200 SUZUKI SX4 2006 1.G Service Manual PDF

Downloaded from www.Manualslib.com manuals search engine 2C-9 Rear Suspension:
Installation
1) Insert wheel stud bolt (1) in hub hole. Rotate wheel
stud bolt slowly to assure that serrations are aligned
with those made by original bolt.
2) Install brake back plate, rear wheel hub and new rear
wheel hub bolts and then tighten rear wheel hub
mounting bolts to specified torque.
CAUTION!
Use new rear wheel hub mounting bolts.

Tightening torque
Rear wheel hub mounting bolt: 73 N·m (7.3 kgf-
m, 53.0 lb-ft)
3) For 4WD model, install rear drive shaft referring to
“Rear Drive Shaft Assembly Removal and
Installation in Section 3A”.
CAUTION!
Never reuse rear drive shaft nut.

Tightening torque
Drive shaft nut (a): 175 N·m (17.5 kgf-m, 127.0
lb-ft)4) Connect wheel speed sensor and tighten wheel
speed sensor bolt (2WD model) to specified torque.
Tightening torque
Wheel speed sensor bolt : 11 N·m (1.1 kgf-m, 8.0
lb-ft)
5) Connect brake pipe (1) to wheel cylinder and tighten
brake pipe flare nut to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft)
6) Install brake drum referring to Step 1) and 2) of
“Installation” under “Rear Brake Drum Removal and
Installation in Section 4C”.
7) Fill reservoir with brake fluid and bleed brake
system. For bleeding operation, see “Air Bleeding of
Brake System in Section 4A”.
8) Install wheel and tighten wheel nuts to specified
torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
9) Upon completion of all jobs, depress brake pedal
with about 300 N (30 kg, 66 lbs) load at least 3 times
so as to obtain proper drum-to-shoe clearance.
Adjust parking brake cable. For adjustment, see
“Parking Brake Inspection and Adjustment in Section
4D”.
10) Check to ensure that brake drum is free from
dragging and proper braking is obtained.
11) Perform brake test (foot brake and parking brake).
12) Check each installed part for fluid leakage.
1
I5JB0A220017-01
1,(a)
1
I7RW01230012-01
(a)
1
I5RW0A230018-01

Downloaded from www.Manualslib.com manuals search engine Wheels and Tires: 2D-2
Replacement Tires
When replacement is necessary, the original equipment
type tire should be used. Refer to the Tire Placard.
Replacement tires should be of the same size, load
range and construction as those originally on the vehicle.
Use of any other size or type tire may affect ride,
handling, speedometer / odometer calibration, vehicle
ground clearance and tire or snow chain clearance to the
body and chassis.
It is recommended that new tires be installed in pairs on
the same axle. If necessary to replace only one tire, it
should be paired with the tire having the most tread, to
equalize braking traction.
WARNING!
Do not mix different types of tires on the
same vehicle such as radial, bias and bias-
belted tires except in emergencies, because
handling may be seriously affected and may
result in loss of control.

The metric term for tire inflation pressure is the kilo
pascal (kPa). Tire pressures is usually printed in both
kPa and kgf/cm
2 on the “Tire Placard”.
Metric tire gauges are available from tool suppliers.
The chart, shown in the table, converts commonly used
inflation pressures from kPa to kgf/cm
2 and psi.
Wheels DescriptionS6RW0D2401002
Wheel Maintenance
Wheel repairs that use welding, heating, or peening are
not approved. All damaged wheels should be replaced.
Replacement Wheels
Wheels must be replaced if they are bent, dented, have
excessive lateral or radial runout, air leak through welds,
have elongated bolt holes, if lug wheel bolts won’t stay
tight, or if they are heavily rusted. Wheels with greater
runout than shown in the following may cause
objectional vibrations.
Replacement wheels must be equivalent to the original
equipment wheels in load capacity, diameter, rim with
offset and mounting configuration. A wheel of improper
size or type may affect wheel and bearing life, brake
cooling, speedometer / odometer calibration, vehicle
ground clearance and tire clearance to body and
chassis.How to Measure Wheel Runout
To measure the wheel runout, it is necessary to use an
accurate dial indicator. The tire may be on or off the
wheel. The wheel should be installed to the wheel
balancer of the like for proper measurement.
Take measurements of both lateral runout “a” and radial
runout “b” at both inside and outside of the rim flange.
With the dial indicator set in place securely, turn the
wheel one full revolution slowly and record every reading
of the indicator.
When the measured runout exceeds the specification
and correction by the balancer adjustment is impossible,
replace the wheel. If the reading is affected by welding,
paint or scratch, it should be ignored.
Lateral runout limit “a”
Aluminum wheel: 0.3 mm (0.012 in.)
Steel wheel: 0.9 mm (0.035 in.)
Radial runout limit “b”
Aluminum wheel: 0.3 mm (0.012 in.)
Steel wheel: 0.7 mm (0.028 in.)
Metric Lug Nuts and Wheel Studs
All models use metric lug nuts and wheel studs.
Metric lug nuts and wheel studs size
M12 x 1.25
If a broken stud is found, see “Front Wheel Hub, Disc,
Bolt and Bearing Check in Section 2B”, “Front Wheel
Hub, Steering Knuckle and Wheel Bearing Removal and
Installation in Section 2B”, “Rear Wheel Hub Assembly
Removal and Installation in Section 2C”. kPa kgf/cm
2psi
Conversion: 1 psi =
6.895 kPa 1 kgf/cm
2 =
98.066 kPa160 1.6 23
180 1.8 26
200 2.0 29
220 2.2 32
240 2.4 35
260 2.6 38
280 2.8 41
300 3.0 44
320 3.2 47
340 3.4 50I4RS0A240001-01
I2RH01240003-01

Downloaded from www.Manualslib.com manuals search engine 3A-1 Drive Shaft / Axle: Front
Driveline / Axle
Drive Shaft / Axle
Front
General Description
Front Drive Shaft ConstructionS6RW0D3111001
A constant velocity ball joint is used on the wheel side of both right and left side drive shaft assemblies. For A/T
vehicle, a tripod type constant velocity joint is used on the differential side and center shaft side. For M/T vehicle, a
double offset type constant velocity joint (DOJ) is used on the differential side and center shaft side. The drive shaft
can slide through the tripod joint or the double offset joint (DOJ) in the extension/contraction direction.
Component Location
Front Drive Shaft Assembly Components LocationS6RW0D3113001
I6RW0D311001-01
1. To transaxle 7. Wheel nut : 200 N⋅m (20.0 kgf-m, 145.0 lb-ft)
2. Drive shaft assembly 8. Center shaft assembly (if equipped) : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)
3. Tie-rod end 9. Center bearing support bolts (if equipped) : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
4. Tie-rod end nut 10. Washer : Do not reuse.
5. Ball stud bolt : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft)
6. Drive shaft nut
: After tightening nut to specified torque,
caulk nut securely.:60 N⋅m (6.0 kgf-m, 43.5 lb-ft)

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 Drive Shaft / Axle: Rear 3A-16
Rear Drive Shaft Assembly Removal and
Installation
S6RW0D3126002
Removal
1) Hoist vehicle and remove rear wheel.
2) Undo caulking of drive shaft nut (1) and then remove
drive shaft nut with pull up parking brake lever.
3) Remove rear drive shaft flange nuts (1), and then
remove rear drive shaft.
Installation
Install drive shaft assembly by reversing removal
procedure and noting the following points.
CAUTION!
• Protect boots from any damage,
preventing them from unnecessary contact
while installing drive shaft.
• Do not hit joint boot with hammer.
Inserting joint only by hands is allowed.

• Tighten each nuts to specified torque referring to
“Rear Drive Shaft Components”.
Rear Drive Shaft Disassembly and ReassemblyS6RW0D3126003
Disassembly
Refer to “Front Drive Shaft Disassembly and
Reassembly” note the following point which is different
from the front drive shaft is described.
• Remove differential side boot big band and small
band as follows.
– For boot big band (and small band) without joint [A]:
Remove boot big band (and small band) by tapping
boot and band with plastic hammer. If it is hard to
remove boot big band (and small band), cut it using
a nipper or an iron saw with care not to damage
joint housing.
– For boot big band (and small band) with joint [B]:
Draw hooks of boot big band (and small band)
together and remove band.
1
I5RW0A230023-01
1
I5RW0A312006-02
I5RW0A312003-01

Downloaded from www.Manualslib.com manuals search engine 3A-17 Drive Shaft / Axle: Rear
Reassembly
Refer to “Front Drive Shaft Disassembly and
Reassembly” note the following points which is different
from the front drive shaft is described.
• Apply grease to each joint.
Grease color
Wheel side: Black
Differential side: Dark gray
Amount
Wheel side: 50 – 70 g (1.8 – 2.5 oz)
Differential side: 70 – 90 g (2.5 – 3.2 oz)
• Drive in the cage (1) by using special tool.
Special tool
(A): 09913–84510
• Fit differential side boot as follows.
– Fit boot (1) to grooves of shaft and housing (2)
adjust length to specification below.
– Insert screw driver into boot and allow air to enter
boot so that air pressure in boot becomes the same
as atmospheric pressure.
Drive shaft boot fixing position (distance
between housing end and small boot band
center)
Left side and right side drive shafts “a”: 142.5
mm (5.61 in.)• Fasten differential side boot band as follows.
CAUTION!
• Bend each boot band against forward
rotation.
• Do not squeeze or distort boot when
fastening it with bands. Distorted boot
caused by squeezing air may reduce its
durability.

– Place differential side boot new big band (3) and
new small band onto boot putting band outer end
(1) against forward rotation (2) as shown in figure.
– Fasten differential side boot new big band (1) and
new small band by drawing hooks (2) with special
tool and engage hooks (3) in slot and window (4).
Special tool
(A): 09943–57021
(A)
1
I5RS0B310009-01
“a”
2
1I5RW0A312007-01
I5RW0A312004-01
(A)
1
4
2
3
I5RW0A312005-01

Downloaded from www.Manualslib.com manuals search engine 3B-1 Differential:
Driveline / Axle
Differential
Precautions
Precaution for Rear Differential Oil LeakageS6RW0D3200001
Whenever vehicle is hoisted for any other service work than oil change, also be sure to check for oil leakage.
Precautions in Diagnosing TroubleS6RW0D3200002
• Do not disconnect the following parts before confirming diagnostic information (DTC, etc.) stored in 4WD control
module memory. These actions will erase memorized information in 4WD control module memory.
– Disconnection of coupler from 4WD control module
– Disconnection of battery cable from battery
– Disconnection of ground wire harness of 4WD control module
– Disconnect main fuse from fuse box
• Diagnostic information stored in 4WD control module memory can be cleared as well as checked by using SUZUKI
scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as
to what functions are available and how to use it.
• Be sure to read “Precautions for Electrical Circuit Service:” before inspection and observe what is written there.

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-3 Differential:
4WD Control System ComponentsS6RW0D3201003
2
1
3
6
5 4
I5RW0A320002-04
1. 4WD control module 3. 4WD LOCK indicator 5. Coupling assembly
2. 4WD AUTO indicator 4. 2WD/4WD switch 6. Coupling air temperature sensor

Downloaded from www.Manualslib.com manuals search engine 3B-5 Differential:
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)