651 SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-36
Rear Differential Disassembly and ReassemblyS6RW0D3206014
Disassembly
1) Remove rear mounting bracket from rear differential
referring to “Front Mounting Arm and/or Rear
Mounting Bracket Assembly Removal and
Installation”.
2) Remove drive shaft flanges.
3) Separate coupling case from differential carrier using
special tool.
Special tool
: 09912–34510
4) Hold companion flange with special tool and then
remove flange nut.
Special tool
(A): 09930–40113
5) Remove companion flange (1) from pinion. Use
special tool if it is hard to remove.
Special tool
(A): 09913–651356) Remove coupling assembly (1) by using hydraulic
press.CAUTION!
Do not drop coupling assembly. If it is
dropped, replace it with a new one.

7) Disassemble coupling case as follows, if necessary.
a) Remove oil seal using special tool.
Special tool
(A): 09913–50121
b) Remove snap ring using snap ring pliers.
c) Remove bearing using special tool and hydraulic
press.
Special tool
(A): 09913–75830
(A)
I5RW0A320027-01
(A)
1
I5RW0A320028-01
1
I5RW0A320029-01
(A)
I5RW0A320030-01
(A)
I5RW0A320031-01

Downloaded from www.Manualslib.com manuals search engine 3B-49 Differential:
Special ToolS6RW0D3208002
09900–20607 09900–20701
Dial gauge Magnetic stand
))
09912–34510 09913–50121
Case separator Oil seal remover
) / )) / )
09913–60910 09913–65135
Bearing and gear puller (40-
60mm)Bearing puller
))
09913–70123 09913–75510
Bearing installing tool Bearing installer
))
09913–75810 09913–75830
Bearing installer Steering pinion bush
installer
) / )) / )
09913–80113 09913–85210
Bearing installer Bearing installer
) / )) / ) / )
09922–76120 09922–76140
Mounting dummy shaft Bevel pinion shaft
) / )) / ) / )

Downloaded from www.Manualslib.com manuals search engine 5B-36 Manual Transmission/Transaxle:
Differential ComponentsS6RW0D5206025
Differential Disassembly and ReassemblyS6RW0D5206026
Disassembly
1) Using special tool, remove left bearing (1).
Special tool
(A): 09913–65135
(B): 09913–852302) Using special tool, remove right bearing (1).
Special tool
(A): 09913–65135
(B): 09913–85230
(C): 09940–54950
I5RW0A520043-02
1. Differential pinion washer 6. Differential case : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft)
2. Differential pinion 7. Final gear : Do not reuse.
3. Differential side gear 8. Final gear bolt : Apply transaxle oil.
4. Side gear washer 9. Differential pinion shaft
5. Differential side bearing 10. Differential pinion shaft pin
(B)
(A)
1
I5RW0A520044-01
(A)
1
(B)
(C)
I5RW0A520045-01

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-39
Special Tools and Equipment
Recommended Service MaterialS6RW0D5208001
NOTE
Required service material is also described in the following.
“Gear Shift Control Lever and Cable Components”
“Gear Shift and Select Shaft Assembly Components”
“Manual Transaxle Assembly Components”
“Input Shaft and Countershaft Components”
“Gear Shift Shaft Components”
“Differential Components”

Special ToolS6RW0D5208002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011) / ) / )
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260) / ) / ) / ) / ) / ) / ) /
) / ) / )
Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110) / ) / ) / ) / )
09900–06107 09900–20607
Snap ring pliers (opening
type)Dial gauge
) / ) / ) / ) / ) / ))
09900–20701 09913–50121
Magnetic stand Oil seal remover
))
09913–65135 09913–70123
Bearing puller Bearing installing tool
) / )) / )
09913–75510 09913–75810
Bearing installer Bearing installer
))
09913–75821 09913–75830
Bearing installer attachment Steering pinion bush
installer
))

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-108
Deployment / Activation Outside of Vehicle
When you intend to return the vehicle to service, deploy
the air bag (inflator) module(s) or activate seat belt
pretensioner(s) outside of the vehicle.
1) Turn ignition switch to LOCK position and remove
key.
2) Wear safety glasses during this deployment /
activation procedure.
3) Check that there is no open, short or damage in
special tools (deployment harness (A) and adapter
cable (B)). If any faulty is found, do not use it and be
sure to use new special tool.
Special tool
(A): 09932–75031
(B): 09932–76510
4) Short two deployment harness leads (1) together by
fully seating one banana plug into the other.
WARNING!
Deployment harness (A) shall remain shorted
and not be connected to 12 volts vehicle
battery till you are ready to deploy air bag
module or activate seat belt pretensioner.

5) Remove air bag (inflator) module(s) or seat belt
pretensioner(s) from vehicle referring to “Driver Air
Bag (Inflator) Module Removal and Installation”,
“Passenger Air Bag (Inflator) Module Removal and
Installation”, “Side-Air Bag (Inflator) Module Removal
and Installation”, “Side Curtain-Air Bag (Inflator)
Module Removal and Installation” or “Front Seat Belt
Removal and Installation in Section 8A”.
WARNING!
• For handing and storage of live air bag
(inflator) module, select place where
ambient temperature below 65 °C (150 °F),
without high humidity and away from
electric noise.
• Always carry live air bag (inflator) module
with trim cover away from you.
• When storing live air bag (inflator) module
or when leaving live air bag (inflator)
module unattended on bench or other
surface, always face trim cover up and
away from surface. It is also prohibited to
place anything on top of the trim cover and
stack air bag (inflator) modules. This is
necessary so that free space is provided to
allow air bag (inflator) module to expand in
the unlikely event of accidental
deployment.
Failure to follow procedures may result in
personal injury.

I4RS0A820084-01
[A]: Always carry air bag (inflator) module with trim cover (air bag opening)
away from body.
[B]: Always place air bag (inflator) module on workbench with trim cover (air
bag opening) up, away from loose objects.
[A]
[B]
I5RW0A820084-03

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-112
10) Connect adapter cable (B) as follows.
Special tool
(B): 09932–76510
• For driver air bag (inflator) module [A]:
Check that driver air bag (inflator) module is
placed with its vinyl trim cover facing up, and
connect adapter cable (B) to driver air bag
(inflator) module.
• For passenger air bag (inflator) module [B]:
Check that passenger air bag (inflator) module is
firmly and properly secured on deployment fixture
(special tool), and connect adapter cable (B) to
passenger air bag (inflator) module.
NOTE
Wind wire harness (5) around at least 2 times.

• For side-air bag (inflator) module [C]:
Verify that side-air bag (inflator) module is firmly
and properly on deployment fixture (special tool),
and connect adapter cable (B) to side-air bag
(inflator) module.
• For side curtain-air bag (inflator) module [D]:
a. Connect adapter cable (B) to side curtain-air
bag (inflator) module.
b. Pile 2 tires (2) and wheel-installed tire (3) on
top of tire with side curtain-air bag (inflator)
(4), and tie them with wire harness (5) as
shown.
Wire harness specifications
Stripped wire harness section 1.25 mm2
(0.0019 in.2) or more (Stripped wire harness
diameter 1.25 mm (0.05 in.) or more)
NOTE
Wind wire harness (5) around at least 2 times.

• For seat belt pretensioner [E]:
a. Connect adapter cable (B) to seat belt
pretensioner.
b. Pile 2 wheel-installed tires (3) on top of tire
with seat belt pretensioner (6), and tie them
with wire harness (5) as shown.
Wire harness specifications
Stripped wire harness section 1.25 mm2
(0.0019 in.2) or more (Stripped wire harness
diameter 1.25 mm (0.05 in.) or more)
NOTE
Wind wire harness (5) around at least 2 times.

c. Drape blanket (7) over those tires.
11) Connect adapter cable (B) to deployment harness
(A) connector and lock connectors with lock lever.
[A]
10 m (33 ft)
(A)
(B)
1
10 m (33 ft)
(A)
(B)1
5
3
2
4
(A)
[B]
[C]
[D]
[E]
7
3
6
5 (A)(B)
1
10 m (33 ft)
10 m (33 ft) (A)
(B)
1
1
10 m (33 ft)
I5JB0A820102-01

Downloaded from www.Manualslib.com manuals search engine 8B-115 Air Bag System:
5) Check that there is no open, short or damage in
special tools (deployment harness (A), adapter cable
(B), (C) and (D)). If any faulty condition is found, do
not use it and be sure to use new special tool. And
connect adapter cable (B), (C) or (D) to deployment
harness (A) and lock connectors with lock slider.
Special tool
(A): 09932–75031
(B): 09932–78332
(C): 09932–77310
(D): 09932–76510
6) Short two deployment harness leads together by
fully seating one banana plug into the other.
WARNING!
Deployment harness (A) shall remain shorted
and not be connected to 12 volts vehicle
battery until you are ready to deploy air bag
(inflator) module or activate seat belt
pretensioner.

7) Connect adapter cable (B), (C) or (D) in series with
deployment harness (A) to air bag (inflator) module
or seat belt pretensioner as follows.
• For driver air bag (inflator) module [A]
Connect adapter cable (B) in series with
deployment harness (A) and push adapter cable
(B) connector to air bag (inflator) module
connector till click can be heard.
• For passenger air bag (inflator) module [B]
Connect adapter cable (B) in series with
deployment harness (A) and push adapter cable
(B) connector to air bag (inflator) module
connector till click can be heard.
• For side-air bag (inflator) module [C]
Connect adapter cable (B) in series with
deployment harness (A) and push adapter cable
(B) connector to side bag (inflator) module
connector till click can be heard.
• For side curtain-air bag (inflator) module [D]
Connect adapter cable (C) in series with
deployment harness (A) and push adapter cable
(C) connector to air bag (inflator) module
connector till click can be heard.
• For seat belt pretensioners [E]
Connect adapter cable (D) in series with
deployment harness (A) to seat belt pretensioner
and lock connector with lock part.
[C] [B]
[D]
[E] [A]
12
(D)
(A)1
1
(A)
(B)
1 (C)
(A)
1
(B)
(A)
1
(B)
(A)
I5RW0A820088-02

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-120
Special ToolS6RW0D8208002
09932–75010 09932–75031
Air bag load tool Air bag deployment harness
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / )) / ) / )
09932–75041 09932–76010
Passenger air bag (inflator)
module deployment fixtureConnector test adapter set
) / )This set includes the
following items. 1.
Connector test adapter kit
(09932-75020), 2.
Connector test adapter &
shorting bar release tool
(09932-76020) ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) /
) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / )
09932–76510 09932–77310
Deployment adapter cable Deployment adapter cable
4P
) / ) / ))
09932–78310 09932–78332
Adapter cable Deployment adapter cable
) / ) / ) / ) / ) / ) / ) /
))
09932–78340 SUZUKI scan tool
Deployment adapter cable —
) / )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 9A-71 Wiring Systems:
TCM
WHTRED
717C06
124C01 E01145457195526C016513
ECM
WHT
ABS
Cont.M
APP sensor Throttle position sensor
Throttle sensor
SUB
open close open close open close
open close
MAIN SUB MAIN
Throttle
motor
REDBLUGRNBRNWHTYELREDBLKWHTGRNREDYELBLU
E08
3
18
1
12E1911
6C482
156435234
RW
RW
4142405443454434365135375250E01 C01
(CAN)
(CAN)
BLKGRY
GRN/WHTGRN/YELBRN
B
P/S
Cont.M
"F-3"
RED/BLU
GWGY
IG COIL
#2 IG COIL
#1
BW
Heater fan
switch"A-3"
"E-1"
RB
"E-2"
ORNGRY/RED
GRY/REDRED/BLU
EVAP thermistor
1
3G32
8
ORN
WHT/BLKBLU/WHTORN
E382
G334
BW
Auto
Unit
A/C
pressure
sensorE36
C343
E37110
2
3
BLU/WHTORN
915
WHT/BLKBLU/WHT
Auto A/C
Manual A/C
1
8915
3
I6RW0C910944-03

Downloaded from www.Manualslib.com manuals search engine Wiring Systems: 9A-72
A-5 Engine and A/C Control System Circuit Diagram (J20A engine)S6RW0D910E042
YEL/RED
E387
L3711012
L389
R15142
PNKYEL/RED
P
PNKYEL/RED
31
433
31
E371 C343
BLK/ORN
BLK/ORN
BLK/ORN
BLK/ORN
19
8
BLK42
R101
1
And
fuel gauge
Main
relay
1
BLK/WHT
BLK/REDBLU/YEL
C312Weld splice
GRN/WHTBLK/WHT
BLK/WHT
BLK/WHT
IG COILJ/B1
15A
FI
BLK/YEL
E2211
23
415A
20
BRN/WHT
BW
YR
4
20A
A/C
Compressor
relay
E229
Relay
BLU/YEL
BLU/YEL
Compressor
C1411
C312
13
E3255
E371 C343
20
E371
C3434BLK/WHT
C42C40
Heated oxygen
sensor
RED/BLU
BRN
A/F sensor CKP
sensorCondenser
fan motor Condenser
fan relay
BLK
BLK/ORNBLK/ORN
BLK/ORN
RED
C01
1
34 2 143 12
4711393237
WHT
3848PNK
ECM
142
3
WHT
WHT
BLK/RED
BLK/REDBLK/WHT
BLK/RED
BLK/RED
BLK/RED
E01496015291
GRY
E22732
4
1
E23032
4
1
BLK/REDBLK/ORN
24
BLKBLK
58 56
BLK/REDRED
16 48
182419
Individual circuit
fuse box (No.1)
BLKBLKBLK/ORNBLK
93
RED/BLK
M
1
2E70
3651
BLUPNK
RED
Knock
sensor
C371
I6RW0C910942-03