PPL SUZUKI SX4 2006 1.G Service Workshop Manual

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 Paint / Coatings: 9L-1
Body, Cab and Accessories
Paint / Coatings
General Description
Anti-Corrosion Treatment ConstructionS6RW0D9C01001
WARNING!
Standard shop practices, particularly eye protection, should be followed during the performance of the
following operations to avoid personal injury.

As rust proof treatment, steel sheets are given corrosion resistance on the interior and/or exterior.
These corrosion resistance steel sheet materials are called one of two-side galvanized steel sheets.
It is for the sake of rust protection that these materials are selected and given a variety of treatments as described
blow.
• Steel sheets are treated with cathodic electro primer which is excellent in corrosion resistance.
• Rust proof wax coatings are applied to door and side sill insides where moisture is liable to stay.
• Vinyl coating is applied to body underside and wheel housing inside.
• Sealer is applied to door hem, engine compartment steel sheet-to-steel sheet joint, and the like portions to prevent
water penetration and resulting in rust occurrence.
In panel replacement or collision damage repair, leaving the relevant area untreated as it is in any operation which
does disturb the rust proof treatment will cause corrosion to that area. Therefore, it is the essential function of any
repair operation to correctly recoat the related surfaces of the relevant area.
All the metal panels are coated with metal conditioners and primer coating during vehicle production. Following the
repair and/or replacement parts installation, every accessible bare metal surface should be cleaned and coated with
rust proof primer. Perform this operation prior to the application of sealer and rust proof wax coating.
Sealer is applied to the specific joints of a vehicle during production. The sealer is intended to prevent dust from
entering the vehicle and serves also as an anticorrosion barrier. The sealer is applied to the door and hood hem areas
and between panels. Correct and reseal the originally sealed joints if damaged. Reseal the attaching joints of a new
replacement panel and reseal the hem area of a replacement door or hood.
Use a quality sealer to seal the flanged joints, overlap joints and seams. The sealer must have flexible characteristics
and paint ability after it’s applied to repair areas.
For the sealer to fill open joints, use caulking material. Select a sealer in conformance with the place and purpose of a
specific use. Observe the manufacturer’s label-stand instructions when using the sealer.
In many cases, repaired places require color painting. When this is required, follow the ordinary techniques specified
for the finish preparation, color painting and undercoating build-up.
Rust proof wax, a penetrative compound, is applied to the metal-to-metal surfaces (door and side sill insides) where it
is difficult to use ordinary undercoating material for coating. Therefore, when selecting the rust proof wax, it may be the
penetrative type.
During the undercoating (vinyl coating) application, care should be taken that sealer is not applied to the engine-
related parts and shock absorber mounting or rotating parts. Following the under coating, make sure that body drain
holes are kept open.
The sequence of the application steps of the anti-corrosion materials are as follows:
1) Clean and prepare the metal surface.
2) Apply primer.
3) Apply sealer (all joints sealed originally).
4) Apply color in areas where color is required such as hem flanges, exposed joints and under body components.
5) Apply anticorrosion compound (penetrative wax).
6) Apply undercoating (rust proof material).

Downloaded from www.Manualslib.com manuals search engine 9L-2 Paint / Coatings:
Plastic Parts FinishingS6RW0D9C01002
Painting
Rigid or hard ABS plastic needs no primer coating.
General acrylic lacquers can be painted properly over hard ABS plastic in terms of adherence.
1) Use cleaning solvent for paint finish to wash each part.
2) Apply conventional acrylic color lacquer to part surface.
3) Follow lacquer directions for required drying time. (Proper drying temperature range is 60 – 70 °C (140 – 158 °F)).
Reference
Plastic parts employ not only ABS (Acrylonitrile Butadiene Styrene) plastic but also polypropylene, vinyl, or the like
plastic. Burning test method to identify ABS plastic is described below.
1) Use a sharp blade to cut off a plastic sliver from the part at its hidden backside.
2) Hold sliver with pincers and set it on fire.
3) Carefully observe condition of the burning plastic.
4) ABS plastic must raise readily distinguishable back smoke while burning with its residue suspended in air
temporarily.
5) Polypropylene must raise no readily distinguishable smoke while burning.

Downloaded from www.Manualslib.com manuals search engine Paint / Coatings: 9L-3
Component Location
Sealant Application AreasS6RW0D9C03001
I7RW019C0007-01

Downloaded from www.Manualslib.com manuals search engine 9L-4 Paint / Coatings:
I7RW019C0002-01
[A]: RH side “B”: Wipe off excess sealant after application. “E”: Never fill up drain holes with sealant.
[B]: LH side “C”: Smooth out sealant with a brush. “F”: Fill gap / hole with sealant.
“A”: Apply sealant. “D”: Do not apply sealant. “G”: R end

Downloaded from www.Manualslib.com manuals search engine Paint / Coatings: 9L-5
I7RW019C0008-01
“A”: Apply sealant. “D”: Do not apply sealant.
“B”: Fill gap / hole with sealant. “E”: Wipe off excess sealant after application.
“C”: Smooth out sealant with a brush.

Downloaded from www.Manualslib.com manuals search engine 9L-6 Paint / Coatings:
I7RW019C0004-01
“A”: Apply sealant. “C”: Never fill up drain holes (“a” to “f”) with sealant.
“B”: Wipe off excess sealant after application. “D”: Apply sealant covering flange end.

Downloaded from www.Manualslib.com manuals search engine Paint / Coatings: 9L-7
I6RW0C9C0004-01
“A”: Apply sealant. “D”: Smooth out sealant with a brush. “G” Apply sealant covering flange end.
“B”: Wipe off excess sealant application. “E”: Smooth out sealant with a brush.
Do not fill hole with sealant.
“C”: Fill gap / hole with sealant. “F”: Do not apply sealant.

Downloaded from www.Manualslib.com manuals search engine 9L-8 Paint / Coatings:
I5RW0C9C0005-01
“A”: Apply sealant. 1. Hole

Downloaded from www.Manualslib.com manuals search engine Paint / Coatings: 9L-9
I5RW0C9C0006-01
“A”: Apply sealant covering flange end.