2006 SUZUKI SX4 section 9

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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

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Driveline / Axle
Precautions
Precautions
Precautions on Driveline / AxleS6RW0D3000001
Precaution for Rear Differential Oil Leakage
Refer to “Precaution for Rear Differential Oil Leakage in Section 3B”.
Precaution in Diagnosing Trouble
Refer to “Precautions in Diagnosing Trouble in Section 3B”.
Precaution on CAN Troubleshooting
Refer to “Precaution on CAN Troubleshooting in Section 1A”.

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

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• When installing left oil seal (1) and right oil seal (2)
using special tool, use care so that oil seals in proper
direction and position as shown in the figure.
Special tool
: 09925–15410
Distance
“a”: 0 – 1 mm (0 – 0.04 in.)
“b”: 8 – 9 mm (0.13 – 0.35 in.)
• Be sure to apply grease to oil seal lip and bearing side
space indicated in the figure.
“A”: Grease 99000–25011 (SUZUKI Super Grease
A) • Press-fit center shaft (1) from left oil seal (2) side.
Specifications
Tightening Torque SpecificationsS6RW0D3117001
NOTE
The specified tightening torque is also described in the following.
“Front Drive Shaft Assembly Components Location”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
2 1
“A”
“b”
“a” “A”
I5RW0A311007-01
12
I5RW0A311008-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Brake hose mounting bolt 25 2.5 18.0)

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Specifications
Tightening Torque SpecificationsS6RW0D3127001
NOTE
The specified tightening torque is also described in the following.
“Rear Drive Shaft Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS6RW0D3128001
NOTE
Required service material is also described in the following.
“Rear Drive Shaft Components”

Special ToolS6RW0D3128002
09913–84510 09943–57021
Bearing installer Pliers, Low-Profile Clamp
))

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Input / Output Signal Table of 4WD Control ModuleS6RW0D3201008
4WD control module outputs the following signals to coupling assembly, indicators, according to the 2WD/4WD switch
operation.
On-Board Diagnostic System DescriptionS6RW0D3201009
For 4WD control system, 4WD control module has the following functions.
• When ignition switch is turned ON with engine at stop, 4WD AUTO indicator (1) and 4WD LOCK indicator (2) turn
on at the same time for 2 seconds in order to check operation of these indicators.
• When 4WD control module detects any malfunction in the following area, 4WD AUTO indicator (1) and 4WD LOCK
indicator (2) flash continuously or turn on and 4WD control module comes into fail-safe mode. For details of fail safe
mode, refer to “Fail-Safe Table”.
– 2WD/4WD switch
– Coupling air temperature sensor
– Coupling assembly
• DTC can be checked by using SUZUKI scan tool (3) connected to DLC (4).
• When 4WD control module detects any malfunction, 4WD control module will switch off the current to coupling
assembly and vehicle is changed to 2WD position.
DLC (Data Link Connector)
Refer to “Data Link Connector (DLC)” under “On-Board Diagnostic System Description in Section 1A”.Output signal (to each component parts)
Coupling
assembly4WD AUTO
indicator4WD LOCK
indicator
Input signal2WD/4WD switch{{{
Coupling air temperature sensor{
ECM{
ABS / ESP® control module{{{
1
2 3
4
I5RW0A320004-01

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CAN Communication System DescriptionS6RW0D3201010
Refer to “CAN Communication System Description in Section 1A” for CAN communication system description.
When 4WD control module receive the signal of abnormal as following information, vehicle is not changed to 4WD-
auto and 4WD-lock position.
4WD Control Module Transmission Data
4WD Control Module Reception Data
ECMCombination
Meter
TransmitDATA 4WD
4WD mode status
4WD auto mode
indication status
4WD lock mode
indication status
4WD diagnostic
trouble codes control
module
4WD clutch
engagement percent
ESP® hydraulic unit /
control module
(if equipped)
4WD clutch control
request impossibility
I7RW01320013-01
Accelerator position
Engine speedECM
DATA
Brake pedal switch signal
4WD
control
moduleWheel speed signal
(front right)
Wheel speed signal
(front left)
Wheel speed signal
(rear right)
Wheel speed signal
(rear left)

ABS hydraulic
unit /control
module
(if equipped)


ESP® hydraulic
unit /control
module
(if equipped)
ABS active
ESP® status signal
Clutch control request for
4WD active
Clutch control request
percent
Engine type signal
Engine torque signal
Receive
I7RW01320002-03

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Diagnostic Information and Procedures
4WD Control System CheckS6RW0D3204001
Refer to the following items for the details of each step.
Step Action Yes No
1) Customer complaint analysis
1) Perform customer complaint analysis.
Was customer complaint analysis performed?Go to Step 2. Perform customer
complaint analysis.
2) DTC check, record and clearance
1) Check for DTC.
Is there any DTC(s)?Print DTC or write them
down and clear them by
referring to “DTC
Clearance”. Go to Step
3.Go to Step 4.
3) Visual inspection
1) Perform visual inspection.
Is there any faulty condition?Repair or replace
malfunction part. Go to
St ep 11 .Go to Step 5.
4) Visual inspection
1) Perform visual inspection.
Is there any faulty condition?Repair or replace
malfunction part. Go to
St ep 11 .Go to Step 8.
5) Trouble symptom confirmation
1) Select 2WD/4WD switch to “2WD”, “4WD-auto” and
“4WD-lock” positions referring to “4WD Control System
Operation Inspection”.
2) Confirm trouble symptom.
Is trouble symptom identified?Go to Step 6. Go to Step 7.
6) Rechecking and record of DTC
1) Recheck for DTC referring to “DTC Check”.
Is there any DTC(s)?Go to Step 9. Go to Step 8.
7) Rechecking and record of DTC
1) Recheck for DTC referring to “DTC Check”.
Is there any DTC(s)?Go to Step 9. Go to Step 10.
8) 4WD control symptom diagnosis
1) Check and repair according to “4WD Control Symptom
Diagnosis”.
Are check and repair complete?Go to Step 11. Check and repair
malfunction part(s). Go
to Step 11.
9) Troubleshooting for DTC
1) Check and repair according to applicable DTC flow.
Are check and repair complete?Go to Step 11. Check and repair
malfunction part(s). Go
to Step 11.
10) Check for intermittent problems
1) Check for intermittent problems referring to “Intermittent
and Poor Connection Inspection in Section 00”.
Is there any faulty condition?Repair or replace
malfunction part(s). Go
to Step 11.Go to Step 11.
11) Final confirmation test
1) Clear DTC if any.
2) Perform final confirmation test.
Is there any problem symptom, DTC or abnormal condition?Go to Step 6. END.