2006 SUZUKI SX4 Rear sensor

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DTC U0100: Lost Communication with ECM .... 3B-27
DTC U0121: Lost Communication with ABS /
ESP® Control Module..................................... 3B-27
DTC U0155: Lost Communication with
Instrument Panel Cluster (IPC) Control
Module ............................................................ 3B-27
Inspection of 4WD Control Module and Its
Circuits ............................................................ 3B-27
Repair Instructions ............................................3B-30
Rear Differential Oil Level Check ...................... 3B-30
Rear Differential Oil Change ............................. 3B-30
2WD/4WD Switch Removal and Installation ..... 3B-31
2WD/4WD Switch Inspection ............................ 3B-31
4WD Control Module Removal and
Installation ....................................................... 3B-31
Coupling Air Temperature Sensor Removal
and Installation ................................................ 3B-31
Coupling Air Temperature Sensor Inspection ... 3B-32
Coupling Assembly Inspection .......................... 3B-32
Rear Differential Mountings Components ......... 3B-33
Front Mounting Arm and/or Rear Mounting
Bracket Assembly Removal and Installation ... 3B-34
Rear Mounting Bracket Assembly
Disassembly and Reassembly ........................ 3B-34
Rear Differential Dismounting and
Remounting ..................................................... 3B-34
Rear Differential Components ........................... 3B-35
Rear Differential Disassembly and
Reassembly .................................................... 3B-36
Rear Differential Inspection ............................... 3B-47
Specifications .....................................................3B-48
Tightening Torque Specifications ...................... 3B-48
Special Tools and Equipment ...........................3B-48
Recommended Service Material ....................... 3B-48
Special Tool ...................................................... 3B-49
Transfer .................................................... 3C-1
General Description ............................................. 3C-1
Transfer Description ............................................ 3C-1Diagnostic Information and Procedures ............3C-1
Transfer Symptom Diagnosis..............................3C-1
Repair Instructions ..............................................3C-2
Transfer Oil Level Check.....................................3C-2
Transfer Oil Change ............................................3C-2
Transfer Dismounting and Remounting ..............3C-3
Transfer Assembly Components .........................3C-4
Transfer Assembly Disassembly and
Reassembly ......................................................3C-5
Reduction Drive Gear Assembly Disassembly
and Reassembly ...............................................3C-7
Reduction Driven Gear Assembly
Disassembly and Reassembly ..........................3C-8
Transfer Right Case and Left Case
Disassembly and Reassembly ..........................3C-9
Transfer Output Retainer Assembly
Disassembly and Reassembly ........................3C-10
Transfer Assembly Inspection ...........................3C-14
Bevel Gear Tooth Contact Inspection ...............3C-14
Specifications .....................................................3C-16
Tightening Torque Specifications ......................3C-16
Special Tools and Equipment ...........................3C-17
Recommended Service Material .......................3C-17
Special Tool ......................................................3C-17
Propeller Shafts ....................................... 3D-1
Precautions ...........................................................3D-1
Propeller Shaft Caution .......................................3D-1
General Description .............................................3D-1
Propeller Shaft Construction ...............................3D-1
Diagnostic Information and Procedures ............3D-1
Propeller Shaft Symptom Diagnosis ...................3D-1
Repair Instructions ..............................................3D-2
Propeller Shaft Joint Check.................................3D-2
Propeller Shaft Assembly Removal and
Installation .........................................................3D-2
Propeller Shaft Inspection ...................................3D-2
Specifications .......................................................3D-3
Tightening Torque Specifications ........................3D-3

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-2
General Description
Rear Differential DescriptionS6RW0D3201001
The differential assembly uses a hypoid bevel pinion and gear.
The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine parts and
specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between hypoid bevel
pinion and gear, it is mandatory to lubricate them by hypoid gear oil.
Coupling DescriptionS6RW0D3201002
Coupling is installed in the forward of Rear differential. The road situation and driving are judged with 4WD control
module based on information from sensor and each control module, and the distribution of driving force of the front
and rear wheel has been changed by controlling the current to coupling. Coupling air temperature sensor is installed in
coupling case and measures the temperature in coupling.
4WD system has three driving positions (2WD, 4WD-auto, 4WD-lock). The position corresponding to the running
situation can be selected by 2WD/4WD switch.
1
2
3
4567810 9
I5RW0A320001-01
1. Companion flange 5. Drive bevel pinion (hypoid gear) 9. Differential pinion
2. Coupling case 6. Differential case 10. Drive bevel gear (hypoid gear)
3. Coupling assembly 7. Differential cover
4. Differential carrier 8. Differential side gear

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Scan Tool DataS6RW0D3204009
Scan Tool Data Definitions
Accel pedal Pos (Accelerator pedal position) (%)
Accelerator pedal opening ratio detected by signal on
CAN communication line fed from ECM.
Engine Speed (RPM)
This parameter indicates engine revolution calculated by
4WD control module.
4WD mode (2WD / AUTO / LOCK / ABS mode / Yaw
cont / ESP® req)
This parameter indicates 4WD mode according to 2WD/
4WD switch signal status detected by 4WD control
module.
4WD current (A)
This parameter indicates input current of coupling
assembly.
Battery voltage (V)
This parameter indicates battery voltage detected by
4WD control module.Coupling temp (°C, °F)
Coupling temperature detected by coupling air
temperature sensor installed in coupling assembly.
Wheel speed (F), Wheel speed (R) (km/h, mph)
Wheel speed is an ABS / ESP® control module internal
parameter. It is computed by reference pulses from the
wheel speed sensor.
F-R Wheel speed diff (Front-rear wheel speed
differential) (rpm)
This parameter indicates rotation difference between
front wheel and rear wheel detected by 4WD control
module.
4WD duty (%)
This parameter indicates operation rate of coupling
assembly. Scan tool data Vehicle conditionNormal condition / reference
values
) Accel pedal PosIgnition switch ON after
warmed up engineAccelerator pedal released 0 – 5%
Accelerator pedal depressed
fully90 – 100%
) Engine speed At engine idle speed Engine idle speed is display
) 4WD mode2WD/4WD switch selected to 2WD position 2WD
2WD/4WD switch selected to AUTO position AUTO
2WD/4WD switch selected to LOCK position LOCK
ABS operating ABS mode
Ignition switch ON and engine stop Relay off
Stability control operating Yaw cont
ESP® operating ESP® mode
) 4WD current Engine running 0 – 200 mA
) Battery voltage At engine idle speed 10 – 14 V
) Coupling temp Engine running –40 °C – 100 °C (–40 °F – 212 °F)
) Wheel speed (F) Vehicle stop 0 km/h, 0 MPH
) Wheel speed (R) Vehicle stop 0 km/h, 0 MPH
) F-R Wheel speed
DiffVehicle stop 0 rpm
) 4WD dutyIgnition switch ON and 2WD/4WD switch selected to
2WD position0%

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Rear Differential Symptom DiagnosisS6RW0D3204011
4WD Control Symptom DiagnosisS6RW0D3204012
Diagnose 4WD system after performing the following inspections.
• Perform 4WD control system check referring to “4WD Control System Check”. Condition Possible cause Correction / Reference Item
Gear noiseDeteriorated or water mixed lubricantRepair and replenish referring to “Rear
Differential Oil Change”.
Inadequate or insufficient lubricantRepair and replenish referring to “Rear
Differential Oil Change”.
Maladjusted backlash between drive
bevel pinion and gearAdjust as prescribed referring to “Rear
Differential Disassembly and Reassembly”.
Improper tooth contact in the mesh
between drive bevel pinion and gearAdjust or replace referring to “Rear Differential
Disassembly and Reassembly”.
Loose drive bevel gear securing boltsReplace or retighten referring to “Rear
Differential Disassembly and Reassembly”.
Damaged differential gear(s) or
differential pinion(s)Replace referring to “Rear Differential
Inspection”.
Bearing noise(Constant noise) Deteriorated or water
mixed lubricantRepair and replenish referring to “Rear
Differential Oil Change”.
(Constant noise) Inadequate or
insufficient lubricantRepair and replenish referring to “Rear
Differential Oil Change”.
(Noise while coasting) Damaged
bearing(s) of drive bevel pinionReplace referring to “Rear Differential
Inspection”.
(Noise while turning) Damaged
differential side bearing(s) or axle
bearing(s)Replace referring to “Rear Differential
Inspection”.
Oil leakageClogged breather plugClean.
Worn or damaged oil sealReplace.
Excessive oilAdjust oil level referring to “Rear Differential Oil
Change”.
Loose differential carrier boltsReplace or retighten.
Condition Possible cause Correction / Reference Item
4WD system does not
operate2WD/4WD switch faultyCheck switch referring to “2WD/4WD Switch
Inspection”.
Coupling air temperature sensor faultyCheck coupling air temperature sensor
referring to “Coupling Air Temperature Sensor
Inspection”.
Coupling assembly faultyCheck coupling assembly referring to
“Coupling Assembly Inspection”.
Wiring or grounding faultyRepair as necessary.
4WD control module faultyCheck 4WD control module referring to
“Inspection of 4WD Control Module and Its
Circuits”.
MAF sensor faultyCheck MAF sensor and its circuit.
Accelerator pedal position (APP) sensor
faultyCheck accelerator pedal position (APP) sensor
and its circuit.
CKP sensor faultyCheck CKP sensor and its circuit.
Front and/or rear wheel speed sensor
faultyCheck front and/or rear wheel speed sensor
and its circuit.
Steering angle sensor faultyCheck steering angle sensor and its circuit.
ABS / ESP® control module faultyCheck ABS / ESP
® control module and its
circuit.
ECM faultyCheck ECM and its circuit.
NoiseDamaged or worn bearing(s)Refer to “Rear Differential Inspection”.

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 3B-35 Differential:
Rear Differential ComponentsS6RW0D3206013
4 5
9
2
30
6
(a)13
12
(a)
3
A
3A
141617 2118
29
3A
1(b)
22
1217G
101217G
11
8OIL
15OIL
19 20OIL
23OIL
25OIL27OIL
27OIL
25OIL
19OIL18
26 28
OIL
26OIL23OIL
24OIL
(c)
14
7
I5RW0A320026-02
1. Flange nut 13. Differential cover bolt 25. Differential gear
2. Companion flange 14. Spacer 26. Spring washer
3. Oil seal
: Apply grease 99000-25010 to oil seal lip.15. Rear bearing 27. Thrust washer
4. Coupling front bearing 16. Shim 28. Pinion shaft
5. Coupling case
: Apply sealant 99000-31260 to mating surface of carrier and coupling
case.17. Bevel pinion 29. Pinion shaft pin
6. Coupling assembly
: Never disassemble.18. Shim 30. Coupling case bolt
7. Snap ring 19. Differential side bearing : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
8. Bevel pinion nut
: Tighten nut so as rotation torque of bevel pinion to be in specified value.20. Bevel gear : 125 N⋅m (12.5 kgf-m, 90.5 lb-ft)
9. Front bearing 21. Differential case : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft)
10. Differential carrier
: Apply sealant 99000-31260 to mating surface of carrier and rear cover.22. Bevel gear bolt : Do not reuse.
11. Coupling air temperature sensor 23. Pinion washer : Apply differential oil.
12. Differential cover 24. Pinion

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Specifications
Tightening Torque SpecificationsS6RW0D3207001
NOTE
The specified tightening torque is also described in the following.
“Rear Differential Mountings Components”
“Rear Differential 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 MaterialS6RW0D3208001
NOTE
Required service material is also described in the following.
“Rear Differential Components”

Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Differential oil level / filler plug 23 2.3 17.0) / )
Differential oil drain plug 23 2.3 17.0)
Coupling air temperature sensor 18 1.8 13.0)
Bevel gear bolt 73 7.3 52.0)
Bevel pinion nut 230 – 340 23.0 – 34.0 166.5 – 246.0)
Differential cover bolt 23 2.3 17.0)
Flange nut 110 11.0 79.5)
Coupling case bolt 23 2.3 17.0)
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25010) / ) / )
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260) / ) / ) / ) / )

Downloaded from www.Manualslib.com manuals search engine 4-ii Table of Contents
Specifications .......................................................4D-4
Tightening Torque Specifications ........................4D-4
ABS ............................................................4E-1
Precautions........................................................... 4E-1
Precautions in Diagnosing Troubles ................... 4E-1
Precautions in On-Vehicle Service...................... 4E-1
General Description ............................................. 4E-2
ABS Description .................................................. 4E-2
ABS Hydraulic Unit / Control Module
Assembly Description ....................................... 4E-3
CAN Communication System Description........... 4E-3
Schematic and Routing Diagram ........................ 4E-4
ABS Schematic ................................................... 4E-4
ABS Wiring Circuit Diagram ................................ 4E-5
Component Location ........................................... 4E-8
ABS Components Location ................................. 4E-8
Diagnostic Information and Procedures ............ 4E-8
ABS Check .......................................................... 4E-8
ABS Warning Light Check................................. 4E-10
EBD Warning Light (Brake Warning Light)
Check .............................................................. 4E-10
DTC Check........................................................ 4E-11
DTC Table ......................................................... 4E-11
DTC Clearance ................................................. 4E-11
Scan Tool Data ................................................. 4E-12
ABS Warning Light Does Not Come ON at
Ignition Switch ON .......................................... 4E-13
ABS Warning Light Comes ON Steady ............. 4E-15
EBD Warning Light (Brake Warning Light)
Comes ON Steady .......................................... 4E-16
Serial Data Link Circuit Check .......................... 4E-17
DTC C1013: Control Module Mismatch ............ 4E-20
DTC C1015: G Sensor Circuit (4WD Model)..... 4E-21
DTC 1016: Brake Light Switch .......................... 4E-22
DTC C1021 / C1022 / C1025 / C1026 / C1031
/ C1032 / C1035 / C1036: Wheel Speed
Sensor Circuit / Sensor or Encoder ................ 4E-23
DTC C1033: Wheel Speed Sensor Deviation ... 4E-25
DTC C1041 / C1042 / C1045 / C1046 / C1051
/ C1052 / C1055 / C1056: Inlet / Outlet
Solenoid .......................................................... 4E-26DTC C1057: Power Supply Voltage Too High
/ Too Low ........................................................ 4E-27
DTC C1061: Pump Motor Circuit ...................... 4E-28
DTC C1063: Solenoid Valve Power Supply
Driver Circuit ................................................... 4E-29
DTC C1071: Control Module Internal Defect .... 4E-30
ABS Hydraulic Unit / Control Module
Assembly Power and Ground Circuit Check ... 4E-30
Repair Instructions ............................................ 4E-31
ABS Hydraulic Unit Operation Check................ 4E-31
ABS Hydraulic Unit / Control Module
Assembly Components ................................... 4E-32
ABS Hydraulic Unit / Control Module
Assembly On-Vehicle Inspection .................... 4E-33
ABS Hydraulic Unit / Control Module
Assembly Removal and Installation ................ 4E-33
Front and Rear Wheel Speed Sensor On-
Vehicle Inspection ........................................... 4E-34
Front Wheel Speed Sensor Removal and
Installation ....................................................... 4E-35
Front and Rear Wheel Speed Sensor
Inspection ........................................................ 4E-36
Rear Wheel Speed Sensor Removal and
Installation (4WD Model) ................................. 4E-36
Rear Wheel Speed Sensor Removal and
Installation (2WD Model) ................................. 4E-36
Front Wheel Speed Sensor Encoder On-
Vehicle Inspection ........................................... 4E-37
Front Wheel Speed Sensor Encoder Removal
and Installation ................................................ 4E-37
Rear Wheel Speed Sensor Encoder On-
Vehicle Inspection ........................................... 4E-37
Rear Wheel Speed Sensor Encoder Removal
and Installation ................................................ 4E-37
G Sensor Removal and Installation (4WD
Model) ............................................................. 4E-38
G Sensor Inspection (4WD Model) ................... 4E-38
Specifications ..................................................... 4E-39
Tightening Torque Specifications ...................... 4E-39
Special Tools and Equipment ........................... 4E-39
Special Tool ...................................................... 4E-39