2006 SUZUKI SX4 engine mount

Downloaded from www.Manualslib.com manuals search engine 1J-4 Charging System:
Diagnostic Information and Procedures
Battery InspectionS6RW0D1A04001
Common Causes of Failure
A battery is not designed to last indefinitely; however,
with proper care, it will provide many years of service. If
the battery performs satisfactorily during test buy fails to
operate properly for no apparent reason, the following
are some factors that may point to the cause of trouble:
• Accessories left on overnight or for an extended
period without the generator operating.
• Slow average driving speed for short periods.
• Electrical load exceeding generator output particularly
with addition of aftermarket equipment.
• Defects in charging system such as high resistance,
slipping drive belt, loose generator output terminal,
faulty generator or voltage regulator. Refer to
“Generator Symptom Diagnosis”.
• Battery abuse, including failure to keep battery cable
terminals clean and tight or loose battery hold down.
• Mechanical problems in electrical system such as
shorted or pinched wires.
Visual Inspection
Check for obvious damage, such as cracked or broken
case or cover, that could permit loss of electrolyte. If
obvious damage is noted, replace battery. Determine
cause of damage and correct as needed.
Generator Symptom DiagnosisS6RW0D1A04002
CAUTION!
• Do not mistake polarities of “IG” terminal
and “L” terminal.
• Do not create short circuit between “IG”
and “L” terminals. Always connect these
terminals through a lamp.
• Do not connect any load between “L” and
“E” terminals.
• When connecting charger or booster
battery to vehicle battery, refer to “Jump
Starting in Case of Emergency”.

Trouble in charging system will show up as one or more
of the following conditions:
1) Faulty indicator lamp operation.
2) An undercharged battery as evidenced by slow
cranking or indicator dark.
3) An overcharged battery as evidenced by excessive
spewing of electrolyte from vents.
Noise from generator may be caused by loose drive
pulley, loose mounting bolts, worn or dirty bearings,
defective diode, or defective stator.
B: Generator output (Battery terminal) IG: Ignition terminal
C: C terminal L: Lamp terminal
E: Ground FR: Field duty monitor
F: Field coil terminal
E FFRC
B
IG
L
I6RW0D1A0003-01

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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 Charging System: 1J-9
Generator Dismounting and RemountingS6RW0D1A06003
1) Disconnect negative cable at battery.
2) Remove right side drive shaft referring to “Front Drive Shaft Assembly Removal and Installation in Section 3A”
3) Dismount in numerical order as shown in figure.
4) Reverse dismounting procedure for remounting.
I6RW0D1A0004-01
1. “B” terminal nut 5. Generator pivot bolt : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
2. “B” terminal wire 6. Generator drive belt : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft)
3. Connector 7. Generator
4. Generator bracket bolt : 5.0 N⋅m (0.5 kg⋅m, 4.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-13
Specifications
Charging System SpecificationsS6RW0D1A07003
Battery
NOTE
The battery used in each vehicle is one of the following two types, depending on specification.

Battery
: 46B24R (40.6AH/5HR), 55B24R (42.5AH/5HR) 12V
Generator
Tightening Torque SpecificationsS6RW0D1A07004
NOTE
The specified tightening torque is also described in the following.
“Generator Dismounting and Remounting”
“Generator Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Battery type 46B24R 55B24R
Rated capacity AH/5HR, 12 Volts 40.6 42.5
Electrolyte L (US / lmp pt.) — 2.8 (5.92 / 4.93)
Type 70 A type
Rated voltage 12 V
Nominal output 70 A
Permissible max. speed 18,000 r/min.
No-load speed 1020 r/min. (rpm)
Regulated voltage 14.2 – 14.8 V (Hi), 12.5 – 13.1 V (Lo)
Exposed brush length Standard: 10.5 mm (0.41 in.)
Limit: 1.5 mm (0.05 in.)
Permissible ambient temperature –30 to 90 °C (–22 to 194 °F)
Polarity Negative ground
Rotation Clockwise viewed from pulley side
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Generator bracket bolt 25 2.5 18.0)
Generator pivot bolt 50 5.0 36.0)
Generator adjusting bolt
Tighten 7.0 0.7 5.0by the specified
procedure. )

Downloaded from www.Manualslib.com manuals search engine 1K-1 Exhaust System:
Engine
Exhaust System
General Description
Exhaust System DescriptionS6RW0D1B01001
The exhaust system consists of an exhaust manifold, three-way catalytic converter (TWC) in catalyst case, exhaust
pipes, a muffler and seals, gasket and etc.
The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of
Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
Diagnostic Information and Procedures
Exhaust System CheckS6RW0D1B04001
WARNING!
To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any
service on the exhaust system should be performed when the system is cool.

At every interval of periodic maintenance service, and when vehicle is raised for other service, check exhaust system
as follows:
• Check rubber mountings for damage, deterioration, and out of position.
• Check exhaust system for leakage, loose connection, dent and damage.
• If bolts or nuts are loosened, tighten them to specified torque referring to “Exhaust System Components”.
• Check nearby body areas damaged, missing, or mispositioned part, open seam, hole connection or any other
defect which could permit exhaust fumes to seep into vehicle.
• Make sure that exhaust system components have enough clearance from underbody to avoid overheating and
possible damage to vehicle underbody.
• Any defect should be fixed at once.
IYSY011B0003-01

Downloaded from www.Manualslib.com manuals search engine Exhaust System: 1K-2
Repair Instructions
Exhaust System ComponentsS6RW0D1B06001
WARNING!
To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any
service on the exhaust system should be performed when the system is cool.

[A]
1
2
3
4
56
7
8
9
10
11
12
12
26
12
12
141515
16
26 12
17
18
18
19
19
20
21
23
22
24
25
(a)(c)
(c)
(d)
(e)
(b)
(a)
(b)(b)
(c)
(c)
(b)
(b)
14(b)
15(b)13
(e)
13
I5RW0C1B0001-01
[A]: Installing location of exhaust manifold bolt and nut. 11. Muffler 22. Exhaust pipe clamp bolt
1. Exhaust manifold gasket 12. Mounting No.1 23. Engine hook
2. Exhaust manifold 13. Heat insulator nut 24. HO2S-1 (connector color: black)
3. Exhaust manifold stiffener 14. Exhaust manifold bolt 25. Heat insulator
4. HO2S-2 (connector color: green) 15. Exhaust manifold nut 26. Mounting No.2
5. Exhaust pipe No.1 gasket 16. Exhaust No.1 pipe bolt : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft)
6. No.1 seal ring 17. Exhaust manifold stiffener bolt : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft)
7. No.2 seal ring 18. Exhaust No.2 pipe bolt : 43 N⋅m (4.3 kgf-m, 31.0 lb-ft)
8. Exhaust No.1 pipe 19. Exhaust center pipe bolt : 29 N⋅m (2.9 kgf-m, 21.0 lb-ft)
9. Exhaust No.2 pipe 20. Exhaust pipe No.2 gasket : 2 N⋅m (0.2 kgf-m, 1.5 lb-ft)

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 Suspension General Diagnosis: 2A-1
Suspension
Suspension General Diagnosis
Diagnostic Information and Procedures
Suspension, Wheels and Tires Symptom DiagnosisS6RW0D2104001
Condition Possible cause Correction / Reference Item
Vehicle pulls (Leads)Mismatched or uneven tiresReplace tires.
Tires not adequately inflatedAdjust tire pressure.
Broken or sagging coil springsReplace coil springs.
Radial tire lateral forceReplace tire.
Disturbed wheel alignmentCheck and adjust wheel alignment.
Brake dragging in one road wheelRepair brake.
Loose, bent or broken front or rear
suspension partsTighten or replace related suspension parts.
Abnormal or excessive
tire wearSagging or broken coil springReplace coil spring.
Tire out of balanceAdjust balance or replace tire.
Disturbed wheel alignmentCheck and adjust wheel alignment.
Faulty strut (shock absorber)Replace strut (shock absorber).
Hard drivingReplace tires.
Overloaded vehicleReplace tires.
Not rotated tiresReplace or rotate tires.
Worn or loose wheel bearingReplace wheel bearing.
Wobbly wheel or tireReplace wheel or tire.
Tires not adequately inflatedAdjust tire pressure.
Front suspension frame and/or
suspension control arm are transformedCheck and replace.
Wheel trampBlister or bump on tireReplace tire.
Improper strut (shock absorber) actionReplace strut (shock absorber).
Shimmy, shake or
vibrationTire or wheel out of balanceBalance wheel or replace tire and/or wheel.
Loosen wheel bearingsReplace wheel bearings.
Worn tie-rod endsReplace tie-rod ends.
Worn lower ball jointsReplace suspension control arm.
Excessive wheel runoutRepair or replace wheel and/or tire.
Blister or bump on tireReplace tire.
Excessively loaded radial runout of tire /
wheel assemblyReplace tire or wheel.
Disturbed wheel alignmentCheck and adjust wheel alignment.
Loose or worn steering linkageTighten or replace steering linkage.
Abnormal noise, front endWorn, sticky or loose tie-rod ends, lower
ball joints, tie-rod inside ball joints or
drive shaft jointsReplace tie-rod end, suspension arm, tie-rod
or drive shaft joint.
Damaged struts or mountingsRepair or replace struts or mountings.
Worn suspension arm bushingsReplace suspension arm bushings.
Loose stabilizer barTighten bolts or nuts and/or replace bushes.
Loose wheel boltsTighten wheel bolts.
Loose suspension bolts or nutsTighten suspension bolts or nuts.
Broken or damaged wheel bearingsReplace wheel bearings.
Broken suspension springsReplace suspension springs.
Worn strut bearingsReplace strut bearing.
Malfunction of Power Steering SystemCheck and correct malfunction.
Low or uneven trim height
NOTE
See NOTE *1.

Broken or sagging coil springsReplace coil springs.
Over loadedCheck loading.
Incorrect coil springsReplace coil spring.
Tires not adequately inflatedAdjust tire pressure.
Ride too softFaulty strut (shock absorber)Replace strut (shock absorber).
Suspension bottomsOverloadedCheck loading.
Faulty strut (shock absorber)Replace strut (shock absorber).
Incorrect, broken or sagging coil springsReplace coil spring.