cable SUZUKI SX4 2006 1.G Service Manual Online

Downloaded from www.Manualslib.com manuals search engine Rear Suspension: 2C-4
Rear Coil Spring Removal and InstallationS6RW0D2306005
CAUTION!
Removal and Installation both coil springs
(right and left) at the same time to avoid rear
axle twisting and other damage.

Removal
1) Hoist vehicle and remove rear wheels.
2) Dismount rear differential (4WD model) referring to
“Rear Differential Dismounting and Remounting in
Section 3B”.
3) Remove rear fender lining (1) and then loosen rear
axle bolt (2) a little.
CAUTION!
Do not reuse rear axle bolt. Otherwise, bolt
may loosen.

4) Support both ends of rear axle (1) by using two floor
jacks (2).5) Detach each lower end (2) of shock absorbers (1)
(right and left) from rear axle.
6) Lower rear axle gradually as far down as the coil
spring can be removed.
CAUTION!
Be careful not to lower rear axle down too
much.
It may cause damage to brake flexible hose,
wheel speed sensor lead wire and parking
brake cable.

7) Remove coil spring (3).
8) Remove spring upper seat (1) from vehicle body and
lower seat (2) from rear axle.
2
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I5RW0A230008-01
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2
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I5RW0A230009-01
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I5RW0A230011-01

Downloaded from www.Manualslib.com manuals search engine Rear Suspension: 2C-6
Rear Axle Removal and InstallationS6RW0D2306007
CAUTION!
Do not drop brake fluid onto painted surface.
Painted surfaces will be damaged.

Removal
1) Hoist vehicle and remove exhaust center pipe and
muffler.
2) Disconnect rear height sensor link (if equipped) from
rear axle referring to “Height Sensor Removal and
Installation (If Equipped) in Section 9B”.
3) Remove rear wheel, rear brake drum and rear wheel
hub referring to “Removal” under “Rear Wheel Hub
Assembly Removal and Installation”.
4) Disconnect brake pipe (1) from brake flexible hoses
(2) and remove E-rings (3).
5) Remove coil springs referring to “Rear Coil Spring
Removal and Installation”.
6) Disconnect wheel speed sensor clamp (1) and
parking brake cable nuts (2) from rear axle.
7) While supporting rear axle at both ends, remove rear
axle bolts and then remove rear axle from chassis by
lowering floor jack gradually.
8) Remove brake pipes from rear axle, if necessary.Installation
CAUTION!
Never reuse rear axle bolts and rear wheel
hub mounting bolts.

1) Install brake pipes to rear axle, if removed.
2) Using floor jacks, install rear axle and new rear axle
bolts (1) and tighten bolts temporarily.
3) Install coil spring referring to “Rear Coil Spring
Removal and Installation”.
4) Install rear wheel hub and wheel speed sensor
referring to “Installation” under “Rear Wheel Hub
Assembly Removal and Installation”.
5) Connect brake flexible hoses (1) to bracket on rear
axle with E-ring (2) and tighten brake pipe flare nuts
(3) to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft)
1 3
2
I5RW0A230013-01
2
1
I5RW0A230015-01
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I5RW0A230017-01
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3,(a)
I5RW0A230019-01

Downloaded from www.Manualslib.com manuals search engine 2C-7 Rear Suspension:
6) Connect rear height sensor link (if equipped) to rear
axle referring to “Height Sensor Removal and
Installation (If Equipped) in Section 9B”.
7) Install exhaust center pipe and muffler.
8) After installing removed parts, bleed air from brake
system referring to “Air Bleeding of Brake System in
Section 4A”. And then adjust parking brake cable
referring to “Parking Brake Inspection and
Adjustment in Section 4D”.
9) Install wheel and tighten wheel nuts to specified
torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
10) Lower hoist and bounce vehicle up and down
several times to stabilize suspension.
11) Tightening shock absorber lower nuts and rear axle
bolts to specified torque.
NOTE
When tightening these nuts and bolts, be
sure that vehicle is not on hoist and in
unloaded condition.

Tightening torque
Rear shock absorber lower nut: 90 N·m (9.0 kgf-
m, 65.0 lb-ft)
Rear axle bolt: 73 N·m (7.3 kgf-m, 53.0 lb-ft)
12) Perform brake test (foot brake and parking brake).
13) Check each installed parts for brake fluid leakage.
Rear Axle and Coil Spring InspectionS6RW0D2306009
• Inspect for cracks, deformation or damage.
• Inspect bushing for damage, wear or breakage.
Replace any defective part.
Rear Axle Bush InspectionS6RW0D2306010
Inspect for cracks, deformation or damage. If necessary,
replace rear axle assembly.
Rear Wheel Disc, Bolt and Bearing InspectionS6RW0D2306011
• Check tightness of wheel nuts and, if necessary,
retighten to specified torque.
• Check wheel disc deformation, damage, crack and
etc.
Replace defective disc with new one.
• Check installation face inside of wheel disc for rust.
As rust affects adversely, remove it thoroughly.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
• Check wear of wheel bearings. When measuring
thrust play, apply a dial gauge to axle shaft center.
When the thrust play exceeds limit, replace bearing.
Rear wheel bearing thrust play
Limit: 0.1 mm (0.004 in.)
• Check noise and smooth rotation of wheel by rotating
wheel. If it is defective, replace bearing.
(a)I5RW0A230022-01
I3RM0A230049-01
I3RM0A230050-01

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
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I7RW01230012-01
(a)
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I5RW0A230018-01

Downloaded from www.Manualslib.com manuals search engine 2D-1 Wheels and Tires:
Suspension
Wheels and Tires
General Description
Tires DescriptionS6RW0D2401001
The tire is of tubeless type. The tire is designed to
operate satisfactorily with loads up to the full rated load
capacity when inflated to the recommended inflation
pressures.
Correct tire pressures and driving habits have an
important influence on tire life. Heavy cornering,
excessively rapid acceleration, and unnecessary sharp
braking increase tire wear.
Tire Placard
The “Tire Placard” is located on the left or right door lock
pillar and should be referred to tire information.
The placard lists the maximum load, tire size and cold
tire pressure where applicable.
NOTE
Whether rim size and/or maximum load are
listed or not depends on regulations of each
country.

Inflation of Tires
The pressure recommended for any model is carefully
calculated to give a satisfactory ride, stability, steering,
tread wear, tire life and resistance to bruises.
Tire pressure, with tires cold, (after vehicle has set for 3
hours or more, or driven less than one mile) should be
checked monthly or before any extended trip. Set to the
specifications on the “Tire Placard” located on the left or
right door lock pillar.
It is normal for tire pressure to increase when the tires
become hot during driving.
Do not bleed or reduce tire pressure after driving.
Bleeding reduces the “Cold Inflation Pressure”.
Higher than recommended pressure can cause:
• Hard ride
• Tire bruising or carcass damage
• Rapid tread wear at center of tire
Unequal pressure on same axle can cause:
• Uneven braking
• Steering lead
• Reduced handling
• Swerve on accelerationLower than recommended pressure can cause:
• Tire squeal on turns
• Hard Steering
• Rapid and uneven wear on the edges of the tread
• Tire rim bruises and rupture
• Tire cord breakage
• High tire temperature
• Reduced handling
• High fuel consumption
Matched Tires and Wheels (Steel Type)
Tires and wheels are match mounted at the assembly
plant.
This means that the radially stiffest part of the tire, or
“high spot”, is matched to the smallest radius or “low
spot” of the wheel.
This is done to provide the smoothest possible ride.
The “high spot” of the tire is originally marked by paint
dot (1) on the outboard sidewall. This paint dot will
eventually wash off the tire.
The “low spot” of the wheel is originally marked by paint
dot (2) on the wheel rim-flange. Properly assembled, the
wheel rims’ paint dot should be aligned with the tires’
paint dot as shown in figure.
Whenever a tire is dismounted from its wheel, it should
be remounted so that the tire and wheel are matched. If
the tire’s paint dot cannot be located, a line should be
scribed on the tire and wheel before dismounting to
assure that it is remounted in the same position.
I2RH01240001-01

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-8
Diagnostic Information and Procedures
4WD Control System CheckS6RW0D3204001
Refer to the following items for the details of each step.
Step Action Yes No
1) Customer complaint analysis
1) Perform customer complaint analysis.
Was customer complaint analysis performed?Go to Step 2. Perform customer
complaint analysis.
2) DTC check, record and clearance
1) Check for DTC.
Is there any DTC(s)?Print DTC or write them
down and clear them by
referring to “DTC
Clearance”. Go to Step
3.Go to Step 4.
3) Visual inspection
1) Perform visual inspection.
Is there any faulty condition?Repair or replace
malfunction part. Go to
St ep 11 .Go to Step 5.
4) Visual inspection
1) Perform visual inspection.
Is there any faulty condition?Repair or replace
malfunction part. Go to
St ep 11 .Go to Step 8.
5) Trouble symptom confirmation
1) Select 2WD/4WD switch to “2WD”, “4WD-auto” and
“4WD-lock” positions referring to “4WD Control System
Operation Inspection”.
2) Confirm trouble symptom.
Is trouble symptom identified?Go to Step 6. Go to Step 7.
6) Rechecking and record of DTC
1) Recheck for DTC referring to “DTC Check”.
Is there any DTC(s)?Go to Step 9. Go to Step 8.
7) Rechecking and record of DTC
1) Recheck for DTC referring to “DTC Check”.
Is there any DTC(s)?Go to Step 9. Go to Step 10.
8) 4WD control symptom diagnosis
1) Check and repair according to “4WD Control Symptom
Diagnosis”.
Are check and repair complete?Go to Step 11. Check and repair
malfunction part(s). Go
to Step 11.
9) Troubleshooting for DTC
1) Check and repair according to applicable DTC flow.
Are check and repair complete?Go to Step 11. Check and repair
malfunction part(s). Go
to Step 11.
10) Check for intermittent problems
1) Check for intermittent problems referring to “Intermittent
and Poor Connection Inspection in Section 00”.
Is there any faulty condition?Repair or replace
malfunction part(s). Go
to Step 11.Go to Step 11.
11) Final confirmation test
1) Clear DTC if any.
2) Perform final confirmation test.
Is there any problem symptom, DTC or abnormal condition?Go to Step 6. END.

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-10
Step 2. DTC check, record and clearance
First, referring to “DTC Check”, check DTC and pending
DTC. If DTC exists, print or write down DTC 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 4WD control
system 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 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
Refer to “DTC Check” for checking procedure.
Step 8. 4WD control symptom diagnosis
Check the parts of the system suspected as a possible
cause referring to “4WD Control Symptom Diagnosis”.
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,
coupling assembly, 4WD control module 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.4WD Position Indicator Operation CheckS6RW0D3204002
1) Turn ignition switch to OFF position.
2) Check that 4WD position indicators turn on for about
2 seconds and then turns off.
If any faulty condition is found, proceed to “4WD
Position Indicator Does Not Come ON at Ignition
Switch ON but Engine Stops” or “4WD Position
Indicator Remains ON Steady at Ignition Switch ON”.
4WD Control System Operation InspectionS6RW0D3204003
NOTE
• It automatically changes into “4WD-auto”
position, when the vehicle speed becomes
specified speed or more at “4WD-lock”
position. It is “4WD-auto” position until
switch will be selected to “4WD-lock”
position at next time.
• When ABS operates while changed of each
position, it is discontinued of change. End
of the ABS operation, and then returned to
the position of before.

1) Inspect switch operation from “4WD-auto” to “2WD”
as follows.
a) Start engine.
b) Push 2WD/4WD switch to “2WD” position.
c) Check that 4WD AUTO indicator and 4WD
LOCK indicator not come ON.
2) Inspect switch operation from “2WD” to “4WD-auto”
as follows.
a) Start engine.
b) Push 2WD/4WD switch to “AUTO” position.
c) Check that 4WD AUTO indicator comes ON
steady and 4WD LOCK indicator not come ON.
3) Inspect switch operation from “4WD-auto” to “4WD-
lock” as follows.
a) Start engine.
b) Push 2WD/4WD switch to “LOCK” position, and
keep it for 3 seconds or more.
c) Check that 4WD AUTO indicator not come ON
and 4WD LOCK indicator comes ON steady.
4) Inspect switch operation from “4WD-lock” to “4WD-
auto” as follows.
a) Start engine.
b) Push 2WD/4WD switch to “AUTO” position.
c) Check that 4WD AUTO indicator comes ON
steady and 4WD LOCK indicator not come ON.

Downloaded from www.Manualslib.com manuals search engine 3B-11 Differential:
Visual InspectionS6RW0D3204004
Check the following parts and systems visually.
DTC CheckS6RW0D3204005
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector
(DLC) (1) located on underside of instrument panel.
Special tool
(A): SUZUKI scan tool
3) Turn ignition switch to ON position.
4) Read DTC according to instructions displayed on
SUZUKI scan tool and print it or write it down. Refer
to SUZUKI scan tool operator’s manual for further
details.
If communication between SUZUKI scan tool and
4WD control module is not possible, check if
SUZUKI scan tool is communicable by connecting it
to 4WD control module in another vehicle. If
communication is possible in this case, SUZUKI
scan tool is in good condition. Then check data link
connector and serial data line (circuit) in the vehicle
with which communication was not possible.
5) After completing the check, turn ignition switch OFF
and disconnect SUZUKI scan tool from data link
connector (DLC).
DTC ClearanceS6RW0D3204006
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector
(DLC) (1) located on underside of instrument panel.
Special tool
(A): SUZUKI scan tool
3) Turn ignition switch to ON position.
4) Erase DTC according to instructions displayed on
SUZUKI scan tool. Refer to SUZUKI scan tool
operator’s manual for further details.
5) After completing clearance, turn ignition switch OFF
and disconnect SUZUKI scan tool from data link
connector (DLC).
6) Perform “DTC Check” and confirm that NO CODES
is displayed.
NOTE
DTC stored in 4WD control module memory
are also cleared in the following cases. Be
careful not to clear them before keeping their
record.
• When power to 4WD control module is cut
off (by disconnecting battery cable,
removing fuse or disconnecting 4WD
control module connectors).
• When the same malfunction (DTC) is not
detected again during 40 engine warm-up
cycles.

Inspection Item Referring
• Rear differential oil ---- level, leakage “Rear Differential Oil Change”
• Transfer gear oil ---- level, leakage “Transfer Oil Change in Section 3C”
• Manual transmission oil ---- level, leakage “Manual Transaxle Oil Change in Section 5B”
• Rear differential mounting(s) ---- wear and looseness
• Fuses ---- burning
• Battery ---- fluid level, corrosion of terminal “Battery Inspection in Section 1J”
• Connectors of electric wire harness ---- disconnection,
friction“Intermittent and Poor Connection Inspection in Section
00”
• Other parts that can be checked visually
1(A)I5RW0A320008-011(A)I5RW0A320008-01

Downloaded from www.Manualslib.com manuals search engine 3B-15 Differential:
4WD Position Indicator Does Not Come ON at Ignition Switch ON but Engine StopsS6RW0D3204013
Wiring Diagram
Circuit Description
4WD position indicator operates according to the signal from 4WD control module. If the 4WD control system is in
good condition, 4WD position indicator light up for 2 seconds when ignition switch is turned to ON position, and then
turned to OFF position. If an abnormality is detected in the system, 4WD position indicator remains lighting.
Troubleshooting
WHTYELRED/BLK
12
WHT/RED
WHT/RED
G26-12
G26-11
RED
BLK
WHT 56 47
12V
G26-10BLK
G26-22
G26-23REDWHT
3
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]
I7RW01320004-01
[A]: 4WD control module connector “G26” (viewed from harness side) 4. Combination meter
1. Main fuse box 5. 4WD AUTO indicator
2. Junction block assembly 6. 4WD LOCK indicator
3. “METER” fuse 7. 4WD control module
Step Action Yes No
14WD position indicator power supply check
1) Turn ignition switch to ON position.
Do other indicators come ON?Go to Step 2. Go to Step 3.
2Check DTC
1) Connect scan tool to DLC with ignition switch OFF.
2) Turn ignition switch to ON position and check DTC.
Is there DTC(s) U0073, U0100, U0121 and/or U0155?Go to applicable DTC
diag. flow.Substitute a known-
good combination meter
and recheck. If 4WD
position indicator still
remains off, substitute a
known-good 4WD
control module and
recheck.