torque SUZUKI SX4 2006 1.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-16
Installation
CAUTION!
When connecting joint, clean outside surface
of pipe where joint is to be inserted, push
joint into pipe till joint lock clicks and check
to ensure that pipes are connected securely,
or fuel leak may occur.

1) Clean mating surfaces of fuel pump assembly and
fuel tank.
2) Put plate (2) on fuel pump assembly (1) by matching
the protrusion of fuel pump assembly (3) to plate
hole (4) as shown.
3) Install new gasket (2), fuel pump assembly (1) and
earth bracket (5) with plate (3) to fuel tank (4).
Tightening torque
Fuel pump assembly bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)
4) Connect fuel feed pipe (1) to fuel pump assembly
(2).5) Install fuel tank to vehicle. Refer to “Fuel Tank
Removal and Installation”.
Main Fuel Level Sensor Removal and
Installation
S6RW0D1706019
CAUTION!
• Do not touch resister plate (1) and deform
arm (2). It may cause main fuel level sensor
to fail.
• Be very careful not to cause damage to
fuel tube installed section (sealed section
in bore). If it be damaged, replace it with
new one, or fuel will leak from the part.

Removal
1) Remove fuel pump assembly from fuel tank referring
to “Fuel Pump Assembly Removal and Installation”.
2) Disconnect main fuel level sensor connector (3).
3) With pressing snap-fit part (2), remove main fuel
level sensor (1) by sliding it in the arrow direction as
shown in figure.
Installation
Reverse removal procedure for installation.
3
1 2 4
I5JB0A171025-01
3
1
2
(a)
4
5
I7RW01170012-01
1
2
I7RW01170011-01
1
2I4RS0A170016-01
1 3
12
I5JB0A171026-01

Downloaded from www.Manualslib.com manuals search engine 1G-17 Fuel System:
Fuel Pump InspectionS6RW0D1706016
• Check fuel pump assembly for damage.
• Check fuel suction filter for evidence of dirt and
contamination.
If present, replace or clean and check for presence of
dirt in fuel tank.
• For electrical circuit, refer to “Fuel Pump and Its
Circuit Check in Section 1A”.
• For inspection of fuel level gauge (1), refer to “Fuel
Level Sensor Inspection in Section 9C”.
Specifications
Tightening Torque SpecificationsS6RW0D1707001
NOTE
The specified tightening torque is also described in the following.
“Fuel System Components”
“Fuel Hose Disconnecting and Reconnecting”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
1
I5JB0A171027-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Fuel delivery pipe bolt 25 2.5 18.0)
Ground wire bolt 11 1.1 8.0)
Fuel tank bolt 45 4.5 33.0)
Fuel filler hose clamp 1.5 0.15 1.0)
Fuel pump assembly bolt 11 1.1 8.0)

Downloaded from www.Manualslib.com manuals search engine 1H-7 Ignition System:
High-Tension Cord InspectionS6RW0D1806002
Measure resistance of high-tension cord (1) by using
ohmmeter.
If resistance exceeds specification, replace high-tension
cord(s).
High-tension cord resistance
No.1 cylinder high-tension cord resistance: 1.4 – 4.0
kΩ
No.3 cylinder high-tension cord resistance: 0.6 – 2.0
kΩ
Spark Plug Removal and InstallationS6RW0D1806003
Removal
1) Remove air cleaner assembly with air intake pipe
and cylinder head upper cover.
2) Pull out high-tension cords by gripping their caps
and then remove ignition coil assemblies referring to
“Ignition Coil Assembly (Including Ignitor) Removal
and Installation”.
3) Remove spark plugs.
Installation
1) Install spark plugs and tighten them to specified
torque.
Tightening torque
Spark plug: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
2) Install ignition coil assemblies referring to “Ignition
Coil Assembly (Including Ignitor) Removal and
Installation”.
3) Install high-tension cords securely by gripping their
caps.
4) Install cylinder head upper cover and air cleaner
assembly with air intake pipe.
Spark Plug InspectionS6RW0D1806004
CAUTION!
• When servicing the iridium / platinum
spark plugs (slender center electrode type
plugs), do not touch the center electrode
to avoid damage to it. The electrode is not
strong enough against mechanical force
as it is slender and its material is not
mechanically tough.
• Do not clean or adjust gap for the iridium /
platinum spark plugs.

Inspect spark plug for:
• Electrode wear
• Carbon deposits
• Insulator damage
If any abnormality is found for nickel spark plugs, adjust
air gap, clean with spark plug cleaner or replace it with
specified new plug.
For iridium / platinum spark plugs, replace it with new
plug.
Spark plug air gap
“a”
: 1.0 – 1.1 mm (0.040 – 0.043 in.)
Spark plug type
NGK: BKR6E-11 (Nickel) / IFR6J11 (Iridium)
DENSO: K20PR-U11 (Nickel)
NOTE
NGK IFR6J11 is highly recommended for
better engine starting performance under –25
°C (–13 °F).

I2RH0B180005-01
IYSQ01181012-01

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-8
Ignition Coil Assembly (Including Ignitor)
Removal and Installation
S6RW0D1806005
Removal
1) Disconnect negative cable at battery.
2) Remove air cleaner assembly with air intake pipe
and cylinder head upper cover.
3) Disconnect ignition coil coupler.
4) Disconnect high-tension cord (3) from ignition coil
assembly (2).
5) Remove ignition coil bolts (1) and then pull out
ignition coil assembly.
Installation
1) Install ignition coil assembly (2).
2) Tighten ignition coil bolts (1) to specified torque, and
then connect ignition coil coupler.
Tightening torque
Ignition coil bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Install high-tension cord (3) to ignition coil assembly
while gripping its cap.
4) Install cylinder head upper cover and air cleaner
assembly with air intake pipe.
5) Connect negative cable to battery.
Ignition Coil Assembly (Including Ignitor)
Inspection
S6RW0D1806006
Measure secondary coil for resistance.
If resistance is out of specification, replace ignition coil
assembly.
Secondary coil resistance
7.6 – 10.2 kΩ at 20 ° (68 °F)
Ignition Timing InspectionS6RW0D1806007
NOTE
• Ignition timing is not adjustable. If ignition
timing is out of specification, check
system related parts.
• Before starting engine, place transmission
gear shift lever in “Neutral”, and set
parking brake.

1) Connect scan tool to DLC (1) with ignition switch
OFF.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
I2RH0B180006-01
I3RM0A180004-01
I2RH0B180007-01
(A) 1I 5 R W 0 C 11 0 0 11 - 0 1

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-10
Specifications
Tightening Torque SpecificationsS6RW0D1807001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Special ToolS6RW0D1808001
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Spark plug 25 2.5 18.0)
Ignition coil bolt 11 1.1 8.0)
09930–76420 SUZUKI scan tool (SUZUKI-
SDT)
Timing-light (dry cell type) —
)This kit includes following
items. 1. SUZUKI-SDT 2.
DLC3 cable 3. USB cable 4.
AC/DC power supply 5.
Voltage meter probe 6.
Storage case )
1
2
34
56

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-2
Condition Possible cause Correction / Reference Item
Motor not running (No
operating sound of
magnetic switch)Transmission range sensor is not in P or
N, or not adjusted (A/T model)Shift in P or N, or adjust sensor. (A/T model)
Battery run downRecharge battery.
Battery voltage too low due to battery
deteriorationReplace battery.
Poor contact in battery terminal
connectionRetighten or replace.
Loose grounding cable connectionRetighten.
Fuse set loose or blown offTighten or replace.
Poor contacting action of ignition switch
and magnetic switchReplace.
Lead wire coupler loose in placeRetighten.
Open-circuit between ignition switch and
magnetic switchRepair.
Open-circuit in pull-in coilReplace magnetic switch.
Brushes are seating poorly or worn
downRepair or replace.
Poor sliding of plunger and/or pinionRepair.
Faulty starting motor control relay“Main Relay, Fuel Pump Relay, Starting Motor
Control Relay, Throttle Actuator Control Relay
and Radiator Cooling Fan Relay Inspection in
Section 1C”.
Faulty ECM and its circuit“Inspection of ECM and Its Circuits in Section
1A”.
Motor not running
(Operating sound of
magnetic switch heard)Battery run downRecharge battery.
Battery voltage too low due to battery
deteriorationReplace battery.
Loose battery cable connectionsRetighten.
Burnt main contact point, or poor
contacting action of magnetic switchReplace magnetic switch.
Brushes are seating poorly or worn
downRepair or replace.
Weakened brush springReplace.
Burnt commutatorReplace armature.
Layer short-circuit of armatureReplace.
Crankshaft rotation obstructedRepair.
Starting motor running
but too slow (small
torque) (If battery and
wiring are satisfactory,
inspect starting motor)Insufficient contact of magnetic switch
main contactsReplace magnetic switch.
Layer short-circuit of armatureReplace.
Disconnected, burnt or worn
commutatorRepair commutator or replace armature.
Worn brushesReplace brush.
Weakened brush springsReplace spring.
Burnt or abnormally worn end bushReplace bush.
Starting motor running,
but not cranking engineWorn pinion tipReplace over-running clutch.
Poor sliding of over-running clutchRepair.
Over-running clutch slippingReplace over-running clutch.
Worn teeth of ring gearReplace flywheel (M/T model) or drive plate (A/
T model).
NoiseAbnormally worn bushReplace bush.
Worn pinion or worn teeth of ring gearReplace over-running clutch, flywheel (M/T
model) or drive plate (A/T model).
Poor sliding of pinion (failure in return
movement)Repair or replace.
Worn internal or planetary gear teethReplace.
Lack of oil in each partLubricate.

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 1J-8 Charging System:
3) After loosening generator bracket bolts (2) and pivot
bolt (3), adjust belt tension to specification described
at step 2) by loosening / tightening generator adjust
bolt (1).
4) Tighten generator bracket bolts and pivot bolt as
specified torque.
Tightening torque
Generator bracket bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Generator pivot bolt (b): 50 N·m (5.0 kgf-m, 36.0
lb-ft)
5) Check belt tension for specification after turning
crankshaft two rotations clockwise.
6) Tighten generator adjusting bolt (1) as specified
torque.
Tightening torque
Generator adjusting bolt (c): Tighten 7.0 N·m (
0.7 kgf-m, 5.0 lb-ft) by the specified procedure.
7) Connect negative cable at battery.
Water Pump / Generator Drive Belt Removal and
Installation
S6RW0D1A06007
Removal
1) Disconnect negative cable at battery.
2) If vehicle equipped with A/C, remove compressor
drive belt before removing water pump belt (1).
Refer to “Compressor Drive Belt Removal and
Installation in Section 7B” or “Compressor Drive Belt
Removal and Installation in Section 7B”.
3) Loosen generator bracket bolts (2) and generator
pivot bolt (3).
4) Loosen generator adjusting bolt (4), and then
remove water pump belt.
installation
1) Install belt (1) to water pump pulley (2), crankshaft
pulley (3) and generator pulley (4).
2) Adjust belt tension referring to “Water Pump /
Generator Drive Belt Tension Inspection and
Adjustment”.
3) If vehicle equipped with A/C, install compressor drive
belt referring to “Compressor Drive Belt Removal
and Installation in Section 7B” or “Compressor Drive
Belt Removal and Installation in Section 7B”.
4) Connect negative cable at battery.
a
I5RW0C160006-01
1, (c)
2, (a)
3, (b)
I5RW0C160007-01
4
23
1
I5RW0C160008-01
2
1
34I5RW0C160009-01

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. )