Abs front SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 00
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Vo l u m e 1
Precautions............................................................... 00-i
Precautions ............................................................ 00-1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubrication ................................. 0B-1
Engine ......................................................................... 1-i
Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1
Aux. Emission Control Devices .............................. 1B-1
Engine Electrical Devices....................................... 1C-1
Engine Mechanical ................................................. 1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System .......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System....................................................... 1H-1
Starting System ....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System ..................................................... 1K-1
Suspension ................................................................. 2-i
Precautions .............................................................. 2-1
Suspension General Diagnosis .............................. 2A-1
Front Suspension ................................................... 2B-1
Rear Suspension.................................................... 2C-1
Wheels and Tires ................................................... 2D-1
Driveline / Axle ........................................................... 3-i
Precautions .............................................................. 3-1
Drive Shaft / Axle ................................................... 3A-1
Differential .............................................................. 3B-1
Transfer .................................................................. 3C-1
Propeller Shafts...................................................... 3D-1
Brakes ......................................................................... 4-i
Precautions .............................................................. 4-1
Brake Control System and Diagnosis .................... 4A-1
Front Brakes........................................................... 4B-1
Rear Brakes ........................................................... 4C-1
Parking Brake......................................................... 4D-1
ABS ........................................................................ 4E-1
Transmission / Transaxle .......................................... 5-i
Precautions .............................................................. 5-1
Automatic Transmission/Transaxle ........................ 5A-1
Manual Transmission/Transaxle ............................ 5B-1
Clutch ..................................................................... 5C-1
Vo l u m e 2
Precautions ............................................................... 00-i
Precautions ............................................................ 00-1
Steering ....................................................................... 6-i
Precautions .............................................................. 6-1
Steering General Diagnosis ................................... 6A-1
Steering Wheel and Column .................................. 6B-1
Power Assisted Steering System ...........................6C-1
HVAC ........................................................................... 7-i
Precautions .............................................................. 7-1
Heater and Ventilation............................................ 7A-1
Air Conditioning System ......................................... 7B-1
Restraint ...................................................................... 8-i
Precautions .............................................................. 8-1
Seat Belts ............................................................... 8A-1
Air Bag System ...................................................... 8B-1
Body, Cab and Accessories ...................................... 9-i
Precautions .............................................................. 9-1
Wiring Systems ...................................................... 9A-1
Lighting Systems .................................................... 9B-1
Instrumentation / Driver Info. / Horn .......................9C-1
Wipers / Washers ...................................................9D-1
Glass / Windows / Mirrors ...................................... 9E-1
Security and Locks ................................................. 9F-1
Seats ..................................................................... 9G-1
Interior Trim ............................................................9H-1
Hood / Fenders / Doors .......................................... 9J-1
Body Structure ....................................................... 9K-1
Paint / Coatings ...................................................... 9L-1
Exterior Trim .......................................................... 9M-1
Control Systems ....................................................... 10-i
Precautions ............................................................ 10-1
Body Electrical Control System ............................ 10B-1
Immobilizer Control System .................................10C-1
Keyless Start System ........................................... 10E-1
TABLE OF CONTENTS

Downloaded from www.Manualslib.com manuals search engine 0A-5 General Information:
Vehicle Lifting PointsS6RW0D0101005
WARNING!
• Before applying hoist to underbody, always take vehicle balance throughout service into
consideration. Vehicle balance on hoist may change depending on what part to be removed.
• Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe,
fuel pipe, bracket or any other part.
• When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up
the vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by
trying to move vehicle body in both ways. Work can be started only after this confirmation.
• Make absolutely sure to lock hoist after vehicle is hoisted up.

When Using Frame Contact Hoist
When Using Floor Jack
WARNING!
If the vehicle to be jacked up only at the front
or rear end, be sure to block the wheels on
ground in order to ensure safety.
After the vehicle is jacked up, be sure to
support it on stands. It is extremely
dangerous to do any work on the vehicle
raised on jack alone.

CAUTION!
Never apply jack against rear suspension
parts (i.e., torsion beam, etc.) or vehicle floor,
or it may get deformed.

1
:2
:3
4
c
5
I5RW0A010001-02
1. Vehicle front3. Floor jack position 5. Cap
2. Support position for frame contact hoist and safety stand 4. Body mounting stay

Downloaded from www.Manualslib.com manuals search engine 0B-9 Maintenance and Lubrication:
Suspension System InspectionS6RW0D0206023
• Inspect front struts and rear shock absorbers for
evidence of oil leakage, dents or any other damage on
sleeves; and inspect anchor ends for deterioration.
Replace defective parts, if any.
• Check front and rear suspension systems for
damaged, loose or missing parts; also for parts
showing signs of wear or lack of lubrication.
Repair or replace defective parts, if any.
• Check front suspension arm ball joint stud dust seals
for leakage, detachment, tear or any other damage.
Replace defective boot, if any.
Steering System InspectionS6RW0D0206024
1) Check steering wheel for play and rattle, holding
vehicle straight on ground.
Steering wheel play
“a”: 0 – 30 mm (0 – 1.1 in.)2) Check bolts and nuts for tightness and retighten
them as necessary. Repair or replace defective
parts, if any.
3) Check steering linkage for looseness and damage.
Repair or replace defective parts, if any.
4) Check boots (1) and (2) of steering linkage and
steering gear case for damage (leak, detachment,
tear, etc.). If damage is found, replace defective boot
with new one.
If any dent is found on steering gear case boots,
correct it to original shape by turning steering wheel
to the right or left as far as it stops and holding it for a
few seconds.
5) Check universal joints (3) of steering shaft for rattle
and damage. If rattle or damage is found, replace
defective part with a new one.
6) Check that steering wheel can be turned fully to the
right and left. Repair or replace defective parts, if
any.
7) If equipped with power steering system, check also,
in addition to check items, that steering wheel can be
turned fully to the right and left more lightly when
engine is running at idle speed than when it is
stopped. Repair, if found faulty.
8) Check wheel alignment referring to “Front Wheel
Alignment Inspection and Adjustment in Section 2B”.
Drive Shaft (Axle) Boots InspectionS6RW0D0206025
Check drive shaft boots (wheel side and differential side)
for leaks, detachment, tear or other damage.
Replace defective parts as necessary.
I4RS0A020011-01
I4RS0A020012-01
I2RH01020026-01
2
3
2
1
1
I4RS0B020007-01
I2RH01310001-01

Downloaded from www.Manualslib.com manuals search engine 1A-10 Engine General Information and Diagnosis:
ECM Transmission Data
ECM Reception Data
BCM TCMCombination
Meter
DATA ECM Transmit
Brake pedal switch signal
Vehicle speed signal
Engine speed signal
Engine torque signal
Accelerator pedal position signal
4WD Control
ModuleKeyless Start
Control
Module
A/C refrigerant pressure
signal
A/C compressor clutch signal
Engine type signal
Immobilizer indicator light control
signal
MIL control signal
Engine coolant temperature signal
Fuel level signal
Fuel consumption signal
Throttle position signal
Driving cycle active
Warm up cycle active
Odometer signal
I6RW0D110003-02
DATA ECM Receive
ABS control
module
Transmission oil temperature signal
Transmission warning light signal Vehicle speed pulse signal A/T selector lever position signal
Transmission actual gear position signal
Wheel speed signal (front right)
Wheel speed signal (front left)
ABS indication signal
A/C switch ON signal
Electric load signalBCM
4WD mode status
Torque request signalTCM
MIL control signal4WD control
module
I6RW0D110013-02

Downloaded from www.Manualslib.com manuals search engine 1A-134 Engine General Information and Diagnosis:
DTC P0500: Vehicle Speed Sensor (VSS) MalfunctionS6RW0D1104050
Wiring Diagram
DTC Detecting Condition and Trouble Area9Check A/C condenser cooling fan control
1) Ignition switch turned OFF.
2) Remove ECM from vehicle body referring to “Engine
Control Module (ECM) Removal and Installation in
Section 1C” and connect connectors to ECM.
3) Run engine and turn ON A/C and blower fan switch.
4) Measure voltage between vehicle body ground and
“E01-58” wire terminal of ECM connector.
Is voltage lower 1.5 V?Intermittent trouble.
Check for intermittent
refer to “Intermittent and
Poor Connection
Inspection in Section
00”. If OK, substitute a
known-good ECM and
recheck.Faulty ECM. Step Action Yes No
[B]
REDWHTC01-13C01-12REDWHT
PPL
5IG112 V
BLK/WHT
BLK/ORN
4
6 [A]
E01-3E01-18REDWHTREDWHT
E01C01
3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238 3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238
BLK
RED
WHT WHT
12V
12V
1
23
4
WHT/BLK
WHT BLKRED/BLK
I6RW0D110043-02
[A]: For M/T model 2. Front right side wheel speed sensor (VSS 2) 5. Output shaft speed sensor
[B]: For A/T model 3. ABS control module 6. TCM
1. Front left side wheel speed sensor (VSS 1) 4. ECM
DTC detecting condition Trouble area
Vehicle speed signal is not input while fuel is cut at deceleration
for 4 seconds at 3600 rpm or less.
(2 driving cycle detection logic)• Wheel speed sensor (VSS) (for M/T model)
• Wheel speed sensor circuit (for M/T model)
• ABS control module assembly (for M/T model)
• Output shaft speed sensor (for A/T model)
• Output shaft speed sensor circuit (for A/T
model)
• TCM malfunction (for A/T model)
• ECM malfunction

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 Suspension General Diagnosis: 2A-1
Suspension
Suspension General Diagnosis
Diagnostic Information and Procedures
Suspension, Wheels and Tires Symptom DiagnosisS6RW0D2104001
Condition Possible cause Correction / Reference Item
Vehicle pulls (Leads)Mismatched or uneven tiresReplace tires.
Tires not adequately inflatedAdjust tire pressure.
Broken or sagging coil springsReplace coil springs.
Radial tire lateral forceReplace tire.
Disturbed wheel alignmentCheck and adjust wheel alignment.
Brake dragging in one road wheelRepair brake.
Loose, bent or broken front or rear
suspension partsTighten or replace related suspension parts.
Abnormal or excessive
tire wearSagging or broken coil springReplace coil spring.
Tire out of balanceAdjust balance or replace tire.
Disturbed wheel alignmentCheck and adjust wheel alignment.
Faulty strut (shock absorber)Replace strut (shock absorber).
Hard drivingReplace tires.
Overloaded vehicleReplace tires.
Not rotated tiresReplace or rotate tires.
Worn or loose wheel bearingReplace wheel bearing.
Wobbly wheel or tireReplace wheel or tire.
Tires not adequately inflatedAdjust tire pressure.
Front suspension frame and/or
suspension control arm are transformedCheck and replace.
Wheel trampBlister or bump on tireReplace tire.
Improper strut (shock absorber) actionReplace strut (shock absorber).
Shimmy, shake or
vibrationTire or wheel out of balanceBalance wheel or replace tire and/or wheel.
Loosen wheel bearingsReplace wheel bearings.
Worn tie-rod endsReplace tie-rod ends.
Worn lower ball jointsReplace suspension control arm.
Excessive wheel runoutRepair or replace wheel and/or tire.
Blister or bump on tireReplace tire.
Excessively loaded radial runout of tire /
wheel assemblyReplace tire or wheel.
Disturbed wheel alignmentCheck and adjust wheel alignment.
Loose or worn steering linkageTighten or replace steering linkage.
Abnormal noise, front endWorn, sticky or loose tie-rod ends, lower
ball joints, tie-rod inside ball joints or
drive shaft jointsReplace tie-rod end, suspension arm, tie-rod
or drive shaft joint.
Damaged struts or mountingsRepair or replace struts or mountings.
Worn suspension arm bushingsReplace suspension arm bushings.
Loose stabilizer barTighten bolts or nuts and/or replace bushes.
Loose wheel boltsTighten wheel bolts.
Loose suspension bolts or nutsTighten suspension bolts or nuts.
Broken or damaged wheel bearingsReplace wheel bearings.
Broken suspension springsReplace suspension springs.
Worn strut bearingsReplace strut bearing.
Malfunction of Power Steering SystemCheck and correct malfunction.
Low or uneven trim height
NOTE
See NOTE *1.

Broken or sagging coil springsReplace coil springs.
Over loadedCheck loading.
Incorrect coil springsReplace coil spring.
Tires not adequately inflatedAdjust tire pressure.
Ride too softFaulty strut (shock absorber)Replace strut (shock absorber).
Suspension bottomsOverloadedCheck loading.
Faulty strut (shock absorber)Replace strut (shock absorber).
Incorrect, broken or sagging coil springsReplace coil spring.

Downloaded from www.Manualslib.com manuals search engine 2A-2 Suspension General Diagnosis:
NOTE
*1: Right-to-left trim height (“H”) difference should be within 15 mm (0.6 in.) with curb weight. (same
with rear side.)

Body leans or sways in
cornersLoose stabilizer barTighten stabilizer bar bolts or nuts, or replace
bushes.
Faulty strut (shock absorber) or
mountingReplace strut (shock absorber) or tighten
mounting.
Broken or sagging coil springsReplace coil springs.
OverloadedCheck loading.
Cupped tiresFront struts defectiveReplace struts.
Worn wheel bearingsReplace wheel bearings.
Excessive tire or wheel run-outReplace tire and/or wheel.
Worn ball jointsReplace suspension control arm.
Tire out of balanceAdjust tire balance. Condition Possible cause Correction / Reference Item
“H”
I2RH01210001-01

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 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