terminal SUZUKI SX4 2006 1.G Service Workshop Manual

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 Engine Cooling System: 1F-8
Radiator Cooling Fan Assembly On-Vehicle
Inspection
S6RW0D1606009
1) Check continuity between terminals. If there is no
continuity, replace radiator fan assembly.
2) Connect battery to radiator fan motor coupler as
shown in figure, then check that the radiator fan
motor operates smoothly. If radiator fan motor does
not operate smoothly, replace radiator fan assembly.
Reference: Fan motor specified current at 12 V
: 5.7 – 7.7 A
Radiator Cooling Fan Relay InspectionS6RW0D1606010
1) Disconnect negative (–) cable from battery.
2) Remove radiator cooling fan relay (1) from main fuse
box.
3) Check that there is no continuity between terminal
“c” and “d”. If there is continuity, replace relay.
4) Connect battery positive (+) terminal to terminal “b”
of relay and battery negative (–) terminal to terminal
“a” of relay, and then check continuity between
terminal “c” and “d”. If there is no continuity, replace
relay.
Radiator Cooling Fan Assembly Removal and
Installation
S6RW0D1606011
Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect connector of cooling fan motor.
3) Drain coolant referring to “Cooling System Draining”.
4) Remove radiator inlet hose (1) and reservoir (2).
I5RW0A160004-01
I5RW0A160005-01
“d” “b”“
a”
“c”
1
I5RW0A160008-02
1
2
I6RW0B160004-02

Downloaded from www.Manualslib.com manuals search engine 1G-9 Fuel System:
Fuel Injector On-Vehicle InspectionS6RW0D1706007
1) Using sound scope (1) or such, check operating
sound of injector (2) when engine is running or
cranking.
Cycle of operating sound should vary according to
engine speed.
If no sound or an unusual sound is heard, check
injector circuit (wire or coupler) or injector.
2) Disconnect connector (1) from injector, connect
ohmmeter between terminals of injector and check
resistance.
If resistance is out of reference value greatly,
replace.
Reference resistance of fuel injector
12.0 Ω at 20 °C, 68 °F
3) Connect connector to injector securely.
Fuel Injector Removal and InstallationS6RW0D1706008
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

Removal
1) Relieve fuel pressure according to “Fuel Pressure
Relief Procedure”.
2) Disconnect negative cable at battery.
3) Remove air cleaner case (1) and air suction hose
(2).
4) Disconnect fuel injector couplers.
5) Disconnect fuel feed hose (4) from fuel delivery pipe
(1).
6) Remove fuel delivery pipe bolts (2).
7) Remove fuel injector(s) (3).
I2RH0B170007-01
I2RH0B170008-01
1
2
I5RW0A140002-01
2
1
4
3
3
I5RW0A170010-01

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

Downloaded from www.Manualslib.com manuals search engine 1I-1 Starting System:
Engine
Starting System
Schematic and Routing Diagram
Cranking System Circuit DiagramS6RW0D1902001
Diagnostic Information and Procedures
Cranking System Symptom DiagnosisS6RW0D1904001
Possible symptoms due to starting system trouble would be as follows:
• Starting motor does not run (or runs slowly)
• Starting motor runs but fails to crank engine
• Abnormal noise is heard
Proper diagnosis must be made to determine exactly where the cause of each trouble lies in battery, wiring harness,
(including starting motor switch), starting motor or engine.
Do not remove motor just because starting motor does not run. Check the following items and narrow down scope of
possible causes.
1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine side) and starting motor terminals
3) Discharge of battery
4) Mounting of starting motor
I4RS0A190001-01
1. Pinion drive lever 6. Magnetic switch contacts 11. Ignition & Starter switch
2. Pinion & Over-running clutch 7. Pull-in coil 12. Battery
3. Magnetic switch 8. Starting motor 13. To ECM
4. Hold-in coil 9. Starting motor control relay
5. Plunger 10. A/T: Transmission range sensor (shift switch)

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 1I-3 Starting System:
Cranking System TestS6RW0D1904002
CAUTION!
Each test must be performed within 3 – 5
seconds to avoid coil from burning.

Pull-In Test
Connect battery to the magnetic switch as shown.
Check that plunger and pinion move outward.
If plunger and pinion don’t move, replace the magnetic
switch.
NOTE
Before testing, disconnect lead wire from
terminal “M” (2).

Hold-In Test
While connected as the figure with plunger out,
disconnect negative lead from terminal “M”.
Check that plunger and pinion remain out.
If plunger and pinion return inward, replace the magnetic
switch.Plunger and Pinion Return Test
Disconnect negative lead from starting motor body.
Check that plunger and pinion return inward.
If plunger and pinion don’t return, replace the magnetic
switch.
No-Load Performance Test
Connect battery and ammeter to starter as shown.
Check that starter rotates smoothly and steadily with
pinion moving out. Check that ammeter indicates
specified current.
Specified current (No-load performance test)
90 A MAX. at 11 V Starting motor does not
stop runningFused contact points of magnetic switchReplace magnetic switch.
Short-circuit between turns of magnetic
switch coil (layer short-circuit)Replace magnetic switch.
Failure of returning action in ignition
switchReplace. Condition Possible cause Correction / Reference Item
1. Terminal “S”
3. Lead wire (switch to motor)
I2RH01190002-01
I2RH01190003-01
I2RH01190004-01
I2RH01190005-01

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 Starting System: 1I-6
Starting Motor InspectionS6RW0D1906003
Plunger
Inspect plunger for wear. Replace if necessary.
Magnetic Switch
Push in plunger and release it. The plunger should
return quickly to its original position. Replace if
necessary.
Pull-in coil open circuit test
Check for continuity across magnetic switch “S” terminal
(1) and “M” terminal (2). If no continuity, coil is open and
should be replaced.Hold-in coil open circuit test
Check for continuity across magnetic switch “S” terminal
(1) and coil case. If no continuity, coil is open and should
be replaced.
Rear Bracket Bush
Inspect bush for wear or damage. Replace if necessary.
Brush
• Check brushes for wear.
Measure length of brushes and if below the limit,
replace the brush.
Brush length
Standard: 12.3 mm (0.48 in.)
Limit: 7.0 mm (0.28 in.)
• Install brushes to each brush holder and check for
smooth movement.
I2RH01190008-01
I2RH01190009-01
I2RH01190010-01
I2RH01190011-01
I2RH01190012-01
I2RH01190013-01

Downloaded from www.Manualslib.com manuals search engine 1J-2 Charging System:
Care of battery
WARNING!
• Never expose battery to open flame or electric spark because of battery generate gas which is
flammable and explosive.
• Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive
acid. Flush any contacted area with water immediately and thoroughly.
• Batteries should always be kept out of reach of children.

1) The battery is a very reliable component, but needs periodical attentions.
• Keep the battery carrier clean.
• Prevent rust formation on the terminal posts.
• Keep the electrolyte up to the upper level uniformly in all cells.
• When keeping battery on vehicle over a long period of time, follow instructions given below.
– Weekly, start the engine and run it until it reaches normal operating temperature with engine speed of 2000 to
3000 rpm. Make sure all electric switches are off before storing the vehicle.
– Recharge the battery twice a month to prevent it from discharging excessively. This is especially important
when ambient temperature is low.
The battery discharges even when it is not used, while vehicles are being stored. Battery electrolyte can
freeze and battery case can crack at cold ambient condition if battery is not properly charged.
2) Keep the battery cable connections clean.
The cable connections, particularly at the positive (+) terminal post, tend to become corroded. The product of
corrosion, or rust, on the mating faces of conductors resists the flow of current.
Clean the terminals and fittings periodically to ensure good metal-to-metal contact, and grease the connections
after each cleaning to protect them against rusting.
3) Be always in the know as to the state of charge of the battery. The simplest way to tell the state of charge is to
carry out a hydrometer test. The hydrometer is an instrument for measuring the specific gravity (S.G.) of the
battery electrolyte. The S.G. of the electrolyte is indicative of the state of charge. Refer to “Battery Inspection”.