clock SUZUKI SX4 2006 1.G Service User Guide

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

Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-13
Specifications
Charging System SpecificationsS6RW0D1A07003
Battery
NOTE
The battery used in each vehicle is one of the following two types, depending on specification.

Battery
: 46B24R (40.6AH/5HR), 55B24R (42.5AH/5HR) 12V
Generator
Tightening Torque SpecificationsS6RW0D1A07004
NOTE
The specified tightening torque is also described in the following.
“Generator Dismounting and Remounting”
“Generator Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Battery type 46B24R 55B24R
Rated capacity AH/5HR, 12 Volts 40.6 42.5
Electrolyte L (US / lmp pt.) — 2.8 (5.92 / 4.93)
Type 70 A type
Rated voltage 12 V
Nominal output 70 A
Permissible max. speed 18,000 r/min.
No-load speed 1020 r/min. (rpm)
Regulated voltage 14.2 – 14.8 V (Hi), 12.5 – 13.1 V (Lo)
Exposed brush length Standard: 10.5 mm (0.41 in.)
Limit: 1.5 mm (0.05 in.)
Permissible ambient temperature –30 to 90 °C (–22 to 194 °F)
Polarity Negative ground
Rotation Clockwise viewed from pulley side
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Generator bracket bolt 25 2.5 18.0)
Generator pivot bolt 50 5.0 36.0)
Generator adjusting bolt
Tighten 7.0 0.7 5.0by the specified
procedure. )

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-42
14) Set dial gauge to bevel pinion mounting dummy and
make 0 (zero) adjustment on surface plate.
NOTE
• When setting dial gauge to mounting
dummy, tighten screw lightly. Be careful
not to overtighten it, which will cause
damage to dial gauge.
• With dial gauge set, turn dummy back and
forth by hand a couple of times and attain
accurate 0 (zero) adjustment.
• It is desirable that short pointer indicates
beyond 2 mm when long one is at 0 (zero).

15) Place zero-adjusted mounting dummy (1) and dial
gauge set on pinion dummy (2) and take
measurement between zero position and extended
dial gauge measuring tip.
NOTE
• Repeat turning back and forth of dummy
and measure distance as far as top surface
of pinion dummy accurately.
• When dial gauge measuring tip extends
from 0 (zero) position, pointer turns
counterclockwise.

16) Necessary adjusting shim thickness is the same
value as measured value by dial gauge.
17) Select adjusting shim(s) (2) closest to obtained value
from among the following available sizes and put it in
place and then press-fit rear bearing (1) to bevel
pinion (3).
Available shim thickness
0.30, 0.60, 0.63, 0.66, 0.69, 0.72, 0.75, 0.78, 0.81,
0.84 and 0.87 mm (0.012, 0.023, 0.024, 0.026,
0.027, 0.028, 0.030, 0.031, 0.032, 0.033 and 0.034
in.)
Special tool
(D): 09925–18011
18) With new pinion spacer (2) inserted as shown in
figure, install front bearing (1) to differential carrier
(3).
NOTE
Apply differential oil to front and rear
bearings.

I5RW0A320051-01
1
2
I5RW0A320052-01
Necessary shim thickness
“e”= Dial gauge measured
value “c”
I3RH01322055-01
I5RW0A320053-01

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-14
8) Install transfer output flange (1) by tapping with
plastic hammer and tighten transfer output flange nut
gradually so as rotational torque of bevel pinion to be
in specified value.
NOTE
• If rotational torque of bevel pinion exceeds
specification given in the following,
replace pinion shaft spacers and tighten
flange nut.
• Before taking measurement of rotational
torque, rotate pinion over ten rounds in
advance.

Bevel pinion bearing preload
: 0.5 – 1.3 N⋅m (0.05 – 0.13 kgf-m, 0.35 – 0.95 lb-ft)
Special tool
(A): 09930–40113
9) Caulk transfer output flange nut (1).
Transfer Assembly InspectionS6RW0D3306010
• Check each bearing for smooth rotation, wear or
discoloration
If found abnormal, replace.
• Check oil seal for leakage and its lip for excessive
hardness
If either is found, replace.
• Check transfer case for cracks.
• Check bevel pinion and bevel gears for wear or
cracks.
Bevel Gear Tooth Contact InspectionS6RW0D3306011
1) After cleaning tooth surface of bevel gear (1), paint
them with gear marking compound evenly by using
brush or sponge etc.
NOTE
When applying red lead paste to teeth, be
sure to paint tooth surfaces uniformly. The
paste must not be too dry or too fluid.

2) Install transfer output retainer assembly referring to
“Transfer Assembly Disassembly and Reassembly”.
3) Turn transfer output flange clockwise and
counterclockwise repeatedly, and remove transfer
output retainer assembly and bevel gear shims from
transfer assembly.
2. Torque wrench
(A)1
2
I5RW0A330043-01
1
I5RW0A330044-01
I3RH01332043-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-8
Brake Fluid Level InspectionS6RW0D4106004
CAUTION!
Do not use shock absorber fluid or any other
fluid which contains mineral oil. Do not use a
container which has been used for mineral oil
or a container which is wet from water.
Mineral oil will cause swelling and distortion
of rubber parts in hydraulic brake system and
water mixed into brake fluid will lower fluid
boiling point. Keep all fluid containers
capped to prevent contamination.

NOTE
Be sure to use particular brake fluid either as
indicated on reservoir cap of that vehicle or
recommended in owner’s manual which
comes along with that vehicle. Use of any
other fluid is strictly prohibited.
Fluid level should be between MIN and MAX
lines marked on reservoir.
When brake warning light lights sometimes
during driving, replenish fluid to MAX level.
When fluid decreases quickly, inspect brake
system for leakage. Correct leaky points and
then refill to specified level.

1) Check master cylinder, reservoir and reservoir hose
(if equipped) for crack, damage and brake fluid
leakage. If any faulty condition exists, correct or
replace.
2) Check that brake fluid level is between MAX (1) and
MIN marks (2) on reservoir.
Brake Light Switch AdjustmentS6RW0D4106005
Adjustment should be made as follows. Pull up brake
pedal toward you and while holding it there, adjust
switch position so that clearance between end of thread
and brake pedal is as specified. Then lock it by turning
clockwise.
Clearance between brake pedal and brake light
switch
“a”: 0.5 – 1.5 mm (0.02 – 0.05 in.)
Air Bleeding of Brake SystemS6RW0D4106006
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

Bleeding operation is necessary to remove air whenever
it entered hydraulic brake system.
Hydraulic lines of brake system are based on the
diagonal split system. When a brake pipe or hose was
disconnected at the wheel, bleeding operation must be
performed at both ends of the line of the removed pipe or
hose. When any joint part of the master cylinder of other
joint part between the master cylinder and each brake
(wheel) was removed, the hydraulic brake system must
be bled at all 4 wheel brakes.
NOTE
Perform bleeding operation starting with rear
brake caliper or wheel cylinder farthest from
master cylinder and then at front caliper of
the same brake line. Do the same on the
other brake line.

1
2
I7RW01410004-01
1. Right front brake caliper 3. Right rear wheel cylinder
2. Left front brake caliper 4. Left rear wheel cylinder
I5RW0A410005-01
I7RW01410005-01

Downloaded from www.Manualslib.com manuals search engine 5A-6 Automatic Transmission/Transaxle:
Clutch / Brake / Planetary Gear Function of Automatic TransaxleS6RW0D5101002
Functions
12
4
3 5 6 7
89
1011
1213
14
15 16 17
18
19
I4RS0A510001-01
1. Input shaft and intermediate shaft 8. One-way No.2 clutch 15. Front sun gear
2. Direct clutch 9. 2nd brake 16. Rear sun gear
3. Reduction drive gear 10. One-way No.1 clutch 17. Final drive gear
4. Planet carrier 11. O/D and 2nd coast brake 18. Reduction driven gear
5. Short planet pinion 12. Reverse clutch 19. Final driven gear
6. Long planet pinion 13. Forward clutch
7. 1st and reverse brake 14. Ring gear
Part name Function
Forward clutch Meshes intermediate shaft and front sun gear
Direct clutch Meshes input shaft and planet carrier
Reverse clutch Meshes intermediate shaft and rear sun gear
O/D and 2nd coast brake Fixes rear sun gear
2nd brake Fixes rear sun gear
1st and reverse brake Fixes planet carrier
One-way No.1 clutch Prevents rear sun gear from turning counterclockwise
One-way No.2 clutch Prevents planet carrier from turning counterclockwise

Downloaded from www.Manualslib.com manuals search engine 5A-112 Automatic Transmission/Transaxle:
53) Remove 2nd brake piston assembly (1).
54) Remove 2nd brake return spring subassembly (2).
55) Remove 2nd brake separator plates (1), discs (2)
and retaining plate (3).
56) Remove brake drum gasket (1).
57) Remove one-way clutch outer race retainer (1).58) Check one-way clutch No.2 as follows.
• Ensure planetary carrier (1) rotates only in
counterclockwise direction “A”, never in clockwise
direction “B”.
• If the planetary carrier rotates both ways or does
not rotate either way, one-way clutch No.2
assembly will need to be replaced with new one-
way clutch No.2 assembly.
59) Remove one-way clutch No.2 assembly (1).
60) Remove planetary gear assembly (1).
1
2
I4RS0A510038-01
I2RH0B510127-01
I2RH0B510128-01
I2RH0B510129-01
I2RH0B510130-01
1
I4RS0A510039-01
I2RH0B510132-01

Downloaded from www.Manualslib.com manuals search engine 5A-148 Automatic Transmission/Transaxle:
20) Check for correct installation of planetary gear
assembly as follows.
Measure the distance “a” by using micrometer
caliper (1) and straightedge (2). If measured value is
out of specification, remove planetary gear assembly
and reinstall it properly.
Distance between planetary gear assembly and
mating surface of transaxle case
“a”: More than 49.9 m (1.965 in.)
21) Apply A/T fluid to one-way clutch No.2 assembly (1),
then install it to planetary gear assembly. After that,
ensure that planetary carrier rotates only in
counterclockwise direction “A”, not in clockwise
direction “B”.22) Install one-way clutch outer race retainer (1).
23) Apply A/T fluid to new brake drum gasket (1), then
install it to transaxle case.
24) Apply A/T fluid to 2nd brake retaining plate (1), discs
(2) and separator plates (3), then install them to
transaxle case.
25) Install 2nd brake return spring subassembly (1) to
transaxle case.
“a”
“a”
2
1
I2RH0B510276-01
I2RH0B510277-01
I2RH0B510278-01
I2RH0B510279-01
2
3
1
I2RH0B510280-01
1
I2RH0B510281-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-151
39) After applying A/T fluid to intermediate shaft thrust
bearing rear race (3), thrust bearing (2) and front
race (1), install them to forward and reverse clutch
assembly (4).
Bearing race dimension
40) Apply A/T fluid to forward and reverse clutch
assembly (1).
Install forward and reverse clutch assembly while
rotating clockwise and counterclockwise frequently
to fit clutch discs to mating hubs.
NOTE
Before installation, align teeth of forward and
reverse clutch discs to facilitate installation.

41) Check for correct installation of forward and reverse
clutch assembly as follows.
Measure distance “a” by using micrometer caliper (1)
and straightedge (2). If out of specification, remove
forward and reverse clutch assembly, forward clutch
hub, rear planetary sun gear subassembly and one-
way clutch No.1 assembly, and reinstall them
properly.
Distance between forward and reverse clutch
assembly and mating surface of transaxle case
“a”: 27.1 – 29.4 mm (1.067 – 1.157 in.)
42) After applying A/T fluid to O/D and 2nd coast brake
retaining plate (4), separator plate (3), discs (2) and
rear plate (1), install them to transaxle case (5). Front race Rear race
Outside
diameter30.6 mm (1.20 in.) 28.2 mm (1.11 in.)
Thickness 2.0 mm (0.08 in.) 2.0 mm (0.08 in.)
I2RH0B510294-01
I2RH0B510295-01
“a”
“a”
1
2
I2RH0B510296-01
I2RH0B510297-01

Downloaded from www.Manualslib.com manuals search engine 5A-154 Automatic Transmission/Transaxle:
57) Apply A/T fluid to direct clutch assembly (1).
Install direct clutch assembly while rotating
clockwise and counterclockwise frequently to fit
clutch discs to mating hub.
NOTE
Before installation, align teeth of direct clutch
discs to facilitate installation.

58) Check for correct installation of direct clutch
assembly as follows.
Measure distance “a” by using micrometer caliper (1)
and straightedge (2). If out of specification, remove
direct clutch assembly, direct clutch hub and reinstall
them properly.
Distance between direct clutch assembly and
mating surface of transaxle case
“a”: 10.5 – 11.3 mm (0.413 – 0.445 in.)59) Install oil pump assembly (1) to transaxle case.
Tightening torque
Oil pump assembly bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
60) Make sure that input shaft (1) turns smoothly.
I2RH0B510309-01
“a”
“a”
1
2
I2RH0B510310-01
I2RH0B510311-01
I2RH0B510312-01