change wheel SUZUKI SX4 2006 1.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-2
General Description
Rear Differential DescriptionS6RW0D3201001
The differential assembly uses a hypoid bevel pinion and gear.
The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine parts and
specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between hypoid bevel
pinion and gear, it is mandatory to lubricate them by hypoid gear oil.
Coupling DescriptionS6RW0D3201002
Coupling is installed in the forward of Rear differential. The road situation and driving are judged with 4WD control
module based on information from sensor and each control module, and the distribution of driving force of the front
and rear wheel has been changed by controlling the current to coupling. Coupling air temperature sensor is installed in
coupling case and measures the temperature in coupling.
4WD system has three driving positions (2WD, 4WD-auto, 4WD-lock). The position corresponding to the running
situation can be selected by 2WD/4WD switch.
1
2
3
4567810 9
I5RW0A320001-01
1. Companion flange 5. Drive bevel pinion (hypoid gear) 9. Differential pinion
2. Coupling case 6. Differential case 10. Drive bevel gear (hypoid gear)
3. Coupling assembly 7. Differential cover
4. Differential carrier 8. Differential side gear

Downloaded from www.Manualslib.com manuals search engine 3B-7 Differential:
CAN Communication System DescriptionS6RW0D3201010
Refer to “CAN Communication System Description in Section 1A” for CAN communication system description.
When 4WD control module receive the signal of abnormal as following information, vehicle is not changed to 4WD-
auto and 4WD-lock position.
4WD Control Module Transmission Data
4WD Control Module Reception Data
ECMCombination
Meter
TransmitDATA 4WD
4WD mode status
4WD auto mode
indication status
4WD lock mode
indication status
4WD diagnostic
trouble codes control
module
4WD clutch
engagement percent
ESP® hydraulic unit /
control module
(if equipped)
4WD clutch control
request impossibility
I7RW01320013-01
Accelerator position
Engine speedECM
DATA
Brake pedal switch signal
4WD
control
moduleWheel speed signal
(front right)
Wheel speed signal
(front left)
Wheel speed signal
(rear right)
Wheel speed signal
(rear left)

ABS hydraulic
unit /control
module
(if equipped)


ESP® hydraulic
unit /control
module
(if equipped)
ABS active
ESP® status signal
Clutch control request for
4WD active
Clutch control request
percent
Engine type signal
Engine torque signal
Receive
I7RW01320002-03

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-14
Rear Differential Symptom DiagnosisS6RW0D3204011
4WD Control Symptom DiagnosisS6RW0D3204012
Diagnose 4WD system after performing the following inspections.
• Perform 4WD control system check referring to “4WD Control System Check”. Condition Possible cause Correction / Reference Item
Gear noiseDeteriorated or water mixed lubricantRepair and replenish referring to “Rear
Differential Oil Change”.
Inadequate or insufficient lubricantRepair and replenish referring to “Rear
Differential Oil Change”.
Maladjusted backlash between drive
bevel pinion and gearAdjust as prescribed referring to “Rear
Differential Disassembly and Reassembly”.
Improper tooth contact in the mesh
between drive bevel pinion and gearAdjust or replace referring to “Rear Differential
Disassembly and Reassembly”.
Loose drive bevel gear securing boltsReplace or retighten referring to “Rear
Differential Disassembly and Reassembly”.
Damaged differential gear(s) or
differential pinion(s)Replace referring to “Rear Differential
Inspection”.
Bearing noise(Constant noise) Deteriorated or water
mixed lubricantRepair and replenish referring to “Rear
Differential Oil Change”.
(Constant noise) Inadequate or
insufficient lubricantRepair and replenish referring to “Rear
Differential Oil Change”.
(Noise while coasting) Damaged
bearing(s) of drive bevel pinionReplace referring to “Rear Differential
Inspection”.
(Noise while turning) Damaged
differential side bearing(s) or axle
bearing(s)Replace referring to “Rear Differential
Inspection”.
Oil leakageClogged breather plugClean.
Worn or damaged oil sealReplace.
Excessive oilAdjust oil level referring to “Rear Differential Oil
Change”.
Loose differential carrier boltsReplace or retighten.
Condition Possible cause Correction / Reference Item
4WD system does not
operate2WD/4WD switch faultyCheck switch referring to “2WD/4WD Switch
Inspection”.
Coupling air temperature sensor faultyCheck coupling air temperature sensor
referring to “Coupling Air Temperature Sensor
Inspection”.
Coupling assembly faultyCheck coupling assembly referring to
“Coupling Assembly Inspection”.
Wiring or grounding faultyRepair as necessary.
4WD control module faultyCheck 4WD control module referring to
“Inspection of 4WD Control Module and Its
Circuits”.
MAF sensor faultyCheck MAF sensor and its circuit.
Accelerator pedal position (APP) sensor
faultyCheck accelerator pedal position (APP) sensor
and its circuit.
CKP sensor faultyCheck CKP sensor and its circuit.
Front and/or rear wheel speed sensor
faultyCheck front and/or rear wheel speed sensor
and its circuit.
Steering angle sensor faultyCheck steering angle sensor and its circuit.
ABS / ESP® control module faultyCheck ABS / ESP
® control module and its
circuit.
ECM faultyCheck ECM and its circuit.
NoiseDamaged or worn bearing(s)Refer to “Rear Differential Inspection”.

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-2
General Description
ABS DescriptionS6RW0D4501001
The ABS (Antilock Brake System) controls the fluid
pressure applied to the wheel cylinder of each brake
from the master cylinder so that each wheel is not locked
even when hard braking is applied.
This ABS has also the following function.
While braking is applied, but before ABS control
becomes effective, braking force is distributed between
the front and rear so as to prevent the rear wheels from
being locked too early for better stability of the vehicle.
The main component parts of this ABS include the
following parts in addition to those of the conventional
brake system.
• Wheel speed sensor which senses revolution speed
of each wheel and outputs its signal.
Rear wheel speed sensor of 4WD vehicle is
integrated in rear wheel hub assembly and supplied
as rear wheel hub assembly part.
Front wheel speed sensor and rear wheel speed
sensor of 2WD model are separated from wheel hub
assembly and supplied as spare parts.
• ABS warning light which lights to inform abnormality
when system fails to operate properly.• ABS hydraulic unit / control module assembly is
incorporated ABS control module, ABS hydraulic unit
(actuator assembly), solenoid valve power supply
driver (transistor), solenoid valve driver (transistor),
pump motor driver (transistor).
– ABS control module which sends operation signal
to ABS hydraulic unit to control fluid pressure
applied to each wheel cylinder based on signal
from each wheel speed sensor so as to prevent
wheel from locking.
– ABS hydraulic unit which operates according to
signal from ABS control module to control fluid
pressure applied to wheel cylinder of each 4
wheels.
– Solenoid valve power supply driver (transistor)
which supplies power to solenoid valve in ABS
hydraulic unit.
– Solenoid valve driver (transistor) which controls
each solenoid valves in ABS hydraulic unit.
– Pump motor driver (transistor) which supplies
power to pump motor in ABS hydraulic unit.
• G sensor which detects body deceleration speed for
4WD model.
This ABS is equipped with Electronic Brake force
Distribution (EBD) system that controls a fluid pressure
of rear wheels to best condition, which is the same
function as that of proportioning valve, by the signal from
wheel sensor independently of change of load due to
load capacity and so on. And if the EBD system fails to
operate properly, the brake warning light lights to inform
abnormality.

Downloaded from www.Manualslib.com manuals search engine 4E-35 ABS:
5) Measure voltage at resistance without wheel
rotation.If voltage is out of specification, check
sensor, mating encoder and their installation
conditions.
Voltage at the resistance (115
Ω) without wheel
rotation
680 – 960 mV
6) Measure voltage at resistance with wheel rotation
and confirm voltage alternately changes between
high and low voltages.If voltage does not change
with wheel rotation, check sensor, mating encoder
and their installation conditions.
Voltage at the resistance (115
Ω) with wheel
rotation
High voltage “a”: 1360 – 1930 mV
Low voltage “b”: 680 – 960 mV
Reference
When using oscilloscope for this check, check if peak-to-
peak voltage and waveform meet specification.
Peak-to-peak voltage at the resistance (115
Ω) with
wheel rotation
High voltage “a”: 1360 to 1930 mV
Low voltage “b”: 680 to 960 mV
Front Wheel Speed Sensor Removal and
Installation
S6RW0D4506006
CAUTION!
• Do not pull wire harness when removing
and installing front wheel speed sensor.
• Do not cause damage to surface of front
wheel speed sensor and do not allow dust,
etc. to enter its installation hole.

Removal
1) Disconnect negative (–) cable from battery.
2) Disconnect front wheel speed sensor connector (1).
3) Hoist vehicle and remove wheel.
4) Remove harness clamp, clamp bolt (2).
5) Remove front wheel speed sensor (3) from knuckle.
[A]: Voltage [B]: Time
I5JB0A450027-01
I5JB0A450028-02
3
1
2
I5RW0A450023-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 5-iii
Diagnostic Information and Procedures ............ 5B-5
Manual Transaxle Symptom Diagnosis............... 5B-5
Repair Instructions .............................................. 5B-5
Manual Transaxle Oil Level Check ..................... 5B-5
Manual Transaxle Oil Change ............................ 5B-6
Differential Side Oil Seal Replacement ............... 5B-7
Gear Shift Control Lever and Cable
Components...................................................... 5B-8
Gear Shift Control Lever and Cable Removal
and Installation .................................................. 5B-9
Gear Select Control Cable Adjustment ............... 5B-9
Back Up Light Switch Removal and
Installation ....................................................... 5B-10
Back Up Light Switch Inspection ....................... 5B-10
Manual Transaxle Unit Components ................. 5B-11
Manual Transaxle Unit Dismounting and
Remounting..................................................... 5B-12
Gear Shift and Select Shaft Assembly
Components.................................................... 5B-13
Gear Shift and Select Shaft Assembly
Removal and Installation................................. 5B-14
Gear Shift and Select Shaft Assembly
Disassembly and Reassembly ........................ 5B-15
Manual Transaxle Assembly Components........ 5B-16
Fifth Gear Disassembly and Reassembly ......... 5B-17
Manual Transaxle Assembly Disassembly
and Reassembly ............................................. 5B-19
Right Case Disassembly and Reassembly ....... 5B-24
Left Case Disassembly and Reassembly.......... 5B-25
Input Shaft and Countershaft Components....... 5B-27
Input Shaft Disassembly and Reassembly........ 5B-28
Countershaft Disassembly and Reassembly .... 5B-31
Gear Shift Shaft Components ........................... 5B-35
5th and Reverse Gear Shift Shafts
Disassembly and Reassembly ........................ 5B-35
Gear Shift Shaft and Fork Inspection ................ 5B-35
Differential Components ................................... 5B-36Differential Disassembly and Reassembly ........ 5B-36
Specifications .....................................................5B-38
Tightening Torque Specifications ...................... 5B-38
Special Tools and Equipment ...........................5B-39
Recommended Service Material ....................... 5B-39
Special Tool ...................................................... 5B-39
Clutch ....................................................... 5C-1
General Description .............................................5C-1
Clutch (Hydraulic Type) Construction .................5C-1
Diagnostic Information and Procedures ............5C-2
Clutch System Symptom Diagnosis ....................5C-2
Repair Instructions ..............................................5C-3
Clutch Pedal Inspection ......................................5C-3
Clutch Fluid Level Inspection ..............................5C-3
Air Bleeding of Clutch System.............................5C-3
Clutch Fluid Pipe and Hose Location ..................5C-4
Clutch Fluid Pipe Removal and Installation.........5C-4
Clutch Fluid Pipe Inspection................................5C-4
Clutch Master Cylinder Removal and
Installation .........................................................5C-5
Clutch Operating Cylinder Assembly
Removal and Installation ...................................5C-5
Clutch Operating Cylinder Assembly
Inspection ..........................................................5C-6
Clutch Cover, Clutch Disc and Flywheel
Components ......................................................5C-6
Clutch Cover, Clutch Disc and Flywheel
Removal and Installation ...................................5C-7
Clutch Cover, Clutch Disc and Flywheel
Inspection ..........................................................5C-8
Specifications .......................................................5C-9
Tightening Torque Specifications ........................5C-9
Special Tools and Equipment ...........................5C-10
Recommended Service Material .......................5C-10
Special Tool ......................................................5C-10

Downloaded from www.Manualslib.com manuals search engine 5A-18 Automatic Transmission/Transaxle:
Step 2. DTC / Freeze Frame Data Check, Record and
Clearance
First, referring to “DTC Check”, check DTC and pending
DTC. If DTC exists, print or write down DTC and freeze
frame data and then clear malfunction DTC(s) by
referring to “DTC Clearance”. Malfunction DTC indicates
malfunction in the system but it is not possible to know
from it whether the malfunction is occurring now or it
occurred in the past and normal condition has been
restored. In order to know that, check symptom in
question according to Step 5 and then recheck DTC
according to Step 6.
Diagnosing a trouble based on the DTC in this step only
or failure to clear the DTC in this step may result in an
faulty diagnosis, trouble diagnosis of a normal circuit or
difficulty in troubleshooting which is otherwise
unnecessary.
Step 3 and 4. Visual Inspection
As a preliminary step, be sure to perform visual check of
the items that support proper function of the engine and
automatic transaxle referring to “Visual Inspection”.
Step 5. Trouble Symptom Confirmation
Check trouble symptoms based on information obtained
in “Step 1. Customer Complaint Analysis: ” and “Step 2.
DTC / Freeze Frame Data Check, Record and
Clearance: ”.
Also, reconfirm DTC according to “DTC Confirmation
Procedure” described in each DTC flow.
Step 6 and 7. Rechecking and Record of DTC and
Freeze Frame Data
Refer to “DTC Check” for checking procedure.Step 8. A/T Basic Check and A/T Symptom
Diagnosis
Perform basic check of A/T according to “A/T Basic
Check” first. When the end of the flow has been reached,
check the parts of the system suspected as a possible
cause referring to “A/T Symptom Diagnosis” and based
on symptoms appearing on the vehicle (symptoms
obtained through steps of customer complaint analysis,
trouble symptom confirmation and/or A/T basic check)
and repair or replace faulty parts, if any.
Step 9. Troubleshooting for DTC
Based on the DTC indicated in Step 6 / 7 and referring to
“applicable DTC flow”, locate the cause of the trouble,
namely in a sensor, switch, wire harness, connector,
actuator, TCM or other part and repair or replace faulty
parts.
Step 10. Check for Intermittent Problem
Check parts where an intermittent trouble is easy to
occur (e.g. wire harness, connector, etc.), referring to
“Intermittent and Poor Connection Inspection in Section
00” and related circuit of DTC recorded in Step 2.
Step 11. Final Confirmation Test
Confirm that the problem symptom has gone and the
vehicle is free from any abnormal conditions. If what has
been repaired is related to the malfunction DTC, clear
the DTC once and check to ensure that no malfunction
DTC is indicated.
Visual InspectionS6RW0D5104002
Visually check the following parts and systems.
Inspection item Referring
• A/T fluid ----- level, leakage, color “Automatic Transaxle Fluid Level Inspection in
Section 0B”
• A/T fluid hoses ----- disconnection, looseness, deterioration “A/T Fluid Cooler Hoses Replacement”
• Throttle cable (if equipped) ----- play (under warm engine),
installation
• A/T select cable ----- installation “Select Cable Removal and Installation”
• Engine oil ----- level, leakage “Engine Oil and Filter Change in Section 0B”
• Engine coolant ----- level, leakage “Engine Coolant Change in Section 0B”
• Engine mountings ----- play, looseness, damage “Engine Assembly Removal and Installation in
Section 1D”
• Suspension ----- play, looseness “Suspension, Wheels and Tires Symptom
Diagnosis in Section 2A”
• Drive shafts ----- damage “Front Drive Shaft Assembly On-Vehicle Inspection
in Section 3A”
• Battery ----- indicator condition, corrosion of terminal “Battery Inspection in Section 1J”
• Connectors of electric wire harness ----- disconnection, friction “Electronic Shift Control System Components
Location”
• Fuses ----- burning
• Parts ----- installation, damage
• Bolts ----- looseness
• Other parts that can be checked visually