2006 SUZUKI SX4 brake fluid

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-17
Engine Assembly Removal and InstallationS6RW0D1406013
Removal
1) Relieve fuel pressure according to “Fuel Pressure
Relief Procedure in Section 1G”.
2) Disconnect negative and positive cable at battery.
3) Disconnect ECM connectors.
4) Remove battery and battery tray with ECM.
5) Remove right and left side engine under covers.
6) Remove A/C compressor belt by referring to
“Compressor Drive Belt Removal and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
7) Drain engine oil referring to “Engine Oil and Filter
Change in Section 0B”.
8) Drain transaxle oil referring to “Manual Transaxle Oil
Change in Section 5B” or “A/T Fluid Change in
Section 5A”.
9) Drain transfer oil referring to “Transfer Oil Change in
Section 3C”.
10) Drain coolant referring to “Cooling System Draining
in Section 1F”
11) Remove air cleaner assembly referring to “Air
Cleaner Assembly Removal and Installation”.
12) With hose connected, detach A/C compressor from
its bracket referring to “Compressor Assembly
Removal and Installation in Section 7B” or
“Compressor Assembly Removal and Installation in
Section 7B”.
CAUTION!
Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

13) Remove cylinder upper cover (1).14) Disconnect the following electric wires/connectors
and each clamps.
• TP sensor (1)
• MAP sensor (2)
• ECT sensor (3)
•EGR valve (4)
• CMP sensor (5)
• Ignition coil assembly (6)
• Injector (7)
•HO2S (8)
• Oil control valve (9) (for engine with VVT system)
• Engine oil pressure switch (10)
• CKP sensor (12)
• Knock sensor (13)
• Generator (14)
• Starting motor (15)
• Ground terminal (16) from cylinder block
• Battery ground cable (17) from transaxle
• Back-up light switch (18) (for M/T model)
• Torque sensor (19)
• P/S motor (20)
• Output shaft speed sensor (VSS) (29) (for A/T
model)
• Solenoid valve (30) (for A/T model)
• Transmission range sensor (31) (for A/T model)
• Input shaft speed sensor (32) (for A/T model)
15) Disconnect the following cables, and remove control
cable bracket (23)
• Gear select control cable (21) (for M/T model)
• Gear shift control cable (22) (for M/T model)
• A/T select cable (33) (for A/T model)
16) Disconnect the following hoses.
• Brake booster hose (24) from intake manifold
• Radiator inlet and outlet hoses (25) from radiator
• Heater inlet and outlet hoses (26) from heater
core
• Fuel feed hose (27) from fuel feed pipe
• Fuel vapor hose (11) from fuel vapor pipe
• Clutch hose (28) from transaxle (for M/T model)
• A/T fluid cooler hoses (for A/T model)
F: Vehicle forward 8. Engine front mounting bracket : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
1. Engine right mounting bracket 9. Engine front mounting
: Be sure to direct yellow mark to forward.: 95 N⋅m (9.5 kgf-m, 69.0 lb-ft)
2. Engine right mounting 10. Transfer : 65 N⋅m (6.5 kgf-m, 47.0 lb-ft)
3. Engine left mounting bracket 11. Suspension frame : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
1
I5RW0A140009-01

Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-7
1) Set parking brake and place automatic transaxle in
PARK (NEUTRAL on manual transaxle). Turn off
ignition, turn off lights and all other electrical loads.
2) Check electrolyte level. If it is below low level line,
add distilled water.
3) Attach end of one jumper cable to positive terminal
of booster battery and the other end of the same
cable to positive terminal of discharged battery. (Use
12-volt battery only to jump start engine).
4) Attach one end of the remaining negative cable to
negative terminal of booster battery, and the other
end to a solid engine ground (such as exhaust
manifold) at least 45 cm (18 in.) away from battery of
vehicle being started.
5) Start engine of vehicle with booster battery and turn
off electrical accessories. Then start engine of the
vehicle with discharged battery.
6) Disconnect jumper cables in the exact reverse order.
With Charging Equipment
CAUTION!
When jump starting engine with charging
equipment, be sure equipment used is 12-
volt and negative ground. Do not use 24-volt
charging equipment. Using such equipment
can cause serious damage to electrical
system or electronic parts.

Battery Dismounting and RemountingS6RW0D1A06002
Dismounting
1) Disconnect negative cable (3).
2) Disconnect positive cable (2).
3) Remove retainer (4).
4) Remove battery (1).
Handling
When handling battery, the following safety precautions
should be followed:
• Hydrogen gas is produced by battery. A flame or
spark near battery may cause the gas to ignite.
• Battery fluid is highly acidic. Avoid spilling on clothing
or other fabric. Any spilled electrolyte should be
flushed with large quantity of water and cleaned
immediately.Remounting
1) Reverse removal procedure.
2) Tighten battery cables securely.
NOTE
Check to be sure that ground cable has
enough clearance to hood panel by terminal.

Water Pump / Generator Drive Belt Tension
Inspection and Adjustment
S6RW0D1A06006
WARNING!
• Disconnect negative cable at battery
before checking and adjusting belt
tension.
• To help avoid danger of being burned, do
not remove radiator cap while engine and
radiator are still hot. Scalding fluid and
steam can be blown out under pressure if
cap is taken off too soon.

1) Inspect belt for cracks, cuts, deformation, wear and
cleanliness. If it is necessary to replace belt, refer to
“Water Pump / Generator Drive Belt Removal and
Installation”.
2) Check belt for tension. Belt is in proper tension when
it deflects the following specification under thumb
pressure (about 10kg or 22 lb.).
If belt tension is out of specification, go to next steps.
Water pump / generator drive belt tension
“a”
Existing belt: 4.5 – 5.5 mm (0.18 – 0.22 in.) as
deflection / 10 kg (22 lbs)
New belt: 4.0 – 4.5mm (0.16 – 0.18 in.) as
deflection / 10 kg (22 lbs)
1. Battery 4. Retainer
2. Positive cable 5. Nut
3. Negative cable
21
4
3
5I7RW011A0005-01

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 Drive Shaft / Axle: Front 3A-4
9) Remove drive shaft assembly.
10) Remove center bearing support bolts (3) and remove
center bearing support (2) with center shaft (1) from
differential side gear, if equipped.
Installation
CAUTION!
• Be careful not to damage oil seals and
boots when installing drive shaft.
• Do not hit joint boot with hammer.
Inserting joint only by hands is allowed.
• Make sure that differential side joint is
inserted fully and its snap ring is seated as
it was.

Install drive shaft assembly by reversing removal
procedure and noting the following points.
• Tighten each bolt and nut to the specified torque
referring to “Front Drive Shaft Assembly Components
Location”.
• Tighten brake hose mounting bolt to specified torque.
Tightening torque
Brake hose mounting bolt: 25 N·m (2.5 kgf-m,
18.0 lb-ft)
• Fill transaxle with oil as specified referring to “Manual
Transaxle Oil Change in Section 5B” or “A/T Fluid
Change in Section 5A” and “Transfer Oil Change in
Section 3C” (4WD model).
• Check toe setting referring to “Front Wheel Alignment
Inspection and Adjustment in Section 2B” and adjust
as required.
Front Drive Shaft Disassembly and ReassemblyS6RW0D3116004
Disassembly
For DOJ type
CAUTION!
Disassembly of wheel side joint is not
allowed. If any noise or damage exists in it,
replace it as assembly.

1) Remove differential side (or center shaft side) boot
big band (1) as follows.
• For boot big band without joint [A]:
Remove boot big band by tapping boot and band
with plastic hammer. If it is hard to remove boot
big band, cut it using a nipper or an iron saw with
care not to damage joint housing.
• For boot big band with joint [B]:
Draw hooks of boot big band together and remove
band.3
2
1I2RH01310007-01
I4RH0A310004-01

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