2006 SUZUKI SX4 Sas

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-12
Water Pump InspectionS6RW0D1606017
CAUTION!
Do not disassemble water pump.
If any repair is required on pump, replace it
as assembly.

Rotate water pump by hand to check for smooth
operation. If pump does not rotate smoothly or makes
abnormal noise, replace it.
Specifications
Tightening Torque SpecificationsS6RW0D1607001
NOTE
The specified tightening torque is also described in the following.
“Cooling System 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 MaterialS6RW0D1608001
I2RH0B160019-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Radiator support bracket bolt 33 3.3 24.0)
Generator bracket bolt 25 2.5 18.0)
Generator pivot bolt 50 5.0 36.0)
Generator adjusting bolt Tighten 7.0 N⋅m (0.7 kgf-m, 5.0 lb-ft) by the
specified procedure.)
Water pump bolt and nut 25 2.5 18.0)
Material SUZUKI recommended product or Specification Note
Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250)

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 Table of Contents 2- i
2
Section 2
CONTENTS
Suspension
Precautions ................................................. 2-1
Precautions............................................................. 2-1
Precautions on Suspension .................................. 2-1
Suspension General Diagnosis.............. 2A-1
Diagnostic Information and Procedures ............ 2A-1
Suspension, Wheels and Tires Symptom
Diagnosis .......................................................... 2A-1
Specifications....................................................... 2A-3
Wheel Alignment Specifications .......................... 2A-3
Front Suspension .................................... 2B-1
General Description ............................................. 2B-1
Front Suspension Construction ........................... 2B-1
Front Wheel Alignment Construction .................. 2B-2
Repair Instructions .............................................. 2B-2
Front Wheel Alignment Inspection and
Adjustment ........................................................ 2B-2
Front Strut Assembly Components ..................... 2B-4
Front Strut Assembly Removal and
Installation ......................................................... 2B-5
Front Strut Assembly Disassembly and
Reassembly ...................................................... 2B-7
Front Strut Assembly Check ............................... 2B-8
Front Wheel Hub and Steering Knuckle
Components...................................................... 2B-9
Front Wheel Hub, Steering Knuckle and
Wheel Bearing Removal and Installation .......... 2B-9
Front Wheel Hub, Disc, Bolt and Bearing
Check .............................................................. 2B-14
Suspension Control Arm / Bushing Removal
and Installation ................................................ 2B-14
Suspension Control Arm / Bushing
Disassembly and Assembly ............................ 2B-15
Suspension Control Arm / Steering Knuckle
Check .............................................................. 2B-16
Suspension Control Arm Bushing Check .......... 2B-16
Suspension Control Arm Joint Check ............... 2B-16
Front Suspension Frame, Stabilizer Bar and/
or Bushing Components ................................. 2B-17
Front Suspension Frame, Stabilizer Bar and/
or Bushing Removal and Installation .............. 2B-18
Front Suspension Frame Check ....................... 2B-20
Front Stabilizer Bar, Bushing and/or Joint
Check .............................................................. 2B-20Front Suspension Fasteners Check .................. 2B-20
Specifications .....................................................2B-21
Tightening Torque Specifications ...................... 2B-21
Special Tools and Equipment ...........................2B-22
Recommended Service Material ....................... 2B-22
Special Tool ...................................................... 2B-22
Rear Suspension ..................................... 2C-1
Repair Instructions ..............................................2C-1
Rear Suspension Components ...........................2C-1
Rear Shock Absorber Removal and
Installation .........................................................2C-2
Rear Shock Absorber Inspection ........................2C-3
Rear Shock Absorber Bush Inspection ...............2C-3
Rear Coil Spring Removal and Installation .........2C-4
Spring Upper Seat / Spring Lower Seat
Inspection ..........................................................2C-5
Rear Axle Removal and Installation ....................2C-6
Rear Axle and Coil Spring Inspection .................2C-7
Rear Axle Bush Inspection ..................................2C-7
Rear Wheel Disc, Bolt and Bearing Inspection ....2C-7
Rear Wheel Hub Assembly Removal and
Installation .........................................................2C-8
Specifications .....................................................2C-10
Tightening Torque Specifications ......................2C-10
Wheels and Tires ..................................... 2D-1
General Description .............................................2D-1
Tires Description .................................................2D-1
Wheels Description .............................................2D-2
Irregular and/or Premature Wear Description .....2D-3
Wear Indicators Description ................................2D-3
Radial Tire Waddle Description...........................2D-3
Radial Tire Lead / Pull Description ......................2D-4
Balancing Wheels Description ............................2D-4
Repair Instructions ..............................................2D-5
Wheel Discs Inspection .......................................2D-5
Wheel Balance Inspection and Adjustment.........2D-5
Tire Rotation........................................................2D-5
Wheel (with Tire) Removal and Installation.........2D-6
Tire Mounting and Dismounting ..........................2D-6
Tire Repair ..........................................................2D-6
Specifications .......................................................2D-7
Wheels and Tires Specifications .........................2D-7
Tightening Torque Specifications ........................2D-7

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 Front Suspension: 2B-8
3) Install bump stopper and strut dust cover onto strut
rod. For installing direction, refer to the figure in
“Front Strut Assembly Components”.
4) Pull strut rod as far up as possible and use care not
to allow it to retract into strut.
5) Install spring seat on coil spring and then spring
upper seat (1) aligning “OUT” mark (3) on spring
upper seat and center of strut bracket (2).
6) Install bearing (3), strut support (2) and strut support
lower nut (1) in this sequence.
Tighten strut support lower nut (1) to specified
torque.
When tightening strut support lower nut, hold stud
with hexagon wrench.
Tightening torque
Strut support lower nut (a): 55 N·m (5.5 kgf-m,
40.0 lb-ft)Front Strut Assembly CheckS6RW0D2206005
• Inspect strut for oil leakage, damage or deformation.
If defect is found, replace strut as an assembly unit,
because it can not be disassembled.
• Inspect strut function referring to the following
procedures:
1) Check and adjust tire pressures as specified.
2) Bounce vehicle body up and down 3 or 4 times
continuously by pushing front end of the vehicle side
body to check strut.
Also, note how many times vehicle body rebounds to
stop after force application.
3) Repeat the same procedure to the other strut to
confirm that the both side struts equally respond.
If conditions of struts are in doubt, compare them with
known-good vehicle or strut.
• Inspect bearing for wear, abnormal noise or gripping.
If defective, replace.
• Inspect coil spring seat for cracks or deformation.
If defective, replace.
• Inspect bump stopper for deterioration.
If defective, replace.
• Inspect rebound stopper and strut mount for wear,
cracks or deformation.
If defective, replace.
I4RS0A220012-01
3
2
1,(a)
I5RW0A220010-02
I4RS0A220014-01

Downloaded from www.Manualslib.com manuals search engine 2B-15 Front Suspension:
Installation
1) Install suspension control arm as shown but tighten
suspension control arm bolts (1) only temporarily.
CAUTION!
Use new control arm bolt.

2) Install steering knuckle with front wheel hub referring
to step 7) to 17) of “Installation” under “Front Wheel
Hub, Steering Knuckle and Wheel Bearing Removal
and Installation”.
3) Install wheel and tighten wheel nuts to specified
torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
4) Lower hoist and vehicle in unloaded condition,
tighten new control arm bolts to specified torque.
Tightening torque
Suspension control arm bolt (a): 95 N·m (9.5
kgf-m, 69.0 lb-ft)
5) Confirm front wheel alignment referring to “Front
Wheel Alignment Inspection and Adjustment”.
Suspension Control Arm / Bushing
Disassembly and Assembly
S6RW0D2206010
Disassembly
1) Cut off bushing flange (rubber) (1) with knife.
2) Push out bushing by using hydraulic press (2) and
special tools.
Special tool
(A): 09943–76310
(B): 09913–75821
1
1
I5RW0A220020-01
(a)
I5RW0A220021-01
I4RS0B220019-01
2
(A) (B)
I4RS0B220020-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-20
12) Install exhaust No.1, No.2 and center pipe referring
to “Exhaust System Components in Section 1K”.
13) Install wheel and tighten nut to specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
14) Install air cleaner assembly referring to “Air Cleaner
Assembly Removal and Installation in Section 1D”.
15) Install hood referring to “Hood Removal and
Installation in Section 9J”.
16) Lower hoist and vehicle in unloaded condition,
tighten suspension control arm bolts to specified
torque.
Tightening torque
Suspension control arm bolt: 95 N·m (9.5 kgf-m,
69.0 lb-ft)
17) Connect negative (–) cable at battery.
18) Confirm front wheel alignment referring to “Front
Wheel Alignment Inspection and Adjustment”.
Front Suspension Frame CheckS6RW0D2206017
Inspect for cracks, deformation or damage.
If defective, replace.
Front Stabilizer Bar, Bushing and/or Joint
Check
S6RW0D2206018
Stabilizer Bar
Inspect for damage or deformation.
If defective, replace.Stabilizer Bushing
Inspect for damage, wear or deterioration.
If defective, replace.
Stabilizer Joint
1) Check for smooth rotation.
2) Check damages of ball stud.
3) Check damages of dust cover.
NOTE
Stabilizer joint (1) cannot be disassembled.

If there is any damage to either parts, stabilizer joint
must be replaced as a complete unit.
Front Suspension Fasteners CheckS6RW0D2206019
Check each bolt and nut fastening suspension parts for
tightness. Tighten loose one, if any, to specified torque,
referring to “Front Suspension Construction”.
I5RW0A220034-01
I5RW0A220035-01
I5RW0A220036-01
1
I4RH01220007-01

Downloaded from www.Manualslib.com manuals search engine 2C-3 Rear Suspension:
3) Remove floor jack from rear axle.
4) Install rear wheel and tighten wheel nuts to specified
torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
5) Lower hoist and bounce vehicle up and down
several times to stabilize suspension.
6) Tighten nuts to specified torque.
Tightening torque
Rear shock absorber upper nut (a): 30 N·m (3.0
kgf-m, 22.0 lb-ft)
Rear shock absorber lower nut (b): 90 N·m (9.0
kgf-m, 65.0 lb-ft)
7) Install access hole cover (1) in quarter inner trim (2).Rear Shock Absorber InspectionS6RW0D2306003
• Inspect for deformation or damage.
• Inspect bushings for wear or damage.
• Inspect for evidence of oil leakage.
Replace any defective parts.
WARNING!
When handling rear shock absorber (1) in
which high-pressure gas is sealed, make
sure to observe the following precautions.
• Don’t disassemble it.
• Don’t put it into the fire.
• Don’t store it where it gets hot.
• Before disposing it, be sure to drill a hole
(approximately 3 mm (0.12 in.) diameter)
(2) in it where indicated by arrow in the
figure and let gas and oil out.
Be sure to wear eye shield since the gas
itself is harmless but the absorber drill
hole debris maybe blown out.

Rear Shock Absorber Bush InspectionS6RW0D2306004
Inspect for cracks, deformation or damage. Replace any
defective parts.
(a)
(b)I5RW0A230006-01
2
1
I5RW0A230002-02
I5RW0A230007-01
I4RS0A230008-01