2006 SUZUKI SX4 Rear sensor

Downloaded from www.Manualslib.com manuals search engine 2B-5 Front Suspension:
Front Strut Assembly Removal and InstallationS6RW0D2206003
CAUTION!
When rebound stopper and strut assembly
were removed, check strut support lower nut
for specified torque before installing strut
assembly.

Removal
1) Remove hood rear seal (1), and then remove cowl
top garnish (2) from vehicle.
NOTE
When servicing component parts of strut
assembly, beforehand loosen strut nut a little
before removing strut assembly. This will
make service work easier. Note that the nut
must not be removed at this point.

2) Hoist vehicle, allowing front suspension to hang free.
3) Remove wheel and disconnect stabilizer joint (1)
from strut bracket.
When loosening joint nut, hold stud with hexagon
wrench (2).4) Remove brake hose mounting bolt (1). Remove
brake hose (2) from bracket and wheel speed sensor
harness (3) from strut bracket as shown in figure.
5) Remove strut bracket bolts and nuts (4).
6) Remove strut nut (1), and remove rebound stopper
(2).
NOTE
Hold strut by hand so that it will not fall off.

7) Remove strut assembly.
2
1
I5RW0A220003-01
1
2
I5RW0A220004-01
3
214
I5RW0A220005-01
2
1
I4RS0A220006-01

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

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

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

7) Remove coil spring (3).
8) Remove spring upper seat (1) from vehicle body and
lower seat (2) from rear axle.
2
1
I5RW0A230008-01
1
2
2
I5RW0A230009-01
1
2
3
I5RW0A230010-01
1
2
I5RW0A230011-01

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

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

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

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

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

Downloaded from www.Manualslib.com manuals search engine Rear Suspension: 2C-8
Rear Wheel Hub Assembly Removal and
Installation
S6RW0D2306012
CAUTION!
Do not allow brake fluid to get on painted
surfaces. Painted surface will be damaged.

Removal
1) Hoist vehicle. Then remove rear wheel and brake
drum.
2) For 4WD model, remove rear drive shaft referring to
“Rear Drive Shaft Assembly Removal and
Installation in Section 3A”.
3) Remove rear brake shoe.
4) Disconnect brake pipe flare nut (1) from wheel
cylinder (3) and put bleeder plug cap (4) onto pipe
(2) to prevent fluid from spilling.5) Disconnect wheel speed sensor (1).
6) Remove brake back plate (2) and rear wheel hub
from rear axle.
7) If necessary, remove wheel stud bolts (1) with
copper hammer or hydraulic press.
CAUTION!
Never remove bolt unless replacement is
necessary.
Be sure to use a new bolt for replacement.

1
42
3
I5RW0A230024-01
[A]: 4WD model
[B]: 2WD model
2 [A]
1 [B]
1
I7RW01230018-01
1
I5JB0A220016-01

Downloaded from www.Manualslib.com manuals search engine 2C-9 Rear Suspension:
Installation
1) Insert wheel stud bolt (1) in hub hole. Rotate wheel
stud bolt slowly to assure that serrations are aligned
with those made by original bolt.
2) Install brake back plate, rear wheel hub and new rear
wheel hub bolts and then tighten rear wheel hub
mounting bolts to specified torque.
CAUTION!
Use new rear wheel hub mounting bolts.

Tightening torque
Rear wheel hub mounting bolt: 73 N·m (7.3 kgf-
m, 53.0 lb-ft)
3) For 4WD model, install rear drive shaft referring to
“Rear Drive Shaft Assembly Removal and
Installation in Section 3A”.
CAUTION!
Never reuse rear drive shaft nut.

Tightening torque
Drive shaft nut (a): 175 N·m (17.5 kgf-m, 127.0
lb-ft)4) Connect wheel speed sensor and tighten wheel
speed sensor bolt (2WD model) to specified torque.
Tightening torque
Wheel speed sensor bolt : 11 N·m (1.1 kgf-m, 8.0
lb-ft)
5) Connect brake pipe (1) to wheel cylinder and tighten
brake pipe flare nut to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft)
6) Install brake drum referring to Step 1) and 2) of
“Installation” under “Rear Brake Drum Removal and
Installation in Section 4C”.
7) Fill reservoir with brake fluid and bleed brake
system. For bleeding operation, see “Air Bleeding of
Brake System in Section 4A”.
8) Install wheel and tighten wheel nuts to specified
torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
9) Upon completion of all jobs, depress brake pedal
with about 300 N (30 kg, 66 lbs) load at least 3 times
so as to obtain proper drum-to-shoe clearance.
Adjust parking brake cable. For adjustment, see
“Parking Brake Inspection and Adjustment in Section
4D”.
10) Check to ensure that brake drum is free from
dragging and proper braking is obtained.
11) Perform brake test (foot brake and parking brake).
12) Check each installed part for fluid leakage.
1
I5JB0A220017-01
1,(a)
1
I7RW01230012-01
(a)
1
I5RW0A230018-01

Downloaded from www.Manualslib.com manuals search engine Rear Suspension: 2C-10
Specifications
Tightening Torque SpecificationsS6RW0D2307001
NOTE
The specified tightening torque is also described in the following.
“Rear Suspension Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Wheel nut 85 8.5 61.5) / ) / ) / ) / )
Rear shock absorber upper nut 30 3.0 22.0)
Rear shock absorber lower nut 90 9.0 65.0) / ) / )
Rear axle bolt 73 7.3 53.0) / )
Brake pipe flare nut 16 1.6 11.5) / )
Rear wheel hub mounting bolt 73 7.3 53.0)
Drive shaft nut 175 17.5 127.0)
Wheel speed sensor bolt 11 1.1 8.0)

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