321 SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine General Information: 0A-2
S:
SAE: Society of Automotive Engineers
SDM: Sensing and Diagnostic Module (Air Bag
Controller, Air bag Control Module)
SDT: Smart Diagnostic Tester
SFI: Sequential Multiport Fuel Injection
SOHC: Single Over Head Camshaft
T:
TBI: Throttle Body Fuel Injection (Single-Point Fuel
Injection, SPI)
TCC: Torque Converter Clutch
TCM: Transmission Control Module (A/T Controller, A/T
Control Module)
TDC: Top Dead Center
TP Sensor: Throttle Position SensorTVV: Thermal Vacuum Valve (Thermal Vacuum
Switching Valve, TVSV, Bimetal Vacuum Switching
Valve, BVSV)
TWC: Three Way Catalytic Converter (Three Way
Catalyst)
2WD: 2 Wheel Drive
U:
USB: Universal Serial Bus
V:
VIN: Vehicle Identification Number
VSS: Vehicle Speed Sensor
VVT: Variable Valve Timing (Camshaft Position Control)
W:
WU-OC: Warm Up Oxidation Catalytic Converter
WU-TWC: Warm Up Three Way Catalytic Converter
SymbolsS6RW0D0101002
Wire Color SymbolsS6RW0D0101003
Symbol Definition Symbol Definition
Tightening torque Apply SUZUKI BOND NO. 1216B
99000-31230
Apply oil (engine, transmission, transfer,
differential)Apply SILICONE SEALANT
99000-31120
Apply fluid (brake, power steering or
automatic transmission fluid)Apply SEALING COMPOUND 366E
99000-31090
Apply SUZUKI SUPER GREASE A
99000-25011
Apply SUZUKI SUPER GREASE C
99000-25030Apply THREAD LOCK 1322
99000-32110
Apply SUZUKI SUPER GREASE E
99000-25050Apply THREAD LOCK 1333B
99000-32020
Apply SUZUKI SUPER GREASE H
99000-25120Apply THREAD LOCK 1342
99000-32050
Apply SUZUKI SUPER GREASE I
99000-25210
Apply SUZUKI BOND NO. 1215
99000-31110Do not reuse
Apply SUZUKI BOND NO. 1207F
99000-31250Note on reassembly
Apply SUZUKI BOND NO. 1217G
99000-31260
Symbol Wire Color Symbol Wire Color
B BLK Black O, Or ORN Orange
Bl BLU Blue R RED Red
Br BRN Brown W WHT White
G GRN Green Y YEL Yellow
Gr GRY Gray P PNK Pink
Lbl LT BLU Light blue V PPL Violet
Lg LT GRN Light green

Downloaded from www.Manualslib.com manuals search engine 1D-18 Engine Mechanical:
17) Remove oil pressure switch bracket (1).
18) Remove suspension control arm referring to
“Suspension Control Arm / Bushing Removal and
Installation in Section 2B”.
19) Disconnect right and left drive shaft joints from
differential gear referring to “Front Drive Shaft
Assembly Removal and Installation in Section 3A”.
20) Remove exhaust No.1, No.2 and center pipes
referring to “Exhaust System Components in Section
1K”.
21) Disconnect propeller shaft referring to “Propeller
Shaft Assembly Removal and Installation in Section
3D” (for 4WD model).
22) Disconnect steering lower shaft from pinion shaft
referring to “Steering Lower Shaft Removal and
Installation in Section 6B”.
23) Fix radiator to body with rope in order to avoid the
radiator fall off when front lower cross member
lowered.
24) Support front suspension frame, front lower cross
member and oil pan using jack at hatched parts (1)
indicated in figure.
[A]: View A [C]: For A/T model
6
3 45
1 7 7
2
8
9
10
A
15
14
16
20 19
26
24
27
12
13 [A]
11
34
232122
25
17 2818 [B] [C]
2930
31
32
17
33
I5RW0C140010-01
[B]: For M/T model 34. steering gear box
2. Exhaust manifold
1
2
I5RW0A140011-01
11
I5RW0A140012-01

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-44
23) Remove differential cover.
24) To measure bevel gear backlash, set dial gauge at
right angle to bevel gear tooth, fix drive bevel pinion
and read dial gauge while moving bevel gear.
If bevel gear backlash is out of specification, repeat
Step 22).
NOTE
• Be sure to apply measuring tip of dial
gauge at right angles to convex side of
tooth.
• Measure at least 4 points on drive bevel
gear periphery.

Drive bevel gear back lash
0.1 – 0.2 mm (0.004 – 0.008 in.)Special tool
(A): 09900–20607
(B): 09900–20701
25) As final step, check gear tooth contact as follows.
a) After cleaning 10 drive bevel gear teeth, paint them with gear marking compound evenly by using brush (1) or
sponge etc.
b) Turn gear to bring its painted part in mesh with drive bevel pinion and turn it back and forth by hand to repeat
their contact.
c) Bring painted part up and check contact pattern, referring to the following table. If contact pattern is not normal,
readjust or replace as necessary according to instruction in the table.
NOTE
Be careful not to turn drive bevel gear more than one full revolution, for it will hinder accurate check.

I5RW0A320057-01
A: Paint gear marking compound evenly
1
A
I5JB0A321040-02

Downloaded from www.Manualslib.com manuals search engine 3B-45 Differential:
Tooth Contact Pattern Diagnosis and Remedy
Normal
High Contact
Pinion is positioned too far from the center of drive
bevel gear (1).
• Increase thickness of pinion (2) height adjusting
shim and position pinion closer to gear center.
• Adjust drive bevel gear backlash to specification.
Low Contact
Pinion is positioned too close to the center of drive
bevel gear (1).
• Decrease thickness of pinion (2) height adjusting
shim and position pinion farther from gear center.
• Adjust drive bevel gear backlash to specification.
If adjustment is impossible, replace differential carrier.
• Check seating of bevel gear or differential case. (Check bevel
gear for runout.)
• If adjustment is impossible, replace drive bevel gear and pinion
set or differential carrier.
Replace drive bevel gear and pinion set or differential case.
I5JB0A321041-05
IYSQ01321072-01
IYSQ01321073-01
IYSQ01321074-01IYSQ01321076-01
IYSQ01321077-01
IYSQ01321078-01
IYSQ01321079-01

Downloaded from www.Manualslib.com manuals search engine 3C-5 Transfer:
Transfer Assembly Disassembly and
Reassembly
S6RW0D3306005
Disassembly
NOTE
It is possible to disassemble transfer
assembly without removing intermediate
shaft with Step 1) to 4) performed if not
necessary.

1) Remove right case oil seal No.1 (1) from transfer
right case using special tool.
Special tool
: 09913–50121
2) Remove snap ring (2) by using snap ring pliers.
3) Remove intermediate shaft (4) with intermediate
shaft bearing (3) from transfer assembly.
4) Remove intermediate shaft bearing (3) from
intermediate shaft (4) by using bearing puller and
hydraulic press.
5) Remove transfer output retainer assembly (1) and
shim (3) by removing retainer bolts (2).
6) Remove transfer case bolts (4).
7) Separate transfer right case (5) from transfer left
case (6) by using special tool.
Special tool
(A): 09912–34510
8) Remove reduction drive gear assembly (7) and
reduction driven gear assembly (9).
9) Remove shim (10) and bearing outer races (8).
NOTE
When it is difficult to remove bearing outer
races from cases, remove them with special
tool.

Special tool
(B): 09944–96011Reassembly
1) Select appropriate shim as follows.
a) Measure distance “a” between taper roller
bearing outer races of reduction driven gear
assembly (1).
b) Measure depth “b” of left case (2) and “c” of right
case (3).
c) Obtain adjusting shim thickness by the following
equation.
9. Pump seal 23. Reduction drive gear right bearing : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
10. Pinion shaft front taper roller bearing 24. Intermediate shaft : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
11. Bevel pinion 25. Oil protect plate bolt
: Apply thread lock cement 99000-32110
to thread part.: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
12. Bevel gear 26. Snap ring : 9 N⋅m (0.9 kgf-m, 6.5 lb-ft)
13. Reduction driven gear 27. Oil protect plate : Do not reuse.
14. Intermediate shaft bearing 28. Shim : Apply transfer oil.
4
3
2
1
I5RW0A330008-01
11. Dowel pin
Necessary
shim
thickness=Depth
“b”+Depth
“c”–Distanc
e “a”+0.1 mm
(0.004
in.)
7
(B)
5
11
310 9 10
8 64
8
(A)
12
2
I5RW0A330009-03
23
1
“b”
“a”“c”
I5RW0A330010-01

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 Automatic Transmission/Transaxle: 5A-83
7) Pull out fluid level gauge (1) again and check fluid
level indicated on it. The lowest fluid level should be
between FULL HOT (2) and LOW HOT (3). If it is
below LOW HOT, add SUZUKI ATF 3317 or Mobil
ATF 3309 up to FULL HOT.
Automatic transaxle fluid
SUZUKI ATF 3317 or Mobil ATF 3309
NOTE
• Do not race engine while checking fluid
level, even after the engine start.
• Do not overfill. Overfilling can cause
foaming and loss of fluid through breather.
Then slippage and transaxle failure can
result.
• Bringing the level from LOW HOT to FULL
HOT requires 0.4 liters (0.85 / 0.70 US/Imp.
pt).
• If vehicle was driven under high load such
as pulling a trailer, fluid level should be
checked about half an hour after it is
stopped.

Level Check at Room (Cold) Temperature – Cold
Check
Fluid level can be checked temporarily at room (cold)
temperature which correspond to 20 – 30 °C (68 – 86
°F). This level check is considered to be preparation
before performing level check under normal operating
(hot) temperature. Checking procedure itself is the same
as that described in “Level Check at Normal Operating
(Hot) Temperature – Hot Check: ”. If fluid level is
between “FULL COLD” (4) and “LOW COLD” (5),
proceed to test drive. And when fluid temperature has
reached normal operating temperature, check fluid level
again and adjust it as necessary.
CAUTION!
Fluid level check at room (cold) temperature
is recommended only for preparation of level
check under normal (hot) operating
condition.
Failure to perform fluid level check under
normal (hot) operating temperature may
result in damage to transaxle.

A/T Fluid ChangeS6RW0D5106003
CAUTION!
Do not use any fluid other than the specified
ATF. Use of any fluid other than the specified
ATF may cause juddering or some other
faulty condition to occur.

1) Lift up vehicle.
2) Remove left side engine under cover.
3) When engine is cool, remove drain plug (1) from oil
pan (2) and drain A/T fluid.
4) Install drain plug (1).
Tightening torque
A/T fluid drain plug (a): 17 N·m (1.7 kgf-m, 12.5
lb-ft)
4. “FULL COLD” mark 5. “LOW COLD” mark
1
54 321
I5RW0C510027-01
1. Fluid level gauge 3. “LOW HOT” mark
2. “FULL HOT” mark
1
54 321
I5RW0C510027-01
21, (a)I5RW0C510029-02

Downloaded from www.Manualslib.com manuals search engine 5A-84 Automatic Transmission/Transaxle:
5) Lower vehicle and pour proper amount of SUZUKI
ATF 3317 or Mobil ATF 3309.
6) Check fluid level referring to “A/T Fluid Level Check”.
Automatic transaxle fluid
: SUZUKI ATF 3317 or Mobil ATF 3309
Automatic transaxle fluid capacity
When draining from drain plug hole: 2.6 liters
(5.49 / 4.58 US/Imp. pt.)
When overhauling: 5.8 liters (12.26 / 10.21 US/
Imp. pt.)
Select Lever ComponentsS6RW0D5106004
Select Lever Assembly Removal and
Installation
S6RW0D5106059
Remove and install select lever referring to “Select Lever
Components”.
When installing select lever nothing the following.
• After installing select lever assembly, adjust select
cable referring to “Select Cable Adjustment”.
Select Lever Knob InstallationS6RW0D5106060
Screw select lever knob onto select lever by specified
numbers of rotation below.
Rotation numbers for select lever knob installation
(a): 11 – 12 rotations
CAUTION!
When installing select lever knob, do not turn
more than specified numbers of rotation.
Otherwise select lever knob is damaged.

1. Fluid level gauge 4. “FULL COLD” mark
2. “FULL HOT” mark 5. “LOW COLD” mark
3. “LOW HOT” mark
1. Shift lock solenoid 3. Connector
2. Select lever assembly 4. “3” position switch
1
54 321
I5RW0C510027-01
1
2 3 4
I5RW0C510028-04
1, (a)
I5RW0C510030-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-157
72) After applying A/T fluid to new O-ring, fit it to valve
body harness connector (3), then install valve body
harness to transaxle case.
CAUTION!
When put valve body harness (1) into
transaxle case, take care not to damage
transmission fluid temperature sensor (2) at
narrow entrance of case.
Careless sensor treatment might cause
sensor malfunction.

Tightening torque
Valve body harness connector bolt (a): 5.5 N·m (
0.55 kgf-m, 4.0 lb-ft)
73) Install manual valve rod (1) to manual valve lever (3)
and then install valve body assembly (2) to transaxle
case.
74) Tighten valve body bolts to specified torque.
Tightening torque
Valve body bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)Valve body bolt length
75) Connect solenoid connectors to solenoid valves
identifying their installing positions by wire colors,
and install transmission fluid temperature sensor to
its clamp.
Solenoid valve coupler specification
I2RH0B510321-01
I2RH0B510322-01
Bolt Length “a” Pieces
A (1) 20 mm (0.79 in.) 6
B (2) 28 mm (1.10 in.) 5
C (3) 49 mm (1.93 in.) 1
D (4) 36 mm (1.42 in.) 1
E (5) 40 mm (1.58 in.) 1
Solenoid valve coupler Wire color
Shift solenoid valve-A (No.1) (1) White
Shift solenoid valve-B (No.2) (2) Black
Timing solenoid valve (3) Yellow
TCC solenoid valve (4)Light green /
Brown
Pressure control solenoid valve (5) Gray / Green
Transmission fluid temperature
sensor (6)Orange
I2RH0B510323-01
1 4
6
3
2
5
I5RW0C510067-02

Downloaded from www.Manualslib.com manuals search engine 5B-16 Manual Transmission/Transaxle:
Manual Transaxle Assembly ComponentsS6RW0D5206014
I5RW0A520018-03
1. Transaxle right case 22. Shift fork bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
2. Transaxle left case
: Apply sealant 99000-31260 to mating surface of left case and right
case.23. 5th gear shift fork
3. Gear shift and select shaft assembly
: Apply sealant 99000-31260 to mating surface of guide case and left
case.24. Needle bearing
4. Transaxle left case plate 25. Input shaft 5th gear
5. Transaxle side cover
: Apply sealant 99000-31260 to mating surface of side cover and left
case.26. Reverse gear shift lever
6. Back up light switch 27. Reverse gear shift lever bolt
: Apply thread lock 99000-32110 to all around thread part of bolt.
7. O-ring28. Reverse gear shaft
8. Differential assembly 29. Washer
9. Oil level / filler plug
: Apply sealant 99000-31260 to all around thread part of plug.30. Reverse idler gear