2006 SUZUKI SX4 Washer

Downloaded from www.Manualslib.com manuals search engine 2B-13 Front Suspension:
9) Install ball joint bolt (1), washer (2), strut bracket
bolts (4) and new nuts (3) from the direction shown
in figure.
10) Tighten suspension arm ball joint bolt (2) to specified
torque.
Tightening torque
Suspension arm ball joint bolt (a): 60 N·m (6.0
kgf-m, 43.5 lb-ft)
11) Tighten new strut bracket nuts (3) to specified
torque.
Tightening torque
Strut bracket nut (b): 140 N·m (14.0 kgf-m, 101.5
lb-ft)
CAUTION!
Never reuse the removed strut bracket nut.

12) Install wheel speed sensor (1).
Tightening torque
Wheel speed sensor mounting bolt (a): 11 N·m (
1.1 kgf-m, 8.0 lb-ft)13) Connect tie-rod end (1) to steering knuckle (2),
tighten new nut (3) to specified torque.
Tightening torque
Tie-rod end nut (a): 45 N·m (4.5 kgf-m, 32.5 lb-ft)
14) Install brake disk (2) and brake caliper (3).
15) Tighten caliper carrier bolt to specified torque.
Tightening torque
Caliper carrier bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
16) Depress foot brake pedal and hold it there.
Tighten new drive shaft nut (1) to specified torque.
Tightening torque
Drive shaft nut (a): 200 N·m (20.0 kgf-m, 145.0
lb-ft)
CAUTION!
Never reuse drive shaft nut (1).

17) Caulk drive shaft nut (1) as shown.
CAUTION!
Be careful not to damage the drive shaft nut
while caulking it. If it is damaged, replace it
with new one.

18) Tighten wheel nuts to specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
19) Confirm front wheel alignment referring to “Front
Wheel Alignment Inspection and Adjustment”.
F: Vehicle front
F
4
3, (b)
2
1, (a)
I7RW01220009-01
1(a)
I5RW0A220017-01
1
3, (a)
2I4RS0B220007-01
I7RW01220013-02

Downloaded from www.Manualslib.com manuals search engine 2C-1 Rear Suspension:
Suspension
Rear Suspension
Repair Instructions
Rear Suspension ComponentsS6RW0D2306001
I6RW0D230001-01
F: Forward 7. Vehicle body 16. Rear drive shaft nut
[A]: 2WD model 8. Rear shock absorber 17. Rear wheel hub assembly
[B]: 4WD model 9. Lower washer : 73 N⋅m (7.3 kgf-m, 53.0 lb-ft)
1. Coil spring 10. Lower nut : 30 N⋅m (3.0 kgf-m, 22.0 lb-ft)
2. Spring upper seat 11. Rear axle : 175 N⋅m (17.5 kgf-m, 127.0 lb-ft)
3. Spring lower seat 12. Rear drive shaft : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft)
4. Upper nut 13. Rear wheel hub mounting bolt : Do not reuse.
5. Upper washer 14. Rear axle bolt
6. Upper bush 15. Brake back plate

Downloaded from www.Manualslib.com manuals search engine Rear Suspension: 2C-2
Rear Shock Absorber Removal and InstallationS6RW0D2306002
Removal
1) Hoist vehicle and remove rear wheel.
2) Remove access hole cover (1) in quarter inner trim
(2).
3) Support rear axle by using floor jack to prevent it
from lowering.
4) Remove absorber lower nut (1) and lower washer.
5) Remove absorber upper nut (2). Then remove shock
absorber (3), upper washers.
6) Remove absorber upper bushes.Installation
1) Install absorber upper bushes (1).
NOTE
For proper installing direction of shock
absorber bushes (1), refer to the figure.

2) Install shock absorber (1), upper washers (2).
Tighten new rear shock absorber upper nut (4) and
lower nut (5) temporarily at this step.
CAUTION!
Use new rear shock absorber upper nut.
Otherwise, nut may loosen.

2
1
I5RW0A230002-02
2
1
3
I5RW0A230003-01
2. Body panel
3. Body panel
1
2
I5RW0A230028-01
14
32
5
I7RW01230017-01

Downloaded from www.Manualslib.com manuals search engine 2C-5 Rear Suspension:
Installation
1) Install spring upper seat (1) to vehicle body and
lower seat (2) to rear axle.
CAUTION!
For proper installing direction of spring
upper seat (1) and spring lower seat (2), refer
to the figure.

2) Install coil spring (3) on spring lower seat (2) of rear
axle and place coil spring end (4) onto spring lower
seat (2) as shown in figure.
3) Jack up rear axle and then install shock absorbers
(1) lower end to rear axle.
Install washers and tighten shock absorber lower
nuts (2) temporarily at this step.4) Remove floor jacks from rear axle.
5) Remount rear differential (4WD model) referring to
“Rear Differential Dismounting and Remounting in
Section 3B”.
6) Install wheel and tighten wheel nuts to specified
torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
7) Lower hoist and bounce vehicle up and down
several times to stabilize suspension.
8) Tighten absorber lower nuts and rear axle bolts to
specified torque.
NOTE
When tightening these nuts and bolts, be
sure that vehicle is not on hoist and in
unloaded condition.

Tightening torque
Rear shock absorber lower nut: 90 N·m (9.0 kgf-
m, 65.0 lb-ft)
Rear axle bolt: 73 N·m (7.3 kgf-m, 53.0 lb-ft)
9) Install rear fender lining.
Spring Upper Seat / Spring Lower Seat
Inspection
S6RW0D2306006
Inspect for cracks, deformation or damage.
Replace any defective part.[A]: Left side F: Vehicle forward
[B]: Right side “a”: 10 mm max
U: Up ward
I7RW01230004-02
1
2I4RS0A230012-01
I4RS0A230015-01

Downloaded from www.Manualslib.com manuals search engine 3A-1 Drive Shaft / Axle: Front
Driveline / Axle
Drive Shaft / Axle
Front
General Description
Front Drive Shaft ConstructionS6RW0D3111001
A constant velocity ball joint is used on the wheel side of both right and left side drive shaft assemblies. For A/T
vehicle, a tripod type constant velocity joint is used on the differential side and center shaft side. For M/T vehicle, a
double offset type constant velocity joint (DOJ) is used on the differential side and center shaft side. The drive shaft
can slide through the tripod joint or the double offset joint (DOJ) in the extension/contraction direction.
Component Location
Front Drive Shaft Assembly Components LocationS6RW0D3113001
I6RW0D311001-01
1. To transaxle 7. Wheel nut : 200 N⋅m (20.0 kgf-m, 145.0 lb-ft)
2. Drive shaft assembly 8. Center shaft assembly (if equipped) : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)
3. Tie-rod end 9. Center bearing support bolts (if equipped) : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
4. Tie-rod end nut 10. Washer : Do not reuse.
5. Ball stud bolt : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft)
6. Drive shaft nut
: After tightening nut to specified torque,
caulk nut securely.:60 N⋅m (6.0 kgf-m, 43.5 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 3B-35 Differential:
Rear Differential ComponentsS6RW0D3206013
4 5
9
2
30
6
(a)13
12
(a)
3
A
3A
141617 2118
29
3A
1(b)
22
1217G
101217G
11
8OIL
15OIL
19 20OIL
23OIL
25OIL27OIL
27OIL
25OIL
19OIL18
26 28
OIL
26OIL23OIL
24OIL
(c)
14
7
I5RW0A320026-02
1. Flange nut 13. Differential cover bolt 25. Differential gear
2. Companion flange 14. Spacer 26. Spring washer
3. Oil seal
: Apply grease 99000-25010 to oil seal lip.15. Rear bearing 27. Thrust washer
4. Coupling front bearing 16. Shim 28. Pinion shaft
5. Coupling case
: Apply sealant 99000-31260 to mating surface of carrier and coupling
case.17. Bevel pinion 29. Pinion shaft pin
6. Coupling assembly
: Never disassemble.18. Shim 30. Coupling case bolt
7. Snap ring 19. Differential side bearing : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
8. Bevel pinion nut
: Tighten nut so as rotation torque of bevel pinion to be in specified value.20. Bevel gear : 125 N⋅m (12.5 kgf-m, 90.5 lb-ft)
9. Front bearing 21. Differential case : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft)
10. Differential carrier
: Apply sealant 99000-31260 to mating surface of carrier and rear cover.22. Bevel gear bolt : Do not reuse.
11. Coupling air temperature sensor 23. Pinion washer : Apply differential oil.
12. Differential cover 24. Pinion

Downloaded from www.Manualslib.com manuals search engine 3B-37 Differential:
8) Remove oil seals from rear differential (1) using
special tool.
Special tool
(A): 09913–50121
9) Remove differential cover (1) using special tool, and
then take out differential assembly, outer race and
shim all at once.
Special tool
(A): 09912–34510
10) Pull out differential side bearings (1) using special
tools.
Special tool
(A): 09913–60910
(B): 09925–88210
11) Remove drive bevel gear (hypoid gear), differential
gears, differential pinions and pinion shaft as follows.
a) With aluminum plates (2) placed on vise first,
grip differential case with it and remove drive
bevel gear (hypoid gear) (3) by removing its bolts
(1).b) Drive out differential side pinion shaft pin with
special tool and hammer.
Special tool
(B): 09922–85811
c) Disassemble differential gears (2), pinions (3),
washers and shaft (4) in differential case (1).
12) Remove bevel pinion nut with special tool.
Special tool
(A): 09927–27910
13) Remove rear bearing (2) from drive bevel pinion (1)
by using bearing puller (3) and hydraulic press.
1(A)I5RW0A320032-01
(A)
1
I5RW0A320033-01
(A)
(B)
1
I5RW0A320034-02
1
3
2
I5RW0A320035-01
I5RW0A320036-01
(A)
I5RW0A320037-04
I3RH01322026-01

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-38
14) Using a hammer and brass bar (1), drive out front
bearing outer race (2).
15) Using a hammer and brass bar (1), drive out rear
bearing outer race (2).
Reassembly
Judging from faulty conditions noted before disassembly
and what is found through visual check of bearing and
gear tooth etc. after disassembly, prepare replacing
parts and proceed to reassembly according to
procedures as described in the following.
CAUTION!
• Bevel gear and pinion must be replaced as
a set when either replacement becomes
necessary.
• When replacing taper roller bearing,
replace as inner race & outer race
assembly.

1) Press-fit bevel pinion bearing outer races to
differential carrier (1) by using special tools and
hydraulic press as shown in the figure.
Special tool
(A): 09913–85210
(B): 09913–75510
2) After applying differential oil to differential gears (4),
pinions (5), pinion shaft (3), side washers (1), spring
washers (7) and pinion washers (2), install them in
differential case (6).
For correct installing direction of side washers and
spring washers, refer to figure.
NOTE
Used left and right differential side washers
are not interchangeable.

3) Check pinion gear (1) for smooth rotation.
1
2
I5RW0A320038-01
1
2
I5RW0A320039-01
(B)(A)
1
I5RW0A320040-02
7 6
4
5
3
21
I5RW0A320041-01
I3RH01322031-01