AIR SUZUKI SX4 2006 1.G Service Repair Manual

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Engine Symptom DiagnosisS6RW0D1104010
Perform troubleshooting referring to the followings when ECM has detected no DTC and no abnormality has been
found in “Visual Inspection” and “Engine Basic Inspection”.
Condition Possible cause Correction / Reference Item
Hard starting (Engine
cranks OK)Faulty spark plug“Spark Plug Inspection in Section 1H”
Leaky high-tension cord“High-Tension Cord Inspection in Section 1H”
Loose connection or disconnection of
high-tension cord(s) or lead wire(s)“High-Tension Cord Removal and Installation
in Section 1H”
Faulty ignition coil“Ignition Coil Assembly (Including Ignitor)
Inspection in Section 1H”
Dirty or clogged fuel hose or pipe“Fuel Pressure Check”
Malfunctioning fuel pump“Fuel Pressure Check”
Air drawn in through intake manifold
gasket or throttle body gasket
Faulty electric throttle body assembly“Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly“Accelerator Pedal Position (APP) Sensor
Assembly Inspection in Section 1C”
Faulty ECT sensor or MAF sensor“Engine Coolant Temperature (ECT) Sensor
Inspection in Section 1C” or “Intake Air
Temperature (IAT) Sensor Inspection in
Section 1C”
Faulty ECM
Low compression“Compression Check in Section 1D”
Poor spark plug tightening or faulty
gasket“Spark Plug Removal and Installation in
Section 1H”
Compression leak from valve seat“Valves and Valve Guides Inspection in
Section 1D”
Sticky valve stem“Valves and Valve Guides Inspection in
Section 1D”
Weak or damaged valve springs“Valve Spring Inspection in Section 1D”
Compression leak at cylinder head
gasket“Cylinder Head Inspection in Section 1D”
Sticking or damaged piston ring“Cylinders, Pistons and Piston Rings
Inspection in Section 1D”
Worn piston, ring or cylinder“Cylinders, Pistons and Piston Rings
Inspection in Section 1D”
Malfunctioning PCV valve“PCV Valve Inspection in Section 1B”
Camshaft position control (VVT) system
out of order (for engine with VVT
system)“Oil Control Valve Inspection (For Engine with
VVT) in Section 1D”
Faulty EGR system“EGR System Inspection (If Equipped) in
Section 1B”
Low oil pressureImproper oil viscosity“Engine Oil and Filter Change in Section 0B”
Malfunctioning oil pressure switch“Oil Pressure Switch Inspection in Section 9C”
Clogged oil strainer“Oil Pan and Oil Pump Strainer Cleaning in
Section 1E”
Functional deterioration of oil pump“Oil Pump Inspection in Section 1E”
Worn oil pump relief valve“Oil Pump Inspection in Section 1E”
Excessive clearance in various sliding
parts

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Engine overheatingInoperative thermostat“Thermostat Inspection in Section 1F”
Poor water pump performance“Water Pump Inspection in Section 1F”
Clogged or leaky radiator“Radiator On-Vehicle Inspection and Cleaning
in Section 1F”
Improper engine oil grade“Engine Oil and Filter Change in Section 0B”
Clogged oil filter or oil strainer“Oil Pressure Check in Section 1E”
Poor oil pump performance“Oil Pressure Check in Section 1E”
Faulty radiator cooling fan control
system“Radiator Cooling Fan Control System Check”
Dragging brakesCondition “Dragging brakes” in “Brakes
Symptom Diagnosis in Section 4A”
Slipping clutch (for M/T model)Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis in Section 5C” for M/T
model
Blown cylinder head gasket“Cylinder Head Inspection in Section 1D”
Air mixed in cooling system
Poor gasoline mileageLeaks or loose connection of high-
tension cord“High-Tension Cord Removal and Installation
in Section 1H”
Faulty spark plug (improper gap, heavy
deposits and burned electrodes, etc.)“Spark Plug Inspection in Section 1H”
Malfunctioning EGR valve“EGR Valve Inspection (If Equipped) in Section
1B”
High idle speedCondition “Improper engine idling or engine
fails to idle”
Poor performance of ECT sensor, MAF
sensor“Engine Coolant Temperature (ECT) Sensor
Inspection in Section 1C”, or “Intake Air
Temperature (IAT) Sensor Inspection in
Section 1C”
Faulty electric throttle body assembly“Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly“Accelerator Pedal Position (APP) Sensor
Assembly Inspection in Section 1C”
Faulty fuel injector(s)“Fuel Injector Circuit Check”
Faulty ECM
Low compression“Compression Check in Section 1D”
Poor valve seating“Valves and Valve Guides Inspection in
Section 1D”
Dragging brakesCondition “Dragging brakes” in “Brakes
Symptom Diagnosis in Section 4A”
Slipping clutch (for M/T model)Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis in Section 5C” for M/T
model
Thermostat out of order“Thermostat Inspection in Section 1F”
Improper tire pressure“Tires Description in Section 2D”
Camshaft position control (VVT) system
out of order (for engine with VVT
system)“Oil Control Valve Inspection (For Engine with
VVT) in Section 1D”
Excessive engine oil
consumption – Oil
leakageBlown cylinder head gasket“Cylinder Head Inspection in Section 1D”
Leaky camshaft oil seals“Camshaft, Tappet and Shim Inspection in
Section 1D” Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 1A-48 Engine General Information and Diagnosis:
Excessive engine oil
consumption – Oil
entering combustion
chamberSticky piston ring“Cylinders, Pistons and Piston Rings
Inspection in Section 1D”
Worn piston and cylinder“Cylinders, Pistons and Piston Rings
Inspection in Section 1D”
Worn piston ring groove and ring“Cylinders, Pistons and Piston Rings
Inspection in Section 1D”
Improper location of piston ring gap“Pistons, Piston Rings, Connecting Rods and
Cylinders Disassembly and Assembly in
Section 1D”
Worn or damaged valve stem seal“Valves and Valve Guides Inspection in
Section 1D”
Worn valve stem“Valves and Valve Guides Inspection in
Section 1D”
Engine hesitates –
Momentary lack of
response as accelerator
is depressed. Can occur
at all vehicle speeds.
Usually most severe when
first trying to make
vehicle move, as from a
stop sign.Spark plug faulty or plug gap out of
adjustment“Spark Plug Inspection in Section 1H”
Leaky high-tension cord“High-Tension Cord Inspection in Section 1H”
Fuel pressure out of specification“Fuel Pressure Check”
Malfunctioning EGR valve“EGR Valve Inspection (If Equipped) in Section
1B”
Poor performance of ECT sensor or
MAF sensor, “Engine Coolant Temperature (ECT) Sensor
Inspection in Section 1C” or “Intake Air
Temperature (IAT) Sensor Inspection in
Section 1C”
Faulty electric throttle body assembly“Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly“Accelerator Pedal Position (APP) Sensor
Assembly Inspection in Section 1C”
Faulty fuel injector“Fuel Injector Circuit Check”
Faulty ECM
Engine overheatingCondition “Engine overheating”
Low compression“Compression Check in Section 1D”
Camshaft position control (VVT) system
out of order (for engine with VVT
system)“Oil Control Valve Inspection (For Engine with
VVT) in Section 1D”
Surge – Engine power
variation under steady
throttle or cruise. Feels
like vehicle speeds up
and down with no change
in accelerator pedal.Leaky or loosely connected high-tension
cord“High-Tension Cord Removal and Installation
in Section 1H”
Faulty spark plug (excess carbon
deposits, improper gap, burned
electrodes, etc.)“Spark Plug Inspection in Section 1H”
Variable fuel pressure“Fuel Pressure Check”
Kinky or damaged fuel hose and lines
Faulty fuel pump (clogged fuel filter)
Malfunctioning EGR valve“EGR Valve Inspection (If Equipped) in Section
1B”
Poor performance of MAF sensor“Intake Air Temperature (IAT) Sensor
Inspection in Section 1C”
Faulty fuel injector“Fuel Injector Circuit Check”
Faulty ECM
Faulty electric throttle body assembly“Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly“Accelerator Pedal Position (APP) Sensor
Assembly Inspection in Section 1C” Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-49
Excessive detonation –
Engine makes
continuously sharp
metallic knocks that
change with throttle
opening. Sounds like pop
corn popping.Faulty spark plug“Spark Plug Inspection in Section 1H”
Loose connection of high-tension cord“High-Tension Cord Removal and Installation
in Section 1H”
Engine overheatingCondition “Engine overheating”
Clogged fuel filter (faulty fuel pump) or
fuel lines“Fuel Pressure Check” or “Fuel Pump and Its
Circuit Check”
Air drawn in through intake manifold or
throttle body gasket
Malfunctioning EGR valve“EGR Valve Inspection (If Equipped) in Section
1B”
Poor performance of knock sensor, ECT
sensor or MAF sensor“DTC P0327 / P0328: Knock Sensor Circuit
Low / High”, “Engine Coolant Temperature
(ECT) Sensor Inspection in Section 1C” or
“Intake Air Temperature (IAT) Sensor
Inspection in Section 1C”
Faulty fuel injector(s)“Fuel Injector Circuit Check”
Faulty ECM
Excessive combustion chamber
deposits“Cylinders, Pistons and Piston Rings
Inspection in Section 1D” and/or “Piston Pins
and Connecting Rods Inspection in Section
1D”
Camshaft position control (VVT) system
out of order (for engine with VVT
system)“Oil Control Valve Inspection (For Engine with
VVT) in Section 1D”
Engine has no powerFaulty spark plug“Spark Plug Inspection in Section 1H”
Faulty ignition coil with ignitor“Ignition Coil Assembly (Including Ignitor)
Inspection in Section 1H”
Leaks, loose connection or
disconnection of high-tension cord“High-Tension Cord Removal and Installation
in Section 1H”
Faulty knock sensor“DTC P0327 / P0328: Knock Sensor Circuit
Low / High”
Clogged fuel hose or pipe“Fuel Pressure Check”
Malfunctioning fuel pump“Fuel Pump and Its Circuit Check”
Air drawn in through intake manifold
gasket or throttle body gasket
Engine overheatingCondition “Engine overheating”
Malfunctioning EGR valve“EGR Valve Inspection (If Equipped) in Section
1B”
Poor performance of ECT sensor or
MAF sensor“Engine Coolant Temperature (ECT) Sensor
Inspection in Section 1C” or “Intake Air
Temperature (IAT) Sensor Inspection in
Section 1C”
Faulty electric throttle body assembly“Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly“Accelerator Pedal Position (APP) Sensor
Assembly Inspection in Section 1C”
Faulty fuel injector(s)“Fuel Injector Circuit Check”
Faulty ECM
Dragging brakesCondition “Dragging brakes” in “Brakes
Symptom Diagnosis in Section 4A”
Slipping clutch (for M/T model)Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis in Section 5C” (for M/T
model)
Low compression“Compression Check in Section 1D”
Camshaft position control (VVT) system
out of order (for engine with VVT
system)“Oil Control Valve Inspection (For Engine with
VVT) in Section 1D” Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 1A-50 Engine General Information and Diagnosis:
Improper engine idling or
engine fails to idleFaulty spark plug“Spark Plug Inspection in Section 1H”
Leaky or disconnected high-tension cord“High-Tension Cord Removal and Installation
in Section 1H”
Faulty ignition coil with ignitor“Ignition Coil Assembly (Including Ignitor)
Inspection in Section 1H”
Fuel pressure out of specification“Fuel Pressure Check”
Leaky manifold, throttle body, or cylinder
head gasket
Malfunctioning EGR valve“EGR Valve Inspection (If Equipped) in Section
1B”
Faulty evaporative emission control
system“EVAP Canister Purge Inspection in Section
1B”
Faulty EGR system“EGR System Inspection (If Equipped) in
Section 1B”
Faulty fuel injector(s)“Fuel Injector Circuit Check”
Poor performance of ECT sensor or
MAF sensor“Engine Coolant Temperature (ECT) Sensor
Inspection in Section 1C”, or “Intake Air
Temperature (IAT) Sensor Inspection in
Section 1C”
Faulty electric throttle body assembly“Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly“Accelerator Pedal Position (APP) Sensor
Assembly Inspection in Section 1C”
Faulty ECM
Loose connection or disconnection of
vacuum hoses
Malfunctioning PCV valve“PCV Valve Inspection in Section 1B”
Engine overheatingCondition “Engine overheating”
Low compression“Compression Check in Section 1D”
Camshaft position control (VVT) system
out of order (for engine with VVT
system)“Oil Control Valve Inspection (For Engine with
VVT) in Section 1D” Condition Possible cause Correction / Reference Item

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Excessive hydrocarbon
(HC) emission or carbon
monoxide (CO)Faulty spark plug“Spark Plug Inspection in Section 1H”
Leaky or disconnected high-tension cord“High-Tension Cord Removal and Installation
in Section 1H”
Faulty ignition coil with ignitor“Ignition Coil Assembly (Including Ignitor)
Inspection in Section 1H”
Low compression“Compression Check in Section 1D”
Lead contamination of three way
catalytic converterCheck for absence of filler neck restrictor.
Faulty evaporative emission control
system“EVAP Canister Purge Inspection in Section
1B”
Fuel pressure out of specification“Fuel Pressure Check”
Closed loop system (A/F feedback
compensation) fails (Poor performance
of ECT sensor or MAF sensor)“Engine Coolant Temperature (ECT) Sensor
Inspection in Section 1C” or “Intake Air
Temperature (IAT) Sensor Inspection in
Section 1C”
Faulty electric throttle body assembly“Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly“Accelerator Pedal Position (APP) Sensor
Assembly Inspection in Section 1C”
Faulty injector(s)“Fuel Injector Circuit Check”
Faulty ECM
Engine not at normal operating
temperature
Clogged air cleaner“Air Cleaner Filter Inspection and Cleaning in
Section 1D”
Vacuum leaks“Engine Vacuum Check in Section 1D”
Camshaft position control (VVT) system
out of order (for engine with VVT
system)“Oil Control Valve Inspection (For Engine with
VVT) in Section 1D”
Excessive nitrogen
oxides (NOx) emissionImproper ignition timing“Ignition Timing Inspection in Section 1H”
Lead contamination of catalytic
converterCheck for absence of filler neck restrictor.
Faulty EGR system“EGR System Inspection (If Equipped) in
Section 1B”
Fuel pressure out of specification“Fuel Pressure Check”
Closed loop system (A/F feedback
compensation) fails (Poor performance
of ECT sensor or MAF sensor)“Engine Coolant Temperature (ECT) Sensor
Inspection in Section 1C” or “Intake Air
Temperature (IAT) Sensor Inspection in
Section 1C”
Faulty electric throttle body assembly“Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly“Accelerator Pedal Position (APP) Sensor
Assembly Inspection in Section 1C”
Faulty injector(s)“Fuel Injector Circuit Check”
Faulty ECM
Camshaft position control (VVT) system
out of order (for engine with VVT
system)“Oil Control Valve Inspection (For Engine with
VVT) in Section 1D” Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-53
Troubleshooting
NOTE
• Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection”.
• When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”.

Step Action Yes No
1MIL power supply check
1) Turn ignition switch to ON position.
Do other warning lights come ON?Go to Step 2. Go to Step 3.
2DTC check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Turn ON ignition switch and check DTC in ECM.
Is there DTC(s) U0073 and/or U0121?Go to applicable DTC
diag. flow.Go to Step 3.
3Combination meter power supply and ground circuit
check
1) Turn ignition switch OFF position.
2) Disconnect connector from combination meter.
3) Check for proper connection to power supply and
ground terminals of combination meter connector.
4) If connections are OK, check that combination meter
circuit is as follows.
• Circuit voltage between combination meter power
supply terminal and vehicle body ground is 10 –14 V.
• Wiring harness resistance of combination meter
ground terminal and vehicle body ground is less than
3 Ω.
Are they in good condition?Go to Step 4. Repair or replace.
4CAN communication line circuit check
1) Check CAN communication line circuit between control
modules for open, short, high resistance and
connections referring to Step 5 to 10 under
“Troubleshooting for Communication Error with Scan
Tool Using CAN”.
Is circuit in good condition?Substitute a known-
good combination meter
and recheck. If MIL still
remains OFF, substitute
a known-good ECM and
recheck.Repair or replace.

Downloaded from www.Manualslib.com manuals search engine 1A-54 Engine General Information and Diagnosis:
Malfunction Indicator Lamp Remains ON after Engine StartsS6RW0D1104012
Wiring Diagram
Refer to “Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can
Be Started)”.
Circuit Description
When the ignition switch is turned ON, ECM causes the main relay to turn ON (close the contact point). Then, ECM
being supplied with the main power, transmits indication ON signal of malfunction indicator lamp (MIL) to combination
meter in order to turn MIL ON. And then, combination meter turns MIL ON. When the engine starts to run and no
malfunction is detected in the system, ECM transmits MIL indication OFF signal to combination meter in order to turn
MIL OFF. And then, combination meter turns MIL OFF, but if a malfunction was or is detected, MIL remains ON even
when the engine is running.
Troubleshooting
NOTE
• Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection”.
• When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”.

Step Action Yes No
1DTC check
1) Start engine and recheck DTC of ECM and TCM (for A/T
model) while engine running.
Is there any DTC(s)?Go to Step 2 of “Engine
and Emission Control
System Check”, Step 2
of “A/T System Check in
Section 5A”.Go to Step 2.
2CAN communication line circuit check
1) Check CAN communication line circuit between control
modules for open, short, high resistance and
connections referring to Step 5 to 10 under
“Troubleshooting for Communication Error with Scan
Tool Using CAN”.
Is circuit in good condition?Substitute a known-
good combination meter
and recheck. If MIL still
remains ON, substitute
a known-good ECM and
recheck.Repair or replace CAN
communication circuit.

Downloaded from www.Manualslib.com manuals search engine 1A-58 Engine General Information and Diagnosis:
DTC Troubleshooting
NOTE
Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to
“Precautions for DTC Troubleshooting”.

Step Action Yes No
1Was “Engine and Emission Control System Check”
performed?Go to Step 2. Go to “Engine and
Emission Control
System Check”.
2Do you have SUZUKI scan tool?Go to Step 3. Go to Step 5.
3Camshaft position control check
1) With ignition switch turned OFF, connect SUZUKI scan
tool.
2) Start engine and warm up to normal operating
temperature.
3) Select menu to “Data List”.
4) Check that “VVT GAP” displayed on SUZUKI scan tool is
0 – 3°.
Is it OK?Go to Step 4. Check valve timing
referring to “Timing
Chain and Chain
Tensioner Removal and
Installation in Section
1D”. If OK, go to Step 5.
4Camshaft position control check
1) Drive vehicle under following conditions.
• Vehicle speed at 80 km/h (50 mile/h).
• Gear position at 5th or D range.
2) Check that “VVT GAP” displayed on SUZUKI scan tool is
0 – 5°.
Is it OK?Substitute a known-
good ECM and recheck.Go to Step 5.
5Oil control circuit visual inspection
1) Remove cylinder head cover referring to “Cylinder Head
Cover Removal and Installation in Section 1D”.
2) Check oil pressure leakage from oil control circuit.
Is it in good condition?Go to Step 6. Repair or replace.
6Oil control valve and oil gallery pipe check
1) Remove oil control valve referring to “Oil Control Valve
Removal and Installation (For Engine with VVT) in
Section 1D”.
2) Remove oil gallery pipe referring to “Timing Chain Cover
Removal and Installation in Section 1D”.
3) Check oil gallery pipe and oil control valve for clog or
sludge.
Are they in good condition?Go to Step 7. Clean oil control valve
and oil gallery pipe.
Replace oil control valve
if a problem is not
solved after cleaning oil
control valve and oil
gallery pipe.
7Oil control valve electrical circuit check
1) Check that oil control valve circuit is in good condition
referring to “DTC P0010: Camshaft Position Actuator
Circuit (for engine with VVT system)”.
Is circuit in good condition?Repair circuit. Go to Step 8.
8Oil control valve check
1) Check oil control valve referring to “Oil Control Valve
Inspection (For Engine with VVT) in Section 1D”.
Is it in good condition?Replace camshaft
timing sprocket.Replace oil control
valve.

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-63
DTC P0101: Mass Air Flow Circuit Range / PerformanceS6RW0D1104017
Wiring Diagram
DTC Detecting Condition and Trouble Area
E01C01
3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238 3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238
BLK/WHT
BLK/RED
BLK/RED
WHTBLK/YELBLK/YEL
BLK/YEL
GRN
BRN/WHT
12V5V
5V
2
34E01-29
E01-1
E01-60
C01-58
C01-15 C01-30
BLK/ORN
BLKBLK
BLK/REDE01-16
BLK/YEL
GRY/BLU
1BLK/RED
C01-25
C01-55 5
E01-31 BLK
GRY/BLU
GRY
GRN/BLKC01-26
C01-27
I6RW0D110022-02
1. MAF and IAT sensor 3. Main relay 5. To other sensors
2. Ignition switch 4. ECM
DTC detecting condition Trouble area
• MAF volume is greater than specified value after warming up engine with
idling condition.
• MAF volume is lower than specified value at high speed condition.
(2 driving cycle detection logic)• Air intake system (clog or leakage)
• MAF sensor circuit
• MAF sensor
• TP sensor and/or its circuit
• MAP sensor and/or its circuit
•ECM