2006 SUZUKI SX4 Sas

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-37
3) Support differential case (1) with soft jawed vise and
remove final gear bolts then take out final gear.
4) Drive out differential pinion shaft (3) pin by using
special tool and hammer and then disassemble
components parts.
Special tool
(A): 09922–85811
Reassembly
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 all parts are clean.
1) Install differential pinion, side gear and pinion shaft
to differential case and measure back rash and
thrust play of differential side gear as follows.
If measured value is out of specification, select
suitable side gear washer from among the following
available size, install it and check again.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06010
a) Differential side gear backlash
• Hold differential assembly with soft jawed vise
and apply measuring tip of dial gauge to side
gear as shown in figure.
• Fixing differential pinion, turn side gear back
and forth and read dial gauge.
Differential side gear backlash
0.10 – 0.15 mm (0.003 – 0.005 in.)
b) Differential side gear thrust play
• Hold differential assembly with soft jawed vise
and apply measuring tip of dial gauge to side
gear as shown in figure.
• Move side gear up and down by hand and
read dial gauge.
Differential side gear thrust play
0.03 – 0.31 mm (0.001 – 0.012 in.)Available side gear washer thickness
2) Drive in spring pin from right side till it is flush with
differential case surface.
3) Press-fit left bearing (1) by using special tool and
hydraulic press.
Special tool
(A): 09913–70123
2. Differential side gear
I5RW0A520046-01
0.85 mm (0.033 in.) 1.05 mm (0.041 in.)
0.9 mm (0.035 in.) 1.1 mm (0.043 in.)
0.95 mm (0.037 in.) 1.15 mm (0.045 in.)
1.0 mm (0.039 in.)
2. Differential case
(B)
(B)
(C)
(A)
(A)
I5RW0A520047-01
I2RH01520074-01

Downloaded from www.Manualslib.com manuals search engine 5C-5 Clutch:
Clutch Master Cylinder Removal and
Installation
S6RW0D5306007
Removal
1) Clean around brake master cylinder reservoir cap
and take out fluid with syringe or such from brake
master cylinder reservoir.
2) Disconnect clutch fluid pipe (4) from clutch master
cylinder (1) referring to “Clutch Fluid Pipe Removal
and Installation”.
3) Disconnect clutch reservoir hose (2).
4) Remove push rod from clutch pedal, and then
remove clutch master cylinder.
Installation
Reverse removal procedure for installation noting the
following.
• Apply grease to push rod tip.
“A”: Grease 99000–25100 (SUZUKI Silicone
Grease)
• Tighten clutch master cylinder nut to specified torque.
Tightening torque
Clutch master cylinder nut: 13 N·m (1.3 kgf-m, 9.5
lb-ft)
Clutch Operating Cylinder Assembly Removal
and Installation
S6RW0D5306008
CAUTION!
• Do not allow fluid to get on painted
surfaces. It may cause painted surface
damage.
• Do not disassemble clutch operating
cylinder assembly.

Removal
1) Clean around reservoir cap of brake master cylinder
and take out fluid with syringe or such.
2) Dismount transaxle assembly referring to “Manual
Transaxle Unit Dismounting and Remounting in
Section 5B”.
3) Loosen clutch fluid pipe flare nut (1) of clutch
operating cylinder assembly (2).
4) Remove clutch pipe joint sleeve (3) from transaxle
and then remove clutch fluid pipe (4).
5) Remove clutch operating cylinder assembly from
transaxle.
3. Brake booster
1
3
2
4
I5RW0A530006-01
“A”
I5RW0A530007-01
3
4
2
1
I5RW0A530008-01

Downloaded from www.Manualslib.com manuals search engine 5C-9 Clutch:
Clutch Disc
Measure depth of rivet head depression, i.e. distance
between rivet head and facing surface.
If depression is found to have reached service limit at
any of rivet holes (2), replace clutch disc assembly (1).
Rivet head depth
Standard: 1.65 – 2.25 mm (0.06 – 0.09 in.)
Limit: 0.5 mm (0.02 in.)Clutch Cover
1) Check diaphragm spring (1) for abnormal wear or
damage.
2) Inspect pressure plate (2) for wear or heat spots.
3) If abnormality is found, replace clutch cover.
Do not disassemble it into diaphragm spring and
pressure plate.
Flywheel
Check surface contacting clutch disc for abnormal wear
or heat spots. Replace or repair as required.
Specifications
Tightening Torque SpecificationsS6RW0D5307001
NOTE
The specified tightening torque is also described in the following.
“Clutch Cover, Clutch Disc and Flywheel Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I4RS0A530019-01
I3RM0A530015-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Clutch master cylinder nut 13 1.3 9.5)
Clutch operating cylinder assembly mounting
bolt10 1.0 7.5)
Clutch fluid pipe flare nut 16 1.6 11.5)
Flywheel bolt 70 7.0 51.0)
Clutch cover bolt 23 2.3 17.0)

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-27
Installation
Reverse removal procedure noting the following
instructions.
• Replenish specified amount of compressor oil to
compressor suction side referring to “Replenishing
Compressor Oil” in “Operation Procedure for
Refrigerant Charge”.
• Install the padding (1) to the installation hole
uniformly.
• Evacuate and charge the A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
• Refill cooling system with coolant referring to “Cooling
System Flush and Refill in Section 1F”.
• Adjust control cables referring to “HVAC Control Unit
Removal and Installation in Section 7A”. (vehicle with
manual type A/C)
Evaporator InspectionS6RW0D7216009
Check the followings.
• Clog of A/C evaporator fins.
If any clogs are found, A/C evaporator fins should be
washed with water, and then should be dried with
compressed air.
• A/C evaporator fins for leakage and breakage.
If any defects are found, repair or replace A/C
evaporator.
• A/C evaporator fittings for leakage.
If any defects are found, repair or replace A/C
evaporator.
Evaporator Temperature Sensor Removal and
Installation
S6RW0D7216010
Removal
1) Remove HVAC unit from vehicle body referring to
“HVAC Unit Removal and Installation”.
2) Remove evaporator temperature sensor (1) from
evaporator by (2) disassembling HVAC unit.
Installation
Reverse the removal procedure noting the following
instruction.
• Install evaporator temperature sensor (1) onto
evaporator (2) as shown.
LH steering vehicle
RH steering vehicle
1
I5RW0A721025-02
3. 138 ± 5 mm (3.3 ± 0.2 in.)
4. Sensor part fixed to 12th fin from pipe fitting side
5. Holding part fixed to 13th fin from pipe fitting side
6. Pipe fitting
1
2
I7RW01721018-01
5
4
6 1
2
3I7RW01721026-01
1
5
642
3
I6RW0C721007-01

Downloaded from www.Manualslib.com manuals search engine Seat Belts: 8A-4
Repair Instructions
Front Seat Belt ComponentsS6RW0D8106001
WARNING!
• Never attempt to disassemble or repair the seat belt pretensioner (retractor). If any abnormality is
found, be sure to replace it with new one as an assembly.
• Be sure to read “Precautions on Service and Diagnosis of Seat Belt” before starting to work and
observe every precaution during work. Neglecting them may result in personal injury or
unactivation of the seat belt pretensioner when necessary.

I7RW01810002-01
1. Sash guide 10. Buckle mounting bolt
2. Anchor plate 11. Sash guide bolt
: Tighten sash guide bolt first, then tighten anchor bolt.
3. Retractor 12. Spacer
4. Buckle 13. Washer
5. Yellow connector (for seat belt pretensioner) 14. Spring washer
6. Retractor mounting bolt 15. Wave washer
7. Shoulder adjuster : 43 N⋅m (4.3 kgf-m, 31.5 lb-ft)
8. Shoulder adjuster bolt
: Tighten upper bolt first, then tighten lower bolt.: 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
9. Anchor bolt
: Tighten sash guide bolt first, then tighten anchor
bolt.

Downloaded from www.Manualslib.com manuals search engine 8A-5 Seat Belts:
Front Seat Belt Removal and InstallationS6RW0D8106002
WARNING!
• Never attempt to disassemble or repair the
retractor (seat belt pretensioner). If any
abnormality is found, be sure to replace it
with new one as an assembly.
• Be sure to read “Precautions on Service
and Diagnosis of Seat Belt” before starting
to work and observe every precaution
during work. Neglecting them may result in
personal injury or unactivation of the seat
belt pretensioner when necessary.

Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system. Refer to “Disabling Air Bag
System in Section 8B”.
3) Remove center pillar lower trim.
4) Disconnect connector (1) from retractor (seat belt
pretensioner) (2) as following steps.
a) Unlock lock button (3) by pulling it.
b) After unlocked, disconnect connector.
5) Remove front seat belts from the vehicle.Installation
Install in reverse order of removal, noting the following.
• Seat belt anchor bolts should have an unified fine
thread (7/16-20 UNF). Under no circumstances
should any different sized or metric screw threads be
used.
• Connect seat belt pretensioner connector (1) to
retractor (seat belt pretensioner) securely as following
steps.
a. Make sure that lock button (2) is unlock position.
b. Insert connector to retractor (seat belt
pretensioner) until it stops with unlocked lock
button (2).
c. Lock connector securely by showing in lock button
(2).
• Enable air bag system. Refer to “Enabling Air Bag
System in Section 8B”.
2
1
3
I5RW0A810002-02
1
2
I5RW0A810003-03

Downloaded from www.Manualslib.com manuals search engine Seat Belts: 8A-6
Front Seat Belt InspectionS6RW0D8106003
WARNING!
• Never attempt to disassemble or repair the
seat belt pretensioner (retractor). If any
abnormality is found, be sure to replace it
with new one as an assembly.
• Be sure to read “Precautions on Service
and Diagnosis of Seat Belt”, before
starting to work and observe every
precaution during work. Neglecting them
may result in personal injury or
unactivation of the seat belt pretensioner
when necessary.
• Never measure resistance of pretensioner
or disassemble it. Otherwise, personal
injury may result.

CAUTION!
If seat belt pretensioner (retractor) was
dropped from a height of 30 cm (1 ft) or more,
it should be replaced.

Seat belts and attaching parts can affect the vital
components and systems of a vehicle.
Therefore, they should be inspected carefully and
replaced with genuine parts only.
Seat Belt
• The seat belt webbing or strap should be free from
damage.
Retractor (with Seat Belt Pretensioner)
1) Let the seat belt retract fully to confirm its easy
retraction.
• The retractor should lock webbing when pulled
quickly.
• The front seat belt retractor (1) should pass the
inspection and should lock webbing even when
tilted (approx. 15°) toward the fore and aft or right
and left directions.2) Check retractor (1) with seat belt pretensioner
appearance visually for following symptoms and if
any one of them is applicable, replace it with a new
one as an assembly.
• Pretensioner has activated.
• There is a crack in seat belt pretensioner
(retractor).
• Seat belt pretensioner (retractor) is damaged or a
strong impact (e.g., dropping) was applied to it.
Anchor Bolt
• Anchor bolts should be torqued to specification.
Belt Latch
• It should be secure when latched.
Seat Belt Buckle Switch
Check driver side seat belt switch and passenger side
seat belt switch for continuity by using ohmmeter.
Seat belt switch specification
Without inserted buckle tongue to buckle catch:
Terminal “A” and “B”: Continuity
With inserted buckle tongue to buckle catch:
Terminal “A” and “B”: No continuityI2RH01810004-01
1. Buckle tongue
2. Buckle catch
I2RH01810005-01
I4RS0B810001-01

Downloaded from www.Manualslib.com manuals search engine 8A-7 Seat Belts:
Rear Seat Belt ComponentsS6RW0D8106004
WARNING!
Be sure to read “Precautions on Service and Diagnosis of Seat Belt” before starting to work and
observe every precaution during work.

I6RW0C810002-01
[A]: A-ELR rear center seat belt model 9. Anchor bolt
: Tighten retractor mounting bolts and sash guide bolt first, then tighten
anchor bolt.
[B]: Non-A-ELR rear center seat belt model 10. Buckle bolt
1. Sash guide 11. Center retractor
2. Anchor plate 12. Center retractor mounting bolt
: Tighten lower bolt first, then tighten upper bolt.
3. Side retractor 13. Sash guide bolt
: Tighten sash guide bolt first, then tighten side retractor mounting bolt.
4. Center seat belt 14. Spring washer
5. Buckle for seat belt 15. Washer
6. Buckle for center seat belt 16. Spacer
7. Seat belt: 43 N⋅m (4.3 kgf-m, 31.5 lb-ft)
8. Side retractor mounting bolt
: Tighten sash guide bolt first, then tighten side retractor mounting bolt.:5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)