2006 SUZUKI SX4 remove seat

Downloaded from www.Manualslib.com manuals search engine 1F-7 Engine Cooling System:
Thermostat Removal and InstallationS6RW0D1606007
Removal
1) Drain coolant referring to “Cooling System Draining”.
2) Remove intake manifold referring to “Intake Manifold
Removal and Installation in Section 1D”.
3) Disconnect water hose (1) and heater hose (2) from
each pipe.
4) Remove thermostat case (3) with thermostat cap (4)
and water inlet pipe (5).
5) Remove water inlet pipe with thermostat cap from
thermostat case.
6) Remove thermostat from thermostat case (3).
Installation
Reverse removal procedure for installation noting the
following points.
• Install thermostat (5) to thermostat case (2) by
aligning air bleed valve (4) of thermostat with mark (3)
of thermostat case and, then install thermostat cap (1)
to thermostat case.
• Use new O-rings when installing.
• Refill cooling system referring to Step 7) to 17) of
“Cooling System Flush and Refill”.
• Verify that there is no coolant leakage at each
connection.
Thermostat InspectionS6RW0D1606008
• Make sure that air bleed valve (1) of thermostat is
clean.
• Check to make sure that valve seat (2) is free from
foreign matters which would prevent valve from
seating tight.
• Check thermostat seal (3) for breakage, deterioration
or any other damage.
• Check thermostatic movement of wax pellet as
follows:
a. Immerse thermostat (1) in water, and heat water
gradually.
b. Check that valve starts to open at specific
temperature.
Temperature at which valve begins to open
80 – 84 °C (176 – 183 °F)
Temperature at which valve become fully open
95 – 97 °C (203 – 206 °F)
Va l v e l i ft
More than 8 mm (0.31 in.) at 95 °C (203 °F)
If valve starts to open at a temperature substantially
below or above specific temperature, thermostat unit
should be replaced with a new one. Such a unit, if
reused, will bring about overcooling or overheating
tendency.
I6RW0B160007-01
4
53
12
I6RW0B160008-01
2. Thermometer 3. Heater
I3RM0A160008-01
I2RH01160012-01

Downloaded from www.Manualslib.com manuals search engine 2B-7 Front Suspension:
Front Strut Assembly Disassembly and
Reassembly
S6RW0D2206004
Disassembly
1) Attach special tool (A) to coil spring as shown. Turn
special tool bolts alternately until coil spring tension
is released. Rotate the strut around its axis to
confirm that the coil spring is released or not.
Special tool
(A): 09943–25010
2) While keeping coil spring compressed with special
tools, remove strut support lower nut with hexagon
wrench as shown figure.
3) Disassemble front strut assembly.Reassembly
For assembly, reverse disassembly procedure, noting
the following instructions.
1) Compress coil spring with special tool (A) until total
length becomes about 280 mm (11.0 in.) as shown.
Length
“a”: 280 mm (11.0 in.)
2) Install compressed coil spring to strut, and place coil
spring end (2) onto spring lower seat (1) as shown.
NOTE
End of coil spring must not interfere with
step of spring lower seat.

(A)
I5RW0A220007-01
I5RW0A220008-01
U: Upper side (small dia.)
L: Lower side (large dia.)
“a”
UL
I5RW0A220009-01
I4RS0A220011-01

Downloaded from www.Manualslib.com manuals search engine Rear Suspension: 2C-4
Rear Coil Spring Removal and InstallationS6RW0D2306005
CAUTION!
Removal and Installation both coil springs
(right and left) at the same time to avoid rear
axle twisting and other damage.

Removal
1) Hoist vehicle and remove rear wheels.
2) Dismount rear differential (4WD model) referring to
“Rear Differential Dismounting and Remounting in
Section 3B”.
3) Remove rear fender lining (1) and then loosen rear
axle bolt (2) a little.
CAUTION!
Do not reuse rear axle bolt. Otherwise, bolt
may loosen.

4) Support both ends of rear axle (1) by using two floor
jacks (2).5) Detach each lower end (2) of shock absorbers (1)
(right and left) from rear axle.
6) Lower rear axle gradually as far down as the coil
spring can be removed.
CAUTION!
Be careful not to lower rear axle down too
much.
It may cause damage to brake flexible hose,
wheel speed sensor lead wire and parking
brake cable.

7) Remove coil spring (3).
8) Remove spring upper seat (1) from vehicle body and
lower seat (2) from rear axle.
2
1
I5RW0A230008-01
1
2
2
I5RW0A230009-01
1
2
3
I5RW0A230010-01
1
2
I5RW0A230011-01

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 Wheels and Tires: 2D-6
Wheel (with Tire) Removal and InstallationS6RW0D2406003
Removal
CAUTION!
Never use heat to loosen tight wheel because
the application of heat to wheel causes the
wheel life shorter and the wheel bearing
damage.

1) Loosen wheel nuts by approximately 180° (half a
rotation).
2) Hoist vehicle.
3) Make sure that the vehicle will not fall off by trying to
move vehicle body in both ways.
4) Remove wheel nuts except one.
5) Support the wheel and/or tire not to drop the wheel
and then remove the nut left with the wheel.
Installation
For installation, reverse removal procedure, noting the
following.
• Wheel nuts must be tightened in sequence and to
specified torque to avoid bending wheel or brake disc
or drum as shown in the figure.
NOTE
Before installing wheels, remove any build-
up of corrosion on wheel mounting surface
and brake disc or drum mounting surface by
scraping and wire brushing. Installing wheels
without good metal-to-metal contact at
mounting surfaces can cause wheel bolts to
loosen, which can later allow a wheel to
come off while vehicle is moving.

Tightening order
“1” – “2” – “3” – “4” – “5”
Tightening torque
Wheel nut (a): 85 N·m (8.5 kgf-m, 61.5 lb-ft)
Tire Mounting and DismountingS6RW0D2406004
WARNING!
Do not stand over tire when inflating. Bead
may break when bead snaps over rim’s safety
hump and cause serious personal injury.
Do not exceed specified pressure when
inflating. If specified pressure will not seat
beads, deflate, re-lubricate and reinflate.
Over inflation may cause bead to break and
cause serious personal injury.

Use a tire changing machine to mount or dismount tires.
Follow equipment manufacturer’s instructions. Do not
use hand tools or tire irons alone to change tires as they
may damage tire beads or wheel rim.
Rim bead seats should be cleaned with a wire brush or
coarse steel wool to remove lubricants, old rubber and
light rust. Before mounting or dismounting a tire, bead
area should be well lubricated with approved tire
lubricant.
After mounting, inflate 330 kPa (47.9 psi) pressure so
that beads are completely seated. Then adjust pressure
to specified shown in the tire placard.
Tire RepairS6RW0D2406005
There are many different materials and techniques on
the market to repair tires. As not all of these work on all
types of tires, tire manufacturers have published detailed
instructions on how and when to repair tires. These
instructions can be obtained from each tire
manufacturer.
IYSQ01240008-01

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 6B-1 Steering Wheel and Column:
Ste eri ng
Steering Wheel and Column
Precautions
Service Precautions of Steering Wheel and ColumnS6RW0D6200001
For service precautions, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”.
Service and Diagnosis
For diagnosis and servicing, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”.
Disabling Air Bag System
For disabling air bag system, refer to “Disabling Air Bag System in Section 8B”.
Enabling Air Bag System
For enabling air bag system, refer to “Enabling Air Bag System in Section 8B”.
Handling and Storage
For handling and storage, refer to “Precautions on Handling and Storage of Air Bag System Components in Section
8B”.
Disposal
For disposal, refer to “Precautions on Disposal of Air Bag and Seat Belt Pretensioner in Section 8B”.
General Description
Steering Wheel and Column ConstructionS6RW0D6201001
This double tube type steering column has the following three important features in addition to the steering function:
• The column is energy absorbing, designed to compress in a front-end collision.
• The ignition switch and lock are mounted conveniently on this column.
• With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehicle.
To insure the energy absorbing action, it is important that only the specified screws, bolts and nuts be used as
designated, and that they are tightened to the specified torque. When the column assembly is removed from the
vehicle, special care must be taken in handling it. Use of a steering wheel puller other than the recommended puller in
this manual or a sharp blow on the end of the steering shaft, leaning on the assembly, or dropping the assembly could
shear the plastic shear pins which maintain column length and position.
The driver air bag (inflator) module is one of the supplemental restraint (air bag) system components and is mounted
to the center of the steering wheel. During certain frontal crashes, the air bag system supplements the restraint of the
driver’s and passenger’s seat belts by deploying the air bags. The air bag (inflator) module should be handled with
care to prevent accidental deployment. When servicing, be sure to observe “Precautions on Service and Diagnosis of
Air Bag System in Section 8B”.

Downloaded from www.Manualslib.com manuals search engine 7A-12 Heater and Ventilation:
Rear Duct Removal and Installation (If
Equipped)
S6RW0D7106016
Removal
1) Disconnect negative (–) cable at battery.
2) Remove front seats referring to “Front Seat Removal
and Installation in Section 9G”.
3) Remove console box referring to “Console Box
Components in Section 9H”.
4) Take off carpet till rear ducts is totally exposed.
5) Remove right and left rear ducts.
6) Remove center rear duct as follows, if necessary.
a) Remove HVAC control unit referring to “HVAC
Control Unit Removal and Installation” (non-A/C
or manual A/C) or “HVAC Control Module
Removal and Installation in Section 7B” (auto A/
C).
b) Remove center rear duct from HVAC unit.
Installation
Reverse removal procedure noting the following
instructions.
• Install HVAC control unit referring to “HVAC Control
Unit Removal and Installation” (non-A/C or manual A/
C) or “HVAC Control Module Removal and Installation
in Section 7B” (auto A/C), if removed.
• Install console box referring to “Console Box
Components in Section 9H”.
• Install front seats referring to “Front Seat Removal
and Installation in Section 9G”.
HVAC Air Filter Removal and Installation (If
Equipped)
S6RW0D7106017
Removal
1) Remove glove box from instrument panel.
2) Remove air filter (1) from HVAC unit while releasing
claws (2).
Installation
Reverse removal procedure noting the following
instructions.
• Position air filter by directing its arrow mark to the
upward.
HVAC Air Filter Inspection (If Equipped)S6RW0D7106018
Reference: “HVAC Air Filter Removal and Installation (If
Equipped)”
Check that filter is not excessively dirty, damage or oily,
clean filter with compressed air from air outlet side of
filter. If abnormality is found, replace filter with new one.
1. Center rear duct 4. Clip
2. Right rear duct 5. HVAC unit
3. Left rear duct
324 5
1
4
I7RW01710019-01
12
2
I6RW0C710010-01
I6RW0C710009-01
I4RS0A710032-01