2006 SUZUKI SX4 check oil

Downloaded from www.Manualslib.com manuals search engine 3B-43 Differential:
19) Using special tool and plastic hammer, drive oil seal
(2) into differential carrier (1) as shown in figure.
Then apply grease to oil seal lip.
NOTE
Install oil seal horizontally to surface of
differential carrier.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Distance between differential carrier and oil seal
“a”
: 0.5 – 1.5 mm (0.02 – 0.06 in.)
Special tool
(A): 09913–85210
20) Tighten bevel pinion nut (1) gradually with special
tool to specified torque while turning bevel pinion.
Set bearing preload of bevel pinion to specification.
NOTE
• Before taking measurement with torque
wrench, check for smooth rotation with
turning bevel pinion 15 revolutions or
more by hand.
• Be sure to tighten gradually and carefully
till specified pinion bearing preload is
obtained. Turning back overtightened
flange nuts should be avoided.
• Measure pinion bearing preload while
turning bevel pinion about 50 rpm.
• Write down measured value of bevel pinion
bearing preload for differential side
bearing shim adjustment.

Special tool
(A): 09927–27910
Tightening torque
Bevel pinion nut: 230 – 340 N·m (23.0 – 34.0 kgf-
m, 166.5 – 246.0 lb-ft)
Bevel pinion bearing preload (Bevel pinion
rotational torque)
: 1.3 – 2.6 N⋅m (13.0 – 26.0 kgf-cm, 11.3 – 22.6 lb-
in.)
21) Install differential case assembly, bearing outer
races, removed shim and differential cover,
temporarily.
NOTE
• Used left and right outer races are not
interchangeable.
• When measuring bevel pinion bearing
preload, install differential cover with
sealant not applied.

22) Select differential side bearing shim so that bevel
pinion bearing preload may be specified value.
NOTE
Select shims so that thickness of right side
shims and left side shims become almost
even.

Bevel pinion bearing preload
Preload measured in Step 20) + 0.3 – 0.7 N⋅m (3 –
7 kgf-cm, 2.6 – 6.0 lb-in.)
Available shim thickness
0.45, 2.30, 2.35, 2.40, 2.45, 2.50, 2.55, 2.60, 2.65
and 2.70 mm (0.017, 0.090, 0.092, 0.094, 0.096,
0.098, 0.100, 0.102, 0.104 and 0.106 in.)
(A)
11
2, “A”
“a”
I5RW0A320054-02
(A)
1
I5RW0A320055-03
I5RW0A320056-01

Downloaded from www.Manualslib.com manuals search engine 3B-47 Differential:
31) Clean mating surface of differential carrier (1) and
coupling case (2), apply sealant to carrier as shown
in figure by such amount that its section is 1.5 mm
(0.059 in.) in diameter, mate coupling case with
differential carrier as shown in figure, and then
tighten bolts to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Coupling case bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
NOTE
Install coupling pin (3) by fitting it to groove
(4) of coupling case.

32) Apply grease to oil seal lip, and then install oil seals
(1) to rear differential (2) using special tool as shown
in figure.
NOTE
Install oil seal horizontally to surface of rear
differential case.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Distance between rear differential and oil seal
“a”
: 1.0 – 2.0 mm (0.04 – 0.08 in.)
Special tool
(A): 09913–75810
33) Install drive shaft flange.
34) Install rear mounting bracket to rear differential
referring to “Front Mounting Arm and/or Rear
Mounting Bracket Assembly Removal and
Installation”.
Rear Differential InspectionS6RW0D3206015
• Check companion flange for wear or damage.
• Check bearings for wear or discoloration.
• Check differential carrier for cracks.
• Check drive bevel pinion and bevel gear for wear or
cracks.
• Check side gears, pinion gears and pinion shaft for
wear or damage.
• Check side gear spline for wear or damage.
1 4
3 2“A”
(a)
I5RW0A320062-04
(A)
2 21, “A”
“a”
I5RW0A320063-02

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-2
Repair Instructions
Transfer Oil Level CheckS6RW0D3306001
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
Transfer oil level / filler plug (a): 23 N·m (2.3 kgf-
m, 17.0 lb-ft)
Transfer Oil ChangeS6RW0D3306002
1) Before changing or inspecting oil, be sure to stop
engine and lift vehicle horizontally.
2) 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 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
Transfer oil drain plug (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
6) Pour new specified oil up to lower end of oil level /
filler plug hole (3).
NOTE
It is highly recommended to use API GL-5
80W-90 gear oil.

Transfer oil specification
: API GL-5 (For SAE classification, refer to
viscosity chart [A] in figure.)
Transfer oil capacity
Reference: 0.6 liters (1.2/1.0 US/lmp. 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
Transfer oil level / filler plug (b): 23 N·m (2.3 kgf-
m, 17.0 lb-ft)
I5RW0A330002-01
I5RW0A330003-01

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-14
8) Install transfer output flange (1) by tapping with
plastic hammer and tighten transfer output flange nut
gradually so as rotational torque of bevel pinion to be
in specified value.
NOTE
• If rotational torque of bevel pinion exceeds
specification given in the following,
replace pinion shaft spacers and tighten
flange nut.
• Before taking measurement of rotational
torque, rotate pinion over ten rounds in
advance.

Bevel pinion bearing preload
: 0.5 – 1.3 N⋅m (0.05 – 0.13 kgf-m, 0.35 – 0.95 lb-ft)
Special tool
(A): 09930–40113
9) Caulk transfer output flange nut (1).
Transfer Assembly InspectionS6RW0D3306010
• Check each bearing for smooth rotation, wear or
discoloration
If found abnormal, replace.
• Check oil seal for leakage and its lip for excessive
hardness
If either is found, replace.
• Check transfer case for cracks.
• Check bevel pinion and bevel gears for wear or
cracks.
Bevel Gear Tooth Contact InspectionS6RW0D3306011
1) After cleaning tooth surface of bevel gear (1), paint
them with gear marking compound evenly by using
brush or sponge etc.
NOTE
When applying red lead paste to teeth, be
sure to paint tooth surfaces uniformly. The
paste must not be too dry or too fluid.

2) Install transfer output retainer assembly referring to
“Transfer Assembly Disassembly and Reassembly”.
3) Turn transfer output flange clockwise and
counterclockwise repeatedly, and remove transfer
output retainer assembly and bevel gear shims from
transfer assembly.
2. Torque wrench
(A)1
2
I5RW0A330043-01
1
I5RW0A330044-01
I3RH01332043-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-4
Rear Brake Hose / Pipe ConstructionS6RW0D4101003
Diagnostic Information and Procedures
Brakes Diagnosis NoteS6RW0D4104001
Road Testing Brakes
Brakes should be tested on dry, clean, smooth and
reasonably level roadway which is not crowned. Road
test brakes by making brake applications with both light
and heavy pedal forces at various speeds to determine if
the vehicle stops evenly and effectively. Also drive
vehicle to see if it leads to one side or the other without
brake application. If it does, check the tire pressure, front
wheel alignment and front suspension attachments for
looseness. See diagnosis table for other causes.
Brake Fluid Leaks
Check the master cylinder fluid levels. While a slight
drop in reservoir level does result from normal lining
wear, an abnormally low level indicates a leak in the
system. In such a case, check the entire brake system
for leakage. If even a slight evidence of leakage is noted,
the cause should be corrected or defective parts should
be replaced.Substandard or Contaminated Brake Fluid
Improper brake fluid, mineral oil or water in the fluid may
cause the brake fluid to boil or the rubber components
(piston cups and brake hoses) in the hydraulic system to
deteriorate.
If the above fluid is included in the system, replace the
master cylinder assembly and other rubber components
(hoses). The master cylinder assembly is disassemble
parts to maintain the performance.
The system must be flushed if there is any doubt as to
the grade of fluid in the system or if fluid has been used
which contained parts that have been subjected to
contaminated fluid.
I6RW0D410001-01
1. To left rear brake hose 5. Left rear brake hose to left brake
2. To right rear brake hose 6. Right rear brake hose to right brake
3. Left rear brake hose : 16 N⋅m (1.6 kgf-m, 12.0 lb-ft)
4. Right rear brake hose

Downloaded from www.Manualslib.com manuals search engine 4A-5 Brake Control System and Diagnosis:
Brakes Symptom DiagnosisS6RW0D4104002
Condition Possible cause Correction / Reference Item
Not enough braking forceBrake oil leakage from brake linesLocate leaking point and repair.
Brake disc or pad stained with oilClean or replace.
Overheated brakesDetermine cause and repair.
Poor contact of shoes on brake drumRepair for proper contact.
Brake shoe stained with oil or wet with
waterReplace.
Badly worn brake padReplace.
Defective wheel cylindersRepair or replace.
Malfunctioning caliper assemblyRepair or replace.
Malfunctioning brake boosterCheck system and replace as necessary.
Malfunctioning brake master cylinderCheck system and replace as necessary.
Air in systemBleed system.
Malfunctioning ABSCheck system and replace as necessary.
Brake pull (Brakes not
working in unison)Pad, disc, shoe and/or drum are wet
with water or stained with oil in some
brakesClean or replace.
Drum-to-shoe clearance out of
adjustment in some brakes
(Malfunctioning auto adjusting
mechanism) Check for inoperative auto adjusting
mechanism.
Disc and/or drum are out of round in
some brakesReplace.
Tires are inflated unequallyInflate equally.
Malfunction in wheel cylinders (rear
drum brake model)Repair or replace.
Disturbed front wheel alignmentAdjust as prescribed.
Unmatched tires on same axleTires with approximately the same amount of
tread should be used on the same axle.
Restricted brake pipes or hosesCheck for soft hoses and damaged lines.
Replace with new hoses and new double-
walled steel brake tubing.
Malfunctioning caliper assemblyCheck for stuck or sluggish pistons and proper
lubrication of caliper slide pin.
Caliper should slide.
Loose suspension partsCheck all suspension mountings.
Loose calipersCheck and torque bolts to specifications.
Noise (high pitched
squeak without brake
applied)Contact wear indicator to brake discReplace brake pad.
Worn rear brake shoeReplace brake shoe.
Excessive pedal travel
(Pedal stroke too large)Partial brake system failureCheck brake systems and repair as necessary.
Brake fluid leakingRepair the leaking point, and bleed air.
Air in system (soft / spongy pedal)Bleed system.
Rear brake system not adjusted
(malfunctioning auto adjusting
mechanism)Repair auto adjusting mechanism.
Adjust rear brakes.
Bent brake shoesReplace brake shoes.
Brake locked Malfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.

Downloaded from www.Manualslib.com manuals search engine 4A-7 Brake Control System and Diagnosis:
Repair Instructions
Brake Pedal ComponentsS6RW0D4106018
CAUTION!
If equipped Brake Pedal Foot Protection
System, never disassemble brake pedal
assembly. Disassemble will spoil its original
function. If faulty condition is found, replace
it with new one.

Brake Pedal Free Height InspectionS6RW0D4106001
1) Check brake pedal free height. If it is not within
specification, check and adjust following item 2) and
6).
Brake pedal free height “a” from carpet
111 – 131 mm (4.4 – 5.1 in.)
2) Check measurement between booster mounting
surface and center of clevis pin hole. When booster
push rod clevis has been reinstalled, it is important
that the measurement is adjusted (refer to “Brake
Booster Inspection”).
3) Check brake light switch position. Adjust it if it is out
of specification.
4) Check pedal for dent.
5) Check brake booster for installation.6) Check brake booster push rod for length.
Brake Pedal Play InspectionS6RW0D4106002
Pedal play should be within the following specification. If
out of specification, check brake light switch for proper
installation position and adjust if necessary.
Also check pedal shaft bolt and booster clevis pin
installation for looseness and replace if defective.
Brake pedal play
“a”
: 1 – 8 mm (0.04 – 0.31 in.)
Excessive Pedal Travel InspectionS6RW0D4106003
1) Start engine.
2) Depress brake pedal a few times.
3) With brake pedal depressed with approximately 300
N (30 kg, 66 lbs) load, measure brake pedal to wall
(dash panel silencer) clearance “a”. If clearance is
out of specification, possible causes are as follows.
If clearance “a” is less than specification, the most
possible cause is that air is in lines or brake fluid
leakage.
Should clearance “a” remain less than specification
even after bleeding of system, other possible but
infrequent cause is malfunction of booster push rod
length out of adjustment.
• Bleed brake system. Refer to “Air Bleeding of
Brake System”.
Brake pedal arm to wall clearance
“a”
When pedal is depressed at 300 N (30 kg, 66 lbs)
: Over 40 mm (1.57 in.)
[A]: A/T model : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
1. Brake pedal : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft)
2. Brake pedal bracket
I6RW0C410004-01
I6RW0C410005-01
“a”I3RH0A410010-01
I6RW0C410006-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-8
Brake Fluid Level InspectionS6RW0D4106004
CAUTION!
Do not use shock absorber fluid or any other
fluid which contains mineral oil. Do not use a
container which has been used for mineral oil
or a container which is wet from water.
Mineral oil will cause swelling and distortion
of rubber parts in hydraulic brake system and
water mixed into brake fluid will lower fluid
boiling point. Keep all fluid containers
capped to prevent contamination.

NOTE
Be sure to use particular brake fluid either as
indicated on reservoir cap of that vehicle or
recommended in owner’s manual which
comes along with that vehicle. Use of any
other fluid is strictly prohibited.
Fluid level should be between MIN and MAX
lines marked on reservoir.
When brake warning light lights sometimes
during driving, replenish fluid to MAX level.
When fluid decreases quickly, inspect brake
system for leakage. Correct leaky points and
then refill to specified level.

1) Check master cylinder, reservoir and reservoir hose
(if equipped) for crack, damage and brake fluid
leakage. If any faulty condition exists, correct or
replace.
2) Check that brake fluid level is between MAX (1) and
MIN marks (2) on reservoir.
Brake Light Switch AdjustmentS6RW0D4106005
Adjustment should be made as follows. Pull up brake
pedal toward you and while holding it there, adjust
switch position so that clearance between end of thread
and brake pedal is as specified. Then lock it by turning
clockwise.
Clearance between brake pedal and brake light
switch
“a”: 0.5 – 1.5 mm (0.02 – 0.05 in.)
Air Bleeding of Brake SystemS6RW0D4106006
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

Bleeding operation is necessary to remove air whenever
it entered hydraulic brake system.
Hydraulic lines of brake system are based on the
diagonal split system. When a brake pipe or hose was
disconnected at the wheel, bleeding operation must be
performed at both ends of the line of the removed pipe or
hose. When any joint part of the master cylinder of other
joint part between the master cylinder and each brake
(wheel) was removed, the hydraulic brake system must
be bled at all 4 wheel brakes.
NOTE
Perform bleeding operation starting with rear
brake caliper or wheel cylinder farthest from
master cylinder and then at front caliper of
the same brake line. Do the same on the
other brake line.

1
2
I7RW01410004-01
1. Right front brake caliper 3. Right rear wheel cylinder
2. Left front brake caliper 4. Left rear wheel cylinder
I5RW0A410005-01
I7RW01410005-01