transmission SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine FOREWORD
This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service
operations, replacement of components (Service) and for disassembly and assembly of major components (Unit
Repair-Overhaul).
VOLUME 1 contains General information, Engine, Suspension, Drive/Axle and Brakes sections (Sections 0 – 5).
VOLUME 2 contains Transmission/Transaxle, Steering, HVAC, Restraint, Body/Cab/Accessories and
Control Systems sections (Sections 6 – 10).
Applicable Model:
SX4 (RW415/RW416) produced at KOSAI plant in Japan with following vehicle identification number
(VIN)
The contents are classified into sections each of which is given a section number as indicated in the Table of
Contents on following page. And on the first page of each individual section is an index of that section.
This manual should be kept in a handy place for ready reference of the service work.
Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials as specified in each description.
All information, illustrations and specifications contained in this literature are based on the latest product infor-
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2006JSAGY############ ~
JS2Y#############~

Downloaded from www.Manualslib.com manuals search engine 00
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1
2
3
4
5
6
7
8
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10
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Vo l u m e 1
Precautions............................................................... 00-i
Precautions ............................................................ 00-1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubrication ................................. 0B-1
Engine ......................................................................... 1-i
Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1
Aux. Emission Control Devices .............................. 1B-1
Engine Electrical Devices....................................... 1C-1
Engine Mechanical ................................................. 1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System .......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System....................................................... 1H-1
Starting System ....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System ..................................................... 1K-1
Suspension ................................................................. 2-i
Precautions .............................................................. 2-1
Suspension General Diagnosis .............................. 2A-1
Front Suspension ................................................... 2B-1
Rear Suspension.................................................... 2C-1
Wheels and Tires ................................................... 2D-1
Driveline / Axle ........................................................... 3-i
Precautions .............................................................. 3-1
Drive Shaft / Axle ................................................... 3A-1
Differential .............................................................. 3B-1
Transfer .................................................................. 3C-1
Propeller Shafts...................................................... 3D-1
Brakes ......................................................................... 4-i
Precautions .............................................................. 4-1
Brake Control System and Diagnosis .................... 4A-1
Front Brakes........................................................... 4B-1
Rear Brakes ........................................................... 4C-1
Parking Brake......................................................... 4D-1
ABS ........................................................................ 4E-1
Transmission / Transaxle .......................................... 5-i
Precautions .............................................................. 5-1
Automatic Transmission/Transaxle ........................ 5A-1
Manual Transmission/Transaxle ............................ 5B-1
Clutch ..................................................................... 5C-1
Vo l u m e 2
Precautions ............................................................... 00-i
Precautions ............................................................ 00-1
Steering ....................................................................... 6-i
Precautions .............................................................. 6-1
Steering General Diagnosis ................................... 6A-1
Steering Wheel and Column .................................. 6B-1
Power Assisted Steering System ...........................6C-1
HVAC ........................................................................... 7-i
Precautions .............................................................. 7-1
Heater and Ventilation............................................ 7A-1
Air Conditioning System ......................................... 7B-1
Restraint ...................................................................... 8-i
Precautions .............................................................. 8-1
Seat Belts ............................................................... 8A-1
Air Bag System ...................................................... 8B-1
Body, Cab and Accessories ...................................... 9-i
Precautions .............................................................. 9-1
Wiring Systems ...................................................... 9A-1
Lighting Systems .................................................... 9B-1
Instrumentation / Driver Info. / Horn .......................9C-1
Wipers / Washers ...................................................9D-1
Glass / Windows / Mirrors ...................................... 9E-1
Security and Locks ................................................. 9F-1
Seats ..................................................................... 9G-1
Interior Trim ............................................................9H-1
Hood / Fenders / Doors .......................................... 9J-1
Body Structure ....................................................... 9K-1
Paint / Coatings ...................................................... 9L-1
Exterior Trim .......................................................... 9M-1
Control Systems ....................................................... 10-i
Precautions ............................................................ 10-1
Body Electrical Control System ............................ 10B-1
Immobilizer Control System .................................10C-1
Keyless Start System ........................................... 10E-1
TABLE OF CONTENTS

Downloaded from www.Manualslib.com manuals search engine Precautions: 00-4
WARNING!
• Whenever raising a vehicle for service, be
sure to follow the instructions under
“Vehicle Lifting Points in Section 0A”.
• When it is necessary to do service work
with the engine running, make sure that
the parking brake is set fully and the
transmission is in Neutral (for manual
transmission vehicles) or Park (for
automatic transmission vehicles), Keep
hands, hair, clothing, tools, etc. away from
the fan and belts when the engine is
running.
• When it is necessary to run the engine
indoors, make sure that the exhaust gas is
forced outdoors.
• Do not perform service work in areas
where combustible materials can come in
contact with a hot exhaust system. When
working with toxic or flammable materials
(such as gasoline and refrigerant), make
sure that the area you work in is well-
ventilated.
• To avoid getting burned, keep away from
hot metal parts such as the radiator,
exhaust manifold, tail pipe, muffler, etc.
• New and used engine oil can be
hazardous. Children and pets may be
harmed by swallowing new or used oil.
Keep new and used oil and used engine oil
filters away from children and pets.
Continuous contact with used engine oil
has been found to cause [skin] cancer in
laboratory animals. Brief contact with used
oil may irritate skin. To minimize your
exposure to used engine oil, wear a long-
sleeve shirt and moisture-proof gloves
(such as dish washing gloves) when
changing engine oil. If engine oil contacts
your skin, wash thoroughly with soap and
water. Launder any clothing or rags if wet
with oil, recycle or properly dispose of
used oil and filters.
• Be sure to observe following instructions
when handling service materials such as
fuel, oil, fluid, coolant, grease, sealant,
thread lock cement, etc. Otherwise, your
health may be ruined.
– Whenever handling any of these service
materials, wear safety glasses to protect
your eyes. If it gets into your eye, it may
cause inflammation.
– Whenever handling any of these service
materials, wear moisture-proof gloves to
protect your skin. If it adheres to your
skin, it may cause inflammation.– Do not swallow any of these service
materials. It would cause diarrhea or
nausea.
– Keep all these materials out of children’s
reach.
• Make sure the bonnet is fully closed and
latched before driving. If it is not, it can fly
up unexpectedly during driving,
obstructing your view and resulting in an
accident.

• Before starting any service work, cover fenders, seats
and any other parts that are likely to get scratched or
stained during servicing. Also, be aware that what you
wear (e.g., buttons) may cause damage to the
vehicle’s finish.
• When performing service to electrical parts that does
not require use of battery power, disconnect the
negative cable of the battery.
• When disconnecting the negative cable from the
battery, be careful to the following.
– Check and record DTCs in ECM, HVAC control
module and/or PS control module if necessary
before disconnecting.
– Record displayed contents of the clock and/or
audio system, etc. before disconnecting and reset it
as before after connecting.
– For vehicle equipped with electric throttle body
system, perform electric throttle body system
calibration referring to “Electric Throttle Body
System Calibration in Section 1C” after
reconnecting the negative cable to the battery.
I2RH01010025-01
I2RH01010026-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 0- i
0
Section 0
CONTENTS
General Information
General Information ................................ 0A-1
General Description ............................................. 0A-1
Abbreviations ...................................................... 0A-1
Symbols .............................................................. 0A-2
Wire Color Symbols ............................................ 0A-2
Fasteners Information ......................................... 0A-3
Vehicle Lifting Points ........................................... 0A-5
Vehicle Identification Number ............................. 0A-6
Engine Identification Number .............................. 0A-6
Transmission Identification Number .................... 0A-6
Component Location ........................................... 0A-7
Warning, Caution and Information Labels
Location ............................................................ 0A-7
Maintenance and Lubrication ................. 0B-1
Precautions........................................................... 0B-1
Precautions for Maintenance and Lubrication ..... 0B-1
Scheduled Maintenance ...................................... 0B-1
Maintenance Schedule under Normal Driving
Conditions ......................................................... 0B-1
Maintenance Recommended under Severe
Driving Conditions ............................................. 0B-2
Repair Instructions .............................................. 0B-3
Accessory Drive Belt Inspection.......................... 0B-3
Accessory Drive Belt Replacement ..................... 0B-3
Valve Lash (Clearance) Inspection ..................... 0B-3
Engine Oil and Filter Change .............................. 0B-4
Engine Coolant Change ...................................... 0B-5
Exhaust System Inspection ................................. 0B-5
Spark Plug Replacement .................................... 0B-5
Air Cleaner Filter Inspection ................................ 0B-6
Air Cleaner Filter Replacement ........................... 0B-6
Fuel Lines and Connections Inspection .............. 0B-6
Fuel Filter Replacement ...................................... 0B-6
Fuel Tank Inspection ........................................... 0B-6PCV Valve Inspection ......................................... 0B-6
Fuel Evaporative Emission Control System
Inspection .......................................................... 0B-6
Brake Discs and Pads (Front) Inspection............ 0B-7
Brake Drums and Shoes (Rear) Inspection ........ 0B-7
Brake Hoses and Pipes Inspection ..................... 0B-7
Brake Fluid Replacement .................................... 0B-7
Brake Lever and Cable Inspection ...................... 0B-7
Clutch Fluid Inspection ........................................ 0B-8
Tires Inspection ................................................... 0B-8
Wheel Discs Inspection ....................................... 0B-8
Wheel Bearing Inspection ................................... 0B-8
Suspension System Inspection ........................... 0B-9
Steering System Inspection ................................ 0B-9
Drive Shaft (Axle) Boots Inspection .................... 0B-9
Propeller Shaft (4WD) Inspection...................... 0B-10
Manual Transaxle Oil Inspection ....................... 0B-10
Manual Transaxle Oil Replacement .................. 0B-10
Automatic Transaxle Fluid Level Inspection...... 0B-10
Automatic Transaxle Fluid Replacement .......... 0B-10
Automatic Transaxle Fluid Cooler Hose
Inspection ........................................................ 0B-10
Transfer Oil Inspection (4WD)........................... 0B-10
Transfer Oil Replacement (4WD) ...................... 0B-10
Rear Deferential Oil Inspection (4WD) .............. 0B-10
Rear Deferential Oil Replacement (4WD) ......... 0B-10
All Latches, Hinges and Locks Inspection......... 0B-10
HVAC Air Filter (If Equipped) Inspection ........... 0B-11
HVAC Air Filter (If Equipped) Replacement ...... 0B-11
Final Inspection for Maintenance Service ......... 0B-11
Specifications .....................................................0B-12
Tightening Torque Specifications ...................... 0B-12
Special Tools and Equipment ...........................0B-12
Recommended Fluids and Lubricants............... 0B-12
Special Tool ...................................................... 0B-12

Downloaded from www.Manualslib.com manuals search engine 0A-1 General Information:
General Information
General Information
General Description
AbbreviationsS6RW0D0101001
A:
ABDC: After Bottom Dead Center
ABS: Anti-lock Brake System
AC: Alternating Current
A/C: Air Conditioning
A-ELR: Automatic-Emergency Locking Retractor
A/F: Air Fuel Mixture Ratio
ALR: Automatic Locking Retractor
API: American Petroleum Institute
APP sensor: Accelerator Pedal Position Sensor
A/T: Automatic Transmission, Automatic Transaxle
AT D C : After Top Dead Center
ATF: Automatic Transmission Fluid, Automatic
Transaxle Fluid
B:
B+: Battery Positive Voltage
BBDC: Before Bottom Dead Center
BCM: Body Electrical Control Module
BTDC: Before Top Dead Center
C:
CAN: Controller Area Network
CKT: Circuit
CKP Sensor: Crankshaft Position Sensor
CMP Sensor: Camshaft Position Sensor
CO: Carbon Monoxide
CPP Switch: Clutch Pedal Position Switch (Clutch
Switch, Clutch Start Switch)
CPU: Central Processing Unit
CRS: Child Restraint System
D:
DC: Direct Current
DLC: Data Link Connector (Assembly Line Diag. Link,
ALDL, Serial Data Link, SDL)
DOHC: Double Over Head Camshaft
DOJ: Double Offset Joint
DRL: Daytime Running Light
DTC: Diagnostic Trouble Code (Diagnostic Code)
E:
EBCM: Electronic Brake Control Module, ABS Control
Module
EBD: Electronic Brake Force Distribution
ECM: Engine Control Module
ECT Sensor: Engine Coolant Temperature Sensor
(Water Temp. Sensor, WTS)
EFE Heater: Early Fuel Evaporation Heater (Positive
Temperature Coefficient, PTC Heater)
EGR: Exhaust Gas Recirculation
EGRT Sensor: EGR Temperature Sensor (Recirculated
Exhaust Gas Temp. Sensor, REGTS)
EPS: Electronic Power Steering
EVAP: Evaporative Emission
EVAP Canister: Evaporative Emission Canister
(Charcoal Canister)F:
4WD: 4 Wheel Drive
G:
GEN: Generator
GND: Ground
GPS: Global Positioning System
H:
HAVC: Heating, Ventilating and Air Conditioning
HC: Hydrocarbons
HO2S: Heated Oxygen Sensor
I:
IAC Valve: Idle Air Control Valve (Idle Speed Control
Solenoid Valve, ISC Solenoid Valve)
IAT Sensor: Intake Air Temperature Sensor (Air
temperature Sensor, ATS)
ICM: Immobilizer Control Module
IG: Ignition
ISC Actuator: Idle Speed Control Actuator
L:
LH: Left Hand
LHD: Left Hand Drive vehicle
LSPV: Load Sensing Proportioning Valve
M:
MAF Sensor: Mass Air Flow Sensor (Air Flow Sensor,
AFS, Air Flow Meter, AFM)
MAP Sensor: Manifold Absolute Pressure Sensor
(Pressure Sensor, PS)
Max: Maximum
MFI: Multiport Fuel Injection (Multipoint Fuel Injection)
Min: Minimum
MIL: Malfunction Indicator Lamp (“SERVICE ENGINE
SOON” Light)
M/T: Manual Transmission, Manual Transaxle
N:
NOx: Nitrogen Oxides
O:
OBD: On-Board Diagnostic System (Self-Diagnosis
Function)
O/D: Overdrive
OHC: Over Head Camshaft
O2S: Oxygen Sensor
P:
PCM: Powertrain Control Module
PCV: Positive Crankcase Ventilation
PNP: Park / Neutral Position
P/S: Power Steering
PSP Switch: Power Steering Pressure Switch (P/S
Pressure Switch)
R:
RH: Right Hand
RHD: Right Hand Drive vehicle

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 General Information: 0A-6
In raising front or rear vehicle end off the floor by jacking,
be sure to put the jack against engine front mounting
member (1) or rear jacking bracket (2).
To perform service with either front or rear vehicle end
jacked up, be sure to place safety stands (1) under
shaded position of vehicle body (front) or body mounting
stay (2) (rear) so that vehicle body is securely supported.
And then check to ensure that vehicle body does not
slide on safety stands (1) and the vehicle is held stable
for safety’s sake.Vehicle Identification NumberS6RW0D0101006
The number is punched on the front dash panel in
engine room and it is also attached on the left side of
instrument panel depending on the vehicle specification.
Engine Identification NumberS6RW0D0101007
The number is punched on cylinder block.
Transmission Identification NumberS6RW0D0101008
The automatic transmission identification number is
located on transmission case.
[A]: Front 3. Cap
[B]: Rear
1
2
I5RW0A010002-02
1 2
[B] [A]
1
3
I5RW0A010003-03
I5RW0C010002-01
I3RM0A010005-01
I4RS0A010008-01

Downloaded from www.Manualslib.com manuals search engine 1A-8 Engine General Information and Diagnosis:
For information about the following items, refer to “Euro
OBD model: ”.
• Warm-up cycle
• Driving cycle
• 2 driving cycle detection logic
• Pending DTC
Data Link Connector (DLC)S6RW0D1101011
NOTE
There are two types of OBD system
depending on the vehicle specification.
For identification, refer to “Precaution on On-
Board Diagnostic (OBD) System”.

DLC (1) is in compliance with SAE J1962 in the shape of
connector and pin assignment.
OBD CAN Hi line (6) and Low line (3) (CAN line of ISO
15765-4) are used for SUZUKI scan tool (SUZUKI-SDT)
(7) or CAN communication OBD generic scan tool to
communicate with ECM (included in immobilizer control)
and TCM (Transmission Control Module) (for A/T
model).
Engine and Emission Control System
Description
S6RW0D1101004
The engine and emission control system is divided into 4
major sub-systems: air intake system, fuel delivery
system, electronic control system and emission control
system.
Air intake system includes air cleaner, throttle body and
intake manifold.
Fuel delivery system includes fuel pump, delivery pipe,
etc.
Electronic control system includes ECM, various sensors
and controlled devices.
Emission control system includes EGR, EVAP and PCV
system.
3. DLC
1
2 3
I5RW0C110001-01
2. B + (Unswitched vehicle battery positive)
4. ECM ground (Signal ground)
5. Vehicle body ground (Chassis ground)
2
45 6
1
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
7
3
1I7RW01110092-01

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-9
CAN Communication System DescriptionS6RW0D1101005
ECM (1), ABS control module (2), BCM (3), combination meter (4), keyless start control module (if equipped with
keyless start control system) (5), 4WD control module (for 4WD model) (6)and TCM (for A/T model) (7) of this vehicle
communicate control data between each control module.
Communication of each control module is established by CAN (Controller Area Network) communication system.
CAN communication system uses the serial communication in which data is transmitted at a high speed. It uses a
twisted pair of two communication lines for the high-speed data transmission. As one of its characteristics, multiple
control modules can communicate simultaneously. In addition, it has a function to detect a communication error
automatically. Each module reads necessary data from the received data and transmits data. ECM communicates
control data with each control module as follows.
[A]
[B]
6
4
51 7
2
3
6
4
51 7
2
3
I6RW0D110002-01
[A]: Non-Taiwan model [B]: Taiwan model

Downloaded from www.Manualslib.com manuals search engine 1A-10 Engine General Information and Diagnosis:
ECM Transmission Data
ECM Reception Data
BCM TCMCombination
Meter
DATA ECM Transmit
Brake pedal switch signal
Vehicle speed signal
Engine speed signal
Engine torque signal
Accelerator pedal position signal
4WD Control
ModuleKeyless Start
Control
Module
A/C refrigerant pressure
signal
A/C compressor clutch signal
Engine type signal
Immobilizer indicator light control
signal
MIL control signal
Engine coolant temperature signal
Fuel level signal
Fuel consumption signal
Throttle position signal
Driving cycle active
Warm up cycle active
Odometer signal
I6RW0D110003-02
DATA ECM Receive
ABS control
module
Transmission oil temperature signal
Transmission warning light signal Vehicle speed pulse signal A/T selector lever position signal
Transmission actual gear position signal
Wheel speed signal (front right)
Wheel speed signal (front left)
ABS indication signal
A/C switch ON signal
Electric load signalBCM
4WD mode status
Torque request signalTCM
MIL control signal4WD control
module
I6RW0D110013-02