2006 SUZUKI SX4 engine mount

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: Front 3A-10
For tripod joint type
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
after disassembly, prepare replacing parts and proceed
to reassembly.
Make sure that wheel side joint assembly (1) and tripod
joint housing (2) are washed thoroughly and air dried.
Replace boot(s) (3) with new one(s).
CAUTION!
• Do not wash boots in degreaser such as
gasoline or kerosene. etc. Washing in
degreaser causes deterioration of boot.
• To ensure full performance of joint as
designed, be sure to distinguish between
two types of grease in repair set and apply
specified volume to respective joint
referring to the followings for identification
of the grease.

1) Wash disassembled parts (except boots). After
washing, dry parts completely by blowing air.
2) Clean boots with cloth.
3) Apply grease to wheel side joint. Use specified
grease in tube in wheel side boot set as a spare
parts.
Grease color
: Black
Amount
: 55 – 75 g (1.9 – 2.6 oz)
4) Install wheel side boot on shaft.
5) Fill up boot inside with specified grease.
6) Place new wheel side boot big band (3) and small
band (4) onto boot putting band outer end (1) against
forward rotation (2) as shown in figure.7) Fasten boot bands (1) securely using special tool as
shown in figure.
CAUTION!
Do not squeeze or distort boot when
fastening it with bands.
Distorted boot caused by squeezing air may
reduce its durability.

Distance “a”
: 2.6 ± 1.4 mm (0.102 ± 0.055 in.)
Special tool
(A): 09943–57010
[A]: Wheel side
[B]: Differential side (or center shaft side)
I4RS0A310007-01
I4RS0A310009-01
(A)
1
(A)
1
“a”
1
I5RS0B310008-01

Downloaded from www.Manualslib.com manuals search engine 3A-11 Drive Shaft / Axle: Front
8) Install damper (1) to specified position on drive shaft,
if equipped.
Drive shaft damper installing position
“a”: 354 mm (13.9 in.) (right side)
“a”: 252 mm (9.9 in.) (left side)
9) Set new differential side (or center shaft side) small
band and new differential side (or center shaft side)
boot (1) on shaft temporarily, and then apply grease
to tripod joint (2). Use specified grease in tube
included in spare parts.
10) Install tripod joint spider (3) on shaft using special
tool with hammer, directing its chamfered spline
toward wheel side, and then fasten it with new snap
ring (4) using snap ring pliers (5).
Special tool
(A): 09925–98221
11) Apply grease (including in spare parts) to inside of
tripod joint housing (1), joint it with tripod joint.
Grease color
“A”: Dark gray
Amount
“A”: 70 – 90 g (2.5 – 3.2 oz)12) Fit boot (1) to grooves of shaft and housing (2) adjust
length to specification below.
13) Insert screw driver into boot and allow air to enter
boot so that air pressure in boot becomes the same
as atmospheric pressure.
Drive shaft boot fixing position (distance
between housing end and small boot band)
Left side drive shaft “a”: 153.9 mm (6.06 in.)
Right side drive shaft “b”: 178 mm (7.01 in.)
CAUTION!
• Bend each boot band against forward
rotation.
• Do not squeeze or distort boot when
fastening it with bands. Distorted boot
caused by squeezing air may reduce its
durability.

14) Place differential side (or center shaft side) boot new
big band (3) and new small band (4) onto boot
putting band outer end (1) against forward rotation
(2) as shown in figure.
I4RS0B310002-01
I7RW01311004-01
I4RS0B310003-01
[A]: Drive shaft inserted into differential side
[B]: Drive shaft inserted into center shaft side
I4RS0B310004-01
I4RS0B310007-01

Downloaded from www.Manualslib.com manuals search engine 3A-13 Drive Shaft / Axle: Front
• When installing left oil seal (1) and right oil seal (2)
using special tool, use care so that oil seals in proper
direction and position as shown in the figure.
Special tool
: 09925–15410
Distance
“a”: 0 – 1 mm (0 – 0.04 in.)
“b”: 8 – 9 mm (0.13 – 0.35 in.)
• Be sure to apply grease to oil seal lip and bearing side
space indicated in the figure.
“A”: Grease 99000–25011 (SUZUKI Super Grease
A) • Press-fit center shaft (1) from left oil seal (2) side.
Specifications
Tightening Torque SpecificationsS6RW0D3117001
NOTE
The specified tightening torque is also described in the following.
“Front Drive Shaft Assembly Components Location”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
2 1
“A”
“b”
“a” “A”
I5RW0A311007-01
12
I5RW0A311008-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Brake hose mounting bolt 25 2.5 18.0)

Downloaded from www.Manualslib.com manuals search engine 3A-17 Drive Shaft / Axle: Rear
Reassembly
Refer to “Front Drive Shaft Disassembly and
Reassembly” note the following points which is different
from the front drive shaft is described.
• Apply grease to each joint.
Grease color
Wheel side: Black
Differential side: Dark gray
Amount
Wheel side: 50 – 70 g (1.8 – 2.5 oz)
Differential side: 70 – 90 g (2.5 – 3.2 oz)
• Drive in the cage (1) by using special tool.
Special tool
(A): 09913–84510
• Fit differential side boot as follows.
– Fit boot (1) to grooves of shaft and housing (2)
adjust length to specification below.
– Insert screw driver into boot and allow air to enter
boot so that air pressure in boot becomes the same
as atmospheric pressure.
Drive shaft boot fixing position (distance
between housing end and small boot band
center)
Left side and right side drive shafts “a”: 142.5
mm (5.61 in.)• Fasten differential side boot band as follows.
CAUTION!
• Bend each boot band against forward
rotation.
• Do not squeeze or distort boot when
fastening it with bands. Distorted boot
caused by squeezing air may reduce its
durability.

– Place differential side boot new big band (3) and
new small band onto boot putting band outer end
(1) against forward rotation (2) as shown in figure.
– Fasten differential side boot new big band (1) and
new small band by drawing hooks (2) with special
tool and engage hooks (3) in slot and window (4).
Special tool
(A): 09943–57021
(A)
1
I5RS0B310009-01
“a”
2
1I5RW0A312007-01
I5RW0A312004-01
(A)
1
4
2
3
I5RW0A312005-01

Downloaded from www.Manualslib.com manuals search engine 3B-11 Differential:
Visual InspectionS6RW0D3204004
Check the following parts and systems visually.
DTC CheckS6RW0D3204005
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector
(DLC) (1) located on underside of instrument panel.
Special tool
(A): SUZUKI scan tool
3) Turn ignition switch to ON position.
4) Read DTC according to instructions displayed on
SUZUKI scan tool and print it or write it down. Refer
to SUZUKI scan tool operator’s manual for further
details.
If communication between SUZUKI scan tool and
4WD control module is not possible, check if
SUZUKI scan tool is communicable by connecting it
to 4WD control module in another vehicle. If
communication is possible in this case, SUZUKI
scan tool is in good condition. Then check data link
connector and serial data line (circuit) in the vehicle
with which communication was not possible.
5) After completing the check, turn ignition switch OFF
and disconnect SUZUKI scan tool from data link
connector (DLC).
DTC ClearanceS6RW0D3204006
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector
(DLC) (1) located on underside of instrument panel.
Special tool
(A): SUZUKI scan tool
3) Turn ignition switch to ON position.
4) Erase DTC according to instructions displayed on
SUZUKI scan tool. Refer to SUZUKI scan tool
operator’s manual for further details.
5) After completing clearance, turn ignition switch OFF
and disconnect SUZUKI scan tool from data link
connector (DLC).
6) Perform “DTC Check” and confirm that NO CODES
is displayed.
NOTE
DTC stored in 4WD control module memory
are also cleared in the following cases. Be
careful not to clear them before keeping their
record.
• When power to 4WD control module is cut
off (by disconnecting battery cable,
removing fuse or disconnecting 4WD
control module connectors).
• When the same malfunction (DTC) is not
detected again during 40 engine warm-up
cycles.

Inspection Item Referring
• Rear differential oil ---- level, leakage “Rear Differential Oil Change”
• Transfer gear oil ---- level, leakage “Transfer Oil Change in Section 3C”
• Manual transmission oil ---- level, leakage “Manual Transaxle Oil Change in Section 5B”
• Rear differential mounting(s) ---- wear and looseness
• Fuses ---- burning
• Battery ---- fluid level, corrosion of terminal “Battery Inspection in Section 1J”
• Connectors of electric wire harness ---- disconnection,
friction“Intermittent and Poor Connection Inspection in Section
00”
• Other parts that can be checked visually
1(A)I5RW0A320008-011(A)I5RW0A320008-01

Downloaded from www.Manualslib.com manuals search engine 3B-31 Differential:
2WD/4WD Switch Removal and InstallationS6RW0D3206003
Removal
1) Disconnect negative cable at battery.
2) Remove console box (2).
3) Remove 2WD/4WD switch (1) from console box.
Installation
Reverse removal procedure for installation.
2WD/4WD Switch InspectionS6RW0D3206004
Check 2WD/4WD switch for continuity between
terminals at each switch position.
If check result is not as specified, replace switch.
4WD Control Module Removal and InstallationS6RW0D3206005
Removal
1) Disconnect negative cable at battery.
2) Remove center ventilation louver referring to “Center
Ventilation Louver Removal and Installation in
Section 7A”.
3) Disconnect connector (1) from 4WD control module.
4) Remove 4WD control module (2).
Installation
Reverse removal procedure for installation.
Coupling Air Temperature Sensor Removal and
Installation
S6RW0D3206006
Removal
1) Dismount rear differential referring to “Rear
Differential Dismounting and Remounting”.
2) Remove coupling air temperature sensor (1) from
rear differential (2).
Installation
Reverse removal procedure for installation, noting the
following point.
• Tighten coupling air temperature sensor to specified
torque.
Tightening torque
Coupling air temperature sensor: 18 N·m (1.8 kgf-
m, 13.0 lb-ft)
1
2
I5RW0A320017-02
Terminal
Switch position
2WD
AUTO
LOCK
11
22
3 3
4 4
5 5
I5RW0A320018-02
2
1
I5RW0A320019-01
12
I5RW0A320020-02

Downloaded from www.Manualslib.com manuals search engine 3B-33 Differential:
Rear Differential Mountings ComponentsS6RW0D3206009
18
10
10
3
24
54
6
(a)11
(a)
(b)9
(b) 7(b)
I5RW0A320022-04
1. Rear differential 6. Front mounting to body bolt 11. Rear mounting bolt
2. Front mounting arm 7. Front mounting to body nut : 80 N⋅m (8.0 kgf-m, 58.0 lb-ft)
3. Mounting arm bolt 8. Rear mounting bracket : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft)
4. Front mounting 9. Rear mounting bracket bolt : Do not reuse.
5. Front mounting bolt 10. Rear mounting

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-34
Front Mounting Arm and/or Rear Mounting
Bracket Assembly Removal and Installation
S6RW0D3206010
Remove and install front mounting arm and/or rear
mounting bracket after rear differential removed.
For tightening torque of each bolt and nut, refer to “Rear
Differential Mountings Components”.
Rear Mounting Bracket Assembly Disassembly
and Reassembly
S6RW0D3206011
Disassembly
Drive out mountings from rear mounting bracket using
special tool and hydraulic press.
Special tool
(A): 09913–70123
(B): 09951–26020
Reassembly
Press mountings in rear mounting bracket using special
tool and hydraulic press with caring its installation
position shown in figure.
Special tool
(A): 09913–85210
(B): 09951–26020
Rear Differential Dismounting and RemountingS6RW0D3206012
Dismounting
1) Lift up vehicle and drain oil from rear differential.
2) Remove propeller shaft referring to “Propeller Shaft
Assembly Removal and Installation in Section 3D”.
3) Remove rear drive shafts assembly referring to
“Rear Drive Shaft Assembly Removal and
Installation in Section 3A”.
4) Support rear differential (3) with transmission jack
(4).
5) Remove mounting arm bolts (2) and rear mounting
bolts (1), and then lower rear differential with rear
mounting bracket.
Remounting
Reverse dismounting procedure for remounting of rear
differential, noting the following points.
• Tighten each bolt to specified torque referring to “Rear
Differential Mountings Components”.
• Fill gear oil to rear differential referring to “Rear
Differential Oil Change”.
(B)
(A)
I5RW0A320023-02
(A)
(B)
I5RW0A320024-02
3
4 21
I5RW0A320025-01