SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-14
Front Wheel Hub, Disc, Bolt and Bearing CheckS6RW0D2206008
• Inspect each wheel disc for dents, distortion and
cracks.
A disc in badly damaged condition must be replaced.
• Check rust of installation face inside of wheel disc.
As rust affects adversely, remove it thoroughly.
• Check tightness of wheel nuts and, if necessary,
retighten them to specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
• Check wear of wheel bearing. When measuring thrust
play, apply a dial gauge to wheel hub as shown in
figure.
Front wheel bearing thrust play
Limit: 0.1 mm (0.004 in.)
• Check wheel bearing noise and smooth wheel rotation
by rotating wheel.
If defective, replace bearing.
Suspension Control Arm / Bushing Removal
and Installation
S6RW0D2206009
CAUTION!
When removal and installing steering
knuckle assembly, be careful not to damage
dust boots of control arm joint by drive shaft
dust cover and brake dust cover.

Removal
1) Hoist vehicle and remove wheel.
2) Remove steering knuckle with front wheel hub
referring to step 2) to 5), 7) to 11) of “Removal” under
“Front Wheel Hub, Steering Knuckle and Wheel
Bearing Removal and Installation”.
3) Remove suspension control arm bolts (1).
4) Remove suspension control arm (2).
I3RM0A220034-01
21
I5RW0A220019-01

Downloaded from www.Manualslib.com manuals search engine 2B-15 Front Suspension:
Installation
1) Install suspension control arm as shown but tighten
suspension control arm bolts (1) only temporarily.
CAUTION!
Use new control arm bolt.

2) Install steering knuckle with front wheel hub referring
to step 7) to 17) of “Installation” under “Front Wheel
Hub, Steering Knuckle and Wheel Bearing Removal
and Installation”.
3) Install wheel and tighten wheel nuts to specified
torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
4) Lower hoist and vehicle in unloaded condition,
tighten new control arm bolts to specified torque.
Tightening torque
Suspension control arm bolt (a): 95 N·m (9.5
kgf-m, 69.0 lb-ft)
5) Confirm front wheel alignment referring to “Front
Wheel Alignment Inspection and Adjustment”.
Suspension Control Arm / Bushing
Disassembly and Assembly
S6RW0D2206010
Disassembly
1) Cut off bushing flange (rubber) (1) with knife.
2) Push out bushing by using hydraulic press (2) and
special tools.
Special tool
(A): 09943–76310
(B): 09913–75821
1
1
I5RW0A220020-01
(a)
I5RW0A220021-01
I4RS0B220019-01
2
(A) (B)
I4RS0B220020-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-16
Assembly
1) Front bushing
Press-fit front bushing (1) by using special tools and
press (2).
Special tool
(A): 09943–76310
(B): 09913–75821
CAUTION!
Be sure to use new bushing.

NOTE
• Before installing bushing, apply soap
water on its circumference to facilitate
bushing installation.

2) Press-fit bushing (1) so that dimensions “A” and “B”
in figure become equal.
Suspension Control Arm / Steering Knuckle
Check
S6RW0D2206011
Inspect for cracks, deformation or damage.
If defective, replace.
Suspension Control Arm Bushing CheckS6RW0D2206012
Inspect for damage, wear or deterioration.
If defective, replace.
Suspension Control Arm Joint CheckS6RW0D2206013
• Check smooth rotation of ball stud.
• Check damages of ball stud.
• Check damages of dust cover.
NOTE
Suspension control arm and arm joint cannot
be separated.

If there is any damage to either parts, control arm must
be replaced as a complete unit.
12
(A) (B)
I4RS0B220021-01
I4RS0A220033-01
I4RS0B220022-01
I4RS0B220023-01

Downloaded from www.Manualslib.com manuals search engine 2B-17 Front Suspension:
Front Suspension Frame, Stabilizer Bar and/or Bushing ComponentsS6RW0D2206014
123 4
56 7
8 8(c)
(a)
6
(b)
(b)
(c)
(c)
I6RW0D220001-02
1. Stabilizer bar 4. Stabilizer bar mounting
bracket bolt7. Front suspension frame : 95 N⋅m (9.5 kgf-m, 36.5 lb-ft)
2. Stabilizer bushing 5. Suspension control arm 8. Front suspension frame mounting bolt : 150 N⋅m (15.0 kgf-m, 108.5 lb-ft)
3. Stabilizer mounting bracket 6. Suspension control arm
mounting bolt: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft) : Do not reuse.

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 Front Suspension: 2B-20
12) Install exhaust No.1, No.2 and center pipe referring
to “Exhaust System Components in Section 1K”.
13) Install wheel and tighten nut to specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
14) Install air cleaner assembly referring to “Air Cleaner
Assembly Removal and Installation in Section 1D”.
15) Install hood referring to “Hood Removal and
Installation in Section 9J”.
16) Lower hoist and vehicle in unloaded condition,
tighten suspension control arm bolts to specified
torque.
Tightening torque
Suspension control arm bolt: 95 N·m (9.5 kgf-m,
69.0 lb-ft)
17) Connect negative (–) cable at battery.
18) Confirm front wheel alignment referring to “Front
Wheel Alignment Inspection and Adjustment”.
Front Suspension Frame CheckS6RW0D2206017
Inspect for cracks, deformation or damage.
If defective, replace.
Front Stabilizer Bar, Bushing and/or Joint
Check
S6RW0D2206018
Stabilizer Bar
Inspect for damage or deformation.
If defective, replace.Stabilizer Bushing
Inspect for damage, wear or deterioration.
If defective, replace.
Stabilizer Joint
1) Check for smooth rotation.
2) Check damages of ball stud.
3) Check damages of dust cover.
NOTE
Stabilizer joint (1) cannot be disassembled.

If there is any damage to either parts, stabilizer joint
must be replaced as a complete unit.
Front Suspension Fasteners CheckS6RW0D2206019
Check each bolt and nut fastening suspension parts for
tightness. Tighten loose one, if any, to specified torque,
referring to “Front Suspension Construction”.
I5RW0A220034-01
I5RW0A220035-01
I5RW0A220036-01
1
I4RH01220007-01

Downloaded from www.Manualslib.com manuals search engine 2B-21 Front Suspension:
Specifications
Tightening Torque SpecificationsS6RW0D2207001
NOTE
The specified tightening torque is also described in the following.
“Front Suspension Construction”
“Front Strut Assembly Components”
“Front Wheel Hub and Steering Knuckle Components”
“Front Suspension Frame, Stabilizer Bar and/or Bushing Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Tie-rod end lock nut 45 4.5 32.5)
Strut bracket nut 140 14.0 101.5) / )
Brake hose mounting bolt 26 2.6 19.0)
Stabilizer joint nut 50 5.0 36.5) / )
Strut nut 50 5.0 36.5)
Wheel nut 85 8.5 61.5) / ) / ) / ) / )
Strut support lower nut 55 5.5 40.0)
Suspension arm ball joint bolt 60 6.0 43.5)
Wheel speed sensor mounting bolt 11 1.1 8.0)
Tie-rod end nut 45 4.5 32.5)
Caliper carrier bolt 85 8.5 61.5)
Drive shaft nut 200 20.0 145.0)
Suspension control arm bolt 95 9.5 69.0) / )
Stabilizer bar mounting bracket bolt Tighten 23 N⋅m (2.3 kgf-m, 17.0 lb-ft) to
specified procedure)
Front suspension frame mounting bolt 150 15.0 108.5)

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-22
Special Tools and Equipment
Recommended Service MaterialS6RW0D2208001
Special ToolS6RW0D2208002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease H P/No.: 99000–25121)
09913–65810 09913–75510
Crankshaft bearing puller Bearing installer
)) / ) / )
09913–75821 09913–85230
Bearing installer attachment Bearing remover tool
) / ))
09925–14520 09942–15511
Bearing and oil seal installer
(80 x 50 mm)Sliding hammer
))
09943–17912 09943–25010
Wheel hub remover Spring compressor
))
09943–37910 09943–76310
Bearing installer & remover Bush remover
)) / )
09944–78220
Bearing installer support
)

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