ECO mode SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine FOREWORD
This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service
operations, replacement of components (Service) and for disassembly and assembly of major components (Unit
Repair-Overhaul).
VOLUME 1 contains General information, Engine, Suspension, Drive/Axle and Brakes sections (Sections 0 – 5).
VOLUME 2 contains Transmission/Transaxle, Steering, HVAC, Restraint, Body/Cab/Accessories and
Control Systems sections (Sections 6 – 10).
Applicable Model:
SX4 (RW415/RW416) produced at KOSAI plant in Japan with following vehicle identification number
(VIN)
The contents are classified into sections each of which is given a section number as indicated in the Table of
Contents on following page. And on the first page of each individual section is an index of that section.
This manual should be kept in a handy place for ready reference of the service work.
Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials as specified in each description.
All information, illustrations and specifications contained in this literature are based on the latest product infor-
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2006JSAGY############ ~
JS2Y#############~

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-12
Steering
• Check to ensure that steering wheel is free from
instability, or abnormally heavy feeling.
• Check that the vehicle does not wander or pull to one
side.
Engine
• Check that engine responds readily at all speeds.
• Check that engine is free from abnormal noise and
abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting system
are free from abnormal noise and abnormal vibration or
any other abnormal condition.Meters and Gauge
Check that speedometer, odometer, fuel meter,
temperature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan
switch lever to highest position for this check.
Specifications
Tightening Torque SpecificationsS6RW0D0207001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Fluids and LubricantsS6RW0D0208001
Special ToolS6RW0D0208002
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Engine oil drain plug 35 3.5 25.5)
Oil filter 14 1.4 10.5 for reference )
Engine oil SG, SH, SJ, SL or SM grade (Refer to “Engine Oil and Filter Change” for engine
oil viscosity.)
Engine coolant
(Ethylene glycol base coolant)“Antifreeze/Anticorrosion coolant”
Brake fluid Refer to reservoir cap of brake master cylinder.
Manual transaxle oil Refer to “Manual Transaxle Oil Change in Section 5B”.
Automatic transaxle fluid Refer to “A/T Fluid Change in Section 5A”.
Transfer oil (4WD) Refer to “Transfer Oil Change in Section 3C”.
Rear differential (4WD) Refer to “Rear Differential Oil Change in Section 3B”.
Door hinges Engine oil or water resistance chassis grease
Hood latch assembly Engine oil or water resistance chassis grease
Key lock cylinder Spray lubricant
09915–47331
Oil filter wrench
)

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-39
*) SHORT FT B1
(SHORT TERM FUEL TRIM)At specified idle speed after warming up –20 – +20%
*) LONG FT B1
(LONG TERM FUEL TRIM)At specified idle speed after warming up –20 – +20%
) TOTAL FUEL TRIM B1 At specified idle speed after warming up –35 – +35%
) FUEL CUTEngine at fuel cut condition ON
Engine at other than fuel cut condition OFF
) O2S B1 S2 ACT
(HEATED OXYGEN
SENSOR-2) (if equipped)At specified idle speed after warming up ACTIVE
) O2S B1 S1 ACT
(HEATED OXYGEN
SENSOR-1)At specified idle speed after warming up ACTIVE
*) CANIST PRG DUTY
(EVAP CANISTER PURGE
FLOW DUTY)At specified idle speed after warming up 0%
*) IGNITION ADVANCE
(IGNITION TIMING
ADVANCE FOR NO.1
CYLINDER)At specified idle speed with no load after warming up 5 – 15° BTDC
*) EGR VALVE OPENING (if
equipped) At specified idle speed after warming up 0%
) VVT GAP
(TARGET-ACTUAL
POSITION) (VVT model)At specified idle speed after warming up 0 – 3°
) FUEL PUMPWithin 2 seconds after ignition switch ON or engine
runningON
Engine at stop with ignition switch ON OFF
) STARTER SW
(STARTER SWITCH)Ignition switch is turned to ST (engine cranking)
positionON
) A/C PRESSURE
(A/C REFERIGERANT
ABSOLUTE PRESSURE)Engine runningA/C ON (A/C is operating) at
ambient temperature: 30 °C
(86 °F) and humidity: 50%1350 – 1650 kPa For more
details, refer to pressure of
high pressure gage under “A/C
System Performance
Inspection in Section 7B”.
A/C OFF (A/C is not
operating) at ambient
temperature: 30 °C (86 °F)
and engine coolant
temperature: 90 – 100 °C
(194 – 212 °F)600 – 1000 kPa After longer
than 10 min from A/C switch
turned off
) A/C SWITCHEngine running after warming up, A/C not operating OFF
Engine running after warming up, A/C operating ON
) A/C COMP RELAY Engine runningA/C switch and blower motor
switch turned ONON
A/C switch and blower motor
switch turned OFFOFF
) BLOWER FAN Ignition switch ON
Blower fan switch: 2nd
speed position or moreON
Blower fan switch: under 1st
speed positionOFF
) ELECTRIC LOADIgnition switch ON / Headlight, small light, all turned
OFFOFF
Ignition switch ON / Headlight, small light, all turned
ONON Scan tool data Vehicle conditionNormal condition /
reference values

Downloaded from www.Manualslib.com manuals search engine 1A-134 Engine General Information and Diagnosis:
DTC P0500: Vehicle Speed Sensor (VSS) MalfunctionS6RW0D1104050
Wiring Diagram
DTC Detecting Condition and Trouble Area9Check A/C condenser cooling fan control
1) Ignition switch turned OFF.
2) Remove ECM from vehicle body referring to “Engine
Control Module (ECM) Removal and Installation in
Section 1C” and connect connectors to ECM.
3) Run engine and turn ON A/C and blower fan switch.
4) Measure voltage between vehicle body ground and
“E01-58” wire terminal of ECM connector.
Is voltage lower 1.5 V?Intermittent trouble.
Check for intermittent
refer to “Intermittent and
Poor Connection
Inspection in Section
00”. If OK, substitute a
known-good ECM and
recheck.Faulty ECM. Step Action Yes No
[B]
REDWHTC01-13C01-12REDWHT
PPL
5IG112 V
BLK/WHT
BLK/ORN
4
6 [A]
E01-3E01-18REDWHTREDWHT
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
RED
WHT WHT
12V
12V
1
23
4
WHT/BLK
WHT BLKRED/BLK
I6RW0D110043-02
[A]: For M/T model 2. Front right side wheel speed sensor (VSS 2) 5. Output shaft speed sensor
[B]: For A/T model 3. ABS control module 6. TCM
1. Front left side wheel speed sensor (VSS 1) 4. ECM
DTC detecting condition Trouble area
Vehicle speed signal is not input while fuel is cut at deceleration
for 4 seconds at 3600 rpm or less.
(2 driving cycle detection logic)• Wheel speed sensor (VSS) (for M/T model)
• Wheel speed sensor circuit (for M/T model)
• ABS control module assembly (for M/T model)
• Output shaft speed sensor (for A/T model)
• Output shaft speed sensor circuit (for A/T
model)
• TCM malfunction (for A/T model)
• ECM malfunction

Downloaded from www.Manualslib.com manuals search engine 1A-206 Engine General Information and Diagnosis:
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”.
• When A/C evaporator outlet air temp. is below 2.5 °C (36.5 °F), A/C remains OFF (“E01-47” terminal
voltage becomes 10 – 14 V). This condition is not abnormal.

Step Action Yes No
1Reception data check from BCM
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Turn ON ignition switch.
3) Check DTC for CAN-DTC.
Is there CAN-DTC?Go to “Troubleshooting
for CAN-DTC”.Go to Step 2.
2A/C switch signal circuit check
1) Start engine and select “Data List” mode on scan tool.
2) Check A/C switch signal under following conditions
respectively.
A/C switch signal
Engine running, A/C switch OFF: OFF
Engine running, A/C switch ON and blower speed
selector turned 1st position or more: ON
Is check result satisfactory?Go to Step 3. Check A/C switch
circuit.
3DTC check of ECT sensor circuit
1) Check ECM for DTC of ECT sensor circuit.
Is there DTC P0116, DTC P0117 or DTC P0118?Go to applicable DTC
diag. flow.Go to Step 4.
4A/C condenser cooling fan control system check
Is A/C condenser cooling fan started when A/C and blower
speed selector switch are turned ON with engine running?Go to Step 10. Go to Step 5.
5A/C condenser cooling fan control circuit check
1) Check DTC with scan tool.
Is DTC P0481 displayed?Go to “DTC P0481:
Cooling Fan 2 (A/C
Condenser Fan) Control
Circuit”.Go to Step 6.

Downloaded from www.Manualslib.com manuals search engine Engine Electrical Devices: 1C-5
Electric Throttle Body System CalibrationS6RW0D1306004
NOTE
If the service described under the
“Precautions of Electric Throttle Body
System Calibration in Section 1A” is
performed, calibrate electric throttle body
system as follows.

1) If electric throttle body assembly and/or accelerator
pedal position (APP) sensor assembly are replaced,
perform following steps.
a) Disconnect negative cable at battery for 20
seconds or more for the purpose of clearing
calibration data of closed throttle position from
memory in ECM.
b) Connect negative cable to battery.
2) Keep ignition switch at ON position for 5 seconds or
more without running engine.
Accelerator Pedal Position (APP) Sensor
Assembly On-Vehicle Inspection
S6RW0D1306005
1) Check that APP sensor assembly has been mounted
to vehicle body properly (no pinched floor carpet,
etc.).
If mounting is not properly, reinstall APP sensor
assembly properly referring to “Accelerator Pedal
Position (APP) Sensor Assembly Removal and
Installation”.
2) Connect scan tool to DLC with ignition switch turned
OFF.
3) Turn ON ignition switch and select “Data List” mode
on scan tool.4) Check that accelerator pedal position sensor voltage
varies as the following graph.
If sensor voltage is out of specified value or does not
vary linearly as the following graph, check APP
sensor assembly referring to “Accelerator Pedal
Position (APP) Sensor Assembly Inspection”.
Accelerator Pedal Position (APP) Sensor
Assembly Removal and Installation
S6RW0D1306006
CAUTION!
• Do not expose APP sensor assembly to
excessive shock like a dropping it. If APP
sensor assembly has been exposed to
excessive shock, it should be replaced.
• Be careful not to expose sensor section of
APP sensor assembly to water.

NOTE
After replacing APP sensor assembly,
perform calibration of throttle valve referring
to “Electric Throttle Body System
Calibration”.

[A]: APP sensor (main) voltage
[B]: APP sensor (sub) voltage
[C]: Voltage
[D]: Idle position of accelerator pedal
[E]: Full depressed position of accelerator pedal
[C]
[D] [E]
3.50 - 4.27 V
1.74 - 2.17 V
0.65 - 0.82 V
0.30 - 0.44 V
[A]
[B]
I7RW01130020-01

Downloaded from www.Manualslib.com manuals search engine 1F-1 Engine Cooling System:
Engine
Engine Cooling System
General Description
Cooling System DescriptionS6RW0D1601001
The cooling system consists of the radiator cap, radiator,
coolant reservoir, hoses, water pump, cooling fan and
thermostat. The radiator is of tube-and-fin type.
Coolant DescriptionS6RW0D1601002
WARNING!
• Do not remove radiator cap to check
engine coolant level; check coolant
visually at the see-through coolant
reservoir. Coolant should be added only to
reservoir as necessary.
• As long as there is pressure in the cooling
system, the temperature can be
considerably higher than the boiling
temperature of the solution in the radiator
without causing the solution to boil.
Removal of the radiator cap while engine is
hot and pressure is high will cause the
solution to boil instantaneously and
possibly with explosive force, spewing the
solution over engine, fenders and person
removing cap. If the solution contains
flammable anti-freeze such as alcohol (not
recommended for use at any time), there is
also the possibility of causing a serious
fire.
• Check to make sure that engine coolant
temperature is cold before removing any
part of cooling system.
• Also be sure to disconnect negative cable
from battery terminal before removing any
part.

The coolant recovery system is standard. The coolant in
the radiator expands with heat, and the coolant is
overflowed to the reservoir.
When the system cools down, the coolant is drawn back
into the radiator.
The cooling system has been filled with a quality coolant
that is a 50/50 mixture of water and ethylene glycol
antifreeze.
This 50/50 mixture coolant solution provides freezing
protection to –36 °C (–33 °F).
• Maintain cooling system freeze protection at –36 °C (–
33 °F) to ensure protection against corrosion and loss
of coolant from boiling. This should be done even if
freezing temperatures are not expected.
• Add ethylene glycol base coolant when coolant has to
be added because of coolant loss or to provide added
protection against freezing at temperature lower than
–36 °C (–33 °F).
NOTE
• Alcohol or methanol base coolant or plain
water alone should not be used in cooling
system at any time as damage to cooling
system could occur.
• Coolant must be mixed with demineralized
water or distilled water.

Anti-freeze proportioning table
Coolant capacity
M/T:
• Engine, radiator and heater: 6.8 liters (14.37/11.97
US/lmp pt.)
• Reservoir: 0.7 liters (1.48/1.23 us/lmp pt.)
• Total: 7.5 liters (15.85/13.20 US/lmp pt.)
A/T:
• Engine, radiator and heater: 6.9 liters (14.58/16.63
US/lmp pt.)
• Reservoir: 0.7 liters (1.48/1.23 us/lmp pt.)
• Total: 7.6 liters (16.06/13.38 US/lmp pt.)For M/T
modelFor A/T
model
Freezing
temperature°C–36–36
°F–33–33
Anti-freeze / Anti-
corrosion coolant
concentration%5050
Ratio of compound
to cooling waterltr. 3.75/3.75 3.8/3.8
US pt. 7.92/7.92 8.03/8.03
Imp pt. 6.60/6.60 6.69/6.69

Downloaded from www.Manualslib.com manuals search engine 1G-7 Fuel System:
Clamp other than around fuel tank
For Quick Joint
Disconnecting
1) Remove mud, dust and/or foreign material between
pipe (1) and quick joint (fuel pipe) (2) by blowing
compressed air.
2) Unlock joint lock by inserting special tool between
pipe and quick joint.
Special tool
(A): 09919–47020
3) Disconnect quick joint from pipe.
Reconnecting
Insert quick joint (fuel pipe) to fuel pipe until they lock
securely (a click is heard), and confirm that quick joint
(fuel pipe) is not disconnected by hand.
Fuel Pressure Relief ProcedureS6RW0D1706003
CAUTION!
This work must not be done when engine is
hot. If done so, it may cause adverse effect to
catalyst.

NOTE
If ECM detects DTC(s) after servicing, clear
DTC(s) referring to “DTC Clearance in
Section 1A”.

1) Make sure that engine is cold.
2) Shift transaxle gear shift lever in “Neutral” (shift
select lever in “P” range for A/T model), set parking
brake and block drive wheels.
3) Remove relay / fuse box cover.
4) Disconnect fuel pump relay (1) from relay / fuse box
(2).
5) Remove fuel filler cap in order to release fuel vapor
pressure in fuel tank, and then reinstall it.
[A]: With short pipe, fit hose as far as it reaches pipe joint as shown.
[B]: With the following type pipe, fit hose as far as its peripheral projection
as shown.
[C]: With bent pipe, fit hose as its bent part as shown or till depth “b”.
[D]: With straight pipe, fit hose till depth “b”.
[E]: With red marked pipe, fit hose end reaches red mark on pipe.
[F]: For fuel tank filler hose, insert it to spool or welding-bead.
“a”: Clamp securely at a position 3 – 7 mm (0.12 – 0.27 in.) from hose end.
“b”: 20 – 30 mm (0.79 – 1.18 in.)
“c”: 0 – 5 mm (0 – 0.19 in.)
“d”: 5 – 12 mm (0.2 – 0.47 in.)
“e”: 38 mm (1.50 in.)
I5RW0A170006-01
4. Red mark
1
2
1 2
(A)
I4RS0A170019-01

Downloaded from www.Manualslib.com manuals search engine 1G-11 Fuel System:
4) Install suitable vinyl tube onto injector nozzle to
prevent fuel from splashing out when injecting.
5) Put graduated cylinder under injector.
6) Operate fuel pump and apply fuel pressure to
injector as follows:
a) When using scan tool:
i) Connect scan tool to DLC with ignition switch
OFF.
ii) Turn ignition switch ON, clear DTC and
select “MISC TEST” mode on scan tool.
iii) Turn fuel pump ON by using scan tool.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
b) When not using scan tool:
i) Remove fuel pump relay from connector.
ii) Connect two terminals of relay connector
using service wire (1) as shown in figure.
CAUTION!
Check to make sure that connection is made
between correct terminals. Wrong
connection can cause damage to ECM, wire
harness, etc.

iii) Turn ignition switch ON.7) Apply battery voltage to injector (1) for 15 seconds
and measure injected fuel volume with graduated
cylinder. Test each injector two or three times. If
injected volume is out of reference value greatly,
replace injector.
Reference injected fuel volume
Approx. 46 cc/15 sec. (1.62/1.55 US/lmp oz/15
sec.)
8) Check fuel leakage from injector nozzle. Do not
operate injector for this check (but fuel pump should
be at work). If fuel leaks (1) more than the following
specifications, replace.
Fuel leakage
Less than 1 drop/min.
9) Remove injector from special tool (A) and disconnect
special tool (B) from injector.
WARNING!
As fuel feed line is still under high fuel
pressure even after inspection, removing
injector directly may cause dangerous spout
of fuel. Before removing injector, make sure
to relieve fuel pressure as follows.
1. Stop operation of fuel pump.
2. Put graduated cylinder under injector.
3. Apply battery voltage to injector until no
fuel is injected from injector.

10) Carry out Steps 3) through 9) on each injector to
obtain 4 readings.
11) After checking, disconnect fuel feed hose from
special tool (A) and remove special tool (B).
12) Connect fuel feed hose to delivery pipe.
(A) 1I5RW0C110011-01
1
I5RW0A170011-02
I2RH0B170013-01