rear 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 00-7 Precautions:
Precautions in Servicing 4WD ModelS6RW0D0000014
CAUTION!
• Never perform any of the following [A], [B]
and [C] types of service work.
If it is performed while 4WD-auto mode or
4WD-lock mode is selected, front wheels
(or rear wheels) drive rear wheels (or front
wheels) and vehicle accident, drivetrain
damage and personal injury may result.
Also, if it is performed while 2WD mode is
selected, the coupling may be damaged
because of the difference in revolution
speed between front wheels and rear
wheels.
• When testing with 2-wheel chassis
dynamometer or speedometer tester, be
sure to select 4WD system to 4WD-auto
mode or 4WD-lock mode and use 2-wheel
free roller together or make the vehicle as
front wheel drive by removing propeller
shaft.• When testing with 2-wheel brake tester, be
sure to observe the following instructions.
Otherwise, drivetrain damage and personal
injury may result.
– Shift transaxle to N (Neutral) position.
– Select 4WD system to 2WD mode.
– Run engine at specified idle speed.
– Rotate wheels (tires) by brake tester at
vehicle speed below 5 km/h (3 mile/h).
– Do not rotate wheels (tires) for 1 min. or
more.
• When using On-vehicle type wheel
balancing equipment (1), be sure to select
4WD system to 4WD-auto mode or 4WD-
lock mode and jack up all four wheels, off
the ground completely and support vehicle
with safety stands (2).
Be careful of other wheels, which will
rotate at the same time.
Using it with 2WD mode may damage
coupling.
• This vehicle should be towed under one of
the following conditions:
– With all wheels on a flatbed truck.
– With all wheels on the ground.

Precautions for Catalytic ConverterS6RW0D0000004
For vehicles equipped with a catalytic converter, use
only unleaded gasoline and be careful not to let a large
amount of unburned gasoline enter the converter or it
can be damaged.
• Conduct a spark jump test only when necessary,
make it as short as possible, and do not open the
throttle.
• Conduct engine compression checks within the
shortest possible time.
• Avoid situations which can result in engine misfire
(e.g. starting the engine when the fuel tank is nearly
empty.)[A]: Testing with 2-wheel chassis dynamometer or speedometer tester.
[B]: Driving front wheels, which are jacked up.
[C]: Towing under the condition where either front or rear wheels can not
rotate.
[A]
[B]
[C]
I3RH0A000004-03
I3RH01010062-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 0- i
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Section 0
CONTENTS
General Information
General Information ................................ 0A-1
General Description ............................................. 0A-1
Abbreviations ...................................................... 0A-1
Symbols .............................................................. 0A-2
Wire Color Symbols ............................................ 0A-2
Fasteners Information ......................................... 0A-3
Vehicle Lifting Points ........................................... 0A-5
Vehicle Identification Number ............................. 0A-6
Engine Identification Number .............................. 0A-6
Transmission Identification Number .................... 0A-6
Component Location ........................................... 0A-7
Warning, Caution and Information Labels
Location ............................................................ 0A-7
Maintenance and Lubrication ................. 0B-1
Precautions........................................................... 0B-1
Precautions for Maintenance and Lubrication ..... 0B-1
Scheduled Maintenance ...................................... 0B-1
Maintenance Schedule under Normal Driving
Conditions ......................................................... 0B-1
Maintenance Recommended under Severe
Driving Conditions ............................................. 0B-2
Repair Instructions .............................................. 0B-3
Accessory Drive Belt Inspection.......................... 0B-3
Accessory Drive Belt Replacement ..................... 0B-3
Valve Lash (Clearance) Inspection ..................... 0B-3
Engine Oil and Filter Change .............................. 0B-4
Engine Coolant Change ...................................... 0B-5
Exhaust System Inspection ................................. 0B-5
Spark Plug Replacement .................................... 0B-5
Air Cleaner Filter Inspection ................................ 0B-6
Air Cleaner Filter Replacement ........................... 0B-6
Fuel Lines and Connections Inspection .............. 0B-6
Fuel Filter Replacement ...................................... 0B-6
Fuel Tank Inspection ........................................... 0B-6PCV Valve Inspection ......................................... 0B-6
Fuel Evaporative Emission Control System
Inspection .......................................................... 0B-6
Brake Discs and Pads (Front) Inspection............ 0B-7
Brake Drums and Shoes (Rear) Inspection ........ 0B-7
Brake Hoses and Pipes Inspection ..................... 0B-7
Brake Fluid Replacement .................................... 0B-7
Brake Lever and Cable Inspection ...................... 0B-7
Clutch Fluid Inspection ........................................ 0B-8
Tires Inspection ................................................... 0B-8
Wheel Discs Inspection ....................................... 0B-8
Wheel Bearing Inspection ................................... 0B-8
Suspension System Inspection ........................... 0B-9
Steering System Inspection ................................ 0B-9
Drive Shaft (Axle) Boots Inspection .................... 0B-9
Propeller Shaft (4WD) Inspection...................... 0B-10
Manual Transaxle Oil Inspection ....................... 0B-10
Manual Transaxle Oil Replacement .................. 0B-10
Automatic Transaxle Fluid Level Inspection...... 0B-10
Automatic Transaxle Fluid Replacement .......... 0B-10
Automatic Transaxle Fluid Cooler Hose
Inspection ........................................................ 0B-10
Transfer Oil Inspection (4WD)........................... 0B-10
Transfer Oil Replacement (4WD) ...................... 0B-10
Rear Deferential Oil Inspection (4WD) .............. 0B-10
Rear Deferential Oil Replacement (4WD) ......... 0B-10
All Latches, Hinges and Locks Inspection......... 0B-10
HVAC Air Filter (If Equipped) Inspection ........... 0B-11
HVAC Air Filter (If Equipped) Replacement ...... 0B-11
Final Inspection for Maintenance Service ......... 0B-11
Specifications .....................................................0B-12
Tightening Torque Specifications ...................... 0B-12
Special Tools and Equipment ...........................0B-12
Recommended Fluids and Lubricants............... 0B-12
Special Tool ...................................................... 0B-12

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
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c
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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 General Information: 0A-6
In raising front or rear vehicle end off the floor by jacking,
be sure to put the jack against engine front mounting
member (1) or rear jacking bracket (2).
To perform service with either front or rear vehicle end
jacked up, be sure to place safety stands (1) under
shaded position of vehicle body (front) or body mounting
stay (2) (rear) so that vehicle body is securely supported.
And then check to ensure that vehicle body does not
slide on safety stands (1) and the vehicle is held stable
for safety’s sake.Vehicle Identification NumberS6RW0D0101006
The number is punched on the front dash panel in
engine room and it is also attached on the left side of
instrument panel depending on the vehicle specification.
Engine Identification NumberS6RW0D0101007
The number is punched on cylinder block.
Transmission Identification NumberS6RW0D0101008
The automatic transmission identification number is
located on transmission case.
[A]: Front 3. Cap
[B]: Rear
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I5RW0A010002-02
1 2
[B] [A]
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I5RW0A010003-03
I5RW0C010002-01
I3RM0A010005-01
I4RS0A010008-01

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-2
NOTE
• “R”: Replace or change
• “I”: Inspect and correct, replace or lubricate if necessary
• For spark plugs, replace every 50,000 km if the local law requires.
• Nickel spark plug: BKR6E-11 (NGK) or K20PR-U11 (DENSO)
• Iridium spark plug: IFR6J11 (NGK)
• Periodic replacement of fuel filter is not necessary if it is not instructed in “Periodic Maintenance
Schedule” section of the Owner’s manual. The scheduled maintenance varies depending on the
vehicle specification.

Maintenance Recommended under Severe Driving ConditionsS6RW0D0205002
If the vehicle is usually used under the conditions corresponding to any severe condition code given below, IT IS
RECOMMENDED that applicable maintenance operation be performed at the particular interval as shown in the
following table.
Severe condition code:
A: Repeated short trips
B: Driving on rough and/or muddy roads
C: Driving on dusty roads
D: Driving in extremely cold weather and/or salted roads
E: Repeated short trips in extremely cold weather
F: Leaded fuel use
G: – – – – –
H: Towing a trailer (if admitted)Automatic transaxle fluidFluid level (I: ))—I—I—I
Fluid change (R: ))Replace every 165,000 km (99,000
miles)
Fluid hose (i: ))———I——
Transfer oil (4WD) (leakage, level) (I: )) I—I—I—
Rear differential oil (4WD) (leakage, level) (I: )) (R: ) 1st 15,000 km only) R or I — I — I —
All latches, hinges and locks (I: ))—I—I—I
HVAC air filter (if equipped) (I: )) (R: ))—IR—IR
Severe
condition codeMaintenanceMaintenance
operationMaintenance interval
– B C D – – – – Accessory drive belt) IEvery 15,000 km
(9,000 miles) or 12 months
) REvery 45,000 km
(27,000 miles) or 36 months
A – C D E F – H Engine oil and oil filter) REvery 7,500 km
(4,500 miles) or 6 months
– – C – – – – – Air cleaner filter *1) IEvery 2,500 km
(1,500 miles)
) REvery 30,000 km
(18,000 miles) or 24 months
A B C – E F – H Spark plugsNickel plug
) REvery 10,000 km (6,000 miles) or 8
months
Iridium plug
(Highly recommended)Every 30,000 km (18,000 miles) or
24 months
– B C D – – – H Wheel bearings) IEvery 15,000 km
(9,000 miles) or 12 months
– B – D E – – HDrive shaft boots / Propeller shaft
(4WD)) / ) IEvery 15,000 km
(9,000 miles) or 12 months IntervalKm (x 1,000) 15 30 45 60 75 90
Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72

Downloaded from www.Manualslib.com manuals search engine 0B-7 Maintenance and Lubrication:
Brake Discs and Pads (Front) InspectionS6RW0D0206014
1) Remove wheel and caliper but don’t disconnect
brake hose from caliper.
2) Check front disc brake pads and discs for excessive
wear, damage and deflection. Replace parts as
necessary. For details, refer to “Front Disc Brake
Pad Inspection in Section 4B” and “Front Brake Disc
Inspection in Section 4B”.
Be sure to torque caliper pin bolts to specification.
Brake Drums and Shoes (Rear) InspectionS6RW0D0206015
1) Remove wheel and brake drum.
2) Check rear brake drums and brake linings for
excessive wear and damage, while wheels and
drums are removed. At the same time, check wheel
cylinders for leaks. Replace these parts as
necessary.
For details, refer to “Rear Brake Drum and Shoe
Inspection in Section 4C”.
Brake Hoses and Pipes InspectionS6RW0D0206016
Perform this inspection where these is enough light and
use a mirror as necessary.
• Check brake hoses and pipes for proper hookup,
leaks, cracks, chafing and other damage.
• Check that hoses and pipes are clear of sharp edges
and moving parts.
Repair or replace any of these parts as necessary.
CAUTION!
After replacing any brake pipe or hose, be
sure to carry out air purge operation.

Brake Fluid ReplacementS6RW0D0206017
Change brake fluid as follows.
Drain existing fluid from brake system completely, fill
system with specified fluid and carry out air purge
operation.
For air purging procedure, refer to “Air Bleeding of Brake
System in Section 4A”.
Brake Lever and Cable InspectionS6RW0D0206018
1) Inspect brake cable for damage and smooth
movement.
Replace cable if it is in deteriorated condition.
I3RM0A020006-01
I5RW0A020004-01
I4RS0A020008-01
I4RS0A020009-01

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-8
2) Check tooth tip of each notch for damage or wear. If
any damage or wear is found, replace parking lever.
3) Check parking brake lever for proper operation and
stroke, and adjust it if necessary.
For checking and adjusting procedures, refer to
“Parking Brake Inspection and Adjustment in Section
4D”.
Parking brake lever stroke
“a”: 4 – 9 notches (with 200 N (20 kg, 44 lbs) of pull
pressure)
Clutch Fluid InspectionS6RW0D0206019
1) Check clutch system for evidence of fluid leakage.
Repair leaky point if any.
2) Check reservoir for fluid level referring to “Clutch
Fluid Level Inspection in Section 5C”.
If fluid is lower than minimum level (1) of reservoir,
refill reservoir with specified brake fluid indicated on
reservoir cap (2).
Tires InspectionS6RW0D0206020
1) Check tires for uneven or excessive wear, or
damage. If defective, replace.
Refer to “Irregular and/or Premature Wear
Description in Section 2D” and “Wear Indicators
Description in Section 2D” for details.
2) Check inflating pressure of each tire and adjust
pressure to specification as necessary.
NOTE
• Tire inflation pressure should be checked
when tires are cool.
• Specified tire inflation pressure should be
found on tire placard or in owner’s manual
which came with the vehicle.

3) Rotate tires. For details, refer to “Tire Rotation in
Section 2D”.
Wheel Discs InspectionS6RW0D0206021
Inspect each wheel disc for dents, distortion and cracks.
A disc in badly damaged condition must be replaced.
Wheel Bearing InspectionS6RW0D0206022
1) Check front wheel bearing for wear, damage,
abnormal noise or rattles. For details, refer to “Front
Wheel Hub, Disc, Bolt and Bearing Check in Section
2B”.
2) Check rear wheel bearing for wear, damage,
abnormal noise or rattles. For details, refer to “Rear
Wheel Disc, Bolt and Bearing Inspection in Section
2C”.
I4RS0B020005-01
1
2
I5RW0A020005-01
1. Wear indicator
I2RH01020022-01
I2RH01020023-01

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
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3
2
1
1
I4RS0B020007-01
I2RH01310001-01

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-10
Propeller Shaft (4WD) InspectionS6RW0D0206026
1) Check propeller shaft connecting bolts for
looseness. If looseness is found, tighten to specified
torque.
2) Check propeller shaft joints for wear, play and
damage. If any defect is found, replace.
3) Check propeller shaft center support for biting of
foreign matter, crank, abnormal noise and damage.
If any defect is found, replace.
Manual Transaxle Oil InspectionS6RW0D0206027
Check transaxle oil for leakage, contamination and level
referring to “Manual Transaxle Oil Level Check in
Section 5B”.
Manual Transaxle Oil ReplacementS6RW0D0206028
Change transaxle oil with new specified oil referring to
“Manual Transaxle Oil Change in Section 5B”.
Automatic Transaxle Fluid Level InspectionS6RW0D0206037
Check fluid for leakage, contamination and level
referring to“A/T Fluid Level Check in Section 5A”.
Automatic Transaxle Fluid ReplacementS6RW0D0206038
Change fluid referring to “A/T Fluid Change in Section
5A”.
Automatic Transaxle Fluid Cooler Hose
Inspection
S6RW0D0206039
Check automatic transaxle fluid cooler hose for fluid
leakage, cracks, damage and deterioration. Replace
hose and/or clamp if any faulty condition is found.
Transfer Oil Inspection (4WD)S6RW0D0206040
Check transfer oil for leakage, contamination and level
referring to “Transfer Oil Level Check in Section 3C”.
Transfer Oil Replacement (4WD)S6RW0D0206030
Change transfer oil with new specified oil referring to
“Transfer Oil Change in Section 3C”.
Rear Deferential Oil Inspection (4WD)S6RW0D0206031
Check differential oil for leakage, contamination and
level referring to “Rear Differential Oil Level Check in
Section 3B”.
Rear Deferential Oil Replacement (4WD)S6RW0D0206032
Change differential oil with new specified oil referring to
“Rear Differential Oil Change in Section 3B”.
All Latches, Hinges and Locks InspectionS6RW0D0206033
Doors
Check that each door of front, rear and back doors
opens and closes smoothly and locks securely when
closed.
If any malfunction is found, lubricate hinge and latch or
repair door lock system.
Engine Hood
Check that secondary latch operates properly (check
that secondary latch keeps hood from opening all the
way even when pulling hood release handle inside
vehicle.) Also check that hood opens and closes
smoothly and properly and hood locks securely when
closed.
If any malfunction is found, lubricate hinge and latch, or
repair hood lock system.I5RW0A020006-01
I5RW0C020001-01
I2RH01020033-01