2006 SUZUKI SX4 light

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 Front Suspension: 2B-12
4) Drive in dust cover so that dimensions “a” and “b”
become equal as shown in the figure.
CAUTION!
When drive in dust cover, be careful not to
deform it.

5) Caulk more than 6 places with a punch.
6) Using special tool and hydraulic press, press fit
wheel hub (1) into wheel bearing (2) (Face grooved
rubber seal side to wheel hub).
Special tool
(A): 09913–75510 7) Apply grease lightly to end face of inner ring (1).
“A”: Grease 99000–25121 (SUZUKI Super
Grease H)
NOTE
Do not apply the grease to the encoder
section to avoid the encoder malfunction.

8) Install steering knuckle with wheel hub and bearing
(1) so that foreign material should not enter wheel
speed sensing point “a”.I2RH01220038-01
I2RH01220039-01
I7RW01220007-01
2. Wheel encoder
3. Drive shaft
I5RW0B220001-01
I7RW01220008-02

Downloaded from www.Manualslib.com manuals search engine Wheels and Tires: 2D-6
Wheel (with Tire) Removal and InstallationS6RW0D2406003
Removal
CAUTION!
Never use heat to loosen tight wheel because
the application of heat to wheel causes the
wheel life shorter and the wheel bearing
damage.

1) Loosen wheel nuts by approximately 180° (half a
rotation).
2) Hoist vehicle.
3) Make sure that the vehicle will not fall off by trying to
move vehicle body in both ways.
4) Remove wheel nuts except one.
5) Support the wheel and/or tire not to drop the wheel
and then remove the nut left with the wheel.
Installation
For installation, reverse removal procedure, noting the
following.
• Wheel nuts must be tightened in sequence and to
specified torque to avoid bending wheel or brake disc
or drum as shown in the figure.
NOTE
Before installing wheels, remove any build-
up of corrosion on wheel mounting surface
and brake disc or drum mounting surface by
scraping and wire brushing. Installing wheels
without good metal-to-metal contact at
mounting surfaces can cause wheel bolts to
loosen, which can later allow a wheel to
come off while vehicle is moving.

Tightening order
“1” – “2” – “3” – “4” – “5”
Tightening torque
Wheel nut (a): 85 N·m (8.5 kgf-m, 61.5 lb-ft)
Tire Mounting and DismountingS6RW0D2406004
WARNING!
Do not stand over tire when inflating. Bead
may break when bead snaps over rim’s safety
hump and cause serious personal injury.
Do not exceed specified pressure when
inflating. If specified pressure will not seat
beads, deflate, re-lubricate and reinflate.
Over inflation may cause bead to break and
cause serious personal injury.

Use a tire changing machine to mount or dismount tires.
Follow equipment manufacturer’s instructions. Do not
use hand tools or tire irons alone to change tires as they
may damage tire beads or wheel rim.
Rim bead seats should be cleaned with a wire brush or
coarse steel wool to remove lubricants, old rubber and
light rust. Before mounting or dismounting a tire, bead
area should be well lubricated with approved tire
lubricant.
After mounting, inflate 330 kPa (47.9 psi) pressure so
that beads are completely seated. Then adjust pressure
to specified shown in the tire placard.
Tire RepairS6RW0D2406005
There are many different materials and techniques on
the market to repair tires. As not all of these work on all
types of tires, tire manufacturers have published detailed
instructions on how and when to repair tires. These
instructions can be obtained from each tire
manufacturer.
IYSQ01240008-01

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-12
DTC TableS6RW0D3204007
NOTE
“O” in transfer position indicator column of the above table means indicator lights up when DTC is
detected.

Fail-Safe TableS6RW0D3204008
This function is provided by the safe mechanism that assures safe driveability even when the coupling assembly,
switch, sensor or its circuit fails. The following table shows the fail safe function for each fail condition of sensor,
coupling assembly, switch, 4WD control module or its circuit. DTC No. Detecting itemDetecting condition
(DTC will set when detecting)4WD
position
Indicator
) C12404WD control module power
supply circuit malfunctionBattery voltage is lower than lower limit voltage for
4WD control module diagnosis.{
) C1243Internal circuit malfunction of
4WD control moduleInternal power supply malfunction of 4WD control
module{
) C1250Coupling air temperature sensor
openSensor output voltage too high{
) C1251Coupling air temperature sensor
shortSensor output voltage too low{
) C1252 Coupling assembly open2WD/4WD switch is changed of 4WD lock position,
and then vehicle is not changed for more than 5
seconds.{
) C1253 Coupling assembly short2WD/4WD switch is changed of 4WD lock position,
and then vehicle is not changed for more than 5
seconds.{
) C1254 2WD/4WD switch malfunctionDifferent switch combination from specification is
detected more than 5 seconds.{
) U0073Control module communication
bus offTransmitting and receiving error of 4WD control
module for specified time continuously{
) U0100 Lost communication with ECMReceiving error of 4WD control module from ECM
for specified time continuously{
) U0121Lost communication with ABS /
ESP® control moduleReceiving error of 4WD control module from ABS /
ESP® control module for specified time
continuously{
) U0155Lost communication with
instrument panel cluster control
moduleReceiving error of 4WD control module from
combination meter for specified time continuously{
DTC No. Trouble Area Fail-Safe Operation
)C12404WD control module power supply circuit
malfunction4WD control module controls the current and
fixed the vehicle to 2WD position.
)C1243Internal circuit malfunction of 4WD control
module
)C1250 Coupling air temperature sensor open
)C1251 Coupling air temperature sensor short
)C1252 Coupling assembly open
)C1253 Coupling assembly short
)C1254 2WD/4WD switch malfunction
)U0073 Control module communication bus off
)U0100 Lost communication with ECM
)U0121Lost communication with ABS / ESP® control
module
)U0155Lost communication with instrument panel
cluster control module

Downloaded from www.Manualslib.com manuals search engine 3B-15 Differential:
4WD Position Indicator Does Not Come ON at Ignition Switch ON but Engine StopsS6RW0D3204013
Wiring Diagram
Circuit Description
4WD position indicator operates according to the signal from 4WD control module. If the 4WD control system is in
good condition, 4WD position indicator light up for 2 seconds when ignition switch is turned to ON position, and then
turned to OFF position. If an abnormality is detected in the system, 4WD position indicator remains lighting.
Troubleshooting
WHTYELRED/BLK
12
WHT/RED
WHT/RED
G26-12
G26-11
RED
BLK
WHT 56 47
12V
G26-10BLK
G26-22
G26-23REDWHT
3
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]
I7RW01320004-01
[A]: 4WD control module connector “G26” (viewed from harness side) 4. Combination meter
1. Main fuse box 5. 4WD AUTO indicator
2. Junction block assembly 6. 4WD LOCK indicator
3. “METER” fuse 7. 4WD control module
Step Action Yes No
14WD position indicator power supply check
1) Turn ignition switch to ON position.
Do other indicators come ON?Go to Step 2. Go to Step 3.
2Check DTC
1) Connect scan tool to DLC with ignition switch OFF.
2) Turn ignition switch to ON position and check DTC.
Is there DTC(s) U0073, U0100, U0121 and/or U0155?Go to applicable DTC
diag. flow.Substitute a known-
good combination meter
and recheck. If 4WD
position indicator still
remains off, substitute a
known-good 4WD
control module and
recheck.

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-16
4WD Position Indicator Remains ON Steady at Ignition Switch ONS6RW0D3204014
Wiring Diagram
Refer to “4WD Position Indicator Does Not Come ON at Ignition Switch ON but Engine Stops”.
Circuit Description
Transfer position indicator operates according to the signal from 4WD control module. If the 4WD control system is in
good condition, 4WD position indicator light up for 2 seconds when ignition switch is turned to ON position, and then
turned to OFF position. If an abnormality is detected in the system, 4WD position indicator remains lighting.
Troubleshooting3CAN communication circuit check
1) Check CAN communication circuit between combination
meter and 4WD control module referring to “DTC U0073:
Control Module Communication Bus Off”.
Is CAN communication circuit in good condition?Go to Step 4. Repair or replace.
4“METER” fuse check
1) Turn ignition switch to OFF position.
2) Check for fuse blown to “METER” fuse in junction block
assembly.
Is “METER” fuse in good condition?Go to Step 5. Replace “METER” fuse
and check for short.
5Combination meter power supply check
1) Remove combination meter referring to “Combination
Meter Removal and Installation in Section 9C”.
2) Check proper connection to “WHT/RED” and “BLK” wire
terminal of combination meter connector.
3) If OK, then turn ignition switch to ON position and
measure voltage between “WHT/RED” wire terminal of
combination meter connector and vehicle body ground.
Is it 10 – 14 V?Go to Step 6. “WHT/RED” wire is
open circuit.
6Combination meter ground circuit check
1) Turn ignition switch to OFF position.
2) Measure resistance between “BLK” wire terminal of
combination meter connector and vehicle body ground.
Is resistance 1
Ω or less?Substitute a known-
good combination meter
and recheck. If 4WD
position indicator still
remains OFF, substitute
a known-good 4WD
control module and
recheck.“BLK” wire is open or
high resistance circuit. Step Action Yes No
Step Action Yes No
1Check DTC
1) Check DTC referring to “DTC Check”.
Is there any DTC(s)?Perform DTC flow to
repair and retry.Go to Step 2.
2CAN communication circuit check
1) Check CAN communication circuit between combination
meter and 4WD control module referring to “DTC U0073:
Control Module Communication Bus Off”.
Is CAN communication circuit in good condition?Substitute a known-
good combination meter
and recheck. If 4WD
position indicator still
remains off, substitute a
known-good 4WD
control module and
recheck.Repair or replace.

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-42
14) Set dial gauge to bevel pinion mounting dummy and
make 0 (zero) adjustment on surface plate.
NOTE
• When setting dial gauge to mounting
dummy, tighten screw lightly. Be careful
not to overtighten it, which will cause
damage to dial gauge.
• With dial gauge set, turn dummy back and
forth by hand a couple of times and attain
accurate 0 (zero) adjustment.
• It is desirable that short pointer indicates
beyond 2 mm when long one is at 0 (zero).

15) Place zero-adjusted mounting dummy (1) and dial
gauge set on pinion dummy (2) and take
measurement between zero position and extended
dial gauge measuring tip.
NOTE
• Repeat turning back and forth of dummy
and measure distance as far as top surface
of pinion dummy accurately.
• When dial gauge measuring tip extends
from 0 (zero) position, pointer turns
counterclockwise.

16) Necessary adjusting shim thickness is the same
value as measured value by dial gauge.
17) Select adjusting shim(s) (2) closest to obtained value
from among the following available sizes and put it in
place and then press-fit rear bearing (1) to bevel
pinion (3).
Available shim thickness
0.30, 0.60, 0.63, 0.66, 0.69, 0.72, 0.75, 0.78, 0.81,
0.84 and 0.87 mm (0.012, 0.023, 0.024, 0.026,
0.027, 0.028, 0.030, 0.031, 0.032, 0.033 and 0.034
in.)
Special tool
(D): 09925–18011
18) With new pinion spacer (2) inserted as shown in
figure, install front bearing (1) to differential carrier
(3).
NOTE
Apply differential oil to front and rear
bearings.

I5RW0A320051-01
1
2
I5RW0A320052-01
Necessary shim thickness
“e”= Dial gauge measured
value “c”
I3RH01322055-01
I5RW0A320053-01

Downloaded from www.Manualslib.com manuals search engine 3C-13 Transfer:
2) Press-fit outer races (front and rear) by using special
tool and hydraulic press.
Special tool
(A): 09913–75520
3) Press-fit front taper roller bearing (1) by using
special tool and hydraulic press.
Special tool
(A): 09925–18011
4) Install bevel pinion with new pinion shaft spacers (1)
and new pump seal (2) to transfer output retainer (3).5) Drive in rear taper roller bearing by using special tool
and tapping lightly with plastic hammer.
Special tool
(A): 09913–84510
6) Apply grease to new oil seal lip.
“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
7) Drive in oil seal (1) by using special tools and
hammer.
Special tool
(A): 09940–54910
(B): 09913–76010
Transfer output flange oil seal installing depth
“a”: 21.0 – 22.0 mm (0.82 – 0.86 in.)
(A)
I5RW0A330038-01
(A)
1
I5RW0A330039-01
1
2
3
I5RW0A330040-02
(A)
I5RW0A330041-02
(B)
(A)
1, “A”
“a”
I5RW0A330042-02