2006 SUZUKI SX4 service

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-22
Special Tools and Equipment
Recommended Service MaterialS6RW0D2208001
Special ToolS6RW0D2208002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease H P/No.: 99000–25121)
09913–65810 09913–75510
Crankshaft bearing puller Bearing installer
)) / ) / )
09913–75821 09913–85230
Bearing installer attachment Bearing remover tool
) / ))
09925–14520 09942–15511
Bearing and oil seal installer
(80 x 50 mm)Sliding hammer
))
09943–17912 09943–25010
Wheel hub remover Spring compressor
))
09943–37910 09943–76310
Bearing installer & remover Bush remover
)) / )
09944–78220
Bearing installer support
)

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 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 Drive Shaft / Axle: Front 3A-14
Special Tools and Equipment
Recommended Service MaterialS6RW0D3118001
NOTE
Required service material is also described in the following.
“Front Drive Shaft Components”

Special ToolS6RW0D3118002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011)
09913–84510 09925–15410
Bearing installer Oil seal installer
))
09925–98221 09943–57010
Bearing installer Band compressor
)) / ) / )
09943–57021
Pliers, Low-Profile Clamp
) / )

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: Rear 3A-18
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
))

Downloaded from www.Manualslib.com manuals search engine 3B-1 Differential:
Driveline / Axle
Differential
Precautions
Precaution for Rear Differential Oil LeakageS6RW0D3200001
Whenever vehicle is hoisted for any other service work than oil change, also be sure to check for oil leakage.
Precautions in Diagnosing TroubleS6RW0D3200002
• Do not disconnect the following parts before confirming diagnostic information (DTC, etc.) stored in 4WD control
module memory. These actions will erase memorized information in 4WD control module memory.
– Disconnection of coupler from 4WD control module
– Disconnection of battery cable from battery
– Disconnection of ground wire harness of 4WD control module
– Disconnect main fuse from fuse box
• Diagnostic information stored in 4WD control module memory can be cleared as well as checked by using SUZUKI
scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as
to what functions are available and how to use it.
• Be sure to read “Precautions for Electrical Circuit Service:” before inspection and observe what is written there.

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-30
Repair Instructions
Rear Differential Oil Level CheckS6RW0D3206001
1) Lift up vehicle and check oil leakage. Repair leaky
point, if any.
2) Remove oil level / filler plug (1) and check oil
contamination and oil level is lower end of oil level /
filler plug hole (2).
If oil is excessive dirty or insufficient, replace oil or
pour specified oil up to plug hole.
3) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Differential oil level / filler plug (a): 23 N·m (2.3
kgf-m, 17.0 lb-ft)
Rear Differential Oil ChangeS6RW0D3206002
1) Before changing or inspecting oil, be sure to stop
engine and lift vehicle horizontally.
2) With vehicle lifted up, check leakage.
If leakage exists, correct it.
NOTE
Whenever vehicle is hoisted for any other
service work than oil change, also be sure to
check for oil leakage.

3) Remove oil filler plug (2).
4) Remove drain plug (1), and drain old oil.
5) Apply sealant to thread of drain plug (1), and tighten
it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)Tightening torque
Differential oil drain plug (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
6) Pour new specified oil until oil level reaches bottom
of oil filler plug hole (3) as shown in figure.
NOTE
• Hypoid gear oil must be used for
differential.
• It is highly recommended to use API GL-5
80W-90 gear oil.

Differential oil specification
: API GL-5 (For SAE classification, refer to
viscosity chart [A] in figure.)
Rear differential oil capacity
Reference: 0.7 – 0.9 liters (1.5/1.2 – 1.9/1.6 US/
Imp. pt.)
7) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Differential oil level / filler plug (b): 23 N·m (2.3
kgf-m, 17.0 lb-ft)
I5RW0A320015-01
I5RW0A320016-02