engine mount SUZUKI SX4 2006 1.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 1G-1 Fuel System:
Engine
Fuel System
Precautions
Precautions on Fuel System ServiceS6RW0D1700001
WARNING!
Before attempting service of any type on fuel system, the following should be always observed in
order to reduce the risk of fire and personal injury.
• Disconnect negative cable at battery.
• Do not smoke, and place no smoking signs near work area.
• Be sure to have CO
2 fire extinguisher handy.
• Be sure to perform work in a well-ventilated area and away from any open flames (such as gas hot
heater).
• Wear safety glasses.
• To relieve fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then
reinstall it.
• As fuel feed line is still under high fuel pressure even after stopping engine, loosening or
disconnecting fuel feed line directly may cause dangerous spout of fuel. Before loosening or
disconnecting fuel feed line, make sure to relieve fuel pressure referring to “Fuel Pressure Relief
Procedure”.
• A small amount of fuel may be released when the fuel line is disconnected. In order to reduce the
risk of personal injury, cover a shop cloth to the fitting to be disconnected. Be sure to put that cloth
in an approved container after disconnecting.
• Never run engine with fuel pump relay disconnected when engine and exhaust system are hot.
• Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each
hose correctly referring to “Fuel Hose Disconnecting and Reconnecting”.
After connecting, make sure that it has no twist or kink.
• When installing injector or fuel feed pipe, lubricate its O-ring with gasoline.
• When servicing the fuel tank, it should be treated with respect, with no contact with sharp edges or
hot surfaces. In addition, the fuel tank should not be dropped since fuel tank, fuel pump and other
components can be damaged by the impact. If dropped, all components should be replaced because
there is a risk of damage.
• The fuel tank is made of resin.
Be sure not to allow solvent (chemical article such as grease and sealant) to attach to the fuel tank
as some chemical reaction may occur, causing the fuel tank to be swollen, hardened or distorted
leakage and resulting in fuel leakage from the fuel tank.

Downloaded from www.Manualslib.com manuals search engine 1G-13 Fuel System:
Fuel Tank Removal and InstallationS6RW0D1706011
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

Removal
1) Relieve fuel pressure in fuel feed line according to
“Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Remove fuel filler cap.
4) Insert hose of a hand operated pump into fuel filler
hose (1) and drain fuel in space “A” as shown in
figure.
CAUTION!
Do not force pump hose into fuel tank.

5) Hoist vehicle, and remove clamp (2), fuel filler hose
(1) and breather hose (3) from fuel filler neck.6) Remove exhaust center pipe referring to “Exhaust
Pipe and Muffler Removal and Installation in Section
1K”.
7) Remove propeller shaft (For 4WD model) referring to
“Propeller Shaft Assembly Removal and Installation
in Section 3D”.
8) Due to absence of fuel tank drain plug, drain fuel
tank by pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
CAUTION!
• Do not force pump hose into fuel tank.
• Never store fuel in an open container due
to possibility of fire or explosion.

9) Disconnect quick joint (fuel pipe) (1) from fuel pipes
(2) referring to “Fuel Hose Disconnecting and
Reconnecting”.
10) Support fuel tank (1) with jack (2) and remove its
mounting bolts (3).
11) Lower fuel tank a little as to disconnect wire harness
at connector (1)and ground wire (2), then remove
fuel tank.
2. Inlet check valve
I4RS0B170022-01
1 23
I5RW0A170012-01
2
1
I5RW0A170014-02
1
2
33
I5RW0A170013-01
1
2
I7RW01170009-01

Downloaded from www.Manualslib.com manuals search engine 1I-1 Starting System:
Engine
Starting System
Schematic and Routing Diagram
Cranking System Circuit DiagramS6RW0D1902001
Diagnostic Information and Procedures
Cranking System Symptom DiagnosisS6RW0D1904001
Possible symptoms due to starting system trouble would be as follows:
• Starting motor does not run (or runs slowly)
• Starting motor runs but fails to crank engine
• Abnormal noise is heard
Proper diagnosis must be made to determine exactly where the cause of each trouble lies in battery, wiring harness,
(including starting motor switch), starting motor or engine.
Do not remove motor just because starting motor does not run. Check the following items and narrow down scope of
possible causes.
1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine side) and starting motor terminals
3) Discharge of battery
4) Mounting of starting motor
I4RS0A190001-01
1. Pinion drive lever 6. Magnetic switch contacts 11. Ignition & Starter switch
2. Pinion & Over-running clutch 7. Pull-in coil 12. Battery
3. Magnetic switch 8. Starting motor 13. To ECM
4. Hold-in coil 9. Starting motor control relay
5. Plunger 10. A/T: Transmission range sensor (shift switch)

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-4
Repair Instructions
Starting Motor Dismounting and RemountingS6RW0D1906001
Dismounting
1) Disconnect negative (–) battery lead at battery.
2) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals.
3) Detach shift & select control cable bracket from transaxle. (M/T model only)
4) Remove starting motor mount bolt (3) and nut (4).
5) Remove starting motor (5).
Remounting
Reverse the dismounting procedure noting the following.
• Tighten battery cable nut (6) to specified torque.
Tightening torque
Starting motor battery cable nut (a): 9.8 N·m (0.98 kgf-m, 7.0 lb-ft)
I4RS0A190002-01
: 9.8 N⋅m (0.98 kgf-m, 7.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 1I-9 Starting System:
Front Housing Bush
Inspect the bush for wear or damage. Replace if
necessary.
Specifications
Cranking System SpecificationsS6RW0D1907002
Tightening Torque SpecificationsS6RW0D1907003
NOTE
The specified tightening torque is also described in the following.
“Starting Motor Dismounting and Remounting”
“Starting Motor 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 MaterialS6RW0D1908001
NOTE
Required service material is also described in the following.
“Starting Motor Components”

I2RH01190024-01
Voltage 12 volts
Output 1.2 kW
Rating 30 seconds
Direction of rotation Clockwise as viewed from pinion side
Brush length Standard: 12.3 mm (0.48 in.) Limit: 7.0 mm (0.28 in.)
Number of pinion teeth 8
Performance Condition Guarantee
Around at 20 °C
(68 °F)No load characteristic 11.0 V90 A maximum
2370 r/min minimum
Load characteristic7.5 V
300 A10.65 N⋅m (1.065 kgf-m, 7.70 lb-ft) minimum
840 r/min minimum
Locked characteristic 4.0 V780 A maximum
20 N⋅m (2.0 kgf-m, 14.5 lb-ft) minimum
Magnetic switch operating voltage 8 volts maximum
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Starting motor battery cable nut 9.8 0.98 7.0)

Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-3
Generator DescriptionS6RW0D1A01002
The basic charging system is the IC integral regulator charging system. The internal components are connected
electrically as shown below.
Charging System Circuit
The generator features a solid state regulator that is mounted inside the generator. All regulator components are
enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the rear housing. The
regulator voltage is being controlled by ECM under some conditions while driving. Refer to “Generator Control System
Description in Section 1A” in related manual.
The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication.
Two brushes carry current through the two slip rings to the field coil mounted on the rotor, and under normal conditions
will provide long period of attention-free service.
The stator windings are assembled inside a laminated core that forms part of the generator frame.
A rectifier bridge connected to the stator windings contains diodes, and electrically changes that stator AC. voltages to
a D.C. voltage which appears at the generator output terminal.
1 26345
4
3B
7
8
9
10E FFRCIG
L
I6RW0D1A0002-01
1. Pulley 6. Field coil B: Generator output (Battery terminal) L: Lamp terminal
2. Pulley nut 7. Regulator C: Generator cut FR: Field duty monitor
3. Rotor fan 8. Brush E: Ground
4. Stator coil 9. Rear end frame F: Field coil terminal
5. Stator core 10. Drive end frame IG: Ignition terminal
B
IG
L
C
E
7
2 4
3
5
FR
610
11
12 13 1
[A]
IG1 9
14
8
I6RW0D1A0001-03
[A]: If equipped with electric load current sensor 4. Diode 8. Battery 12. Combination meter
1. Generator with regulator assembly 5. Field coil (rotor coil) 9. Electric load current sensor (if equipped) 13. CAN driver
2. I.C. regulator 6. Charge indicator light 10. ECM 14. Main fuse box
3. Stator coil 7. Main switch 11. BCM

Downloaded from www.Manualslib.com manuals search engine 1J-4 Charging System:
Diagnostic Information and Procedures
Battery InspectionS6RW0D1A04001
Common Causes of Failure
A battery is not designed to last indefinitely; however,
with proper care, it will provide many years of service. If
the battery performs satisfactorily during test buy fails to
operate properly for no apparent reason, the following
are some factors that may point to the cause of trouble:
• Accessories left on overnight or for an extended
period without the generator operating.
• Slow average driving speed for short periods.
• Electrical load exceeding generator output particularly
with addition of aftermarket equipment.
• Defects in charging system such as high resistance,
slipping drive belt, loose generator output terminal,
faulty generator or voltage regulator. Refer to
“Generator Symptom Diagnosis”.
• Battery abuse, including failure to keep battery cable
terminals clean and tight or loose battery hold down.
• Mechanical problems in electrical system such as
shorted or pinched wires.
Visual Inspection
Check for obvious damage, such as cracked or broken
case or cover, that could permit loss of electrolyte. If
obvious damage is noted, replace battery. Determine
cause of damage and correct as needed.
Generator Symptom DiagnosisS6RW0D1A04002
CAUTION!
• Do not mistake polarities of “IG” terminal
and “L” terminal.
• Do not create short circuit between “IG”
and “L” terminals. Always connect these
terminals through a lamp.
• Do not connect any load between “L” and
“E” terminals.
• When connecting charger or booster
battery to vehicle battery, refer to “Jump
Starting in Case of Emergency”.

Trouble in charging system will show up as one or more
of the following conditions:
1) Faulty indicator lamp operation.
2) An undercharged battery as evidenced by slow
cranking or indicator dark.
3) An overcharged battery as evidenced by excessive
spewing of electrolyte from vents.
Noise from generator may be caused by loose drive
pulley, loose mounting bolts, worn or dirty bearings,
defective diode, or defective stator.
B: Generator output (Battery terminal) IG: Ignition terminal
C: C terminal L: Lamp terminal
E: Ground FR: Field duty monitor
F: Field coil terminal
E FFRC
B
IG
L
I6RW0D1A0003-01

Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-7
1) Set parking brake and place automatic transaxle in
PARK (NEUTRAL on manual transaxle). Turn off
ignition, turn off lights and all other electrical loads.
2) Check electrolyte level. If it is below low level line,
add distilled water.
3) Attach end of one jumper cable to positive terminal
of booster battery and the other end of the same
cable to positive terminal of discharged battery. (Use
12-volt battery only to jump start engine).
4) Attach one end of the remaining negative cable to
negative terminal of booster battery, and the other
end to a solid engine ground (such as exhaust
manifold) at least 45 cm (18 in.) away from battery of
vehicle being started.
5) Start engine of vehicle with booster battery and turn
off electrical accessories. Then start engine of the
vehicle with discharged battery.
6) Disconnect jumper cables in the exact reverse order.
With Charging Equipment
CAUTION!
When jump starting engine with charging
equipment, be sure equipment used is 12-
volt and negative ground. Do not use 24-volt
charging equipment. Using such equipment
can cause serious damage to electrical
system or electronic parts.

Battery Dismounting and RemountingS6RW0D1A06002
Dismounting
1) Disconnect negative cable (3).
2) Disconnect positive cable (2).
3) Remove retainer (4).
4) Remove battery (1).
Handling
When handling battery, the following safety precautions
should be followed:
• Hydrogen gas is produced by battery. A flame or
spark near battery may cause the gas to ignite.
• Battery fluid is highly acidic. Avoid spilling on clothing
or other fabric. Any spilled electrolyte should be
flushed with large quantity of water and cleaned
immediately.Remounting
1) Reverse removal procedure.
2) Tighten battery cables securely.
NOTE
Check to be sure that ground cable has
enough clearance to hood panel by terminal.

Water Pump / Generator Drive Belt Tension
Inspection and Adjustment
S6RW0D1A06006
WARNING!
• Disconnect negative cable at battery
before checking and adjusting belt
tension.
• To help avoid danger of being burned, do
not remove radiator cap while engine and
radiator are still hot. Scalding fluid and
steam can be blown out under pressure if
cap is taken off too soon.

1) Inspect belt for cracks, cuts, deformation, wear and
cleanliness. If it is necessary to replace belt, refer to
“Water Pump / Generator Drive Belt Removal and
Installation”.
2) Check belt for tension. Belt is in proper tension when
it deflects the following specification under thumb
pressure (about 10kg or 22 lb.).
If belt tension is out of specification, go to next steps.
Water pump / generator drive belt tension
“a”
Existing belt: 4.5 – 5.5 mm (0.18 – 0.22 in.) as
deflection / 10 kg (22 lbs)
New belt: 4.0 – 4.5mm (0.16 – 0.18 in.) as
deflection / 10 kg (22 lbs)
1. Battery 4. Retainer
2. Positive cable 5. Nut
3. Negative cable
21
4
3
5I7RW011A0005-01

Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-9
Generator Dismounting and RemountingS6RW0D1A06003
1) Disconnect negative cable at battery.
2) Remove right side drive shaft referring to “Front Drive Shaft Assembly Removal and Installation in Section 3A”
3) Dismount in numerical order as shown in figure.
4) Reverse dismounting procedure for remounting.
I6RW0D1A0004-01
1. “B” terminal nut 5. Generator pivot bolt : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
2. “B” terminal wire 6. Generator drive belt : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft)
3. Connector 7. Generator
4. Generator bracket bolt : 5.0 N⋅m (0.5 kg⋅m, 4.0 lb-ft)

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. )