engine mount SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-46
26) Clean mating surface of differential carrier (1) and
differential cover, apply sealant to carrier as shown
in figure by such amount that its section is 1.5 mm
(0.059 in.) in diameter, mate differential cover with
differential carrier, and then tighten bolts to specified
torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Differential cover bolt: 23 N·m (2.3 kgf-m, 17.0
lb-ft)
27) Assemble coupling case as follows.
a) Install bearing using special tool and hydraulic
press.
Special tool
(A): 09913–75830
b) Install snap ring using snap ring pliers.
c) Apply grease to oil seal lip, install oil seal (2) to
coupling case (1) using special tool as shown in
figure.
NOTE
Install oil seal horizontally to surface of
coupling case.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Distance between case and oil seal “a”
: 1.5 – 2.5 mm (0.06 – 0.10 in.)
Special tool
(A): 09913–7581028) Install spacer (1) to coupling assembly (2) as shown
in figure.
29) Install grommet of coupling harness into groove of
coupling case and then install coupling assembly by
using hydraulic press.
30) Install companion flange to pinion, and then hold
companion flange with special tool and tighten flange
nut.
Tightening torque
Flange nut: 110 N·m (11.0 kgf-m, 79.5 lb-ft)
Special tool
(A): 09930–40113
“A”
1
I5RW0A320058-02
(A)
I5RW0A320059-02
(A)
1 12, “A”“a”
I5RW0A320060-02
12
12
I5RW0A320065-01
(A)
I5RW0A320061-01

Downloaded from www.Manualslib.com manuals search engine 3B-47 Differential:
31) Clean mating surface of differential carrier (1) and
coupling case (2), apply sealant to carrier as shown
in figure by such amount that its section is 1.5 mm
(0.059 in.) in diameter, mate coupling case with
differential carrier as shown in figure, and then
tighten bolts to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Coupling case bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
NOTE
Install coupling pin (3) by fitting it to groove
(4) of coupling case.

32) Apply grease to oil seal lip, and then install oil seals
(1) to rear differential (2) using special tool as shown
in figure.
NOTE
Install oil seal horizontally to surface of rear
differential case.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Distance between rear differential and oil seal
“a”
: 1.0 – 2.0 mm (0.04 – 0.08 in.)
Special tool
(A): 09913–75810
33) Install drive shaft flange.
34) Install rear mounting bracket to rear differential
referring to “Front Mounting Arm and/or Rear
Mounting Bracket Assembly Removal and
Installation”.
Rear Differential InspectionS6RW0D3206015
• Check companion flange for wear or damage.
• Check bearings for wear or discoloration.
• Check differential carrier for cracks.
• Check drive bevel pinion and bevel gear for wear or
cracks.
• Check side gears, pinion gears and pinion shaft for
wear or damage.
• Check side gear spline for wear or damage.
1 4
3 2“A”
(a)
I5RW0A320062-04
(A)
2 21, “A”
“a”
I5RW0A320063-02

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-48
Specifications
Tightening Torque SpecificationsS6RW0D3207001
NOTE
The specified tightening torque is also described in the following.
“Rear Differential Mountings Components”
“Rear Differential 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 MaterialS6RW0D3208001
NOTE
Required service material is also described in the following.
“Rear Differential Components”

Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Differential oil level / filler plug 23 2.3 17.0) / )
Differential oil drain plug 23 2.3 17.0)
Coupling air temperature sensor 18 1.8 13.0)
Bevel gear bolt 73 7.3 52.0)
Bevel pinion nut 230 – 340 23.0 – 34.0 166.5 – 246.0)
Differential cover bolt 23 2.3 17.0)
Flange nut 110 11.0 79.5)
Coupling case bolt 23 2.3 17.0)
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25010) / ) / )
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260) / ) / ) / ) / )

Downloaded from www.Manualslib.com manuals search engine 3B-49 Differential:
Special ToolS6RW0D3208002
09900–20607 09900–20701
Dial gauge Magnetic stand
))
09912–34510 09913–50121
Case separator Oil seal remover
) / )) / )
09913–60910 09913–65135
Bearing and gear puller (40-
60mm)Bearing puller
))
09913–70123 09913–75510
Bearing installing tool Bearing installer
))
09913–75810 09913–75830
Bearing installer Steering pinion bush
installer
) / )) / )
09913–80113 09913–85210
Bearing installer Bearing installer
) / )) / ) / )
09922–76120 09922–76140
Mounting dummy shaft Bevel pinion shaft
) / )) / ) / )

Downloaded from www.Manualslib.com manuals search engine 3C-1 Transfer:
Driveline / Axle
Transfer
General Description
Transfer DescriptionS6RW0D3301001
The transfer is mounted on transaxle case by fastening bolt with reduction drive gear in transfer and differential case in
transaxle coupled by involute spline. Driving force from transaxle is transmitted to propeller shaft through reduction
drive gear, reduction driven gear and bevel gear of transfer. As bevel gears, which change the direction of driving
torque axis to the direction of the angle with 90 degrees, hypoid gears are provided. Hypoid gears have an advantage
of preventing gear noise, at the same time, they require accurate adjustment of tooth contact and backlash.
Diagnostic Information and Procedures
Transfer Symptom DiagnosisS6RW0D3304001
2
1
8
34
5
6
7
9
10I5RW0A330001-01
1. Intermediate shaft 5. Reduction driven gear 9. Transfer output retainer
2. Left case 6. Bevel gear 10. Transfer output flange
3. Reduction drive gear 7. Bevel pinion
4. Right case 8. Spacer
Condition Possible cause Correction / Reference Item
NoiseInadequate or insufficient lubricantReplenish.
Damaged or worn bearing(s)Replace.
Damaged or worn gear(s)Replace.
Preload of taper roller bearing is
reducedAdjust.

Downloaded from www.Manualslib.com manuals search engine 3C-3 Transfer:
Transfer Dismounting and RemountingS6RW0D3306003
Dismounting
1) Disconnect negative cable at battery.
2) Drain transaxle oil and transfer oil.
3) Remove drive shafts assembly referring to “Front
Drive Shaft Assembly Removal and Installation in
Section 3A”.
4) Remove exhaust No.1, No.2 and center pipes
referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
5) Remove suspension frame, engine front mounting
member and mounting member referring to “Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation in Section 2B” and “Engine
Assembly Removal and Installation in Section 1D”.
6) Remove engine rear mounting bracket (1) and
stiffeners (2) from transfer.
7) Support transfer with transmission jack.
8) Remove transfer to transaxle bolts (1), and then
lower transfer assembly (2).Remounting
Reverse dismounting procedure for remounting of
transfer, noting the following points.
• Apply grease to left case (1) as shown in figure.
“A”: Grease 99000–25010 (SUZUKI Super Grease
A)
• Tighten engine rear mounting bracket nut to specified
torque referring to “Engine Mountings Components in
Section 1D”.
• Tighten bolts to specified torque as follows.
Tightening torque
Stiffener No.1 bolt and No.2 bolt (a): 55 N·m (5.5
kgf-m, 40.0 lb-ft)
Transfer to transaxle bolt (b): 98 N·m (9.8 kgf-m,
71.0 lb-ft)
2
2
1I5RW0A330004-01
1
1
2
I5RW0A330005-02
I5RW0C330001-01
(a)
(a)
(b)
(b)
2
I5RW0A330006-02

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-6
d) Select a shim which is close to half thickness of
the calculated value (necessary shim thickness)
from among the available shims to install it
between bearing and case at each of right and
left sides.
For example:
Measure distance “a” is 110.75 mm (4.360 in.).
Measure depth “b” is 85.8 mm (3.378 in.).
Measure depth “c” is 26.55 mm (1.045 in.).
Necessary shim thickness = 85.8 mm (3.378 in.)
+ 26.55 mm (1.045 in.) – 110.75 mm (4.360 in.) +
0.1 mm (0.004 in.) = 1.7 mm (0.067 in.)
1.7 mm (0.067 in.) ÷ 2 = 0.85 mm (0.033 in.)
Calculated thickness of new shim = 0.85 mm
(0.033 in.)
Available reduction driven gear shim
thickness
0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90, 0.95,
1.00 and 1.05 mm (0.024, 0.026, 0.028, 0.030,
0.031, 0.033, 0.035, 0.037, 0.039 and 0.041 in.)
2) Clean mating surface of right and left cases, and
apply sealant to right case (1) as shown in figure by
such amount that its section is 1.2 mm (0.047 in.) in
diameter.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
3) Assemble the following parts in right and left cases
by reversing disassembling procedure.
• Reduction drive gear assembly (1)
• Reduction driven gear assembly (3)
• Bearing outer races (2)
• Reduction driven gear shims (5)
• Dowel pin (6)
4) Tighten transfer case bolts (4) to specified torque.
Tightening torque
Transfer case bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)5) Select bevel pinion shim (3) referring to step 1) of
“Reassembly” under “Transfer Output Retainer
Assembly Disassembly and Reassembly”.
6) Inspect tooth contact according to “Bevel Gear Tooth
Contact Inspection”.
7) Install transfer output retainer assembly (2) with
bevel pinion shim (3) to transfer left case (4) by
tightening retainer bolt (1) to specified torque.
Tightening torque
Transfer output retainer bolt (a): 55 N·m (5.5 kgf-
m, 40.0 lb-ft)
8) Install bolt to bolt hole of flange (2), set dial gauge
measuring tip at right angles to bolt (1) as shown in
figure. Holding reduction driven gear by hand, take
measurement backlash of pinion and bevel gear.
NOTE
If backlash exceeds specification given
below, adjust it by changing thickness ratio
of shims assembled in right and left cases in
Step 3).

Special tool
(A): 09900–20607
(B): 09900–20701
Bevel pinion & bevel gear backlash
: 0.1 – 0.2 mm (0.0039 – 0.0078 in.)
1
“A”
I5RW0A330011-01
6
4, (a) 5 2
31
2
5
I5RW0A330012-02
4
3
21, (a)
1, (a)
I5RW0A330013-02
(A)
1
(B)
2
I5RW0A330014-02

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-12
c) Tighten bevel pinion nut (special tool) so that
specified bearing preload is obtained.
NOTE
Before taking measurement, check for
rotation by hand more than 15 revolutions.

Tightening torque
Rotational torque of bevel pinion (Bearing
preload): 0.50 – 1.30 N·m (0.05 – 0.13 kgf-m,
0.35 – 0.95 lb-ft)
d) Measure height “b” in figure by using vernier
caliper.
Calculate “c” by using measured value.e) Obtain adjusting shim thickness by the following
equation.
f) Select a shim closest to the calculated value
(necessary shim thickness) from among the
available shims or combine shims to become
closest to calculated value.
For example:
Measure distance “b” is 69.95 mm (2.754 in.).
“c” = 69.95 mm (2.754 in.) – 40.0 mm (1.757 in.)
= 29.95 mm (1.179 in.)
“f” = 29.95 mm (1.179 in.) + 74.0 mm (2.913 in.)
– 101.95 mm (4.014 in.) = 2.0 mm (0.079 in.)
Calculated thickness of new shim = 2.0 mm
(0.079 in.)
Available bevel pinion shim thickness
0.30, 1.85, 1.88, 1.91, 1.94, 1.97, 2.00, 2.03,
2.06, 2.09, 2.12 and 2.15 mm (0.012, 0.072,
0.074, 0.075, 0.076, 0.077, 0.078, 0.079, 0.081,
0.082, 0.083 and 0.084 in.) Distance “c” = Height “b” –Height “a” 40 mm
(1.575 in.)
I5RW0A330036-02
“a”
“b”
“c”
I5RW0A330046-01
Necessary
shim
thickness “f”=Distance
“c”+Distance
“d”
–Distance
“e”
74.0 mm
(2.913 in.)101.95 mm
(4.014 in.)
“d”: Pinion shaft mounting distance 74.0 mm (2.913 in.)
“e”: Distance from end face of left case to axis of reduction driven gear
101.95 mm (4.014 in.)
“f”: Necessary shim thickness
“d” “e”
“f ”
I5RW0A330037-01

Downloaded from www.Manualslib.com manuals search engine 4A-5 Brake Control System and Diagnosis:
Brakes Symptom DiagnosisS6RW0D4104002
Condition Possible cause Correction / Reference Item
Not enough braking forceBrake oil leakage from brake linesLocate leaking point and repair.
Brake disc or pad stained with oilClean or replace.
Overheated brakesDetermine cause and repair.
Poor contact of shoes on brake drumRepair for proper contact.
Brake shoe stained with oil or wet with
waterReplace.
Badly worn brake padReplace.
Defective wheel cylindersRepair or replace.
Malfunctioning caliper assemblyRepair or replace.
Malfunctioning brake boosterCheck system and replace as necessary.
Malfunctioning brake master cylinderCheck system and replace as necessary.
Air in systemBleed system.
Malfunctioning ABSCheck system and replace as necessary.
Brake pull (Brakes not
working in unison)Pad, disc, shoe and/or drum are wet
with water or stained with oil in some
brakesClean or replace.
Drum-to-shoe clearance out of
adjustment in some brakes
(Malfunctioning auto adjusting
mechanism) Check for inoperative auto adjusting
mechanism.
Disc and/or drum are out of round in
some brakesReplace.
Tires are inflated unequallyInflate equally.
Malfunction in wheel cylinders (rear
drum brake model)Repair or replace.
Disturbed front wheel alignmentAdjust as prescribed.
Unmatched tires on same axleTires with approximately the same amount of
tread should be used on the same axle.
Restricted brake pipes or hosesCheck for soft hoses and damaged lines.
Replace with new hoses and new double-
walled steel brake tubing.
Malfunctioning caliper assemblyCheck for stuck or sluggish pistons and proper
lubrication of caliper slide pin.
Caliper should slide.
Loose suspension partsCheck all suspension mountings.
Loose calipersCheck and torque bolts to specifications.
Noise (high pitched
squeak without brake
applied)Contact wear indicator to brake discReplace brake pad.
Worn rear brake shoeReplace brake shoe.
Excessive pedal travel
(Pedal stroke too large)Partial brake system failureCheck brake systems and repair as necessary.
Brake fluid leakingRepair the leaking point, and bleed air.
Air in system (soft / spongy pedal)Bleed system.
Rear brake system not adjusted
(malfunctioning auto adjusting
mechanism)Repair auto adjusting mechanism.
Adjust rear brakes.
Bent brake shoesReplace brake shoes.
Brake locked Malfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-6
Dragging brakes (Without
a very light drag is
present in all brakes
immediately after pedal is
released)Master cylinder pistons not returning
correctlyReplace master cylinder.
Restricted brake pipes or hosesCheck for soft hoses or damaged pipes and
replace with new hoses and/or new brake
piping.
Incorrect parking brake adjustment on
rear brakesCheck and adjust to correct specifications.
Weakened or broken return springs in
the drum brakeReplace.
Sluggish parking brake cables or linkageRepair or replace.
Wheel cylinder or caliper piston stickingRepair as necessary.
Badly worn piston seal in caliperReplace piston seal.
Improper brake pedal free heightCheck brake pedal free height.
Pedal pulsation (Pedal
pulsates when depressed
for braking)Damaged wheel bearingsReplace wheel bearings.
Distorted steering knuckle or rear wheel
spindle or rear axle shaftReplace knuckle or rear wheel spindle or rear
axle shaft.
Excessive disc lateral runoutCheck per instructions. If not within
specifications, replace or machine disc.
Rear drums out of roundCheck runout.
Repair or replace drum as necessary.
Braking noiseGlazed brake pad and/or brake shoeRepair or replace brake pad and/or brake
shoe.
Worn or distorted brake shoeReplace brake shoe.
Loose front wheel bearingsReplace wheel hub.
Distorted backing plates or loose
mounting boltsReplace or retighten securing bolts.
Contact wear indicator to brake discReplace brake pads.
Brake warning light lights
after engine startParking brake appliedRelease parking brake and check that brake
warning light turns off.
Insufficient amount of brake fluidInvestigate leaky point, correct it and add
brake fluid.
Brake fluid leakingInvestigate leaky point, correct it and add
brake fluid.
Brake warning light circuit faultyRepair circuit.
Malfunctioning EBD systemCheck system referring to “EBD Warning Light
(Brake Warning Light) Comes ON Steady in
Section 4E”.
Brake warning light turns
on when brake is appliedBrake fluid leakingInvestigate leaky point, correct it and add
brake fluid.
Insufficient amount of brake fluidInvestigate leaky point, correct it and add
brake fluid.
Brake warning light fails
to turn on even when
parking brake is appliedBrake warning light circuit faultyReplace bulb or repair circuit.
ABS warning light turns
on after engine startMalfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light turns
on when brake is appliedMalfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light after
ignition switch has turned
ON Bulb burnt outReplace bulb.
Malfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light flashesNew ABS hydraulic unit / control module
assembly installed.Perform “ABS Hydraulic Unit Operation Check
in Section 4E”. Condition Possible cause Correction / Reference Item