2006 SUZUKI SX4 rear

Downloaded from www.Manualslib.com manuals search engine 9J-2 Hood / Fenders / Doors:
Front Fender ComponentsS6RW0D9A06003
Front Fender Removal and InstallationS6RW0D9A06004
Removal
1) Remove side sill splash guard and front fender splash guard (if equipped) referring to “Splash Guard Removal and
Installation (If Equipped) in Section 9M”.
2) Remove front fender lining.
3) Remove front bumper referring to “Front Bumper and Rear Bumper Components in Section 9K”.
4) Remove headlight assembly referring to “Headlight Housing Removal and Installation in Section 9B”.
5) Disconnect connector from side turn signal light (if equipped).
6) Remove front fender cover.
7) Remove front fender.
Installation
Reverse removal procedure to install front fender noting the following instruction.
• If paint on fender bolt is peeled off, be sure to apply paint again.
• Adjust panel clearance referring to “Panel Clearance in Section 9K”.
13
2
I5RW0A9A0004-01
1. Front fender lining 2. Front fender 3. Front fender cover

Downloaded from www.Manualslib.com manuals search engine Hood / Fenders / Doors: 9J-5
Rear Door Assembly ComponentsS6RW0D9A06007
Rear Door Assembly Removal and InstallationS6RW0D9A06008
Refer to “Front Door Assembly Removal and Installation” as removal and installation procedures are basically the
same. However, note the following.
• Tighten rear door hinge bolts and nuts to specified torque referring to “Rear Door Assembly Components”.
2
2
4
5
4 3
1
6
(a)
(a)
(b)
a(a) b
(a)
a(a)
b
(a)
I6RW0B9A0005-01
1. Door panel 4. Rear door hinge nut : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
2. Door hinge
: Apply lithium grease 99000-25011 to rotating part.
: Apply sealant 99000-31110 to contact face.5. Door open stopper bolt : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
3. Door open stopper 6. Rear door opening weather-strip a, b: Rear door hinge bolt
Loosen and tightening order: a→b

Downloaded from www.Manualslib.com manuals search engine 9J-6 Hood / Fenders / Doors:
Rear End Door Assembly ComponentsS6RW0D9A06009
Rear End Door Assembly Removal and
Installation
S6RW0D9A06010
WARNING!
Be careful enough when you open and shut
with door balancer has not adhered to rear
end door.
Otherwise, Rear end door doses in weight
and is injured.

Removal
1) Remove rear end door trim (1).
2) Remove related section of head lining and rear trim.
3) Disconnect rear end door harness couplers (2) and
washer hose (3).
4) Remove rear end door balancers (4).
5) Remove door hinge nuts (5) and remove rear end
door assembly (6).
BA
A
B
A
A
A
A
A
AA
A
A
5
614 2
(a)
(a)
[A]
3
7
8
9
I6RW0B9A0006-01
[A]: Rear end door spoiler installation position 4. Rear end door balancer 8. Cap
1. Rear end door panel assembly 5. Rear end door trim 9. Clip
2. Rear end door window glass 6. Rear end door opening wether-strip : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
3. Rear end door hinge
: Apply lithium grease 99000-25011 to door hinge
moving section.
: Apply sealant 99000-31110 to contact face.7. Rear end door spoiler

Downloaded from www.Manualslib.com manuals search engine Hood / Fenders / Doors: 9J-7
WARNING!
Handling of rear end door balancer (damper)
• Handle balancer carefully. Do not scar or
scratch exposed surface of its piston rod,
and never allow any paint or oil to stick to
its surface.
• Do not turn piston rod with balancer fully
extended.
• Do not disassemble balancer (1) because
its cylinder is filled with gas.
Discarding of rear end door balancer
(damper)
• The gas itself in balancer is harmless but it
may issue out of the hole together with
chips generated by the drill (2). Therefore,
be sure to wear goggle when drilling.
• Using a 2 to 3 mm (0.08 to 0.12 in.) drill (2),
make a hole to remove gas inside as
shown before discarding.

Installation
Reverse removal procedure noting the following.
• Tighten rear end door balancer bolt to specified
torque.
Tightening torque
Rear end door balancer bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lb-ft)
• Secure wiring harness (1).
• Adjust door latch striker position by referring to “Rear
End Door Lock Assembly Removal and Installation in
Section 9F”.
• Adjust door cushion so that door contacts body when
closed.
• Apply sealant to contact face “A” of door hinge (1) and
apply grease to rotating part “B” of hinge (1).
Specified sealant and grease.
“A”: Sealant 99000–31110 (SUZUKI Bond
No.1215)
“B”: Grease 99000–25011 (SUZUKI Super Grease
A)
AB
A
A
A
A
AAA
AAA
B
3
5
461
4
2
2
I5RW0A9A0008-03
I2RH019A0010-01
(a)
(a)
I5RW0A9A0009-02
1
I5RW0A9A0010-01
I2RH019A1012-01

Downloaded from www.Manualslib.com manuals search engine 9J-8 Hood / Fenders / Doors:
Specifications
Tightening Torque SpecificationsS6RW0D9A07001
NOTE
The specified tightening torque is also described in the following.
“Front Door Assembly Components”
“Rear Door Assembly Components”
“Rear End Door Assembly 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 MaterialS6RW0D9A08001
NOTE
Required service material is also described in the following.
“Front Door Assembly Components”
“Rear Door Assembly Components”
“Rear End Door Assembly Components”

Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Hood latch bolt 10 1.0 7.5)
Rear end door balancer bolt 23 2.3 17.0)
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011) / )
Sealant SUZUKI Bond No.1215 P/No.: 99000–31110) / ) / )

Downloaded from www.Manualslib.com manuals search engine Body Structure: 9K-1
Body, Cab and Accessories
Body Structure
Repair Instructions
Front Bumper and Rear Bumper ComponentsS6RW0D9B06001
1 24
5
6
3
78
9
10
I6RW0C9B0003-01
1. Front bumper 5. Front bumper lower member 9. Reflector
2. Radiator upper grill 6. Front bumper holder 10. License garnish(if equipped)
3. Retainer(if equipped) 7. Rear bumper holder

Downloaded from www.Manualslib.com manuals search engine 9K-2 Body Structure:
Cowl Top and Front Lower Crossmember ComponentsS6RW0D9B06002 4. Front bumper upper member 8. Rear bumper
I6RW0D9B0001-01
1. Cowl top garnish 3. Hood rear seal : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
2. Cowl top panel 4. Front lower crossmember

Downloaded from www.Manualslib.com manuals search engine 9K-4 Body Structure:
Rear end Door
Hole to hole distance
a
a'
b'
b
f
cc'
f'
d
d'
e
I5RW0A9B0004-03
a (a’). Wire harness hole c (c’). Combination lamp installation upper hole e. Rear end door striker installation left side hole
b (b’). Rear end door balancer lower hole d (d’). Rear bumper installation hole f (f’). Rear seat back striker installation rear hole
a-a’: 342 mm (13.465 in.) a’-e: 906 mm (36.669 in.) d-d’: 970 mm (38.189 in.)
a-d: 909 mm (35.787 in.) b-b’: 987 mm (38.858 in.) e-f: 753 mm (29.646 in.)
a-e: 898 mm (35.354 in.) b-c’: 1,117 mm (43.976 in.) e-f’: 784 mm (30.866 in.)
a’-c’: 686 mm (27.008 in.) c-c’: 1,104 mm (43.465 in.)