2006 SUZUKI SX4 rear assembly

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-12
Steering
• Check to ensure that steering wheel is free from
instability, or abnormally heavy feeling.
• Check that the vehicle does not wander or pull to one
side.
Engine
• Check that engine responds readily at all speeds.
• Check that engine is free from abnormal noise and
abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting system
are free from abnormal noise and abnormal vibration or
any other abnormal condition.Meters and Gauge
Check that speedometer, odometer, fuel meter,
temperature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan
switch lever to highest position for this check.
Specifications
Tightening Torque SpecificationsS6RW0D0207001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Fluids and LubricantsS6RW0D0208001
Special ToolS6RW0D0208002
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Engine oil drain plug 35 3.5 25.5)
Oil filter 14 1.4 10.5 for reference )
Engine oil SG, SH, SJ, SL or SM grade (Refer to “Engine Oil and Filter Change” for engine
oil viscosity.)
Engine coolant
(Ethylene glycol base coolant)“Antifreeze/Anticorrosion coolant”
Brake fluid Refer to reservoir cap of brake master cylinder.
Manual transaxle oil Refer to “Manual Transaxle Oil Change in Section 5B”.
Automatic transaxle fluid Refer to “A/T Fluid Change in Section 5A”.
Transfer oil (4WD) Refer to “Transfer Oil Change in Section 3C”.
Rear differential (4WD) Refer to “Rear Differential Oil Change in Section 3B”.
Door hinges Engine oil or water resistance chassis grease
Hood latch assembly Engine oil or water resistance chassis grease
Key lock cylinder Spray lubricant
09915–47331
Oil filter wrench
)

Downloaded from www.Manualslib.com manuals search engine 1-iv Table of Contents
Crankshaft Inspection .......................................1D-63
Main Bearings Inspection ..................................1D-65
Sensor Plate Inspection ....................................1D-70
Rear Oil Seal Inspection ...................................1D-70
Flywheel Inspection...........................................1D-70
Cylinder Block Inspection ..................................1D-70
Specifications .....................................................1D-71
Tightening Torque Specifications ......................1D-71
Special Tools and Equipment ...........................1D-73
Recommended Service Material .......................1D-73
Special Tool ......................................................1D-73
Engine Lubrication System.....................1E-1
General Description ............................................. 1E-1
Engine Lubrication Description ........................... 1E-1
Diagnostic Information and Procedures ............ 1E-2
Oil Pressure Check ............................................. 1E-2
Repair Instructions .............................................. 1E-3
Oil Pan and Oil Pump Strainer Components....... 1E-3
Oil Pan and Oil Pump Strainer Removal and
Installation ......................................................... 1E-4
Oil Pan and Oil Pump Strainer Cleaning ............. 1E-5
Oil Pump Components ........................................ 1E-6
Oil Pump Removal and Installation ..................... 1E-6
Oil Pump Disassembly and Reassembly ............ 1E-6
Oil Pump Inspection ............................................ 1E-7
Specifications ....................................................... 1E-9
Tightening Torque Specifications ........................ 1E-9
Special Tools and Equipment ............................. 1E-9
Recommended Service Material ......................... 1E-9
Special Tool ........................................................ 1E-9
Engine Cooling System ........................... 1F-1
General Description ............................................. 1F-1
Cooling System Description ................................ 1F-1
Coolant Description ............................................. 1F-1
Schematic and Routing Diagram ........................ 1F-2
Coolant Circulation .............................................. 1F-2
Diagnostic Information and Procedures ............ 1F-3
Engine Cooling Symptom Diagnosis ................... 1F-3
Repair Instructions .............................................. 1F-4
Cooling System Components.............................. 1F-4
Coolant Level Check ........................................... 1F-5
Engine Cooling System Inspection and
Cleaning ............................................................ 1F-5
Cooling System Draining..................................... 1F-5
Cooling System Flush and Refill ......................... 1F-6
Cooling Water Pipes or Hoses Removal and
Installation ......................................................... 1F-6
Thermostat Removal and Installation.................. 1F-7
Thermostat Inspection......................................... 1F-7
Radiator Cooling Fan Assembly On-Vehicle
Inspection .......................................................... 1F-8
Radiator Cooling Fan Relay Inspection............... 1F-8
Radiator Cooling Fan Assembly Removal and
Installation ......................................................... 1F-8
Radiator Cooling Fan Disassembly and
Reassembly ...................................................... 1F-9
Radiator On-Vehicle Inspection and Cleaning .... 1F-9Radiator Removal and Installation ...................... 1F-9
Water Pump / Generator Drive Belt Tension
Inspection and Adjustment.............................. 1F-10
Water Pump / Generator Drive Belt Removal
and Installation ................................................ 1F-10
Water Pump Removal and Installation .............. 1F-11
Water Pump Inspection ..................................... 1F-12
Specifications ..................................................... 1F-12
Tightening Torque Specifications ...................... 1F-12
Special Tools and Equipment ........................... 1F-12
Recommended Service Material ....................... 1F-12
Fuel System ............................................. 1G-1
Precautions .......................................................... 1G-1
Precautions on Fuel System Service ................. 1G-1
General Description ............................................ 1G-2
Fuel System Description .................................... 1G-2
Fuel Delivery System Description ...................... 1G-2
Fuel Pump Description ....................................... 1G-2
Schematic and Routing Diagram ....................... 1G-3
Fuel Delivery System Diagram........................... 1G-3
Diagnostic Information and Procedures ........... 1G-3
Fuel Pressure Inspection ................................... 1G-3
Fuel Cut Operation Inspection ........................... 1G-4
Repair Instructions ............................................. 1G-5
Fuel System Components .................................. 1G-5
Fuel Hose Disconnecting and Reconnecting ..... 1G-6
Fuel Pressure Relief Procedure ......................... 1G-7
Fuel Leakage Check Procedure......................... 1G-8
Fuel Lines On-Vehicle Inspection ...................... 1G-8
Fuel Pipe Removal and Installation.................... 1G-8
Fuel Injector On-Vehicle Inspection ................... 1G-9
Fuel Injector Removal and Installation ............... 1G-9
Fuel Injector Inspection .................................... 1G-10
Fuel Filler Cap Inspection ................................ 1G-12
Fuel Tank Inlet Valve Removal and
Installation ...................................................... 1G-12
Fuel Tank Inlet Valve Inspection ...................... 1G-12
Fuel Tank Removal and Installation ................. 1G-13
Fuel Tank Inspection ........................................ 1G-14
Fuel Tank Purging Procedure .......................... 1G-15
Fuel Pump On-Vehicle Inspection.................... 1G-15
Fuel Pump Assembly Removal and
Installation ...................................................... 1G-15
Main Fuel Level Sensor Removal and
Installation ...................................................... 1G-16
Fuel Pump Inspection ...................................... 1G-17
Specifications .................................................... 1G-17
Tightening Torque Specifications ..................... 1G-17
Special Tools and Equipment .......................... 1G-18
Special Tool ..................................................... 1G-18
Ignition System ........................................ 1H-1
General Description .............................................1H-1
Ignition System Construction ..............................1H-1
Schematic and Routing Diagram ........................1H-2
Ignition System Wiring Circuit Diagram...............1H-2
Component Location ...........................................1H-3
Ignition System Components Location................1H-3

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-209
Electric Load Signal Circuit CheckS6RW0D1104079
Wiring Diagram
E01 C01
3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238 3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238
BLK/WHT
BLK/RED
WHT
BRN/WHT
12V5V
10
E01-29
E01-1
E01-60BLK/YEL
BLK/YEL
139BLK/REDE01-16
BLU/WHT
BLU/WHTE01-19
E01-19
14
3 4
YEL
2
12
BLK/WHT
BLKBLK/YEL
GRN
WHT/BLU
BLU
1 56
11 7
8
C01-58
C01-15C01-30
BLK/ORN
BLKBLKE01-31BLK
17 16
WHTREDE01-18E01-3 15WHTREDWHTREDWHTRED [A]
17
WHTRED
18E01-18E01-3 1615WHTREDWHTRED
[B]
19
I6RW0D110057-02
[A]: Junction block with BCM model 6. Junction block assembly 13. Blower speed selector (Auto A/C model)
[B]: Junction block without BCM model 7. “IG COIL” fuse 14. Blower speed selector (Manual A/C model)
1. Individual circuit fuse box No.1 8. “IG2 SIG” fuse 15. Electric load signal (rear defogger signal and headlight
signal), etc.
2. “BLW” fuse 9. ECM 16. BCM
3. “FI” fuse 10. Main relay 17. ABS control module
4. “IGN” fuse 11. Blower motor relay 18. CAN junction connector
5. Ignition switch 12. Blower motor 19. To other control module connected CAN

Downloaded from www.Manualslib.com manuals search engine 1D-60 Engine Mechanical:
Main Bearings, Crankshaft and Cylinder Block
Removal and Installation
S6RW0D1406038
Removal
1) Remove engine assembly from vehicle referring to
“Engine Assembly Removal and Installation”.
2) Remove clutch cover, clutch disc and flywheel (drive
plate for A/T) by using special tool.
Special tool
(A): 09924–178103) Remove piston and connecting rod referring to
“Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation”.
4) Remove rear oil seal housing (1).
5) Loosen main bearing cap No.1 and No.2 bolts in
such order as indicated in figure and remove them.
6) Remove crankshaft from cylinder block.
7) Remove sensor plate from crankshaft.
5. Main bearing
: See “B”15. Flywheel or drive plate bolt : 22 N⋅m (2.2 kgf-m, 16.0 lb-ft)
6. Sensor plate 16. Rear oil seal housing mounting bolt : 5 N⋅m (0.5 kgf-m, 4.0 lb-ft)
7. Crankshaft timing sprocket key 17. Main bearing cap No.2 bolt : 70 N⋅m (7.0 kgf-m, 51.0 lb-ft)
8. Crankshaft 18. Main bearing cap No.1 bolt
: See “D”: Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the specified
procedure.
9. Thrust bearing 19. O-ring : Tighten 30 N⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N⋅m (5.0 kgf-
m, 36.5 lb-ft) and 60° by the specified procedure.
10. Rear oil seal housing
: See “C”20. Oil filter adapter case : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
“A”: When installing CKP sensor, use new sensor mounting bolt. : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
“B”: Upper half of bearing has an oil groove.
Do not apply oil between connecting rod and bearing or between bearing cap and
bearing.:10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
“C”: Apply sealant 99000-31250 to mating surface. : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
“D”: Make sure main bearing cap No.1 bolt deformation when reuse it due to plastic
deformation tightening referring to “Main Bearings Inspection”.: Do not reuse.
: Apply engine oil to inside / sliding surface.
I2RH0B140125-01
I2RH0B140126-01
I2RH0B140127-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-63
9) Install rear oil seal housing (1) and tighten new bolts
to specified torque by using special tool.
Special tool
(A): 09911–97720
Tightening torque
Rear oil seal housing bolt: 11 N·m (1.1 kgf-m, 8.0
lb-ft)
10) Install flywheel (drive plate for A/T).
Using special tool, lock flywheel or drive plate, and
tighten flywheel or drive plate bolts to specified
torque.
NOTE
Use new flywheel or drive plate bolts.

Special tool
(A): 09924–17810
Tightening torque
Flywheel or drive plate bolt (a): 70 N·m (7.0 kgf-
m, 51.0 lb-ft)
11) Install piston and connecting rod referring to
“Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation”.
12) Install cylinder head referring to “Valves and Cylinder
Head Removal and Installation”.13) Install camshafts, tappet and shim referring to
“Camshaft, Tappet and Shim Removal and
Installation”.
14) Install timing chain referring to “Timing Chain and
Chain Tensioner Removal and Installation”.
15) Install timing chain cover referring to “Timing Chain
Cover Removal and Installation”.
16) Install cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”.
17) Install oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
18) Install engine assembly to vehicle referring to
“Engine Assembly Removal and Installation”.
Crankshaft InspectionS6RW0D1406039
Crankshaft Runout
Using a dial gauge, measure runout at center journal.
Rotate crankshaft slowly. If runout exceeds its limit,
replace crankshaft.
Crankshaft runout
Limit: 0.02 mm (0.0008 in.)
Crankshaft Thrust Play
1) Measure this play with crankshaft set in cylinder
block in the normal manner, that is with thrust
bearing (1) and journal bearing caps installed.
Thickness of crankshaft thrust bearing
Standard: 2.470 – 2.520 mm (0.0972 – 0.0992 in.)
Oversize (0.125 mm (0.0049 in.)): 2.533 – 2.583
mm (0.0997 – 0.1017 in.)
A: Crankshaft side
I4RS0A140019-01
I2RH0B140134-01
I2RH0B140135-01
I2RH0B140136-01

Downloaded from www.Manualslib.com manuals search engine 1F-9 Engine Cooling System:
5) Remove cooling fan mounting bolts (1).
6) Remove radiator cooling fan assembly (2).
Installation
Reverse removal procedure for installation noting the
following.
• Refill cooling system referring to Step 7) to 17) of
“Cooling System Flush and Refill”.
• After installation, verify there is no coolant leakage at
each connection.
Radiator Cooling Fan Disassembly and
Reassembly
S6RW0D1606018
Disassembly
1) Remove fan (1) from cooling fan motor (2).
2) Remove fan motor (2) from cooling fan guide (3).
Reassembly
Reverse disassembly procedures for reassembly.
Radiator On-Vehicle Inspection and CleaningS6RW0D1606012
Inspection
Check radiator for leakage or damage. Straighten bent
fins, if any.
Cleaning
Clean frontal area of radiator cores.
Radiator Removal and InstallationS6RW0D1606013
Removal
1) Disconnect negative cable at battery.
2) Drain coolant referring to “Cooling System Draining”.
3) Remove front bumper referring to “Front Bumper
and Rear Bumper Components in Section 9K”.
4) Remove cooling fan assembly referring to “Radiator
Cooling Fan Assembly Removal and Installation”.
5) Remove condenser fan referring to “Condenser
Cooling Fan Removal and Installation in Section 7B”.
6) Remove radiator outlet hose from radiator.
7) Remove radiator from vehicle.
Installation
Reverse removal procedures, noting the following.
Tighten radiator support bracket bolts to specified
torque.
Tightening torque
Radiator support bracket bolt: 33 N·m (3.3 kgf-m,
24.0 lb-ft)
• Refill cooling system referring to Step 7) to 17) of
“Cooling System Flush and Refill”.
• After installation, verify there is no coolant leakage
each connection.
I5RW0C160014-01
I5RW0C160005-01
I2RH01160014-01

Downloaded from www.Manualslib.com manuals search engine 1I-5 Starting System:
Starting Motor ComponentsS6RW0D1906002
I4RS0A190003-01
1. Front housing 7. Plate 13. Planetary gear 19. Rear bush
2. Bush 8. Seal rubber 14. Packing 20. Starting motor battery cable nut
3. Pinion stop ring 9. Magnetic switch 15. Yoke : 9.8 N⋅m (0.98 kgf-m, 7.0 lb-ft)
4. Over-running clutch 10. Ball 16. Armature : Do not reuse.
5. Lever 11. Internal gear 17. Brush assembly : Apply grease 99000-25011 to sliding surface of each part.
6. Plunger 12. Planetary carrier shaft 18. Rear bracket

Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-3
Generator DescriptionS6RW0D1A01002
The basic charging system is the IC integral regulator charging system. The internal components are connected
electrically as shown below.
Charging System Circuit
The generator features a solid state regulator that is mounted inside the generator. All regulator components are
enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the rear housing. The
regulator voltage is being controlled by ECM under some conditions while driving. Refer to “Generator Control System
Description in Section 1A” in related manual.
The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication.
Two brushes carry current through the two slip rings to the field coil mounted on the rotor, and under normal conditions
will provide long period of attention-free service.
The stator windings are assembled inside a laminated core that forms part of the generator frame.
A rectifier bridge connected to the stator windings contains diodes, and electrically changes that stator AC. voltages to
a D.C. voltage which appears at the generator output terminal.
1 26345
4
3B
7
8
9
10E FFRCIG
L
I6RW0D1A0002-01
1. Pulley 6. Field coil B: Generator output (Battery terminal) L: Lamp terminal
2. Pulley nut 7. Regulator C: Generator cut FR: Field duty monitor
3. Rotor fan 8. Brush E: Ground
4. Stator coil 9. Rear end frame F: Field coil terminal
5. Stator core 10. Drive end frame IG: Ignition terminal
B
IG
L
C
E
7
2 4
3
5
FR
610
11
12 13 1
[A]
IG1 9
14
8
I6RW0D1A0001-03
[A]: If equipped with electric load current sensor 4. Diode 8. Battery 12. Combination meter
1. Generator with regulator assembly 5. Field coil (rotor coil) 9. Electric load current sensor (if equipped) 13. CAN driver
2. I.C. regulator 6. Charge indicator light 10. ECM 14. Main fuse box
3. Stator coil 7. Main switch 11. BCM