torque SUZUKI SX4 2006 1.G Service Workshop Manual

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

Downloaded from www.Manualslib.com manuals search engine 4A-5 Brake Control System and Diagnosis:
Brakes Symptom DiagnosisS6RW0D4104002
Condition Possible cause Correction / Reference Item
Not enough braking forceBrake oil leakage from brake linesLocate leaking point and repair.
Brake disc or pad stained with oilClean or replace.
Overheated brakesDetermine cause and repair.
Poor contact of shoes on brake drumRepair for proper contact.
Brake shoe stained with oil or wet with
waterReplace.
Badly worn brake padReplace.
Defective wheel cylindersRepair or replace.
Malfunctioning caliper assemblyRepair or replace.
Malfunctioning brake boosterCheck system and replace as necessary.
Malfunctioning brake master cylinderCheck system and replace as necessary.
Air in systemBleed system.
Malfunctioning ABSCheck system and replace as necessary.
Brake pull (Brakes not
working in unison)Pad, disc, shoe and/or drum are wet
with water or stained with oil in some
brakesClean or replace.
Drum-to-shoe clearance out of
adjustment in some brakes
(Malfunctioning auto adjusting
mechanism) Check for inoperative auto adjusting
mechanism.
Disc and/or drum are out of round in
some brakesReplace.
Tires are inflated unequallyInflate equally.
Malfunction in wheel cylinders (rear
drum brake model)Repair or replace.
Disturbed front wheel alignmentAdjust as prescribed.
Unmatched tires on same axleTires with approximately the same amount of
tread should be used on the same axle.
Restricted brake pipes or hosesCheck for soft hoses and damaged lines.
Replace with new hoses and new double-
walled steel brake tubing.
Malfunctioning caliper assemblyCheck for stuck or sluggish pistons and proper
lubrication of caliper slide pin.
Caliper should slide.
Loose suspension partsCheck all suspension mountings.
Loose calipersCheck and torque bolts to specifications.
Noise (high pitched
squeak without brake
applied)Contact wear indicator to brake discReplace brake pad.
Worn rear brake shoeReplace brake shoe.
Excessive pedal travel
(Pedal stroke too large)Partial brake system failureCheck brake systems and repair as necessary.
Brake fluid leakingRepair the leaking point, and bleed air.
Air in system (soft / spongy pedal)Bleed system.
Rear brake system not adjusted
(malfunctioning auto adjusting
mechanism)Repair auto adjusting mechanism.
Adjust rear brakes.
Bent brake shoesReplace brake shoes.
Brake locked Malfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.

Downloaded from www.Manualslib.com manuals search engine 4A-9 Brake Control System and Diagnosis:
1) Fill master cylinder reservoir with specified brake
fluid and keep at least one-half full of fluid during
bleeding operation.
Brake fluid
: Refer to reservoir cap
2) Remove bleeder plug cap. Attach a vinyl tube to
bleeder plug, and insert the other end into container.
3) Depress brake pedal several times, and then while
holding it depressed, loosen bleeder plug about one-
third to one-half turn.
4) When fluid pressure in cylinder is almost depleted,
retighten bleeder plug.
5) Repeat this operation until there are no more air
bubbles in hydraulic line.
6) When bubbles stop, depress and hold brake pedal
and tighten bleeder plug.
Tightening torque
Front brake caliper bleeder plug: 9 N·m (0.9 kgf-
m, 6.5 lb-ft)
Rear wheel cylinder bleeder plug: 8 N·m (0.8
kgf-m, 6.0 lb-ft)
7) Then attach bleeder plug cap.
8) After completing bleeding operation, apply fluid
pressure to pipe line and check for leakage.
9) Replenish fluid into reservoir up to specified level
referring to “Brake Fluid Level Inspection”.
10) Check brake pedal for sponginess. If found spongy,
repeat entire procedure of bleeding.
Front Brake Hose / Pipe Removal and
Installation
S6RW0D4106007
CAUTION!
Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid, flush it with water immediately
if any fluid is spilled.

Removal
1) Raise and support vehicle properly. Remove tire and
wheel.
NOTE
This operation is not necessary when
removing pipes connecting master cylinder.

2) Clean dirt and foreign material from both flexible
hose end and pipe end fittings.
3) Drain brake fluid in reservoir.
4) Remove brake flexible hose or pipe.
Installation
Reverse brake flexible hose removal procedure, noting
the following.
• Make sure that steering wheel is in straight-forward
position and flexible hose has not twist or kink.
• Install clamps and tighten nuts referring to “Front
Brake Hose / Pipe Construction”.
• Install brake flexible hose (1) to caliper as shown in
figure.
Tightening torque
Flexible hose joint bolt (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
I2RH01410016-01
I2RH01410017-01

Downloaded from www.Manualslib.com manuals search engine 4A-13 Brake Control System and Diagnosis:
3) Drain brake fluid in reservoir.
4) Disconnect clutch reservoir hose from reservoir (M/T
model).
5) Disconnect brake pipes (1) connected to master
cylinder.
6) Remove master cylinder fixing nuts (2).
7) Remove master cylinder (3) and O-ring.
Installation
1) Install new O-ring (2) to master cylinder assembly
(1).
2) Apply grease to piston rod “A”.
Use specified grease in spare to master cylinder or
brake booster as supply parts.
3) Install master cylinder assembly (1) to brake booster
(3) and tighten master cylinder fixing nuts to
specified torque.
Tightening torque
Master cylinder fixing nut (a): 18 N·m (1.8 kgf-
m, 13.0 lb-ft)4) Connect brake pipe to master cylinder and tighten
flare nuts to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft)
5) Connect clutch reservoir hose to reservoir and install
reservoir hose clamp (M/T model).
6) Connect fluid level switch connector and clamp.
7) Fill reservoir with specified brake fluid up to its MAX
level.
8) After completing the work, bleed air from brake and
clutch system referring to “Air Bleeding of Brake
System” and bleed air from clutch system referring to
“Air Bleeding of Clutch System in Section 5C” (M/T
model).
9) Check each installed parts for fluid leakage.
10) Check brake pedal for play referring to “Brake Pedal
Play Inspection”.
11) Perform brake test and check fluid leakage.
Master Cylinder InspectionS6RW0D4106013
• Depress brake pedal a few times and retain brake
pedal. If pedal gone down, replace the brake master
cylinder assembly.
• Check master cylinder for leakage, corrosion and
smooth operation.
• Inspect distance “a” to be the following.
If measurement is out of specification, replace master
cylinder assembly.
Distance
“a”: 72.0 mm (2.83 in.) or more
2
1
3I7RW01410012-01
(a)3
2
1
"A"
I7RW01410019-01
(a)I7RW01410013-01
I7RW01410014-01

Downloaded from www.Manualslib.com manuals search engine 4A-15 Brake Control System and Diagnosis:
2) Hold brake pedal depressed for 30 seconds. If pedal
height does not change, condition is good. But it isn’t
if pedal rises.
Brake Booster Removal and InstallationS6RW0D4106015
Removal
1) Remove master cylinder assembly from booster
referring to “Master Cylinder Removal and
Installation”.
2) Disconnect vacuum hose from booster referring to
“Master Cylinder and Brake Booster Components”.
3) Remove front brake pipe (from master cylinder
primary and secondary to ABS hydraulic unit pipe)
referring to “Front Brake Hose / Pipe Removal and
Installation”.
4) Remove clip (1) and then remove push rod clevis pin
(2).
5) Loosen booster mounting nuts (3) and then remove
booster.Installation
1) Install booster to dash panel. Then connect push rod
clevis pin (2) and clip (1).
2) Tighten booster mounting nuts (3) to specified
torque.
Tightening torque
Booster mounting nut (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft)
3) Connect vacuum hose to booster referring to
“Master Cylinder and Brake Booster Components”.
4) Install front brake pipe (from master cylinder primary
and secondary to ABS hydraulic unit pipe) referring
to “Front Brake Hose / Pipe Removal and
Installation”.
5) Install master cylinder assembly to booster referring
to “Master Cylinder Removal and Installation”.
6) Fill reservoir with specified fluid.
7) Bleed air from brake system referring to “Air
Bleeding of Brake System” and at the same time
bleed air from clutch system referring to “Air
Bleeding of Clutch System in Section 5C” (M/T
model).
8) Check pedal height and play referring to “Brake
Pedal Free Height Inspection” and “Brake Pedal
Play Inspection”.
9) Check each installed part for fluid leakage and
perform brake test.
Brake Booster InspectionS6RW0D4106016
• Check brake booster for damage and operation.
• Check boot for damage and deterioration.
• Check for push clevis rod distance.
If any malfunction is found, replace brake booster.
H: Hold
T: 30 seconds
I2RH01410010-01
3
3 1 2
I5RW0A410019-02
3,(a)
3,(a) 1 2
I5RW0A410021-02

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-16
Booster Push Clevis Rod AdjustmentS6RW0D4106017
Install push clevis rod (1) so that measurement “a” is
obtained and torque nut (2) to specification.
Tightening torque
Clevis pin lock nut (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft)
Clevis installing position (length “a”)
“a”: 129.5 - 130.5 mm (5.10 - 5.13 in.)
Specifications
Tightening Torque SpecificationsS6RW0D4107001
NOTE
The specified tightening torque is also described in the following.
“Front Brake Hose / Pipe Construction”
“Rear Brake Hose / Pipe Construction”
“Brake Pedal Components”
“Master Cylinder and Brake Booster 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 MaterialS6RW0D4108001
NOTE
Required service material is also described in the following.
“Master Cylinder and Brake Booster Components”

Special ToolS6RW0D4108002
IYSQ01410050-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Front brake caliper bleeder plug 9 0.9 6.5)
Rear wheel cylinder bleeder plug 8 0.8 6.0)
Flexible hose joint bolt 23 2.3 17.0)
Master cylinder fixing nut 18 1.8 13.0)
Brake pipe flare nut 16 1.6 11.5)
Booster mounting nut 13 1.3 9.5)
Clevis pin lock nut 26 2.6 19.0)
09916–44310
Valve guide remover (5 mm)
) / )