ECU SUZUKI SX4 2006 1.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: Front 3A-12
15) Fasten differential side (or center shaft side) boot big
band (1) and small band (5) by drawing hooks (2)
with special tool and engage hooks (3) in slot and
window (4).
Special tool
(A): 09943–57021Center Shaft and Center Bearing Support
Disassembly and Reassembly (If Equipped)
S6RW0D3116005
Disassembly
1) Using hydraulic press (1), draw out center shaft (2)
from center bearing.
2) Remove oil seals from center bearing support (3).
3) Remove bearing support circlip (1) using snap ring
pliers (2).
4) Remove center bearing from center bearing support.
Reassembly
Install center shaft by reversing removal procedure and
noting the following points.
• When installing bearing support circlip (1), make sure
that if fits in circlip groove in center bearing support (2)
securely as shown.
(A)
1
4
2
3
(A)
5
4
2
3
I4RS0B310008-02
I3RM0A310012-01
I7RW01311005-01
2
1
I5RW0A311006-01

Downloaded from www.Manualslib.com manuals search engine 3A-15 Drive Shaft / Axle: Rear
Rear
General Description
Rear Drive Shaft ConstructionS6RW0D3121001
Refer to “Front Drive Shaft Construction”.
Repair Instructions
Rear Drive Shaft ComponentsS6RW0D3126001
I5RW0A312001-01
1. Differential side joint (Constant velocity DOJ joint)
: Apply dark gray grease included in spare part to
joint.6. Wheel side joint (Constant velocity ball joint)
: Apply black grease included in spare part to
joint.11. Boot (wheel side)
2. Snap ring 7. Cage : 175 N⋅m (17.5 kgf-m, 126.5 lb-ft)
3. Boot band (Large) 8. Drive shaft nut
: After tightening nut, caulk nut securely.: 80 N⋅m (8.0 kgf-m, 58.0 lb-ft)
4. Boot (Differential side) 9. Rear drive shaft flange nut : Do not reuse.
5. Boot band (Small) 10. Circrip

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 Transfer: 3C-4
• Pour transaxle oil and transfer oil referring to “Manual
Transaxle Oil Change in Section 5B” and “Transfer Oil
Change”.
Transfer Assembly ComponentsS6RW0D3306004
1
2
6
9
1110
8
7
3A
4
5
36
OIL
(a) 5
(a)
OIL
28
18
30
27
25
21
28
13
12
22OIL
OIL
32A
31A
1322(d)
34A
33
23A
2019
(c)1217G
291217G
(b)
35
15A
26
26 14
24
17
161217G(b)
A
I5RW0A330007-05
1. Transfer output flange nut
: After tightening nut so as rotational torque
of bevel pinion to be in specified value,
caulk nut securely.15. Dowel pin 29. Transfer right case
: Apply sealant 99000-31260 to
mating surface with right case.
2. Transfer output flange 16. Oil drain plug
: Apply sealant 99000-31260 to thread
part.30. Oil level / filler plug
: Apply sealant 99000-31260 to
thread part.
3. Oil seal
: Apply grease 99000-25010 to oil seal lip.17. Transfer left case
: Apply grease 99000-25010 to left case.31. Left case oil seal No.1
: Apply grease 99000-25010 to oil
seal lip.
4. Pinion shaft rear taper roller bearing 18. Transfer case bolt 32. Left case oil seal No.2
: Apply grease 99000-25010 to oil
seal lip.
5. Transfer output retainer bolt 19. Reduction drive gear left bearing 33. Right case oil seal No.3
: Apply grease 99000-25010 to oil
seal lip.
6. O-ring
: Apply grease 99000-25010 to all around
surface.20. Reduction drive gear 34. Right case oil seal No.2
: Apply grease 99000-25010 to oil
seal lip.
7. Shim 21. Reduction driven gear left taper roller
bearing35. Right case oil seal No.1
: Apply grease 99000-25010 to oil
seal lip.
8. Spacer 22. Reduction driven gear right taper roller
bearing36. Transfer output retainer

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-6
Dragging brakes (Without
a very light drag is
present in all brakes
immediately after pedal is
released)Master cylinder pistons not returning
correctlyReplace master cylinder.
Restricted brake pipes or hosesCheck for soft hoses or damaged pipes and
replace with new hoses and/or new brake
piping.
Incorrect parking brake adjustment on
rear brakesCheck and adjust to correct specifications.
Weakened or broken return springs in
the drum brakeReplace.
Sluggish parking brake cables or linkageRepair or replace.
Wheel cylinder or caliper piston stickingRepair as necessary.
Badly worn piston seal in caliperReplace piston seal.
Improper brake pedal free heightCheck brake pedal free height.
Pedal pulsation (Pedal
pulsates when depressed
for braking)Damaged wheel bearingsReplace wheel bearings.
Distorted steering knuckle or rear wheel
spindle or rear axle shaftReplace knuckle or rear wheel spindle or rear
axle shaft.
Excessive disc lateral runoutCheck per instructions. If not within
specifications, replace or machine disc.
Rear drums out of roundCheck runout.
Repair or replace drum as necessary.
Braking noiseGlazed brake pad and/or brake shoeRepair or replace brake pad and/or brake
shoe.
Worn or distorted brake shoeReplace brake shoe.
Loose front wheel bearingsReplace wheel hub.
Distorted backing plates or loose
mounting boltsReplace or retighten securing bolts.
Contact wear indicator to brake discReplace brake pads.
Brake warning light lights
after engine startParking brake appliedRelease parking brake and check that brake
warning light turns off.
Insufficient amount of brake fluidInvestigate leaky point, correct it and add
brake fluid.
Brake fluid leakingInvestigate leaky point, correct it and add
brake fluid.
Brake warning light circuit faultyRepair circuit.
Malfunctioning EBD systemCheck system referring to “EBD Warning Light
(Brake Warning Light) Comes ON Steady in
Section 4E”.
Brake warning light turns
on when brake is appliedBrake fluid leakingInvestigate leaky point, correct it and add
brake fluid.
Insufficient amount of brake fluidInvestigate leaky point, correct it and add
brake fluid.
Brake warning light fails
to turn on even when
parking brake is appliedBrake warning light circuit faultyReplace bulb or repair circuit.
ABS warning light turns
on after engine startMalfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light turns
on when brake is appliedMalfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light after
ignition switch has turned
ON Bulb burnt outReplace bulb.
Malfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light flashesNew ABS hydraulic unit / control module
assembly installed.Perform “ABS Hydraulic Unit Operation Check
in Section 4E”. Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 4B-3 Front Brakes:
3) Install caliper and tighten caliper pin bolts to
specified torque.
Tightening torque
Caliper pin bolt (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft)
4) Install front wheel referring to “Wheel (with Tire)
Removal and Installation in Section 2D”.
5) Check brake effectiveness.
Front Disc Brake Pad InspectionS6RW0D4206004
Check pad lining for wear. When the wear exceeds limit,
replace with new one.
CAUTION!
Never polish pad lining with sandpaper. If
lining is polished with sandpaper, hard
particles of sandpaper will be deposited in
lining and may damage disc. When pad lining
requires correction, replace it with a new one.

Front disc brake pad thickness (lining thickness)
Standard: 10 mm (0.39 in.)
Limit: 10 mm (0.39 in.)
NOTE
When pads are removed, visually inspect
caliper for brake fluid leak. Correct leaky
point, if any.

Front Disc Brake Caliper Removal and
Installation
S6RW0D4206005
Removal
1) Hoist vehicle and remove front wheel.
2) Remove brake flexible hose joint bolt (1) from caliper
(2). As this will allow fluid to flow out of hose (3),
have a container ready beforehand.
3) Remove caliper pin bolts (1).
4) Remove caliper from caliper carrier.
Installation
1) Install caliper to caliper carrier.
2) Torque caliper pin bolts to specification.
NOTE
Make sure that boots are fit into groove
securely.

Tightening torque
Caliper pin bolt (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft)
(a)
I7RW01420005-02
I2RH01420005-01
I7RW01420006-01
1
I7RW01420003-01
(a)
I7RW01420005-02

Downloaded from www.Manualslib.com manuals search engine 4B-5 Front Brakes:
Assembly
Assemble parts in reverse order of disassembly,
observing the following instructions.
CAUTION!
• Wash each part cleanly before installation
in the same fluid as the one used in master
cylinder reservoir.
• Never use other fluid or thinner.
• Before installing piston seal and cylinder
boot to cylinder, apply rubber grease
included in piston seal set or brake fluid to
them.
• Install a new piston seal into groove in
cylinder securely making sure that it is not
twisted.
• After reassembling brake lines, bleed air
from them.

Before installing caliper to carrier, install slide pins with
rubber grease included in slide pin / boot set applied into
caliper carrier hole and check for its smooth movement
in thrust direction.
• Install piston seal, boot and piston to caliper referring
to the following instructions.
1) Replace with a new piston seal (1) at every overhaul.
After applying rubber grease included in piston seal
set or brake fluid, fit piston seal (1) into groove in
cylinder taking care not to twist it.2) Before inserting piston (1) into cylinder, apply rubber
grease included in piston seal set or brake fluid to
new boot (a) and install it onto piston as shown.
3) Fit boot as it is in figure into boot groove in cylinder
with fingers.
4) Insert piston into cylinder by hand and fit boot in boot
groove in piston.
NOTE
Check that boot is fitted in boot groove
securely all around piston and cylinder.

IYSQ01420021-01
1
I2RH01420017-01
A: 1 grooved side directed cylinder side
B: 2 grooved side directed pad side
I4RS0B420015-01
I2RH01420019-01
I2RH01420020-01

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-8
Component Location
ABS Components LocationS6RW0D4503001
Diagnostic Information and Procedures
ABS CheckS6RW0D4504001
Refer to the following items for the details of each step.
1
2
6
2
6
26
264
5
7
3
8
I5RW0A450006-02
1. ABS hydraulic unit / control module assembly 5. EBD warning light (Brake warning light)
2. Wheel speed sensors 6. Wheel speed sensor encoder (included in wheel hub assembly)
3. Brake light switch 7. Data link connector
4. ABS warning light 8. G sensor (4WD model)
Step Action Yes No
1) Malfunction analysis
1) Perform “Customer complaint analysis: ”.
2) Perform “Problem symptom confirmation: ”.
3) Perform “DTC check, record and clearance: ” and
recheck DTC.
Is there any malfunction DTC?Go to Step 4. Go to Step 2.
2) Driving test
1) Perform “Step 2: Driving Test: ”.
Is trouble symptom identified?Go to Step 3. Go to Step 6.
3) DTC check
1) Perform “DTC Check”.
Is it malfunction code?Go to Step 4. Go to Step 5.
4) ABS check
1) Inspect and repair referring to applicable DTC flow.
Does trouble recur?Go to Step 5. Go to Step 7.
5) Brakes diagnosis
1) Inspect and repair referring to “Brakes Symptom
Diagnosis in Section 4A”.
Does trouble recur?Go to Step 3. Go to Step 7.

Downloaded from www.Manualslib.com manuals search engine 4E-9 ABS:
Step 1: Malfunction Analysis
Customer complaint analysis
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a questionnaire form as shown in the following will facilitate collecting information to the
point required for proper analysis and diagnosis.
Customer questionnaire (Example) 6) Check for intermittent problem
1) Check intermittent troubles referring to “Intermittent and
Poor Connection Inspection in Section 00” and related
circuit of trouble code recorded in Step 1.
Does trouble recur?Go to Step 4. Go to Step 7.
7) Final confirmation test
1) Perform “Step 7: Final Confirmation Test: ”.
Does trouble recur?Go to Step 3. End. Step Action Yes No
I2RH01450014-01

Downloaded from www.Manualslib.com manuals search engine 4E-21 ABS:
DTC C1015: G Sensor Circuit (4WD Model)S6RW0D4504013
Wiring Diagram
Refer to “Wiring Diagram” under “DTC C1013: Control Module Mismatch”.
DTC Detecting Condition and Trouble Area
NOTE
When a vehicle is lifted up and its wheel(s) is turned, this DTC is set.
In such case, clear the DTC and check again.

Troubleshooting DTC Detecting Condition Trouble Area
• G sensor signal voltage is out of specified range.
• Vehicle behavior and G sensor signal is disagreed.• G sensor
• G sensor circuit
• ABS control module
Step Action Yes No
1Was “ABS Check” performed?Go to Step 2. Go to “ABS Check”.
2Is G sensor installed its bracket securely?Go to Step 3. Tighten G sensor bolt
and recheck.
3G sensor check
1) Disconnect G sensor connector and ABS hydraulic unit /
control module connector with ignition switch turned
OFF.
2) Check for proper connection to G sensor connector and
ABS hydraulic unit / control module terminals of “E08-3”
and “E08-6”.
3) If OK then check G sensor referring to “G Sensor
Inspection (4WD Model)”.
Is it in good condition?Go to Step 4. Replace G sensor.
4G sensor power source voltage check
1) Turn ignition switch to ON position and measure voltage
between “GRN/ORN terminal of G sensor connector and
vehicle body ground.
Is it 10 – 14 V?Go to Step 5. “GRN/ORN” circuit
open.
5G sensor signal circuit and ground circuit check
1) Measure resistance between following terminals.
• Between “E08-3” terminal and “GRN/BLK” terminal of
G sensor.
• Between “E08-6” terminal and “GRN/YEL” terminal of
G sensor.
Is each resistance less than 2
Ω?Go to Step 6. “GRN/BLK” and/or
“GRN/YEL” wire circuits
in open or high
resistance.
6G sensor ground circuit check
1) Connect ABS hydraulic unit / control module connector
with ignition switch turned OFF.
2) Turn ignition switch to ON position and measure voltage
between “GRN/BLK” terminal of G sensor connector and
vehicle body ground.
Is it 0 V?Substitute a known-
good ABS hydraulic unit
/ control module
assembly and recheck.“GRN/BLK” circuit to
power circuit.