Can k SUZUKI SX4 2006 1.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine 00-9 Precautions:
• When connecting connectors, also hold connectors
and put them together until they lock securely (a click
is heard).
• When installing the wiring harness, fix it with clamps
so that no slack is left.
• When installing vehicle parts, be careful so that the
wiring harness is not interfered with or caught by any
other part.
• To avoid damage to the harness, protect its part which
may contact against a part forming a sharp angle by
winding tape or the like around it.• Be careful not to touch the electrical terminals of parts
which use microcomputers (e.g. electronic control unit
like as ECM, PCM, P/S controller, etc.). The static
electricity from your body can damage these parts.
• Never connect any tester (voltmeter, ohmmeter, or
whatever) to electronic control unit when its coupler is
disconnected. Attempt to do it may cause damage to
it.
• Never connect an ohmmeter to electronic control unit
with its coupler connected to it. Attempt to do it may
cause damage to electronic control unit and sensors.
• Be sure to use a specified voltmeter / ohmmeter.
Otherwise, accurate measurements may not be
obtained or personal injury may result. If not specified,
use a voltmeter with high impedance (M Ω/V
minimum) or a digital type voltmeter.
• When taking measurements at electrical connectors
using a tester probe, be sure to insert the probe (2)
from the wire harness side (backside) of the
connector (1).
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Downloaded from www.Manualslib.com manuals search engine Precautions: 00-10
• When connecting meter probe (2) from terminal side
of coupler (1) because it can’t be connected from
harness side, use extra care not to bend male
terminal of coupler of force its female terminal open
for connection.
In case of such coupler as shown connect probe as
shown to avoid opening female terminal.
Never connect probe where male terminal is
supposed to fit.
• When checking connection of terminals, check its
male half for bend and female half for excessive
opening and both for locking (looseness), corrosion,
dust, etc.
• Before measuring voltage at each terminal, check to
make sure that battery voltage is 11 V or higher. Such
terminal voltage check at low battery voltage will lead
to erroneous diagnosis.Air Bag WarningS6RW0D0000008
WARNING!
For vehicles equipped with Supplemental
Restraint (Air Bag) System:
• Service on and around the air bag system
components or wiring must be performed
only by an authorized SUZUKI dealer. Refer
to “Air Bag System Components, Wiring
and Connectors Location in Section 8B” in
order to confirm whether you are
performing service on or near the air bag
system components or wiring. Please
observe all WARNINGS in Air Bag System
section and “Precautions on Service and
Diagnosis of Air Bag System in Section
8B” before performing service on or
around the air bag system components or
wiring. Failure to follow WARNINGS could
result in unintentional activation of the
system or could render the system
inoperative. Either of these two conditions
may result in severe injury.
• Technical service work must be started at
least 90 seconds after the ignition switch is
turned to the LOCK position and the
negative cable is disconnected from the
battery. Otherwise, the system may be
activated by reserve energy in the Sensing
and Diagnostic Module (SDM).

Air Bag System Service WarningS6RW0D0000009
WARNING!
• Service on or around the air bag system
components or wiring must be performed
only by an authorized SUZUKI dealer.
Please observe all WARNINGS in Air Bag
System section and “Precautions on
Service and Diagnosis of Air Bag System
in Section 8B” before performing service
on or around the air bag system
components or wiring. Failure to follow
WARNINGS could result in unintended
activation of the system or could render
the system inoperative. Either of these two
conditions may result in severe injury.
• The procedures in the air bag system
section must be followed in the order
listed to disable the air bag system
temporarily and prevent false DTCs from
setting. Failure to follow procedures could
result in possible activation of the air bag
system, personal injury or otherwise
unneeded air bag system repairs.

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Downloaded from www.Manualslib.com manuals search engine 00-13 Precautions:
Voltage Check
If voltage is supplied to the circuit being checked, voltage
check can be used as circuit check.
1) With all connectors connected and voltage applied to
the circuit being checked, measure voltage between
each terminal and body ground.
a) If measurements were taken as shown in the
figure and results were as listed in the following,
it means that the circuit is open between
terminals “B-1” and “A-1”.
Voltage between
“C-1” and body ground: Approx. 5 V
“B-1” and body ground: Approx. 5 V
“A-1” and body ground: 0 V
b) Also, if measured values were as listed in the
following, it means that there is a resistance
(abnormality) of such level that corresponds to
the voltage drop in the circuit between terminals
“A-1” and “B-1”.
Voltage between
“C-1” and body ground: Approx. 5 V
“B-1” and body ground: Approx. 5 V
“A-1” and body ground: Approx. 3 VShort Circuit Check (Wire Harness to Ground)
1) Disconnect negative (–) cable at battery.
2) Disconnect connectors at both ends of the circuit to
be checked.
NOTE
If the circuit to be checked is connected to
other parts (1), disconnect all connectors of
those parts.
Otherwise, diagnosis will be misled.

3) Measure resistance between terminal at one end of
circuit (“A-1” terminal in the figure) and body ground.
If continuity is indicated, it means that there is a short
to ground between terminals “A-1” and “C-1” of the
circuit.
4) Disconnect the connector included in circuit
(connector-B) and measure resistance between “A-
1” and body ground. If continuity is indicated, it
means that the circuit is shorted to the ground
between terminals “A-1” and “B-1”.
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1. To other parts
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Downloaded from www.Manualslib.com manuals search engine Precautions: 00-14
Intermittent and Poor Connection InspectionS6RW0D0006002
Most intermittent are caused by faulty electrical
connections or wiring, although a sticking relay or
solenoid can occasionally be at fault. When checking it
for proper connection, perform careful check of suspect
circuits for:
• Poor mating of connector halves, or terminals not fully
seated in the connector body (backed out).
• Dirt or corrosion on the terminals. The terminals must
be clean and free of any foreign material which could
impede proper terminal contact. However, cleaning
the terminal with a sand paper or the like is prohibited.
• Damaged connector body, exposing the terminals to
moisture and dirt, as well as not maintaining proper
terminal orientation with the component or mating
connector.
• Improperly formed or damaged terminals.
Check each connector terminal in problem circuits
carefully to ensure good contact tension by using the
corresponding mating terminal.
If contact tension is not enough, reform it to increase
contact tension or replace.• Poor terminal-to-wire connection.
Check each wire harness in problem circuits for poor
connection by shaking it by hand lightly. If any
abnormal condition is found, repair or replace.
• Wire insulation which is rubbed through, causing an
intermittent short as the bare area touches other
wiring or parts of the vehicle.
• Wiring broken inside the insulation. This condition
could cause continuity check to show a good circuit,
but if only 1 or 2 strands of a multi-strand-type wire
are intact, resistance could be far too high.
If any abnormality is found, repair or replace.
1. Check contact tension by inserting and removing just once.
2. Check each terminal for bend and proper alignment.
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Downloaded from www.Manualslib.com manuals search engine Table of Contents 0- i
0
Section 0
CONTENTS
General Information
General Information ................................ 0A-1
General Description ............................................. 0A-1
Abbreviations ...................................................... 0A-1
Symbols .............................................................. 0A-2
Wire Color Symbols ............................................ 0A-2
Fasteners Information ......................................... 0A-3
Vehicle Lifting Points ........................................... 0A-5
Vehicle Identification Number ............................. 0A-6
Engine Identification Number .............................. 0A-6
Transmission Identification Number .................... 0A-6
Component Location ........................................... 0A-7
Warning, Caution and Information Labels
Location ............................................................ 0A-7
Maintenance and Lubrication ................. 0B-1
Precautions........................................................... 0B-1
Precautions for Maintenance and Lubrication ..... 0B-1
Scheduled Maintenance ...................................... 0B-1
Maintenance Schedule under Normal Driving
Conditions ......................................................... 0B-1
Maintenance Recommended under Severe
Driving Conditions ............................................. 0B-2
Repair Instructions .............................................. 0B-3
Accessory Drive Belt Inspection.......................... 0B-3
Accessory Drive Belt Replacement ..................... 0B-3
Valve Lash (Clearance) Inspection ..................... 0B-3
Engine Oil and Filter Change .............................. 0B-4
Engine Coolant Change ...................................... 0B-5
Exhaust System Inspection ................................. 0B-5
Spark Plug Replacement .................................... 0B-5
Air Cleaner Filter Inspection ................................ 0B-6
Air Cleaner Filter Replacement ........................... 0B-6
Fuel Lines and Connections Inspection .............. 0B-6
Fuel Filter Replacement ...................................... 0B-6
Fuel Tank Inspection ........................................... 0B-6PCV Valve Inspection ......................................... 0B-6
Fuel Evaporative Emission Control System
Inspection .......................................................... 0B-6
Brake Discs and Pads (Front) Inspection............ 0B-7
Brake Drums and Shoes (Rear) Inspection ........ 0B-7
Brake Hoses and Pipes Inspection ..................... 0B-7
Brake Fluid Replacement .................................... 0B-7
Brake Lever and Cable Inspection ...................... 0B-7
Clutch Fluid Inspection ........................................ 0B-8
Tires Inspection ................................................... 0B-8
Wheel Discs Inspection ....................................... 0B-8
Wheel Bearing Inspection ................................... 0B-8
Suspension System Inspection ........................... 0B-9
Steering System Inspection ................................ 0B-9
Drive Shaft (Axle) Boots Inspection .................... 0B-9
Propeller Shaft (4WD) Inspection...................... 0B-10
Manual Transaxle Oil Inspection ....................... 0B-10
Manual Transaxle Oil Replacement .................. 0B-10
Automatic Transaxle Fluid Level Inspection...... 0B-10
Automatic Transaxle Fluid Replacement .......... 0B-10
Automatic Transaxle Fluid Cooler Hose
Inspection ........................................................ 0B-10
Transfer Oil Inspection (4WD)........................... 0B-10
Transfer Oil Replacement (4WD) ...................... 0B-10
Rear Deferential Oil Inspection (4WD) .............. 0B-10
Rear Deferential Oil Replacement (4WD) ......... 0B-10
All Latches, Hinges and Locks Inspection......... 0B-10
HVAC Air Filter (If Equipped) Inspection ........... 0B-11
HVAC Air Filter (If Equipped) Replacement ...... 0B-11
Final Inspection for Maintenance Service ......... 0B-11
Specifications .....................................................0B-12
Tightening Torque Specifications ...................... 0B-12
Special Tools and Equipment ...........................0B-12
Recommended Fluids and Lubricants............... 0B-12
Special Tool ...................................................... 0B-12

Downloaded from www.Manualslib.com manuals search engine 0A-1 General Information:
General Information
General Information
General Description
AbbreviationsS6RW0D0101001
A:
ABDC: After Bottom Dead Center
ABS: Anti-lock Brake System
AC: Alternating Current
A/C: Air Conditioning
A-ELR: Automatic-Emergency Locking Retractor
A/F: Air Fuel Mixture Ratio
ALR: Automatic Locking Retractor
API: American Petroleum Institute
APP sensor: Accelerator Pedal Position Sensor
A/T: Automatic Transmission, Automatic Transaxle
AT D C : After Top Dead Center
ATF: Automatic Transmission Fluid, Automatic
Transaxle Fluid
B:
B+: Battery Positive Voltage
BBDC: Before Bottom Dead Center
BCM: Body Electrical Control Module
BTDC: Before Top Dead Center
C:
CAN: Controller Area Network
CKT: Circuit
CKP Sensor: Crankshaft Position Sensor
CMP Sensor: Camshaft Position Sensor
CO: Carbon Monoxide
CPP Switch: Clutch Pedal Position Switch (Clutch
Switch, Clutch Start Switch)
CPU: Central Processing Unit
CRS: Child Restraint System
D:
DC: Direct Current
DLC: Data Link Connector (Assembly Line Diag. Link,
ALDL, Serial Data Link, SDL)
DOHC: Double Over Head Camshaft
DOJ: Double Offset Joint
DRL: Daytime Running Light
DTC: Diagnostic Trouble Code (Diagnostic Code)
E:
EBCM: Electronic Brake Control Module, ABS Control
Module
EBD: Electronic Brake Force Distribution
ECM: Engine Control Module
ECT Sensor: Engine Coolant Temperature Sensor
(Water Temp. Sensor, WTS)
EFE Heater: Early Fuel Evaporation Heater (Positive
Temperature Coefficient, PTC Heater)
EGR: Exhaust Gas Recirculation
EGRT Sensor: EGR Temperature Sensor (Recirculated
Exhaust Gas Temp. Sensor, REGTS)
EPS: Electronic Power Steering
EVAP: Evaporative Emission
EVAP Canister: Evaporative Emission Canister
(Charcoal Canister)F:
4WD: 4 Wheel Drive
G:
GEN: Generator
GND: Ground
GPS: Global Positioning System
H:
HAVC: Heating, Ventilating and Air Conditioning
HC: Hydrocarbons
HO2S: Heated Oxygen Sensor
I:
IAC Valve: Idle Air Control Valve (Idle Speed Control
Solenoid Valve, ISC Solenoid Valve)
IAT Sensor: Intake Air Temperature Sensor (Air
temperature Sensor, ATS)
ICM: Immobilizer Control Module
IG: Ignition
ISC Actuator: Idle Speed Control Actuator
L:
LH: Left Hand
LHD: Left Hand Drive vehicle
LSPV: Load Sensing Proportioning Valve
M:
MAF Sensor: Mass Air Flow Sensor (Air Flow Sensor,
AFS, Air Flow Meter, AFM)
MAP Sensor: Manifold Absolute Pressure Sensor
(Pressure Sensor, PS)
Max: Maximum
MFI: Multiport Fuel Injection (Multipoint Fuel Injection)
Min: Minimum
MIL: Malfunction Indicator Lamp (“SERVICE ENGINE
SOON” Light)
M/T: Manual Transmission, Manual Transaxle
N:
NOx: Nitrogen Oxides
O:
OBD: On-Board Diagnostic System (Self-Diagnosis
Function)
O/D: Overdrive
OHC: Over Head Camshaft
O2S: Oxygen Sensor
P:
PCM: Powertrain Control Module
PCV: Positive Crankcase Ventilation
PNP: Park / Neutral Position
P/S: Power Steering
PSP Switch: Power Steering Pressure Switch (P/S
Pressure Switch)
R:
RH: Right Hand
RHD: Right Hand Drive vehicle

Downloaded from www.Manualslib.com manuals search engine 0A-5 General Information:
Vehicle Lifting PointsS6RW0D0101005
WARNING!
• Before applying hoist to underbody, always take vehicle balance throughout service into
consideration. Vehicle balance on hoist may change depending on what part to be removed.
• Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe,
fuel pipe, bracket or any other part.
• When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up
the vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by
trying to move vehicle body in both ways. Work can be started only after this confirmation.
• Make absolutely sure to lock hoist after vehicle is hoisted up.

When Using Frame Contact Hoist
When Using Floor Jack
WARNING!
If the vehicle to be jacked up only at the front
or rear end, be sure to block the wheels on
ground in order to ensure safety.
After the vehicle is jacked up, be sure to
support it on stands. It is extremely
dangerous to do any work on the vehicle
raised on jack alone.

CAUTION!
Never apply jack against rear suspension
parts (i.e., torsion beam, etc.) or vehicle floor,
or it may get deformed.

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:2
:3
4
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1. Vehicle front3. Floor jack position 5. Cap
2. Support position for frame contact hoist and safety stand 4. Body mounting stay

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-4
Engine Oil and Filter ChangeS6RW0D0206004
WARNING!
• New and used engine oil can be
hazardous.
Be sure to read “WARNING” in “General
Precautions in Section 00” and observe
what is written there.
• Step 1) – 7) outlined below must be
performed with ENGINE NOT RUNNING.
For Step 8), be sure to have adequate
ventilation while engine is running.

Before draining engine oil, check engine for oil leakage.
If any evidence of leakage is found, make sure to correct
defective part before proceeding to the following work.
1) Drain engine oil by removing drain plug.
2) After draining oil, wipe drain plug clean. Reinstall
drain plug.
Tightening torque
Engine oil drain plug (a): 35 N·m (3.5 kgf-m, 25.5
lb-ft)
3) Loosen oil filter by using oil filter wrench (special
tool).
Special tool
(A): 09915–47331
NOTE
Before fitting new oil filter, be sure to oil its
O-ring. Use engine oil for this purpose.

4) Screw new filter on oil filter stand by hand until the
filter O-ring contacts mounting surface.
CAUTION!
To tighten oil filter properly, it is important to
accurately identify the position at which filter
O-ring first contacts mounting surface.

5) Tighten the filter (1) 3/4 turn from the point of contact
with the mounting surface using an oil filter wrench
(2).
Tightening torque
Oil filter (b): 14 N·m (1.4 kgf-m, 10.5 lb-ft) for
reference
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Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-6
Air Cleaner Filter InspectionS6RW0D0206008
1) Remove air cleaner case clamps.
2) Take air cleaner filter out of case.
3) Check that filter is not excessively dirty, damaged or
oily, clean filter with compressed air from air outlet
side of filter.
4) Install air cleaner filter and clamp cap securely.
Air Cleaner Filter ReplacementS6RW0D0206009
Replace air cleaner filter with new one according to
Steps 1), 2) and 4) of “Air Cleaner Filter Inspection”.
Fuel Lines and Connections InspectionS6RW0D0206010
Visually inspect fuel lines and connections for evidence
of fuel leakage, hose cracking and damage. Make sure
all clamps are secure.
Repair leaky joints, if any.
Replace hoses that are suspected of being cracked.
Fuel Filter ReplacementS6RW0D0206041
Fuel filter is installed in fuel pump assembly in fuel tank.
Replace fuel filter or fuel pump assembly with new one,
referring to “Fuel Pump Assembly Removal and
Installation in Section 1G” for proper procedure.
Fuel Tank InspectionS6RW0D0206011
Check fuel tank damage, cracks, fuel leakage, corrosion
and tank bolts looseness.
If a problem is found, repair or replace.
PCV Valve InspectionS6RW0D0206012
Check crankcase ventilation hose and PCV hose for
leaks, cracks or clog, and PCV valve for stick or clog.
Refer to “PCV Valve Inspection in Section 1B” for PCV
valve checking procedure.
Fuel Evaporative Emission Control System
Inspection
S6RW0D0206013
1) Visually inspect hoses for cracks, damage, or
excessive bends. Inspect all clamps for damage and
proper position.
2) Check EVAP canister for operation and clog,
referring to “EVAP Canister Inspection in Section
1B”.
If a malfunction is found, repair or replace.
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Downloaded from www.Manualslib.com manuals search engine 0B-9 Maintenance and Lubrication:
Suspension System InspectionS6RW0D0206023
• Inspect front struts and rear shock absorbers for
evidence of oil leakage, dents or any other damage on
sleeves; and inspect anchor ends for deterioration.
Replace defective parts, if any.
• Check front and rear suspension systems for
damaged, loose or missing parts; also for parts
showing signs of wear or lack of lubrication.
Repair or replace defective parts, if any.
• Check front suspension arm ball joint stud dust seals
for leakage, detachment, tear or any other damage.
Replace defective boot, if any.
Steering System InspectionS6RW0D0206024
1) Check steering wheel for play and rattle, holding
vehicle straight on ground.
Steering wheel play
“a”: 0 – 30 mm (0 – 1.1 in.)2) Check bolts and nuts for tightness and retighten
them as necessary. Repair or replace defective
parts, if any.
3) Check steering linkage for looseness and damage.
Repair or replace defective parts, if any.
4) Check boots (1) and (2) of steering linkage and
steering gear case for damage (leak, detachment,
tear, etc.). If damage is found, replace defective boot
with new one.
If any dent is found on steering gear case boots,
correct it to original shape by turning steering wheel
to the right or left as far as it stops and holding it for a
few seconds.
5) Check universal joints (3) of steering shaft for rattle
and damage. If rattle or damage is found, replace
defective part with a new one.
6) Check that steering wheel can be turned fully to the
right and left. Repair or replace defective parts, if
any.
7) If equipped with power steering system, check also,
in addition to check items, that steering wheel can be
turned fully to the right and left more lightly when
engine is running at idle speed than when it is
stopped. Repair, if found faulty.
8) Check wheel alignment referring to “Front Wheel
Alignment Inspection and Adjustment in Section 2B”.
Drive Shaft (Axle) Boots InspectionS6RW0D0206025
Check drive shaft boots (wheel side and differential side)
for leaks, detachment, tear or other damage.
Replace defective parts as necessary.
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