section 9 SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 9H-4 Interior Trim:
Specifications
Tightening Torque SpecificationsS6RW0D9807001
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
Sun visor screw 4 0.4 3.0)

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

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Front Fender ComponentsS6RW0D9A06003
Front Fender Removal and InstallationS6RW0D9A06004
Removal
1) Remove side sill splash guard and front fender splash guard (if equipped) referring to “Splash Guard Removal and
Installation (If Equipped) in Section 9M”.
2) Remove front fender lining.
3) Remove front bumper referring to “Front Bumper and Rear Bumper Components in Section 9K”.
4) Remove headlight assembly referring to “Headlight Housing Removal and Installation in Section 9B”.
5) Disconnect connector from side turn signal light (if equipped).
6) Remove front fender cover.
7) Remove front fender.
Installation
Reverse removal procedure to install front fender noting the following instruction.
• If paint on fender bolt is peeled off, be sure to apply paint again.
• Adjust panel clearance referring to “Panel Clearance in Section 9K”.
13
2
I5RW0A9A0004-01
1. Front fender lining 2. Front fender 3. Front fender cover

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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

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Rear End Door Assembly ComponentsS6RW0D9A06009
Rear End Door Assembly Removal and
Installation
S6RW0D9A06010
WARNING!
Be careful enough when you open and shut
with door balancer has not adhered to rear
end door.
Otherwise, Rear end door doses in weight
and is injured.

Removal
1) Remove rear end door trim (1).
2) Remove related section of head lining and rear trim.
3) Disconnect rear end door harness couplers (2) and
washer hose (3).
4) Remove rear end door balancers (4).
5) Remove door hinge nuts (5) and remove rear end
door assembly (6).
BA
A
B
A
A
A
A
A
AA
A
A
5
614 2
(a)
(a)
[A]
3
7
8
9
I6RW0B9A0006-01
[A]: Rear end door spoiler installation position 4. Rear end door balancer 8. Cap
1. Rear end door panel assembly 5. Rear end door trim 9. Clip
2. Rear end door window glass 6. Rear end door opening wether-strip : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
3. Rear end door hinge
: Apply lithium grease 99000-25011 to door hinge
moving section.
: Apply sealant 99000-31110 to contact face.7. Rear end door spoiler

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WARNING!
Handling of rear end door balancer (damper)
• Handle balancer carefully. Do not scar or
scratch exposed surface of its piston rod,
and never allow any paint or oil to stick to
its surface.
• Do not turn piston rod with balancer fully
extended.
• Do not disassemble balancer (1) because
its cylinder is filled with gas.
Discarding of rear end door balancer
(damper)
• The gas itself in balancer is harmless but it
may issue out of the hole together with
chips generated by the drill (2). Therefore,
be sure to wear goggle when drilling.
• Using a 2 to 3 mm (0.08 to 0.12 in.) drill (2),
make a hole to remove gas inside as
shown before discarding.

Installation
Reverse removal procedure noting the following.
• Tighten rear end door balancer bolt to specified
torque.
Tightening torque
Rear end door balancer bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lb-ft)
• Secure wiring harness (1).
• Adjust door latch striker position by referring to “Rear
End Door Lock Assembly Removal and Installation in
Section 9F”.
• Adjust door cushion so that door contacts body when
closed.
• Apply sealant to contact face “A” of door 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)
AB
A
A
A
A
AAA
AAA
B
3
5
461
4
2
2
I5RW0A9A0008-03
I2RH019A0010-01
(a)
(a)
I5RW0A9A0009-02
1
I5RW0A9A0010-01
I2RH019A1012-01

Downloaded from www.Manualslib.com manuals search engine 9J-8 Hood / Fenders / Doors:
Specifications
Tightening Torque SpecificationsS6RW0D9A07001
NOTE
The specified tightening torque is also described in the following.
“Front Door Assembly Components”
“Rear Door Assembly Components”
“Rear End Door Assembly 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 MaterialS6RW0D9A08001
NOTE
Required service material is also described in the following.
“Front Door Assembly Components”
“Rear Door Assembly Components”
“Rear End Door Assembly Components”

Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Hood latch bolt 10 1.0 7.5)
Rear end door balancer bolt 23 2.3 17.0)
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011) / )
Sealant SUZUKI Bond No.1215 P/No.: 99000–31110) / ) / )

Downloaded from www.Manualslib.com manuals search engine 9K-6 Body Structure:
Hole to hole distance
c
a
a’a
b b’
c
b’
I5RW0A9B0006-03
a (a’). Front end of windshield upper installation section c. Parking brake cable bracket installation front hole
b (b’). Front end of windshield lower installation section
a-a’: 1,052 mm (41.417 in.) a-b’: 1,428 mm (56.220 in.) b-b’: 1,328 mm (52.283 in.)
a-b: 801 mm (31.535 in.) a-c: 1,280 mm (50.394 in.) b-c: 1,511 mm (59.488 in.)

Downloaded from www.Manualslib.com manuals search engine 9K-10 Body Structure:
Panel ClearanceS6RW0D9B07002
Panel to panel distance
Tightening Torque SpecificationsS6RW0D9B07003
NOTE
The specified tightening torque is also described in the following.
“Cowl Top and Front Lower Crossmember Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
b
wa
v
c
d
f
g
j
h
ei
u
l
km
n
xo
r
t
sp
q
I6RW0C9B0004-01
a: 0 – 1.5 mm (0 – 0.059 in.) m: 4.0 – 6.0 mm (0.157 – 0.236 in.)
b: 2.7 – 4.7 mm (0.106 – 0.185 in.) n: 4.1 – 6.1 mm (0.161 – 0.240 in.)
c: 3.6 – 5.6 mm (0.142 – 0.220 in.) o: 0 – 1.0 mm (0 – 0.039 in.)
d: 1.0 – 3.0 mm (0.039 – 0.118 in.)
(For vehicle with splash guard)p: 5.2 – 7.2 mm (0.205 – 0.283 in.)
e: 4.8 – 6.8 mm (0.189 – 0.268 in.) q: 2.0 mm (0.079 in.)
f: 4.0 – 6.0 mm (0.157 – 0.236 in.) r: 7.5 – 9.0 mm (0.295 – 0.354 in.)
g: 3.6 – 5.6 mm (0.142 – 0.220 in.) s: 5.0 – 7.0 mm (0.197 – 0.276 in.)
h: 3.6 – 5.6 mm (0.142 – 0.220 in.) t: 4.0 – 6.0 mm (0.157 – 0.236 in.)
i: 4.8 – 6.8 mm (0.189 – 0.268 in.) u: 1.0 – 3.0 mm (0.039 – 0.118 in.)
(For vehicle with splash guard)
j: 4.0 – 6.0 mm (0.157 – 0.236 in.) v: 1.0 – 3.0 mm (0.039 – 0.118 in.)
(For vehicle with splash guard)
k: 3.5 – 5.5 mm (0.138 – 0.217 in.) w: 1.0 – 3.0 mm (0.039 – 0.118 in.)
(For vehicle with splash guard)
l: 3.5 – 5.5 mm (0.138 – 0.217 in.) x: 1.0 – 3.0 mm (0.039 – 0.118 in.)
(For vehicle with splash guard)

Downloaded from www.Manualslib.com manuals search engine Exterior Trim: 9M-2
Splash Guard Removal and Installation (If Equipped)S6RW0D9D06002
Specifications
Tightening Torque SpecificationsS6RW0D9D07001
NOTE
The specified tightening torque is also described in the following.
“Roof Molding Removal and Installation”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
A
B
A
AA
A
A
C
B
C
A
A
AA
B
AAAA
AAAA
C
1
23
I5RW0C9D0001-02
1. Side sill splash guard 2. Front fender splash guard 3. Rear fender splash guard