rear SUZUKI SX4 2006 1.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine Suspension General Diagnosis: 2A-1
Suspension
Suspension General Diagnosis
Diagnostic Information and Procedures
Suspension, Wheels and Tires Symptom DiagnosisS6RW0D2104001
Condition Possible cause Correction / Reference Item
Vehicle pulls (Leads)Mismatched or uneven tiresReplace tires.
Tires not adequately inflatedAdjust tire pressure.
Broken or sagging coil springsReplace coil springs.
Radial tire lateral forceReplace tire.
Disturbed wheel alignmentCheck and adjust wheel alignment.
Brake dragging in one road wheelRepair brake.
Loose, bent or broken front or rear
suspension partsTighten or replace related suspension parts.
Abnormal or excessive
tire wearSagging or broken coil springReplace coil spring.
Tire out of balanceAdjust balance or replace tire.
Disturbed wheel alignmentCheck and adjust wheel alignment.
Faulty strut (shock absorber)Replace strut (shock absorber).
Hard drivingReplace tires.
Overloaded vehicleReplace tires.
Not rotated tiresReplace or rotate tires.
Worn or loose wheel bearingReplace wheel bearing.
Wobbly wheel or tireReplace wheel or tire.
Tires not adequately inflatedAdjust tire pressure.
Front suspension frame and/or
suspension control arm are transformedCheck and replace.
Wheel trampBlister or bump on tireReplace tire.
Improper strut (shock absorber) actionReplace strut (shock absorber).
Shimmy, shake or
vibrationTire or wheel out of balanceBalance wheel or replace tire and/or wheel.
Loosen wheel bearingsReplace wheel bearings.
Worn tie-rod endsReplace tie-rod ends.
Worn lower ball jointsReplace suspension control arm.
Excessive wheel runoutRepair or replace wheel and/or tire.
Blister or bump on tireReplace tire.
Excessively loaded radial runout of tire /
wheel assemblyReplace tire or wheel.
Disturbed wheel alignmentCheck and adjust wheel alignment.
Loose or worn steering linkageTighten or replace steering linkage.
Abnormal noise, front endWorn, sticky or loose tie-rod ends, lower
ball joints, tie-rod inside ball joints or
drive shaft jointsReplace tie-rod end, suspension arm, tie-rod
or drive shaft joint.
Damaged struts or mountingsRepair or replace struts or mountings.
Worn suspension arm bushingsReplace suspension arm bushings.
Loose stabilizer barTighten bolts or nuts and/or replace bushes.
Loose wheel boltsTighten wheel bolts.
Loose suspension bolts or nutsTighten suspension bolts or nuts.
Broken or damaged wheel bearingsReplace wheel bearings.
Broken suspension springsReplace suspension springs.
Worn strut bearingsReplace strut bearing.
Malfunction of Power Steering SystemCheck and correct malfunction.
Low or uneven trim height
NOTE
See NOTE *1.

Broken or sagging coil springsReplace coil springs.
Over loadedCheck loading.
Incorrect coil springsReplace coil spring.
Tires not adequately inflatedAdjust tire pressure.
Ride too softFaulty strut (shock absorber)Replace strut (shock absorber).
Suspension bottomsOverloadedCheck loading.
Faulty strut (shock absorber)Replace strut (shock absorber).
Incorrect, broken or sagging coil springsReplace coil spring.

Downloaded from www.Manualslib.com manuals search engine 2A-2 Suspension General Diagnosis:
NOTE
*1: Right-to-left trim height (“H”) difference should be within 15 mm (0.6 in.) with curb weight. (same
with rear side.)

Body leans or sways in
cornersLoose stabilizer barTighten stabilizer bar bolts or nuts, or replace
bushes.
Faulty strut (shock absorber) or
mountingReplace strut (shock absorber) or tighten
mounting.
Broken or sagging coil springsReplace coil springs.
OverloadedCheck loading.
Cupped tiresFront struts defectiveReplace struts.
Worn wheel bearingsReplace wheel bearings.
Excessive tire or wheel run-outReplace tire and/or wheel.
Worn ball jointsReplace suspension control arm.
Tire out of balanceAdjust tire balance. Condition Possible cause Correction / Reference Item
“H”
I2RH01210001-01

Downloaded from www.Manualslib.com manuals search engine Suspension General Diagnosis: 2A-3
Specifications
Wheel Alignment SpecificationsS6RW0D2107001
To e “b” – “a”
Front: IN 1 ± 1 mm (IN 0.0393 ± 0.0393 (in.))
Rear: IN 5 ± 5 mm (IN 0.1969 ± 0.1969 (in.))
Toe (degree) (Each wheel)
“d”
Front: IN 1’ ± 2’ (Reference information)
Rear: IN 17’ ± 17’ (Reference information)
Camber
“c”
Front: –10’ ± 1°
Rear: –1° ± 1°
Caster
Front: 3° 40’ ± 2°Side Slip (On one person)
Front: 0 to IN 3.0 mm/m (0 to IN 0.118 (in./3.3 ft))
(Reference information)
Steering Angle (Turning Angle)
Inside: 36.0° ± 2°
Outside: 32.1° (Reference information)
NOTE
• Toe value in the specification table was
measured by using a toe-in gauge.
• Rear toe, front camber, rear camber and
front caster are not adjustable.

“a”“d”
“b”F [A]
21
90
“c” [B]
I7RW01210001-02
[A]: Toe-in (Top view) 1. Center line of wheel F. Forward
[B]: Camber (Front view) 2. Body center

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-2
Front Wheel Alignment ConstructionS6RW0D2201002
Among factors for front wheel alignment, only toe setting
can be adjusted. Camber and caster are not adjustable.
Therefore, should camber or caster be out of
specification due to the damage caused by hazardous
road conditions or collision, whether the damage is in
body or in suspension should be determined and
damaged body should be repaired or damaged
suspension should be replaced.
Preliminary Checks Prior to Adjustment Front Wheel
Alignment
Steering and vibration complaints are not always the
result of improper wheel alignment. An additional item to
be checked is the possibility of tire lead due to worn or
improperly manufactured tires. “Lead” is the vehicle
deviation from a straight path on a level road without
hand pressure on the steering wheel. Refer to “Radial
Tire Lead / Pull Description in Section 2D” in order to
determine if the vehicle has a tire lead problem. Before
making any adjustment affecting wheel alignment, the
following checks and inspections should be made to
ensure correctness of alignment readings and alignment
adjustments:• Check all tires for proper inflation pressures and
approximately the same tread wear.
• Check for loose of ball joints. Check tie-rod ends; if
excessive looseness is noted, it must be corrected
before adjusting.
• Check for run-out of wheels and tires.
• Check vehicle trim heights; if it is out of limit and a
correction is needed, it must be done before adjusting
toe.
• Check for loose of suspension control arms.
• Check for loose or missing stabilizer bar attachments.
• Consideration must be given to excess loads, such as
tool boxes. If this excess load is normally carried in
vehicle, it should remain in vehicle during alignment
checks.
• Consider condition of equipment being used to check
alignment and follow manufacturer’s instructions.
• Regardless of equipment used to check alignment,
vehicle must be placed on a level surface.
NOTE
To prevent possible incorrect reading of toe,
camber or caster, vehicle front and rear end
must be moved up and down a few times
before inspection.

Repair Instructions
Front Wheel Alignment Inspection and
Adjustment
S6RW0D2206001
Toe Inspection and Adjustment
Preparation for toe inspection and adjustment.
• Place vehicle in unloaded state on level surface.
• Set steering wheel in straight state.
• Check that inflation pressure of each tire is adjusted
properly and wheel is free from deflection.
• Check that each suspension part is free from bend,
dent, wear or damage in any other form.
• Check that ground clearance at the right and left is
just about the same.Inspection
Measure toe with toe-in gauge (1).
Toe should be within following specifications.
If toe is out of the specification, adjust toe properly.
To e
IN 1.0 ± 1.0 mm (0.0394 ± 0.0394 in.)
I2RH01220062-01

Downloaded from www.Manualslib.com manuals search engine 2B-5 Front Suspension:
Front Strut Assembly Removal and InstallationS6RW0D2206003
CAUTION!
When rebound stopper and strut assembly
were removed, check strut support lower nut
for specified torque before installing strut
assembly.

Removal
1) Remove hood rear seal (1), and then remove cowl
top garnish (2) from vehicle.
NOTE
When servicing component parts of strut
assembly, beforehand loosen strut nut a little
before removing strut assembly. This will
make service work easier. Note that the nut
must not be removed at this point.

2) Hoist vehicle, allowing front suspension to hang free.
3) Remove wheel and disconnect stabilizer joint (1)
from strut bracket.
When loosening joint nut, hold stud with hexagon
wrench (2).4) Remove brake hose mounting bolt (1). Remove
brake hose (2) from bracket and wheel speed sensor
harness (3) from strut bracket as shown in figure.
5) Remove strut bracket bolts and nuts (4).
6) Remove strut nut (1), and remove rebound stopper
(2).
NOTE
Hold strut by hand so that it will not fall off.

7) Remove strut assembly.
2
1
I5RW0A220003-01
1
2
I5RW0A220004-01
3
214
I5RW0A220005-01
2
1
I4RS0A220006-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-18
Front Suspension Frame, Stabilizer Bar and/or
Bushing Removal and Installation
S6RW0D2206015
WARNING!
When supporting and installing front
suspension frame, be sure to apply some
supporting equipment (such as mission jack)
at well-balanced position in the center
section of front suspension frame so as to
prevent from its drop. Otherwise drop and
injure.

CAUTION!
When removal and installing suspension
control arm, be careful not to damage dust
boots of suspension control arm joint by
drive shaft dust cover and brake dust cover.

Removal
1) Disconnect negative (–) cable at battery.
2) Remove air cleaner assembly referring to “Air
Cleaner Assembly Removal and Installation in
Section 1D”.
3) Remove hood referring to “Hood Removal and
Installation in Section 9J”.
4) Hoist vehicle and remove front wheels.
5) Remove exhaust No.1, No.2 and center pipes
referring to “Exhaust System Components in Section
1K”.
6) Remove steering gear case mounting bolt referring
to “Steering Gear Case Assembly Components in
Section 6C”.
7) Fix steering gear case to body with rope to avoid the
steering gear case fall off when front suspension
frame is lowered.
8) Remove suspension control arms and disconnect
stabilizer joints.
9) Support engine assembly by using chain hoist (1).10) Remove engine rear mounting nut and mounting
member nut referring to “Engine Mountings
Components in Section 1D”.
11) Support front suspension frame (2) with mission jack
(1).
12) Remove engine rear mounting, mounting member
bolt and front suspension frame mounting bolts (1).
13) Lower front suspension frame.
14) Remove stabilizer bar (1) with bushing from
suspension frame (2).
1
I5RW0A220026-01
2
1
I4RS0A220042-01
1
1
I7RW01220012-01
12
I7RW01220016-01

Downloaded from www.Manualslib.com manuals search engine 2B-19 Front Suspension:
Installation
1) Install stabilizer bar (1), stabilizer bushing (2) and
stabilizer mounting bracket (3) to front suspension
frame as shown in figure while ensuring that
stabilizer is centered, side-to-side.
NOTE
• For proper installing direction of stabilizer
mounting bracket (3), place oblong to rear
and circular hole to front.
• For correct installation of stabilizer bar,
side-to-side, be sure that stopper ring (4)
on stabilizer bar aligns with mounting
bush, both right and left, as shown in
figure.

2) Tighten stabilizer bar mounting bracket bolts to
specified torque.
NOTE
Tighten stabilizer bar mounting bracket rear
bolt (5) after front bolt (6).

Tightening torque
Stabilizer bar mounting bracket bolt (a): Tighten
23 N⋅m (2.3 kgf-m, 17.0 lb-ft) to specified
procedure
3) Support front suspension frame (2) with mission jack
(1) and jack up it.4) Align lugs (1) (right and left) of front suspension
frame with whole (2) in vehicle body.
5) Tighten front suspension frame bolts to specified
torque.
Tightening torque
Front suspension frame mounting bolt: 150 N·m
(15.0 kgf-m, 108.5 lb-ft)
6) Remove mission jack from front suspension frame.
7) Install engine rear mounting and tighten mounting
member bolts referring to “Engine Mountings
Components in Section 1D”.
8) Remove chain hoist from engine assembly.
9) Tighten steering gear case mounting bolts referring
to “Steering Gear Case Assembly Components in
Section 6C”.
10) Install suspension control arms referring to
“Suspension Control Arm / Bushing Removal and
Installation”.
11) Install stabilizer joint (1) and tighten nut to specified
torque.
When tightening nut, hold stud with hexagon wrench
(2).
Tightening torque
Stabilizer joint nut (a): 50 N·m (5.0 kgf-m, 36.5
lb-ft)
1
F
3
4
5,(a)
6,(a)
2
I5RW0A220029-02
2
1
I4RS0A220042-01
2
1
I5RW0A220030-01
1 2
(a)
I5RW0A220033-01

Downloaded from www.Manualslib.com manuals search engine 2C-1 Rear Suspension:
Suspension
Rear Suspension
Repair Instructions
Rear Suspension ComponentsS6RW0D2306001
I6RW0D230001-01
F: Forward 7. Vehicle body 16. Rear drive shaft nut
[A]: 2WD model 8. Rear shock absorber 17. Rear wheel hub assembly
[B]: 4WD model 9. Lower washer : 73 N⋅m (7.3 kgf-m, 53.0 lb-ft)
1. Coil spring 10. Lower nut : 30 N⋅m (3.0 kgf-m, 22.0 lb-ft)
2. Spring upper seat 11. Rear axle : 175 N⋅m (17.5 kgf-m, 127.0 lb-ft)
3. Spring lower seat 12. Rear drive shaft : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft)
4. Upper nut 13. Rear wheel hub mounting bolt : Do not reuse.
5. Upper washer 14. Rear axle bolt
6. Upper bush 15. Brake back plate

Downloaded from www.Manualslib.com manuals search engine Rear Suspension: 2C-2
Rear Shock Absorber Removal and InstallationS6RW0D2306002
Removal
1) Hoist vehicle and remove rear wheel.
2) Remove access hole cover (1) in quarter inner trim
(2).
3) Support rear axle by using floor jack to prevent it
from lowering.
4) Remove absorber lower nut (1) and lower washer.
5) Remove absorber upper nut (2). Then remove shock
absorber (3), upper washers.
6) Remove absorber upper bushes.Installation
1) Install absorber upper bushes (1).
NOTE
For proper installing direction of shock
absorber bushes (1), refer to the figure.

2) Install shock absorber (1), upper washers (2).
Tighten new rear shock absorber upper nut (4) and
lower nut (5) temporarily at this step.
CAUTION!
Use new rear shock absorber upper nut.
Otherwise, nut may loosen.

2
1
I5RW0A230002-02
2
1
3
I5RW0A230003-01
2. Body panel
3. Body panel
1
2
I5RW0A230028-01
14
32
5
I7RW01230017-01

Downloaded from www.Manualslib.com manuals search engine 2C-3 Rear Suspension:
3) Remove floor jack from rear axle.
4) Install rear wheel and tighten wheel nuts to specified
torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
5) Lower hoist and bounce vehicle up and down
several times to stabilize suspension.
6) Tighten nuts to specified torque.
Tightening torque
Rear shock absorber upper nut (a): 30 N·m (3.0
kgf-m, 22.0 lb-ft)
Rear shock absorber lower nut (b): 90 N·m (9.0
kgf-m, 65.0 lb-ft)
7) Install access hole cover (1) in quarter inner trim (2).Rear Shock Absorber InspectionS6RW0D2306003
• Inspect for deformation or damage.
• Inspect bushings for wear or damage.
• Inspect for evidence of oil leakage.
Replace any defective parts.
WARNING!
When handling rear shock absorber (1) in
which high-pressure gas is sealed, make
sure to observe the following precautions.
• Don’t disassemble it.
• Don’t put it into the fire.
• Don’t store it where it gets hot.
• Before disposing it, be sure to drill a hole
(approximately 3 mm (0.12 in.) diameter)
(2) in it where indicated by arrow in the
figure and let gas and oil out.
Be sure to wear eye shield since the gas
itself is harmless but the absorber drill
hole debris maybe blown out.

Rear Shock Absorber Bush InspectionS6RW0D2306004
Inspect for cracks, deformation or damage. Replace any
defective parts.
(a)
(b)I5RW0A230006-01
2
1
I5RW0A230002-02
I5RW0A230007-01
I4RS0A230008-01