Hub SUZUKI SX4 2006 1.G Service Owner's Manual

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

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-6
Installation
Install brake back plate by reversing removal procedure,
noting the instructions.
CAUTION!
Never reuse rear wheel hub mounting bolts.

• Install rear wheel hub and brake back plate, and then
tighten mounting bolt. Refer to “Rear Drum Brake
Components”.
• Install parking brake cable (1) to brake back plate.
Tightening torque
Parking cable cap nut (a): 11 N·m (1.1 kgf-m, 8.0
lb-ft)• After installing all removed parts, bleed air from brake
system referring to “Air Bleeding of Brake System in
Section 4A”. and then adjust parking brake cable
referring to “Parking Brake Inspection and Adjustment
in Section 4D”.
Specifications
Tightening Torque SpecificationsS6RW0D4307001
NOTE
The specified tightening torque is also described in the following.
“Rear Drum Brake Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS6RW0D4308001
NOTE
Required service material is also described in the following.
“Rear Drum Brake Components”

1
(a)
I4RS0A430024-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Wheel cylinder mounting bolt 12 1.2 9.0)
Rear brake pipe flare nut 16 1.6 11.5)
Parking cable cap nut 11 1.1 8.0)

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-2
General Description
ABS DescriptionS6RW0D4501001
The ABS (Antilock Brake System) controls the fluid
pressure applied to the wheel cylinder of each brake
from the master cylinder so that each wheel is not locked
even when hard braking is applied.
This ABS has also the following function.
While braking is applied, but before ABS control
becomes effective, braking force is distributed between
the front and rear so as to prevent the rear wheels from
being locked too early for better stability of the vehicle.
The main component parts of this ABS include the
following parts in addition to those of the conventional
brake system.
• Wheel speed sensor which senses revolution speed
of each wheel and outputs its signal.
Rear wheel speed sensor of 4WD vehicle is
integrated in rear wheel hub assembly and supplied
as rear wheel hub assembly part.
Front wheel speed sensor and rear wheel speed
sensor of 2WD model are separated from wheel hub
assembly and supplied as spare parts.
• ABS warning light which lights to inform abnormality
when system fails to operate properly.• ABS hydraulic unit / control module assembly is
incorporated ABS control module, ABS hydraulic unit
(actuator assembly), solenoid valve power supply
driver (transistor), solenoid valve driver (transistor),
pump motor driver (transistor).
– ABS control module which sends operation signal
to ABS hydraulic unit to control fluid pressure
applied to each wheel cylinder based on signal
from each wheel speed sensor so as to prevent
wheel from locking.
– ABS hydraulic unit which operates according to
signal from ABS control module to control fluid
pressure applied to wheel cylinder of each 4
wheels.
– Solenoid valve power supply driver (transistor)
which supplies power to solenoid valve in ABS
hydraulic unit.
– Solenoid valve driver (transistor) which controls
each solenoid valves in ABS hydraulic unit.
– Pump motor driver (transistor) which supplies
power to pump motor in ABS hydraulic unit.
• G sensor which detects body deceleration speed for
4WD model.
This ABS is equipped with Electronic Brake force
Distribution (EBD) system that controls a fluid pressure
of rear wheels to best condition, which is the same
function as that of proportioning valve, by the signal from
wheel sensor independently of change of load due to
load capacity and so on. And if the EBD system fails to
operate properly, the brake warning light lights to inform
abnormality.

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-8
Component Location
ABS Components LocationS6RW0D4503001
Diagnostic Information and Procedures
ABS CheckS6RW0D4504001
Refer to the following items for the details of each step.
1
2
6
2
6
26
264
5
7
3
8
I5RW0A450006-02
1. ABS hydraulic unit / control module assembly 5. EBD warning light (Brake warning light)
2. Wheel speed sensors 6. Wheel speed sensor encoder (included in wheel hub assembly)
3. Brake light switch 7. Data link connector
4. ABS warning light 8. G sensor (4WD model)
Step Action Yes No
1) Malfunction analysis
1) Perform “Customer complaint analysis: ”.
2) Perform “Problem symptom confirmation: ”.
3) Perform “DTC check, record and clearance: ” and
recheck DTC.
Is there any malfunction DTC?Go to Step 4. Go to Step 2.
2) Driving test
1) Perform “Step 2: Driving Test: ”.
Is trouble symptom identified?Go to Step 3. Go to Step 6.
3) DTC check
1) Perform “DTC Check”.
Is it malfunction code?Go to Step 4. Go to Step 5.
4) ABS check
1) Inspect and repair referring to applicable DTC flow.
Does trouble recur?Go to Step 5. Go to Step 7.
5) Brakes diagnosis
1) Inspect and repair referring to “Brakes Symptom
Diagnosis in Section 4A”.
Does trouble recur?Go to Step 3. Go to Step 7.

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-24
DTC Troubleshooting
Step Action Yes No
1Was “ABS Check” performed?Go to Step 2. Go to “ABS Check”.
2Check tire condition
1) Check that tire pressure is specifications.
Are they in good condition?Go to Step 3. Replace tire or adjust
tire pressure and
recheck.
3Wheel speed sensor circuit check
1) Disconnect ABS hydraulic unit / control module
connector and applicable wheel speed sensor connector
with ignition switch turned OFF.
2) Check for proper connection to ABS hydraulic unit /
control module connector at applicable terminals and
terminals of applicable wheel speed sensor.
3) If OK then check applicable wheel speed sensor circuit
for open, short and high resistance.
Is each applicable wheel speed sensor circuit in good
condition?Go to Step 4. Repair circuit and
recheck
4Wheel speed sensor check
1) Inspection applicable wheel speed sensor referring to
“Front and Rear Wheel Speed Sensor Inspection”.
Is it in good condition?Go to Step 5. Clean or replace.
5Wheel speed sensor encoder check
1) Inspection applicable wheel speed sensor encoder
referring to “Front Wheel Speed Sensor Encoder On-
Vehicle Inspection” and/or “Rear Wheel Speed Sensor
Encoder On-Vehicle Inspection”.
Is it in good condition?Go to Step 6. Clean or replace wheel
hub assembly.
6Wheel speed sensor signal check
1) Inspection applicable wheel speed sensor referring to
“Front and Rear Wheel Speed Sensor On-Vehicle
Inspection”.
Is it in good condition?Substitute a known-
good wheel hub
assembly and recheck.
If DTC detected,
substitute a known-
good ABS hydraulic unit
/ control module and
recheck.Replace wheel speed
sensor and recheck.

Downloaded from www.Manualslib.com manuals search engine 4E-25 ABS:
DTC C1033: Wheel Speed Sensor DeviationS6RW0D4504016
Wiring Diagram
Refer to “Wiring Diagram” under “DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel
Speed Sensor Circuit / Sensor or Encoder”.
DTC Detecting Condition and Trouble Area
DTC Troubleshooting DTC Detecting Condition Trouble Area
• Three or more sensor signals seem to be effected by
temporary failure suspicion at the same time.
• One wheel or more are controlled by ABS for more than
specified time.• Wheel speed sensor
• Wheel speed sensor circuit
• Wheel encoder
• ABS control module
• Tire (flat tire)
Step Action Yes No
1Was “ABS Check” performed?Go to Step 2. Go to “ABS Check”.
2Check DTC for ABS
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Turn ignition switch ON and check DTC for ABS.
Is DTC C1021, C1022, C1025, C1026, C1031, C1032,
C1035 and/or C1036 detected together?Go to “DTC C1021 /
C1022 / C1025 / C1026
/ C1031 / C1032 /
C1035 / C1036: Wheel
Speed Sensor Circuit /
Sensor or Encoder” and
recheck.Go to Step 3.
3Check tire condition
1) Check that tire pressure is specifications.
Are they in good condition?Go to Step 4. Replace tire or adjust
tire pressure and
recheck.
4Wheel speed sensor circuit check
1) Disconnect ABS hydraulic unit / control module
connector and all wheel speed sensor connectors with
ignition switch turned OFF.
2) Check for proper connection to ABS hydraulic unit /
control module connector and terminals of wheel speed
sensor.
3) If OK then check all wheel speed sensors circuit for
open, short and high resistance.
Are wheel speed sensor circuits in good condition?Go to Step 5. Repair circuit and
recheck.
5Wheel speed sensor check
1) Inspection all wheel speed sensors referring to “Front
and Rear Wheel Speed Sensor Inspection”.
Are they in good condition?Go to Step 6. Clean or replace.
6Wheel speed sensor encoder check
1) Inspection all wheel speed sensor encoders referring to
“Front Wheel Speed Sensor Encoder On-Vehicle
Inspection” and “Rear Wheel Speed Sensor Encoder
On-Vehicle Inspection”.
Are they in good condition?Go to Step 7. Clean or replace wheel
hub assembly.
7Wheel speed sensor signal check
1) Inspection all wheel speed sensors referring to “Front
and Rear Wheel Speed Sensor On-Vehicle Inspection”.
Are they in good condition?Substitute a known-
good wheel hub
assembly and recheck.
If DTC detected,
substitute a known-
good ABS hydraulic unit
/ control module and
recheck.Replace wheel speed
sensor and recheck.

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-36
Installation
1) Check that no foreign material is attached to sensor
(1) and wheel speed sensor encoder (included in
wheel hub assembly).
2) Install it by reversing removal procedure.
NOTE
Before fitting wheel speed sensor, be sure to
silicon grease to its O-ring.

Tightening torque
Front wheel speed sensor bolt (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
Front wheel speed sensor harness clamp bolt
(b): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Check that there is no clearance between sensor
and knuckle.
Front and Rear Wheel Speed Sensor InspectionS6RW0D4506007
Check sensor for damage.
If any malcondition is found, replace.
Rear Wheel Speed Sensor Removal and
Installation (4WD Model)
S6RW0D4506008
CAUTION!
Rear wheel speed sensor is included in rear
wheel hub assembly. If rear wheel speed
sensor needs to be replaced, replace it as a
rear wheel hub assembly.

For removal and Installation of rear wheel speed sensor
(included in rear wheel hub), refer to “Rear Wheel Hub
Assembly Removal and Installation in Section 2C”.
Rear Wheel Speed Sensor Removal and
Installation (2WD Model)
S6RW0D4506009
CAUTION!
• Do not pull wire harness when removing
and installing rear wheel speed sensor.
• Do not cause damage to surface of rear
wheel speed sensor and do not allow dust,
etc. to enter its installation hole.

Removal
1) Disconnect negative (–) cable from battery.
2) Hoist vehicle, and remove wheel.
3) Disconnect rear wheel speed sensor connector.
4) Remove harness clamp.
5) Remove rear wheel speed sensor from wheel hub.
Installation
1) Check that no foreign material is attached to sensor
and encoder (included in wheel hub assembly).
2) Install it by reversing removal procedure.
NOTE
Before fitting wheel speed sensor, be sure to
silicon grease to its O-ring.

Tightening torque
Rear wheel speed sensor bolt: 11 N·m (1.1 kgf-
m, 8.0 lb-ft)
3) Check that there is no clearance between sensor
and wheel hub.[A]: OK [B]: NG
1
2
(b)
(a)
I5RW0A450025-01
[A][B]
11
I5RW0A450024-01
I5JB0A450031-01
[A]: OK [B]: NG
[A][B]
11
I5RW0A450024-01

Downloaded from www.Manualslib.com manuals search engine 4E-37 ABS:
Front Wheel Speed Sensor Encoder On-Vehicle
Inspection
S6RW0D4506010
Before inspecting front wheel speed sensor encoder,
remove front drive shaft referring to “Front Drive Shaft
Assembly Removal and Installation in Section 3A”.
• Check sensor encoder (1) for crack, damage or
deformation.
• Turn wheel and check if sensor encoder rotation is
free from eccentricity and looseness.
• Check that no foreign material is attached.
If any faulty is found, clean or replace. Refer to “Front
Wheel Hub, Steering Knuckle and Wheel Bearing
Removal and Installation in Section 2B”.
Front Wheel Speed Sensor Encoder Removal
and Installation
S6RW0D4506011
CAUTION!
Front wheel speed sensor encoder is
included in front wheel hub assembly. If front
wheel speed sensor encoder needs to be
replaced, replace it as a front wheel hub
assembly.

For removal and installation of front wheel hub
assembly, referring to “Front Wheel Hub, Steering
Knuckle and Wheel Bearing Removal and Installation in
Section 2B”.
Rear Wheel Speed Sensor Encoder On-Vehicle
Inspection
S6RW0D4506012
For 4WD model
Refer to “Rear Wheel Speed Sensor On-Vehicle
Inspection”.
For 2WD model
Before inspecting rear wheel speed sensor encoder,
remove rear wheel speed sensor referring to “Rear
Wheel Speed Sensor Removal and Installation (2WD
Model)”.
• Check encoder (1) for crack, damage or deformation.
• Turn wheel and check if encoder rotation is free from
eccentricity and looseness.
• Check that no foreign material is attached.
If any faulty is found, clean or replace. Refer to “Rear
Wheel Hub Assembly Removal and Installation in
Section 2C”.
Rear Wheel Speed Sensor Encoder Removal
and Installation
S6RW0D4506013
CAUTION!
Rear wheel speed sensor encoder is included
in rear wheel hub assembly. If rear wheel
speed sensor encoder needs to be replaced,
replace it as a rear wheel hub assembly.

For removal and installation of front wheel hub
assembly, referring to “Rear Wheel Hub Assembly
Removal and Installation in Section 2C”.
1
I5RW0A450026-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-103
1. Torque converter 37. Transmission range sensor 73. Rear planetary sun gear subassembly
2. Torque converter housing
: Apply sealant 99000-31230 to mating
surface to transaxle case.38. Cooler check valve 74. Rear sun gear thrust bearing race
3. Oil strainer assembly
: Replace oil strainer when overhauling.39. Spring 75. Rear sun gear thrust bearing
4. Parking lock pawl shaft 40. Transaxle case plug 76. Forward clutch hub
5. Parking lock pawl 41. Fluid filler tube 77. Intermediate shaft thrust bearing race
6. Parking lock pawl return spring 42. Fluid level gauge 78. Intermediate shaft thrust bearing
7. Parking lock pawl rod 43. Fluid cooler inlet pipe 79. 2nd brake piston snap ring
8. Parking lock pawl bracket 44. Fluid cooler outlet pipe 80. O/D and 2nd coast brake retaining
plate snap ring
9. Manual detent spring 45. 2nd brake gasket 81. O/D and 2nd coast brake retaining
plate
10. Manual valve lever 46. Brake drum gasket 82. O/D and 2nd coast brake disc
11. Manual valve lever pin 47. Pipe union 83. O/D and 2nd coast brake separator
plate
12. Manual shift shaft 48. Reduction drive gear nut
: After tightening nut so as rotational
torque of reduction drive gear to be in
specified value, caulk nut securely.84. O/D and 2nd coast brake rear plate
13. Manual shift shaft oil seal
: Apply grease 99000-25030 to oil seal
lip.49. Reduction drive gear 85. Rear cover seal ring
14. Differential side oil seal
: Apply grease 99000-25030 to oil seal
lip.50. Planetary ring gear subassembly 86. Reverse clutch drum thrust bearing
15. Torque converter housing plug 51. Breather hose 87. Rear cover plug
16. Lubrication LH tube 52. Breather union 88. Transaxle rear cover
: Apply sealant 99000-31230 to mating
surface.
17. Lubrication RH tube 53. Input shaft speed sensor 89. Harness bracket
18. Fluid reservoir RH plate 54. Valve body harness 90. Select cable clamp
19. Input shaft front thrust bearing 55. 1st and reverse brake piston 91. Governor apply No.1 gasket
20. Input shaft rear thrust bearing 56. O-ring 92. Output shaft speed sensor (VSS)
21. Input shaft rear thrust bearing race 57. 1st and reverse brake return spring
subassembly93. One-way clutch outer race retainer
22. Direct clutch hub 58. 1st and reverse brake disc 94. Select cable bracket
23. Lubrication tube clamp 59. 1st and reverse brake separator plate : Do not reuse.
24. Fluid reservoir LH plate 60. 1st and reverse brake retaining plate : Apply automatic transaxle fluid.
25. Governor apply No.2 gasket 61. 1st and reverse brake snap ring : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
26. Automatic transaxle case 62. Planetary gear assembly : 7.0 N⋅m (0.7 kgf-m, 5.0 lb-ft)
27. Accumulator piston O-ring 63. Planetary carrier thrust washer
: Apply grease 99000-25030 to slide
contact face.: 7.5 N⋅m (0.75 kgf-m, 5.5 lb-ft)
28. Accumulator spring 64. One-way clutch No.2 assembly : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
29. C2 accumulator piston 65. 2nd brake retaining plate : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
30. C1 accumulator piston 66. 2nd brake disc : 17 N⋅m (1.7 kgf-m, 12.5 lb-ft)
31. B1 accumulator piston 67. 2nd brake separator plate : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft)
32. Oil pan gasket 68. 2nd brake return spring subassembly : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
33. Oil pan 69. Front sun gear thrust bearing race : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
34. A/T fluid drain plug 70. Front planetary sun gear : 33 N⋅m (3.3 kgf-m, 24.0 lb-ft)
35. Manual select lever 71. Planetary gear thrust bearing
36. Lock washer 72. One-way clutch No.1 assembly

Downloaded from www.Manualslib.com manuals search engine 5A-108 Automatic Transmission/Transaxle:
29) Remove input shaft rear thrust bearing (1) and thrust
bearing race (2).
NOTE
If input shaft rear thrust bearing is not found,
it may have been taken out with direct clutch
assembly.

30) Remove direct clutch hub (1).
31) Remove differential assembly (1) and countershaft
assembly (2).32) Remove governor apply No.2 gasket (1).
33) Remove fluid reservoir LH plate (1).
34) Turn over transaxle and remove rear cover assembly
(1).
35) Remove reverse clutch drum thrust bearing (1).
NOTE
If reverse clutch drum thrust bearing is not
found, it may have been taken out with rear
cover assembly.

I2RH0B510102-01
I2RH0B510103-01
1
2
I4RS0A510036-01
I2RH0B510105-01
I2RH0B510106-01
1
I4RS0A510037-01
I2RH0B510108-01