light SUZUKI SX4 2006 1.G Service Manual Online

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-22
DTC 1016: Brake Light SwitchS6RW0D4504014
Wiring Diagram
DTC Detecting Condition and Trouble Area
NOTE
When a vehicle is lifted up and its wheel(s) is turned, this DTC is set.
In such case, clear the DTC and check again.

Troubleshooting
WHTGRN
34 712V
E08-7
E08-9GRN/ORN
2
8
112V
GRN/WHT
WHTGRN[A]E08
1
2
3
4
5
6
7 12
13
14
15
16
17
18
19
20
21
228
9
10
11
23
24
25
26
I7RW01450006-05
[A]: ABS control module connector (viewed from terminal side) 3. Ignition switch 6. Brake light
1. Battery 4. Junction block assembly 7. ABS hydraulic unit / control module assembly
2. Main fuse box 5. Brake light switch 8. To ECM and shift lock relay (A/T model)
DTC Detecting Condition Trouble Area
Brake light switch signal voltage becomes 4.8 – 8.0 V for
specified time.• Brake light circuit
• Brake light switch
• ABS control module
Step Action Yes No
1Was “ABS Check” performed?Go to Step 2. Go to “ABS Check”.
2Brake light operation check
1) Turn ignition switch to ON position and depress brake
pedal.
Does brake light turn ON?Go to Step 3. Repair brake light
switch, brake light and/
or brake light circuit and
recheck.
3Brake light switch signal circuit check
1) Disconnect ABS hydraulic unit / control module and
brake light switch connector with ignition switch turned
OFF.
2) Check for proper connection to “E08-7” terminal of ABS
hydraulic unit / control module and “GRN/WHT” wire
terminal of brake light switch.
3) If OK then measurer resistance between terminal of
“E08-7” and “GRN/WHT” wire terminal of brake light
switch connector.
Is it less than 2
Ω?Substitute a known-
good ABS hydraulic unit
/ control module and
recheck.“GRN/WHT” wire open
or high resistance.

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-34
Installation
1) Install hydraulic unit / control module assembly by
reversing removal procedure noting the following.
Install ABS hydraulic unit / control module assembly
bracket bolt as follows.
a) Tighten bracket bolt (1) and (2) by hand.
b) Then tighten bracket bolt to specified torque.
Tightening order (1) → (2)
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft)
ABS hydraulic unit / control module assembly
bolt (b): 9 N·m (0.9 kgf-m, 6.5 lb-ft)
ABS hydraulic unit / control module assembly
bracket bolt (c): 26 N·m (2.6 kgf-m, 19.0 lb-ft)2) Bleed air from brake system referring to “Air
Bleeding of Brake System in Section 4A”.
3) Check each installed part for fluid leakage and
perform “ABS Hydraulic Unit Operation Check”.
NOTE
For new ABS hydraulic unit / control module
assembly, if “ABS Hydraulic Unit Operation
Check” has not been performed, ABS
warning light may flash when ignition switch
is turned ON position.
Accordingly preform “ABS Hydraulic Unit
Operation Check” to stop flashing of ABS
warning light.

Front and Rear Wheel Speed Sensor On-Vehicle
Inspection
S6RW0D4506005
Output Voltage Inspection
1) Disconnect negative (–) cable from battery.
2) Hoist vehicle a little.
3) Disconnect wheel speed sensor connector.
4) Set up measuring device as shown in figure, the
resistance to 115 Ω and the power supply voltage to
12 V.
CAUTION!
Incorrect voltage and/or wrong connection
cause damage to wheel speed sensor.

I6RW0C450011-01
1. Wheel speed sensor connector 4. “BLK” wire terminal
2. Resistance (115Ω) 5. Power supply (12 V)
3. “WHT” wire terminal
V
41
3
2
5
I5JB0A450026-03

Downloaded from www.Manualslib.com manuals search engine Table of Contents 5- i
5
Section 5
CONTENTS
Transmission / Transaxle
Precautions ................................................. 5-1
Precautions............................................................. 5-1
Precautions on Transmission / Transaxle ............. 5-1
Automatic Transmission/Transaxle ....... 5A-1
Precautions........................................................... 5A-1
Precautions in Diagnosing Trouble ..................... 5A-1
Precautions for Disassembly and
Reassembly ...................................................... 5A-1
General Description ............................................. 5A-3
A/T Description ................................................... 5A-3
Clutch / Brake / Planetary Gear Function of
Automatic Transaxle ......................................... 5A-6
Table of Component Operation ........................... 5A-7
A/T Diagnosis General Description ..................... 5A-7
On-Board Diagnostic System Description ........... 5A-8
CAN Communication System Description........... 5A-9
Schematic and Routing Diagram ...................... 5A-10
Transmission Control Module (TCM) Wiring
Diagram .......................................................... 5A-10
Automatic Gear Shift Table ............................... 5A-12
Component Location ......................................... 5A-14
Electronic Shift Control System Components
Location .......................................................... 5A-14
Diagnostic Information and Procedures .......... 5A-16
A/T System Check ............................................ 5A-16
Visual Inspection ............................................... 5A-18
Malfunction Indicator Lamp (MIL) Check .......... 5A-19
Transmission Warning Light Check (Non-
Euro-OBD model) ........................................... 5A-19
DTC Table ......................................................... 5A-19
DTC Check ....................................................... 5A-21
DTC Clearance ................................................. 5A-22
Fail-Safe Table .................................................. 5A-22
Scan Tool Data ................................................. 5A-24
A/T Basic Check ............................................... 5A-27
Road Test ......................................................... 5A-27
Manual Road Test ............................................. 5A-30
Engine Brake Test ............................................ 5A-30
Stall Test ........................................................... 5A-31
Time Lag Test ................................................... 5A-32
Line Pressure Test ............................................ 5A-32
“P” Range Test.................................................. 5A-33
A/T Symptom Diagnosis ................................... 5A-34Transmission Warning Light Circuit Check –
Light Remains “ON” at Ignition Switch ON
(Non-Euro-OBD Model)................................... 5A-41
Transmission Warning Light Circuit Check –
Light Does Not Come “ON” at Ignition Switch
ON (Non-Euro-OBD Model)............................ 5A-41
DTC P0602: Control Module Programming
Error ................................................................ 5A-42
DTC P0705: Transmission Range Sensor
Circuit Malfunction (PRNDL Input) .................. 5A-42
DTC P0707: Transmission Range Sensor
Circuit Low ...................................................... 5A-44
DTC P0711: Transmission Fluid Temperature
Sensor “A” Control Range / Performance ....... 5A-46
DTC P0712: Transmission Fluid Temperature
Sensor Circuit Low .......................................... 5A-47
DTC P0713: Transmission Fluid Temperature
Sensor Circuit High ......................................... 5A-48
DTC P0717: Input / Turbine Speed Sensor
Circuit Malfunction........................................... 5A-50
DTC P0722: Output Speed Sensor (VSS)
Circuit No Signal ............................................. 5A-51
DTC P0741 / P0742: TCC Circuit
Performance or Stuck OFF / TCC Circuit
Stuck ON ......................................................... 5A-53
DTC P0751 / P0752 / P0756 / P0757: Shift
Solenoid Malfunction ....................................... 5A-54
DTC P0787: Shift / Timing Solenoid Control
Circuit Low ...................................................... 5A-55
DTC P0788: Shift / Timing Solenoid Control
Circuit High...................................................... 5A-57
DTC P0961: Pressure Control Solenoid “A”
Control Circuit Range / Performance .............. 5A-58
DTC P0962: Pressure Control Solenoid
Control Circuit Low .......................................... 5A-60
DTC P0963: Pressure Control Solenoid
Control Circuit High ......................................... 5A-62
DTC P0973 / P0976: Shift Solenoid-A (No.1)
Control Circuit Low / Shift Solenoid-B (No.2)
Control Circuit Low .......................................... 5A-64
DTC P0974 / P0977: Shift Solenoid-A (No.1)
/ Shift Solenoid-B (No.2) Control Circuit High .. 5A-66
DTC P1702: Internal Control Module Memory
Check Sum Error............................................. 5A-68

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 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-3
General Description
A/T DescriptionS6RW0D5101001
This automatic transaxle is electronic control full automatic transaxle with forward 3-speed plus overdrive (O/D) and
reverse 1-speed.
The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an automatically controlled lock-up
mechanism.
The gear change device consists of a ravigneau type planetary gear unit, 3 multiple disc type clutches, 3 multiple disc
type brakes and 2 one-way clutches.
The hydraulic pressure control device consists of a valve body assembly, pressure control solenoid valve (linear
solenoid), 2 shift solenoid valves, TCC solenoid valve (TCC pressure control solenoid valve) (linear solenoid) and a
timing solenoid valve. Optimum line pressure complying with engine torque is produced by the pressure control
solenoid valve in dependence upon control signal from transmission control module (TCM). This makes it possible to
control the line pressure with high accuracy in accordance with the engine power and running conditions to achieve
smooth shifting characteristics and high efficiency.
A clutch-to-clutch control system is provided for shifting between 3rd gear and 4th gear. This clutch-to-clutch control
system is made to function optimally, so that hydraulic pressure controls such as shown below are conducted.
• When upshifting from 3rd gear to 4th gear, to adjust the drain hydraulic pressure at releasing the forward clutch, a
timing solenoid valve is used to switch a hydraulic passage with an orifice to another during shifting.
• When downshifting from 4th gear to 3rd gear, to adjust the line pressure applied to the forward clutch at engaging
the forward clutch, a timing solenoid valve is used to switch a hydraulic passage with an orifice to another during
shifting.
• When upshifting from 3rd gear to 4th gear with engine throttle opened, to optimize the line pressure applied to the
forward clutch at releasing the forward clutch, the learning control is processed to compensate the switching timing
of the timing solenoid at every shifting.
• When downshifting from 4th gear to 3rd gear with engine throttle opened, to optimize the line pressure applied to
the forward clutch at engaging the forward clutch, the learning control is processed to compensate the line pressure
at every shifting.
Employing the ravigneau type planetary gear unit and this clutch-to-clutch control system greatly simplifies the
construction to make possible a lightweight and compact transaxle.
A line pressure learning control is conducted to provide optimum shifting time at every upshifting with engine throttle
opened. If long upshifting time is detected, the subsequent line pressure applied during upshifting is intensified. On the
contrary, if short upshifting time is detected, the subsequent line pressure applied during upshifting is weakened.

Downloaded from www.Manualslib.com manuals search engine 5A-8 Automatic Transmission/Transaxle:
On-Board Diagnostic System DescriptionS6RW0D5101005
NOTE
There are two types of OBD system
depending on the vehicle specification.For
identification, refer to “Precaution on On-
Board Diagnostic (OBD) System in Section
1A”.

For automatic transaxle control system, TCM has the
following functions.
• For Euro OBD model, when the ignition switch is
turned ON with the engine at a stop, MIL (1) turns ON
to check the bulb of the MIL.
• For Euro OBD model, when TCM detects a
malfunction in A/T control system TCM desires turning
on MIL and stores malfunction DTC in TCM memory.
(If it detects that continuously 3 driving cycles are
normal after detecting a malfunction, however, it
makes MIL turn OFF although DTC stored in its
memory will remain.)
• For Euro OBD model, it is possible to communicate
with TCM through data link connector (DLC) (2) by
using not only SUZUKI scan tool (3) but also CAN
communication OBD generic scan tool. (Diagnostic
information can be checked and erased by using scan
tool.)
• For non-Euro-OBD model, when ignition switch is
turned ON and no malfunction in A/T control system is
detected, transmission warning light (4) lights for
about 2 seconds after ignition switch is turned ON and
then goes OFF for bulb check.• For non-Euro-OBD model, when TCM detects a
malfunction in A/T control system, it indicates
transmission warning light (4) and stores malfunction
DTC in its memory.
• For information about the following items, refer to “On-
Board Diagnostic System Description in Section 1A”.
– Warm-up cycle
– Driving cycle
– 2 driving cycle detection logic
– Pending DTC
– Freeze frame date
1
3 2
4
I6RW0B510001-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-9
CAN Communication System DescriptionS6RW0D5101006
Refer to “CAN Communication System Description in Section 1A” for CAN communication System description. TCM
communicates control data with each control module as follows.
TCM Transmission Data
TCM Reception Data
DATA TCMTransmit
Transmission oil temperarure
signal
Torque request signal
Vehicle speed pulse signal
Transmission warning light
signal
MIL control signal
Transmission actual gear position
signal
A/T select lever position signal
Transmission diagnostic trouble
code (DTC)
ECMCombination
meterBCM
4WD control
module
(if equipped)
I6RW0D510001-01
Engine torque signal
Accelerator pedal position signal
Engine speed signal
Throttle position signal
A/C compressor clutch signal
Engine coolant temperature signal
Vehicle speed pulse signal
Brake pedal switch signal
Driving cycle active
Warm up cycle active Reception data from ECM
I6RW0D510002-02

Downloaded from www.Manualslib.com manuals search engine 5A-10 Automatic Transmission/Transaxle:
Schematic and Routing Diagram
Transmission Control Module (TCM) Wiring DiagramS6RW0D5102001
12V
12V
12V
IG1
118
9
10
P
R
N
D
2
L12
2.5V
5V
12V
5V
12V
12V
12V
WHT
BLK
BLK
BLK
BLK
PPLBLK/WHT
BLK/ORN
IG11
RED/BLK
YEL/BLKYEL/BLU
LT GRN/BLK
+BB
WHT/RED
14
20 15
16
17
19
12V18
1 2
3
132126
24 27
28
29
30
65
16 15 14 13 12 1143
24 23 212210 9 8 721
19 20 18 17 C06
17 16
26 2515 14 65 342
13 12
23 22 2411 10 9
21 20 1987
18 1 C07
[A]
22
25
YELYEL/GRN
WHT
P
N
BRN LT/GRN
ORN
BLK/YEL
BLU/BLK
GRY
LT GRN/BLKWHT/BLU
WHT/BLK
C06-11
C06-12
C06-16
C06-15
C06-14
C06-4
C06-2
C06-1
C06-23C06-6 C06-24C06-5
C06-3
RED
GRN GRN/ORNPNK/BLK
GRN/YEL
LT GRN/BLKC07-6
C07-16
C07-23 C07-25
C07-20
C07-1
C07-8
C07-7
C07-19
C07-18
4IG11 23
C07-9
YEL
RED
WHTBLU35 34
3637
5REDWHT
7
WHT
RED
33
4
6
C06-7C06-17WHT
REDREDWHT
WHT
12V12V
WHTRED
WHTREDREDWHT
31
32
RED
WHTRED[B]
[C]
I6RW0D510003-02
1. TCM 15. Shift solenoid valve-A (No.1) 29. “ST SIG” fuse
2. Input shaft speed sensor 16. Shift solenoid valve-B (No.2) 30. “ST” fuse
3. Output shaft speed sensor / VSS 17. Timing solenoid valve 31. MIL
4. ECM 18. TCC solenoid valve 32. Transmission warning light (non-Euro-OBD model)
5. Combination meter 19. Pressure control solenoid valve 33. ABS control module
6. BCM 20. A/T 34. To Data link connector
7. 4WD control module (if equipped) 21. A/T relay 35. To BCM
8. “3” position switch 22. Inhibitor switch (including transmission range
sensor)36. Junction connector
9. Shift lock solenoid 23. Starter motor relay 37. Keyless start control module (if equipped)
10. Brake light switch 24. Ignition switch [A]: Terminal arrangement of TCM connector (viewed
from harness side)
11. Transmission range sensor 25. Starter motor [B]: Junction block with BCM model
12. Backup lamp 26. “DOME” fuse [C]: Junction block without BCM model
13. Data link connector (DLC) 27. “AT” fuse
14. Transmission fluid temperature sensor 28. “IG1 SIG” fuse

Downloaded from www.Manualslib.com manuals search engine 5A-14 Automatic Transmission/Transaxle:
Component Location
Electronic Shift Control System Components LocationS6RW0D5103001
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

5*
17
15
1
2
8
9
1011
12
13
16*18 19
14
7
6
3420
[B]
[A]5*
I6RW0D510004-01
[A]: Junction block with BCM model 7. Input shaft speed sensor 15. ECM
[B]: Junction block without BCM model 8. TCC solenoid valve 16. TCM
1. Engine 9. Transmission fluid temperature sensor 17. AT relay
2. Transaxle 10. Timing solenoid valve 18. “3” position switch
3. MIL 11. Pressure control solenoid valve 19. Select lever
4. Transaxle select position indicator 12. Shift solenoid valve-B (No.2) 20. Transmission warning light (non-Euro-OBD model)
5. Junction block assembly (included in BCM) 13. Shift solenoid valve-A (No.1)