SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-14
8) Install transfer output flange (1) by tapping with
plastic hammer and tighten transfer output flange nut
gradually so as rotational torque of bevel pinion to be
in specified value.
NOTE
• If rotational torque of bevel pinion exceeds
specification given in the following,
replace pinion shaft spacers and tighten
flange nut.
• Before taking measurement of rotational
torque, rotate pinion over ten rounds in
advance.

Bevel pinion bearing preload
: 0.5 – 1.3 N⋅m (0.05 – 0.13 kgf-m, 0.35 – 0.95 lb-ft)
Special tool
(A): 09930–40113
9) Caulk transfer output flange nut (1).
Transfer Assembly InspectionS6RW0D3306010
• Check each bearing for smooth rotation, wear or
discoloration
If found abnormal, replace.
• Check oil seal for leakage and its lip for excessive
hardness
If either is found, replace.
• Check transfer case for cracks.
• Check bevel pinion and bevel gears for wear or
cracks.
Bevel Gear Tooth Contact InspectionS6RW0D3306011
1) After cleaning tooth surface of bevel gear (1), paint
them with gear marking compound evenly by using
brush or sponge etc.
NOTE
When applying red lead paste to teeth, be
sure to paint tooth surfaces uniformly. The
paste must not be too dry or too fluid.

2) Install transfer output retainer assembly referring to
“Transfer Assembly Disassembly and Reassembly”.
3) Turn transfer output flange clockwise and
counterclockwise repeatedly, and remove transfer
output retainer assembly and bevel gear shims from
transfer assembly.
2. Torque wrench
(A)1
2
I5RW0A330043-01
1
I5RW0A330044-01
I3RH01332043-01

Downloaded from www.Manualslib.com manuals search engine 3C-15 Transfer:
4) Bring painted part up and check contact pattern referring to the following chart. If contact pattern is not normal,
readjust or replace as necessary according to instruction in chart.
NOTE
• Be careful not to turn bevel gear more than one full revolution, for it will hinder accurate check.
• If bevel gear back lash and bevel pinion shims are adjusted properly, correct tooth contact should
be provided.
If correct tooth contact is not provided even when they are adjusted properly, however, there may be
an abnormal condition in worn tooth, transfer case or retainer. Check each component and replace
as necessary.

Gear tooth contact table
Tooth contact pattern Diagnosis and remedy
Normal
High contact
Pinion is positioned too far from the center of drive bevel
gear.
• Decrease thickness of bevel pinion shim and position
pinion closer to gear center.
• Adjust drive bevel gear backlash to specification.
Low contact
Pinion is positioned too close to the center of drive bevel
gear.
• Increase thickness of bevel pinion shim and position
pinion farther from gear center.
• Adjust drive bevel gear backlash to specification.
These contact patterns indicate that the “offset” of
reduction driven gear is too much or too little. The
remedy is to change the division of the bevel gear
shim(s).
I5RW0A330045-01
I3RH01332045-01
I3RH01332046-01
I3RH01332047-01

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-16
Specifications
Tightening Torque SpecificationsS6RW0D3307001
NOTE
The specified tightening torque is also described in the following.
“Transfer Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. These contact patterns, located on toe or heel on both
drive and coast sides, mean that 1) both pinion and gear
are defective, 2) retainer is not true, or 3) gear is not
properly seated on transfer case. The remedy is to
replace the defective member.
Irregular patterns: If the pattern is not oval, it means that
bevel gear is defective. High or low spots on tooth
surfaces or on the seat of bevel gear are the cause of
irregular patterns appearing on some teeth. The remedy
is to replace the pinion and gear set and, if the seat is
defective, so is transfer case. Tooth contact pattern Diagnosis and remedy
I3RH01332048-01
I3RH01332049-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Transfer oil level / filler plug 23 2.3 17.0) / )
Transfer oil drain plug 23 2.3 17.0)
Stiffener No.1 bolt and No.2 bolt 55 5.5 40.0)
Transfer to transaxle bolt 98 9.8 71.0)
Transfer case bolt 23 2.3 17.0)
Transfer output retainer bolt 55 5.5 40.0)
Oil plate bolt 9 0.9 6.5)
Rotational torque of bevel pinion (Bearing
preload)0.50 – 1.30 0.05 – 0.13 0.35 – 0.95)

Downloaded from www.Manualslib.com manuals search engine 3C-17 Transfer:
Special Tools and Equipment
Recommended Service MaterialS6RW0D3308001
NOTE
Required service material is also described in the following.
“Transfer Assembly Components”

Special ToolS6RW0D3308002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25010) / ) / ) / ) / )
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260) / ) / ) / )
09900–20607 09900–20701
Dial gauge Magnetic stand
))
09912–34510 09913–50121
Case separator Oil seal remover
)) / )
09913–75520 09913–76010
Bearing installer Bearing installer
))
09913–84510 09913–85210
Bearing installer Bearing installer
) / ) / ))
09913–85230 09922–76140
Bearing remover tool Bevel pinion shaft
) / )) / )
09922–76150 09922–76340
Bevel pinion nut Bevel pinion rear collar
))

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-18
09922–76430 09924–07710
Bevel pinion front collar Synchronizer hub installer
) / ))
09924–74510 09924–84510–005
Bearing and oil seal handle Bearing installer attachment
(D)
)) / )
09925–15410 09925–16310
Oil seal installer Bearing installer
) / ) / ) / ))
09925–18011 09925–98221
Transmission gear, bush
and bearing installerBearing installer
))
09930–40113 09940–54910
Flywheel rotor holder Front fork oil seal install
driver
) / ))
09944–88210 09944–96011
Bearing housing installer Bearing outer race remover
))

Downloaded from www.Manualslib.com manuals search engine 3D-1 Propeller Shafts:
Driveline / Axle
Propeller Shafts
Precautions
Propeller Shaft CautionS6RW0D3400001
CAUTION!
• All propeller shaft fasteners are an important attaching part in that it could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with one
of the same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to assure proper retention of this part.
• Never attempt to heat, quench or straighten any propeller shaft part. Replace it with a new part, or
damage to the part may result.

General Description
Propeller Shaft ConstructionS6RW0D3401001
Universal joints and ball joint require no maintenance. They are lubricated for life and can not be lubricated on the
vehicle. If a universal joint becomes noisy or worn, it must be replaced.
The propeller shaft is a balanced unit. Handle it carefully so that balance can be maintained.
Diagnostic Information and Procedures
Propeller Shaft Symptom DiagnosisS6RW0D3404001
1(a)1
(a)
2
3(b)
I5RW0A340004-01
1. Propeller shaft flange bolt : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
2. Center support nut : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
3. Propeller shaft assembly
Condition Possible cause Correction / Reference Item
Abnormal noiseLoose propeller shaft flange bolt and/or
center support nutTighten propeller shaft flange bolt and/or
center support nut.
Spider bearing worn out or stuckReplace propeller shaft.
Wear spiderReplace propeller shaft.
VibrationDeformed propeller shaftReplace.

Downloaded from www.Manualslib.com manuals search engine Propeller Shafts: 3D-2
Repair Instructions
Propeller Shaft Joint CheckS6RW0D3406001
If universal joints and ball joint are suspected of
producing chattering or rattling noise, inspect them for
wear. For universal joint, check to see if cross spider
rattles in yokes are worn down and replace defective
propeller shaft assembly with new one.
Noise coming from universal joint and ball joint can be
easily distinguished from other noises because rhythm
of chattering or rattling is in step with cruising speed.
Noise is pronounced particularly on standing start or in
coasting condition (when braking effect of engine is
showing in the drive line).
Propeller Shaft Assembly Removal and
Installation
S6RW0D3406002
Removal
1) Hoist vehicle.
2) Before removing propeller shaft assembly, give
match marks (2) on joint flange and propeller shaft
as shown.
3) Separate propeller shaft assembly (1) from transfer
output flange and rear differential flange.4) Remove propeller shaft by removing center support
nuts (1).
CAUTION!
Use care not to drop it. Otherwise, vibration
may occur during driving.

Installation
Reverse removal procedure to install propeller shaft,
noting the following point.
• When installing propeller shaft, align the match marks
(2). Otherwise, vibration may occur during driving.
• Use the following specification to torque each bolt and
nut.
Tightening torque
Propeller shaft bolt: 23 N·m (2.3 kgf-m, 17.0 lb-ft)
Center support nut: 55 N·m (5.5 kgf-m, 40.0 lb-ft)
Propeller Shaft InspectionS6RW0D3406003
1) Check propeller shaft joints for wear, play and
damage. If any defect is found, replace.
2) Check propeller shaft center support for biting of
foreign matter, crack, abnormal noise and damage. If
any defect is found, replace.
I5JB0A340003-01
2
2
1
1
I5RW0A340002-01
1I5RW0A340003-01

Downloaded from www.Manualslib.com manuals search engine 3D-3 Propeller Shafts:
Specifications
Tightening Torque SpecificationsS6RW0D3407001
NOTE
The specified tightening torque is also described in the following.
“Propeller Shaft Construction”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Propeller shaft bolt 23 2.3 17.0)
Center support nut 55 5.5 40.0)

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 4-ii Table of Contents
Specifications .......................................................4D-4
Tightening Torque Specifications ........................4D-4
ABS ............................................................4E-1
Precautions........................................................... 4E-1
Precautions in Diagnosing Troubles ................... 4E-1
Precautions in On-Vehicle Service...................... 4E-1
General Description ............................................. 4E-2
ABS Description .................................................. 4E-2
ABS Hydraulic Unit / Control Module
Assembly Description ....................................... 4E-3
CAN Communication System Description........... 4E-3
Schematic and Routing Diagram ........................ 4E-4
ABS Schematic ................................................... 4E-4
ABS Wiring Circuit Diagram ................................ 4E-5
Component Location ........................................... 4E-8
ABS Components Location ................................. 4E-8
Diagnostic Information and Procedures ............ 4E-8
ABS Check .......................................................... 4E-8
ABS Warning Light Check................................. 4E-10
EBD Warning Light (Brake Warning Light)
Check .............................................................. 4E-10
DTC Check........................................................ 4E-11
DTC Table ......................................................... 4E-11
DTC Clearance ................................................. 4E-11
Scan Tool Data ................................................. 4E-12
ABS Warning Light Does Not Come ON at
Ignition Switch ON .......................................... 4E-13
ABS Warning Light Comes ON Steady ............. 4E-15
EBD Warning Light (Brake Warning Light)
Comes ON Steady .......................................... 4E-16
Serial Data Link Circuit Check .......................... 4E-17
DTC C1013: Control Module Mismatch ............ 4E-20
DTC C1015: G Sensor Circuit (4WD Model)..... 4E-21
DTC 1016: Brake Light Switch .......................... 4E-22
DTC C1021 / C1022 / C1025 / C1026 / C1031
/ C1032 / C1035 / C1036: Wheel Speed
Sensor Circuit / Sensor or Encoder ................ 4E-23
DTC C1033: Wheel Speed Sensor Deviation ... 4E-25
DTC C1041 / C1042 / C1045 / C1046 / C1051
/ C1052 / C1055 / C1056: Inlet / Outlet
Solenoid .......................................................... 4E-26DTC C1057: Power Supply Voltage Too High
/ Too Low ........................................................ 4E-27
DTC C1061: Pump Motor Circuit ...................... 4E-28
DTC C1063: Solenoid Valve Power Supply
Driver Circuit ................................................... 4E-29
DTC C1071: Control Module Internal Defect .... 4E-30
ABS Hydraulic Unit / Control Module
Assembly Power and Ground Circuit Check ... 4E-30
Repair Instructions ............................................ 4E-31
ABS Hydraulic Unit Operation Check................ 4E-31
ABS Hydraulic Unit / Control Module
Assembly Components ................................... 4E-32
ABS Hydraulic Unit / Control Module
Assembly On-Vehicle Inspection .................... 4E-33
ABS Hydraulic Unit / Control Module
Assembly Removal and Installation ................ 4E-33
Front and Rear Wheel Speed Sensor On-
Vehicle Inspection ........................................... 4E-34
Front Wheel Speed Sensor Removal and
Installation ....................................................... 4E-35
Front and Rear Wheel Speed Sensor
Inspection ........................................................ 4E-36
Rear Wheel Speed Sensor Removal and
Installation (4WD Model) ................................. 4E-36
Rear Wheel Speed Sensor Removal and
Installation (2WD Model) ................................. 4E-36
Front Wheel Speed Sensor Encoder On-
Vehicle Inspection ........................................... 4E-37
Front Wheel Speed Sensor Encoder Removal
and Installation ................................................ 4E-37
Rear Wheel Speed Sensor Encoder On-
Vehicle Inspection ........................................... 4E-37
Rear Wheel Speed Sensor Encoder Removal
and Installation ................................................ 4E-37
G Sensor Removal and Installation (4WD
Model) ............................................................. 4E-38
G Sensor Inspection (4WD Model) ................... 4E-38
Specifications ..................................................... 4E-39
Tightening Torque Specifications ...................... 4E-39
Special Tools and Equipment ........................... 4E-39
Special Tool ...................................................... 4E-39