Ignition switch SUZUKI SX4 2006 1.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine 1A-18 Engine General Information and Diagnosis:
Engine and Emission Control Input / Output TableS6RW0D1101010
INPUTOUTPUT
ELECTRIC CONTROL DEVICE
BAROMETRIC PRESSURE SENSOR
BRAKE LIGHT SWITCH
START SWITCH
IGNITION SWITCH
A/C REFRIGERANT PRESSURE SENSOR (if equipped with A/C)
BLOWER SWITCH
A/C SWITCH (if equipped with A/C)
A/C EVAP OUTLET AIR TEMP. SENSOR (if equipped with A/C)
WHEEL SPEED SENSOR
HEATED OXYGEN SENSOR-1
HEATED OXYGEN SENSOR-2 (if equipped)
IAT SENSOR OF MAF AND IAT SENSOR MAF SENSOR OF MAF AND IAT SENSOR
ECT SENSOR
TP SENSOR
THROTTLE ACTUATOR
A/C CONDENSER FAN RELAY FUEL PUMP RELAY
FUEL INJECT
THROTTLE ACTUATOR CONTROL RELAYOR
HO2S HEATER
IGNITION COIL WITH IGNITER
EGR VALVE (if equipped)
EVAP CANISTER PURGE VALVEA/C COMPRESSOR RELAY (if equipped with A/C)RADIATOR FAN RELAY
MIL
MAIN RELAY
OIL CONTROL VALVE (for engine with VVT system) SIGNAL FROM SENSOR, SWITCH AND CONTROL MODULE
ABS CONTROL MODULE
KNOCK SENSOR
MAP SENSOR (if equipped)
CMP SENSOR
CKP SENSOR
IMMOBILIZER CONTROL MODULE (in ECM)
ELECTRIC LOAD (head light, rear defogger
TCM (for A/T model
P/S CONTROL MODULE))
APP SENSOR
I6RW0D110015-03

Downloaded from www.Manualslib.com manuals search engine 1A-20 Engine General Information and Diagnosis:
1. Air cleaner 17. Radiator cooling fan 33. A/C switch (A/C model)
2. EVAP canister purge valve 18. A/C condenser cooling fan 34. A/C evaporator outlet air temp. sensor (manual A/C
model)
3. MAF and IAT sensor 19. Combination meter 35. Immobilizer coil antenna
4. TP sensor 20. BCM 36. Main relay
5. MAP sensor (if equipped) 21. Ignition switch37. Wheel speed sensor (VSS) (for M/T model)
6. EGR valve (if equipped) 22. Starter magnetic switch 38. Oil control valve
7. EVAP canister 23. Heated oxygen sensor (HO2S)-2 (if
equipped)39. ABS control module
8. Tank pressure control valve (built-in fuel pump) 24. DLC 40. Starting motor control relay
9. Fuel pump (with pressure regulator) 25. Electric load 41. A/C refrigerant pressure sensor (A/C model)
10. Ignition coil assembly 26. Fuel level sensor 42. APP sensor
11. Fuel injector 27. Brake light 43. Throttle actuator control relay
12. Heated oxygen sensor (HO2S)-1 28. Brake light switch 44. Throttle actuator
13. Knock sensor 29. ECM 45. TCM (for A/T model)
14. ECT sensor 30. Barometric pressure sensor 46. Output shaft speed sensor (VSS) (for A/T model)
15. CMP sensor 31. Battery
16. CKP sensor 32. A/C compressor relay (A/C model)

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-21
Component Location
Electronic Control System Components LocationS6RW0D1103001
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

H*E*
10
D
G* C
6A
B*
e
3*
12*
a8 13
b
1
5-1
d
2
11
g
4
7
9
i
j
Fh k f
n
c J
5
K*
14
I6RW0D110016-03
Information sensors Control devices Others
1. MAF and IAT sensor a: Fuel injector A: ECM
2. Electric throttle body assembly
(built-in throttle position sensor and throttle
actuator)b: EVAP canister purge valve B: Combination meter
3. Brake light switch c: Fuel pump relay C: EVAP canister
4. ECT sensor d: EGR valve (if equipped) D: A/C evaporator outlet air temp. sensor
(if equipped with A/C)
5. Heated oxygen sensor-1 e: Malfunction indicator lamp E: Data link connector
5-1. Heated oxygen sensor-2 (if equipped) f: Radiator cooling fan relay F: A/C compressor relay (if equipped with A/C)
6. Battery g: Ignition coil assembly (with ignitor) G: BCM (included in junction block assembly)
7. CMP sensor (for engine with VVT system) h: Main relay H: Immobilizer coil antenna
8. MAP sensor (if equipped) i: Oil control valve (for engine with VVT system) J: A/C refrigerant pressure sensor
(if equipped with A/C)
9. CKP sensor j: A/C condenser cooling fan relay K: TCM (for A/T model)
10. Fuel level sensor k: Starting motor control relay
11. Knock sensor m: Immobilizer indicator lamp
12. APP sensor n: Throttle actuator control relay
13. Front wheel speed sensor (RH, LH) (VSS)
14. CMP sensor (for engine without VVT system)

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-25
Step 2: DTC / Freeze Frame Data Check, Record and
Clearance
First, check DTC (including pending DTC), referring to
“DTC Check”. If DTC is indicated, print it and freeze
frame data or write them down and then clear them by
referring to “DTC Clearance”. DTC indicates malfunction
that occurred in the system but does not indicate
whether it exists now or it occurred in the past and the
normal condition has been restored now. To check which
case applies, check the symptom in question according
to Step 5 and recheck DTC according to Step 6 and 7.
Attempt to diagnose a trouble based on DTC in this step
only or failure to clear the DTC in this step will lead to
incorrect diagnosis, trouble diagnosis of a normal circuit
or difficulty in troubleshooting.
Step 3 and 4: Visual Inspection
As a preliminary step, be sure to perform visual check of
the items that support proper function of the engine
referring to “Visual Inspection”.
Step 5: Trouble Symptom Confirmation
Based on information obtained in “Step 1: Customer
Complaint Analysis: ” and “Step 2: DTC / Freeze Frame
Data Check, Record and Clearance: ”, confirm trouble
symptoms. Also, reconfirm DTC according to “DTC
Confirmation Procedure” described in each DTC diag.
flow.
Step 6 and 7: Rechecking and Record of DTC /
Freeze Frame Data
Refer to “DTC Check” for checking procedure.
Step 8: Engine Basic Inspection and Engine
Symptom Diagnosis
Perform basic engine check according to “Engine Basic
Inspection” first. When the end of the flow has been
reached, check the parts of the system suspected as a
possible cause referring to “Engine Symptom Diagnosis”
and based on symptoms appearing on the vehicle
(symptoms obtained through steps of customer
complaint analysis, trouble symptom confirmation and/or
basic engine check) and repair or replace faulty parts, if
any.
Step 9: Troubleshooting for DTC (See each DTC
Diag. Flow)
Based on the DTC indicated in Step 6 or 7 and referring
to the applicable DTC diag. flow, locate the cause of the
trouble, namely in a sensor, switch, wire harness,
connector, actuator, ECM or other part and repair or
replace faulty parts.Step 10: Intermittent Problems Check
Check parts where an intermittent trouble is easy to
occur (e.g., wire harness, connector, etc.), referring to
“Intermittent and Poor Connection Inspection in Section
00” and related circuit of DTC recorded in Step 2.
Step 11: Final Confirmation Test
Confirm that the problem symptom has gone and the
engine is free from any abnormal conditions. If what has
been repaired is related to the DTC, clear the DTC once,
perform DTC confirmation procedure and confirm that no
DTC is indicated.
Malfunction Indicator Lamp (MIL) CheckS6RW0D1104002
1) Turn ON ignition switch (with engine at stop) and
check that MIL (1) lights.
If MIL does not light up (or MIL dims) but engine can
be starting, go to “Malfunction Indicator Lamp Does
Not Come ON with Ignition Switch ON and Engine
Stop (but Engine Can Be Started)” for
troubleshooting.
If MIL does not light with ignition switch ON and
engine does not start though it is cranked up, go to
“ECM Power and Ground Circuit Check”.
2) Start engine and check that MIL turns OFF.
If MIL remains ON and no DTC is stored in ECM, go
to “Malfunction Indicator Lamp Remains ON after
Engine Starts” for troubleshooting.
DTC CheckS6RW0D1104085
NOTE
• There are two types of OBD system
depending on the vehicle specification.
For identification, refer to “Precaution on
On-Board Diagnostic (OBD) System”.
1
I4RS0A110012-01

Downloaded from www.Manualslib.com manuals search engine 1A-26 Engine General Information and Diagnosis:
• The MIL is turned on when the ECM and/or
TCM detect malfunction(s). Each ECM and
TCM stores diagnostic information as the
diagnostic trouble code (DTC) in its
memory and outputs the DTC to the scan
tool.
Therefore, check both of the ECM and TCM
for any DTC with the scan tool because the
DTC stored in ECM and TCM is not read
and displayed at a time. However, each of
the ECM and TCM needs not to be checked
with the generic scan tool because the
DTC stored in ECM and TCM is read and
displayed at a time.

1) Prepare CAN communication OBD generic scan tool
or SUZUKI scan tool.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
2) With ignition switch OFF, connect it to DLC (1)
located on underside of instrument panel at driver’s
seat side.
3) Turn ignition switch ON and confirm that MIL lights.
4) Read DTC and freeze frame data according to
instructions displayed on scan tool and print them or
write them down. Refer to scan tool operator’s
manual for details.
If communication between scan tool and ECM is not
possible, go to “Troubleshooting for Communication
Error with Scan Tool Using CAN”.
5) After completing the check, turn ignition switch off
and disconnect scan tool from DLC.
DTC ClearanceS6RW0D1104004
NOTE
There are two types of OBD system
depending on the vehicle specification.
For identification, refer to “Precaution on On-
Board Diagnostic (OBD) System”.

1) Connect SUZUKI scan tool or CAN communication
OBD generic scan tool to data link connector in the
same manner as when making this connection for
DTC check.2) Turn ignition switch OFF and then ON.
3) Erase DTC and pending DTC according to
instructions displayed on scan tool. Freeze frame
data is cleared with the DTC. Refer to scan tool
operator’s manual for further details.
If communication between scan tool and ECM is not
possible, go to “Troubleshooting for Communication
Error with Scan Tool Using CAN”.
4) After completing the clearance, turn ignition switch
OFF and disconnect scan tool from data link
connector.
NOTE
DTC and freeze frame data stored in ECM
memory are also cleared in the following
cases. Be careful not to clear them before
keeping their record.
• When power to ECM is cut off (by
disconnecting battery cable, removing
fuse or disconnecting ECM connectors).
• When the same malfunction (DTC) is not
detected again during 40 engine warm-up
cycles. (See “Warm-Up Cycle” of “On-
Board Diagnostic System Description”.)

Troubleshooting for Communication Error with
Scan Tool Using CAN
S6RW0D1104083
Perform this troubleshooting when it is not possible to
communicate between scan tool and ECM/TCM.
NOTE
• When performing this troubleshooting, be
sure to have full understanding of
“Precaution on CAN Troubleshooting” and
observe it.
• It may be possible that CAN system has
trouble because of fuse blown or low
battery voltage. Before troubleshooting,
check to make sure that fuse, battery
voltage and generator status are normal.
• When disconnecting each control module
connector in this troubleshooting, various
DTCs will be detected. Be sure to clear
DTCs in the following control modules
after completing this troubleshooting.
–ECM
–BCM
–TCM
– Keyless start control module
– 4WD control module
– HVAC control module (Auto A/C model)
– P/S control module

(A) 1I5RW0C110011-01

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-29
Troubleshooting
Step Action Yes No
1Scan tool check
1) Disconnect scan tool from DLC with ignition switch
turned OFF.
2) Check for proper connection to all terminals of scan tool
connector.
3) If OK, connect scan tool to another vehicle of this type
with ignition switch turned OFF.
4) Check communication between scan tool and ECM by
DTC check in ECM.
Is it possible to check DTC in ECM?Go to Step 2. Scan tool faulty. Refer
to its operator’s manual.
2DLC power circuit check
1) Check for proper connection to all DLC (1) terminals with
ignition switch turned OFF.
2) If OK, measure voltage between +B terminal (2) of DLC
and vehicle body ground with ignition switch turned to
ON position.
Is voltage 10 – 14 V?Go to Step 3. Repair power circuit.
3DLC ground circuit check
1) Ignition switch turn to OFF position.
2) Check DLC (1) ground circuits as follows.
• Measure resistance between signal ground terminal
(2) of DLC and vehicle body ground.
• Measure resistance between body ground terminal (3)
of DLC and vehicle body ground.
Is resistance 1
Ω or less?Go to Step 4. Repair ground circuit(s).
4DTC Check
1) Turn ignition switch to OFF position.
2) Connect scan tool to DLC.
3) Check DTC in the following control modules that
communicate with scan tool by K-line.
•BCM
• Keyless start control module
• 4WD control module
Is there any DTC other than CAN-DTC?Go to applicable
troubleshooting of DTC
other than CAN-DTC.Go to Step 5.
2
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
1
I7RW01110096-01
23 1
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
I7RW01110097-01

Downloaded from www.Manualslib.com manuals search engine 1A-30 Engine General Information and Diagnosis:
5CAN line check between DLC and BCM
1) Turn ignition switch to OFF position.
2) Disconnect BCM connector from BCM.
3) Check for proper connection to all terminals of BCM
connector.
4) If OK, check CAN lines between DLC and BCM
connector for open, short to power circuit, short to
ground circuit, short to other CAN line and high
resistance.
Are CAN lines between DLC and BCM connector in good
condition?Go to Step 6. Repair CAN line.
6Control module connector check
1) Turn ignition switch to OFF position.
2) Disconnect all the following control module connectors.
• Control modules communicated by CAN
–ECM
–TCM
– ABS control module
–BCM
– Combination meter
– Keyless start control module
– 4WD control module
3) Check for proper connection to each CAN line terminal
of all control module (communicated by CAN)
connectors.
4) If OK, connect connectors of all control module/sensor
communicated by CAN securely.
5) Check communication between scan tool and ECM/TCM
by DTC check in ECM/TCM.
Is it possible to check DTC in ECM and TCM?Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.Go to Step 7.
7CAN line check
1) Turn ignition switch to OFF position.
2) Disconnect connectors of all control module
communicated by CAN.
3) Check all the following CAN lines for open, short to
power circuit, short to ground circuit, short to other CAN
line and high resistance.
• Between BCM connector and ABS control module
connector
• Between ABS control module connector and ECM
connector
• Between ECM connector and TCM connector
• Between BCM connector and keyless start control
module connector
• Between combination meter connector and 4WD
control module connector
• Between BCM connector and combination meter
connector
Are all CAN lines in good condition?Go to Step 8. Repair CAN line. Step Action Yes No

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-31
8Communication check between scan tool and ECM
1) Turn ignition switch to OFF position.
2) Connect ECM, BCM, ABS control module and
combination meter connectors.
3) Check communication between scan tool and ECM by
DTC check in ECM.
Is it possible to check DTC in ECM?A/T model: Go to Step
9.
M/T model: Substitute a
known-good ECM and
recheck.Go to Step 4 through
Step 11 of
“Troubleshooting for
CAN-DTC”.
9Communication check between scan tool and TCM
1) Turn ignition switch to OFF position.
2) Connect TCM connectors.
3) Check communication between scan tool and TCM by
DTC check in TCM.
Is it possible to check DTC in TCM?Identify malfunction
control module by
performing Step 13
through Step 14 of
“Troubleshooting for
CAN-DTC”.Go to Step 10.
10Internal circuit check in ECM
1) Turn ignition switch to OFF position and then disconnect
negative (–) cable at battery.
2) Disconnect TCM connectors.
3) Measure resistance between the followings
• Between CAN High terminal on DLC and “C06-17”
terminal on TCM connector
• Between CAN Low terminal on DLC and “C06-7”
terminal on TCM connector
Is each resistance 0 – 1
Ω?Substitute a known-
good TCM and recheck.Substitute a known-
good ECM and recheck. Step Action Yes No

Downloaded from www.Manualslib.com manuals search engine 1A-34 Engine General Information and Diagnosis:
)
U*P0420Catalyst system efficiency below
thresholdOutput waveforms of HO2S-1 and HO2S-2 are similar.2 driving
cycles
)
U*P0443Evaporative emission system purge
control valve circuitMonitor signal of EVAP canister purge valve is different
from command signal. (circuit open or shorted to ground)2 driving
cycles
) P0462 Fuel level sensor circuit lowCircuit voltage of fuel level sensor is less than
specification.—
) P0463 Fuel level sensor circuit highCircuit voltage of fuel level sensor is more than
specification.—
)
U*P0480Fan 1 control circuitMonitor signal of radiator cooling fan relay is different from
command signal.1 driving
cycle
)
UP0481Fan 2 control circuitMonitor signal of A/C condenser cooling fan relay is
different from command signal.—
) *P0500 Vehicle speed sensor No VSS signal during fuel cut for specified time or longer.2 driving
cycles
) P0532A/C refrigerant pressure sensor
circuit lowOutput voltage of A/C refrigerant pressure sensor is less
than specification.—
) P0533A/C refrigerant pressure sensor
circuit highOutput voltage of A/C refrigerant pressure sensor is more
than specification.—
) *P0601Internal control module memory
check sum errorData write error or check sum error.1 driving
cycle
) P0602 Control module programming error Data programming error.1 driving
cycle
) *P0607 Control module performance Data programming error.1 driving
cycle
)
U*P0616Starter relay circuit lowStarter signal is low voltage even though engine is started
with vehicle at stop.2 driving
cycles
)
U*P0617Starter relay circuit highStarter signal is high voltage for specified time while
engine is running.2 driving
cycles
) *P1510
ECM backup power supply
malfunctionBackup power voltage is out of specification after starting
engine.1 driving
cycle
) *P2101Throttle actuator control motor
circuit range/performanceMonitor signal of throttle actuator output (duty output) is
inconsistent with throttle actuator control command.1 driving
cycle
) *P2102Throttle actuator control motor
circuit lowPower supply voltage of throttle actuator control circuit is
lower than specification even if throttle actuator control
relay turned on.1 driving
cycle
) *P2103Throttle actuator control motor
circuit highPower supply voltage of throttle actuator control circuit is
higher than specification even if throttle actuator control
relay turned off.1 driving
cycle
) *P2111Throttle actuator control system –
stuck openThrottle valve default opening is greater than 8° from
complementary closed position when diagnosing throttle
valve at ignition switch turned OFF.1 driving
cycle
) *P2119Throttle actuator control throttle
body range/performanceDifference between actual throttle valve opening angle
and opening angle calculated by ECM is more than
specification.1 driving
cycle
) *P2122Pedal position sensor (main) circuit
low inputOutput voltage of pedal position sensor (main) is lower
than specification.1 driving
cycle
) *P2123Pedal position sensor (main) circuit
high inputOutput voltage of pedal position sensor (main) is higher
than specification.1 driving
cycle
) *P2127Pedal position sensor (sub) circuit
low inputOutput voltage of pedal position sensor (sub) is lower
than specification.1 driving
cycle
) *P2128Pedal position sensor (sub) circuit
high inputOutput voltage of pedal position sensor (sub) is higher
than specification.1 driving
cycle
) *P2135Throttle position sensor (main / sub)
voltage correlationDifference between the opening angle based on throttle
position sensor (main) and the opening angle based on
throttle position sensor (sub) is more than specification.1 driving
cycle DTC No. Detecting itemDetecting condition
(DTC will set when detecting:)MIL

Downloaded from www.Manualslib.com manuals search engine 1A-38 Engine General Information and Diagnosis:
Scan Tool DataS6RW0D1104007
As the data values are standard values estimated on the basis of values obtained from the normally operating vehicles
by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases
where the checked value does not fall within each specified data range. Therefore, judgment as abnormal should not
be made by checking with these data alone.
Also, conditions that can be checked by the scan tool are those detected by ECM and output from ECM as commands
and there may be cases where the engine or actuator is not operating (in the condition) as indicated by the scan tool.
Be sure to use the timing light to check the ignition timing.
NOTE
• There are two types of OBD system depending on the vehicle specification.
For identification, refer to “Precaution on On-Board Diagnostic (OBD) System”.
• With the CAN communication generic scan tool, only star (*) marked data in the following table can
be read.
• When checking the data with the engine running at idle or racing, be sure to shift M/T gear to the
neutral position and A/T gear to the “Park” position and pull the parking brake fully. Also, if nothing
or “no load” is indicated, turn OFF A/C (if equipped with A/C), all electric loads, P/S and all the other
necessary switches.

Scan tool data Vehicle conditionNormal condition /
reference values
*) COOLANT TEMP
(ENGINE COOLANT TEMP.)At specified idle speed after warming up 80 – 100 °C, 176 – 212 °F
*) INTAKE AIR TEMP. At specified idle speed after warming up–5 °C (23 °F) + environmental
temp. to 40 °C (104 °F) +
environmental temp.
*) ENGINE SPEED It idling with no load after warming up Desired idle speed ± 50 rpm
) DESIRED IDLE
(DESIRED IDLE SPEED)It idling with radiator cooling fan stopped and all
electrical parts turned OFF after warming up, M/T at
neutral700 rpm
*) MAF
(MASS AIR FLOW RATE)At specified idle speed with no load after warming up1.0 – 4.0 g/s 0.14 – 0.52 lb/
min.
At 2500 r/min. with no load after warming up4.0 – 9.0 g/s 0.53 – 1.58 lb/
min.
*) CALC LOAD
(CALCULATED LOAD
VA L U E )At specified idle speed with no load after warming up 16 – 36%
At 2500 r/min. with no load after warming up 10 – 30%
*) MAP
(INTAKE MANIFOLD
ABSOLUTE PRESSURE) (if
equipped)At specified idle speed with no load after warming up 24 – 38 kPa, 7.1 – 11.2 in.Hg
*) THROTTLE POSITION
(RELATIVE THROTTLE
POSITION)Ignition switch ON /
warmed up engine
stoppedAccelerator pedal released 0 – 12%
Accelerator pedal depressed
fully90 – 100%
*) BAROMETRIC PRES —Barometric pressure is
displayed
) FUEL TANK LEVEL Ignition switch ON 0 – 100%
*) BATTERY VOLTAGE Ignition switch ON / engine at stop 10 – 14 V
) BRAKE SWITCH Ignition switch ONBrake pedal is released OFF
Brake pedal is depressed ON
*) FUEL SYSTEM B1
(FUEL SYSTEM STATUS)At specified idle speed after warming up CLSD (closed loop)
*) O2S B1 S1
(HEATED OXYGEN
SENSOR-1)At specified idle speed after warming up 0.1 – 0.95 V
*)
O2S B1 S2
(HEATED OXYGEN
SENSOR-2) (if equipped)At 2000 r/min. for 3 min. or longer after warming up 0.1 – 0.95 V