2006 SUZUKI SX4 shaft

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-2
Condition Possible cause Correction / Reference Item
Motor not running (No
operating sound of
magnetic switch)Transmission range sensor is not in P or
N, or not adjusted (A/T model)Shift in P or N, or adjust sensor. (A/T model)
Battery run downRecharge battery.
Battery voltage too low due to battery
deteriorationReplace battery.
Poor contact in battery terminal
connectionRetighten or replace.
Loose grounding cable connectionRetighten.
Fuse set loose or blown offTighten or replace.
Poor contacting action of ignition switch
and magnetic switchReplace.
Lead wire coupler loose in placeRetighten.
Open-circuit between ignition switch and
magnetic switchRepair.
Open-circuit in pull-in coilReplace magnetic switch.
Brushes are seating poorly or worn
downRepair or replace.
Poor sliding of plunger and/or pinionRepair.
Faulty starting motor control relay“Main Relay, Fuel Pump Relay, Starting Motor
Control Relay, Throttle Actuator Control Relay
and Radiator Cooling Fan Relay Inspection in
Section 1C”.
Faulty ECM and its circuit“Inspection of ECM and Its Circuits in Section
1A”.
Motor not running
(Operating sound of
magnetic switch heard)Battery run downRecharge battery.
Battery voltage too low due to battery
deteriorationReplace battery.
Loose battery cable connectionsRetighten.
Burnt main contact point, or poor
contacting action of magnetic switchReplace magnetic switch.
Brushes are seating poorly or worn
downRepair or replace.
Weakened brush springReplace.
Burnt commutatorReplace armature.
Layer short-circuit of armatureReplace.
Crankshaft rotation obstructedRepair.
Starting motor running
but too slow (small
torque) (If battery and
wiring are satisfactory,
inspect starting motor)Insufficient contact of magnetic switch
main contactsReplace magnetic switch.
Layer short-circuit of armatureReplace.
Disconnected, burnt or worn
commutatorRepair commutator or replace armature.
Worn brushesReplace brush.
Weakened brush springsReplace spring.
Burnt or abnormally worn end bushReplace bush.
Starting motor running,
but not cranking engineWorn pinion tipReplace over-running clutch.
Poor sliding of over-running clutchRepair.
Over-running clutch slippingReplace over-running clutch.
Worn teeth of ring gearReplace flywheel (M/T model) or drive plate (A/
T model).
NoiseAbnormally worn bushReplace bush.
Worn pinion or worn teeth of ring gearReplace over-running clutch, flywheel (M/T
model) or drive plate (A/T model).
Poor sliding of pinion (failure in return
movement)Repair or replace.
Worn internal or planetary gear teethReplace.
Lack of oil in each partLubricate.

Downloaded from www.Manualslib.com manuals search engine 1I-5 Starting System:
Starting Motor ComponentsS6RW0D1906002
I4RS0A190003-01
1. Front housing 7. Plate 13. Planetary gear 19. Rear bush
2. Bush 8. Seal rubber 14. Packing 20. Starting motor battery cable nut
3. Pinion stop ring 9. Magnetic switch 15. Yoke : 9.8 N⋅m (0.98 kgf-m, 7.0 lb-ft)
4. Over-running clutch 10. Ball 16. Armature : Do not reuse.
5. Lever 11. Internal gear 17. Brush assembly : Apply grease 99000-25011 to sliding surface of each part.
6. Plunger 12. Planetary carrier shaft 18. Rear bracket

Downloaded from www.Manualslib.com manuals search engine 1J-8 Charging System:
3) After loosening generator bracket bolts (2) and pivot
bolt (3), adjust belt tension to specification described
at step 2) by loosening / tightening generator adjust
bolt (1).
4) Tighten generator bracket bolts and pivot bolt as
specified torque.
Tightening torque
Generator bracket bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Generator pivot bolt (b): 50 N·m (5.0 kgf-m, 36.0
lb-ft)
5) Check belt tension for specification after turning
crankshaft two rotations clockwise.
6) Tighten generator adjusting bolt (1) as specified
torque.
Tightening torque
Generator adjusting bolt (c): Tighten 7.0 N·m (
0.7 kgf-m, 5.0 lb-ft) by the specified procedure.
7) Connect negative cable at battery.
Water Pump / Generator Drive Belt Removal and
Installation
S6RW0D1A06007
Removal
1) Disconnect negative cable at battery.
2) If vehicle equipped with A/C, remove compressor
drive belt before removing water pump belt (1).
Refer to “Compressor Drive Belt Removal and
Installation in Section 7B” or “Compressor Drive Belt
Removal and Installation in Section 7B”.
3) Loosen generator bracket bolts (2) and generator
pivot bolt (3).
4) Loosen generator adjusting bolt (4), and then
remove water pump belt.
installation
1) Install belt (1) to water pump pulley (2), crankshaft
pulley (3) and generator pulley (4).
2) Adjust belt tension referring to “Water Pump /
Generator Drive Belt Tension Inspection and
Adjustment”.
3) If vehicle equipped with A/C, install compressor drive
belt referring to “Compressor Drive Belt Removal
and Installation in Section 7B” or “Compressor Drive
Belt Removal and Installation in Section 7B”.
4) Connect negative cable at battery.
a
I5RW0C160006-01
1, (c)
2, (a)
3, (b)
I5RW0C160007-01
4
23
1
I5RW0C160008-01
2
1
34I5RW0C160009-01

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)

Downloaded from www.Manualslib.com manuals search engine 2B-9 Front Suspension:
Front Wheel Hub and Steering Knuckle ComponentsS6RW0D2206006
Front Wheel Hub, Steering Knuckle and Wheel
Bearing Removal and Installation
S6RW0D2206007
CAUTION!
When removal and installing steering
knuckle assembly, be careful not to damage
dust boots of control arm joint by drive shaft
dust cover and brake dust cover.

Removal
1) Hoist vehicle and remove wheel.
2) Uncaulk drive shaft nut (1).
3) Depress foot brake pedal and hold it. Remove drive
shaft nut (1).4) Remove caliper carrier bolts and then caliper (1) with
carrier.
NOTE
Hang removed caliper with a wire hook or the
like (3) so as to prevent brake hose (4) from
bending, twisting or tension.
Do not depress brake pedal during caliper
removal.
Don’t operate brake pedal with caliper
removed.

5) Pull brake disc (2) off by using two 8 mm bolts.
(a)5
6 4
3 7
2
1
I7RW01220014-01
1. Front wheel hub 4. Steering knuckle 7. Dust cover
2. Circlip 5. Drive shaft nut
: Calk, after tightening.: 200 N⋅m (20.0 kgf-m, 145.0 lb-ft)
3. Wheel bearing
: Face grooved rubber seal side to wheel hub.6. Hub bolt : Do not reuse.
I5JB0A220013-01
I5JB0A220014-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-12
4) Drive in dust cover so that dimensions “a” and “b”
become equal as shown in the figure.
CAUTION!
When drive in dust cover, be careful not to
deform it.

5) Caulk more than 6 places with a punch.
6) Using special tool and hydraulic press, press fit
wheel hub (1) into wheel bearing (2) (Face grooved
rubber seal side to wheel hub).
Special tool
(A): 09913–75510 7) Apply grease lightly to end face of inner ring (1).
“A”: Grease 99000–25121 (SUZUKI Super
Grease H)
NOTE
Do not apply the grease to the encoder
section to avoid the encoder malfunction.

8) Install steering knuckle with wheel hub and bearing
(1) so that foreign material should not enter wheel
speed sensing point “a”.I2RH01220038-01
I2RH01220039-01
I7RW01220007-01
2. Wheel encoder
3. Drive shaft
I5RW0B220001-01
I7RW01220008-02