cable SUZUKI SX4 2006 1.G Service Owners Manual

Downloaded from www.Manualslib.com manuals search engine 3B-31 Differential:
2WD/4WD Switch Removal and InstallationS6RW0D3206003
Removal
1) Disconnect negative cable at battery.
2) Remove console box (2).
3) Remove 2WD/4WD switch (1) from console box.
Installation
Reverse removal procedure for installation.
2WD/4WD Switch InspectionS6RW0D3206004
Check 2WD/4WD switch for continuity between
terminals at each switch position.
If check result is not as specified, replace switch.
4WD Control Module Removal and InstallationS6RW0D3206005
Removal
1) Disconnect negative cable at battery.
2) Remove center ventilation louver referring to “Center
Ventilation Louver Removal and Installation in
Section 7A”.
3) Disconnect connector (1) from 4WD control module.
4) Remove 4WD control module (2).
Installation
Reverse removal procedure for installation.
Coupling Air Temperature Sensor Removal and
Installation
S6RW0D3206006
Removal
1) Dismount rear differential referring to “Rear
Differential Dismounting and Remounting”.
2) Remove coupling air temperature sensor (1) from
rear differential (2).
Installation
Reverse removal procedure for installation, noting the
following point.
• Tighten coupling air temperature sensor to specified
torque.
Tightening torque
Coupling air temperature sensor: 18 N·m (1.8 kgf-
m, 13.0 lb-ft)
1
2
I5RW0A320017-02
Terminal
Switch position
2WD
AUTO
LOCK
11
22
3 3
4 4
5 5
I5RW0A320018-02
2
1
I5RW0A320019-01
12
I5RW0A320020-02

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-50
09922–76150 09922–76250
Bevel pinion nut Bevel gear dummy
) / )) / )
09922–76330 09922–76340
Bevel pinion rear collar Bevel pinion rear collar
) / ) / )) / ) / )
09922–76420 09922–76530
Bevel pinion front collar Bevel pinion gauge block
) / ) / )) / )
09922–85811 09925–18011
Spring pin remover (4.5 mm) Transmission gear, bush
and bearing installer
) / ))
09925–88210 09926–48010
Bearing puller attachment Universal joint assembling
tool
) / )) / )
09927–27910 09930–40113
Holder, bevel pinion Flywheel rotor holder
) / )) / )
09951–26020 SUZUKI scan tool
Bush remover & installer
support—
) / )This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12. ) / )

Downloaded from www.Manualslib.com manuals search engine 3C-3 Transfer:
Transfer Dismounting and RemountingS6RW0D3306003
Dismounting
1) Disconnect negative cable at battery.
2) Drain transaxle oil and transfer oil.
3) Remove drive shafts assembly referring to “Front
Drive Shaft Assembly Removal and Installation in
Section 3A”.
4) Remove exhaust No.1, No.2 and center pipes
referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
5) Remove suspension frame, engine front mounting
member and mounting member referring to “Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation in Section 2B” and “Engine
Assembly Removal and Installation in Section 1D”.
6) Remove engine rear mounting bracket (1) and
stiffeners (2) from transfer.
7) Support transfer with transmission jack.
8) Remove transfer to transaxle bolts (1), and then
lower transfer assembly (2).Remounting
Reverse dismounting procedure for remounting of
transfer, noting the following points.
• Apply grease to left case (1) as shown in figure.
“A”: Grease 99000–25010 (SUZUKI Super Grease
A)
• Tighten engine rear mounting bracket nut to specified
torque referring to “Engine Mountings Components in
Section 1D”.
• Tighten bolts to specified torque as follows.
Tightening torque
Stiffener No.1 bolt and No.2 bolt (a): 55 N·m (5.5
kgf-m, 40.0 lb-ft)
Transfer to transaxle bolt (b): 98 N·m (9.8 kgf-m,
71.0 lb-ft)
2
2
1I5RW0A330004-01
1
1
2
I5RW0A330005-02
I5RW0C330001-01
(a)
(a)
(b)
(b)
2
I5RW0A330006-02

Downloaded from www.Manualslib.com manuals search engine Table of Contents 4- i
4
Section 4
CONTENTS
Brakes
Precautions ................................................. 4-1
Precautions............................................................. 4-1
Precautions for Brakes .......................................... 4-1
Brake Control System and Diagnosis ... 4A-1
Precautions........................................................... 4A-1
Precautions on Brake .......................................... 4A-1
General Description ............................................. 4A-1
Brakes Construction ............................................ 4A-1
Brake Pedal Foot Protection System
Construction (If Equipped) ................................ 4A-2
Front Brake Hose / Pipe Construction................. 4A-3
Rear Brake Hose / Pipe Construction ................. 4A-4
Diagnostic Information and Procedures ............ 4A-4
Brakes Diagnosis Note ....................................... 4A-4
Brakes Symptom Diagnosis ................................ 4A-5
Repair Instructions .............................................. 4A-7
Brake Pedal Components ................................... 4A-7
Brake Pedal Free Height Inspection ................... 4A-7
Brake Pedal Play Inspection ............................... 4A-7
Excessive Pedal Travel Inspection ..................... 4A-7
Brake Fluid Level Inspection ............................... 4A-8
Brake Light Switch Adjustment ........................... 4A-8
Air Bleeding of Brake System ............................. 4A-8
Front Brake Hose / Pipe Removal and
Installation ......................................................... 4A-9
Rear Brake Hose / Pipe Removal and
Installation ....................................................... 4A-10
Brake Hose and Pipe Inspection ....................... 4A-10
Master Cylinder and Brake Booster
Components.................................................... 4A-11
Master Cylinder Reservoir Removal and
Installation ....................................................... 4A-11
Master Cylinder Removal and Installation......... 4A-12
Master Cylinder Inspection ............................... 4A-13
Booster Operation Inspection ........................... 4A-14
Brake Booster Removal and Installation ........... 4A-15
Brake Booster Inspection .................................. 4A-15
Booster Push Clevis Rod Adjustment ............... 4A-16
Specifications..................................................... 4A-16
Tightening Torque Specifications ...................... 4A-16
Special Tools and Equipment ........................... 4A-16
Recommended Service Material ....................... 4A-16
Special Tool ...................................................... 4A-16
Front Brakes ............................................ 4B-1
Repair Instructions ..............................................4B-1
Front Disc Brake Components ............................ 4B-1
Front Disc Brake Pad On-Vehicle Inspection ...... 4B-2
Front Disc Brake Pad Removal and
Installation ......................................................... 4B-2
Front Disc Brake Pad Inspection......................... 4B-3
Front Disc Brake Caliper Removal and
Installation ......................................................... 4B-3
Front Disc Brake Caliper Disassembly and
Assembly........................................................... 4B-4
Front Disc Brake Caliper Inspection.................... 4B-6
Front Brake Disc Removal and Installation ......... 4B-6
Front Brake Disc Inspection ................................ 4B-7
Specifications .......................................................4B-8
Tightening Torque Specifications ........................ 4B-8
Special Tools and Equipment .............................4B-8
Recommended Service Material ......................... 4B-8
Special Tool ........................................................ 4B-8
Rear Brakes.............................................. 4C-1
Repair Instructions ..............................................4C-1
Rear Drum Brake Components ...........................4C-1
Rear Brake Drum Removal and Installation ........4C-2
Rear Brake Drum and Shoe Inspection ..............4C-2
Rear Brake Shoe On-Vehicle Inspection ............4C-3
Rear Brake Shoe Removal and Installation ........4C-3
Rear Brake Shoe Inspection ...............................4C-4
Wheel Cylinder Removal and Installation ...........4C-4
Wheel Cylinder Inspection ..................................4C-5
Brake Back Plate Removal and Installation ........4C-5
Specifications .......................................................4C-6
Tightening Torque Specifications ........................4C-6
Special Tools and Equipment .............................4C-6
Recommended Service Material .........................4C-6
Parking Brake .......................................... 4D-1
General Description .............................................4D-1
Parking Brake Cable Construction ......................4D-1
Repair Instructions ..............................................4D-2
Parking Brake Inspection and Adjustment ..........4D-2
Parking Brake Cable Removal and
Installation .........................................................4D-2
Parking Brake Lever Removal and Installation ....4D-3

Downloaded from www.Manualslib.com manuals search engine 4A-1 Brake Control System and Diagnosis:
Brakes
Brake Control System and Diagnosis
Precautions
Precautions on BrakeS6RW0D4100001
Air Bag Warning
Refer to“Air Bag Warning in Section 00”.
Brakes Diagnosis Note
Refer to “Brakes Diagnosis Note”.
General Description
Brakes ConstructionS6RW0D4101001
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two
in front and four in rear).
The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make two
independent circuits. One connects front right & rear left brakes and the other connects front left & rear right brakes.
In this brake system, the disc brake is used for the front wheel brake and drum brake (leading / trailing shoes) for the
rear brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and
mechanical linkage system. The same brake shoes of rear drum brake are used for both parking and foot brakes.
NOTE
• The figures show LH steering vehicle.
• The difference between RH steering vehicle and LH steering vehicle is the location of the brake
master cylinder, the brake booster and ABS hydraulic unit / control module assembly.

A
421
37
7
658
I7RW01410001-01
1. Brake booster 4. Primary side 7. Parking brake cable
2. Master cylinder 5. ABS hydraulic unit / control module assembly 8. 4-way joint
3. Secondary side 6. Parking brake lever A: Forward

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-6
Dragging brakes (Without
a very light drag is
present in all brakes
immediately after pedal is
released)Master cylinder pistons not returning
correctlyReplace master cylinder.
Restricted brake pipes or hosesCheck for soft hoses or damaged pipes and
replace with new hoses and/or new brake
piping.
Incorrect parking brake adjustment on
rear brakesCheck and adjust to correct specifications.
Weakened or broken return springs in
the drum brakeReplace.
Sluggish parking brake cables or linkageRepair or replace.
Wheel cylinder or caliper piston stickingRepair as necessary.
Badly worn piston seal in caliperReplace piston seal.
Improper brake pedal free heightCheck brake pedal free height.
Pedal pulsation (Pedal
pulsates when depressed
for braking)Damaged wheel bearingsReplace wheel bearings.
Distorted steering knuckle or rear wheel
spindle or rear axle shaftReplace knuckle or rear wheel spindle or rear
axle shaft.
Excessive disc lateral runoutCheck per instructions. If not within
specifications, replace or machine disc.
Rear drums out of roundCheck runout.
Repair or replace drum as necessary.
Braking noiseGlazed brake pad and/or brake shoeRepair or replace brake pad and/or brake
shoe.
Worn or distorted brake shoeReplace brake shoe.
Loose front wheel bearingsReplace wheel hub.
Distorted backing plates or loose
mounting boltsReplace or retighten securing bolts.
Contact wear indicator to brake discReplace brake pads.
Brake warning light lights
after engine startParking brake appliedRelease parking brake and check that brake
warning light turns off.
Insufficient amount of brake fluidInvestigate leaky point, correct it and add
brake fluid.
Brake fluid leakingInvestigate leaky point, correct it and add
brake fluid.
Brake warning light circuit faultyRepair circuit.
Malfunctioning EBD systemCheck system referring to “EBD Warning Light
(Brake Warning Light) Comes ON Steady in
Section 4E”.
Brake warning light turns
on when brake is appliedBrake fluid leakingInvestigate leaky point, correct it and add
brake fluid.
Insufficient amount of brake fluidInvestigate leaky point, correct it and add
brake fluid.
Brake warning light fails
to turn on even when
parking brake is appliedBrake warning light circuit faultyReplace bulb or repair circuit.
ABS warning light turns
on after engine startMalfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light turns
on when brake is appliedMalfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light after
ignition switch has turned
ON Bulb burnt outReplace bulb.
Malfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light flashesNew ABS hydraulic unit / control module
assembly installed.Perform “ABS Hydraulic Unit Operation Check
in Section 4E”. Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 4C-1 Rear Brakes:
Brakes
Rear Brakes
Repair Instructions
Rear Drum Brake ComponentsS6RW0D4306001
11
2
3
4
5
6 7
12
1411310 16
19 15
17
98
18
F
(a)
(b)
(c)
(d)
I6RW0D430001-01
1. Brake drum 10. Wheel cylinder 19. Bleeder plug
2. Brake shoe 11. Brake back plate : 73 N⋅m (7.3 kgf-m, 53 lb-ft)
3. Shoe return spring 12. Rear wheel hub : 12 N⋅m (1.2 kgf-m, 9.0 lb-ft)
4. Brake adjuster 13. Nut (4WD model) : 7 N⋅m (0.7 kgf-m, 5.0 lb-ft)
5. Antirattle spring 14. Parking cable : 175 N⋅m (17.5 kgf-m, 127.0 lb-ft)
6. Hold down spring 15. Rear wheel hub mounting bolt : Heat-resistant brake grease
7. Shoe hold down pin 16. Wheel cylinder mounting bolt : Do not reuse.
8. Push nut 17. Rear axle : Apply brake fluid
9. Brake shoe lever 18. Plug

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-2
Rear Brake Drum Removal and InstallationS6RW0D4306002
Removal
1) Hoist vehicle and remove rear wheel.
2) Release parking brake lever.
3) Remove brake drum (1) by using 8 mm bolts (2) (2
pcs).
Installation
1) Before installing brake drum, to maximize brake
shoe-to-drum clearance, put screwdriver between
rod and ratchet and push down ratchet.
NOTE
The figure show ratchet position where brake
shoe-to-drum clearance is maximum.

2) Confirm that inside of brake drum and brake shoes
are free from dirt and oil. And then install brake
drum.
3) Start engine and then depress brake pedal with
about 300 N (30 kg, 66 lbs) load at least 3 times until
adjuster actuator clicking sound from drum brake
can not be heard so as to obtain proper drum-to-
shoe clearance.
Adjust parking brake cable referring to “Parking
Brake Inspection and Adjustment in Section 4D”.
4) Install rear wheel.
5) Check to ensure that brake drum is free from
dragging and proper braking is obtained. Perform
brake test (foot brake and parking brake).
Rear Brake Drum and Shoe InspectionS6RW0D4306003
Brake Drum
Inspect brake drum for wear.
If drum inner diameter is exceeds the limit or uneven or
stepped wear is excessive, replace the drum.
Rear brake drum inner diameter
“a”
Standard: 220 mm (8.66 in.)
Limit: 222 mm (8.74 in.)
1. Rod 2. Ratchet
I7RW01431002-01
I2RH01430009-01
IYSQ01430007-01

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-4
3) Remove return springs, brake shoes and adjuster.
4) Disconnect parking brake shoe lever (1) from
parking brake cable (2).
5) Remove push nut (1).
6) Remove parking brake shoe lever (2) from shoe rim
(3).
Installation
Install parts in reverse order of removal, noting the
following.
• Before installing rear brake shoe to brake back plate,
clean brake back plate and apply heat-resistance
brake grease to A on which shoe rims rest.
• Push and rotate 90° hold down pin and install hold
down pin and hold down spring.
• Install brake drum referring to “Rear Brake Drum
Removal and Installation”.Rear Brake Shoe InspectionS6RW0D4306006
• Check ratchet of brake adjuster (1) assembly for wear
or damage.
• Check shoe return spring, antirattle spring, quadrant
spring and shoe hold down spring for damage,
corrosion and weakening.
• Check for smooth movement of brake shoe lever (2)
along shoe rim.
If any defective or malfunction is found, repair or replace.
Wheel Cylinder Removal and InstallationS6RW0D4306007
Removal
1) Remove brake drum referring to “Rear Brake Drum
Removal and Installation”.
2) Remove brake shoe referring to “Rear Brake Shoe
Removal and Installation”.
3) Loosen brake pipe flare nut (1) but only within the
extent that fluid does not leak.
4) Remove wheel cylinder mounting bolt (3).
Disconnect brake pipe from wheel cylinder and put
bleeder plug cap (2) onto pipe to prevent fluid from
spilling.
I2RH01430013-01
1
2 3
I4RS0A430014-01
A
A
I6JB0A430002-01
I4RS0A430016-01
1
2
3
I7RW01431004-01

Downloaded from www.Manualslib.com manuals search engine 4C-5 Rear Brakes:
Installation
1) Take off bleeder plug cap from brake pipe and
connect pipe to wheel cylinder (1) just enough to
prevent fluid from leaking.
2) Install wheel cylinder (1) to brake back plate (2), and
tighten wheel cylinder mounting bolt to specified
torque.
Tightening torque
Wheel cylinder mounting bolt (a): 12 N·m (1.2
kgf-m, 9.0 lb-ft)
3) Tighten flare nut of brake pipe (3) to specified torque.
Tightening torque
Rear brake pipe flare nut (b): 16 N·m (1.6 kgf-m,
11.5 lb-ft)
4) Install bleeder plug cap (4) taken off from pipe back
to bleeder plug.
5) Install brake shoes. Refer to “Rear Brake Shoe
Removal and Installation”.
6) Install brake drum. Refer to “Rear Brake Drum
Removal and Installation”.
7) Fill reservoir with brake fluid and bleed brake
system. For bleeding operation refer to “Air Bleeding
of Brake System in Section 4A”.
8) Upon completion of all jobs, depress brake pedal
with about 300 N (30 kg, 66 lbs) load at least 15
times until adjuster actuator clicking sound from
drum brake can not be heard so as to obtain proper
drum-to-shoe clearance.
Adjust parking brake cable referring to “Parking
Brake Inspection and Adjustment in Section 4D”.
9) Install rear wheel.
10) Check to ensure that brake drum is free from
dragging and proper braking is obtained. Remove
vehicle from hoist and perform brake test (foot brake
and parking brake).Wheel Cylinder InspectionS6RW0D4306008
Inspect wheel cylinder disassembled parts for wear,
cracks, corrosion or damage.
NOTE
Clean wheel cylinder components with brake
fluid.

Brake Back Plate Removal and InstallationS6RW0D4306009
Removal
1) Remove rear wheel hub referring to “Rear Wheel
Hub Assembly Removal and Installation in Section
2C”.
2) Remove parking brake cable (1) from brake back
plate.
3) Remove wheel cylinder from brake back plate
referring to “Wheel Cylinder Removal and
Installation”.
(b)3
4(a)
(a)
1
2
I7RW01431005-01
I6RW0D430002-02
1
I4RS0A430020-01