2006 SUZUKI SX4 transaxle

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 1G-7 Fuel System:
Clamp other than around fuel tank
For Quick Joint
Disconnecting
1) Remove mud, dust and/or foreign material between
pipe (1) and quick joint (fuel pipe) (2) by blowing
compressed air.
2) Unlock joint lock by inserting special tool between
pipe and quick joint.
Special tool
(A): 09919–47020
3) Disconnect quick joint from pipe.
Reconnecting
Insert quick joint (fuel pipe) to fuel pipe until they lock
securely (a click is heard), and confirm that quick joint
(fuel pipe) is not disconnected by hand.
Fuel Pressure Relief ProcedureS6RW0D1706003
CAUTION!
This work must not be done when engine is
hot. If done so, it may cause adverse effect to
catalyst.

NOTE
If ECM detects DTC(s) after servicing, clear
DTC(s) referring to “DTC Clearance in
Section 1A”.

1) Make sure that engine is cold.
2) Shift transaxle gear shift lever in “Neutral” (shift
select lever in “P” range for A/T model), set parking
brake and block drive wheels.
3) Remove relay / fuse box cover.
4) Disconnect fuel pump relay (1) from relay / fuse box
(2).
5) Remove fuel filler cap in order to release fuel vapor
pressure in fuel tank, and then reinstall it.
[A]: With short pipe, fit hose as far as it reaches pipe joint as shown.
[B]: With the following type pipe, fit hose as far as its peripheral projection
as shown.
[C]: With bent pipe, fit hose as its bent part as shown or till depth “b”.
[D]: With straight pipe, fit hose till depth “b”.
[E]: With red marked pipe, fit hose end reaches red mark on pipe.
[F]: For fuel tank filler hose, insert it to spool or welding-bead.
“a”: Clamp securely at a position 3 – 7 mm (0.12 – 0.27 in.) from hose end.
“b”: 20 – 30 mm (0.79 – 1.18 in.)
“c”: 0 – 5 mm (0 – 0.19 in.)
“d”: 5 – 12 mm (0.2 – 0.47 in.)
“e”: 38 mm (1.50 in.)
I5RW0A170006-01
4. Red mark
1
2
1 2
(A)
I4RS0A170019-01

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-4
Repair Instructions
Starting Motor Dismounting and RemountingS6RW0D1906001
Dismounting
1) Disconnect negative (–) battery lead at battery.
2) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals.
3) Detach shift & select control cable bracket from transaxle. (M/T model only)
4) Remove starting motor mount bolt (3) and nut (4).
5) Remove starting motor (5).
Remounting
Reverse the dismounting procedure noting the following.
• Tighten battery cable nut (6) to specified torque.
Tightening torque
Starting motor battery cable nut (a): 9.8 N·m (0.98 kgf-m, 7.0 lb-ft)
I4RS0A190002-01
: 9.8 N⋅m (0.98 kgf-m, 7.0 lb-ft)

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 Charging System: 1J-7
1) Set parking brake and place automatic transaxle in
PARK (NEUTRAL on manual transaxle). Turn off
ignition, turn off lights and all other electrical loads.
2) Check electrolyte level. If it is below low level line,
add distilled water.
3) Attach end of one jumper cable to positive terminal
of booster battery and the other end of the same
cable to positive terminal of discharged battery. (Use
12-volt battery only to jump start engine).
4) Attach one end of the remaining negative cable to
negative terminal of booster battery, and the other
end to a solid engine ground (such as exhaust
manifold) at least 45 cm (18 in.) away from battery of
vehicle being started.
5) Start engine of vehicle with booster battery and turn
off electrical accessories. Then start engine of the
vehicle with discharged battery.
6) Disconnect jumper cables in the exact reverse order.
With Charging Equipment
CAUTION!
When jump starting engine with charging
equipment, be sure equipment used is 12-
volt and negative ground. Do not use 24-volt
charging equipment. Using such equipment
can cause serious damage to electrical
system or electronic parts.

Battery Dismounting and RemountingS6RW0D1A06002
Dismounting
1) Disconnect negative cable (3).
2) Disconnect positive cable (2).
3) Remove retainer (4).
4) Remove battery (1).
Handling
When handling battery, the following safety precautions
should be followed:
• Hydrogen gas is produced by battery. A flame or
spark near battery may cause the gas to ignite.
• Battery fluid is highly acidic. Avoid spilling on clothing
or other fabric. Any spilled electrolyte should be
flushed with large quantity of water and cleaned
immediately.Remounting
1) Reverse removal procedure.
2) Tighten battery cables securely.
NOTE
Check to be sure that ground cable has
enough clearance to hood panel by terminal.

Water Pump / Generator Drive Belt Tension
Inspection and Adjustment
S6RW0D1A06006
WARNING!
• Disconnect negative cable at battery
before checking and adjusting belt
tension.
• To help avoid danger of being burned, do
not remove radiator cap while engine and
radiator are still hot. Scalding fluid and
steam can be blown out under pressure if
cap is taken off too soon.

1) Inspect belt for cracks, cuts, deformation, wear and
cleanliness. If it is necessary to replace belt, refer to
“Water Pump / Generator Drive Belt Removal and
Installation”.
2) Check belt for tension. Belt is in proper tension when
it deflects the following specification under thumb
pressure (about 10kg or 22 lb.).
If belt tension is out of specification, go to next steps.
Water pump / generator drive belt tension
“a”
Existing belt: 4.5 – 5.5 mm (0.18 – 0.22 in.) as
deflection / 10 kg (22 lbs)
New belt: 4.0 – 4.5mm (0.16 – 0.18 in.) as
deflection / 10 kg (22 lbs)
1. Battery 4. Retainer
2. Positive cable 5. Nut
3. Negative cable
21
4
3
5I7RW011A0005-01

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 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