2006 SUZUKI SX4 front drive shaft assembly

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-43
THROTTLE MOTOR RELAY (ON/OFF)
ON: Throttle actuator (motor) control activated by ECM.
OF: Throttle actuator (motor) control stopped by ECM.
VEHICLE SPEED (km/h, mph)
It is computed based on pulse signals from front wheel
speed sensor (RH, LH) (for M/T model) or output shaft
speed sensor (VSS) (for A/T model).INJ PULSE WIDTH (FUEL INJECTION PULSE WIDTH,
msec.)
This parameter indicates time of the injector drive (valve
opening) pulse which is output from ECM (but injector
drive time of NO.1 cylinder for multiport fuel injection).
Visual InspectionS6RW0D1104008
Visually check the following parts and systems.
Engine Basic InspectionS6RW0D1104009
This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found
in “Visual Inspection”.
Follow the flow carefully.Inspection item Reference section
• Engine oil – level, leakage “Engine Oil and Filter Change in Section 0B”
• Engine coolant – level, leakage “Coolant Level Check in Section 1F”
• Fuel – level, leakage“Fuel Lines and Connections Inspection in
Section 0B”
• Air cleaner element – dirt, clogging “Air Cleaner Filter Inspection in Section 0B”
• Battery – fluid level, corrosion of terminal“Battery Dismounting and Remounting in
Section 1J”
• Water pump belt – tension damage“Accessory Drive Belt Inspection in Section
0B”
• Throttle valve – operating sound“Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
• Vacuum hoses of air intake system – disconnection, looseness,
deterioration, bend“Vacuum Hose Inspection in Section 1B”
• Connectors of electric wire harness – disconnection, friction
• Fuses – burning
• Parts – installation, bolt – looseness
• Parts – deformation
• Other parts that can be checked visually
Also check the following items at engine start, if possible
• Malfunction indicator lamp – Operation “Malfunction Indicator Lamp (MIL) Check”
• Charge warning lamp – Operation “Generator Symptom Diagnosis in Section 1J”
• Engine oil pressure warning lamp – Operation “Oil Pressure Switch Inspection in Section 9C”
• Engine coolant temp. meter – Operation“Engine Coolant Temperature (ECT) Sensor
Inspection in Section 1C”
• Fuel level meter – Operation “Fuel Level Sensor Inspection in Section 9C”
• Tachometer – Operation
• Abnormal air being inhaled from air intake system
• Exhaust system – leakage of exhaust gas, noise
• Other parts that can be checked visually
Step Action Yes No
1Was “Engine and Emission Control System Check”
performed?Go to Step 2. Go to “Engine and
Emission Control
System Check”.
2Check battery voltage
Is it 11 V or more?Go to Step 3. Charge or replace
battery.
3Is vehicle equipped with keyless start control system?Go to Step 4. Go to Step 5.

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Crankshaft Position (CKP) Sensor InspectionS6RW0D1306015
Visual check
• Check that O-ring is free from damage.
• Check that end face of sensor and signal pulley tooth
are free from any metal particles and damage.
Performance check
1) Remove metal particles on end face of CKP sensor,
if any.
2) Arrange 12 V battery (1) and connect its positive
terminal to “Vin” terminal (2) and negative terminal to
“Ground” terminal (3) of sensor. Then using
ohmmeter, measure resistance between “Vout”
terminal (4) of sensor and negative terminal of
battery by passing magnetic substance (iron) (5)
while keeping approximately 1 mm (0.03 in.) gap
with respect to end face of CKP sensor.
If resistance does not vary as specified below,
replace CKP sensor.
CKP sensor resistance
Resistance varies from less than 220 Ω (ON) to
infinity (OFF) or from infinity (OFF) to less than 220
Ω (ON)
Knock Sensor Removal and InstallationS6RW0D1306016
Removal
1) Disconnect negative cable at battery.
2) Hoist vehicle.
3) Remove right side drive shaft referring to “Front
Drive Shaft Assembly Removal and Installation in
Section 3A”.
4) Disconnect knock sensor connector (1).
5) Remove knock sensor (2) from cylinder block.
Installation
Reverse removal procedure for installation.
Tightening torque
Knock sensor (a): 22 N·m (2.2 kgf-m, 16.0 lb-ft)
[A]: non-VVT model [B]: VVT model
I3RB0A130006-01
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1
2, (a)
I5RW0A130009-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-17
Engine Assembly Removal and InstallationS6RW0D1406013
Removal
1) Relieve fuel pressure according to “Fuel Pressure
Relief Procedure in Section 1G”.
2) Disconnect negative and positive cable at battery.
3) Disconnect ECM connectors.
4) Remove battery and battery tray with ECM.
5) Remove right and left side engine under covers.
6) Remove A/C compressor belt by referring to
“Compressor Drive Belt Removal and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
7) Drain engine oil referring to “Engine Oil and Filter
Change in Section 0B”.
8) Drain transaxle oil referring to “Manual Transaxle Oil
Change in Section 5B” or “A/T Fluid Change in
Section 5A”.
9) Drain transfer oil referring to “Transfer Oil Change in
Section 3C”.
10) Drain coolant referring to “Cooling System Draining
in Section 1F”
11) Remove air cleaner assembly referring to “Air
Cleaner Assembly Removal and Installation”.
12) With hose connected, detach A/C compressor from
its bracket referring to “Compressor Assembly
Removal and Installation in Section 7B” or
“Compressor Assembly Removal and Installation in
Section 7B”.
CAUTION!
Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

13) Remove cylinder upper cover (1).14) Disconnect the following electric wires/connectors
and each clamps.
• TP sensor (1)
• MAP sensor (2)
• ECT sensor (3)
•EGR valve (4)
• CMP sensor (5)
• Ignition coil assembly (6)
• Injector (7)
•HO2S (8)
• Oil control valve (9) (for engine with VVT system)
• Engine oil pressure switch (10)
• CKP sensor (12)
• Knock sensor (13)
• Generator (14)
• Starting motor (15)
• Ground terminal (16) from cylinder block
• Battery ground cable (17) from transaxle
• Back-up light switch (18) (for M/T model)
• Torque sensor (19)
• P/S motor (20)
• Output shaft speed sensor (VSS) (29) (for A/T
model)
• Solenoid valve (30) (for A/T model)
• Transmission range sensor (31) (for A/T model)
• Input shaft speed sensor (32) (for A/T model)
15) Disconnect the following cables, and remove control
cable bracket (23)
• Gear select control cable (21) (for M/T model)
• Gear shift control cable (22) (for M/T model)
• A/T select cable (33) (for A/T model)
16) Disconnect the following hoses.
• Brake booster hose (24) from intake manifold
• Radiator inlet and outlet hoses (25) from radiator
• Heater inlet and outlet hoses (26) from heater
core
• Fuel feed hose (27) from fuel feed pipe
• Fuel vapor hose (11) from fuel vapor pipe
• Clutch hose (28) from transaxle (for M/T model)
• A/T fluid cooler hoses (for A/T model)
F: Vehicle forward 8. Engine front mounting bracket : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
1. Engine right mounting bracket 9. Engine front mounting
: Be sure to direct yellow mark to forward.: 95 N⋅m (9.5 kgf-m, 69.0 lb-ft)
2. Engine right mounting 10. Transfer : 65 N⋅m (6.5 kgf-m, 47.0 lb-ft)
3. Engine left mounting bracket 11. Suspension frame : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
1
I5RW0A140009-01

Downloaded from www.Manualslib.com manuals search engine 1D-18 Engine Mechanical:
17) Remove oil pressure switch bracket (1).
18) Remove suspension control arm referring to
“Suspension Control Arm / Bushing Removal and
Installation in Section 2B”.
19) Disconnect right and left drive shaft joints from
differential gear referring to “Front Drive Shaft
Assembly Removal and Installation in Section 3A”.
20) Remove exhaust No.1, No.2 and center pipes
referring to “Exhaust System Components in Section
1K”.
21) Disconnect propeller shaft referring to “Propeller
Shaft Assembly Removal and Installation in Section
3D” (for 4WD model).
22) Disconnect steering lower shaft from pinion shaft
referring to “Steering Lower Shaft Removal and
Installation in Section 6B”.
23) Fix radiator to body with rope in order to avoid the
radiator fall off when front lower cross member
lowered.
24) Support front suspension frame, front lower cross
member and oil pan using jack at hatched parts (1)
indicated in figure.
[A]: View A [C]: For A/T model
6
3 45
1 7 7
2
8
9
10
A
15
14
16
20 19
26
24
27
12
13 [A]
11
34
232122
25
17 2818 [B] [C]
2930
31
32
17
33
I5RW0C140010-01
[B]: For M/T model 34. steering gear box
2. Exhaust manifold
1
2
I5RW0A140011-01
11
I5RW0A140012-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-21
12) Install oil pressure switch bracket (1).
13) Connect right and left drive shaft joints to differential
gear referring to “Front Drive Shaft Assembly
Removal and Installation in Section 3A”.
14) Install suspension control arm referring to
“Suspension Control Arm / Bushing Removal and
Installation in Section 2B”.
15) Install cylinder upper cover (1).16) Install A/C compressor to its bracket (if equipped)
referring to “Compressor Assembly Removal and
Installation in Section 7B” or “Compressor Assembly
Removal and Installation in Section 7B”.
17) Adjust A/C compressor drive belt referring to
“Compressor Drive Belt Removal and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
18) Install air cleaner assembly referring to “Air Cleaner
Assembly Removal and Installation”.
19) Check to ensure that all removed parts are back in
place. Reinstall any necessary parts which have not
been reinstalled.
20) Refill cooling system with coolant referring to
“Cooling System Flush and Refill in Section 1F”.
21) Refill engine with engine oil referring to “Engine Oil
and Filter Change in Section 0B”.
22) Refill transaxle oil referring to “Manual Transaxle Oil
Change in Section 5B” or “A/T Fluid Change in
Section 5A”.
23) Refill transfer oil referring to “Transfer Oil Change in
Section 3C”.
24) Install battery and battery tray with ECM.
25) Connect ECM wire harness.
26) Connect positive and negative cable at battery.
27) Install right and left side engine under covers.
28) Verify that there is no fuel leakage, coolant leakage,
oil leakage and exhaust gas leakage at each
connection.
2. Exhaust manifold
1
2
I5RW0A140011-01
1
I5RW0A140009-01

Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-9
Generator Dismounting and RemountingS6RW0D1A06003
1) Disconnect negative cable at battery.
2) Remove right side drive shaft referring to “Front Drive Shaft Assembly Removal and Installation in Section 3A”
3) Dismount in numerical order as shown in figure.
4) Reverse dismounting procedure for remounting.
I6RW0D1A0004-01
1. “B” terminal nut 5. Generator pivot bolt : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
2. “B” terminal wire 6. Generator drive belt : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft)
3. Connector 7. Generator
4. Generator bracket bolt : 5.0 N⋅m (0.5 kg⋅m, 4.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Suspension General Diagnosis: 2A-1
Suspension
Suspension General Diagnosis
Diagnostic Information and Procedures
Suspension, Wheels and Tires Symptom DiagnosisS6RW0D2104001
Condition Possible cause Correction / Reference Item
Vehicle pulls (Leads)Mismatched or uneven tiresReplace tires.
Tires not adequately inflatedAdjust tire pressure.
Broken or sagging coil springsReplace coil springs.
Radial tire lateral forceReplace tire.
Disturbed wheel alignmentCheck and adjust wheel alignment.
Brake dragging in one road wheelRepair brake.
Loose, bent or broken front or rear
suspension partsTighten or replace related suspension parts.
Abnormal or excessive
tire wearSagging or broken coil springReplace coil spring.
Tire out of balanceAdjust balance or replace tire.
Disturbed wheel alignmentCheck and adjust wheel alignment.
Faulty strut (shock absorber)Replace strut (shock absorber).
Hard drivingReplace tires.
Overloaded vehicleReplace tires.
Not rotated tiresReplace or rotate tires.
Worn or loose wheel bearingReplace wheel bearing.
Wobbly wheel or tireReplace wheel or tire.
Tires not adequately inflatedAdjust tire pressure.
Front suspension frame and/or
suspension control arm are transformedCheck and replace.
Wheel trampBlister or bump on tireReplace tire.
Improper strut (shock absorber) actionReplace strut (shock absorber).
Shimmy, shake or
vibrationTire or wheel out of balanceBalance wheel or replace tire and/or wheel.
Loosen wheel bearingsReplace wheel bearings.
Worn tie-rod endsReplace tie-rod ends.
Worn lower ball jointsReplace suspension control arm.
Excessive wheel runoutRepair or replace wheel and/or tire.
Blister or bump on tireReplace tire.
Excessively loaded radial runout of tire /
wheel assemblyReplace tire or wheel.
Disturbed wheel alignmentCheck and adjust wheel alignment.
Loose or worn steering linkageTighten or replace steering linkage.
Abnormal noise, front endWorn, sticky or loose tie-rod ends, lower
ball joints, tie-rod inside ball joints or
drive shaft jointsReplace tie-rod end, suspension arm, tie-rod
or drive shaft joint.
Damaged struts or mountingsRepair or replace struts or mountings.
Worn suspension arm bushingsReplace suspension arm bushings.
Loose stabilizer barTighten bolts or nuts and/or replace bushes.
Loose wheel boltsTighten wheel bolts.
Loose suspension bolts or nutsTighten suspension bolts or nuts.
Broken or damaged wheel bearingsReplace wheel bearings.
Broken suspension springsReplace suspension springs.
Worn strut bearingsReplace strut bearing.
Malfunction of Power Steering SystemCheck and correct malfunction.
Low or uneven trim height
NOTE
See NOTE *1.

Broken or sagging coil springsReplace coil springs.
Over loadedCheck loading.
Incorrect coil springsReplace coil spring.
Tires not adequately inflatedAdjust tire pressure.
Ride too softFaulty strut (shock absorber)Replace strut (shock absorber).
Suspension bottomsOverloadedCheck loading.
Faulty strut (shock absorber)Replace strut (shock absorber).
Incorrect, broken or sagging coil springsReplace coil spring.

Downloaded from www.Manualslib.com manuals search engine 2B-1 Front Suspension:
Suspension
Front Suspension
General Description
Front Suspension ConstructionS6RW0D2201001
1
4 3
2
7
6
8
))
5
9(a)
(b)
(b)
(b)
(b)
(c)
(c)
(d)
(d)
(e)(f)
(g)
(h)
(i)
(h)
F
I7RW01220002-03
1. Front strut assembly 8. Front suspension frame : 200 N⋅m (20.0 kgf-m, 145.0 lb-ft)
2. Front drive shaft 9. Suspension control arm : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
3. Steering knuckle : 140 N⋅m (14.0 kgf-m, 101.5 lb-ft) : 95 N⋅m (9.5 kgf-m, 69.0 lb-ft)
4. Front wheel hub : 150 N⋅m (15.0 kgf-m, 108.5 lb-ft) : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
5. Stabilizer joint : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) : Do not reuse.
6. Stabilizer bar : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft) F: Forward
7. Tie-rod : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)