2006 SUZUKI SX4 PPL

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-14
Front Wheel Hub, Disc, Bolt and Bearing CheckS6RW0D2206008
• Inspect each wheel disc for dents, distortion and
cracks.
A disc in badly damaged condition must be replaced.
• Check rust of installation face inside of wheel disc.
As rust affects adversely, remove it thoroughly.
• Check tightness of wheel nuts and, if necessary,
retighten them to specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
• Check wear of wheel bearing. When measuring thrust
play, apply a dial gauge to wheel hub as shown in
figure.
Front wheel bearing thrust play
Limit: 0.1 mm (0.004 in.)
• Check wheel bearing noise and smooth wheel rotation
by rotating wheel.
If defective, replace bearing.
Suspension Control Arm / Bushing Removal
and Installation
S6RW0D2206009
CAUTION!
When removal and installing steering
knuckle assembly, be careful not to damage
dust boots of control arm joint by drive shaft
dust cover and brake dust cover.

Removal
1) Hoist vehicle and remove wheel.
2) Remove steering knuckle with front wheel hub
referring to step 2) to 5), 7) to 11) of “Removal” under
“Front Wheel Hub, Steering Knuckle and Wheel
Bearing Removal and Installation”.
3) Remove suspension control arm bolts (1).
4) Remove suspension control arm (2).
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Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-16
Assembly
1) Front bushing
Press-fit front bushing (1) by using special tools and
press (2).
Special tool
(A): 09943–76310
(B): 09913–75821
CAUTION!
Be sure to use new bushing.

NOTE
• Before installing bushing, apply soap
water on its circumference to facilitate
bushing installation.

2) Press-fit bushing (1) so that dimensions “A” and “B”
in figure become equal.
Suspension Control Arm / Steering Knuckle
Check
S6RW0D2206011
Inspect for cracks, deformation or damage.
If defective, replace.
Suspension Control Arm Bushing CheckS6RW0D2206012
Inspect for damage, wear or deterioration.
If defective, replace.
Suspension Control Arm Joint CheckS6RW0D2206013
• Check smooth rotation of ball stud.
• Check damages of ball stud.
• Check damages of dust cover.
NOTE
Suspension control arm and arm joint cannot
be separated.

If there is any damage to either parts, control arm must
be replaced as a complete unit.
12
(A) (B)
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Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-18
Front Suspension Frame, Stabilizer Bar and/or
Bushing Removal and Installation
S6RW0D2206015
WARNING!
When supporting and installing front
suspension frame, be sure to apply some
supporting equipment (such as mission jack)
at well-balanced position in the center
section of front suspension frame so as to
prevent from its drop. Otherwise drop and
injure.

CAUTION!
When removal and installing suspension
control arm, be careful not to damage dust
boots of suspension control arm joint by
drive shaft dust cover and brake dust cover.

Removal
1) Disconnect negative (–) cable at battery.
2) Remove air cleaner assembly referring to “Air
Cleaner Assembly Removal and Installation in
Section 1D”.
3) Remove hood referring to “Hood Removal and
Installation in Section 9J”.
4) Hoist vehicle and remove front wheels.
5) Remove exhaust No.1, No.2 and center pipes
referring to “Exhaust System Components in Section
1K”.
6) Remove steering gear case mounting bolt referring
to “Steering Gear Case Assembly Components in
Section 6C”.
7) Fix steering gear case to body with rope to avoid the
steering gear case fall off when front suspension
frame is lowered.
8) Remove suspension control arms and disconnect
stabilizer joints.
9) Support engine assembly by using chain hoist (1).10) Remove engine rear mounting nut and mounting
member nut referring to “Engine Mountings
Components in Section 1D”.
11) Support front suspension frame (2) with mission jack
(1).
12) Remove engine rear mounting, mounting member
bolt and front suspension frame mounting bolts (1).
13) Lower front suspension frame.
14) Remove stabilizer bar (1) with bushing from
suspension frame (2).
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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.
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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.
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Downloaded from www.Manualslib.com manuals search engine Wheels and Tires: 2D-2
Replacement Tires
When replacement is necessary, the original equipment
type tire should be used. Refer to the Tire Placard.
Replacement tires should be of the same size, load
range and construction as those originally on the vehicle.
Use of any other size or type tire may affect ride,
handling, speedometer / odometer calibration, vehicle
ground clearance and tire or snow chain clearance to the
body and chassis.
It is recommended that new tires be installed in pairs on
the same axle. If necessary to replace only one tire, it
should be paired with the tire having the most tread, to
equalize braking traction.
WARNING!
Do not mix different types of tires on the
same vehicle such as radial, bias and bias-
belted tires except in emergencies, because
handling may be seriously affected and may
result in loss of control.

The metric term for tire inflation pressure is the kilo
pascal (kPa). Tire pressures is usually printed in both
kPa and kgf/cm
2 on the “Tire Placard”.
Metric tire gauges are available from tool suppliers.
The chart, shown in the table, converts commonly used
inflation pressures from kPa to kgf/cm
2 and psi.
Wheels DescriptionS6RW0D2401002
Wheel Maintenance
Wheel repairs that use welding, heating, or peening are
not approved. All damaged wheels should be replaced.
Replacement Wheels
Wheels must be replaced if they are bent, dented, have
excessive lateral or radial runout, air leak through welds,
have elongated bolt holes, if lug wheel bolts won’t stay
tight, or if they are heavily rusted. Wheels with greater
runout than shown in the following may cause
objectional vibrations.
Replacement wheels must be equivalent to the original
equipment wheels in load capacity, diameter, rim with
offset and mounting configuration. A wheel of improper
size or type may affect wheel and bearing life, brake
cooling, speedometer / odometer calibration, vehicle
ground clearance and tire clearance to body and
chassis.How to Measure Wheel Runout
To measure the wheel runout, it is necessary to use an
accurate dial indicator. The tire may be on or off the
wheel. The wheel should be installed to the wheel
balancer of the like for proper measurement.
Take measurements of both lateral runout “a” and radial
runout “b” at both inside and outside of the rim flange.
With the dial indicator set in place securely, turn the
wheel one full revolution slowly and record every reading
of the indicator.
When the measured runout exceeds the specification
and correction by the balancer adjustment is impossible,
replace the wheel. If the reading is affected by welding,
paint or scratch, it should be ignored.
Lateral runout limit “a”
Aluminum wheel: 0.3 mm (0.012 in.)
Steel wheel: 0.9 mm (0.035 in.)
Radial runout limit “b”
Aluminum wheel: 0.3 mm (0.012 in.)
Steel wheel: 0.7 mm (0.028 in.)
Metric Lug Nuts and Wheel Studs
All models use metric lug nuts and wheel studs.
Metric lug nuts and wheel studs size
M12 x 1.25
If a broken stud is found, see “Front Wheel Hub, Disc,
Bolt and Bearing Check in Section 2B”, “Front Wheel
Hub, Steering Knuckle and Wheel Bearing Removal and
Installation in Section 2B”, “Rear Wheel Hub Assembly
Removal and Installation in Section 2C”. kPa kgf/cm
2psi
Conversion: 1 psi =
6.895 kPa 1 kgf/cm
2 =
98.066 kPa160 1.6 23
180 1.8 26
200 2.0 29
220 2.2 32
240 2.4 35
260 2.6 38
280 2.8 41
300 3.0 44
320 3.2 47
340 3.4 50I4RS0A240001-01
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Downloaded from www.Manualslib.com manuals search engine Wheels and Tires: 2D-6
Wheel (with Tire) Removal and InstallationS6RW0D2406003
Removal
CAUTION!
Never use heat to loosen tight wheel because
the application of heat to wheel causes the
wheel life shorter and the wheel bearing
damage.

1) Loosen wheel nuts by approximately 180° (half a
rotation).
2) Hoist vehicle.
3) Make sure that the vehicle will not fall off by trying to
move vehicle body in both ways.
4) Remove wheel nuts except one.
5) Support the wheel and/or tire not to drop the wheel
and then remove the nut left with the wheel.
Installation
For installation, reverse removal procedure, noting the
following.
• Wheel nuts must be tightened in sequence and to
specified torque to avoid bending wheel or brake disc
or drum as shown in the figure.
NOTE
Before installing wheels, remove any build-
up of corrosion on wheel mounting surface
and brake disc or drum mounting surface by
scraping and wire brushing. Installing wheels
without good metal-to-metal contact at
mounting surfaces can cause wheel bolts to
loosen, which can later allow a wheel to
come off while vehicle is moving.

Tightening order
“1” – “2” – “3” – “4” – “5”
Tightening torque
Wheel nut (a): 85 N·m (8.5 kgf-m, 61.5 lb-ft)
Tire Mounting and DismountingS6RW0D2406004
WARNING!
Do not stand over tire when inflating. Bead
may break when bead snaps over rim’s safety
hump and cause serious personal injury.
Do not exceed specified pressure when
inflating. If specified pressure will not seat
beads, deflate, re-lubricate and reinflate.
Over inflation may cause bead to break and
cause serious personal injury.

Use a tire changing machine to mount or dismount tires.
Follow equipment manufacturer’s instructions. Do not
use hand tools or tire irons alone to change tires as they
may damage tire beads or wheel rim.
Rim bead seats should be cleaned with a wire brush or
coarse steel wool to remove lubricants, old rubber and
light rust. Before mounting or dismounting a tire, bead
area should be well lubricated with approved tire
lubricant.
After mounting, inflate 330 kPa (47.9 psi) pressure so
that beads are completely seated. Then adjust pressure
to specified shown in the tire placard.
Tire RepairS6RW0D2406005
There are many different materials and techniques on
the market to repair tires. As not all of these work on all
types of tires, tire manufacturers have published detailed
instructions on how and when to repair tires. These
instructions can be obtained from each tire
manufacturer.
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Downloaded from www.Manualslib.com manuals search engine Table of Contents 3- i
3
Section 3
CONTENTS
Driveline / Axle
Precautions ................................................. 3-1
Precautions............................................................. 3-1
Precautions on Driveline / Axle ............................. 3-1
Drive Shaft / Axle ..................................... 3A-1
Front ......................................................................... 3A-1
General Description ............................................. 3A-1
Front Drive Shaft Construction ............................ 3A-1
Component Location ........................................... 3A-1
Front Drive Shaft Assembly Components
Location ............................................................ 3A-1
Diagnostic Information and Procedures ............ 3A-2
Front Drive Shaft Symptom Diagnosis ................ 3A-2
Repair Instructions .............................................. 3A-2
Front Drive Shaft Components ........................... 3A-2
Front Drive Shaft Assembly On-Vehicle
Inspection.......................................................... 3A-3
Front Drive Shaft Assembly Removal and
Installation ......................................................... 3A-3
Front Drive Shaft Disassembly and
Reassembly ...................................................... 3A-4
Center Shaft and Center Bearing Support
Disassembly and Reassembly (If Equipped) .. 3A-12
Specifications..................................................... 3A-13
Tightening Torque Specifications ...................... 3A-13
Special Tools and Equipment ........................... 3A-14
Recommended Service Material ....................... 3A-14
Special Tool ...................................................... 3A-14
Rear ........................................................................ 3A-15
General Description ........................................... 3A-15
Rear Drive Shaft Construction .......................... 3A-15
Repair Instructions ............................................ 3A-15
Rear Drive Shaft Components .......................... 3A-15
Rear Drive Shaft Assembly Removal and
Installation ....................................................... 3A-16
Rear Drive Shaft Disassembly and
Reassembly .................................................... 3A-16
Specifications..................................................... 3A-18
Tightening Torque Specifications ...................... 3A-18
Special Tools and Equipment ........................... 3A-18
Recommended Service Material ....................... 3A-18
Special Tool ...................................................... 3A-18
Differential ................................................ 3B-1
Precautions...........................................................3B-1
Precaution for Rear Differential Oil Leakage....... 3B-1
Precautions in Diagnosing Trouble ..................... 3B-1
General Description .............................................3B-2
Rear Differential Description ............................... 3B-2
Coupling Description ........................................... 3B-2
4WD Control System Components ..................... 3B-3
4WD Control System Description........................ 3B-4
Function of 4WD Control System Component .... 3B-4
4WD Control System Wiring Circuit Diagram...... 3B-5
Terminal Arrangement of 4WD Control
Module .............................................................. 3B-5
Input / Output Signal Table of 4WD Control
Module .............................................................. 3B-6
On-Board Diagnostic System Description ........... 3B-6
CAN Communication System Description........... 3B-7
Diagnostic Information and Procedures ............3B-8
4WD Control System Check ............................... 3B-8
4WD Position Indicator Operation Check.......... 3B-10
4WD Control System Operation Inspection ...... 3B-10
Visual Inspection ............................................... 3B-11
DTC Check........................................................ 3B-11
DTC Clearance ................................................. 3B-11
DTC Table ......................................................... 3B-12
Fail-Safe Table .................................................. 3B-12
Scan Tool Data ................................................. 3B-13
Rear Differential Symptom Diagnosis ............... 3B-14
4WD Control Symptom Diagnosis..................... 3B-14
4WD Position Indicator Does Not Come ON at
Ignition Switch ON but Engine Stops .............. 3B-15
4WD Position Indicator Remains ON Steady
at Ignition Switch ON....................................... 3B-16
DTC C1240: 4WD Control Module Power
Supply Circuit Malfunction............................... 3B-17
DTC C1243: Internal Circuit Malfunction of
4WD Control Module ....................................... 3B-18
DTC C1250: Coupling Air Temperature
Sensor Circuit Open ........................................ 3B-19
DTC C1251: Coupling Air Temperature
Sensor Circuit Short ........................................ 3B-21
DTC C1252: Coupling Assembly Circuit Open .. 3B-22
DTC C1253: Coupling Assembly Circuit Short .. 3B-24
DTC C1254: 2WD/4WD Switch Malfunction ..... 3B-25
DTC U0073: Control Module Communication
Bus Off ............................................................ 3B-27