SUZUKI SX4 2006 1.G Service Workshop Manual

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 9G-5 Seats:
Specifications
Tightening Torque SpecificationsS6RW0D9707001
NOTE
The specified tightening torque is also described in the following.
“Front Seat Components”
“Rear Seat 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 MaterialS6RW0D9708001
NOTE
Required service material is also described in the following.
“Front Seat Components”
“Rear Seat Components”

Downloaded from www.Manualslib.com manuals search engine Interior Trim: 9H-1
Body, Cab and Accessories
Interior Trim
Repair Instructions
Floor Carpet Removal and InstallationS6RW0D9806001
Removal
1) Remove front seat and rear seat referring to “Front
Seat Removal and Installation in Section 9G” and
“Rear Seat Removal and Installation in Section 9G”.
2) Remove seat belt lower anchor bolts (front and rear).
3) Remove side sill scuffs (1) (front and rear), front
pillar lower trims (2), center pillar inner lower trims
(3), back panel trim (4), rear quarter lower trims (5).4) Remove console box referring to “Console Box
Components”.
5) Remove floor carpet.
Installation
Reverse removal sequence to install front floor carpet,
noting the following instruction.
• For tightening torque of rear seat mounting bolt, refer
to “Rear Seat Components in Section 9G”.
• For tightening torque of front seat mounting bolt, refer
to “Front Seat Components in Section 9G”.
• For tightening torque of seat belt lower anchor bolt,
refer to “Front Seat Belt Components in Section 8A”
and “Rear Seat Belt Components in Section 8A”.
6. Forward
B
C
A
4
C
BC
BB
B
31
B
B
5
B
B
B
CCC
2
1B
B
A1
6
I5RW0A980003-02

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Head Lining Removal and InstallationS6RW0D9806002
WARNING!
Refer to “Air Bag System Service Warning in
Section 00” before starting service work.

Removal
1) Remove sun visor (1).
2) Remove dome lights of front (1) and center (2).3) Remove front pillar upper trims (1) rear side sill
scuffs (2), center pillar inner lower trims (3), center
pillar inner upper trims (4), back panel trim (5), rear
quarter lower trims (6) and rear quarter upper trims
(7).
1
I5RW0A980001-01
12
I5RW0A980002-01
[A]: With curtain air bag [B]: Without curtain air bag
32
4
B
B
B
C
A
A
AB
B
A
B
B
[A] [B]
7
6
BBBA
A
AAA
B
B
B
CCC
5
C
BC
BB
B
11
C
I5RW0A980004-03

Downloaded from www.Manualslib.com manuals search engine Interior Trim: 9H-3
4) Remove assistant grip (1).
5) Remove head lining clips (2) at rear end and remove
head lining (3).Installation
Reverse removal procedure noting the following.
• Fix sun visor clip (1) first and adjust head lining in
position and fix three clips (2) at rear end.
• Tighten sun visor screw to specified torque.
Tightening torque
Sun visor screw (a): 4 N·m (0.4 kgf-m, 3.0 lb-ft)
Console Box ComponentsS6RW0D9806003 4. Clip 5. Flat head driver
“A”4
5
21 1
3“A”“A”
“A”“A”
I7RW01980001-01
2
1
(a)
I5RW0A980006-01
BA
B
A
A
B
AAA
AAA
A
AAAA
A
AA
2
3
1
4
I5RW0A980007-02
1. Console box 2. Front console box garnish 3. Rear console box garnish 4. Console side cover

Downloaded from www.Manualslib.com manuals search engine 9H-4 Interior Trim:
Specifications
Tightening Torque SpecificationsS6RW0D9807001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Sun visor screw 4 0.4 3.0)

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

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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