW01710005-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-3
Manual A/C Electronic Input Output TableS6RW0D7211002
A/C Operation Description at ECMS6RW0D7211003
ECM controls the A/C compressor relay and condenser cooling fan relay according to signals from HVAC control unit,
A/C refrigerant pressure sensor, ECT sensor and evaporator temperature sensor. The A/C switch ON signal from
HVAC control unit is transmitted to ECM through BCM. For CAN communication system, refer to “CAN
Communication System Description in Section 1A”.
ECM turns ON the A/C compressor relay when the vehicle state satisfy conditions described below.
• A/C switch ON signal is inputted from HVAC control unit
• A/C refrigerant pressure is within specified range
• Evaporator temperature is within specified range
• Engine speed is within specified range
• Engine coolant temperature is lower than specified value
• Throttle opening is lower than specified value
• Vehicle is not in either state of starting or quick acceleration
• ECT sensor malfunction is not detected
• A/C refrigerant pressure sensor malfunction is not detected
Condenser Cooling Fan Relay Control
ECM turn ON the condenser cooling fan relay at the same time when ECM turn ON the A/C compressor relay.
ECM
BCM
A/C switch Air intake selector
A/C refrigerant pressure sensor
A/C evaporator temperature sensorCompressor relay
ECT sensor
Condensor cooling fan relay
*
Wheel speed sensor (VSS)
HVAC control unit
Blower motor Blower motor resistor
Air intake control actuator
*Blower speed selector
ABS control module
I6RW0C721001-01
*: CAN communication

Downloaded from www.Manualslib.com manuals search engine 7B-26 Air Conditioning System: Manual Type
HVAC Unit Removal and InstallationS6RW0D7216008
Removal
1) Recover refrigerant from A/C system with recovery
and recycling equipment referring to “Recovery” in
“Operation Procedure for Refrigerant Charge”.
2) Drain engine coolant referring to “Cooling System
Draining in Section 1F”, and then disconnect heater
hoses from HVAC unit.
3) Remove cowl top cover from vehicle body referring
to “Cowl Top and Front Lower Crossmember
Components in Section 9K”
4) Remove instrument panel from vehicle body
referring to “Instrument Panel Removal and
Installation in Section 9C”.
5) Loosen a bolt (1) and remove pipes from expansion
valve (2).6) Remove HVAC unit (1) from vehicle body by
removing nuts (2).
7. Cover (without HVAC air
filter)14. Heater core 21. Temperature control lever : Do not reuse.
1
2
I7RW01721016-01
2
2
2
1
I7RW01710003-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-27
Installation
Reverse removal procedure noting the following
instructions.
• Replenish specified amount of compressor oil to
compressor suction side referring to “Replenishing
Compressor Oil” in “Operation Procedure for
Refrigerant Charge”.
• Install the padding (1) to the installation hole
uniformly.
• Evacuate and charge the A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
• Refill cooling system with coolant referring to “Cooling
System Flush and Refill in Section 1F”.
• Adjust control cables referring to “HVAC Control Unit
Removal and Installation in Section 7A”. (vehicle with
manual type A/C)
Evaporator InspectionS6RW0D7216009
Check the followings.
• Clog of A/C evaporator fins.
If any clogs are found, A/C evaporator fins should be
washed with water, and then should be dried with
compressed air.
• A/C evaporator fins for leakage and breakage.
If any defects are found, repair or replace A/C
evaporator.
• A/C evaporator fittings for leakage.
If any defects are found, repair or replace A/C
evaporator.
Evaporator Temperature Sensor Removal and
Installation
S6RW0D7216010
Removal
1) Remove HVAC unit from vehicle body referring to
“HVAC Unit Removal and Installation”.
2) Remove evaporator temperature sensor (1) from
evaporator by (2) disassembling HVAC unit.
Installation
Reverse the removal procedure noting the following
instruction.
• Install evaporator temperature sensor (1) onto
evaporator (2) as shown.
LH steering vehicle
RH steering vehicle
1
I5RW0A721025-02
3. 138 ± 5 mm (3.3 ± 0.2 in.)
4. Sensor part fixed to 12th fin from pipe fitting side
5. Holding part fixed to 13th fin from pipe fitting side
6. Pipe fitting
1
2
I7RW01721018-01
5
4
6 1
2
3I7RW01721026-01
1
5
642
3
I6RW0C721007-01