2006 SUZUKI SX4 manual transaxle oil

Downloaded from www.Manualslib.com manuals search engine 1E-2 Engine Lubrication System:
Diagnostic Information and Procedures
Oil Pressure CheckS6RW0D1504001
WARNING!
To avoid the danger of being burned, do not
touch the exhaust system when the system is
hot. Any service on the exhaust system
should be performed when the system is
cool.

NOTE
Prior to checking oil pressure, check the
following.
• Oil level in oil pan
If oil level is low, add oil up to full level
mark (hole) (1) on oil level gauge referring
to “Engine Oil and Filter Change in Section
0B”.
• Oil quality
If oil is discolored or deteriorated, change
it. For particular oil to be used, refer to
“Engine Oil and Filter Change in Section
0B”.
• Oil leaks
If leak is found, repair it.

1) Disconnect oil pressure switch coupler (1).
2) Remove oil pressure switch (2) from cylinder block.3) Install special tools (oil pressure gauge) to vacated
threaded hole of oil pressure switch.
Special tool
(A): 09915–77310
(B): 09915–78211
4) Start engine and warm engine up to normal
operating temperature.
NOTE
Be sure to shift transaxle gear shift lever in
“Neutral”, set parking brake and block drive
wheels.

5) After warming up, raise engine speed to 4,000 r/min.
and measure oil pressure.
Oil pressure specification
More than 270 kPa (2.7 kgf/cm2, 39.8 psi) at 4,000
r/min. (rpm)
6) After checking oil pressure, stop engine and remove
oil pressure gauge and attachment.
7) Before reinstalling oil pressure switch (2), be sure to
wrap its screw threads with sealing tape (1) and
tighten switch to specified torque.
NOTE
If sealing tape edge is bulged out from screw
threads of switch, cut it off.

Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft)
2. Low level mark (hole)
I2RH0B150002-01
I2RH0B150003-01
I2RH0B150004-01
I2RH0B150005-01

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-5
4) Install oil pan to cylinder block temporarily.
5) Insert dowel pin (1) in hole (2) of oil pan in order to
locate oil pan precisely.
NOTE
Dowel pin is available as a spare part (part
number: 04211–13189).

6) After fitting oil pan to cylinder block, run in securing
bolts and start tightening at the center: move wrench
outward, tightening one bolt at a time. Tighten bolts
and nuts to specified torque.
Tightening torque
Oil pan bolt (M6) (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Oil pan bolt (M10) (c): 55 N·m (5.5 kgf-m, 40.0 lb-
ft)
Oil pan nut (e): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
7) After applying engine oil to drain plug, install new
gasket and drain plug to oil pan.
Tighten drain plug to specified torque.
Tightening torque
Oil pan drain plug (b): 35 N·m (3.5 kgf-m, 25.5 lb-
ft)
8) Tighten transaxle stiffener bolts to specified torque.
Tightening torque
Transaxle stiffener bolt (d): 55 N·m (5.5 kgf-m,
40.0 lb-ft)9) Install clutch housing lower plate (1) and then tighten
clutch housing lower plate bolt to specified torque.
Tightening torque
Clutch housing lower plate bolt (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
10) For 4WD model, remount transfer referring to
“Transfer Dismounting and Remounting in Section
3C”.
11) Install oil level gauge.
12) Refill engine with engine oil referring to “Engine Oil
and Filter Change in Section 0B”.
13) Verify that there is no engine oil leakage and exhaust
gas leakage at each connection.
Oil Pan and Oil Pump Strainer CleaningS6RW0D1506003
• Clean sealing surface between oil pan and cylinder
block.
Remove oil, old sealant, and dust from sealing
surface.
• Clean oil pump strainer screen (1).
21I4RS0A150007-01
(a)
(b)
(c)(e)
(d)I4RS0A150008-01
1,(a)
I5RW0A150003-01
I2RH0B150016-01

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-9
Specifications
Tightening Torque SpecificationsS6RW0D1507001
NOTE
The specified tightening torque is also described in the following.
“Oil Pan and Oil Pump Strainer Components”
“Oil Pump Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS6RW0D1508001
NOTE
Required service material is also described in the following.
“Oil Pan and Oil Pump Strainer Components”
“Oil Pump Components”

Special ToolS6RW0D1508002
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Oil pressure switch 13 1.3 9.5)
Oil pump strainer bolt 11 1.1 8.0)
Oil pump strainer bracket bolt 11 1.1 8.0)
Oil pan bolt (M6) 11 1.1 8.0)
Oil pan bolt (M10) 55 5.5 40.0)
Oil pan nut 11 1.1 8.0)
Oil pan drain plug 35 3.5 25.5)
Transaxle stiffener bolt 55 5.5 40.0)
Clutch housing lower plate bolt 11 1.1 8.0)
Oil pump rotor plate bolt 11 1.1 8.0)
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260)
09915–77310 09915–78211
Oil pressure gauge (0-10kg/
cm2)Oil pressure gauge
attachment
))

Downloaded from www.Manualslib.com manuals search engine 1J-6 Charging System:
3) Ground “F” terminal and start engine, then measure
voltage at “B” terminal as shown in figure.
• Voltage is higher than standard value. It is
considered that generator itself is good but IC
regulator has been damaged, replace IC
regulator.
• Voltage is lower than standard value. It is
considered that generator itself has problem,
check the generator.
Load Check
1) Run engine at 2,000 rpm and turn on head light and
heater motor.
2) Measure current and if it is less than 20 A, repair or
replace generator.Generator Test (Overcharged Battery Check)S6RW0D1A04004
1) To determine battery condition, refer to “Battery
Description”.
2) If obvious overcharged condition exists as evidenced
by excessive spewing of electrolyte, measure
generator “B” terminal voltage at engine 2000 rpm.
3) If measured voltage is higher than upper limit value,
disassemble generator.
4) Check ground of brushes. If brushes are not
grounded, replace IC regulator. Then check field coil
for grounds and shorts.
Repair Instructions
Jump Starting in Case of EmergencyS6RW0D1A06001
With Auxiliary (Booster) Battery
CAUTION!
If vehicle is manual transaxle model and has
a catalytic converter, do not push or tow it to
start. Damage to its emission system and/or
to other parts may result.

Both booster and discharged battery should be treated
carefully when using jumper cables. Follow the
procedure outlined as follows, being careful not to cause
sparks.
WARNING!
• Departure from these conditions or
procedure described as follows could
result in:
– Serious personal injury (particularly to
eyes) or property damage from such
causes as battery explosion, battery
acid, or electrical burns.
– Damage to electronic components of
either vehicle.
• Remove rings, watches, and other jewelry.
Wear approved eye protection.
• Be careful so that metal tools or jumper
cables do not contact positive battery
terminal (or metal in contact with it) and
any other metal on vehicle, because a
short circuit could occur.
• Do not connect negative cable directly to
negative terminal of dead battery.

I2RH011A0008-01
[A]: Regulated voltage (V)
[B]: Heatsink temperature (°C)
16.0
12.0
14.2 15.3
14.8
14.2
13.3 14.8
15.0
11.0 14.0
13.0 [A]
12.5 13.6
13.1
12.5
11.613.1
[B] -30 0 25 135
H
L
I2RH0B1A0005-01

Downloaded from www.Manualslib.com manuals search engine 3A-3 Drive Shaft / Axle: Front
Front Drive Shaft Assembly On-Vehicle
Inspection
S6RW0D3116002
• Check boots for breakage or deterioration.
• Check wheel side joint for rattle or smooth rotation.
• Check differential side (or center shaft side) joint for
smooth rotation.
If any abnormality is found, replace.
Front Drive Shaft Assembly Removal and
Installation
S6RW0D3116003
Removal
1) Hoist vehicle and remove front wheel.
2) Undo caulking and remove drive shaft nut (1) with
brake pedal depressed.
3) Drain transaxle oil and transfer oil (4WD model).
4) Disconnect tie-rod end (1) from steering knuckle (2)
using puller (3).5) Remove brake hose mounting bolt (1) and brake
hose (2) from bracket and then detach wheel speed
sensor harness (3) from strut bracket.
6) Remove suspension control arm ball joint bolt (4)
from knuckle.
7) Disconnect front suspension control arm ball joint
stud from steering knuckle.
8) Using tire lever (1) or plastic hammer (3), pull out
drive shaft joint (2) so as to release snap ring fitting
of joint spline at differential side, at center shaft or at
transfer side.
I6RW0B310005-01
I3RM0A310003-01
[A]: Left side shaft
[B]: Right side shaft of 2WD vehicle
[C]: Right side shaft of 4WD vehicle
I6RW0D311003-01
I5RW0A311003-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: Front 3A-4
9) Remove drive shaft assembly.
10) Remove center bearing support bolts (3) and remove
center bearing support (2) with center shaft (1) from
differential side gear, if equipped.
Installation
CAUTION!
• Be careful not to damage oil seals and
boots when installing drive shaft.
• Do not hit joint boot with hammer.
Inserting joint only by hands is allowed.
• Make sure that differential side joint is
inserted fully and its snap ring is seated as
it was.

Install drive shaft assembly by reversing removal
procedure and noting the following points.
• Tighten each bolt and nut to the specified torque
referring to “Front Drive Shaft Assembly Components
Location”.
• Tighten brake hose mounting bolt to specified torque.
Tightening torque
Brake hose mounting bolt: 25 N·m (2.5 kgf-m,
18.0 lb-ft)
• Fill transaxle with oil as specified referring to “Manual
Transaxle Oil Change in Section 5B” or “A/T Fluid
Change in Section 5A” and “Transfer Oil Change in
Section 3C” (4WD model).
• Check toe setting referring to “Front Wheel Alignment
Inspection and Adjustment in Section 2B” and adjust
as required.
Front Drive Shaft Disassembly and ReassemblyS6RW0D3116004
Disassembly
For DOJ type
CAUTION!
Disassembly of wheel side joint is not
allowed. If any noise or damage exists in it,
replace it as assembly.

1) Remove differential side (or center shaft side) boot
big band (1) as follows.
• For boot big band without joint [A]:
Remove boot big band by tapping boot and band
with plastic hammer. If it is hard to remove boot
big band, cut it using a nipper or an iron saw with
care not to damage joint housing.
• For boot big band with joint [B]:
Draw hooks of boot big band together and remove
band.3
2
1I2RH01310007-01
I4RH0A310004-01

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 3C-3 Transfer:
Transfer Dismounting and RemountingS6RW0D3306003
Dismounting
1) Disconnect negative cable at battery.
2) Drain transaxle oil and transfer oil.
3) Remove drive shafts assembly referring to “Front
Drive Shaft Assembly Removal and Installation in
Section 3A”.
4) Remove exhaust No.1, No.2 and center pipes
referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
5) Remove suspension frame, engine front mounting
member and mounting member referring to “Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation in Section 2B” and “Engine
Assembly Removal and Installation in Section 1D”.
6) Remove engine rear mounting bracket (1) and
stiffeners (2) from transfer.
7) Support transfer with transmission jack.
8) Remove transfer to transaxle bolts (1), and then
lower transfer assembly (2).Remounting
Reverse dismounting procedure for remounting of
transfer, noting the following points.
• Apply grease to left case (1) as shown in figure.
“A”: Grease 99000–25010 (SUZUKI Super Grease
A)
• Tighten engine rear mounting bracket nut to specified
torque referring to “Engine Mountings Components in
Section 1D”.
• Tighten bolts to specified torque as follows.
Tightening torque
Stiffener No.1 bolt and No.2 bolt (a): 55 N·m (5.5
kgf-m, 40.0 lb-ft)
Transfer to transaxle bolt (b): 98 N·m (9.8 kgf-m,
71.0 lb-ft)
2
2
1I5RW0A330004-01
1
1
2
I5RW0A330005-02
I5RW0C330001-01
(a)
(a)
(b)
(b)
2
I5RW0A330006-02