Water pump SUZUKI SX4 2006 1.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-2
Schematic and Routing Diagram
Coolant CirculationS6RW0D1602001
While the engine is warmed up (thermostat closed), coolant circulates as follows.
When coolant is warmed up to normal temperature and the thermostat opens, coolant passes through the radiator
core to be cooled as follows.
7
5
6
4
3
2
81
I5RW0C160001-02
1. Radiator inlet hose 3. Thermostat 5. Throttle body 7. Heater core
2. Radiator outlet hose 4. Water pump 6. Engine 8. Radiator
7
5
6
4
3
2
81
I5RW0C160002-02
1. Radiator inlet hose 3. Thermostat 5. Throttle body 7. Heater core
2. Radiator outlet hose 4. Water pump 6. Engine 8. Radiator

Downloaded from www.Manualslib.com manuals search engine 1F-3 Engine Cooling System:
Diagnostic Information and Procedures
Engine Cooling Symptom DiagnosisS6RW0D1604001
Condition Possible cause Correction / Reference Item
Engine overheats
(Radiator fan operates)Loose or broken water pump beltAdjust or replace.
Not enough coolantCheck coolant level and add as necessary.
Faulty thermostatReplace.
Faulty water pumpReplace.
Dirty or bent radiator finsClean or remedy.
Coolant leakage on cooling systemRepair.
Clogged radiatorCheck and replace radiator as necessary.
Faulty radiator capReplace.
Dragging brakesAdjust brake.
Slipping clutchReplace.
Poor charge batteryCheck and replace as necessary.
Poor generation generatorCheck and repair.
ECT sensor faultyCheck and replace as necessary.
Radiator fan motor faultyCheck and replace as necessary.
ECM faultyCheck and replace as necessary.
Wiring or grounding faultyRepair as necessary.
Equipped with too much electric load
part(s)Dismount.
Engine overheats
(Radiator fan does not
operate)Fuse blownCheck fuse of relay/fuse box and check for
short circuit to ground.
Radiator cooling fan relay faultyCheck and replace as necessary.
ECT sensor faultyCheck and replace as necessary.
Radiator cooling fan motor faultyCheck and replace as necessary.
Wiring or grounding faultyRepair as necessary.
ECM faultyCheck and replace as necessary.

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Repair Instructions
Cooling System ComponentsS6RW0D1606001
I5RW0C160012-01
1. Radiator 11. Thermostat case water outlet pipe 21. Heater outlet No.1 hose
2. Reservoir 12. Thermostat case 22. Radiator cooling fan assembly
For disassembly and reassembly, refer
to “Radiator Cooling Fan Disassembly
and Reassembly”.
3. Radiator cap 13. Thermostat 23. To cylinder head
4. Drain plug 14. Thermostat cap 24. To water pump
5. Radiator outlet hose 15. Water bypass No.1 hose 25. To heater core
6. Radiator inlet hose 16. Water inlet No.1 pipe : 15 N⋅m (1.5 kgf-m, 11.0 lb-ft)
7. Water outlet cap 17. Water inlet hose : 33 N⋅m (3.3 kgf-m, 24.0 lb-ft)
8. ECT sensor 18. Water inlet No.2 pipe : Do not reuse.
9. Water outlet cap gasket 19. Radiator support bracket bolt
10. O-ring 20. Heater inlet hose

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Water Pump / Generator Drive Belt Tension
Inspection and Adjustment
S6RW0D1606014
WARNING!
• Disconnect negative cable at battery
before checking and adjusting belt
tension.
• To help avoid danger of being burned, do
not remove radiator cap while engine and
radiator are still hot. Scalding fluid and
steam can be blown out under pressure if
cap is taken off too soon.

1) Inspect belt for cracks, cuts, deformation, wear and
cleanliness. If it is necessary to replace belt, refer to
“Water Pump / Generator Drive Belt Removal and
Installation”.
2) Check belt for tension. Belt is in proper tension when
it deflects the following specification under thumb
pressure (about 100 N (10kgf, 22 lbs.).
If belt tension is out of specification, go to next steps.
Water pump / generator drive belt tension
“a”: 4.5 – 5.5 mm (0.18 – 0.22 in.) as deflection /
100 N (10kgf, 22lbs)
NOTE
When replacing belt with a new one, adjust
belt tension to 4.0 – 4.5 mm (0.16 – 0.18 in.).

3) After loosening generator bracket bolts (2) and pivot
bolt (3), adjust belt tension to specification described
at step 2) by loosening / tightening generator adjust
bolt (1).
4) Tighten generator bracket bolts and pivot bolt as
specified torque.
Tightening torque
Generator bracket bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Generator pivot bolt (b): 50 N·m (5.0 kgf-m, 36.0
lb-ft)5) Check belt tension for specification after turning
crankshaft two rotations clockwise.
6) Tighten generator adjusting bolt (1) as specified
torque.
Tightening torque
Generator adjusting bolt (c): Tighten 7.0 N⋅m
(0.7 kgf-m, 5.0 lb-ft) by the specified procedure.
7) Connect negative cable at battery.
Water Pump / Generator Drive Belt Removal and
Installation
S6RW0D1606015
Removal
1) Disconnect negative cable at battery.
2) If vehicle equipped with A/C, remove compressor
drive belt before removing water pump belt (1).
Refer to “Compressor Drive Belt Removal and
Installation in Section 7B” or “Compressor Drive Belt
Removal and Installation in Section 7B”.
3) Loosen generator bracket bolts (2) and generator
pivot bolt (3).
4) Loosen generator adjusting bolt (4), and then
remove water pump belt.
a
I5RW0C160006-01
1, (c)
2, (a)
3, (b)
I5RW0C160007-01
4
23
1
I5RW0C160008-01

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Installation
1) Install belt (1) to water pump pulley (2), crankshaft
pulley (3) and generator pulley (4).
2) Adjust belt tension referring to “Water Pump /
Generator Drive Belt Tension Inspection and
Adjustment”.
3) If vehicle equipped with A/C, install compressor drive
belt referring to “Compressor Drive Belt Removal
and Installation in Section 7B” or “Compressor Drive
Belt Removal and Installation in Section 7B”.
4) Connect negative cable at battery.
Water Pump Removal and InstallationS6RW0D1606016
Removal
1) Disconnect negative cable at battery.
2) Drain coolant.
3) Remove water pump / generator drive belt referring
to “Water Pump / Generator Drive Belt Removal and
Installation”.
4) Remove water pump pulley.
5) Remove water pump assembly (1).Installation
1) Apply sealant to mating surface of water pump (1) as
shown in figure.
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
Sealant quantity (to mating surface of water
pump)
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
2) Install water pump assembly (1) to cylinder block
and tighten bolts and nut to specified torque.
Tightening torque
Water pump bolt and nut (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
3) Install water pump pulley.
4) Install water pump / generator drive belt referring to
“Water Pump / Generator Drive Belt Removal and
Installation”.
5) Install A/C compressor belt referring to “Compressor
Drive Belt Removal and Installation in Section 7B” or
“Compressor Drive Belt Removal and Installation in
Section 7B”.
6) Refill cooling system referring to Step 7) to 17) of
“Cooling System Flush and Refill”.
7) Connect negative cable at battery.
8) Check each part for leakage.
2
1
34I5RW0C160009-01
I5RW0C160011-01
I3RM0A160016-01
I5RW0C160010-01

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Water Pump InspectionS6RW0D1606017
CAUTION!
Do not disassemble water pump.
If any repair is required on pump, replace it
as assembly.

Rotate water pump by hand to check for smooth
operation. If pump does not rotate smoothly or makes
abnormal noise, replace it.
Specifications
Tightening Torque SpecificationsS6RW0D1607001
NOTE
The specified tightening torque is also described in the following.
“Cooling System 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 MaterialS6RW0D1608001
I2RH0B160019-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Radiator support bracket bolt 33 3.3 24.0)
Generator bracket bolt 25 2.5 18.0)
Generator pivot bolt 50 5.0 36.0)
Generator adjusting bolt Tighten 7.0 N⋅m (0.7 kgf-m, 5.0 lb-ft) by the
specified procedure.)
Water pump bolt and nut 25 2.5 18.0)
Material SUZUKI recommended product or Specification Note
Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250)

Downloaded from www.Manualslib.com manuals search engine 1G-15 Fuel System:
Fuel Tank Purging ProcedureS6RW0D1706013
WARNING!
• Before starting the following procedure, be
sure to observe “Precautions on Fuel
System Service” in order to reduce the risk
of fire and personal injury.
• This purging procedure will not remove all
fuel vapor.
Do not attempt any repair on tank using
heat of flame as an explosion resulting in
personal injury could occur.

CAUTION!
Never remain water in fuel tank after washing,
or fuel tank inside will get corrosion.

The following procedure are used for purging fuel tank.
1) After removing fuel tank, remove all hoses, pipes
and fuel pump assembly from fuel tank.
2) Drain all remaining fuel from tank.
3) Place fuel tank to flushing area.
4) Fill tank with warm water or tap water, and agitate
vigorously and drain. Repeat this washing until
inside of tank is clean. Replace tank if its inside is
rusty.
5) Completely flush out remaining water after washing.
6) Be sure to dry fuel tank assembly thoroughly out of
direct sunlight after washing.
Fuel Pump On-Vehicle InspectionS6RW0D1706014
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

NOTE
The fuel pressure regulator is incorporated
with the fuel pump assembly so individual
inspection of it is impossible.

1) Remove filler cap and turn ON ignition switch (2).
Then fuel pump operating sound should be heard
from fuel filler (1) for about 2 seconds and stop. Be
sure to reinstall fuel filler cap after checking.
If the check result is not satisfactory, go to “Fuel
Pump and Its Circuit Check in Section 1A”.2) Turn OFF ignition switch and leave over 10 minutes
as it is.
3) Fuel pressure should be felt at fuel feed hose (1) for
about 2 seconds after ignition switch ON.
If fuel pressure is not felt, go to “Fuel Pressure
Check in Section 1A”.
Fuel Pump Assembly Removal and InstallationS6RW0D1706015
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

Removal
1) Remove fuel tank from vehicle referring to “Fuel
Tank Removal and Installation”.
2) Disconnect fuel pipe (1) from fuel pump assembly (2)
referring to “Fuel Hose Disconnecting and
Reconnecting”.
3) Remove fuel pump assembly and earth bracket from
fuel tank.
IVSY01170013-01
1I5RW0A170019-01
1
2
I7RW01170011-01

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1) Set parking brake and place automatic transaxle in
PARK (NEUTRAL on manual transaxle). Turn off
ignition, turn off lights and all other electrical loads.
2) Check electrolyte level. If it is below low level line,
add distilled water.
3) Attach end of one jumper cable to positive terminal
of booster battery and the other end of the same
cable to positive terminal of discharged battery. (Use
12-volt battery only to jump start engine).
4) Attach one end of the remaining negative cable to
negative terminal of booster battery, and the other
end to a solid engine ground (such as exhaust
manifold) at least 45 cm (18 in.) away from battery of
vehicle being started.
5) Start engine of vehicle with booster battery and turn
off electrical accessories. Then start engine of the
vehicle with discharged battery.
6) Disconnect jumper cables in the exact reverse order.
With Charging Equipment
CAUTION!
When jump starting engine with charging
equipment, be sure equipment used is 12-
volt and negative ground. Do not use 24-volt
charging equipment. Using such equipment
can cause serious damage to electrical
system or electronic parts.

Battery Dismounting and RemountingS6RW0D1A06002
Dismounting
1) Disconnect negative cable (3).
2) Disconnect positive cable (2).
3) Remove retainer (4).
4) Remove battery (1).
Handling
When handling battery, the following safety precautions
should be followed:
• Hydrogen gas is produced by battery. A flame or
spark near battery may cause the gas to ignite.
• Battery fluid is highly acidic. Avoid spilling on clothing
or other fabric. Any spilled electrolyte should be
flushed with large quantity of water and cleaned
immediately.Remounting
1) Reverse removal procedure.
2) Tighten battery cables securely.
NOTE
Check to be sure that ground cable has
enough clearance to hood panel by terminal.

Water Pump / Generator Drive Belt Tension
Inspection and Adjustment
S6RW0D1A06006
WARNING!
• Disconnect negative cable at battery
before checking and adjusting belt
tension.
• To help avoid danger of being burned, do
not remove radiator cap while engine and
radiator are still hot. Scalding fluid and
steam can be blown out under pressure if
cap is taken off too soon.

1) Inspect belt for cracks, cuts, deformation, wear and
cleanliness. If it is necessary to replace belt, refer to
“Water Pump / Generator Drive Belt Removal and
Installation”.
2) Check belt for tension. Belt is in proper tension when
it deflects the following specification under thumb
pressure (about 10kg or 22 lb.).
If belt tension is out of specification, go to next steps.
Water pump / generator drive belt tension
“a”
Existing belt: 4.5 – 5.5 mm (0.18 – 0.22 in.) as
deflection / 10 kg (22 lbs)
New belt: 4.0 – 4.5mm (0.16 – 0.18 in.) as
deflection / 10 kg (22 lbs)
1. Battery 4. Retainer
2. Positive cable 5. Nut
3. Negative cable
21
4
3
5I7RW011A0005-01

Downloaded from www.Manualslib.com manuals search engine 1J-8 Charging System:
3) After loosening generator bracket bolts (2) and pivot
bolt (3), adjust belt tension to specification described
at step 2) by loosening / tightening generator adjust
bolt (1).
4) Tighten generator bracket bolts and pivot bolt as
specified torque.
Tightening torque
Generator bracket bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Generator pivot bolt (b): 50 N·m (5.0 kgf-m, 36.0
lb-ft)
5) Check belt tension for specification after turning
crankshaft two rotations clockwise.
6) Tighten generator adjusting bolt (1) as specified
torque.
Tightening torque
Generator adjusting bolt (c): Tighten 7.0 N·m (
0.7 kgf-m, 5.0 lb-ft) by the specified procedure.
7) Connect negative cable at battery.
Water Pump / Generator Drive Belt Removal and
Installation
S6RW0D1A06007
Removal
1) Disconnect negative cable at battery.
2) If vehicle equipped with A/C, remove compressor
drive belt before removing water pump belt (1).
Refer to “Compressor Drive Belt Removal and
Installation in Section 7B” or “Compressor Drive Belt
Removal and Installation in Section 7B”.
3) Loosen generator bracket bolts (2) and generator
pivot bolt (3).
4) Loosen generator adjusting bolt (4), and then
remove water pump belt.
installation
1) Install belt (1) to water pump pulley (2), crankshaft
pulley (3) and generator pulley (4).
2) Adjust belt tension referring to “Water Pump /
Generator Drive Belt Tension Inspection and
Adjustment”.
3) If vehicle equipped with A/C, install compressor drive
belt referring to “Compressor Drive Belt Removal
and Installation in Section 7B” or “Compressor Drive
Belt Removal and Installation in Section 7B”.
4) Connect negative cable at battery.
a
I5RW0C160006-01
1, (c)
2, (a)
3, (b)
I5RW0C160007-01
4
23
1
I5RW0C160008-01
2
1
34I5RW0C160009-01

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Specifications
Item Specifications
Torque converterTy p e
Stall torque ratio3-element, 1-step, 2-phase type (with TCC (lock-up)
mechanism)
1.9 – 2.1
Oil pumpTy p e
Drive systemInternal involute gear type oil pump (non crescent type)
Engine driven
Gear change
deviceType Forward 4-step, reverse 1-step planetary gear type
Shift position“P” range Gear in neutral, output shaft fixed, engine start
“R” range Reverse
“N” range Gear in neutral, engine start
“D” range Forward 1st ↔ 2nd ↔ 3rd ↔ 4th automatic gear
change
“3” rangeForward 1st ↔ 2nd ↔ 3rd ← 4th automatic gear
change
“2” range Forward 1st ↔ 2nd ← 3rd automatic gear change
“L” rangeForward 1st ← 2nd ← 3rd reduction, and fixed at 1st
gear
Gear
ratio1st 2.875 Number of teeth Front sun gear: 24
2nd 1.568 Rear sun gear: 30
3rd 1.000 Long planet pinion: 20
4th (overdrive gear) 0.697 Short planet pinion: 19
Reverse (reverse gear) 2.300 Ring gear: 69
Control elementsWet type multiple-disc clutch... 3 sets
Wet type multiple-disc brake... 3 sets
One-way clutch... 2 sets
Reduction gear ratio 1.023
Final gear reduction ratio 4.277
Lubrication Lubrication system Force feed system by oil pump
Cooling Cooling system Radiator assisted cooling (water-cooled)
Fluid used SUZUKI ATF 3317 or Mobil ATF 3309