2006 SUZUKI SX4 engine oil

Downloaded from www.Manualslib.com manuals search engine 3C-13 Transfer:
2) Press-fit outer races (front and rear) by using special
tool and hydraulic press.
Special tool
(A): 09913–75520
3) Press-fit front taper roller bearing (1) by using
special tool and hydraulic press.
Special tool
(A): 09925–18011
4) Install bevel pinion with new pinion shaft spacers (1)
and new pump seal (2) to transfer output retainer (3).5) Drive in rear taper roller bearing by using special tool
and tapping lightly with plastic hammer.
Special tool
(A): 09913–84510
6) Apply grease to new oil seal lip.
“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
7) Drive in oil seal (1) by using special tools and
hammer.
Special tool
(A): 09940–54910
(B): 09913–76010
Transfer output flange oil seal installing depth
“a”: 21.0 – 22.0 mm (0.82 – 0.86 in.)
(A)
I5RW0A330038-01
(A)
1
I5RW0A330039-01
1
2
3
I5RW0A330040-02
(A)
I5RW0A330041-02
(B)
(A)
1, “A”
“a”
I5RW0A330042-02

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 Transfer: 3C-16
Specifications
Tightening Torque SpecificationsS6RW0D3307001
NOTE
The specified tightening torque is also described in the following.
“Transfer Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. These contact patterns, located on toe or heel on both
drive and coast sides, mean that 1) both pinion and gear
are defective, 2) retainer is not true, or 3) gear is not
properly seated on transfer case. The remedy is to
replace the defective member.
Irregular patterns: If the pattern is not oval, it means that
bevel gear is defective. High or low spots on tooth
surfaces or on the seat of bevel gear are the cause of
irregular patterns appearing on some teeth. The remedy
is to replace the pinion and gear set and, if the seat is
defective, so is transfer case. Tooth contact pattern Diagnosis and remedy
I3RH01332048-01
I3RH01332049-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Transfer oil level / filler plug 23 2.3 17.0) / )
Transfer oil drain plug 23 2.3 17.0)
Stiffener No.1 bolt and No.2 bolt 55 5.5 40.0)
Transfer to transaxle bolt 98 9.8 71.0)
Transfer case bolt 23 2.3 17.0)
Transfer output retainer bolt 55 5.5 40.0)
Oil plate bolt 9 0.9 6.5)
Rotational torque of bevel pinion (Bearing
preload)0.50 – 1.30 0.05 – 0.13 0.35 – 0.95)

Downloaded from www.Manualslib.com manuals search engine 3C-17 Transfer:
Special Tools and Equipment
Recommended Service MaterialS6RW0D3308001
NOTE
Required service material is also described in the following.
“Transfer Assembly Components”

Special ToolS6RW0D3308002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25010) / ) / ) / ) / )
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260) / ) / ) / )
09900–20607 09900–20701
Dial gauge Magnetic stand
))
09912–34510 09913–50121
Case separator Oil seal remover
)) / )
09913–75520 09913–76010
Bearing installer Bearing installer
))
09913–84510 09913–85210
Bearing installer Bearing installer
) / ) / ))
09913–85230 09922–76140
Bearing remover tool Bevel pinion shaft
) / )) / )
09922–76150 09922–76340
Bevel pinion nut Bevel pinion rear collar
))

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-18
09922–76430 09924–07710
Bevel pinion front collar Synchronizer hub installer
) / ))
09924–74510 09924–84510–005
Bearing and oil seal handle Bearing installer attachment
(D)
)) / )
09925–15410 09925–16310
Oil seal installer Bearing installer
) / ) / ) / ))
09925–18011 09925–98221
Transmission gear, bush
and bearing installerBearing installer
))
09930–40113 09940–54910
Flywheel rotor holder Front fork oil seal install
driver
) / ))
09944–88210 09944–96011
Bearing housing installer Bearing outer race remover
))

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-2
Brake Pedal Foot Protection System Construction (If Equipped)S6RW0D4101004
Should a front crash occur and the engine push the dash panel toward the interior side, the brake pedal bracket is also
pushed toward the interior side. In this case, the brake pedal lever comes off from the brake pedal, thereby preventing
the brake pedal from moving rearward.
CAUTION!
Never disassemble brake pedal assembly. Disassemble will spoil its original function. If faulty
condition is found, replace it with new one.

[A]: Before crash 2. Brake booster 5. Brake pedal bracket
[B]: After crash 3. Brake pedal lever
1. Brake pedal 4. Booster push clevis rod
I6RW0C410001-02

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”.