Ecm SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-4
Diagnostic Information and Procedures
Ignition System Symptom DiagnosisS6RW0D1804001
Reference Waveform of Ignition SystemS6RW0D1804002
Refer to “Reference waveform No.5”, “Reference waveform No.6” and “Reference waveform No.7” under “Inspection
of ECM and Its Circuits in Section 1A” for waveform of Ignition trigger signal.
Ignition System CheckS6RW0D1804003
Condition Possible cause Correction / Reference Item
Engine cranks, but will
not start or hard to start
(No spark)Blown fuse for ignition coilReplace.
Loose connection or disconnection of
lead wire or high-tension cord(s)Connect securely.
Faulty high-tension cord(s)Replace.
Faulty spark plug(s)Replace.
Faulty ignition coilReplace ignition coil assembly.
Faulty CKP sensor or CKP sensor plateClean, tighten or replace.
Faulty CMP sensor or sensor rotor tooth
of camshaftClean, tighten or replace.
Faulty ECMReplace.
Poor fuel economy or
engine performanceIncorrect ignition timingCheck related sensors and CKP sensor plate.
Faulty spark plug(s) or high-tension
cord(s)Adjust, clean or replace.
Faulty ignition coil assemblyReplace.
Faulty CKP sensor or CKP sensor plateClean, tighten or replace.
Faulty CMP sensor or sensor rotor tooth
of camshaftClean, tighten or replace.
Faulty knock sensorReplace.
Faulty ECMReplace.
Step Action Yes No
1Was “Engine and Emission Control System Check”
performed?Go to Step 2. Go to “Engine and
Emission Control
System Check in
Section 1A”.
2Ignition spark test
1) Check all spark plugs for condition and type referring to
“Spark Plug Inspection”.
2) If OK, perform ignition spark test referring to “Ignition
Spar k Tes t”.
Is spark emitted from all spark plugs?Go to Step 12. Go to Step 3.
3DTC check
1) Perform DTC check referring to “DTC Check in Section
1A”.
Is DTC stored in ECM?Go to applicable DTC
diag. flow.Go to Step 4.
4Electrical connection check
1) Check ignition coil assemblies and high-tension cords
for electrical connection.
Are they connected securely?Go to Step 5. Connect securely.
5High-tension cords check
1) Check high-tension cord for resistance referring to
“High-Tension Cord Inspection”.
Is check result satisfactory?Go to Step 6. Replace high-tension
cord(s).

Downloaded from www.Manualslib.com manuals search engine 1H-5 Ignition System:
6Ignition coil assembly power supply and ground circuit
check
1) Check ignition coil assembly power supply and ground
circuits for open and short.
Are circuits in good condition?Go to Step 7. Repair or replace.
7Ignition coil assembly check
1) Check ignition coil for resistance referring to “Ignition
Coil Assembly (Including Ignitor) Inspection”.
Is check result satisfactory?Go to Step 8. Replace ignition coil
assembly.
8CKP sensor check
1) Check CKP sensor referring to “Crankshaft Position
(CKP) Sensor Inspection in Section 1C”.
Is check result satisfactory?Go to Step 9. Tighten CKP sensor
bolt, replace CKP
sensor or CKP sensor
plate.
9CMP sensor check
1) Check CMP sensor referring to “Camshaft Position
(CMP) Sensor Inspection in Section 1C”.
Is check result satisfactory?Go to Step 10. Tighten CMP sensor
bolt, replace CMP
sensor or intake
camshaft.
10Ignition trigger signal circuit check
1) Check ignition trigger signal wire for open, short and
poor connection.
Is circuit in good condition?Go to Step 11. Repair or replace.
11A known-good ignition coil assembly substitution
1) Substitute a known-good ignition coil assembly and then
repeat Step 2.
Is check result of Step 2 satisfactory?Go to Step 12. Substitute a known-
good ECM and then
repeat Step 2.
12Ignition timing check
1) Check initial ignition timing and ignition timing advance
referring to “Ignition Timing Inspection”.
Is check result satisfactory?System is in good
condition.Go to Step 13.
13Knock sensor check
1) Confirm that knock sensor circuit is in good condition
referring to “DTC P0327 / P0328: Knock Sensor Circuit
Low / High in Section 1A”.
2) Check oscilloscope waveform of knock sensor signal
referring to “Reference waveform No.19” and
“Reference waveform No.20” under “Inspection of ECM
and Its Circuits in Section 1A”.
Is check result satisfactory?Check CMP sensor,
CMP sensor rotor tooth
of camshaft, CKP
sensor, CKP sensor
plate and/or input
signals related to this
system.Substitute a known-
good knock sensor and
recheck. Step Action Yes No

Downloaded from www.Manualslib.com manuals search engine 1H-9 Ignition System:
2) Start engine and warm it up to normal operating
temperature.
3) Make sure that all of electrical loads except ignition
are switched off.
4) Check to be sure that idle speed is within
specification.
5) Fix ignition timing by using “Fixed Spark Control” of
“Engine / Active Test” mode on scan tool.
6) Set timing light (1) to high-tension cord for No.1
cylinder and check that ignition timing is within
specification.
Initial ignition timing
fixed with SUZUKI scan tool: 5 ± 3° BTDC (at
specified idle speed)
Ignition order
1 – 3 – 4 – 2
Special tool
(A): 09930–764207) If ignition timing is out of specification, check the
followings.
• CKP sensor
• CKP sensor plate
• TP sensor
• CMP sensor
• CMP sensor rotor tooth of camshaft
• Vehicle speed signal from ABS hydraulic unit /
control module
• Knock sensor
• Timing chain cover installation
8) After checking initial ignition timing, release ignition
timing fixation by using scan tool.
9) With engine idling (throttle opening at closed position
and vehicle stopped), check that ignition timing is
about 5° – 15° BTDC (Constant variation within a
few degrees from 5° – 15° BTDC indicates no
abnormality but proves operation of electronic timing
control system.) Also, check that increasing engine
speed advances ignition timing.
If the check results are not satisfactory, check CKP
sensor and ECM.
1, (A)10
0I3RB0A180004-01

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 Charging System: 1J-3
Generator DescriptionS6RW0D1A01002
The basic charging system is the IC integral regulator charging system. The internal components are connected
electrically as shown below.
Charging System Circuit
The generator features a solid state regulator that is mounted inside the generator. All regulator components are
enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the rear housing. The
regulator voltage is being controlled by ECM under some conditions while driving. Refer to “Generator Control System
Description in Section 1A” in related manual.
The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication.
Two brushes carry current through the two slip rings to the field coil mounted on the rotor, and under normal conditions
will provide long period of attention-free service.
The stator windings are assembled inside a laminated core that forms part of the generator frame.
A rectifier bridge connected to the stator windings contains diodes, and electrically changes that stator AC. voltages to
a D.C. voltage which appears at the generator output terminal.
1 26345
4
3B
7
8
9
10E FFRCIG
L
I6RW0D1A0002-01
1. Pulley 6. Field coil B: Generator output (Battery terminal) L: Lamp terminal
2. Pulley nut 7. Regulator C: Generator cut FR: Field duty monitor
3. Rotor fan 8. Brush E: Ground
4. Stator coil 9. Rear end frame F: Field coil terminal
5. Stator core 10. Drive end frame IG: Ignition terminal
B
IG
L
C
E
7
2 4
3
5
FR
610
11
12 13 1
[A]
IG1 9
14
8
I6RW0D1A0001-03
[A]: If equipped with electric load current sensor 4. Diode 8. Battery 12. Combination meter
1. Generator with regulator assembly 5. Field coil (rotor coil) 9. Electric load current sensor (if equipped) 13. CAN driver
2. I.C. regulator 6. Charge indicator light 10. ECM 14. Main fuse box
3. Stator coil 7. Main switch 11. BCM

Downloaded from www.Manualslib.com manuals search engine 3-ii Table of Contents
DTC U0100: Lost Communication with ECM .... 3B-27
DTC U0121: Lost Communication with ABS /
ESP® Control Module..................................... 3B-27
DTC U0155: Lost Communication with
Instrument Panel Cluster (IPC) Control
Module ............................................................ 3B-27
Inspection of 4WD Control Module and Its
Circuits ............................................................ 3B-27
Repair Instructions ............................................3B-30
Rear Differential Oil Level Check ...................... 3B-30
Rear Differential Oil Change ............................. 3B-30
2WD/4WD Switch Removal and Installation ..... 3B-31
2WD/4WD Switch Inspection ............................ 3B-31
4WD Control Module Removal and
Installation ....................................................... 3B-31
Coupling Air Temperature Sensor Removal
and Installation ................................................ 3B-31
Coupling Air Temperature Sensor Inspection ... 3B-32
Coupling Assembly Inspection .......................... 3B-32
Rear Differential Mountings Components ......... 3B-33
Front Mounting Arm and/or Rear Mounting
Bracket Assembly Removal and Installation ... 3B-34
Rear Mounting Bracket Assembly
Disassembly and Reassembly ........................ 3B-34
Rear Differential Dismounting and
Remounting ..................................................... 3B-34
Rear Differential Components ........................... 3B-35
Rear Differential Disassembly and
Reassembly .................................................... 3B-36
Rear Differential Inspection ............................... 3B-47
Specifications .....................................................3B-48
Tightening Torque Specifications ...................... 3B-48
Special Tools and Equipment ...........................3B-48
Recommended Service Material ....................... 3B-48
Special Tool ...................................................... 3B-49
Transfer .................................................... 3C-1
General Description ............................................. 3C-1
Transfer Description ............................................ 3C-1Diagnostic Information and Procedures ............3C-1
Transfer Symptom Diagnosis..............................3C-1
Repair Instructions ..............................................3C-2
Transfer Oil Level Check.....................................3C-2
Transfer Oil Change ............................................3C-2
Transfer Dismounting and Remounting ..............3C-3
Transfer Assembly Components .........................3C-4
Transfer Assembly Disassembly and
Reassembly ......................................................3C-5
Reduction Drive Gear Assembly Disassembly
and Reassembly ...............................................3C-7
Reduction Driven Gear Assembly
Disassembly and Reassembly ..........................3C-8
Transfer Right Case and Left Case
Disassembly and Reassembly ..........................3C-9
Transfer Output Retainer Assembly
Disassembly and Reassembly ........................3C-10
Transfer Assembly Inspection ...........................3C-14
Bevel Gear Tooth Contact Inspection ...............3C-14
Specifications .....................................................3C-16
Tightening Torque Specifications ......................3C-16
Special Tools and Equipment ...........................3C-17
Recommended Service Material .......................3C-17
Special Tool ......................................................3C-17
Propeller Shafts ....................................... 3D-1
Precautions ...........................................................3D-1
Propeller Shaft Caution .......................................3D-1
General Description .............................................3D-1
Propeller Shaft Construction ...............................3D-1
Diagnostic Information and Procedures ............3D-1
Propeller Shaft Symptom Diagnosis ...................3D-1
Repair Instructions ..............................................3D-2
Propeller Shaft Joint Check.................................3D-2
Propeller Shaft Assembly Removal and
Installation .........................................................3D-2
Propeller Shaft Inspection ...................................3D-2
Specifications .......................................................3D-3
Tightening Torque Specifications ........................3D-3

Downloaded from www.Manualslib.com manuals search engine 3B-5 Differential:
4WD Control System Wiring Circuit DiagramS6RW0D3201006
Terminal Arrangement of 4WD Control ModuleS6RW0D3201007
5V
5V
12V
G26-3
YEL
GRY
G26-2
G26-22G26-23REDWHT
G26-13
G26-14
G26-12
G26-11
G26-10BLK
WHT/RED
RED/BLK
GRY/YEL
RED/WHT
12V
L102-1
L102-4
1
37
9
10
12
13
14
12V
G26-21BLU
G26-25
G26-24ORN
BRN
5V
28
11
WHT
WHT
WHTWHTWHTWHT
WHT
RED
RED
RED
REDRED
RED
RED
46
5
L174-4BLK/ORNL174-5L174-1
I7RW01320001-01
1. Coupling assembly 6. ECM 11. Data link connector (DLC)
2. Coupling air temperature sensor 7. 4WD control module 12. “IG COIL” fuse
3. Combination meter 8. 2WD/4WD switch 13. “4WD” fuse
4. BCM 9. “4WD” switch 14. Main fuse box
5. ABS / ESP® control module 10. “4WD lock” switch
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 25 26
[A]
I4JA01332038-01
[A]: Connector “G26” viewed from harness side
Te r m i n a l C i r c u i t Te r m i n a l C i r c u i t
G26-2 Coupling assembly (power) G26-14 “4WD lock” switch
G26-3 Coupling assembly (ground) G26-21 Data link connector (DLC)
G26-10 Ground G26-22 CAN communication line (high)
G26-11 Power source for internal memory G26-23 CAN communication line (low)
G26-12 Power source G26-24 Coupling air temperature sensor (ground)
G26-13 “4WD” switch G26-25 Coupling air temperature sensor (power)

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-6
Input / Output Signal Table of 4WD Control ModuleS6RW0D3201008
4WD control module outputs the following signals to coupling assembly, indicators, according to the 2WD/4WD switch
operation.
On-Board Diagnostic System DescriptionS6RW0D3201009
For 4WD control system, 4WD control module has the following functions.
• When ignition switch is turned ON with engine at stop, 4WD AUTO indicator (1) and 4WD LOCK indicator (2) turn
on at the same time for 2 seconds in order to check operation of these indicators.
• When 4WD control module detects any malfunction in the following area, 4WD AUTO indicator (1) and 4WD LOCK
indicator (2) flash continuously or turn on and 4WD control module comes into fail-safe mode. For details of fail safe
mode, refer to “Fail-Safe Table”.
– 2WD/4WD switch
– Coupling air temperature sensor
– Coupling assembly
• DTC can be checked by using SUZUKI scan tool (3) connected to DLC (4).
• When 4WD control module detects any malfunction, 4WD control module will switch off the current to coupling
assembly and vehicle is changed to 2WD position.
DLC (Data Link Connector)
Refer to “Data Link Connector (DLC)” under “On-Board Diagnostic System Description in Section 1A”.Output signal (to each component parts)
Coupling
assembly4WD AUTO
indicator4WD LOCK
indicator
Input signal2WD/4WD switch{{{
Coupling air temperature sensor{
ECM{
ABS / ESP® control module{{{
1
2 3
4
I5RW0A320004-01

Downloaded from www.Manualslib.com manuals search engine 3B-7 Differential:
CAN Communication System DescriptionS6RW0D3201010
Refer to “CAN Communication System Description in Section 1A” for CAN communication system description.
When 4WD control module receive the signal of abnormal as following information, vehicle is not changed to 4WD-
auto and 4WD-lock position.
4WD Control Module Transmission Data
4WD Control Module Reception Data
ECMCombination
Meter
TransmitDATA 4WD
4WD mode status
4WD auto mode
indication status
4WD lock mode
indication status
4WD diagnostic
trouble codes control
module
4WD clutch
engagement percent
ESP® hydraulic unit /
control module
(if equipped)
4WD clutch control
request impossibility
I7RW01320013-01
Accelerator position
Engine speedECM
DATA
Brake pedal switch signal
4WD
control
moduleWheel speed signal
(front right)
Wheel speed signal
(front left)
Wheel speed signal
(rear right)
Wheel speed signal
(rear left)

ABS hydraulic
unit /control
module
(if equipped)


ESP® hydraulic
unit /control
module
(if equipped)
ABS active
ESP® status signal
Clutch control request for
4WD active
Clutch control request
percent
Engine type signal
Engine torque signal
Receive
I7RW01320002-03