esp SUZUKI SX4 2006 1.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine 1J-2 Charging System:
Care of battery
WARNING!
• Never expose battery to open flame or electric spark because of battery generate gas which is
flammable and explosive.
• Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive
acid. Flush any contacted area with water immediately and thoroughly.
• Batteries should always be kept out of reach of children.

1) The battery is a very reliable component, but needs periodical attentions.
• Keep the battery carrier clean.
• Prevent rust formation on the terminal posts.
• Keep the electrolyte up to the upper level uniformly in all cells.
• When keeping battery on vehicle over a long period of time, follow instructions given below.
– Weekly, start the engine and run it until it reaches normal operating temperature with engine speed of 2000 to
3000 rpm. Make sure all electric switches are off before storing the vehicle.
– Recharge the battery twice a month to prevent it from discharging excessively. This is especially important
when ambient temperature is low.
The battery discharges even when it is not used, while vehicles are being stored. Battery electrolyte can
freeze and battery case can crack at cold ambient condition if battery is not properly charged.
2) Keep the battery cable connections clean.
The cable connections, particularly at the positive (+) terminal post, tend to become corroded. The product of
corrosion, or rust, on the mating faces of conductors resists the flow of current.
Clean the terminals and fittings periodically to ensure good metal-to-metal contact, and grease the connections
after each cleaning to protect them against rusting.
3) Be always in the know as to the state of charge of the battery. The simplest way to tell the state of charge is to
carry out a hydrometer test. The hydrometer is an instrument for measuring the specific gravity (S.G.) of the
battery electrolyte. The S.G. of the electrolyte is indicative of the state of charge. Refer to “Battery Inspection”.

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-8
3) Install bump stopper and strut dust cover onto strut
rod. For installing direction, refer to the figure in
“Front Strut Assembly Components”.
4) Pull strut rod as far up as possible and use care not
to allow it to retract into strut.
5) Install spring seat on coil spring and then spring
upper seat (1) aligning “OUT” mark (3) on spring
upper seat and center of strut bracket (2).
6) Install bearing (3), strut support (2) and strut support
lower nut (1) in this sequence.
Tighten strut support lower nut (1) to specified
torque.
When tightening strut support lower nut, hold stud
with hexagon wrench.
Tightening torque
Strut support lower nut (a): 55 N·m (5.5 kgf-m,
40.0 lb-ft)Front Strut Assembly CheckS6RW0D2206005
• Inspect strut for oil leakage, damage or deformation.
If defect is found, replace strut as an assembly unit,
because it can not be disassembled.
• Inspect strut function referring to the following
procedures:
1) Check and adjust tire pressures as specified.
2) Bounce vehicle body up and down 3 or 4 times
continuously by pushing front end of the vehicle side
body to check strut.
Also, note how many times vehicle body rebounds to
stop after force application.
3) Repeat the same procedure to the other strut to
confirm that the both side struts equally respond.
If conditions of struts are in doubt, compare them with
known-good vehicle or strut.
• Inspect bearing for wear, abnormal noise or gripping.
If defective, replace.
• Inspect coil spring seat for cracks or deformation.
If defective, replace.
• Inspect bump stopper for deterioration.
If defective, replace.
• Inspect rebound stopper and strut mount for wear,
cracks or deformation.
If defective, replace.
I4RS0A220012-01
3
2
1,(a)
I5RW0A220010-02
I4RS0A220014-01

Downloaded from www.Manualslib.com manuals search engine 3-ii Table of Contents
DTC U0100: Lost Communication with ECM .... 3B-27
DTC U0121: Lost Communication with ABS /
ESP® Control Module..................................... 3B-27
DTC U0155: Lost Communication with
Instrument Panel Cluster (IPC) Control
Module ............................................................ 3B-27
Inspection of 4WD Control Module and Its
Circuits ............................................................ 3B-27
Repair Instructions ............................................3B-30
Rear Differential Oil Level Check ...................... 3B-30
Rear Differential Oil Change ............................. 3B-30
2WD/4WD Switch Removal and Installation ..... 3B-31
2WD/4WD Switch Inspection ............................ 3B-31
4WD Control Module Removal and
Installation ....................................................... 3B-31
Coupling Air Temperature Sensor Removal
and Installation ................................................ 3B-31
Coupling Air Temperature Sensor Inspection ... 3B-32
Coupling Assembly Inspection .......................... 3B-32
Rear Differential Mountings Components ......... 3B-33
Front Mounting Arm and/or Rear Mounting
Bracket Assembly Removal and Installation ... 3B-34
Rear Mounting Bracket Assembly
Disassembly and Reassembly ........................ 3B-34
Rear Differential Dismounting and
Remounting ..................................................... 3B-34
Rear Differential Components ........................... 3B-35
Rear Differential Disassembly and
Reassembly .................................................... 3B-36
Rear Differential Inspection ............................... 3B-47
Specifications .....................................................3B-48
Tightening Torque Specifications ...................... 3B-48
Special Tools and Equipment ...........................3B-48
Recommended Service Material ....................... 3B-48
Special Tool ...................................................... 3B-49
Transfer .................................................... 3C-1
General Description ............................................. 3C-1
Transfer Description ............................................ 3C-1Diagnostic Information and Procedures ............3C-1
Transfer Symptom Diagnosis..............................3C-1
Repair Instructions ..............................................3C-2
Transfer Oil Level Check.....................................3C-2
Transfer Oil Change ............................................3C-2
Transfer Dismounting and Remounting ..............3C-3
Transfer Assembly Components .........................3C-4
Transfer Assembly Disassembly and
Reassembly ......................................................3C-5
Reduction Drive Gear Assembly Disassembly
and Reassembly ...............................................3C-7
Reduction Driven Gear Assembly
Disassembly and Reassembly ..........................3C-8
Transfer Right Case and Left Case
Disassembly and Reassembly ..........................3C-9
Transfer Output Retainer Assembly
Disassembly and Reassembly ........................3C-10
Transfer Assembly Inspection ...........................3C-14
Bevel Gear Tooth Contact Inspection ...............3C-14
Specifications .....................................................3C-16
Tightening Torque Specifications ......................3C-16
Special Tools and Equipment ...........................3C-17
Recommended Service Material .......................3C-17
Special Tool ......................................................3C-17
Propeller Shafts ....................................... 3D-1
Precautions ...........................................................3D-1
Propeller Shaft Caution .......................................3D-1
General Description .............................................3D-1
Propeller Shaft Construction ...............................3D-1
Diagnostic Information and Procedures ............3D-1
Propeller Shaft Symptom Diagnosis ...................3D-1
Repair Instructions ..............................................3D-2
Propeller Shaft Joint Check.................................3D-2
Propeller Shaft Assembly Removal and
Installation .........................................................3D-2
Propeller Shaft Inspection ...................................3D-2
Specifications .......................................................3D-3
Tightening Torque Specifications ........................3D-3

Downloaded from www.Manualslib.com manuals search engine 3A-7 Drive Shaft / Axle: Front
Reassembly
For DOJ type
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
after disassembly, prepare replacing parts and proceed
to reassembly.
Make sure that wheel side joint assembly and DOJ
housing are washed thoroughly and air dried.
Replace boot(s) with new one(s).
CAUTION!
• Do not wash boots in degreaser such as
gasoline or kerosene. etc. Washing in
degreaser causes deterioration of boot.
• To ensure full performance of joint as
designed, be sure to distinguish between
two types of grease in repair set and apply
specified volume to respective joint
referring to the followings for identification
of the grease.

1) Wash disassembled parts (except boots). After
washing, dry parts completely by blowing air.
2) Clean boots with cloth.
3) Apply grease to wheel side joint. Use specified
grease in tube in wheel side boot set as a spare
parts.
Grease color
: Black
Amount
: 55 – 75 g (1.9 – 2.6 oz)
4) Install wheel side boot on shaft.
5) Fill up boot inside with specified grease.
6) Fit boot (1) to grooves of shaft and housing (2).
7) Insert screw driver into boot and allow air to enter
boot so that air pressure in boot becomes the same
as atmospheric pressure.
8) Place new wheel side boot big band (3) and small
band (4) onto boot putting band outer end (1) against
forward rotation (2) as shown in figure.9) Fasten boot bands (1) using special tool as shown in
figure.
CAUTION!
Do not squeeze or distort boot when
fastening it with bands.
Distorted boot caused by squeezing air may
reduce its durability.

Distance “a”
: 2.6 ± 1.4 mm (0.102 ± 0.055 in.)
Special tool
(A): 09943–57010
21I5RS0B310007-01
I4RS0A310009-01
(A)
1
(A)
1
“a”
1
I5RS0B310008-01

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For tripod joint type
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
after disassembly, prepare replacing parts and proceed
to reassembly.
Make sure that wheel side joint assembly (1) and tripod
joint housing (2) are washed thoroughly and air dried.
Replace boot(s) (3) with new one(s).
CAUTION!
• Do not wash boots in degreaser such as
gasoline or kerosene. etc. Washing in
degreaser causes deterioration of boot.
• To ensure full performance of joint as
designed, be sure to distinguish between
two types of grease in repair set and apply
specified volume to respective joint
referring to the followings for identification
of the grease.

1) Wash disassembled parts (except boots). After
washing, dry parts completely by blowing air.
2) Clean boots with cloth.
3) Apply grease to wheel side joint. Use specified
grease in tube in wheel side boot set as a spare
parts.
Grease color
: Black
Amount
: 55 – 75 g (1.9 – 2.6 oz)
4) Install wheel side boot on shaft.
5) Fill up boot inside with specified grease.
6) Place new wheel side boot big band (3) and small
band (4) onto boot putting band outer end (1) against
forward rotation (2) as shown in figure.7) Fasten boot bands (1) securely using special tool as
shown in figure.
CAUTION!
Do not squeeze or distort boot when
fastening it with bands.
Distorted boot caused by squeezing air may
reduce its durability.

Distance “a”
: 2.6 ± 1.4 mm (0.102 ± 0.055 in.)
Special tool
(A): 09943–57010
[A]: Wheel side
[B]: Differential side (or center shaft side)
I4RS0A310007-01
I4RS0A310009-01
(A)
1
(A)
1
“a”
1
I5RS0B310008-01

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

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4WD Control System DescriptionS6RW0D3201004
4WD Shift Control
The 4WD control module operates the coupling assembly according to the 2WD/4WD switch operation to the selected
position (2WD, 4WD-auto or 4WD-lock). Also, the 4WD control system has 4WD AUTO indicator and 4WD LOCK
indicator in order to inform the 4WD control system condition.
Indicator Operation
The 4WD control module output operation signal of the 4WD AUTO indicator and the 4WD LOCK indicator. Indicators
as follows in order to inform what state the 4WD control system is.
Function of 4WD Control System ComponentS6RW0D3201005
Operation
Condition
Indicator
4WD AUTO
indicatorOFF• Ignition switch is OFF.
• Vehicle is at “2WD” position or “4WD-lock” position.
ON• Within 2 seconds after ignition switch is turn ON (checking indicator
operation).
• Vehicle is at “4WD-auto” position.
• 4WD control module detects DTC of 4WD control system.
Blinking at intervals of 2
seconds continuously• 4WD control module detects the rotation difference of front wheel and
rear wheel and/or temperature of transfer more than specified
temperature.
4WD LOCK
indicatorOFF• Ignition switch is OFF.
• Vehicle is at “2WD” position or “4WD-auto” position.
ON• Within 2 seconds after ignition switch is turn ON (checking indicator
operation).
• Vehicle is at “4WD-lock” position.
• 4WD control module detects DTC of 4WD control system.
Part Name Function
2WD/4WD switch Output ON and OFF signal of 2WD/4WD switch to 4WD control module.
4WD AUTO indicator Indicates vehicle is at 4WD-auto position or not.
4WD LOCK indicator Indicates vehicle is at 4WD-lock position or not.
4WD control module • Controlled of current to coupling assembly and vehicle switching to each position.
• Diagnosis 4WD control system components.
• Output operation signal of indicator to BCM.
Coupling assembly The driving force of corresponding to the signal from 4WD control module transmitted
to the rear wheel.

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4WD Control System Wiring Circuit DiagramS6RW0D3201006
Terminal Arrangement of 4WD Control ModuleS6RW0D3201007
5V
5V
12V
G26-3
YEL
GRY
G26-2
G26-22G26-23REDWHT
G26-13
G26-14
G26-12
G26-11
G26-10BLK
WHT/RED
RED/BLK
GRY/YEL
RED/WHT
12V
L102-1
L102-4
1
37
9
10
12
13
14
12V
G26-21BLU
G26-25
G26-24ORN
BRN
5V
28
11
WHT
WHT
WHTWHTWHTWHT
WHT
RED
RED
RED
REDRED
RED
RED
46
5
L174-4BLK/ORNL174-5L174-1
I7RW01320001-01
1. Coupling assembly 6. ECM 11. Data link connector (DLC)
2. Coupling air temperature sensor 7. 4WD control module 12. “IG COIL” fuse
3. Combination meter 8. 2WD/4WD switch 13. “4WD” fuse
4. BCM 9. “4WD” switch 14. Main fuse box
5. ABS / ESP® control module 10. “4WD lock” switch
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 25 26
[A]
I4JA01332038-01
[A]: Connector “G26” viewed from harness side
Te r m i n a l C i r c u i t Te r m i n a l C i r c u i t
G26-2 Coupling assembly (power) G26-14 “4WD lock” switch
G26-3 Coupling assembly (ground) G26-21 Data link connector (DLC)
G26-10 Ground G26-22 CAN communication line (high)
G26-11 Power source for internal memory G26-23 CAN communication line (low)
G26-12 Power source G26-24 Coupling air temperature sensor (ground)
G26-13 “4WD” switch G26-25 Coupling air temperature sensor (power)

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-6
Input / Output Signal Table of 4WD Control ModuleS6RW0D3201008
4WD control module outputs the following signals to coupling assembly, indicators, according to the 2WD/4WD switch
operation.
On-Board Diagnostic System DescriptionS6RW0D3201009
For 4WD control system, 4WD control module has the following functions.
• When ignition switch is turned ON with engine at stop, 4WD AUTO indicator (1) and 4WD LOCK indicator (2) turn
on at the same time for 2 seconds in order to check operation of these indicators.
• When 4WD control module detects any malfunction in the following area, 4WD AUTO indicator (1) and 4WD LOCK
indicator (2) flash continuously or turn on and 4WD control module comes into fail-safe mode. For details of fail safe
mode, refer to “Fail-Safe Table”.
– 2WD/4WD switch
– Coupling air temperature sensor
– Coupling assembly
• DTC can be checked by using SUZUKI scan tool (3) connected to DLC (4).
• When 4WD control module detects any malfunction, 4WD control module will switch off the current to coupling
assembly and vehicle is changed to 2WD position.
DLC (Data Link Connector)
Refer to “Data Link Connector (DLC)” under “On-Board Diagnostic System Description in Section 1A”.Output signal (to each component parts)
Coupling
assembly4WD AUTO
indicator4WD LOCK
indicator
Input signal2WD/4WD switch{{{
Coupling air temperature sensor{
ECM{
ABS / ESP® control module{{{
1
2 3
4
I5RW0A320004-01

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