brakes SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine FOREWORD
This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service
operations, replacement of components (Service) and for disassembly and assembly of major components (Unit
Repair-Overhaul).
VOLUME 1 contains General information, Engine, Suspension, Drive/Axle and Brakes sections (Sections 0 – 5).
VOLUME 2 contains Transmission/Transaxle, Steering, HVAC, Restraint, Body/Cab/Accessories and
Control Systems sections (Sections 6 – 10).
Applicable Model:
SX4 (RW415/RW416) produced at KOSAI plant in Japan with following vehicle identification number
(VIN)
The contents are classified into sections each of which is given a section number as indicated in the Table of
Contents on following page. And on the first page of each individual section is an index of that section.
This manual should be kept in a handy place for ready reference of the service work.
Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials as specified in each description.
All information, illustrations and specifications contained in this literature are based on the latest product infor-
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2006JSAGY############ ~
JS2Y#############~

Downloaded from www.Manualslib.com manuals search engine 00
0
1
2
3
4
5
6
7
8
9
10
11
Vo l u m e 1
Precautions............................................................... 00-i
Precautions ............................................................ 00-1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubrication ................................. 0B-1
Engine ......................................................................... 1-i
Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1
Aux. Emission Control Devices .............................. 1B-1
Engine Electrical Devices....................................... 1C-1
Engine Mechanical ................................................. 1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System .......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System....................................................... 1H-1
Starting System ....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System ..................................................... 1K-1
Suspension ................................................................. 2-i
Precautions .............................................................. 2-1
Suspension General Diagnosis .............................. 2A-1
Front Suspension ................................................... 2B-1
Rear Suspension.................................................... 2C-1
Wheels and Tires ................................................... 2D-1
Driveline / Axle ........................................................... 3-i
Precautions .............................................................. 3-1
Drive Shaft / Axle ................................................... 3A-1
Differential .............................................................. 3B-1
Transfer .................................................................. 3C-1
Propeller Shafts...................................................... 3D-1
Brakes ......................................................................... 4-i
Precautions .............................................................. 4-1
Brake Control System and Diagnosis .................... 4A-1
Front Brakes........................................................... 4B-1
Rear Brakes ........................................................... 4C-1
Parking Brake......................................................... 4D-1
ABS ........................................................................ 4E-1
Transmission / Transaxle .......................................... 5-i
Precautions .............................................................. 5-1
Automatic Transmission/Transaxle ........................ 5A-1
Manual Transmission/Transaxle ............................ 5B-1
Clutch ..................................................................... 5C-1
Vo l u m e 2
Precautions ............................................................... 00-i
Precautions ............................................................ 00-1
Steering ....................................................................... 6-i
Precautions .............................................................. 6-1
Steering General Diagnosis ................................... 6A-1
Steering Wheel and Column .................................. 6B-1
Power Assisted Steering System ...........................6C-1
HVAC ........................................................................... 7-i
Precautions .............................................................. 7-1
Heater and Ventilation............................................ 7A-1
Air Conditioning System ......................................... 7B-1
Restraint ...................................................................... 8-i
Precautions .............................................................. 8-1
Seat Belts ............................................................... 8A-1
Air Bag System ...................................................... 8B-1
Body, Cab and Accessories ...................................... 9-i
Precautions .............................................................. 9-1
Wiring Systems ...................................................... 9A-1
Lighting Systems .................................................... 9B-1
Instrumentation / Driver Info. / Horn .......................9C-1
Wipers / Washers ...................................................9D-1
Glass / Windows / Mirrors ...................................... 9E-1
Security and Locks ................................................. 9F-1
Seats ..................................................................... 9G-1
Interior Trim ............................................................9H-1
Hood / Fenders / Doors .......................................... 9J-1
Body Structure ....................................................... 9K-1
Paint / Coatings ...................................................... 9L-1
Exterior Trim .......................................................... 9M-1
Control Systems ....................................................... 10-i
Precautions ............................................................ 10-1
Body Electrical Control System ............................ 10B-1
Immobilizer Control System .................................10C-1
Keyless Start System ........................................... 10E-1
TABLE OF CONTENTS

Downloaded from www.Manualslib.com manuals search engine 0B-11 Maintenance and Lubrication:
HVAC Air Filter (If Equipped) InspectionS6RW0D0206034
Check HVAC air filter for dirt and dust referring to “HVAC
Air Filter Inspection (If Equipped) in Section 7A”. If air
filter is dirty, clean or replace air filter with new one.
HVAC Air Filter (If Equipped) ReplacementS6RW0D0206035
Replace HVAC air filter with new one referring to “HVAC
Air Filter Removal and Installation (If Equipped) in
Section 7A”.
Final Inspection for Maintenance ServiceS6RW0D0206036
WARNING!
When carrying out road tests, select a safe
place where no man or no running vehicle is
seen so as to prevent any accident.

Seats
Check that seat slides smoothly and locks securely at
any position. Also check that reclining mechanism of
front seat back allows it to be locked at any angle.
Seat Belt
Inspect belt system including webbing, buckles, latch
plates, retractors and anchors for damage or wear.
Check that seat belt is securely locked. If “REPLACE
BELT” label on seat belt is visible, replace belt.
Battery Electrolyte Level Check
Check that the electrolyte level of all battery cells is
between the upper and lower level lines on the case. If
battery is equipped with built-in indicator, check battery
condition by the indicator.
Accelerator Pedal Operation
Check that pedal operates smoothly without getting
caught or interfered by any other part.
Engine Start
Check engine start for readiness.
WARNING!
Before performing the following check, be
sure to have enough room around the
vehicle. Then, firmly apply both the parking
brake and the regular brakes. Do not use the
accelerator pedal. If the engine starts, be
ready to turn off the ignition promptly. Take
these precautions because the vehicle could
move without warning and possibly cause
personal injury or property damage.

On automatic transaxle vehicles, try to start the engine in
each select lever position. The starting motor should
crank only in “P” (Park) or “N” (Neutral).
On manual transaxle vehicles, place the shift lever in
“Neutral,” depress clutch pedal fully and try to start.
Exhaust System Check
Check for leakage, cracks or loose supports.
Clutch (for Manual Transaxle)
Check for the following.
• Clutch is completely released when depressing clutch
pedal,
• No slipping clutch occurs when releasing pedal and
accelerating.
• Clutch itself is free from any abnormal condition.
Gearshift or Select Lever
Check gear shift or select lever for smooth shifting to all
positions and for good performance of transaxle in any
position.
With automatic transaxle equipped vehicle, also check
that shift indicator indicates properly according to which
position select lever is shifted to.
With automatic transaxle equipped vehicle, make sure
that vehicle is at complete stop when shifting select lever
to “P” range position and release all brakes.
Brake
Foot brake
Check the following:
• that brake pedal has proper travel,
• that brake works properly,
• that it is free from noise,
• that vehicle does not pull to one side when brake is
applied.
• and that brake do not drag.
Parking brake
Check that lever has proper travel.
WARNING!
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property
damage. Be prepared to apply regular brake
quickly even if vehicle should start to move.

Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and brake
lever is pulled all the way.

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-47
Engine overheatingInoperative thermostat“Thermostat Inspection in Section 1F”
Poor water pump performance“Water Pump Inspection in Section 1F”
Clogged or leaky radiator“Radiator On-Vehicle Inspection and Cleaning
in Section 1F”
Improper engine oil grade“Engine Oil and Filter Change in Section 0B”
Clogged oil filter or oil strainer“Oil Pressure Check in Section 1E”
Poor oil pump performance“Oil Pressure Check in Section 1E”
Faulty radiator cooling fan control
system“Radiator Cooling Fan Control System Check”
Dragging brakesCondition “Dragging brakes” in “Brakes
Symptom Diagnosis in Section 4A”
Slipping clutch (for M/T model)Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis in Section 5C” for M/T
model
Blown cylinder head gasket“Cylinder Head Inspection in Section 1D”
Air mixed in cooling system
Poor gasoline mileageLeaks or loose connection of high-
tension cord“High-Tension Cord Removal and Installation
in Section 1H”
Faulty spark plug (improper gap, heavy
deposits and burned electrodes, etc.)“Spark Plug Inspection in Section 1H”
Malfunctioning EGR valve“EGR Valve Inspection (If Equipped) in Section
1B”
High idle speedCondition “Improper engine idling or engine
fails to idle”
Poor performance of ECT sensor, MAF
sensor“Engine Coolant Temperature (ECT) Sensor
Inspection in Section 1C”, or “Intake Air
Temperature (IAT) Sensor Inspection in
Section 1C”
Faulty electric throttle body assembly“Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly“Accelerator Pedal Position (APP) Sensor
Assembly Inspection in Section 1C”
Faulty fuel injector(s)“Fuel Injector Circuit Check”
Faulty ECM
Low compression“Compression Check in Section 1D”
Poor valve seating“Valves and Valve Guides Inspection in
Section 1D”
Dragging brakesCondition “Dragging brakes” in “Brakes
Symptom Diagnosis in Section 4A”
Slipping clutch (for M/T model)Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis in Section 5C” for M/T
model
Thermostat out of order“Thermostat Inspection in Section 1F”
Improper tire pressure“Tires Description in Section 2D”
Camshaft position control (VVT) system
out of order (for engine with VVT
system)“Oil Control Valve Inspection (For Engine with
VVT) in Section 1D”
Excessive engine oil
consumption – Oil
leakageBlown cylinder head gasket“Cylinder Head Inspection in Section 1D”
Leaky camshaft oil seals“Camshaft, Tappet and Shim Inspection in
Section 1D” Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-49
Excessive detonation –
Engine makes
continuously sharp
metallic knocks that
change with throttle
opening. Sounds like pop
corn popping.Faulty spark plug“Spark Plug Inspection in Section 1H”
Loose connection of high-tension cord“High-Tension Cord Removal and Installation
in Section 1H”
Engine overheatingCondition “Engine overheating”
Clogged fuel filter (faulty fuel pump) or
fuel lines“Fuel Pressure Check” or “Fuel Pump and Its
Circuit Check”
Air drawn in through intake manifold or
throttle body gasket
Malfunctioning EGR valve“EGR Valve Inspection (If Equipped) in Section
1B”
Poor performance of knock sensor, ECT
sensor or MAF sensor“DTC P0327 / P0328: Knock Sensor Circuit
Low / High”, “Engine Coolant Temperature
(ECT) Sensor Inspection in Section 1C” or
“Intake Air Temperature (IAT) Sensor
Inspection in Section 1C”
Faulty fuel injector(s)“Fuel Injector Circuit Check”
Faulty ECM
Excessive combustion chamber
deposits“Cylinders, Pistons and Piston Rings
Inspection in Section 1D” and/or “Piston Pins
and Connecting Rods Inspection in Section
1D”
Camshaft position control (VVT) system
out of order (for engine with VVT
system)“Oil Control Valve Inspection (For Engine with
VVT) in Section 1D”
Engine has no powerFaulty spark plug“Spark Plug Inspection in Section 1H”
Faulty ignition coil with ignitor“Ignition Coil Assembly (Including Ignitor)
Inspection in Section 1H”
Leaks, loose connection or
disconnection of high-tension cord“High-Tension Cord Removal and Installation
in Section 1H”
Faulty knock sensor“DTC P0327 / P0328: Knock Sensor Circuit
Low / High”
Clogged fuel hose or pipe“Fuel Pressure Check”
Malfunctioning fuel pump“Fuel Pump and Its Circuit Check”
Air drawn in through intake manifold
gasket or throttle body gasket
Engine overheatingCondition “Engine overheating”
Malfunctioning EGR valve“EGR Valve Inspection (If Equipped) in Section
1B”
Poor performance of ECT sensor or
MAF sensor“Engine Coolant Temperature (ECT) Sensor
Inspection in Section 1C” or “Intake Air
Temperature (IAT) Sensor Inspection in
Section 1C”
Faulty electric throttle body assembly“Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly“Accelerator Pedal Position (APP) Sensor
Assembly Inspection in Section 1C”
Faulty fuel injector(s)“Fuel Injector Circuit Check”
Faulty ECM
Dragging brakesCondition “Dragging brakes” in “Brakes
Symptom Diagnosis in Section 4A”
Slipping clutch (for M/T model)Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis in Section 5C” (for M/T
model)
Low compression“Compression Check in Section 1D”
Camshaft position control (VVT) system
out of order (for engine with VVT
system)“Oil Control Valve Inspection (For Engine with
VVT) in Section 1D” Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 1F-3 Engine Cooling System:
Diagnostic Information and Procedures
Engine Cooling Symptom DiagnosisS6RW0D1604001
Condition Possible cause Correction / Reference Item
Engine overheats
(Radiator fan operates)Loose or broken water pump beltAdjust or replace.
Not enough coolantCheck coolant level and add as necessary.
Faulty thermostatReplace.
Faulty water pumpReplace.
Dirty or bent radiator finsClean or remedy.
Coolant leakage on cooling systemRepair.
Clogged radiatorCheck and replace radiator as necessary.
Faulty radiator capReplace.
Dragging brakesAdjust brake.
Slipping clutchReplace.
Poor charge batteryCheck and replace as necessary.
Poor generation generatorCheck and repair.
ECT sensor faultyCheck and replace as necessary.
Radiator fan motor faultyCheck and replace as necessary.
ECM faultyCheck and replace as necessary.
Wiring or grounding faultyRepair as necessary.
Equipped with too much electric load
part(s)Dismount.
Engine overheats
(Radiator fan does not
operate)Fuse blownCheck fuse of relay/fuse box and check for
short circuit to ground.
Radiator cooling fan relay faultyCheck and replace as necessary.
ECT sensor faultyCheck and replace as necessary.
Radiator cooling fan motor faultyCheck and replace as necessary.
Wiring or grounding faultyRepair as necessary.
ECM faultyCheck and replace as necessary.

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 Precautions: 4-1
Brakes
Precautions
Precautions
Precautions for BrakesS6RW0D4000001
Suspension Caution
Refer to “Suspension Caution in Section 00”.
Wheels and Tires Caution
Refer to “Wheels and Tires Caution in Section 00”.
Brake Caution
Refer to “Brake Caution in Section 00”.
General Precautions
Refer to “General Precautions in Section 00”.
Vehicle Lifting Points
Refer to “Vehicle Lifting Points in Section 0A”.
Fastener Caution
Refer to “Fastener Caution in Section 00”.
Fastener Information
Refer to “Fasteners Information in Section 0A”.
Precaution on CAN Troubleshooting
Refer to “Precaution on CAN Troubleshooting in Section 1A”.

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-4
Rear Brake Hose / Pipe ConstructionS6RW0D4101003
Diagnostic Information and Procedures
Brakes Diagnosis NoteS6RW0D4104001
Road Testing Brakes
Brakes should be tested on dry, clean, smooth and
reasonably level roadway which is not crowned. Road
test brakes by making brake applications with both light
and heavy pedal forces at various speeds to determine if
the vehicle stops evenly and effectively. Also drive
vehicle to see if it leads to one side or the other without
brake application. If it does, check the tire pressure, front
wheel alignment and front suspension attachments for
looseness. See diagnosis table for other causes.
Brake Fluid Leaks
Check the master cylinder fluid levels. While a slight
drop in reservoir level does result from normal lining
wear, an abnormally low level indicates a leak in the
system. In such a case, check the entire brake system
for leakage. If even a slight evidence of leakage is noted,
the cause should be corrected or defective parts should
be replaced.Substandard or Contaminated Brake Fluid
Improper brake fluid, mineral oil or water in the fluid may
cause the brake fluid to boil or the rubber components
(piston cups and brake hoses) in the hydraulic system to
deteriorate.
If the above fluid is included in the system, replace the
master cylinder assembly and other rubber components
(hoses). The master cylinder assembly is disassemble
parts to maintain the performance.
The system must be flushed if there is any doubt as to
the grade of fluid in the system or if fluid has been used
which contained parts that have been subjected to
contaminated fluid.
I6RW0D410001-01
1. To left rear brake hose 5. Left rear brake hose to left brake
2. To right rear brake hose 6. Right rear brake hose to right brake
3. Left rear brake hose : 16 N⋅m (1.6 kgf-m, 12.0 lb-ft)
4. Right rear brake hose