Front bumper SUZUKI SX4 2006 1.G Service Workshop Manual
[x] Cancel search | Manufacturer: SUZUKI, Model Year: 2006, Model line: SX4, Model: SUZUKI SX4 2006 1.GPages: 1556, PDF Size: 37.31 MB
Page 374 of 1556
Downloaded from www.Manualslib.com manuals search engine 1F-9 Engine Cooling System:
5) Remove cooling fan mounting bolts (1).
6) Remove radiator cooling fan assembly (2).
Installation
Reverse removal procedure for installation noting the
following.
• Refill cooling system referring to Step 7) to 17) of
“Cooling System Flush and Refill”.
• After installation, verify there is no coolant leakage at
each connection.
Radiator Cooling Fan Disassembly and
Reassembly
S6RW0D1606018
Disassembly
1) Remove fan (1) from cooling fan motor (2).
2) Remove fan motor (2) from cooling fan guide (3).
Reassembly
Reverse disassembly procedures for reassembly.
Radiator On-Vehicle Inspection and CleaningS6RW0D1606012
Inspection
Check radiator for leakage or damage. Straighten bent
fins, if any.
Cleaning
Clean frontal area of radiator cores.
Radiator Removal and InstallationS6RW0D1606013
Removal
1) Disconnect negative cable at battery.
2) Drain coolant referring to “Cooling System Draining”.
3) Remove front bumper referring to “Front Bumper
and Rear Bumper Components in Section 9K”.
4) Remove cooling fan assembly referring to “Radiator
Cooling Fan Assembly Removal and Installation”.
5) Remove condenser fan referring to “Condenser
Cooling Fan Removal and Installation in Section 7B”.
6) Remove radiator outlet hose from radiator.
7) Remove radiator from vehicle.
Installation
Reverse removal procedures, noting the following.
Tighten radiator support bracket bolts to specified
torque.
Tightening torque
Radiator support bracket bolt: 33 N·m (3.3 kgf-m,
24.0 lb-ft)
• Refill cooling system referring to Step 7) to 17) of
“Cooling System Flush and Refill”.
• After installation, verify there is no coolant leakage
each connection.
I5RW0C160014-01
I5RW0C160005-01
I2RH01160014-01
Page 963 of 1556
Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-23
Condenser Cooling Fan InspectionS6RW0D7216003
1) Check condenser cooling fan motor for resistance
between terminal “a” and “b” as shown.
If there is no continuity, replace condenser cooling
fan motor.
2) Connect battery to condenser cooling fan motor
terminal “a” and “b” as shown in figure, and then
check if the condenser cooling fan motor operates
smoothly.
Reference
Condenser cooling fan specified current at 12 V:
7 A maximum
Condenser Assembly On-Vehicle InspectionS6RW0D7216004
Check the followings.
• Clog of condenser fins
If any clog is found, condenser fins should be washed
with water and should be dried with compressed air.
• Condenser fins for leakage and breakage
If any defects are found, repair or replace condenser.
• Condenser fittings for leakage.
If any defects are found, repair or replace condenser.
Condenser Assembly Removal and InstallationS6RW0D7216005
CAUTION!
Do not damage condenser fins. If condenser
fin is bent, straighten it by using flat head
screwdriver or pair of pliers.
Removal
1) Recover refrigerant from A/C system referring to
“Operation Procedure for Refrigerant Charge”.
NOTE
The amount of removed compressor oil must
be measured for replenishing compressor
oil.
2) Remove front bumper referring to “Front Bumper
and Rear Bumper Components in Section 9K”.
3) Disconnect discharge hose (1) and liquid pipe (2)
from condenser assembly (3).
4) Remove radiator assembly and condenser assembly
mounting bolts (4).
ab
I5RW0A721018-02
a
b
I5RW0A721019-02
1
2
3
4
4
I7RW01721025-04
Page 1143 of 1556
Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-104
Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air
Bag System”.
3) Remove front bumper referring to “Front Bumper
and Rear Bumper Components in Section 9K”.
4) Disconnect forward impact-sensor connector (1)
sliding connector outer (2) as shown.
5) Remove forward impact-sensor bolt (3) and forward
impact-sensor (4) from apron-side-member (driver
side) (5).
Installation
CAUTION!
Proper operation of forward impact-sensor
requires sensor be rigidly attached to vehicle
structure and that the arrow on sensor be
pointing toward the front of the vehicle.
1) Check that none of the following faulty conditions
exists.
• Bend, deformity or rust of front panel.
• Foreign matter on mating surface of sensor.
2) Install forward impact-sensor (1) to apron-side-
member (driver side) (3) and tighten mounting bolt
(2) to specified torque.
Tightening torque
Forward impact-sensor mounting bolt (a): 9 N·m
(0.9 kgf-m, 6.5 lb-ft)3) Connect forward impact-sensor connector (4) by
pushing connector till click is heard from it.
4) Install front bumper referring to “Front Bumper and
Rear Bumper Components in Section 9K”.
5) Enable air bag system referring to “Enabling Air Bag
System”.
6) Connect negative (–) cable at battery.
Forward Impact-Sensor InspectionS6RW0D8206014
WARNING!
During service procedures, be very careful
when handling a sensor.
• Never strike or jar a sensor.
• A sensor and mounting bracket bolts must
be carefully torqued to assure proper
operation. Under loose connection, it
could cause improper operation of the air
bag system.
CAUTION!
• Never disassemble forward impact-sensor.
• Sensor should be replaced when it was
dropped from a height of 90 cm (3 ft) or
more.
• Check sensor for dents, cracks or deformation.
• Check sensor connector (sensor side and harness
side) and sensor connector lock mechanism for
damage or crack.
• Check connector terminals for bend, corrosion or rust.
4
2
3
5
1
I7RW01821035-01
1
2, (a)
4
3
I6RW0B820038-01
Page 1165 of 1556
Downloaded from www.Manualslib.com manuals search engine Table of Contents 9-v
Power Door Lock System Symptom
Diagnosis (If Equipped)..................................... 9F-3
Power Door Lock System Operation
Inspection (If Equipped) .................................... 9F-3
Keyless Entry System Symptom Diagnosis (If
Equipped).......................................................... 9F-4
Keyless Entry System Operation Inspection
(If Equipped) ..................................................... 9F-5
Door Lock Function of Keyless Start System
Symptom Diagnosis (If Equipped) .................... 9F-5
Rear End Door Opener System Symptom
Diagnosis (If Equipped)..................................... 9F-5
Rear End Door Opener System Operation
Inspection (If Equipped) .................................... 9F-5
Repair Instructions .............................................. 9F-6
Front Door Lock Assembly Components ............ 9F-6
Front Door Lock Assembly Removal and
Installation ......................................................... 9F-6
Front Door Lock Assembly Inspection ................ 9F-8
Power Door Lock Switch Inspection (If
Equipped).......................................................... 9F-8
Door Key Cylinder Switch Inspection (If
Equipped).......................................................... 9F-8
Power Door Lock Actuator Inspection (If
Equipped).......................................................... 9F-9
Rear Door Lock Assembly Components ........... 9F-10
Rear Door Lock Assembly Removal and
Installation ....................................................... 9F-10
Rear Door Lock Assembly Inspection ............... 9F-10
Rear End Door Lock Assembly Components.... 9F-11
Rear End Door Lock Assembly Removal and
Installation ....................................................... 9F-12
Rear End Door Lock Assembly Inspection........ 9F-12
Rear End Door Opener Switch Inspection (If
Equipped)........................................................ 9F-12
Replacement of Transmitter Battery (Other
than Keyless Start Model) ............................... 9F-13
Programming Transmitter Code for Keyless
Entry System (Other than Keyless Start
Model) ............................................................. 9F-13
Keyless Entry Answer Back Function
Change-over Procedure (If Equipped) ............ 9F-14
Keyless Entry Receiver Removal and
Installation (If Equipped)................................. 9F-14
Keyless Entry Receiver and Its Circuit
Inspection (If Equipped) .................................. 9F-15
Specifications..................................................... 9F-16
Tightening Torque Specifications ...................... 9F-16
Special Tools and Equipment ........................... 9F-16
Recommended Service Material ....................... 9F-16
Seats ......................................................... 9G-1
Diagnostic Information and Procedures ............9G-1
Front Seat Heater Symptom Diagnosis (If
Equipped)..........................................................9G-1
Repair Instructions ..............................................9G-2
Front Seat Components ......................................9G-2
Front Seat Removal and Installation ...................9G-3Front Seat Heater Switch (Driver and
Passenger Side) Inspection (If Equipped)........ 9G-3
Front Seat Heater Wire Inspection (If
Equipped) ......................................................... 9G-3
Rear Seat Components...................................... 9G-4
Rear Seat Removal and Installation................... 9G-4
Specifications ...................................................... 9G-5
Tightening Torque Specifications ....................... 9G-5
Special Tools and Equipment ............................ 9G-5
Recommended Service Material ........................ 9G-5
Interior Trim ............................................. 9H-1
Repair Instructions ..............................................9H-1
Floor Carpet Removal and Installation ................9H-1
Head Lining Removal and Installation.................9H-2
Console Box Components ..................................9H-3
Specifications .......................................................9H-4
Tightening Torque Specifications ........................9H-4
Hood / Fenders / Doors ............................ 9J-1
Repair Instructions .............................................. 9J-1
Hood Removal and Installation ........................... 9J-1
Hood Inspection and Adjustment ........................ 9J-1
Front Fender Components .................................. 9J-2
Front Fender Removal and Installation ............... 9J-2
Front Door Assembly Components ..................... 9J-3
Front Door Assembly Removal and
Installation ......................................................... 9J-3
Rear Door Assembly Components...................... 9J-5
Rear Door Assembly Removal and
Installation ......................................................... 9J-5
Rear End Door Assembly Components .............. 9J-6
Rear End Door Assembly Removal and
Installation ......................................................... 9J-6
Specifications ....................................................... 9J-8
Tightening Torque Specifications ........................ 9J-8
Special Tools and Equipment ............................. 9J-8
Recommended Service Material ......................... 9J-8
Body Structure......................................... 9K-1
Repair Instructions ..............................................9K-1
Front Bumper and Rear Bumper Components .... 9K-1
Cowl Top and Front Lower Crossmember
Components ...................................................... 9K-2
Specifications .......................................................9K-3
Body Dimensions ................................................ 9K-3
Panel Clearance................................................ 9K-10
Tightening Torque Specifications ...................... 9K-10
Paint / Coatings ........................................9L-1
General Description ............................................. 9L-1
Anti-Corrosion Treatment Construction............... 9L-1
Plastic Parts Finishing ......................................... 9L-2
Component Location ........................................... 9L-3
Sealant Application Areas ................................... 9L-3
Under Coating Application Areas ...................... 9L-10
Anti-Corrosion Compound Application Area ..... 9L-12
Exterior Trim ............................................ 9M-1
Page 1337 of 1556
Downloaded from www.Manualslib.com manuals search engine Lighting Systems: 9B-18
Reference waveform No.1
Vehicle speed signal (1).
Vehicle speed signal is pulse. Pulse frequency varies
depending on vehicle speed.
Repair Instructions
Headlight Housing Removal and InstallationS6RW0D9206001
WARNING!
• To avoid danger of being burned, don’t
touch when the bulb is hot.
• Don’t touch glass surface of bulb, to avoid
deteriorate as the case may be unclear
when bulb light on at dirty condition.
• Be sure to read “Precautions for Discharge
Headlight Service (If Equipped)” before
starting to service work.
Removal
1) Disconnect negative (–) cable at battery.
2) Remove front bumper. Refer to “Front Bumper and
Rear Bumper Components in Section 9K”.
3) Remove headlight mounting bolts.
4) Detach headlight housing (1) from vehicle.
5) Disconnect couplers (2) from headlight housing (1).Installation
Reverse removal procedure noting the following.
• Install headlight mounting bolts and clip (1), and then
tighten headlight mounting bolts (“1” – “2”) according
to numerical order as shown in figure.
• After installation, be sure to inspect and adjust aiming
referring to “Headlight Aiming Adjustment with
Screen”. Measurement terminal CH 1: “G14-16” to “G14-9”
Oscilloscope setting CH 1: 2 V
TIME: 20 ms/DIV
Measurement condition Engine is running and
vehicle speed 40 km/h (24
mph)
I6RW0C920013-02
2
1I5RW0A920004-01
1
“2”
“1”
I5RW0A920005-01
Page 1345 of 1556
Downloaded from www.Manualslib.com manuals search engine Lighting Systems: 9B-26
Front Fog Light Assembly Removal and
Installation (If Equipped)
S6RW0D9206014
WARNING!
• To avoid danger of being burned, don’t
touch when the bulb is hot.
• Don’t touch glass surface of bulb to avoid
deteriorate as the case may be unclear
when bulb light on at dirty condition.
Removal
1) Disconnect negative (–) cable at battery.
2) Remove front bumper. Refer to “Front Bumper and
Rear Bumper Components in Section 9K”.
3) Disconnect coupler from fog light (1).
4) Detach fog light pushing clips to arrow direction.
Installation
Reverse removal procedure for installation nothing the
following:
• After installing, adjust aiming referring to “Front Fog
Light Aiming Adjustment with Screen (If Equipped)”.
Front Fog Light Switch Inspection (If Equipped)S6RW0D9206016
NOTE
Front fog lights light up only when headlight
switch is in HEADLIGHT position (low or high
beams) or SMALL position. Front fog lights
turn OFF automatically when headlight
switch is turned to OFF position. If front fog
light switch holds ON position, front fog
lights turn ON automatically when headlight
switch is tuned to HEADLIGHT position (low
or high beams) or SMALL position again.
Check for continuity between terminals at each switch
position. If check result is not as specified, replace
switch.
Front Fog Light Aiming Adjustment with Screen
(If Equipped)
S6RW0D9206018
Basic Aiming
NOTE
• Unless otherwise obligated by local
regulations, adjust front fog light aiming
according to the following procedure.
• An example in case that the light-to-wall
distance 10 m is shown in the illustration.
The beam descending distance “H” is
calculated when “a” is 10 m with the
specification angle “b” (1.14°).
1) Make sure the following items.
• Place vehicle on a flat surface in front of blank wall
(screen) (1) ahead of front fog light surface.
Distance between screen and front fog light
“a”: 10 m (32.8 ft.)
• Adjust air pressure of all tired to the specified
value respectively.
• Bounce vehicle body up and down by hand to
stabilize suspension.
• Carry out aiming with a driver aboard.
Driver’s weight
75 kg (165 lb)
1
I6RW0B920006-01
1
2
3
4
5
Switch PositionTerminal
ON (PUSH IN)231
54
OFF
I4RS0A920021-01
Page 1362 of 1556
Downloaded from www.Manualslib.com manuals search engine 9C-10 Instrumentation / Driver Info. / Horn:
Cigarette Lighter Symptom Diagnosis (If Equipped)S6RW0D9304013
Horn Symptom DiagnosisS6RW0D9304014
Information Display Symptom Diagnosis (If Equipped)S6RW0D9304015
NOTE
This thermometer indicates the ambient temperature in the under side of front bumper member. Under
any one of the following listed conditions, however, even when the ambient temperature goes up, the
thermometer display does not rise so as to correct the rise of the ambient temperature caused by the
radiant heat of the engine. When the ambient temperature drops, the thermometer reading follows the
change in the temperature.
Be sure to bear this in mind when diagnosing trouble.
• The vehicle speed is 30 km/h (18 mph) or lower.
• Vehicle speed signal is faulty.
• The ignition switch is turned on again within 2 hours.
Condition Possible cause Correction / Reference Item
Cigarette lighter shows
no operationCircuit fuse blownReplace fuse and check for short circuit.
Cigarette lighter faultyCheck cigarette lighter.
Ignition switch faultyCheck ignition switch referring to “Ignition
Switch Inspection”.
Wiring or grounding faultyRepair circuit.
Condition Possible cause Correction / Reference Item
Horn does not operateCircuit fuse blownReplace fuse and check for short circuit.
Horn switch faultyCheck horn switch.
Horn relay faultyCheck horn relay referring to “Horn Relay
Inspection”.
Wiring or grounding faultyRepair circuit.
Horn faultyCheck horn referring to “Horn Inspection”.
Condition Possible cause Correction / Reference Item
No displaying of
information displayCircuit fuse BlownReplace fuse and check for short circuit.
Wiring or grounding faultyRepair circuit.
Information display unit faultyReplace unit.
Incorrect thermometer
displayOutside air temperature sensor faultyCheck outside air temperature sensor referring
to “Outside Air Temperature Sensor Inspection
(If Equipped)”.
Vehicle speed signal faultyCheck ECM for DTC referring to “DTC Check
in Section 1A”.
Wiring or grounding faultyRepair circuit.
Information display unit faultyReplace unit.
BCM faultyReplace after making sure that none of above
parts is faulty.
Display of thermometer
does not change at –30
°C
(–22
°F)Outside air temperature is –30 °C (–22
°F) or less—
Outside air temperature sensor faultyCheck outside air temperature sensor referring
to “Outside Air Temperature Sensor Inspection
(If Equipped)”.
Information display unit faultyReplace unit.
BCM faultyReplace after making sure that none of above
parts is faulty.
Page 1369 of 1556
Downloaded from www.Manualslib.com manuals search engine Instrumentation / Driver Info. / Horn: 9C-17
Outside Air Temperature Sensor Removal and
Installation (If Equipped)
S6RW0D9306013
Removal
1) Disconnect negative (–) cable at battery.
2) Remove front bumper referring to “Front Bumper
and Rear Bumper Components in Section 9K”.
3) Disconnect connector from outside air temperature
sensor.
4) Remove outside air temperature sensor (1) from
front bumper member.
Installation
Reverse removal procedure for installation.
Outside Air Temperature Sensor Inspection (If
Equipped)
S6RW0D9306014
Measure resistance of outside air temperature sensor
using an ohmmeter.
If resistance is out of specification, replace outside air
temperature sensor.
Outside air temperature sensor resistance
1.61 kΩ – 1.79 kΩ at 25 °C (77 °F)
Instrument Panel Removal and InstallationS6RW0D9306015
WARNING!
Refer to “Air Bag Warning in Section 00”
before starting service work.
Removal
1) Disconnect negative cable at battery.
2) Disable air bag system referring to “Disabling Air
Bag System in Section 8B”.
3) Remove dash side trims (4) and steering column
hole cover (1).
4) Turn steering wheel to remove steering column
cover screws (3).
5) Remove steering column covers (2).
6) Remove glove box (1).
7) Remove hood latch release lever (2).
8) Remove console box referring to “Console Box
Components in Section 9H”.
9) Remove instrument panel center lower bracket bolts
(1).
“A”: Resistance “B”: Temperature
1
I5RW0A930012-01
“B” “A”5.50
1.70
0
3225
77
F
I4RS0A930017-01
2
3
1
4I7RW01930010-01
2
1I4RS0B930008-01
1
I5RW0A930014-01
Page 1372 of 1556
Downloaded from www.Manualslib.com manuals search engine 9C-20 Instrumentation / Driver Info. / Horn:
GPS Antenna Removal and Installation (If
Equipped)
S6RW0D9306027
Removal
1) Remove combination meter cluster panel referring to
step 1) to 4) of “Combination Meter Removal and
Installation”.
2) Disconnect GPS antenna connector from navigation
unit referring to “Audio Unit Removal and Installation
(If Equipped)”.
3) Remove GPS antenna (1).
Installation
Reverse removal procedure.
Horn Removal and InstallationS6RW0D9306020
Removal
1) Disconnect negative (–) cable at battery.
2) Remove front bumper referring to “Front Bumper
and Rear Bumper Components in Section 9K”.
3) Disconnect horn connector (1).
4) Remove horn (2).
Installation
Reverse removal procedure for installation.
Horn InspectionS6RW0D9306021
1) Disconnect negative (–) cable at battery.
2) Remove front bumper referring to “Front Bumper
and Rear Bumper Components in Section 9K”.
3) Disconnect horn connector (1).
4) Connect battery positive (+) to terminal of horn
connector (2) and negative (–) terminal to body
ground.
If horn is not sounding, replace horn.
Horn Relay InspectionS6RW0D9306022
1) Disconnect negative (–) cable at battery.
2) Remove junction block.
3) Remove horn relay (1) from junction block (2).
4) Check that there is no continuity between terminals
“c” and “d”. If there is continuity, replace relay.
5) Check that there is continuity between terminals “c”
and “d” when a 12 V battery is connected to
terminals “a” and “b”. If malfunction is found, replace
it with a new one.
1
I5RW0A930022-01
12I7RW01930015-01
12
I7RW01930016-01
1
2
I4RS0B930018-01
ba
c
dc
ad
bI3JA01920006-01
Page 1377 of 1556
Downloaded from www.Manualslib.com manuals search engine Wipers / Washers: 9D-3
Washer Tank and Washer Pump Removal and
Installation
S6RW0D9406002
Removal
1) Disconnect negative (–) cable at battery.
2) Remove front bumper referring to “Front Bumper
and Rear Bumper Components in Section 9K”.
3) Disconnect washer pump lead wire couplers and
hoses.
4) Remove washer tank attaching bolts (4).
5) Remove washer tank (1).
6) Remove windshield washer pump (2) and rear
washer pump (3) from washer tank (1).
Installation
Install washer tank and washer pump by reversing
removal procedure, noting the following instructions.
• Connect washer pump connector(s) and hose
securely.
Washer Pump InspectionS6RW0D9406003
1) Connect battery positive (+) and negative (–)
terminals to pump (+) and (–) terminals respectively.
2) Check windshield and rear washer pumps for
operation.
If pump does not operate, replace washer pump.
Windshield Wiper Removal and InstallationS6RW0D9406004
Removal
1) Disconnect negative (–) cable at battery.
2) Remove wiper pivot caps (1) and wiper arm nuts (2),
and remove windshield wiper arms with wiper blades
(3).
3) Remove cowl top garnish referring to “Cowl Top and
Front Lower Crossmember Components in Section
9K”.
4) Disconnect coupler from windshield wiper motor.
5) Remove bolts (1), and remove windshield wiper
assembly (2).
5. Rear wiper arm with blade assembly 12. Wiper switch : 8 N⋅m (0.8 kgf-m, 6.0 lb-ft)
6. Rear wiper motor 13. Rear wiper relay : 5 N⋅m (0.5 kgf-m, 4.0 lb-ft)
7. Washer pump for windshield washer 14. Junction block.
5. Right side headlight housing
1
4
34245
I7RW01940007-01
I5RW0A940004-01
1
3 3
2
I4RS0B940003-03
21I5RW0A940005-02