meter SUZUKI SX4 2006 1.G Service Owners Manual

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-6
d) Select a shim which is close to half thickness of
the calculated value (necessary shim thickness)
from among the available shims to install it
between bearing and case at each of right and
left sides.
For example:
Measure distance “a” is 110.75 mm (4.360 in.).
Measure depth “b” is 85.8 mm (3.378 in.).
Measure depth “c” is 26.55 mm (1.045 in.).
Necessary shim thickness = 85.8 mm (3.378 in.)
+ 26.55 mm (1.045 in.) – 110.75 mm (4.360 in.) +
0.1 mm (0.004 in.) = 1.7 mm (0.067 in.)
1.7 mm (0.067 in.) ÷ 2 = 0.85 mm (0.033 in.)
Calculated thickness of new shim = 0.85 mm
(0.033 in.)
Available reduction driven gear shim
thickness
0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90, 0.95,
1.00 and 1.05 mm (0.024, 0.026, 0.028, 0.030,
0.031, 0.033, 0.035, 0.037, 0.039 and 0.041 in.)
2) Clean mating surface of right and left cases, and
apply sealant to right case (1) as shown in figure by
such amount that its section is 1.2 mm (0.047 in.) in
diameter.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
3) Assemble the following parts in right and left cases
by reversing disassembling procedure.
• Reduction drive gear assembly (1)
• Reduction driven gear assembly (3)
• Bearing outer races (2)
• Reduction driven gear shims (5)
• Dowel pin (6)
4) Tighten transfer case bolts (4) to specified torque.
Tightening torque
Transfer case bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)5) Select bevel pinion shim (3) referring to step 1) of
“Reassembly” under “Transfer Output Retainer
Assembly Disassembly and Reassembly”.
6) Inspect tooth contact according to “Bevel Gear Tooth
Contact Inspection”.
7) Install transfer output retainer assembly (2) with
bevel pinion shim (3) to transfer left case (4) by
tightening retainer bolt (1) to specified torque.
Tightening torque
Transfer output retainer bolt (a): 55 N·m (5.5 kgf-
m, 40.0 lb-ft)
8) Install bolt to bolt hole of flange (2), set dial gauge
measuring tip at right angles to bolt (1) as shown in
figure. Holding reduction driven gear by hand, take
measurement backlash of pinion and bevel gear.
NOTE
If backlash exceeds specification given
below, adjust it by changing thickness ratio
of shims assembled in right and left cases in
Step 3).

Special tool
(A): 09900–20607
(B): 09900–20701
Bevel pinion & bevel gear backlash
: 0.1 – 0.2 mm (0.0039 – 0.0078 in.)
1
“A”
I5RW0A330011-01
6
4, (a) 5 2
31
2
5
I5RW0A330012-02
4
3
21, (a)
1, (a)
I5RW0A330013-02
(A)
1
(B)
2
I5RW0A330014-02

Downloaded from www.Manualslib.com manuals search engine 4B-7 Front Brakes:
Installation
1) Install caliper assembly to steering knuckle.
CAUTION!
Make sure that flexible hose is not twisted
when installing caliper assembly. If it is
twisted, reinstall it using care not to twist it.

2) Torque caliper carrier bolts to specification.
Tightening torque
Caliper carrier bolt (a): 85 N·m (8.5 kgf-m, 61.5
lb-ft)
3) Install front wheel referring to “Wheel (with Tire)
Removal and Installation in Section 2D”.
4) Perform brake test.
Front Brake Disc InspectionS6RW0D4206009
• Using magnetic stand and with dial gauge positioned
at about 10 mm (0.39 in.) inward from periphery of
disc, measure deflection of disc.
If it exceeds the limit, correct or replace the brake
disc.
Front brake disc deflection
Limit: 0.10 mm (0.004 in.) max.
Special tool
(A): 09900–20607
(B): 09900-20701
• Using micrometer, measure thickness of brake disc.
If it is less than limit, replace brake disc.
Front brake disc thickness
Standard: 22.0 mm (0.87 in.)
Limit: 20.0 mm (0.79 in.)
I4RS0B420012-01I4RS0B420013-01
I4RS0B420014-01

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 4E-1 ABS:
Brakes
ABS
Precautions
Precautions in Diagnosing TroublesS6RW0D4500001
To ensure that the trouble diagnosis is done accurately
and smoothly, observe the following and follow “ABS
Check”.
• Diagnostic information stored in ABS control module
memory can be cleared as well as checked by using
SUZUKI 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.
• If the vehicle was operated in any of the following
ways, ABS warning light may light momentarily but
this does not indicate anything abnormal in ABS.
– The vehicle was driven with parking brake pulled.
– The vehicle was driven with brake dragging.
– The vehicle was stuck in mud, sand, etc.
– Wheel spin occurred while driving.
– Wheel(s) was rotated while the vehicle was jacked
up.
• Be sure to read “Precautions for Electrical Circuit
Service in Section 00” and “Precaution for CAN
Communication System in Section 00” before
inspection and observe what is written there.
• Be sure to use the trouble diagnosis procedure as
described in “ABS Check”. Failure to follow it may
result in incorrect diagnosis. (Some other diagnosis
trouble code may be stored by mistake in the memory
of ABS control module during inspection.)• When disconnecting ABS hydraulic unit / control
module connector (1), pull up lock lever (2) of
connector.
When connecting, set the connector on ABS hydraulic
unit / control module assembly and pull down the lock
lever (2) until it locks.
• Communication of ECM, BCM, combination meter,
4WD control module (if equipped), keyless start
control module (if equipped), TCM (if equipped), data
link connector and ABS control module is established
by CAN (Control Area Network).
Therefore, be sure to read “Precautions for Installing
Mobile Communication Equipment in Section 00”
before inspection and handling CAN communication
line.
Precautions in On-Vehicle ServiceS6RW0D4500002
When connector is connected to ABS hydraulic unit /
control module assembly, do not disconnect connectors
of sensors with ignition switch ON. Otherwise, DTC will
be set in ABS control module.
[A]: Disconnect C: Pull up to disconnect
[B]: Connect D: Pull down to connect
2 1
CD
[A]
[B]
I5RW0A450001-01

Downloaded from www.Manualslib.com manuals search engine 4E-3 ABS:
ABS Hydraulic Unit / Control Module Assembly
Description
S6RW0D4501002
ABS control module is a component of ABS hydraulic
unit / control module assembly and has the following
functions.
Self-Diagnosis Function
ABS control module diagnoses conditions of the system
component parts (whether or not there is any
abnormality) all the time and indicates the results
(warning of abnormality occurrence and DTC) through
the ABS warning light as described.• When ignition switch is turned ON, ABS warning light
lights for 2 seconds to check its circuit.
• When no abnormality has been detected (the system
is in good condition), ABS warning light turns OFF
after 2 seconds.
• When an abnormality in the system is detected, ABS
warning light lights and the area where that
abnormality lies is stored in the memory of EEPROM
in ABS control module.
CAN Communication System DescriptionS6RW0D4501003
Refer to “CAN Communication System Description in Section 1A” for CAN communication system description. ABS
control module communicates control data with each control module as follows.
ABS Control Module Transmission Data
1
I4RS0A450001-01
Wheel speed signal (Front-right)
Wheel speed signal (Front-left)
Wheel speed signal (Rear-right)
Wheel speed signal (Rear-left)
ABS active
ABS indication
EBD indicationCombination Meter
TransmitDATA
ABS control module ECM 4WD control module
I7RW01450001-06

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-4
Schematic and Routing Diagram
ABS SchematicS6RW0D4502001
13
2
8
6
5 7
12
4
15
17
1614
9
18
19
11 10
20
21221323
INPUTOUTPUT
ABS control module
Wheel speed sensor (LR)
Wheel speed sensor (RF)
G sensor
(4WD model only)Wheel speed sensor (LF)Pump motor
driver (transistor)
Solenoid valve power
supply driver (transistor)Hydraulic unit
Pump motor
LF inlet solenoid valve
LF outlet solenoid valve
LR inlet solenoid valve
LR outlet solenoid valve
RF inlet solenoid valve
RF outlet solenoid valve
RR inlet solenoid valve
RR outlet solenoid valve
“ABS” warning lamp
“EBD” warning lamp
(Brake warning lamp)Data link connector
ABS hydraulic unit/control
module assembly
Wheel speed sensor (RR)
Brake light switch
CAN driver
Combination meter
Wheel speed signal
ECM
Wheel speed signal
ABS avtive signal
ABS avtive signal
4WD control module
(4WD model only)
Solenoid valve
driver (transistor)
I7RW01450016-01

Downloaded from www.Manualslib.com manuals search engine 4E-5 ABS:
ABS Wiring Circuit DiagramS6RW0D4502002 1. ABS hydraulic unit / control module assembly 9. Brake light switch 17. Wheel speed sensor (Left-rear)
2. ABS control module 10. ABS warning light 18. Battery
3. ABS hydraulic unit 11. EBD warning light (Brake warning light) 19. Ignition switch
4. Solenoid valve power supply driver (transistor)12. Light driver module 20. G sensor (4WD model)
5. Solenoid valve driver (transistor) 13. Data link connector 21. ECM
6. Pump motor driver (transistor) 14. Wheel speed sensor (Right-front) 22. Combination meter
7. Solenoid valve 15. Wheel speed sensor (Left-front) 23. 4WD control module
8. Pump motor 16. Wheel speed sensor (Right-rear)
BLU
WHT12VGRN/ORN 34
30E08-9
RED
WHT26
WHT/RED
12V
E08-7
19GRN
GRN
E08-16
12V
21REDRED/BLK
12V
BLKWHTE08-22 E08-11
23BLKWHTLT GRN/BLKLT GRN
12V
E08-10 E08-21
E08-23
E08-26
E08-1E08-12
24BLKWHT
12V
YELBRNE08-19 E08-2027
1 2
E08-6
9
9
9
WHTRED
12VE08-25
M
BLK
BLK
WHT/BLUWHT/RED
WHT/BLUE08-24
WHT
E08 [C] [A]
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
GRN/WHT
22
12V
BLKWHTWHTWHT/BLKE08-17 E08-18
GRN/ORN28
2033
31
29
25
32
GRN/YELE08-3GRN/BLK10
8
17
18
+BB
RED/BLKRED/BLK
REDWHTREDWHT
RED
BLK
WHT
14 13 12 76 5
1516
REDWHT
11
RED
WHT
9 9
E08-13E08-2
99
I6RW0D450004-01

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-6
17+BB
18BLU
WHT12VGRN/ORN 34
30E08-9
RED
WHT 1226
WHT/RED
12V
E08-7
19GRN
GRN
E08-16
12V
5
76
21REDRED/BLK
12V
BLKWHTE08-22 E08-11
23BLKWHTLT GRN/BLKLT GRN
12V
E08-10 E08-21
E08-23
E08-26
E08-1E08-12
24BLKWHT
12V
YELBRNE08-19 E08-20
27
1 2
RED/BLK
WHTRED
WHTRED
WHTRED9
E08-2E08-13WHT
E08-6
RED
9
9
11
9
9
9
REDWHT
WHTRED
12VE08-25
M
BLK
BLK
WHT/BLUWHT/RED
WHT/BLUE08-24
WHT
E08 [A]
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
GRN/WHT
22
12V
BLKWHTWHTWHT/BLKE08-17 E08-18
GRN/ORN28
2033
31
29
25
15
32
GRN/YELE08-3GRN/BLK
8
12V
12V
13
14RED/BLK
RED/BLU
WHTRED6
16
10
BLK [B]
I6RW0D450001-02
[A]: Junction block with BCM 10. G sensor (4WD model) 22. Right-front wheel speed sensor
[B]: Junction block without BCM 11. 4WD control module 23. Left-rear wheel speed sensor
[C]: Terminal arrangement of ABS control module
connector (viewed from terminal side)12. BCM 24. Right-rear wheel speed sensor
1. Battery 13. Brake fluid level switch 25. ABS hydraulic unit / control module assembly
2. Main fuse box 14. Parking brake switch 26. Brake light switch
3. Ignition switch 15. CAN junction connector 27. Brake light
4. Junction block assembly 16. Keyless start control module 28. To ECM and shift lock relay (A/T model)
5. Combination meter 17. Data link connector (DLC) 29. Pump motor driver (transistor)
6. ABS warning light 18. To BCM, 4WD control module, P/S control
module, HVAC control module (auto A/C
model) and SDM30. Pump motor
7. EBD warning light (brake warning light)19. ECM 31. Solenoid valve power supply driver
8. Light driver module 20. TCM (A/T model) 32. Solenoid valve
9. CAN driver 21. Left-front wheel speed sensor 33. Solenoid valve driver (transistor)

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-12
Scan Tool DataS6RW0D4504007
The parameter data below are values measured with the
scan tool when the normally operating vehicle is under
the following conditions. When taking measurements for
comparison by using the scan tool, be sure to check that
the vehicle is under the following conditions.
• Apply parking brake and block wheels.
• Ignition switch ON.
• Turn OFF air conditioner (if equipped).
• Apply no load to power steering (if equipped). (Don’t
turn it)
• Turn OFF all electric loads (except ignition).
• No DTC.
• ABS is not operated. (Normal braking operation)Scan Tool Data Definition
Battery Volt (V)
Battery Voltage is an analog input signal read by the
ABS control module. Certain ABS control module
functions will be modified if the battery voltage falls
below or rises above programmed thresholds.
Pump Motor Driver (V)
This parameter indicates the operational condition of the
pump motor driver (transistor).
RF Wheel Speed, LF Wheel Speed, RR Wheel Speed
and LF Wheel Speed (km/h, MPH)
Wheel speed is an ABS control module internal
parameter. It is computed by reference pulses from the
wheel speed sensor.
Brake Switch (ON, OFF)
This switch signal informs the ABS control module
whether the brake is active or not.
G Sensor (G)
4WD model: Vehicle acceleration is measured by G
sensor and output to ABS control module as the linear
voltage.
2WD model: Fixed 2.54 G.
Solenoid Valve Power Supply Driver (ON, OFF)
ABS control module monitor the supply voltage to
solenoid valve power supply driver. If the voltage is
supplied, ON is displayed. Beside, OFF is displayed.
Inlet Solenoid RF, Inlet Solenoid LF, Inlet Solenoid
RR, Inlet Solenoid LR (ON, OFF)
This parameter indicates the operational condition of the
inlet solenoid valve.
Outlet Solenoid RF, Inlet Solenoid LF, Inlet Solenoid
RR, Inlet Solenoid LR (ON, OFF)
This parameter indicates the operational condition of the
outlet solenoid valve. Scan Tool
DataStandards Condition
) Battery
Voltage10.0 – 16.0 V —
) Pump
Motor Driver0.0 V —
) RF Wheel
Speed0 km/h, 0.0 MPH Vehicle stop
) LF Wheel
Speed0 km/h, 0.0 MPH Vehicle stop
) RR Wheel
Speed0 km/h, 0.0 MPH Vehicle stop
) LR Wheel
Speed0 km/h, 0.0 MPH Vehicle stop
) Brake
SwitchONBrake pedal
depressed
OFFBrake pedal
released
) G sensor0.00G
(4WD model)Place vehicle on the
level
2.54G
(2WD model)Place vehicle on the
level
) Solenoid
Valve Power
Supply DriverON Ignition switch ON
) Inlet
SolenoidRF
OFF Vehicle stop LF
RR
LR
) Outlet
SolenoidRF
OFF Vehicle stop LF
RR
LR

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-14
Circuit Description
ABS control module transmits indication ON signal of ABS warning light to combination meter in order to turn ABS
warning light ON. And then, combination meter turns ABS warning light ON.
If the ABS is in good condition, ABS control module transmits indication ON signal to combination meter in order to
turn ABS warning light ON at the ignition switch ON, keeps it ON for 2 seconds and then turns it OFF. If an abnormality
in the system is detected, ABS warning light is turned ON continuously by ABS control module. Also, it is turned ON
continuously by light driver module when ABS control module connector is disconnected.
Troubleshooting
G241 [D]
132 4 5 6 7 8 9 10111213141516
17 1918 20 2122 23 24 25 26 27 28 29 30 31 32E08 [C]
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
G05 [E]
1 2 3 4 765 8 9 10 11 14 15 16
36 34 33 32 3135 24 23 2122 28 27 2526 37 39 38 4018 17 13 12 19 20
30 29
WHTGRN
3
E08-2
E08-13REDWHT 5
4 13
9
E08-23
E08-26BLKBLK
67
BLK
REDWHTG241-7G241-10
G241-16
12V
E08-25E08-24
E08-9
WHT/REDWHT/BLU
GRN/ORN
9
2
1
14
G241-31
RED/BLK
8
REDWHT9
12V
12V
11
12G05-7
G05-1G05-3
G05-8
RED/BLK
RED/BLU
10
[B]
I6RW0D450002-02
[A]: Junction block with BCM 6. ABS warning light
[B]: Junction block without BCM 7. EBD warning light (brake warning light)
[C]: ABS control module connector (viewed from terminal side) 8. Light driver module
[D]: Combination meter connector (viewed from terminal side) 9. CAN driver
[E]: BCM (viewed from harness side) 10. BCM
1. Battery 11. Brake fluid level switch
2. Main fuse box 12. Parking brake switch
3. Ignition switch 13. ABS hydraulic unit / control module assembly
4. Junction block assembly 14. CAN junction connector
5. Combination meter
Step Action Yes No
1Warning light check
1) Turn ignition switch to ON position.
Do other warning lights come ON?Substitute a known-
good combination meter
and recheck. If warning
light remains OFF,
substitute a known-
good ABS hydraulic unit
/ control module
assembly and recheck.Go to Step 2.
2Fuse check
Is circuit fuse for combination meter in good condition?Go to Step 3. Replace fuse and check
for short circuit to
ground.