Continuously Variable Transaxle (Cvt): Other Suzuki SX4 I рестайлинг

General Service Procedure Information

When repairing CVT, it is necessary to conduct the on-vehicle test to investigate where the cause of the trouble lies first.

If the transaxle is repaired 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.

Functions

CVT MECHANICAL FUNCTION

Shift Lock Solenoid Control

This system consists of shift lock solenoid control system and interlock cable control system. The shift lock solenoid control system is so designed that the select lever can not be shifted from "P" range position unless ignition switch is turned to "ON" or "ACC" position and the brake pedal is depressed. And interlock cable control system is so designed that select lever cannot be shifted from "P" range position unless ignition switch is turned to "ACC" or "ON" position. Also, ignition key cannot be pulled out of key slot unless select lever is in "P" range.

Shift Lock Solenoid Manual Release

Remove plug cap of select lever and push down shift lock solenoid release plate (1) inside of plug hole with a flat-head screwdriver or the like. Then, select lever can be moved from "P" range position to another range even without depressing the brake pedal. (To shift select lever from "P" range to any other position, turn ignition switch to "ACC" or "ON" position.)

Scheme 98

Monitoring Procedure

Input signal of the following are checked for open, short of circuit by monitoring input voltage.

1. Primary and secondary pressure sensor power supply circuit (P0641)
2. Transmission range sensor (P0707)
3. CVT fluid temperature sensor (P0712, P0713)
4. Primary pulley pressure sensor (P0842, P0843)
5. Secondary pressure sensor (P0847, P0848)
6. Line pressure control solenoid valve (P0962, P0963)
7. Secondary pressure control solenoid valve (P0966, P0967)
8. Sensor ground circuit (P1970)
9. TCC solenoid valve (P2763, P2764)

Enable conditions

PRIMARY AND SECONDARY PRESSURE SENSOR POWER SUPPLY CIRCUIT MONITOR ENABLE CONDITIONS CHART

Typical malfunction thresholds

PRIMARY AND SECONDARY PRESSURE SENSOR POWER SUPPLY CIRCUIT MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

TRANSMISSION RANGE SENSOR CIRCUIT MONITOR ENABLE CONDITIONS CHART

TRANSMISSION RANGE SENSOR CIRCUIT MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT MONITOR ENABLE CONDITIONS CHART

TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

PRIMARY PRESSURE SENSOR CIRCUIT MONITOR ENABLE CONDITIONS CHART

PRIMARY PRESSURE SENSOR CIRCUIT MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

SECONDARY PRESSURE SENSOR CIRCUIT MONITOR ENABLE CONDITIONS CHART

SECONDARY PRESSURE SENSOR CIRCUIT MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

LINE PRESSURE CONTROL SOLENOID VALVE CIRCUIT MONITOR ENABLE CONDITIONS CHART

LINE PRESSURE CONTROL SOLENOID VALVE CIRCUIT MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

SECONDARY PRESSURE CONTROL SOLENOID VALVE CIRCUIT MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

SENSOR GROUND CIRCUIT MONITOR ENABLE CONDITIONS CHART

SENSOR GROUND CIRCUIT MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

TCC SOLENOID VALVE CIRCUIT MONITOR ENABLE CONDITIONS CHART

TCC SOLENOID VALVE CIRCUIT MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

Input signal of the following are checked for circuit strategy rationality by monitoring each sensor, actuator and vehicle condition.

1. TCM (P062F)
2. Brake switch (P0703)
3. Transmission range sensor (P0705)
4. Transmission fluid temperature sensor (P0711)
5. Primary pulley speed sensor (P0716, P0717)
6. Secondary pulley speed sensor (P0721, P0722)
7. TCC solenoid valve (P0741)
8. Secondary pressure control solenoid valve (P0776, P0777)
9. Primary pressure sensor/secondary pressure sensor (P0871)
10. Line pressure control solenoid valve (P0961)
11. Lock-up/select switching solenoid valve (P1810)
12. Stepper motor (P1816, P1818)
13. CAN communication (U0073, U0100)

TCM INTERNAL CIRCUIT/MEMORY MONITOR ENABLE CONDITIONS CHART

BRAKE SWITCH RATIONALITY MONITOR ENABLE CONDITIONS CHART

BRAKE SWITCH RATIONALITY MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

TRANSMISSION RANGE SENSOR RATIONALITY MONITOR ENABLE CONDITIONS CHART

TRANSMISSION RANGE SENSOR RATIONALITY MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

TRANSMISSION FLUID TEMPERATURE SENSOR RATIONALITY MONITOR ENABLE CONDITIONS CHART

TRANSMISSION FLUID TEMPERATURE SENSOR RATIONALITY MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

Table P0711

TRANSMISSION FLUID TEMPERATURE RANGE CHART

PRIMARY PULLEY SPEED SENSOR RATIONALITY MONITOR ENABLE CONDITIONS CHART

Table TCC ON command

PRIMARY PULLEY SPEED SENSOR RATIONALITY MONITOR ACCELERATOR PEDAL POSITION CHART

PO717 SYMPTOM DIAGNOSIS DESCRIPTION CHART

PO716; PO717 TYPICAL MALFUNCTION THRESHOLDS CHART

SECONDARY PULLEY SPEED SENSOR RATIONALITY MONITOR ENABLE CONDITIONS CHART

SECONDARY PULLEY SPEED SENSOR RATIONALITY MONITOR ACCELERATOR PEDAL POSITION CHART

PO722 SYMPTOM DIAGNOSIS DESCRIPTION CHART

PO721; PO722 TYPICAL MALFUNCTION THRESHOLDS CHART

TCC SOLENOID VALVE RATIONALITY MONITOR ENABLE CONDITIONS CHART

TCC SOLENOID VALVE RATIONALITY MONITOR ACCELERATOR PEDAL POSITION CHART

TCC SOLENOID VALVE RATIONALITY MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

SECONDARY PRESSURE CONTROL SOLENOID VALVE RATIONALITY MONITOR ENABLE CONDITIONS CHART

SECONDARY PRESSURE CONTROL SOLENOID VALVE RATIONALITY MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

PRIMARY PRESSURE SENSOR/SECONDARY PRESSURE SENSOR RATIONALITY MONITOR ENABLE CONDITIONS CHART

PRIMARY PRESSURE SENSOR/SECONDARY PRESSURE SENSOR RATIONALITY MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

Table P0871 low

P0871 LOW SYMPTOM DIAGNOSIS DESCRIPTION CHART

Table P0871 high

P0871 HIGH SYMPTOM DIAGNOSIS DESCRIPTION CHART

LINE PRESSURE CONTROL SOLENOID VALVE RATIONALITY MONITOR ENABLE CONDITIONS CHART

LINE PRESSURE CONTROL SOLENOID VALVE RATIONALITY MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

LOCK-UP/SELECT SOLENOID VALVE RATIONALITY MONITOR ENABLE CONDITIONS CHART

LOCK-UP/SELECT SOLENOID VALVE RATIONALITY MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

STEPPER MOTOR CIRCUIT RATIONALITY MONITOR ENABLE CONDITIONS CHART

STEPPER MOTOR CIRCUIT RATIONALITY MONITOR TYPICAL MALFUNCTION THRESHOLDS CHART

CAN COMMUNICATION SIGNAL RATIONALITY MONITOR ENABLE CONDITIONS CHART

Scheme 99

Scheme 100

Scheme 101

CVT System Check

Refer to the following items for the details of each step.

SYMPTOM DIAGNOSIS DESCRIPTION CHART

Step 1. Customer Complaint Analysis

Record details of the problem (failure, complaint) and how it occurred as described by the customer.

For this purpose, use of such an inspection form as shown in the following page as an example will facilitate collecting information to the point required for proper analysis and diagnosis.

Note. The form is a standard sample. It should be modified according to conditions characteristic of each market.

Scheme 102

Malfunction Indicator Lamp (MIL) Check

Refer to MALFUNCTION INDICATOR LAMP (MIL) CHECK .

Scheme 103

TCM

As the data values given in the following table are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases where the checked value does not fall within each specified data range. Therefore, judgment as abnormal should not be made by checking with these data alone.

Also, condition in the following table that can be checked by the scan tool are those detected by TCM and output from TCM as commands and there may be cases where the CVT or actuator is not operating (in the condition) as indicated by the scan tool.

Note. The following scan tool data related to CVT can be checked only by communicating with TCM.

SYMPTOM DIAGNOSIS DESCRIPTION CHART

Vehicle Speed (km/h/mph)

This parameter indicates vehicle speed calculated by TCM based on secondary pulley speed sensor signal.

Engine Speed (RPM)

This parameter indicates engine speed information received from ECM.

Primary Pulley Speed (RPM)

This parameter indicates primary pulley speed detected by primary pulley speed sensor.

Secondary Pulley Speed (RPM)

This parameter indicates secondary pulley speed detected by secondary pulley speed sensor.

Primary Oil Pres (MPa)

This parameter indicates line pressure detected by primary pressure sensor.

Secondary Oil Pres (MPa)

This parameter indicates secondary pressure detected by secondary pressure sensor.

CVTF Temperature (°C, °F)

This parameter indicates CVT fluid temperature detected CVT fluid temperature sensor.

ECT (Engine Coolant Temperature, °C, °F)

This parameter indicates engine coolant temperature information received from ECM.

Battery Voltage (V)

This parameter indicates battery positive voltage inputted through CVT relay to TCM.

Throttle Position (%)

This parameter indicates throttle position information received from ECM.

Accel Actual Position (%)

This parameter indicates accelerator pedal opening ratio information from ECM.

Gear Actual Ratio

This parameter indicates current gear ratio calculated by TCM based on primary pulley speed and secondary pulley speed.

Lock Up Solenoid (Com) (Command, mA)

This parameter indicates control current value that TCM outputs to TCC solenoid valve.

Lock Up Solenoid (Mon) (Monitor, mA)

This parameter indicates current value that flows to TCC solenoid valve.

Line Press Solenoid (Com) (Command, mA)

This parameter indicates control current value that TCM outputs to line pressure control solenoid valve.

Line Press Solenoid (Mon) (Monitor, mA)

This parameter indicates current value that flows to line pressure control solenoid valve.

Secondary Solenoid (Com) (Command, mA)

This parameter indicates control current value that TCM outputs to secondary pressure control solenoid valve.

Secondary Solenoid (Mon) (Monitor, mA)

This parameter indicates current value that flows to secondary pressure control solenoid valve.

Manual Gear Position (deactive, 1st, 2nd, 3rd, 4th, 5th, 6th)

This parameter indicates the state of manual mode shift position detected by TCM.

Shift Down SW (ON/OFF)

This parameter indicates the states of shift-down switch.

Shift Up SW (ON/OFF)

This parameter indicates the states of shift-up switch.

Manual Mode SW (ON/OFF)

This parameter indicates the states of manual mode switch.

Transaxle Range (P, R, N, D)

This parameter indicates the state of each range switch in transmission range sensor.

ABS Active (ON/OFF)

This parameter indicates ABS status.

A/C Comp Clutch (ON/OFF)

This parameter indicates air conditioner compressor clutch information received from ECM.

ON: A/C compressor clutch engaged.

OFF: A/C compressor clutch disengaged.

Brake Switch (ON/OFF)

This parameter indicates brake light switch information received from ECM.

ON: Brake light switch is ON. (Brake pedal depressed)

OFF: Brake light switch is OFF. (Brake pedal released)

Paddle Up SW (ON/OFF)

This parameter indicates the states of paddle-up switch "+".

Paddle Down SW (ON/OFF)

This parameter indicates the states of paddle-down switch "-".

Switching Solenoid (Mon) (ON/OFF)

This parameter indicates the state of lock-up/select switching solenoid valve.

Switching Solenoid (Com) (ON/OFF)

This parameter indicates the output state of TCM to lock-up/select switching solenoid valve.

CVT Basic Check

This check is important for troubleshooting when TCM has detected no DTC and no abnormality has been noted in Visual Inspection . Follow the flow carefully.

SYMPTOM DIAGNOSIS DESCRIPTION CHART

CVT Gear Shift Table

CVT gear shift schedule is shown in the following table. Test-drive the vehicle on a flat road in the "D" position.

Note. The values are for reference only.

Shift table

CVT RPM SHIFT TABLE

Lock-up point

CVT LOCK UP CLUTCH STATUS CHART

MIL Does Not Come ON with Ignition Switch in ON Position and Engine Stopped (but Engine Can Be Started)

Refer to MIL DOES NOT COME ON WITH IGNITION SWITCH IN ON POSITION AND ENGINE STOPPED (BUT ENGINE CAN BE STARTED) .

MIL Remains ON after Engine Starts

Refer to MIL REMAINS ON AFTER ENGINE STARTS .

Table for Step 4

SELECT LEVER POSITION VOLTAGE CHART

SELECT LEVER POSITION VOLTAGE CHART

Connector "C09"

CONNECTOR C09 CHART

Connector "C10"

C10 CONNECTOR CHART

Reference Waveform

Note. Waveform analysis is as follows. Waveform might change for measurement condition and vehicle spec.

CAN Communication Signal

CAN communication signal (High) (1)

CAN COMMUNICATION (HIGH) WAVEFORM SIGNAL DESCRIPTION CHART

CAN communication signal (Low) (2)

CAN COMMUNICATION (LOW) WAVEFORM SIGNAL DESCRIPTION CHART

Measurement condition

Scheme 104

1. Engine: Stop
2. Ignition switch: ON

TCC solenoid valve signal

TCC solenoid valve signal (1)

TCC SOLENOID VALVE WAVEFORM SIGNAL DESCRIPTION CHART

Measurement condition

Scheme 105

Scheme 106

1. Vehicle: Running
2. CVT: Lock-up on after warming up
3. Vehicle: Running
4. CVT: Lock-up off after warming up

Secondary pressure control solenoid valve signal

Secondary pressure control solenoid valve signal (1)

SECONDARY PRESSURE CONTROL SOLENOID VALVE WAVEFORM SIGNAL DESCRIPTION CHART

Measurement condition

Scheme 107

Scheme 108

1. Engine: Running after warming up
2. Select lever position: "D" range
3. Accelerator pedal: Depressed fully
4. Engine: Idle speed
5. Select lever position: "D" range
6. Accelerator pedal: Released

Line pressure control solenoid valve signal

Line pressure control valve signal (1)

LINE PRESSURE CONTROL SOLENOID VALVE WAVEFORM SIGNAL DESCRIPTION CHART

Measurement condition

Scheme 109

Scheme 110

1. Engine: Running after warming up
2. Select lever position: "D" range
3. Accelerator pedal: Depressed fully
4. Engine: Idle speed
5. Select lever position: "D" range
6. Accelerator pedal: Released

Stepper motor signal

Stepper motor No. 1 signal (1)

STEPPER MOTOR NO. 1 WAVEFORM SIGNAL DESCRIPTION CHART

Stepper motor No. 2 signal (2)

STEPPER MOTOR NO. 2 WAVEFORM SIGNAL DESCRIPTION CHART

Stepper motor No. 3 signal (1)

STEPPER MOTOR NO. 3 WAVEFORM SIGNAL DESCRIPTION CHART

Stepper motor No. 4 signal (2)

STEPPER MOTOR NO. 4 WAVEFORM SIGNAL DESCRIPTION CHART

Measurement condition

Scheme 111

1. Ignition switch: For 10 sec. from ignition switch turned ON

Secondary pulley speed sensor signal

Secondary pulley speed sensor signal (1)

SECONDARY PULLEY SPEED SENSOR WAVEFORM SIGNAL DESCRIPTION CHART

Measurement condition

Scheme 112

Scheme 113

1. Vehicle: Drive vehicle at 40 km/h (25 mile/h)
2. CVT: After warming up
3. Vehicle: Drive vehicle at 20 km/h (12 mile/h)
4. CVT: After warming up

Primary pulley speed sensor signal

Primary pulley speed sensor signal (1)

PRIMARY PULLEY SPEED SENSOR WAVEFORM SIGNAL DESCRIPTION CHART

Measurement condition

Scheme 114

Scheme 115

1. Vehicle: Drive vehicle at 40 km/h (25 mile/h)
2. CVT: After warming up
3. Vehicle: Drive vehicle at 20 km/h (12 mile/h)
4. CVT: After warming up

Scheme 116

TCM Learning Control Initialization

Scheme 117

1. Select initialization procedure from table below. TCM LEARNING CONTROL REPAIR INSTRUCTIONS Initialization procedure Service item [A] When replacing TCM with new one [B] When replacing TCM with used one When replacing CVT assembly When replacing valve body assembly
2. Perform selected learning procedure as follows. Initialization procedure [A]: Turn on ignition switch and shift select lever "P" range. Check that the shift position indicator in the combination meter comes on in approx. 2 sec. after turned on ignition switch. If the shift position indicator does not come on, check the following item: Check for open or shorted to ground in the wiring harness between TCM and ROM in the transaxle. See «Inspection of TCM and Its Circuits»(ref-514590-S37757617982012112100000) Check for proper terminal connection to TCM connector and solenoid connector. Initialization procedure [B]: Turn off ignition switch and connect SUZUKI scan tool to DLC (1) located on underside of instrument panel on driver's side. Special Tool (A): SUZUKI scan tool (SUZUKI-SDT) Select "Learning Value Initialization" function under "Utility" mode on SUZUKI scan tool, and follow the instructions displayed on SUZUKI scan tool. Turn off ignition switch and wait for 10 sec. Shift select lever to "P" range. Check that the shift position indicator in the combination meter comes on in approx. 2 sec. after turned on ignition switch. If the shift position indicator does not come on, check the following item: Check for open or shorted to ground in the wiring harness between TCM and ROM in the transaxle. See «Inspection of TCM and Its Circuits»(ref-514590-S37757617982012112100000) Check for proper terminal connection to TCM connector and solenoid connector. Select "Data List" mode on SUZUKI scan tool. Cool down CVT fluid to ambient temperature. Start engine. Depress brake pedal fully and repeat shift operation from "N" range to "D" range, and from "N" range to "R" range 3 times for each gear shift. If excessive shift shock is observed, repeat shift operation from "N" range to "D" range, and from "N" range to "R" range 10 times for each gear shift. NOTE: When operating the select lever, hold it for more than 2 sec. in each range. Do not move the select lever from "N" range to other ranges until engine speed stabilizes. Depress brake pedal fully at idle speed and hold in "D" range for 20 sec. Drive vehicle so that CVT fluid temperature reaches 40 °C (104 °F) Drive vehicle at 40 - 50 km/h (25 - 31 mile/h) constantly for 5 sec. in "D" range. Drive vehicle so that CVT fluid temperature reaches 80 °C (176 °F) Repeat Step i ), j ) and Step l ).

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 CVT fluid temperature has reached 70 - 80 °C (158 - 176 °F), check CVT fluid level again and adjust it as necessary.

Scheme 118

Note. If smell of burning, discoloration or heavy dirt is present in CVT fluid, replacement of CVT assembly will be required.

Recommended Service Material

RECOMMENDED SERVICE MATERIAL REFERENCE CHART

Note. Required service material is also described in the following. SELECT CABLE COMPONENTS CVT ASSEMBLY COMPONENTS