engine mount SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Security and Locks: 9F-6
Repair Instructions
Front Door Lock Assembly ComponentsS6RW0D9606001
Front Door Lock Assembly Removal and
Installation
S6RW0D9606002
Removal
1) Remove door trim and door sealing cover referring to
step 1) to 6) of “Front Door Glass Removal and
Installation in Section 9E”.
2) Raise window all the way up.
3) Remove door sash (1).4) Remove key cylinder mounting bolt (1), and then
remove key cylinder (2).
5) Disconnect door opening control rod (1) from outside
handle.
6) Disconnect door lock motor lead wire at coupler (if
equipped).
(a)
(b)
5
3
6
1 4
2
I5RW0A960003-01
1. Front door latch assembly
: Apply lithium grease 99000-25011 to sliding and rotating parts and spring if any.4. Latch striker : 5.0 N⋅m
(0.5 kgf-m, 4.0 lb-ft)
2. Outside handle assembly
: Apply lithium grease 99000-25011 to sliding part.5. Key cylinder : 10 N⋅m
(1.0 kgf-m, 7.5 lb-ft)
3. Outside handle frame
: Apply lithium grease 99000-25011 to sliding part and spring.6. Inside handle bezel
1
I4RS0A960007-01
12
I4RS0B960005-01

Downloaded from www.Manualslib.com manuals search engine Security and Locks: 9F-10
Rear Door Lock Assembly ComponentsS6RW0D9606007
Rear Door Lock Assembly Removal and
Installation
S6RW0D9606008
Removal
1) Remove rear door glass referring to “Rear Door
Glass Removal and Installation in Section 9E”.
2) Disconnect door lock motor lead wire (If equipped).
3) Remove door latch mounting screws (1) and remove
door latch assembly (2).
Installation
Reverse removal procedure to install rear door lock
assembly referring to the following instruction and “Front
Door Lock Assembly Removal and Installation”.• Tighten door latch screw to specified torque.
Tightening torque
Door latch screw (a): 5.0 N·m (0.5 kgf-m, 4.0 lb-ft)
• Install door trim referring to “Rear Door Glass
Removal and Installation in Section 9E”.
Rear Door Lock Assembly InspectionS6RW0D9606009
• Check that door opens and closes smoothly and
properly.
• Check that door stops in the secondary latched
position properly (preventing door from opening
freely) and that door closes completely in the fully
latched position.
• Adjust door latch striker position referring to “Front
Door Lock Assembly Removal and Installation”, if
necessary.
(a)
(b) 1
6
2
5
34
I5RW0A960006-01
1. Outside handle
: Apply lithium grease 99000-25011 to sliding part.4. Latch striker : 5.0 N⋅m
(0.5 kgf-m, 4.0 lb-ft)
2. Outside handle frame
: Apply lithium grease 99000-25011 to sliding part and spring.5. Inside handle bezel : 10 N⋅m
(1.0 kgf-m, 7.5 lb-ft)
3. Rear door latch assembly
: Apply lithium grease 99000-25011 to sliding part.6. Out side handle cap
1 2
I4RS0A960013-01
(a)
I4RS0A960014-01

Downloaded from www.Manualslib.com manuals search engine 9F-11 Security and Locks:
Rear End Door Lock Assembly ComponentsS6RW0D9606010
1
3
(a)
(b)4
5
2
6
7
8
i
ii iv
iii
(c)
8
(c)
8(c)
I7RW01960007-04
1. Rear end door latch assembly
(rear end door switch is built in this assembly)5. Emergency lever
: Rear end door is unlocked by pushing emergency lever
with flat head driver if rear end door lock can not be
released by door opener switch.: 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
2. Rear end door opener switch 6. Rear end door request switch
(if equipped): 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
3. Latch striker 7. Rear end door license garnish : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft)
4. Door handle 8. Rear end door license garnish mounting nut
: Tighten nuts in such order as indicated in figure.

Downloaded from www.Manualslib.com manuals search engine Seats: 9G-2
Repair Instructions
Front Seat ComponentsS6RW0D9706001
3
2
8
7
a
c
4
d
b
1
5
5
4
6
64
a
b
c
d
(b)
(b)
(b)
(b)
(a)
(a)
(a)
(a)
A
A
A
(b)
(c)
BA
A
A
B
A
B
I6RW0C970001-01
1. Seat cushion7. Side air bag module (if equipped)
2. Seat back
: Apply lithium grease 99000-25011 to sliding part of reclining.8. Side air bag harness (if equipped)
3. Headrest: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Cover: 35 N⋅m (3.5 kgf-m, 25.5 lb-ft)
5. Seat adjuster
: Apply lithium grease 99000-25011 to seat adjuster inside.: 28 N⋅m (2.8 kgf-m, 20.5 lb-ft) (Seat lifter type)
35 N⋅m (3.5 kgf-m, 25.5 lb-ft) (Non seat lifter type)
6. Knoba, b, c, d: Seat back mounting bolt
Seat mounting bolt
Tightening order: a → b → c → d

Downloaded from www.Manualslib.com manuals search engine 9G-3 Seats:
Front Seat Removal and InstallationS6RW0D9706002
Removal
1) Disable air bag system referring to “Disabling Air
Bag System in Section 8B”.
2) Disconnect seat harness coupler and side air bag
coupler, if equipped.
3) Remove 4 mounting bolts to remove seat assembly.
4) Disassemble and repair seat as necessary.
Installation
Reverse removal procedure to install front seat.
• Torque to specifications as shown in “Front Seat
Components”.
• Enable air bag system referring to “Enabling Air Bag
System in Section 8B”.
Front Seat Heater Switch (Driver and Passenger
Side) Inspection (If Equipped)
S6RW0D9706005
1) Confirm that ignition switch is OFF position.
2) Remove console box.
3) Disconnect seat heater switch coupler and remove
seat heater switch.
4) Check for continuity between terminals at each
switch position as shown below. If check result is not
as specified, replace.
Front Seat Heater Wire Inspection (If Equipped)S6RW0D9706006
1) Confirm that seat heater switch is OFF position.
2) Disconnect coupler of seat heater under the seat
cushion.
3) Measure resistance between terminals as shown
below. If resistance is out of specification, replace
faulty seat cushion and/or seat back including seat
heater.
Seat heater circuit resistance
Seat cushion side [A] (between terminal “B” and
“C”, between terminal “A” and “C”): 4.7 – 5.7 Ω
(at 20 °C, 68 °F)
Seat back side [B] (between terminal “F” and
“D”: 10.7 – 13.1 Ω (at 20 °C, 68 °F)
I5RW0B970001-02
1. Heater wire [A]: Seat cushion side
2. Thermostat [B]: Seat back side
ABCDE F [A] [B]
11
2
I5JB0A970002-01

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 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

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-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

Downloaded from www.Manualslib.com manuals search engine Body Structure: 9K-3
Specifications
Body DimensionsS6RW0D9B07001
Engine Room
Hole to hole distance
ab
c
d
e
f
g
h
i
j
l
k
b'
c'
d'
g'
h'
j'
I5RW0A9B0003-01
a. Jig hole (φ 8 mm) e. Cover installation hole (φ 12 mm) i. Jig hole left side (φ 7 mm)
b (b’). Cowl top side cover
installation holef. Hood cushion installation hole j (j’). Cowl garnish installation hole (φ 8 mm)
c (c’). Aiming hole (φ 12 mm) g (g’). Front fender installation hole k. Right side engine mounting installation upper front hole
d (d’). Headlight installation hole h (h’). Front bumper lower member installation lower hole l. Left side engine mounting installation upper front hole
a-d: 623 mm (24.543 in.) b-c’: 1,375 mm (54.134 in.) d’-i: 586 mm (23.071 in.)
a-e: 662 mm (26.063 in.) b-e: 679 mm (26.732 in.) g-g’: 1,549 mm (60.984 in.)
a-f: 761 mm (29.961 in.) b-g: 468 mm (18.425 in.) h-h’: 966 mm (38.031 in.)
a-l: 459 mm (18.070 in.) b’-c’: 341 mm (13.425 in.) h-l: 411 mm (16.181 in.)
a-j: 338 mm (13.307 in.) c-c’: 1,249 mm (49.173 in.) h’-i: 651 mm (25.630 in.)
a-k: 916 mm (36.063 in.) d-d’: 1,016 mm (40.000 in.) j-j’: 1,298 mm (51.102 in.)
b-b’: 1,421 mm (54.945 in.) d-i: 564 mm (22.205 in.) k-l: 918 mm (36.142 in.)