brake SUZUKI SX4 2006 1.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine 0A-5 General Information:
Vehicle Lifting PointsS6RW0D0101005
WARNING!
• Before applying hoist to underbody, always take vehicle balance throughout service into
consideration. Vehicle balance on hoist may change depending on what part to be removed.
• Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe,
fuel pipe, bracket or any other part.
• When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up
the vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by
trying to move vehicle body in both ways. Work can be started only after this confirmation.
• Make absolutely sure to lock hoist after vehicle is hoisted up.

When Using Frame Contact Hoist
When Using Floor Jack
WARNING!
If the vehicle to be jacked up only at the front
or rear end, be sure to block the wheels on
ground in order to ensure safety.
After the vehicle is jacked up, be sure to
support it on stands. It is extremely
dangerous to do any work on the vehicle
raised on jack alone.

CAUTION!
Never apply jack against rear suspension
parts (i.e., torsion beam, etc.) or vehicle floor,
or it may get deformed.

1
:2
:3
4
c
5
I5RW0A010001-02
1. Vehicle front3. Floor jack position 5. Cap
2. Support position for frame contact hoist and safety stand 4. Body mounting stay

Downloaded from www.Manualslib.com manuals search engine 0B-1 Maintenance and Lubrication:
General Information
Maintenance and Lubrication
Precautions
Precautions for Maintenance and LubricationS6RW0D0200001
Air Bag Warning
Refer to “Air Bag Warning in Section 00”.
Scheduled Maintenance
Maintenance Schedule under Normal Driving ConditionsS6RW0D0205001
NOTE
• This interval should be judged by odometer reading or months, whichever comes first.
• This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km
(54,000 miles), carry out the same services at the same intervals respectively.

IntervalKm (x 1,000) 15 30 45 60 75 90
Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
Engine
Accessory drive belt (I: ), R: ))——I——R
Valve lash (clearance) (I: ))—I—I—I
Engine oil and oil filter (R: )) RRRRRR
Engine coolant (R: ))——R——R
Exhaust system (I: ))—I—I—I
Ignition system
Spark plugs (R: ))When unleaded fuel is usedNickel Plug — — R — — R
Iridium Plug
(Highly recommended)Replace every 105,000 km (63,000
miles) or 84 months
When leaded fuel is used, refer to “Maintenance Recommended under Severe Driving
Conditions”.
Fuel system
Air cleaner filter (R: ), I: ))Paved-road I I R I I R
Dusty conditionsRefer to “Maintenance Recommended
under Severe Driving Conditions”.
Fuel lines and connections (I: ))—I—I—I
Fuel filter (see NOTE below) (R: ))Replace every 105,000 km (63,000
miles)
Fuel tank (I: ))——I——I
Emission control system
PCV valve (I: )) ————— I
Fuel evaporative emission control system (I: )) ————— I
Brake
Brake discs and pads (thickness, wear, damage) (I: )) IIIIII
Brake drums and shoes (wear, damage) (I: ))—I—I—I
Brake hoses and pipes (leakage, damage, clamp) (I: ))—I—I—I
Brake fluid (R: ))—R—R—R
Brake lever and cable (damage, stroke, operation) (I: ))Inspect at first 15,000 km (9,000 miles
only)
Chassis and body
Clutch (fluid leakage, level) (I: ))—I—I—I
Tires (wear, damage, rotation) / wheels (damage) (I: ) / )) IIIIII
Suspension system (tightness, damage, rattle, breakage) (I: ))—I—I—I
Steering system (tightness, damage, breakage, rattle) (I: ))—I—I—I
Drive shaft (axle) boots / Propeller shaft (4WD) (I: )) (I: ))——I——I
Manual transaxle oil (leakage, level) (I: ) 1st 15,000 km only) (R: ))I—R——R

Downloaded from www.Manualslib.com manuals search engine 0B-7 Maintenance and Lubrication:
Brake Discs and Pads (Front) InspectionS6RW0D0206014
1) Remove wheel and caliper but don’t disconnect
brake hose from caliper.
2) Check front disc brake pads and discs for excessive
wear, damage and deflection. Replace parts as
necessary. For details, refer to “Front Disc Brake
Pad Inspection in Section 4B” and “Front Brake Disc
Inspection in Section 4B”.
Be sure to torque caliper pin bolts to specification.
Brake Drums and Shoes (Rear) InspectionS6RW0D0206015
1) Remove wheel and brake drum.
2) Check rear brake drums and brake linings for
excessive wear and damage, while wheels and
drums are removed. At the same time, check wheel
cylinders for leaks. Replace these parts as
necessary.
For details, refer to “Rear Brake Drum and Shoe
Inspection in Section 4C”.
Brake Hoses and Pipes InspectionS6RW0D0206016
Perform this inspection where these is enough light and
use a mirror as necessary.
• Check brake hoses and pipes for proper hookup,
leaks, cracks, chafing and other damage.
• Check that hoses and pipes are clear of sharp edges
and moving parts.
Repair or replace any of these parts as necessary.
CAUTION!
After replacing any brake pipe or hose, be
sure to carry out air purge operation.

Brake Fluid ReplacementS6RW0D0206017
Change brake fluid as follows.
Drain existing fluid from brake system completely, fill
system with specified fluid and carry out air purge
operation.
For air purging procedure, refer to “Air Bleeding of Brake
System in Section 4A”.
Brake Lever and Cable InspectionS6RW0D0206018
1) Inspect brake cable for damage and smooth
movement.
Replace cable if it is in deteriorated condition.
I3RM0A020006-01
I5RW0A020004-01
I4RS0A020008-01
I4RS0A020009-01

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-8
2) Check tooth tip of each notch for damage or wear. If
any damage or wear is found, replace parking lever.
3) Check parking brake lever for proper operation and
stroke, and adjust it if necessary.
For checking and adjusting procedures, refer to
“Parking Brake Inspection and Adjustment in Section
4D”.
Parking brake lever stroke
“a”: 4 – 9 notches (with 200 N (20 kg, 44 lbs) of pull
pressure)
Clutch Fluid InspectionS6RW0D0206019
1) Check clutch system for evidence of fluid leakage.
Repair leaky point if any.
2) Check reservoir for fluid level referring to “Clutch
Fluid Level Inspection in Section 5C”.
If fluid is lower than minimum level (1) of reservoir,
refill reservoir with specified brake fluid indicated on
reservoir cap (2).
Tires InspectionS6RW0D0206020
1) Check tires for uneven or excessive wear, or
damage. If defective, replace.
Refer to “Irregular and/or Premature Wear
Description in Section 2D” and “Wear Indicators
Description in Section 2D” for details.
2) Check inflating pressure of each tire and adjust
pressure to specification as necessary.
NOTE
• Tire inflation pressure should be checked
when tires are cool.
• Specified tire inflation pressure should be
found on tire placard or in owner’s manual
which came with the vehicle.

3) Rotate tires. For details, refer to “Tire Rotation in
Section 2D”.
Wheel Discs InspectionS6RW0D0206021
Inspect each wheel disc for dents, distortion and cracks.
A disc in badly damaged condition must be replaced.
Wheel Bearing InspectionS6RW0D0206022
1) Check front wheel bearing for wear, damage,
abnormal noise or rattles. For details, refer to “Front
Wheel Hub, Disc, Bolt and Bearing Check in Section
2B”.
2) Check rear wheel bearing for wear, damage,
abnormal noise or rattles. For details, refer to “Rear
Wheel Disc, Bolt and Bearing Inspection in Section
2C”.
I4RS0B020005-01
1
2
I5RW0A020005-01
1. Wear indicator
I2RH01020022-01
I2RH01020023-01

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 Maintenance and Lubrication: 0B-12
Steering
• Check to ensure that steering wheel is free from
instability, or abnormally heavy feeling.
• Check that the vehicle does not wander or pull to one
side.
Engine
• Check that engine responds readily at all speeds.
• Check that engine is free from abnormal noise and
abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting system
are free from abnormal noise and abnormal vibration or
any other abnormal condition.Meters and Gauge
Check that speedometer, odometer, fuel meter,
temperature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan
switch lever to highest position for this check.
Specifications
Tightening Torque SpecificationsS6RW0D0207001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Fluids and LubricantsS6RW0D0208001
Special ToolS6RW0D0208002
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Engine oil drain plug 35 3.5 25.5)
Oil filter 14 1.4 10.5 for reference )
Engine oil SG, SH, SJ, SL or SM grade (Refer to “Engine Oil and Filter Change” for engine
oil viscosity.)
Engine coolant
(Ethylene glycol base coolant)“Antifreeze/Anticorrosion coolant”
Brake fluid Refer to reservoir cap of brake master cylinder.
Manual transaxle oil Refer to “Manual Transaxle Oil Change in Section 5B”.
Automatic transaxle fluid Refer to “A/T Fluid Change in Section 5A”.
Transfer oil (4WD) Refer to “Transfer Oil Change in Section 3C”.
Rear differential (4WD) Refer to “Rear Differential Oil Change in Section 3B”.
Door hinges Engine oil or water resistance chassis grease
Hood latch assembly Engine oil or water resistance chassis grease
Key lock cylinder Spray lubricant
09915–47331
Oil filter wrench
)

Downloaded from www.Manualslib.com manuals search engine 1A-10 Engine General Information and Diagnosis:
ECM Transmission Data
ECM Reception Data
BCM TCMCombination
Meter
DATA ECM Transmit
Brake pedal switch signal
Vehicle speed signal
Engine speed signal
Engine torque signal
Accelerator pedal position signal
4WD Control
ModuleKeyless Start
Control
Module
A/C refrigerant pressure
signal
A/C compressor clutch signal
Engine type signal
Immobilizer indicator light control
signal
MIL control signal
Engine coolant temperature signal
Fuel level signal
Fuel consumption signal
Throttle position signal
Driving cycle active
Warm up cycle active
Odometer signal
I6RW0D110003-02
DATA ECM Receive
ABS control
module
Transmission oil temperature signal
Transmission warning light signal Vehicle speed pulse signal A/T selector lever position signal
Transmission actual gear position signal
Wheel speed signal (front right)
Wheel speed signal (front left)
ABS indication signal
A/C switch ON signal
Electric load signalBCM
4WD mode status
Torque request signalTCM
MIL control signal4WD control
module
I6RW0D110013-02

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-13
Engine and Emission Control System Flow Diagram
Intake manifoldExhaust
manifold
Exhaust gas Air
Fuel Vapor
War m up
catalystExhaust
pipe
EVAP canister
purge valve
Fuel injector
ECT
sensor
ECM
Heater
control
Heater
control
(if equipped)
Barometric pressure sensor HO2S-1HO2S-2
(if equipped) Engine
CMP
sensorCKP
sensor
Knock
sensorIgnition
coil with
igniter
APP sensor
A/C compressor
clutch
Generator
Immobilizer
coil antenna
P/S control
module
Brake light
switch
Air cleaner
IAT
sensorMAF
sensor
A/C refrigerant
pressure sensor
TP
sensor Throttle body
assembly
Throttle
actuator
A/C condenser
fan
DLC
Radiator
fan
Combination meter
· MIL
· Coolant Temp.
· Immobilizer indicator light
· Tachometer
· Speedometer
· Fuel level
· Odometer4WD
control module
Wheel speed
sensor (VSS)
(M/T)
· Electric load
· A/C switch ON
BCM
Keyless start
control module
ABS control module
Blower speed
selector
MAP sensor
(if equipped)EGR valve
(if equipped)
Check
valve
EVAP
canister
Fuel level sensorFuel tankFuel
pump
CMP actuator
oil control valve
(VVT model)
TCM
Output shaft speed
(VSS) sensor (A/T)
Three way
catalyst (if
equipped)
I6RW0D110004-03

Downloaded from www.Manualslib.com manuals search engine 1A-14 Engine General Information and Diagnosis:
ECM Input / Output Circuit Diagram
51 50
+B
54
IG1+BB
ST64
65
67
BLK/WHTWHT/RED
BRN/WHTBLK/RED
BLK/RED
57
: 71
: 72 : 5V : 12V68 IG1
BLK
WHT
GRY
YEL/GRNWHT
66
58
61
62
63 55
70
60 59
53
WHT
4+B
5
PNK
RED/YEL
BLK/ORN
C01-20
C01-21
8RED62C01-56
13WHT/BLKE01-57
ORNE01-54
21
23WHTRED
WHTRED
22
E01-3E01-18
C01-13C01-12
YEL/RED 24E01-24
YEL/BLK
YEL/RED 25E01-28E01-13
E01-30
E01-16
E01-60E01-1
E01-29
GRN/WHTE01-20
C01-48
E01-2
GRN/YEL47
48
GRN/WHTC01-5
C01-6
44
45RED/BLKE01-58
42
43GRY46E01-47
40LT GRN41BLU/REDE01-46
38
39
PNKBLKGRN/WHTE01-15
GRN/REDGRN/WHT37YELREDC01-59C01-60
35BLU/BLKC01-29
31
32
33
34BLU/YELBLU/WHT
BLU/REDBLU/ORNC01-17C01-16
C01-1C01-2
BLK/ORNBLKC01-30
C01-58C01-15
E01-31BLKBLK
49RED/BLU
BRNE01-4
E01-26 9
GRY
BLK/YELGRY/BLU
GRN/BLKC01-26C01-27
C01-25 +B
IG16
7WHT
BRNRED/BLU
BLK/WHT
3 3
ORN
BLK/RED
C01-57
C01-10
C01-11
C01-46
C01-47
GRY/REDC01-14
11LT GRNGRY/BLUGRY/BLU12RED/BLU
C01-55
E01-55
C01-24
10
RED/BLKGRY/BLUC01-53
IG2
IG2
69RED/WHTC01-52
26
RED
BRNGRN
BLU
GRN
WHTBLK
28
30 2927
3YEL
GRYC01-41C01-42C01-40
C01-43C01-44
C01-45
E01-45E01-32
C01-54
BRN/YELWHT/RED
GRN/REDGRN/ORN
C01-18C01-1936C01-3C01-4
56
1
52
IG2+BB
BLU/WHT
BLU/WHT
14
15
17
16
E01-19
E01-19
18
19
BRNGRNBLU
REDYELWHT
E01-353
BLK
E01-37E01-52
E01-34E01-36E01-51
E01-50
2
20BLU/YELC01-28
I6RW0D110005-03
1. ECM 25. Immobilizer coil antenna 49. P/S control module
2. APP sensor assembly 26. Throttle actuator control relay 50. Brake light
3. Shield wire 27. “THR MOT” fuse 51. Brake light switch
4. CMP sensor 28. Electric throttle body assembly 52. To ABS control module
5. CKP sensor 29. Throttle actuator 53. “STOP” fuse
6. HO2S-1 30. TP sensor 54. Main relay

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-17
Connector: E01
Terminal Wire color Circuit Terminal Wire color Circuit
1 BLK/RED Main power supply 31 BLK Ground for ECM
2WHT/REDPower source for ECM internal
memory32 GRNPower supply of throttle
actuator drive circuit.
3REDCAN communication line (active
high signal) to ABS control
module assembly33 — —
4BRNEngine revolution signal output
for EPS control module34 REDOutput for 5 V power source of
APP sensor (sub)
5— — 35BRNOutput for 5 V power source of
APP sensor (main)
6 — — 36 YEL APP sensor (sub) signal
7 — — 37 GRN APP sensor (main) signal
8— — 38— —
9— — 39— —
10 — — 40 — —
11 — — 4 1 — —
12 — — 42 — —
13 YEL/REDClock signal for immobilizer coil
antenna43 — —
14 — — 44 — —
15 GRN/WHT Fuel pump relay output 45 BRNThrottle actuator control relay
output
16 BLK/RED Main power supply 46 LT GRNRadiator cooling fan relay
output
17 — — 47 GRYA/C compressor relay output
(if equipped with A/C)
18 WHTCAN communication line (active
low signal) to ABS control
module assembly48 — —
19 BLU/WHTElectric load signal for heater
blower motor49 — —
20 GRN/WHT Brake light switch signal 50 BLKGround for shield wire of APP
sensor
21 — — 51 WHTGround for APP sensor (sub)
signal
22 — — 52 BLUGround for APP sensor (main)
signal
23 — — 53 — —
24 YEL/RED Fuel level sensor signal 54 ORN Ground for sensors
25 — — 55 RED/BLUA/C refrigerant pressure
sensor signal
(if equipped with A/C)
26 RED/BLU EPS signal 56 WHT/GRN —
27 — — 57 WHT/BLKA/C evaporator outlet air temp.
sensor signal
(if equipped with A/C)
28 YEL/BLKSerial communication line for
immobilizer coil antenna58 RED/BLK —
29 BLK/WHT Ignition switch signal 59 — —
30 WHTStarting motor control relay
output60 BRN/WHT Main power supply relay output