PPL SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 9F-13 Security and Locks:
If check result is not as specified, replace switch.
Replacement of Transmitter Battery (Other than
Keyless Start Model)
S6RW0D9606014
NOTE
For keyless start model, perform
“Replacement of Remote Controller Battery
in Section 10E” instead of “Replacement of
Transmitter Battery (Other than Keyless Start
Model)”.

If transmitter becomes unreliable, replace transmitter
battery as follows.
1) Remove screw (1) and transmitter cover (2).
2) Remove transmitter (3) from transmitter holder (4).
CAUTION!
Use care not to allow grease or dirt to be
attached on the printed circuit board and the
battery.

3) With tip of flat blade screwdriver put in slot of
transmitter, pry it open.
4) Replace the battery (lithium disc-type CR 1620 or
equivalent battery) so its (+) terminal faces “+” mark
on transmitter.
5) Fit together transmitter (3) and install it into
transmitter holder (4).
6) Install transmitter cover (2) and screw (1).7) Make sure that door locks can be operated with
transmitter.
NOTE
• To prevent theft, be sure to break the
transmitter before discarding it.
• Dispose of the used battery properly
according to applicable rules or
regulations. Do not dispose of lithium
batteries with ordinary household trash.

Programming Transmitter Code for Keyless
Entry System (Other than Keyless Start Model)
S6RW0D9606015
NOTE
• Three transmitter codes can be registered.
• When a new transmitter code is registered,
the oldest one will be cleared.
• As for vehicle equipped with keyless start
system, perform “Registration Procedure
for Remote Controller ID Code in Section
10E” instead of “Programming Transmitter
Code for Keyless Entry System (Other than
Keyless Start Model)”.

If transmitter or BCM (included in junction block
assembly) is replaced with a new one or additional
transmitter(s) is necessary, program transmitter code(s).
1) Confirm that all doors are closed and ignition key is
out of ignition key cylinder.
2) Open driver side door.
3) Turn ignition switch to ON position, and then drawn
ignition key from ignition key cylinder within 10
seconds after that.
4) Push and release driver side door switch (1) at 3
times by hand within 20 seconds after removing
ignition key from ignition key cylinder.
5) Turn ignition switch to ON position, and then drawn
ignition key from ignition key cylinder within 10
seconds after that. All doors automatically lock and
unlock once.
With this, registration mode.
1
“a”
“b”
I5RW0A960009-02
234
1I4RS0B960014-01

Downloaded from www.Manualslib.com manuals search engine 9F-15 Security and Locks:
Keyless Entry Receiver and Its Circuit Inspection (If Equipped)S6RW0D9606017
1) Check that the voltage between the following terminals and body ground are specifications under each conditions.
If check result is not as specified, check applicable circuit for open or short. If circuit is normal, proceed to next
step.
Oscilloscope setting
CH1: 2V/DIV
CH2: 2V/DIV
TIME: 200 ms/DIV
1) Recheck keyless entry receiver as follows.
a) Substitute a known-good keyless entry receiver.
b) Record key code referring to “Programming Transmitter Code for Keyless Entry System (Other than Keyless
Start Model)”.
c) Recheck keyless entry receiver system.
1. Keyless entry receiver
2. Keyless entry receiver connector (view from harness side)
Terminal Circuit Specification Condition
1 Power sourceFigure [A] Push “Lock” or “Unlock” button on transmitter.
0 – 1 V Except the above-mentioned condition.
3Lock/Unlock output
signal circuitFigure [A] Push “Lock” or “Unlock” button on transmitter.
0 – 1 V Except the above-mentioned condition.
4 Ground 0 – 1 V —
1. Lock/Unlock out put signal
2. Power source
1 2 3 4
V
2
1
I5RW0A960011-02
I4RS0A960024-01

Downloaded from www.Manualslib.com manuals search engine Seats: 9G-2
Repair Instructions
Front Seat ComponentsS6RW0D9706001
3
2
8
7
a
c
4
d
b
1
5
5
4
6
64
a
b
c
d
(b)
(b)
(b)
(b)
(a)
(a)
(a)
(a)
A
A
A
(b)
(c)
BA
A
A
B
A
B
I6RW0C970001-01
1. Seat cushion7. Side air bag module (if equipped)
2. Seat back
: Apply lithium grease 99000-25011 to sliding part of reclining.8. Side air bag harness (if equipped)
3. Headrest: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Cover: 35 N⋅m (3.5 kgf-m, 25.5 lb-ft)
5. Seat adjuster
: Apply lithium grease 99000-25011 to seat adjuster inside.: 28 N⋅m (2.8 kgf-m, 20.5 lb-ft) (Seat lifter type)
35 N⋅m (3.5 kgf-m, 25.5 lb-ft) (Non seat lifter type)
6. Knoba, b, c, d: Seat back mounting bolt
Seat mounting bolt
Tightening order: a → b → c → d

Downloaded from www.Manualslib.com manuals search engine Seats: 9G-4
Rear Seat ComponentsS6RW0D9706003
Rear Seat Removal and InstallationS6RW0D9706004
Removal
1) Fold rear seat back forward.
2) Remove seat mounting bolts and nuts to remove seat assembly.
3) Disassemble and repair seat as necessary.
Installation
Reverse removal procedure to install rear seat.
• Torque to specifications in “Rear Seat Components”.
3
5
4
4
4
7
4
2
6
b
c
a
(d)
(a)
(d)
(b)
(b)
(b)
(c)
A
7A
(b)
8
I6RW0C970002-01
1. Seat cushion:35 N⋅m (3.5 kgf-m, 25.5 lb-ft)
2. Seat back:23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
3. Head rest (if equipped):25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
4. Cover:45 N⋅m (4.5 kgf-m, 33.0 lb-ft)
5. Rear center seat belt (if equipped) a, b, c: Seat back striker mounting bolt
6. Seat back striker: Tightening order (Left side): a→b→c
7. Rear cushion leg
: Apply lithium grease to 99000-25011 to cushion leg.: Tightening order (Right side): b→a→c
8. Rear seat back lock

Downloaded from www.Manualslib.com manuals search engine Hood / Fenders / Doors: 9J-1
Body, Cab and Accessories
Hood / Fenders / Doors
Repair Instructions
Hood Removal and InstallationS6RW0D9A06001
Removal
CAUTION!
Place cloth to prevent body from any
damage.

1) Remove hood silencer (4).
2) Disconnect window washer hose (1) from hood.
3) Remove 4 mounting bolts (3) to detach hood (2).
Installation
Reverse removal procedure noting the following.
• Apply sealant to contact face “A” of hood hinge.
Specified sealant.
“A”: Sealant 99000–31110 (SUZUKI Bond
No.1215)
• Adjust hood lock position if necessary referring to
“Hood Inspection and Adjustment”.
Hood Inspection and AdjustmentS6RW0D9A06002
Inspection
• Check that hood opens and closes smoothly and
properly. Lubricate if necessary.
• Check that hood stops in the secondary latched
position properly (preventing hood from opening
freely) and that hood closes completely in the fully
latched position.
• Adjust hood locks position, if necessary.Adjustment
Adjust the following point:
• Hood position adjustment.
Fore-and-aft and right-and-left adjustment.
Adjust hood clearance by loosening hood mounting
bolts. Refer to “Panel Clearance in Section 9K”.
• Vertical adjustment
If only one side (right or left) of hood is not level with
front fender, make it level by tightening or loosening
hood cushion (1).
• Hood lock position adjustment
a. Loosen hood lock bolts.
b. Adjust hood lock height position so the hood is
locked without looseness.
c. Tighten hood latch bolts to specified torque.
Tightening torque
Hood latch bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-
ft)
d. Make sure the hood is locked smoothly and
securely.
2
4
1
3 “A”
“A”
I5RW0A9A0001-01
1
I5RW0A9A0002-01
(a)(a)
I5RW0A9A0003-01

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-3
Front Door Assembly ComponentsS6RW0D9A06005
Front Door Assembly Removal and InstallationS6RW0D9A06006
Removal
1) Remove front fender referring to “Front Fender
Removal and Installation”.
2) Disconnect door harness lead wires at each coupler.
3) Remove door open stopper (1).4) Support door panel (1) using a jack (2) with rags (3)
and a piece of wood (4) placed between jack (2) and
panel (1) as shown.
2
24
45
3
1
6
(a)
(a)
(c) a
(b)
b(b)
a(b) b
(b)
I6RW0B9A0002-01
1. Door panel 5. Door open stopper bolt : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
2. Door hinge
: Apply lithium grease 99000-25011 to rotating part.
: Apply sealant 99000-31110 to contact face.6. Front door opening weather-strip a, b: Front door hinge bolt (door side)
Loosen and tightening order: a→b
3. Door open stopper : 27 N⋅m (2.7 kgf-m, 19.5 lb-ft)
4. Front door hinge bolt (body side) : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
I4RS0A9A0005-01
I2RH019A0003-01

Downloaded from www.Manualslib.com manuals search engine 9J-4 Hood / Fenders / Doors:
5) Remove door assembly (1) by loosening hinge
mounting bolts (2).
Installation
Reverse removal procedure to install door assembly
noting the following instructions.
• When replacing door, coat replacement door inside
with wax for proper anti-corrosion treatment. Refer to
“Sealant Application Areas in Section 9L”.
• Apply sealant to contact face “A” of 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) • Tighten front door hinge bolts and door open stopper
bolt to specified torque referring to “Front Door
Assembly Components”.
• When door open stopper (1) is installed, be careful
make sure punch mark (2) comes to the top.
Door open stopper installing direction
Left side door: L punch mark is upward
Right side door: R punch mark is upward
• Adjust door latch striker position referring to “Front
Door Lock Assembly Removal and Installation in
Section 9F”.
• After installation, open and close the door to check
looseness.
1
2
I4RS0A9A0006-01
I6RW0B9A0003-01
I6RW0B9A0004-01

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