Starting system SUZUKI SX4 2006 1.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine 1A-212 Engine General Information and Diagnosis:
Repair Instructions
Idle Speed and IAC Throttle Valve Opening
Inspection
S6RW0D1106001
Before idle speed check, make sure of the following.
• Lead wires and hoses of electronic fuel injection and
engine and emission control systems are connected
securely.
• Valve lash is checked according to maintenance
schedule.
• Ignition timing is within specification.
• All accessories (wipers, heater, lights, A/C, etc.) are
out of service.
• Air cleaner has been properly installed and is in good
condition.
• No abnormal air drawn in from air intake system.After all items are confirmed, check idle speed and IAC
throttle opening as follows.NOTE
Before starting engine, place transmission
gear shift lever in “Neutral”, and set parking
brake and block drive wheels.

Step Action Yes No
1Is there DTC(s) of ECT sensor circuit (DTC P0116 / P0117 /
P0118) and/or radiator cooling fan circuit (DTC P0480)?Go to corresponding
DTC flow.Go to Step 2.
2Radiator cooling fan control circuit check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Start engine and select “Data List” on scan tool.
3) Warm up engine until coolant temp. is 100 °C, 212 °F or
higher and A/C switch turns OFF (if equipped with A/C).
(If engine coolant temp. dose not rise, check engine
cooling system or ECT sensor.)
Is radiator cooling fan started when engine coolant temp.
reached above temp.?Radiator cooling fan
control system is in
good condition.Perform from Step 2 to
Step 7 in DTC P0480
diag. flow. If OK, Go to
Ste p 3.
3Radiator cooling fan control check
1) Disconnect radiator cooling fan motor connector with
ignition switch turned OFF.
2) Run engine when ECT is over 100 °C, 212 °F.
3) Measure voltage between vehicle body ground and
“BLU/RED” wire terminal of disconnected radiator
cooling fan motor connector.
Is voltage 10 – 14 V?Go to Step 4. “BLU/RED” wire is open
or high resistance
circuit.
4Check radiator cooling fan wire circuit check
1) Turn ignition switch to OFF position.
2) Measure resistance between “BLK” wire terminal of
disconnected radiator cooling fan motor connector and
vehicle body ground.
Is resistance below 1
Ω?Go to Step 5. “BLK” wire is open or
high resistance circuit.
5Radiator cooling fan check
1) Check radiator cooling fan referring to “Radiator Cooling
Fan Assembly On-Vehicle Inspection in Section 1F”.
Is it in good condition?Substitute a known-
good ECM and recheck.Faulty radiator cooling
fan.

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-17
Engine Assembly Removal and InstallationS6RW0D1406013
Removal
1) Relieve fuel pressure according to “Fuel Pressure
Relief Procedure in Section 1G”.
2) Disconnect negative and positive cable at battery.
3) Disconnect ECM connectors.
4) Remove battery and battery tray with ECM.
5) Remove right and left side engine under covers.
6) Remove A/C compressor belt by referring to
“Compressor Drive Belt Removal and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
7) Drain engine oil referring to “Engine Oil and Filter
Change in Section 0B”.
8) Drain transaxle oil referring to “Manual Transaxle Oil
Change in Section 5B” or “A/T Fluid Change in
Section 5A”.
9) Drain transfer oil referring to “Transfer Oil Change in
Section 3C”.
10) Drain coolant referring to “Cooling System Draining
in Section 1F”
11) Remove air cleaner assembly referring to “Air
Cleaner Assembly Removal and Installation”.
12) With hose connected, detach A/C compressor from
its bracket referring to “Compressor Assembly
Removal and Installation in Section 7B” or
“Compressor Assembly Removal and Installation in
Section 7B”.
CAUTION!
Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

13) Remove cylinder upper cover (1).14) Disconnect the following electric wires/connectors
and each clamps.
• TP sensor (1)
• MAP sensor (2)
• ECT sensor (3)
•EGR valve (4)
• CMP sensor (5)
• Ignition coil assembly (6)
• Injector (7)
•HO2S (8)
• Oil control valve (9) (for engine with VVT system)
• Engine oil pressure switch (10)
• CKP sensor (12)
• Knock sensor (13)
• Generator (14)
• Starting motor (15)
• Ground terminal (16) from cylinder block
• Battery ground cable (17) from transaxle
• Back-up light switch (18) (for M/T model)
• Torque sensor (19)
• P/S motor (20)
• Output shaft speed sensor (VSS) (29) (for A/T
model)
• Solenoid valve (30) (for A/T model)
• Transmission range sensor (31) (for A/T model)
• Input shaft speed sensor (32) (for A/T model)
15) Disconnect the following cables, and remove control
cable bracket (23)
• Gear select control cable (21) (for M/T model)
• Gear shift control cable (22) (for M/T model)
• A/T select cable (33) (for A/T model)
16) Disconnect the following hoses.
• Brake booster hose (24) from intake manifold
• Radiator inlet and outlet hoses (25) from radiator
• Heater inlet and outlet hoses (26) from heater
core
• Fuel feed hose (27) from fuel feed pipe
• Fuel vapor hose (11) from fuel vapor pipe
• Clutch hose (28) from transaxle (for M/T model)
• A/T fluid cooler hoses (for A/T model)
F: Vehicle forward 8. Engine front mounting bracket : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
1. Engine right mounting bracket 9. Engine front mounting
: Be sure to direct yellow mark to forward.: 95 N⋅m (9.5 kgf-m, 69.0 lb-ft)
2. Engine right mounting 10. Transfer : 65 N⋅m (6.5 kgf-m, 47.0 lb-ft)
3. Engine left mounting bracket 11. Suspension frame : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
1
I5RW0A140009-01

Downloaded from www.Manualslib.com manuals search engine 1D-20 Engine Mechanical:
6) Install engine right mounting bracket (1) and engine
left mounting bush bolt (2), and then tighten bolt and
nuts to specified torque.
Tightening torque
Engine right mounting bracket nut (a): 65 N·m (
6.5 kgf-m, 47.0 lb-ft)
Engine right mounting bush bolt (b): 55 N·m (5.5
kgf-m, 40.0 lb-ft)
Engine left mounting bush bolt (c): 85 N·m (8.5
kgf-m, 61.5 lb-ft)
7) Install suspension frame mounting bolts (1) and front
lower cross member bolts (2). And then tighten bolts
to specified torque.
Tightening torque
Suspension frame mounting bolt (a): 150 N·m (
15.0 kgf-m, 108.5 lb-ft)
Front lower cross member bolt (b): 55 N·m (5.5
kgf-m, 40.0 lb-ft)8) Connect steering lower shaft from pinion shaft
referring to “Steering Lower Shaft Removal and
Installation in Section 6B”.
9) Connect propeller shaft referring to “Propeller Shaft
Assembly Removal and Installation in Section 3D”
(for 4WD model)
10) Install exhaust No.1, No.2 and center pipes referring
to “Exhaust System Components in Section 1K”.
11) Reverse disconnected hoses, cables and electric
wires for connection noting the following.
• Tighten bolts and nuts to specified torque.
Tightening torque
Starting motor terminal nut (a): 11 N·m (1.1 kgf-
m, 8.0 lb-ft)
Generator terminal nut (b): 5 N·m (0.5 kgf-m, 4.0
lb-ft)
Battery ground bolt (c): 25 N·m (2.5 kgf-m, 18.0
lb-ft)
Ground terminal bolt (d): 11 N·m (1.1 kgf-m, 8.0
lb-ft)
1
(b)(a)
2,(c)
I5RW0C140031-01
2,(b)
1,(a)
I5RW0A140016-01
[A]: For M/T model [B]: For A/T model
(d)
(a)
(b)
(c)
(c)
[A]
[B]
I5RW0C140013-02

Downloaded from www.Manualslib.com manuals search engine 1G-3 Fuel System:
Schematic and Routing Diagram
Fuel Delivery System DiagramS6RW0D1702001
Diagnostic Information and Procedures
Fuel Pressure InspectionS6RW0D1704001
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.

1) Relieve fuel pressure in fuel feed line referring to
“Fuel Pressure Relief Procedure”.
2) Disconnect fuel feed hose from fuel delivery pipe.
3) Connect special tools and hose between fuel feed
hose (1) and fuel delivery pipe as shown in figure,
and clamp hoses securely in order to ensure that no
leaks occur during checking.
Special tool
(A): 09912–58442
(B): 09912–58432
(C): 09912–58490
73 6
1 4
5
8
9
2
I7RW01170002-02
1. Fuel tank 4. Delivery pipe 7. Fuel filter
2. Fuel pump assembly 5. Fuel injector 8. Fuel level sensor (gauge)
3. Fuel pressure regulator 6. Fuel feed line 9. Fuel pump
(C) (B)
(A)
1I5RW0A170002-02

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-6
Fuel Hose Disconnecting and ReconnectingS6RW0D1706002
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.

For Connection Other Than Quick Joint
• Clamp around fuel tank
NOTE
Be sure to install hose to spool of pipe surely.

9. Fuel tank bolt 19. Grommet
10. Fuel tank belt 20. O-ring
I7RW01170005-01
[A]: Connection A “b”: 30 mm (1.18 in.) 1. Pipe
[B]: Connection B “c”: 38 mm (1.50 in.) 2. Hose
[C]: Connection C “d”: 5 – 12 mm (0.20 – 0.48 in.) 3. Clamp
[D]: Connection D “e”: 7 – 14 mm (0.28 – 0.55 in.) : 1.5 N⋅m (0.15 kgf-m, 1.0 lb-ft)
“a”: 3 – 7 mm (0.12 – 0.28 in.) “f”: 2 mm (0.08 in.)

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-8
6) Start engine and run it until engine stops for lack of
fuel. Repeat cranking engine 2 – 3 times for about 3
seconds each time in order to dissipate fuel pressure
in lines. Fuel connections are now safe for servicing.
7) After servicing, connect fuel pump relay (1) to relay /
fuse box and install relay / fuse box cover.
Fuel Leakage Check ProcedureS6RW0D1706004
After performing any service on fuel system, check to
make sure that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate
fuel pump) and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply
fuel pressure to fuel line until fuel pressure is felt by
hand placed on fuel feed hose.
2) In this state, check to see that there are no fuel
leakages from any part of fuel system.
Fuel Lines On-Vehicle InspectionS6RW0D1706005
CAUTION!
Due to the fact that fuel feed line (1) is under
high pressure, use special care when
servicing it.

Visually inspect fuel lines for evidence of fuel leakage,
hose crack and deterioration or damage.
Make sure all clamps are secure.
Replace parts as needed.
Fuel Pipe Removal and InstallationS6RW0D1706006
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 in fuel feed line according to
“Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Disconnect fuel hose (3) from fuel pipe (2) at the
front and rear of each fuel pipe referring to “Fuel
Hose Disconnecting and Reconnecting”.
4) Mark the location of clamps (1) on fuel pipes (2), so
that the clamps can be reinstalled to where they
were.
5) Remove clamps (1) from vehicle body, fuel pipes and
brake pipes.
CAUTION!
Be careful not to bent and damage fuel pipes
and brake pipes when removing clamp.

6) Remove fuel pipe (2).
Installation
1) Install clamps to marked location on pipes. If clamp
is deformed, its claw is bent or broken, replace it with
new one.
2) Install pipes with pipe clamps to vehicle.
3) Connect fuel hoses and pipes to each pipe referring
to “Fuel Hose Disconnecting and Reconnecting”.
4) Connect negative cable at battery.
5) With engine OFF, turn ignition switch to ON position
and check for fuel leaks.
1
2
I5RW0A170007-01
1
I5RW0A170008-01
2
3
1
I5RW0A170009-01

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 Fuel System: 1G-10
Installation
Reverse removal procedure for installation noting the
following.
• Replace injector O-ring (1) with new one using care
not to damage it.
• Check if cushion (2) is scored or damaged. If it is,
replace with new one.
• Apply thin coat of fuel to O-rings (1), and then install
injectors (3) into delivery pipe (4) and cylinder head.
Make sure that injectors rotate smoothly (6). If not,
probable cause is incorrect installation of O-ring.
Replace O-ring with new one.
• Tighten delivery pipe bolts (5) to specified torque and
make sure that injectors rotate smoothly.
Tightening torque
Fuel delivery pipe bolt (a): 25 N·m (2.5 kgf-m, 18.0
lb-ft)
• After installation, with engine OFF and ignition switch
ON, check for fuel leaks around fuel line connection.Fuel Injector InspectionS6RW0D1706009
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.
• Put injector and battery as far away as
possible in order to reduce risk of fire and
personal injury when connecting/
disconnecting test lead to/from battery.

1) Relieve fuel pressure according to “Fuel Pressure
Relief Procedure” if equipped.
2) Disconnect fuel feed hose from delivery pipe.
3) Set special tools as follows.
Special tool
(A): 09912–58421
(B): 09930–88530
(C): 09912–57610
a) Fit washer (1) (inside diameter 13.5 – 14.5
mm(0.532 – 0.570 in.)) to injector (2), and then
install injector to special tool (A).
b) Connect special tool (B) to injector.
c) Install special tool (C) to special tool (A).
d) Connect fuel feed hose to special tool (A).
I3RM0A170011-01
(B)
(A)
(A)(C)
2
1
I6RW0B170014-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-12
Fuel Filler Cap InspectionS6RW0D1706010
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.

Remove cap (1), and check gasket for even filler neck
imprint, and deterioration or any damage. If gasket (2) is
in malcondition, replace cap.
NOTE
If cap requires replacement, only a cap with
the same features should be used. Failure to
use correct cap can result in fire and
personal injury.

Fuel Tank Inlet Valve Removal and InstallationS6RW0D1706017
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal
1) Remove fuel tank referring to “Fuel Tank Removal
and Installation”.
2) Remove fuel tank inlet valve (1) using flat head rod
(2) or the like.
CAUTION!
Be careful not to damage fuel tank inlet
valve(1) with flat head rod (2) or the like.

Installation
1) Install fuel tank inlet valve (1) to fuel tank.
2) Install fuel tank referring to “Fuel Tank Removal and
Installation”.
Fuel Tank Inlet Valve InspectionS6RW0D1706018
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Check fuel tank inlet valve for the following.
If any damage or malfunction is found, replace.
•Damage
• Smooth opening and closing
I2RH01170008-01
I7RW01170013-01
I2RH0B170018-01
I2RH0B170019-01

Downloaded from www.Manualslib.com manuals search engine 1G-13 Fuel System:
Fuel Tank Removal and InstallationS6RW0D1706011
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 in fuel feed line according to
“Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Remove fuel filler cap.
4) Insert hose of a hand operated pump into fuel filler
hose (1) and drain fuel in space “A” as shown in
figure.
CAUTION!
Do not force pump hose into fuel tank.

5) Hoist vehicle, and remove clamp (2), fuel filler hose
(1) and breather hose (3) from fuel filler neck.6) Remove exhaust center pipe referring to “Exhaust
Pipe and Muffler Removal and Installation in Section
1K”.
7) Remove propeller shaft (For 4WD model) referring to
“Propeller Shaft Assembly Removal and Installation
in Section 3D”.
8) Due to absence of fuel tank drain plug, drain fuel
tank by pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
CAUTION!
• Do not force pump hose into fuel tank.
• Never store fuel in an open container due
to possibility of fire or explosion.

9) Disconnect quick joint (fuel pipe) (1) from fuel pipes
(2) referring to “Fuel Hose Disconnecting and
Reconnecting”.
10) Support fuel tank (1) with jack (2) and remove its
mounting bolts (3).
11) Lower fuel tank a little as to disconnect wire harness
at connector (1)and ground wire (2), then remove
fuel tank.
2. Inlet check valve
I4RS0B170022-01
1 23
I5RW0A170012-01
2
1
I5RW0A170014-02
1
2
33
I5RW0A170013-01
1
2
I7RW01170009-01