2006 SUZUKI SX4 brake line

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 Wheels and Tires: 2D-4
Equipment manufacture’s recommendations
Radial Tire Lead / Pull DescriptionS6RW0D2401006
“Lead / Pull” is the deviation of the vehicle from a straight
path on a level road even with no pressure on the
steering wheel.
Lead is usually caused by the following conditions.
• Improper tire and wheel alignment.
• Uneven brake assemblies.
• Tire construction.
The way in which a tire is built can produce lead in a
vehicle. An example of this is placement of the belt. Off
center belts on radial tires can cause the tire to develop
a side force while rolling straight down the road. If one
side of the tire has a little larger diameter than the other,
the tire will tend to roll to one side. This will develop a
side force which can produce vehicle lead.
The procedure in the figure (Lead Diagnosis) should be
used to make sure that wheel alignment is not mistaken
for tire lead.
• Part of the lead diagnosis procedure is different from
the proper tire rotation pattern currently in the owner
and service manuals. If a medium to high mileage tire
is moved to the other side of the vehicle, be sure to
check that ride roughness has not developed
• Rear tires will not cause lead.
Balancing Wheels DescriptionS6RW0D2401007
There are two types of wheel and tire balance: static and
dynamic. Static balance, as shown in figure, is the equal
distribution of weight around the wheel. Wheels that are
statically unbalanced cause a bouncing action called
tramp. This condition will eventually cause uneven tire
wear.Dynamic balance, as shown in figure, is the equal
distribution of weight on each side of the wheel
centerline so that when the tire spins there is no
tendency for the assembly to move from side to side.
Wheels that are dynamically unbalanced may cause
shimmy.
Inflate tires to recommended pressure
Road test vehicle on level unrouned road in both directions
Switch front tires side to side and road test again
Lead corrected,
if roughness results, replace tiresLeads in same directionLeads reverses direction
Put tires back in original position
and check alignmentInstall a known-good tire on one front side
Lead remains install a known-good
tire in place of other front tire
Lead remains known-good tires are not goodLead corrected replace tire
Lead corrected replace tire
I2RH01240007-01
1. Heavy spot wheel tramp [A]: Before correction
2. Balance weights addition point [B]: Corrective weights
3. C/L of spindle
1. Heavy spot wheel shimmy [C]: Before correction
2. Balance weights addition point [D]: Corrective weights
3. C/L of spindle
I2RH01240008-01
I2RH01240009-01

Downloaded from www.Manualslib.com manuals search engine 3A-3 Drive Shaft / Axle: Front
Front Drive Shaft Assembly On-Vehicle
Inspection
S6RW0D3116002
• Check boots for breakage or deterioration.
• Check wheel side joint for rattle or smooth rotation.
• Check differential side (or center shaft side) joint for
smooth rotation.
If any abnormality is found, replace.
Front Drive Shaft Assembly Removal and
Installation
S6RW0D3116003
Removal
1) Hoist vehicle and remove front wheel.
2) Undo caulking and remove drive shaft nut (1) with
brake pedal depressed.
3) Drain transaxle oil and transfer oil (4WD model).
4) Disconnect tie-rod end (1) from steering knuckle (2)
using puller (3).5) Remove brake hose mounting bolt (1) and brake
hose (2) from bracket and then detach wheel speed
sensor harness (3) from strut bracket.
6) Remove suspension control arm ball joint bolt (4)
from knuckle.
7) Disconnect front suspension control arm ball joint
stud from steering knuckle.
8) Using tire lever (1) or plastic hammer (3), pull out
drive shaft joint (2) so as to release snap ring fitting
of joint spline at differential side, at center shaft or at
transfer side.
I6RW0B310005-01
I3RM0A310003-01
[A]: Left side shaft
[B]: Right side shaft of 2WD vehicle
[C]: Right side shaft of 4WD vehicle
I6RW0D311003-01
I5RW0A311003-01

Downloaded from www.Manualslib.com manuals search engine 4A-5 Brake Control System and Diagnosis:
Brakes Symptom DiagnosisS6RW0D4104002
Condition Possible cause Correction / Reference Item
Not enough braking forceBrake oil leakage from brake linesLocate leaking point and repair.
Brake disc or pad stained with oilClean or replace.
Overheated brakesDetermine cause and repair.
Poor contact of shoes on brake drumRepair for proper contact.
Brake shoe stained with oil or wet with
waterReplace.
Badly worn brake padReplace.
Defective wheel cylindersRepair or replace.
Malfunctioning caliper assemblyRepair or replace.
Malfunctioning brake boosterCheck system and replace as necessary.
Malfunctioning brake master cylinderCheck system and replace as necessary.
Air in systemBleed system.
Malfunctioning ABSCheck system and replace as necessary.
Brake pull (Brakes not
working in unison)Pad, disc, shoe and/or drum are wet
with water or stained with oil in some
brakesClean or replace.
Drum-to-shoe clearance out of
adjustment in some brakes
(Malfunctioning auto adjusting
mechanism) Check for inoperative auto adjusting
mechanism.
Disc and/or drum are out of round in
some brakesReplace.
Tires are inflated unequallyInflate equally.
Malfunction in wheel cylinders (rear
drum brake model)Repair or replace.
Disturbed front wheel alignmentAdjust as prescribed.
Unmatched tires on same axleTires with approximately the same amount of
tread should be used on the same axle.
Restricted brake pipes or hosesCheck for soft hoses and damaged lines.
Replace with new hoses and new double-
walled steel brake tubing.
Malfunctioning caliper assemblyCheck for stuck or sluggish pistons and proper
lubrication of caliper slide pin.
Caliper should slide.
Loose suspension partsCheck all suspension mountings.
Loose calipersCheck and torque bolts to specifications.
Noise (high pitched
squeak without brake
applied)Contact wear indicator to brake discReplace brake pad.
Worn rear brake shoeReplace brake shoe.
Excessive pedal travel
(Pedal stroke too large)Partial brake system failureCheck brake systems and repair as necessary.
Brake fluid leakingRepair the leaking point, and bleed air.
Air in system (soft / spongy pedal)Bleed system.
Rear brake system not adjusted
(malfunctioning auto adjusting
mechanism)Repair auto adjusting mechanism.
Adjust rear brakes.
Bent brake shoesReplace brake shoes.
Brake locked Malfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.

Downloaded from www.Manualslib.com manuals search engine 4A-7 Brake Control System and Diagnosis:
Repair Instructions
Brake Pedal ComponentsS6RW0D4106018
CAUTION!
If equipped Brake Pedal Foot Protection
System, never disassemble brake pedal
assembly. Disassemble will spoil its original
function. If faulty condition is found, replace
it with new one.

Brake Pedal Free Height InspectionS6RW0D4106001
1) Check brake pedal free height. If it is not within
specification, check and adjust following item 2) and
6).
Brake pedal free height “a” from carpet
111 – 131 mm (4.4 – 5.1 in.)
2) Check measurement between booster mounting
surface and center of clevis pin hole. When booster
push rod clevis has been reinstalled, it is important
that the measurement is adjusted (refer to “Brake
Booster Inspection”).
3) Check brake light switch position. Adjust it if it is out
of specification.
4) Check pedal for dent.
5) Check brake booster for installation.6) Check brake booster push rod for length.
Brake Pedal Play InspectionS6RW0D4106002
Pedal play should be within the following specification. If
out of specification, check brake light switch for proper
installation position and adjust if necessary.
Also check pedal shaft bolt and booster clevis pin
installation for looseness and replace if defective.
Brake pedal play
“a”
: 1 – 8 mm (0.04 – 0.31 in.)
Excessive Pedal Travel InspectionS6RW0D4106003
1) Start engine.
2) Depress brake pedal a few times.
3) With brake pedal depressed with approximately 300
N (30 kg, 66 lbs) load, measure brake pedal to wall
(dash panel silencer) clearance “a”. If clearance is
out of specification, possible causes are as follows.
If clearance “a” is less than specification, the most
possible cause is that air is in lines or brake fluid
leakage.
Should clearance “a” remain less than specification
even after bleeding of system, other possible but
infrequent cause is malfunction of booster push rod
length out of adjustment.
• Bleed brake system. Refer to “Air Bleeding of
Brake System”.
Brake pedal arm to wall clearance
“a”
When pedal is depressed at 300 N (30 kg, 66 lbs)
: Over 40 mm (1.57 in.)
[A]: A/T model : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
1. Brake pedal : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft)
2. Brake pedal bracket
I6RW0C410004-01
I6RW0C410005-01
“a”I3RH0A410010-01
I6RW0C410006-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-8
Brake Fluid Level InspectionS6RW0D4106004
CAUTION!
Do not use shock absorber fluid or any other
fluid which contains mineral oil. Do not use a
container which has been used for mineral oil
or a container which is wet from water.
Mineral oil will cause swelling and distortion
of rubber parts in hydraulic brake system and
water mixed into brake fluid will lower fluid
boiling point. Keep all fluid containers
capped to prevent contamination.

NOTE
Be sure to use particular brake fluid either as
indicated on reservoir cap of that vehicle or
recommended in owner’s manual which
comes along with that vehicle. Use of any
other fluid is strictly prohibited.
Fluid level should be between MIN and MAX
lines marked on reservoir.
When brake warning light lights sometimes
during driving, replenish fluid to MAX level.
When fluid decreases quickly, inspect brake
system for leakage. Correct leaky points and
then refill to specified level.

1) Check master cylinder, reservoir and reservoir hose
(if equipped) for crack, damage and brake fluid
leakage. If any faulty condition exists, correct or
replace.
2) Check that brake fluid level is between MAX (1) and
MIN marks (2) on reservoir.
Brake Light Switch AdjustmentS6RW0D4106005
Adjustment should be made as follows. Pull up brake
pedal toward you and while holding it there, adjust
switch position so that clearance between end of thread
and brake pedal is as specified. Then lock it by turning
clockwise.
Clearance between brake pedal and brake light
switch
“a”: 0.5 – 1.5 mm (0.02 – 0.05 in.)
Air Bleeding of Brake SystemS6RW0D4106006
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

Bleeding operation is necessary to remove air whenever
it entered hydraulic brake system.
Hydraulic lines of brake system are based on the
diagonal split system. When a brake pipe or hose was
disconnected at the wheel, bleeding operation must be
performed at both ends of the line of the removed pipe or
hose. When any joint part of the master cylinder of other
joint part between the master cylinder and each brake
(wheel) was removed, the hydraulic brake system must
be bled at all 4 wheel brakes.
NOTE
Perform bleeding operation starting with rear
brake caliper or wheel cylinder farthest from
master cylinder and then at front caliper of
the same brake line. Do the same on the
other brake line.

1
2
I7RW01410004-01
1. Right front brake caliper 3. Right rear wheel cylinder
2. Left front brake caliper 4. Left rear wheel cylinder
I5RW0A410005-01
I7RW01410005-01

Downloaded from www.Manualslib.com manuals search engine 4A-9 Brake Control System and Diagnosis:
1) Fill master cylinder reservoir with specified brake
fluid and keep at least one-half full of fluid during
bleeding operation.
Brake fluid
: Refer to reservoir cap
2) Remove bleeder plug cap. Attach a vinyl tube to
bleeder plug, and insert the other end into container.
3) Depress brake pedal several times, and then while
holding it depressed, loosen bleeder plug about one-
third to one-half turn.
4) When fluid pressure in cylinder is almost depleted,
retighten bleeder plug.
5) Repeat this operation until there are no more air
bubbles in hydraulic line.
6) When bubbles stop, depress and hold brake pedal
and tighten bleeder plug.
Tightening torque
Front brake caliper bleeder plug: 9 N·m (0.9 kgf-
m, 6.5 lb-ft)
Rear wheel cylinder bleeder plug: 8 N·m (0.8
kgf-m, 6.0 lb-ft)
7) Then attach bleeder plug cap.
8) After completing bleeding operation, apply fluid
pressure to pipe line and check for leakage.
9) Replenish fluid into reservoir up to specified level
referring to “Brake Fluid Level Inspection”.
10) Check brake pedal for sponginess. If found spongy,
repeat entire procedure of bleeding.
Front Brake Hose / Pipe Removal and
Installation
S6RW0D4106007
CAUTION!
Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid, flush it with water immediately
if any fluid is spilled.

Removal
1) Raise and support vehicle properly. Remove tire and
wheel.
NOTE
This operation is not necessary when
removing pipes connecting master cylinder.

2) Clean dirt and foreign material from both flexible
hose end and pipe end fittings.
3) Drain brake fluid in reservoir.
4) Remove brake flexible hose or pipe.
Installation
Reverse brake flexible hose removal procedure, noting
the following.
• Make sure that steering wheel is in straight-forward
position and flexible hose has not twist or kink.
• Install clamps and tighten nuts referring to “Front
Brake Hose / Pipe Construction”.
• Install brake flexible hose (1) to caliper as shown in
figure.
Tightening torque
Flexible hose joint bolt (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
I2RH01410016-01
I2RH01410017-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-14
Booster Operation InspectionS6RW0D4106014
There are two ways to perform this inspection, with and
without a tester. Ordinarily, it is possible to roughly
determine its condition without using a tester.
NOTE
For this check, make sure that no air is in
hydraulic line.

Check Air Tightness
1) Start engine.
2) Stop engine after running for 1 – 2 minutes.
3) Depress brake pedal several times with the same
load as in ordinary braking and observe pedal travel.
If pedal goes down deep the first time but its travel
decreases as it is depressed the second and more
times, air tightness is obtained.
4) If pedal travel doesn’t change, air tightness isn’t
obtained.
NOTE
If defective, inspect vacuum lines and sealing
parts, and replace any faulty part. When this
has been done, repeat the entire test.

Check Operation
1) With engine stopped, depress brake pedal several
times with the same load and make sure that pedal
travel doesn’t change.
2) Start engine while depressing brake pedal. If pedal
travel increases a little, operation is satisfactory. But
no change in pedal travel indicates malfunction.
Check Air Tightness Under Load
1) With engine running, depress brake pedal. Then
stop engine while holding brake pedal depressed.
1. 1st 2. 2nd 3. 3rd
1. 1st, 2nd, 3rd
I2RH01410005-01
I2RH01410006-01
H: Hold
I2RH01410007-01
I2RH01410008-01
I2RH01410009-01