bearing SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-41
09940–54910 09940–54950
Front fork oil seal install
driverBearing installer attachment
))
09941–64511 09942–15511
Bearing and oil seal remover
(30 mm Min.)Sliding hammer
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09944–96011 09952–06010
Bearing outer race remover Dial gauge plate No.1
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Downloaded from www.Manualslib.com manuals search engine 5C-1 Clutch:
Transmission / Transaxle
Clutch
General Description
Clutch (Hydraulic Type) ConstructionS6RW0D5301001
The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type,
which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward.
The disc, carrying four torsional coil springs, is positioned on the transaxle input shaft with an involute spline fit.
The clutch cover is secured to the flywheel, and carries the diaphragm spring in such a way that the peripheral edge
part of the spring pushes on the pressure plate against the flywheel (with the disc in between), when the clutch release
bearing (incorporated in clutch operating cylinder) is held back. This is the engaged condition of the clutch.
Depressing the clutch pedal causes the release bearing (incorporated in clutch operating cylinder) to advance and
pushes on the tips of the tapered fingers of the diaphragm spring. When this happens, the diaphragm spring pulls the
pressure plate away from the flywheel, thereby interrupting the flow of drive from flywheel through clutch disc to
transaxle input shaft. Clutch fluid is supplied from brake fluid reservoir. Clutch fluid level can be checked by brake fluid
level of brake fluid reservoir.
I5RW0A530001-01
1. Crankshaft 4. Pressure plate 7. Operating cylinder assembly
2. Flywheel 5. Clutch cover 8. Input shaft bearing
3. Clutch disc 6. Diaphragm spring 9. Input shaft

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-2
Diagnostic Information and Procedures
Clutch System Symptom DiagnosisS6RW0D5304001
Condition Possible cause Correction / Reference Item
SlippingImproper clutch pedal free travelBleed air or replace master cylinder.
Worn or oily clutch disc facingReplace disc.
Warped disc, pressure plate or flywheel
surfaceReplace disc, clutch cover or flywheel.
Weakened diaphragm springReplace clutch cover.
Master cylinder piston or seal cup not
returningReplace master cylinder.
Dragging clutchImproper clutch pedal free travelBleed air or replace master cylinder.
Weakened diaphragm spring, or worn
spring tipReplace clutch cover.
Rusted input shaft splinesLubricate.
Damaged or worn splines of transaxle
input shaftReplace input shaft.
Excessively wobbly clutch discReplace disc.
Clutch facings broken or dirty with oilReplace disc.
Fluid leakageRepair or replace.
Clutch vibrationGlazed (glass-like) clutch facingsRepair or replace disc.
Clutch facings dirty with oilReplace disc.
Release bearing slides unsmoothlyReplace clutch operating cylinder assembly.
Wobbly clutch disc, or poor facing
contactReplace disc.
Weakened torsion springs in clutch discReplace disc.
Clutch disc rivets looseReplace disc.
Distorted pressure plate or flywheel
surfaceReplace clutch cover or flywheel.
Weakened engine mountingReplace engine mounting.
Loosened engine mounting bolt or nutRetighten engine mounting bolt or nut.
Noisy clutchWorn or broken release bearingReplace clutch operating cylinder assembly.
Input shaft front bearing worn downReplace input shaft bearing.
Excessive rattle of clutch disc hubReplace disc.
Cracked clutch discReplace disc.
Pressure plate and diaphragm spring
rattlingReplace clutch cover.
Grabbing clutchClutch disc facings soaked with oilReplace disc.
Clutch disc facings excessively wornReplace disc.
Rivet heads showing out of facingReplace disc.
Weakened torsion springsReplace disc.

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-6
Installation
1) Install clutch operating cylinder assembly (2) to
transaxle. Tighten new mounting bolts to specified
torque.
Tightening torque
Clutch operating cylinder assembly mounting
bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
2) Connect clutch fluid pipe (4) to clutch operating
cylinder assembly temporarily.
3) Install clutch pipe joint sleeve (3) to transaxle
securely and then tighten clutch fluid pipe flare nut
(1) to specified torque.
Tightening torque
Clutch fluid pipe flare nut (b): 16 N·m (1.6 kgf-
m, 11.5 lb-ft)4) Remount transaxle assembly referring to “Manual
Transaxle Unit Dismounting and Remounting in
Section 5B”.
5) Bleed air from system and check clutch pedal free
travel. Refer to “Air Bleeding of Clutch System” and
“Clutch Pedal Inspection”.
Clutch Operating Cylinder Assembly InspectionS6RW0D5306013
Check clutch fluid leakage, spring for damage and
bearing for smooth rotation. If malfunction is found,
replace clutch operating cylinder assembly.
Clutch Cover, Clutch Disc and Flywheel ComponentsS6RW0D5306010
3
4
(a)
2
1, (b)
I5RW0A530009-01
I5RW0B530005-03
2
1
3(a)
6
4
5
(b)
I6RW0C530001-01
1. Clutch cover 4. Flywheel : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
2. Clutch disc 5. Input shaft bearing : 70 N⋅m (7.0 kgf-m, 51.0 lb-ft)
3. Clutch cover bolt 6. Flywheel bolt : Do not reuse.

Downloaded from www.Manualslib.com manuals search engine 5C-7 Clutch:
Clutch Cover, Clutch Disc and Flywheel
Removal and Installation
S6RW0D5306011
Removal
1) Dismount manual transaxle assembly referring to
“Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
2) Hold flywheel with special tool and remove clutch
cover bolts (1), clutch cover (2) and clutch disc.
Special tool
(A): 09924–17811
3) Pull out input shaft bearing (1) from flywheel (2), use
the following special tool if necessary.
Special tool
(A): 09921–26020
(B): 09930–301044) Remove flywheel (1) from crankshaft using special
tool.
Special tool
(A): 09924–17810
Installation
NOTE
Before assembling, make sure that flywheel
surface and pressure plate surface have
been cleaned and dried thoroughly.

1) Install flywheel (2) to crankshaft and tighten new
bolts (1) to specification.
Special tool
(A): 09924–17810
Tightening torque
Flywheel bolt (a): 70 N·m (7.0 kgf-m, 51.0 lb-ft)
I4RS0A530014-01
I2RH01530023-01
I4RS0A530015-02
I2RH01530024-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-8
2) Using special tool, install input shaft bearing to
flywheel (1).
Special tool
(B): 09925–98210
3) Aligning clutch disc to flywheel center using special
tool, install clutch cover (1) and bolts (2). Then
tighten bolts (2) to specification.
NOTE
• While tightening clutch cover bolts,
compress clutch disc with special tool
(clutch center guide) by hand so that disc
is centered.
• Tighten cover bolts little by little evenly in
diagonal order.

Special tool
(A): 09924–17811
(B): 09923–36320
Tightening torque
Clutch cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)4) Slightly apply grease to input shaft (1), then join
manual transaxle assembly with engine referring to
“Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
“A”: Grease 99000–25210 (SUZUKI Super
Grease I)
NOTE
When inserting transaxle input shaft to clutch
disc, turn crankshaft little by little to match
the splines.

Clutch Cover, Clutch Disc and Flywheel
Inspection
S6RW0D5306012
Input Shaft Bearing
Check bearing (1) for smooth rotation and replace it if
abnormality is found.
I4RS0A530016-01
I4RS0A530017-01
1
“A”I5RW0A530013-01
I3RM0A530014-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-10
Special Tools and Equipment
Recommended Service MaterialS6RW0D5308001
Special ToolS6RW0D5308002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Silicone Grease P/No.: 99000–25100)
SUZUKI Super Grease I P/No.: 99000–25210)
09921–26020 09923–36320
Bearing remover Clutch center guide (15 mm)
))
09924–17810 09924–17811
Flywheel holder (drive plate
stopper)Flywheel holder
) / )) / )
09925–98210 09930–30104
Input shaft bearing installer Sliding shaft
))

Downloaded from www.Manualslib.com manuals search engine 6A-1 Steering General Diagnosis:
Ste eri ng
Steering General Diagnosis
Precautions
Precautions for Steering DiagnosisS6RW0D6100001
Since the problems in steering involve several systems, they must all be considered when diagnosing a complaint. To
avoid using the wrong symptom, always road test the vehicle first. Proceed with the following preliminary inspection
and correct any defects which are found.
1) Inspect tires for proper pressure and uneven wear.
2) Raise vehicle on a hoist and inspect steering system for loose or damaged parts.
3) Spin front wheels. Inspect for out-of-round tires, out-of-balance tires, bent rims, loosen and/or rough wheel
bearings.
Diagnostic Information and Procedures
Steering Symptom DiagnosisS6RW0D6104001
Condition Possible cause Correction / Reference Item
Hard steeringTire not adequately inflatedInflate tires to proper pressure.
Malfunction of power steering systemCheck and correct. Refer to “P/S System
Symptom Diagnosis in Section 6C”.
Bind in tie-rod end ball studs or lower
ball jointsReplace tie-rod end or front suspension control
arm.
Disturbed front wheel alignmentCheck and adjust front wheel alignment.
Bind in steering columnRepair or replace steering column assembly.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Too much play in steeringWheel bearings wornReplace wheel bearing.
Loose steering gear case boltsTighten gear case bolts.
Faulty steering gear case assemblyReplace steering gear case assembly.
Worn steering shaft jointsReplace steering lower shaft assembly.
Worn tie-rod ends or tie-rod inside ball
jointsReplace tie-rod end or tie-rod.
Worn lower ball jointsReplace front suspension control arm.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Poor return abilityBind in tie-rod end ball studsReplace tie-rod end.
Bind in ball jointsReplace front suspension control arm.
Bind in steering columnReplace steering column assembly.
Disturbed front end alignmentCheck and adjust front end alignment.
Faulty steering gear case assemblyReplace steering gear case assembly.
Tires not adequately inflatedAdjust tire pressure.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Rack and pinion noise
(Rattle or chuckle)Loose steering gear case boltsTighten steering gear case bolts.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Faulty steering gear case assemblyReplace steering gear case assembly.
Broken or otherwise damaged wheel
bearing(s)Replace wheel bearing(s).
Wander or poor steering
stabilityMismatched or uneven tiresReplace or inflate tires to proper pressure.
Loosen ball joints and tie-rod endsReplace suspension control arm or tie-rod end.
Faulty struts or mountingsReplace strut or repair mounting.
Loose stabilizer barTighten or replace stabilizer bar or bush.
Broken or sagging coil springsReplace coil spring.
Rack and pinion adjustmentCheck and adjustment rack and pinion torque.
Disturbed front wheel alignmentCheck and adjust front wheel alignment.
Faulty steering gear case assemblyReplace steering gear case assembly.

Downloaded from www.Manualslib.com manuals search engine Steering General Diagnosis: 6A-2
Steering System InspectionS6RW0D6104002
Check steering system referring to the following items.Erratic steering when
brakingWorn wheel bearingsReplace wheel bearing.
Broken or sagging coil springsReplace coil spring.
Wheel tires are inflated unequallyInflate tires to proper pressure.
Disturbed front wheel alignmentCheck and adjust front wheel alignment.
Brakes not working in unisonCheck and repair brake system.
Leaking wheel cylinder or caliperRepair or replace wheel cylinder or caliper.
Warped discsReplace brake disc.
Badly worn brake liningsReplace brake shoe lining.
Drum is out of round in some brakesReplace brake drum.
Defective wheel cylindersReplace or repair wheel cylinder. Condition Possible cause Correction / Reference Item
Inspection Item Referring section
Steering wheel Play, rattle “Steering Wheel Play Check in Section 6C”
Tie-rod end Looseness and damage “Tie-Rod End Inspection in Section 6C”
Wheel alignment “Front Wheel Alignment Inspection and Adjustment in
Section 2B”
Tie-rod end boot Damage “Tie-Rod End Boot On-Vehicle Inspection in Section 6C”
Steering rack boot Damage “Steering Rack Boot Inspection in Section 6C”
Steering shaft joint Rattle and damage “Steering Shaft Joint On-Vehicle Inspection in Section 6C”
EPS system Operation “EPS System Check in Section 6C”

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-6
3) Install steering column upper cover (1) and lower
cover (2).
CAUTION!
When installing covers, be careful so that
each lead wire is not caught between covers.
Otherwise, each lead wire is damaged.

4) Install steering wheel to steering column. Refer to
“Steering Wheel Removal and Installation”.
5) Connect negative (–) cable to battery.
6) Enable air bag system referring to “Enabling Air Bag
System in Section 8B”.
Centering Contact Coil Cable AssemblyS6RW0D6206004
1) Check that vehicle’s wheels (front tires) are set at
straight-ahead position.
2) Check that ignition switch is at LOCK position.
3) Turn contact coil counterclockwise slowly with a light
force till contact coil will not turn any further.
NOTE
Contact coil can turn about 5 turns at the
maximum, that is, if it is at the center
position, can turn about two and a half turns
both clockwise and counterclockwise.

4) From the position where contact coil became unable
to turn any further (it stopped), turn it back clockwise
about two and a half rotations and align center mark
with alignment mark (1).
Contact Coil Cable Assembly InspectionS6RW0D6206005
Refer to “Contact Coil Cable and Its Circuit Check in
Section 8B”.
Steering Column Removal and InstallationS6RW0D6206008
CAUTION!
Once the steering column is removed from
the vehicle, the column is extremely
susceptible to damage.
• Dropping the column assembly on its end
could collapse the steering shaft or loosen
the plastic shear pins which maintain
column length.
• Leaning on the column assembly could
cause it to bend or deform.
Any of the damage could impair the column’s
collapsible design.
Steering column mounting nuts should not
be loosened with steering shaft joint upper
side bolt tightened as this could cause
damage to shaft joint bearing.

NOTE
When servicing steering column or any
column-mounted component, remove
steering wheel. But when removing steering
column simply to gain access to instrument
panel components, leave steering wheel
installed on steering column.

3. Standard screw 4. Tapping screw
2
1
3
4
I6RW0B620003-01
I4RS0A620012-01
1
I4RS0A620013-01