service SUZUKI SX4 2006 1.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 1J-12 Charging System:
4) Check slip rings for roughness or scoring. If rough or
scored, replace the rotor.
Using a vernier caliper, measure the slip ring
diameter. If the diameter is less than minimum,
replace the rotor.
Slip ring diameter
Standard: 14.2 – 14.4 mm (0.560 – 0.566 in.)
Limit: 12.8 mm (0.503 in.)
Stator
1) Using an ohmmeter, check all leads for continuity. If
there is no continuity, replace the stator.
2) Using an ohmmeter, check that there is no continuity
between coil leads and stator core. If there is
continuity, replace the stator.
Brush and Brush Holder
Check each brush for wear by measuring its length as
shown. If the brush is found worn down to service limit,
replace the brush.
Exposed brush length “a”
Standard: 10.5 mm (0.41 in.)
Limit: 1.5 mm (0.05 in.)Rectifier
1) Using an ohmmeter, connect one tester probe to the
“B” terminal (1) and the other to each rectifier
terminal (2).
2) Reverse the polarity of the tester probes and repeat
Step 1).
3) Check that one shows continuity and the other
shows no continuity.
If there is continuity, replace the rectifier.
4) Using an ohmmeter, connect one tester probe to
each negative terminal (1) and the other to each
rectifier terminal (2).
5) Reverse the polarity of the tester probes and repeat
Step 4).
6) Check that one shows continuity and the other
shows no continuity.
If there is continuity, replace the rectifier.
IYSQ011A0044-01
I2RH011A0014-01
I2RH011A0015-01
IYSQ011A0047-01
I1JA011A0002-01
I2RH011A0017-01

Downloaded from www.Manualslib.com manuals search engine 1K-1 Exhaust System:
Engine
Exhaust System
General Description
Exhaust System DescriptionS6RW0D1B01001
The exhaust system consists of an exhaust manifold, three-way catalytic converter (TWC) in catalyst case, exhaust
pipes, a muffler and seals, gasket and etc.
The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of
Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
Diagnostic Information and Procedures
Exhaust System CheckS6RW0D1B04001
WARNING!
To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any
service on the exhaust system should be performed when the system is cool.

At every interval of periodic maintenance service, and when vehicle is raised for other service, check exhaust system
as follows:
• Check rubber mountings for damage, deterioration, and out of position.
• Check exhaust system for leakage, loose connection, dent and damage.
• If bolts or nuts are loosened, tighten them to specified torque referring to “Exhaust System Components”.
• Check nearby body areas damaged, missing, or mispositioned part, open seam, hole connection or any other
defect which could permit exhaust fumes to seep into vehicle.
• Make sure that exhaust system components have enough clearance from underbody to avoid overheating and
possible damage to vehicle underbody.
• Any defect should be fixed at once.
IYSY011B0003-01

Downloaded from www.Manualslib.com manuals search engine Exhaust System: 1K-2
Repair Instructions
Exhaust System ComponentsS6RW0D1B06001
WARNING!
To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any
service on the exhaust system should be performed when the system is cool.

[A]
1
2
3
4
56
7
8
9
10
11
12
12
26
12
12
141515
16
26 12
17
18
18
19
19
20
21
23
22
24
25
(a)(c)
(c)
(d)
(e)
(b)
(a)
(b)(b)
(c)
(c)
(b)
(b)
14(b)
15(b)13
(e)
13
I5RW0C1B0001-01
[A]: Installing location of exhaust manifold bolt and nut. 11. Muffler 22. Exhaust pipe clamp bolt
1. Exhaust manifold gasket 12. Mounting No.1 23. Engine hook
2. Exhaust manifold 13. Heat insulator nut 24. HO2S-1 (connector color: black)
3. Exhaust manifold stiffener 14. Exhaust manifold bolt 25. Heat insulator
4. HO2S-2 (connector color: green) 15. Exhaust manifold nut 26. Mounting No.2
5. Exhaust pipe No.1 gasket 16. Exhaust No.1 pipe bolt : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft)
6. No.1 seal ring 17. Exhaust manifold stiffener bolt : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft)
7. No.2 seal ring 18. Exhaust No.2 pipe bolt : 43 N⋅m (4.3 kgf-m, 31.0 lb-ft)
8. Exhaust No.1 pipe 19. Exhaust center pipe bolt : 29 N⋅m (2.9 kgf-m, 21.0 lb-ft)
9. Exhaust No.2 pipe 20. Exhaust pipe No.2 gasket : 2 N⋅m (0.2 kgf-m, 1.5 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 1K-3 Exhaust System:
Exhaust Manifold Removal and InstallationS6RW0D1B06002
Removal
WARNING!
To avoid danger of being burned, do not
service exhaust system while it is still hot.
Service should be performed after system
cools down.

1) Disconnect negative cable at battery.
2) Disconnect HO2S-1 connector (1) (connector color:
black) and HO2S-2 connector (2) (connector color:
green), and then detach it from its stay.
3) Remove exhaust manifold stiffener (1).
4) Remove HO2S-2 (3) from exhaust manifold and
exhaust No.1 pipe, if necessary.
5) Disconnect exhaust No.1 pipe (2) from exhaust
manifold.6) Remove exhaust manifold (1) and its gasket from
cylinder head.
Installation
1) Install new gasket to cylinder head. Then install
exhaust manifold.
Tighten manifold bolts (1) and nuts (2) to specified
torque.
Tightening torque
Exhaust manifold bolt (a): 50 N·m (5.0 kgf-m,
36.5 lb-ft)
Exhaust manifold nut (b): 50 N·m (5.0 kgf-m,
36.5 lb-ft)
NOTE
Be sure to install exhaust manifold bolts and
nuts to proper location as shown in figure.

10. Exhaust center pipe 21. Exhaust pipe clamp : Do not reuse.
2
1
I5RW0C1B0002-01
2 3
1
I5RW0A1B0003-01
1
I5RW0A1B0004-01
1,(a)2,(b)2,(b)
I5RW0A1B0005-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 2- i
2
Section 2
CONTENTS
Suspension
Precautions ................................................. 2-1
Precautions............................................................. 2-1
Precautions on Suspension .................................. 2-1
Suspension General Diagnosis.............. 2A-1
Diagnostic Information and Procedures ............ 2A-1
Suspension, Wheels and Tires Symptom
Diagnosis .......................................................... 2A-1
Specifications....................................................... 2A-3
Wheel Alignment Specifications .......................... 2A-3
Front Suspension .................................... 2B-1
General Description ............................................. 2B-1
Front Suspension Construction ........................... 2B-1
Front Wheel Alignment Construction .................. 2B-2
Repair Instructions .............................................. 2B-2
Front Wheel Alignment Inspection and
Adjustment ........................................................ 2B-2
Front Strut Assembly Components ..................... 2B-4
Front Strut Assembly Removal and
Installation ......................................................... 2B-5
Front Strut Assembly Disassembly and
Reassembly ...................................................... 2B-7
Front Strut Assembly Check ............................... 2B-8
Front Wheel Hub and Steering Knuckle
Components...................................................... 2B-9
Front Wheel Hub, Steering Knuckle and
Wheel Bearing Removal and Installation .......... 2B-9
Front Wheel Hub, Disc, Bolt and Bearing
Check .............................................................. 2B-14
Suspension Control Arm / Bushing Removal
and Installation ................................................ 2B-14
Suspension Control Arm / Bushing
Disassembly and Assembly ............................ 2B-15
Suspension Control Arm / Steering Knuckle
Check .............................................................. 2B-16
Suspension Control Arm Bushing Check .......... 2B-16
Suspension Control Arm Joint Check ............... 2B-16
Front Suspension Frame, Stabilizer Bar and/
or Bushing Components ................................. 2B-17
Front Suspension Frame, Stabilizer Bar and/
or Bushing Removal and Installation .............. 2B-18
Front Suspension Frame Check ....................... 2B-20
Front Stabilizer Bar, Bushing and/or Joint
Check .............................................................. 2B-20Front Suspension Fasteners Check .................. 2B-20
Specifications .....................................................2B-21
Tightening Torque Specifications ...................... 2B-21
Special Tools and Equipment ...........................2B-22
Recommended Service Material ....................... 2B-22
Special Tool ...................................................... 2B-22
Rear Suspension ..................................... 2C-1
Repair Instructions ..............................................2C-1
Rear Suspension Components ...........................2C-1
Rear Shock Absorber Removal and
Installation .........................................................2C-2
Rear Shock Absorber Inspection ........................2C-3
Rear Shock Absorber Bush Inspection ...............2C-3
Rear Coil Spring Removal and Installation .........2C-4
Spring Upper Seat / Spring Lower Seat
Inspection ..........................................................2C-5
Rear Axle Removal and Installation ....................2C-6
Rear Axle and Coil Spring Inspection .................2C-7
Rear Axle Bush Inspection ..................................2C-7
Rear Wheel Disc, Bolt and Bearing Inspection ....2C-7
Rear Wheel Hub Assembly Removal and
Installation .........................................................2C-8
Specifications .....................................................2C-10
Tightening Torque Specifications ......................2C-10
Wheels and Tires ..................................... 2D-1
General Description .............................................2D-1
Tires Description .................................................2D-1
Wheels Description .............................................2D-2
Irregular and/or Premature Wear Description .....2D-3
Wear Indicators Description ................................2D-3
Radial Tire Waddle Description...........................2D-3
Radial Tire Lead / Pull Description ......................2D-4
Balancing Wheels Description ............................2D-4
Repair Instructions ..............................................2D-5
Wheel Discs Inspection .......................................2D-5
Wheel Balance Inspection and Adjustment.........2D-5
Tire Rotation........................................................2D-5
Wheel (with Tire) Removal and Installation.........2D-6
Tire Mounting and Dismounting ..........................2D-6
Tire Repair ..........................................................2D-6
Specifications .......................................................2D-7
Wheels and Tires Specifications .........................2D-7
Tightening Torque Specifications ........................2D-7

Downloaded from www.Manualslib.com manuals search engine 2B-5 Front Suspension:
Front Strut Assembly Removal and InstallationS6RW0D2206003
CAUTION!
When rebound stopper and strut assembly
were removed, check strut support lower nut
for specified torque before installing strut
assembly.

Removal
1) Remove hood rear seal (1), and then remove cowl
top garnish (2) from vehicle.
NOTE
When servicing component parts of strut
assembly, beforehand loosen strut nut a little
before removing strut assembly. This will
make service work easier. Note that the nut
must not be removed at this point.

2) Hoist vehicle, allowing front suspension to hang free.
3) Remove wheel and disconnect stabilizer joint (1)
from strut bracket.
When loosening joint nut, hold stud with hexagon
wrench (2).4) Remove brake hose mounting bolt (1). Remove
brake hose (2) from bracket and wheel speed sensor
harness (3) from strut bracket as shown in figure.
5) Remove strut bracket bolts and nuts (4).
6) Remove strut nut (1), and remove rebound stopper
(2).
NOTE
Hold strut by hand so that it will not fall off.

7) Remove strut assembly.
2
1
I5RW0A220003-01
1
2
I5RW0A220004-01
3
214
I5RW0A220005-01
2
1
I4RS0A220006-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-22
Special Tools and Equipment
Recommended Service MaterialS6RW0D2208001
Special ToolS6RW0D2208002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease H P/No.: 99000–25121)
09913–65810 09913–75510
Crankshaft bearing puller Bearing installer
)) / ) / )
09913–75821 09913–85230
Bearing installer attachment Bearing remover tool
) / ))
09925–14520 09942–15511
Bearing and oil seal installer
(80 x 50 mm)Sliding hammer
))
09943–17912 09943–25010
Wheel hub remover Spring compressor
))
09943–37910 09943–76310
Bearing installer & remover Bush remover
)) / )
09944–78220
Bearing installer support
)

Downloaded from www.Manualslib.com manuals search engine Wheels and Tires: 2D-4
Equipment manufacture’s recommendations
Radial Tire Lead / Pull DescriptionS6RW0D2401006
“Lead / Pull” is the deviation of the vehicle from a straight
path on a level road even with no pressure on the
steering wheel.
Lead is usually caused by the following conditions.
• Improper tire and wheel alignment.
• Uneven brake assemblies.
• Tire construction.
The way in which a tire is built can produce lead in a
vehicle. An example of this is placement of the belt. Off
center belts on radial tires can cause the tire to develop
a side force while rolling straight down the road. If one
side of the tire has a little larger diameter than the other,
the tire will tend to roll to one side. This will develop a
side force which can produce vehicle lead.
The procedure in the figure (Lead Diagnosis) should be
used to make sure that wheel alignment is not mistaken
for tire lead.
• Part of the lead diagnosis procedure is different from
the proper tire rotation pattern currently in the owner
and service manuals. If a medium to high mileage tire
is moved to the other side of the vehicle, be sure to
check that ride roughness has not developed
• Rear tires will not cause lead.
Balancing Wheels DescriptionS6RW0D2401007
There are two types of wheel and tire balance: static and
dynamic. Static balance, as shown in figure, is the equal
distribution of weight around the wheel. Wheels that are
statically unbalanced cause a bouncing action called
tramp. This condition will eventually cause uneven tire
wear.Dynamic balance, as shown in figure, is the equal
distribution of weight on each side of the wheel
centerline so that when the tire spins there is no
tendency for the assembly to move from side to side.
Wheels that are dynamically unbalanced may cause
shimmy.
Inflate tires to recommended pressure
Road test vehicle on level unrouned road in both directions
Switch front tires side to side and road test again
Lead corrected,
if roughness results, replace tiresLeads in same directionLeads reverses direction
Put tires back in original position
and check alignmentInstall a known-good tire on one front side
Lead remains install a known-good
tire in place of other front tire
Lead remains known-good tires are not goodLead corrected replace tire
Lead corrected replace tire
I2RH01240007-01
1. Heavy spot wheel tramp [A]: Before correction
2. Balance weights addition point [B]: Corrective weights
3. C/L of spindle
1. Heavy spot wheel shimmy [C]: Before correction
2. Balance weights addition point [D]: Corrective weights
3. C/L of spindle
I2RH01240008-01
I2RH01240009-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 3- i
3
Section 3
CONTENTS
Driveline / Axle
Precautions ................................................. 3-1
Precautions............................................................. 3-1
Precautions on Driveline / Axle ............................. 3-1
Drive Shaft / Axle ..................................... 3A-1
Front ......................................................................... 3A-1
General Description ............................................. 3A-1
Front Drive Shaft Construction ............................ 3A-1
Component Location ........................................... 3A-1
Front Drive Shaft Assembly Components
Location ............................................................ 3A-1
Diagnostic Information and Procedures ............ 3A-2
Front Drive Shaft Symptom Diagnosis ................ 3A-2
Repair Instructions .............................................. 3A-2
Front Drive Shaft Components ........................... 3A-2
Front Drive Shaft Assembly On-Vehicle
Inspection.......................................................... 3A-3
Front Drive Shaft Assembly Removal and
Installation ......................................................... 3A-3
Front Drive Shaft Disassembly and
Reassembly ...................................................... 3A-4
Center Shaft and Center Bearing Support
Disassembly and Reassembly (If Equipped) .. 3A-12
Specifications..................................................... 3A-13
Tightening Torque Specifications ...................... 3A-13
Special Tools and Equipment ........................... 3A-14
Recommended Service Material ....................... 3A-14
Special Tool ...................................................... 3A-14
Rear ........................................................................ 3A-15
General Description ........................................... 3A-15
Rear Drive Shaft Construction .......................... 3A-15
Repair Instructions ............................................ 3A-15
Rear Drive Shaft Components .......................... 3A-15
Rear Drive Shaft Assembly Removal and
Installation ....................................................... 3A-16
Rear Drive Shaft Disassembly and
Reassembly .................................................... 3A-16
Specifications..................................................... 3A-18
Tightening Torque Specifications ...................... 3A-18
Special Tools and Equipment ........................... 3A-18
Recommended Service Material ....................... 3A-18
Special Tool ...................................................... 3A-18
Differential ................................................ 3B-1
Precautions...........................................................3B-1
Precaution for Rear Differential Oil Leakage....... 3B-1
Precautions in Diagnosing Trouble ..................... 3B-1
General Description .............................................3B-2
Rear Differential Description ............................... 3B-2
Coupling Description ........................................... 3B-2
4WD Control System Components ..................... 3B-3
4WD Control System Description........................ 3B-4
Function of 4WD Control System Component .... 3B-4
4WD Control System Wiring Circuit Diagram...... 3B-5
Terminal Arrangement of 4WD Control
Module .............................................................. 3B-5
Input / Output Signal Table of 4WD Control
Module .............................................................. 3B-6
On-Board Diagnostic System Description ........... 3B-6
CAN Communication System Description........... 3B-7
Diagnostic Information and Procedures ............3B-8
4WD Control System Check ............................... 3B-8
4WD Position Indicator Operation Check.......... 3B-10
4WD Control System Operation Inspection ...... 3B-10
Visual Inspection ............................................... 3B-11
DTC Check........................................................ 3B-11
DTC Clearance ................................................. 3B-11
DTC Table ......................................................... 3B-12
Fail-Safe Table .................................................. 3B-12
Scan Tool Data ................................................. 3B-13
Rear Differential Symptom Diagnosis ............... 3B-14
4WD Control Symptom Diagnosis..................... 3B-14
4WD Position Indicator Does Not Come ON at
Ignition Switch ON but Engine Stops .............. 3B-15
4WD Position Indicator Remains ON Steady
at Ignition Switch ON....................................... 3B-16
DTC C1240: 4WD Control Module Power
Supply Circuit Malfunction............................... 3B-17
DTC C1243: Internal Circuit Malfunction of
4WD Control Module ....................................... 3B-18
DTC C1250: Coupling Air Temperature
Sensor Circuit Open ........................................ 3B-19
DTC C1251: Coupling Air Temperature
Sensor Circuit Short ........................................ 3B-21
DTC C1252: Coupling Assembly Circuit Open .. 3B-22
DTC C1253: Coupling Assembly Circuit Short .. 3B-24
DTC C1254: 2WD/4WD Switch Malfunction ..... 3B-25
DTC U0073: Control Module Communication
Bus Off ............................................................ 3B-27

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