2006 SUZUKI SX4 oil temperature

Downloaded from www.Manualslib.com manuals search engine 1J-6 Charging System:
3) Ground “F” terminal and start engine, then measure
voltage at “B” terminal as shown in figure.
• Voltage is higher than standard value. It is
considered that generator itself is good but IC
regulator has been damaged, replace IC
regulator.
• Voltage is lower than standard value. It is
considered that generator itself has problem,
check the generator.
Load Check
1) Run engine at 2,000 rpm and turn on head light and
heater motor.
2) Measure current and if it is less than 20 A, repair or
replace generator.Generator Test (Overcharged Battery Check)S6RW0D1A04004
1) To determine battery condition, refer to “Battery
Description”.
2) If obvious overcharged condition exists as evidenced
by excessive spewing of electrolyte, measure
generator “B” terminal voltage at engine 2000 rpm.
3) If measured voltage is higher than upper limit value,
disassemble generator.
4) Check ground of brushes. If brushes are not
grounded, replace IC regulator. Then check field coil
for grounds and shorts.
Repair Instructions
Jump Starting in Case of EmergencyS6RW0D1A06001
With Auxiliary (Booster) Battery
CAUTION!
If vehicle is manual transaxle model and has
a catalytic converter, do not push or tow it to
start. Damage to its emission system and/or
to other parts may result.

Both booster and discharged battery should be treated
carefully when using jumper cables. Follow the
procedure outlined as follows, being careful not to cause
sparks.
WARNING!
• Departure from these conditions or
procedure described as follows could
result in:
– Serious personal injury (particularly to
eyes) or property damage from such
causes as battery explosion, battery
acid, or electrical burns.
– Damage to electronic components of
either vehicle.
• Remove rings, watches, and other jewelry.
Wear approved eye protection.
• Be careful so that metal tools or jumper
cables do not contact positive battery
terminal (or metal in contact with it) and
any other metal on vehicle, because a
short circuit could occur.
• Do not connect negative cable directly to
negative terminal of dead battery.

I2RH011A0008-01
[A]: Regulated voltage (V)
[B]: Heatsink temperature (°C)
16.0
12.0
14.2 15.3
14.8
14.2
13.3 14.8
15.0
11.0 14.0
13.0 [A]
12.5 13.6
13.1
12.5
11.613.1
[B] -30 0 25 135
H
L
I2RH0B1A0005-01

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

Downloaded from www.Manualslib.com manuals search engine 3-ii Table of Contents
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

Downloaded from www.Manualslib.com manuals search engine 3B-5 Differential:
4WD Control System Wiring Circuit DiagramS6RW0D3201006
Terminal Arrangement of 4WD Control ModuleS6RW0D3201007
5V
5V
12V
G26-3
YEL
GRY
G26-2
G26-22G26-23REDWHT
G26-13
G26-14
G26-12
G26-11
G26-10BLK
WHT/RED
RED/BLK
GRY/YEL
RED/WHT
12V
L102-1
L102-4
1
37
9
10
12
13
14
12V
G26-21BLU
G26-25
G26-24ORN
BRN
5V
28
11
WHT
WHT
WHTWHTWHTWHT
WHT
RED
RED
RED
REDRED
RED
RED
46
5
L174-4BLK/ORNL174-5L174-1
I7RW01320001-01
1. Coupling assembly 6. ECM 11. Data link connector (DLC)
2. Coupling air temperature sensor 7. 4WD control module 12. “IG COIL” fuse
3. Combination meter 8. 2WD/4WD switch 13. “4WD” fuse
4. BCM 9. “4WD” switch 14. Main fuse box
5. ABS / ESP® control module 10. “4WD lock” switch
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 25 26
[A]
I4JA01332038-01
[A]: Connector “G26” viewed from harness side
Te r m i n a l C i r c u i t Te r m i n a l C i r c u i t
G26-2 Coupling assembly (power) G26-14 “4WD lock” switch
G26-3 Coupling assembly (ground) G26-21 Data link connector (DLC)
G26-10 Ground G26-22 CAN communication line (high)
G26-11 Power source for internal memory G26-23 CAN communication line (low)
G26-12 Power source G26-24 Coupling air temperature sensor (ground)
G26-13 “4WD” switch G26-25 Coupling air temperature sensor (power)

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-14
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 Differential: 3B-32
Coupling Air Temperature Sensor InspectionS6RW0D3206007
CAUTION!
Do not heat up coupling air temperature
sensor more than 100 °C (212 °F). Otherwise,
coupling air temperature sensor will be
damaged.

• Blow hot air to temperature sensing part (2) of
coupling air temperature sensor (3) using hot air drier
(4) and measure resistance between sensor terminals
while heating air gradually.
If measured resistance does not show such
characteristic as shown, replace air temperature
sensor.
Coupling Assembly InspectionS6RW0D3206008
• Check coupling assembly for oil leakage. If leakage
exists, replace it.
• Measure resistance between “a” terminal and “b”
terminal of coupling connector (1).
If measured resistance is out of specification, check
harness for open or short.
If OK, replace coupling assembly.
Coupling assembly resistance
: 2 – 3 Ω
[A]: Lower limit [D]: Resistance
[B]: Normal [E]: Temperature
[C]: Upper limit 1. Temperature gauge
020
32 68 17680 (6.00)
(0.34) (2.56)
1
4
23
[D]
[C]
[B]
[A]
[E]
I5RW0A320021-01
1
“a” “b”I5RW0A320064-01

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