2006 SUZUKI SX4 cable

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.

Downloaded from www.Manualslib.com manuals search engine 3B-31 Differential:
2WD/4WD Switch Removal and InstallationS6RW0D3206003
Removal
1) Disconnect negative cable at battery.
2) Remove console box (2).
3) Remove 2WD/4WD switch (1) from console box.
Installation
Reverse removal procedure for installation.
2WD/4WD Switch InspectionS6RW0D3206004
Check 2WD/4WD switch for continuity between
terminals at each switch position.
If check result is not as specified, replace switch.
4WD Control Module Removal and InstallationS6RW0D3206005
Removal
1) Disconnect negative cable at battery.
2) Remove center ventilation louver referring to “Center
Ventilation Louver Removal and Installation in
Section 7A”.
3) Disconnect connector (1) from 4WD control module.
4) Remove 4WD control module (2).
Installation
Reverse removal procedure for installation.
Coupling Air Temperature Sensor Removal and
Installation
S6RW0D3206006
Removal
1) Dismount rear differential referring to “Rear
Differential Dismounting and Remounting”.
2) Remove coupling air temperature sensor (1) from
rear differential (2).
Installation
Reverse removal procedure for installation, noting the
following point.
• Tighten coupling air temperature sensor to specified
torque.
Tightening torque
Coupling air temperature sensor: 18 N·m (1.8 kgf-
m, 13.0 lb-ft)
1
2
I5RW0A320017-02
Terminal
Switch position
2WD
AUTO
LOCK
11
22
3 3
4 4
5 5
I5RW0A320018-02
2
1
I5RW0A320019-01
12
I5RW0A320020-02

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-50
09922–76150 09922–76250
Bevel pinion nut Bevel gear dummy
) / )) / )
09922–76330 09922–76340
Bevel pinion rear collar Bevel pinion rear collar
) / ) / )) / ) / )
09922–76420 09922–76530
Bevel pinion front collar Bevel pinion gauge block
) / ) / )) / )
09922–85811 09925–18011
Spring pin remover (4.5 mm) Transmission gear, bush
and bearing installer
) / ))
09925–88210 09926–48010
Bearing puller attachment Universal joint assembling
tool
) / )) / )
09927–27910 09930–40113
Holder, bevel pinion Flywheel rotor holder
) / )) / )
09951–26020 SUZUKI scan tool
Bush remover & installer
support—
) / )This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12. ) / )

Downloaded from www.Manualslib.com manuals search engine 3C-3 Transfer:
Transfer Dismounting and RemountingS6RW0D3306003
Dismounting
1) Disconnect negative cable at battery.
2) Drain transaxle oil and transfer oil.
3) Remove drive shafts assembly referring to “Front
Drive Shaft Assembly Removal and Installation in
Section 3A”.
4) Remove exhaust No.1, No.2 and center pipes
referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
5) Remove suspension frame, engine front mounting
member and mounting member referring to “Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation in Section 2B” and “Engine
Assembly Removal and Installation in Section 1D”.
6) Remove engine rear mounting bracket (1) and
stiffeners (2) from transfer.
7) Support transfer with transmission jack.
8) Remove transfer to transaxle bolts (1), and then
lower transfer assembly (2).Remounting
Reverse dismounting procedure for remounting of
transfer, noting the following points.
• Apply grease to left case (1) as shown in figure.
“A”: Grease 99000–25010 (SUZUKI Super Grease
A)
• Tighten engine rear mounting bracket nut to specified
torque referring to “Engine Mountings Components in
Section 1D”.
• Tighten bolts to specified torque as follows.
Tightening torque
Stiffener No.1 bolt and No.2 bolt (a): 55 N·m (5.5
kgf-m, 40.0 lb-ft)
Transfer to transaxle bolt (b): 98 N·m (9.8 kgf-m,
71.0 lb-ft)
2
2
1I5RW0A330004-01
1
1
2
I5RW0A330005-02
I5RW0C330001-01
(a)
(a)
(b)
(b)
2
I5RW0A330006-02

Downloaded from www.Manualslib.com manuals search engine Table of Contents 4- i
4
Section 4
CONTENTS
Brakes
Precautions ................................................. 4-1
Precautions............................................................. 4-1
Precautions for Brakes .......................................... 4-1
Brake Control System and Diagnosis ... 4A-1
Precautions........................................................... 4A-1
Precautions on Brake .......................................... 4A-1
General Description ............................................. 4A-1
Brakes Construction ............................................ 4A-1
Brake Pedal Foot Protection System
Construction (If Equipped) ................................ 4A-2
Front Brake Hose / Pipe Construction................. 4A-3
Rear Brake Hose / Pipe Construction ................. 4A-4
Diagnostic Information and Procedures ............ 4A-4
Brakes Diagnosis Note ....................................... 4A-4
Brakes Symptom Diagnosis ................................ 4A-5
Repair Instructions .............................................. 4A-7
Brake Pedal Components ................................... 4A-7
Brake Pedal Free Height Inspection ................... 4A-7
Brake Pedal Play Inspection ............................... 4A-7
Excessive Pedal Travel Inspection ..................... 4A-7
Brake Fluid Level Inspection ............................... 4A-8
Brake Light Switch Adjustment ........................... 4A-8
Air Bleeding of Brake System ............................. 4A-8
Front Brake Hose / Pipe Removal and
Installation ......................................................... 4A-9
Rear Brake Hose / Pipe Removal and
Installation ....................................................... 4A-10
Brake Hose and Pipe Inspection ....................... 4A-10
Master Cylinder and Brake Booster
Components.................................................... 4A-11
Master Cylinder Reservoir Removal and
Installation ....................................................... 4A-11
Master Cylinder Removal and Installation......... 4A-12
Master Cylinder Inspection ............................... 4A-13
Booster Operation Inspection ........................... 4A-14
Brake Booster Removal and Installation ........... 4A-15
Brake Booster Inspection .................................. 4A-15
Booster Push Clevis Rod Adjustment ............... 4A-16
Specifications..................................................... 4A-16
Tightening Torque Specifications ...................... 4A-16
Special Tools and Equipment ........................... 4A-16
Recommended Service Material ....................... 4A-16
Special Tool ...................................................... 4A-16
Front Brakes ............................................ 4B-1
Repair Instructions ..............................................4B-1
Front Disc Brake Components ............................ 4B-1
Front Disc Brake Pad On-Vehicle Inspection ...... 4B-2
Front Disc Brake Pad Removal and
Installation ......................................................... 4B-2
Front Disc Brake Pad Inspection......................... 4B-3
Front Disc Brake Caliper Removal and
Installation ......................................................... 4B-3
Front Disc Brake Caliper Disassembly and
Assembly........................................................... 4B-4
Front Disc Brake Caliper Inspection.................... 4B-6
Front Brake Disc Removal and Installation ......... 4B-6
Front Brake Disc Inspection ................................ 4B-7
Specifications .......................................................4B-8
Tightening Torque Specifications ........................ 4B-8
Special Tools and Equipment .............................4B-8
Recommended Service Material ......................... 4B-8
Special Tool ........................................................ 4B-8
Rear Brakes.............................................. 4C-1
Repair Instructions ..............................................4C-1
Rear Drum Brake Components ...........................4C-1
Rear Brake Drum Removal and Installation ........4C-2
Rear Brake Drum and Shoe Inspection ..............4C-2
Rear Brake Shoe On-Vehicle Inspection ............4C-3
Rear Brake Shoe Removal and Installation ........4C-3
Rear Brake Shoe Inspection ...............................4C-4
Wheel Cylinder Removal and Installation ...........4C-4
Wheel Cylinder Inspection ..................................4C-5
Brake Back Plate Removal and Installation ........4C-5
Specifications .......................................................4C-6
Tightening Torque Specifications ........................4C-6
Special Tools and Equipment .............................4C-6
Recommended Service Material .........................4C-6
Parking Brake .......................................... 4D-1
General Description .............................................4D-1
Parking Brake Cable Construction ......................4D-1
Repair Instructions ..............................................4D-2
Parking Brake Inspection and Adjustment ..........4D-2
Parking Brake Cable Removal and
Installation .........................................................4D-2
Parking Brake Lever Removal and Installation ....4D-3

Downloaded from www.Manualslib.com manuals search engine 4A-1 Brake Control System and Diagnosis:
Brakes
Brake Control System and Diagnosis
Precautions
Precautions on BrakeS6RW0D4100001
Air Bag Warning
Refer to“Air Bag Warning in Section 00”.
Brakes Diagnosis Note
Refer to “Brakes Diagnosis Note”.
General Description
Brakes ConstructionS6RW0D4101001
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two
in front and four in rear).
The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make two
independent circuits. One connects front right & rear left brakes and the other connects front left & rear right brakes.
In this brake system, the disc brake is used for the front wheel brake and drum brake (leading / trailing shoes) for the
rear brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and
mechanical linkage system. The same brake shoes of rear drum brake are used for both parking and foot brakes.
NOTE
• The figures show LH steering vehicle.
• The difference between RH steering vehicle and LH steering vehicle is the location of the brake
master cylinder, the brake booster and ABS hydraulic unit / control module assembly.

A
421
37
7
658
I7RW01410001-01
1. Brake booster 4. Primary side 7. Parking brake cable
2. Master cylinder 5. ABS hydraulic unit / control module assembly 8. 4-way joint
3. Secondary side 6. Parking brake lever A: Forward

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-6
Dragging brakes (Without
a very light drag is
present in all brakes
immediately after pedal is
released)Master cylinder pistons not returning
correctlyReplace master cylinder.
Restricted brake pipes or hosesCheck for soft hoses or damaged pipes and
replace with new hoses and/or new brake
piping.
Incorrect parking brake adjustment on
rear brakesCheck and adjust to correct specifications.
Weakened or broken return springs in
the drum brakeReplace.
Sluggish parking brake cables or linkageRepair or replace.
Wheel cylinder or caliper piston stickingRepair as necessary.
Badly worn piston seal in caliperReplace piston seal.
Improper brake pedal free heightCheck brake pedal free height.
Pedal pulsation (Pedal
pulsates when depressed
for braking)Damaged wheel bearingsReplace wheel bearings.
Distorted steering knuckle or rear wheel
spindle or rear axle shaftReplace knuckle or rear wheel spindle or rear
axle shaft.
Excessive disc lateral runoutCheck per instructions. If not within
specifications, replace or machine disc.
Rear drums out of roundCheck runout.
Repair or replace drum as necessary.
Braking noiseGlazed brake pad and/or brake shoeRepair or replace brake pad and/or brake
shoe.
Worn or distorted brake shoeReplace brake shoe.
Loose front wheel bearingsReplace wheel hub.
Distorted backing plates or loose
mounting boltsReplace or retighten securing bolts.
Contact wear indicator to brake discReplace brake pads.
Brake warning light lights
after engine startParking brake appliedRelease parking brake and check that brake
warning light turns off.
Insufficient amount of brake fluidInvestigate leaky point, correct it and add
brake fluid.
Brake fluid leakingInvestigate leaky point, correct it and add
brake fluid.
Brake warning light circuit faultyRepair circuit.
Malfunctioning EBD systemCheck system referring to “EBD Warning Light
(Brake Warning Light) Comes ON Steady in
Section 4E”.
Brake warning light turns
on when brake is appliedBrake fluid leakingInvestigate leaky point, correct it and add
brake fluid.
Insufficient amount of brake fluidInvestigate leaky point, correct it and add
brake fluid.
Brake warning light fails
to turn on even when
parking brake is appliedBrake warning light circuit faultyReplace bulb or repair circuit.
ABS warning light turns
on after engine startMalfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light turns
on when brake is appliedMalfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light after
ignition switch has turned
ON Bulb burnt outReplace bulb.
Malfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light flashesNew ABS hydraulic unit / control module
assembly installed.Perform “ABS Hydraulic Unit Operation Check
in Section 4E”. Condition Possible cause Correction / Reference Item