service SUZUKI SX4 2006 1.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine Table of Contents 1-v
Diagnostic Information and Procedures ............ 1H-4
Ignition System Symptom Diagnosis................... 1H-4
Reference Waveform of Ignition System............. 1H-4
Ignition System Check ........................................ 1H-4
Ignition Spark Test .............................................. 1H-6
Repair Instructions .............................................. 1H-6
High-Tension Cord Removal and Installation...... 1H-6
High-Tension Cord Inspection ............................ 1H-7
Spark Plug Removal and Installation .................. 1H-7
Spark Plug Inspection ......................................... 1H-7
Ignition Coil Assembly (Including Ignitor)
Removal and Installation................................... 1H-8
Ignition Coil Assembly (Including Ignitor)
Inspection.......................................................... 1H-8
Ignition Timing Inspection ................................... 1H-8
Specifications..................................................... 1H-10
Tightening Torque Specifications ...................... 1H-10
Special Tools and Equipment ........................... 1H-10
Special Tool ...................................................... 1H-10
Starting System ......................................... 1I-1
Schematic and Routing Diagram ......................... 1I-1
Cranking System Circuit Diagram ........................ 1I-1
Diagnostic Information and Procedures ............. 1I-1
Cranking System Symptom Diagnosis ................. 1I-1
Cranking System Test.......................................... 1I-3
Repair Instructions ............................................... 1I-4
Starting Motor Dismounting and Remounting ...... 1I-4
Starting Motor Components ................................. 1I-5
Starting Motor Inspection ..................................... 1I-6
Specifications........................................................ 1I-9
Cranking System Specifications........................... 1I-9
Tightening Torque Specifications ......................... 1I-9
Special Tools and Equipment.............................. 1I-9
Recommended Service Material .......................... 1I-9
Charging System ...................................... 1J-1
General Description ............................................. 1J-1
Battery Description .............................................. 1J-1
Generator Description ......................................... 1J-3
Diagnostic Information and Procedures ............ 1J-4
Battery Inspection ............................................... 1J-4
Generator Symptom Diagnosis ........................... 1J-4
Generator Test (Undercharged Battery
Check) ............................................................... 1J-5
Generator Test (Overcharged Battery Check) .... 1J-6
Repair Instructions .............................................. 1J-6
Jump Starting in Case of Emergency.................. 1J-6
Battery Dismounting and Remounting ................ 1J-7
Water Pump / Generator Drive Belt Tension
Inspection and Adjustment ................................ 1J-7
Water Pump / Generator Drive Belt Removal
and Installation .................................................. 1J-8
Generator Dismounting and Remounting............ 1J-9
Generator Components..................................... 1J-10
Generator Inspection......................................... 1J-11
Specifications ..................................................... 1J-13
Charging System Specifications ....................... 1J-13
Tightening Torque Specifications ...................... 1J-13
Exhaust System ....................................... 1K-1
General Description .............................................1K-1
Exhaust System Description ............................... 1K-1
Diagnostic Information and Procedures ............1K-1
Exhaust System Check ....................................... 1K-1
Repair Instructions ..............................................1K-2
Exhaust System Components ............................. 1K-2
Exhaust Manifold Removal and Installation ........ 1K-3
Exhaust Pipe and Muffler Removal and
Installation ......................................................... 1K-4
Specifications .......................................................1K-5
Tightening Torque Specifications ........................ 1K-5

Downloaded from www.Manualslib.com manuals search engine 1-1 Precautions:
Engine
Precautions
Precautions
Precautions for EngineS6RW0D1000001
Air Bag Warning
Refer to “Air Bag Warning in Section 00”.
Precautions on Engine Service
Refer to “Precautions on Engine Service in Section 1A”.
Precautions in Diagnosing Trouble
Refer to “Precautions in Diagnosing Trouble in Section 1A”.
Precautions of ECM Circuit Inspection
Refer to “Precautions of ECM Circuit Inspection in Section 1A”.
Precautions on Fuel System Service
Refer to “Precautions on Fuel System Service in Section 1G”.
Precaution for CAN Communication System
Refer to “Precaution for CAN Communication System in Section 00”.
Precautions for Catalytic Converter
Refer to “Precautions for Catalytic Converter in Section 00”.
Precautions for Electrical Circuit Service
Refer to “Precautions for Electrical Circuit Service in Section 00”.

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Engine
Engine General Information and Diagnosis
Precautions
Precautions on Engine ServiceS6RW0D1100001
CAUTION!
The following information on engine service
should be noted carefully, as it is important in
preventing damage, and in contributing to
reliable engine performance.

• When raising or supporting engine for any reason, do
not use a jack under oil pan. Due to small clearance
between oil pan and oil pump strainer, jacking against
oil pan may cause it to be bent against strainer,
resulting in damaged oil pick-up unit.
• It should be kept in mind, while working on engine,
that 12-volt electrical system is capable of violent and
damaging short circuits.
When performing any work where electrical terminals
can be grounded, ground cable of the battery should
be disconnected at battery.
• Any time the air cleaner, throttle body or intake
manifold is removed, the intake opening should be
covered. This will protect against accidental entrance
of foreign material which could follow intake passage
into cylinder and cause extensive damage when
engine is started.
Precaution on On-Board Diagnostic (OBD)
System
S6RW0D1100006
There are two types of On-Board Diagnostic (OBD)
system, Euro OBD system and non-Euro-OBD system,
depending on the vehicle specification.
It is possible to identify each OBD system by checking if
it is equipped with the HO2S-2 or not.
• Euro OBD model is equipped with HO2S-2.
• Non-Euro-OBD model is not equipped with HO2S-2.
NOTE
For Taiwan model, bear in mind that it is non-
Euro-OBD model which is equipped with
HO2S-2.

As the diagnosis function is different between these two
types, be sure to fully understand the OBD system
referring to “On-Board Diagnostic System Description”.
OBD System Summary Table
Precautions in Diagnosing TroubleS6RW0D1100002
NOTE
There are two types of OBD system
depending on the vehicle specification.
For identification, refer to “Precaution on On-
Board Diagnostic (OBD) System”.

• Don’t disconnect ECM couplers from ECM, battery
cable from battery, ECM ground wire harness from
engine or main fuse before confirming diagnostic
information (DTC, freeze frame data, etc.) stored in
ECM memory. Such disconnection will erase
memorized information in ECM memory.
• Diagnostic information stored in ECM memory can be
cleared as well as checked by using SUZUKI scan
tool or CAN communication OBD generic scan tool.
Before using scan tool, read its Operator’s
(Instruction) Manual carefully to have good
understanding as to what functions are available and
how to use it.
For Euro OBD model, it is indistinguishable which
module turns on MIL because not only ECM but also
TCM (for A/T model) turns on MIL (for details of on-
board diagnostic system for A/T model, refer to “On-
Board Diagnostic System Description in Section 5A”
for A/T).
Therefore, check both ECM and TCM (for A/T model)
for DTC when MIL lights on.
IYSQ01110001-01
Euro OBD
model (with
HO2S-2)Non-Euro-OBD
model (without
HO2S-2)
Quantity of DTC
related to engine
controlApprox. 100 Approx. 50 to 80
Freeze frame
dataAvailable Not available
SUZUKI scan tool
(SUZUKI- SDT)Available Available
CAN
communication
OBD generic
scan toolAvailable Not available

Downloaded from www.Manualslib.com manuals search engine 1A-2 Engine General Information and Diagnosis:
• When checking ECM for DTC, keep in mind that DTC
is displayed on the scan tool as follows depending on
the scan tool used.
– SUZUKI scan tool displays DTC detected by ECM.
– CAN communication OBD generic scan tool
displays DTC detected by each of ECM and TCM
(for A/T model) simultaneously.
• Priorities for diagnosing troubles
If two or more DTCs are stored, proceed to the DTC
flow which has been detected earliest in the order and
follow the instruction in that flow.
If no instructions are given, troubleshoot DTCs
according to the following priorities.
a. DTCs other than DTC P0171 / P0172 (Fuel
system too lean / too rich), DTC P0300 / P0301 /
P0302 / P0303 / P0304 (Misfire detected) and
DTC P0401 / P0402 (EGR flow malfunction)
b. DTC P0171 / P0172 (Fuel system too lean / too
rich) and DTC P0401 / P0402 (EGR flow
malfunction)
c. DTC P0300 / P0301 / P0302 / P0303 / P0304
(Misfire detected)
• Be sure to read “Precautions for Electrical Circuit
Service in Section 00” before inspection and observe
what is written there.
• ECM replacement:
When substituting a known-good ECM, check for the
following conditions. Neglecting this check may cause
damage to a known-good ECM.
– Resistance value of all relays, actuators is as
specified respectively.
– MAP sensor, A/C refrigerant pressure sensor (if
equipped with A/C), accelerator pedal position
(APP) sensor and TP sensor are in good condition
and none of power circuits of these sensors is
shorted to ground.
• Communication of ECM, BCM, combination meter,
keyless start control module (if equipped with keyless
start control system), 4WD control module (if
equipped), TCM (for A/T model) and ABS control
module, is established by CAN (Controller Area
Network). (For more detail of CAN communication for
ECM, refer to “CAN Communication System
Description”). Therefore, handle CAN communication
line with care referring to “Precaution for CAN
Communication System in Section 00”.
• Immobilizer transponder code registration after
replacing ECM (Immobilizer model)
When ECM is replaced with new one or with another
one, make sure to register immobilizer transponder
code to ECM correctly according to “Procedure after
ECM Replacement in Section 10C”.Precautions for DTC TroubleshootingS6RW0D1100003
• 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”.
• Upon completion of inspection and repair work,
perform “DTC Confirmation Procedure” and confirm
that the trouble has been corrected.
Precautions of ECM Circuit InspectionS6RW0D1100004
• ECM connectors are waterproofed. Each terminal of
the ECM connectors is sealed up with the grommet.
Therefore, when measuring circuit voltage, resistance
and/or pulse signal at ECM connector, do not insert
the tester’s probe into the sealed terminal at the
harness side. When measuring circuit voltage,
resistance and/or pulse signal at ECM connector,
connect the special tool to the ECM connectors. And,
insert the tester’s probe into the special tool’s
connectors at the harness side, and then measure
voltage, resistance and/or pulse signal. Or, ECM and
its circuits may be damaged by water.
• Wire colors of the special tool’s connectors are
different from the ones of the ECM connectors.
However, the circuit arrangement of the special tool’s
connectors is same as the one of the ECM
connectors. Therefore, measure circuit voltage and
resistance by identifying the terminal location subject
to the measurement.
Precautions of Electric Throttle Body System
Calibration
S6RW0D1100005
After performing one of works described below, it is
necessary to re-register the completely closed throttle
valve reference position stored in memory of ECM. (For
detailed information, refer to “Description of Electric
Throttle Body System Calibration”.) For the procedure to
register such data in ECM, refer to “Electric Throttle
Body System Calibration in Section 1C”.
• To shut off backup power of ECM for such purposes of
battery replacement or “DOME” fuse removal
• To erase DTCs P0122, P0123, P0222, P0223, P2101,
P2102, P2103, P2111, P2112, P2119 and/or P2135
• To replace ECM
• To replace throttle body and/or accelerator pedal
position (APP) sensor assembly

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-5
General Description
Statement on Cleanliness and CareS6RW0D1101001
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousands of an
millimeter (ten thousands of an inch).
Accordingly, when any internal engine parts are
serviced, care and cleanliness are important.
It should be understood that proper cleaning and
protection of machined surfaces and friction areas is part
of the repair procedure. This is considered standard
shop practice even if not specifically stated.
• A liberal coating of engine oil should be applied to
friction areas during assembly to protect and lubricate
the surfaces on initial operation.
• Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.
At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.
• Battery cables should be disconnected before any
major work is performed on the engine.
Failure to disconnect cables may result in damage to
wire harness or other electrical parts.
• The four cylinders of the engine are identified by
numbers; No.1 (1), No.2 (2), No.3 (3) and No.4 (4)
counted from crankshaft pulley side to flywheel side.
Engine Diagnosis General DescriptionS6RW0D1101002
NOTE
There are two types of OBD system
depending on the vehicle specification.
For identification, refer to “Precaution on On-
Board Diagnostic (OBD) System”.

This vehicle is equipped with an engine and emission
control system which are under control of ECM.
The engine and emission control system in this vehicle
are controlled by ECM. ECM has an On-Board
Diagnostic system which detects a malfunction in this
system and abnormality of those parts that influence the
engine exhaust emission. When diagnosing engine
troubles, be sure to have full understanding of the outline
of “On-Board Diagnostic System Description” and each
item in “Precautions in Diagnosing Trouble” and execute
diagnosis according to “Engine and Emission Control
System Check”.
There is a close relationship between the engine
mechanical, engine cooling system, ignition system,
exhaust system, etc. and the engine and emission
control system in their structure and operation. In case of
an engine trouble, even when the malfunction indicator
lamp (MIL) doesn’t turn ON, it should be diagnosed
according to “Engine and Emission Control System
Check”.
On-Board Diagnostic System DescriptionS6RW0D1101003
NOTE
There are two types of OBD system
depending on the vehicle specification.
For identification, refer to “Precaution on On-
Board Diagnostic (OBD) System”.

Euro OBD model
ECM in this vehicle has the following functions.
• When the ignition switch is turned ON with the engine
at a stop, malfunction indicator lamp (MIL) (1) turns
ON to check the circuit of the malfunction indicator
lamp (1).
• When ECM detects a malfunction which gives an
adverse effect to vehicle emission while the engine is
running, it makes the malfunction indicator lamp (1) in
the meter cluster of the instrument panel turn ON or
flash (flashing only when detecting a misfire which
can cause damage to the catalyst) and stores the
malfunction area in its memory.
(If it detects that continuously 3 driving cycles are
normal after detecting a malfunction, however, it
makes MIL (1) turn OFF although DTC stored in its
memory will remain.)
1
234
I3RM0A110001-01

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-195
6ECM ground circuit check
1) Turn ignition switch to OFF position.
2) Disconnect connectors from ECM.
3) Measure resistance between each “E01-31”, “C01-58”,
“C01-15” and “C01-30” terminals of ECM connector and
body ground.
Is resistance 1
Ω or less?Substitute a known-
good ECM and recheck.“BLK/ORN” or “BLK”
wire is open or high
resistance circuit.
7Main relay circuit check
1) Disconnect connectors from ECM with ignition switch
turned OFF.
2) Using service wire, ground “E01-60” terminal of ECM
connector and measure voltage between each “E01-1”
and “E01-16” terminals of ECM connector and body
ground.
Is voltage 10 – 14 V?Go to Step 11. Go to Step 8.
8Main relay circuit check
1) Remove main relay (1) from individual circuit fuse box
No.1.
2) Check for proper connection to main relay connector at
“BLK/YEL” and “BLK/RED” wire terminals.
3) If OK, measure resistance between each “E01-1” and
“E01-16” wire terminals of ECM connector and “BLK/
RED” wire terminal of main relay connector.
Is resistance 1
Ω or less?Go to Step 9. “BLK/RED” wire is open
circuit or high resistance
circuit.
9Main relay circuit check
1) Remove main relay from individual circuit fuse box No.1
with ignition switch turned OFF.
2) Measure voltage between “BLK/YEL” wire terminal of
main relay connector and body ground.
Is voltage 10 – 14 V?Go to Step 10. “BLK/YEL” wire is open
circuit.
10Main relay check
1) Check main relay referring to “Main Relay, Fuel Pump
Relay, Starting Motor Control Relay, Throttle Actuator
Control Relay and Radiator Cooling Fan Relay
Inspection in Section 1C”.
Is main relay in good condition?“BRN/WHT” wire is
open or high resistance
circuit.Replace main relay. Step Action Yes No
1
I5RW0A110059-02

Downloaded from www.Manualslib.com manuals search engine 1A-200 Engine General Information and Diagnosis:
6Fuel pump relay drive signal check
1) Measure voltage within 2 second after ignition switch is
turned ON.
Is voltage 0 – 1 V?Go to Step 7. Substitute a known-
good ECM and recheck.
7Wire circuit check
1) Turn OFF ignition switch.
2) Detach fuel tank referring to “Fuel Tank Removal and
Installation in Section 1G”.
3) Disconnect connector from fuel pump.
4) Measure resistance between “PNK” wire terminal of fuel
pump connector and vehicle body ground.
Is resistance infinity?Go to Step 8. “PNK” wire is shorted to
ground.
8Fuel pump circuit check
1) Connect service wire between “E01-15” terminal of ECM
connector and vehicle body ground.
2) Turn ON ignition switch, measure voltage between
“PNK” terminal at fuel pump connector and vehicle body
ground.
Is voltage 10 – 14 V?Go to Step 9. “PNK” wire is open
circuit.
9Fuel pump circuit check
1) Turn OFF ignition switch.
2) Measure resistance between “BLK” wire terminal at fuel
pump connector and vehicle body ground.
Is resistance less than 5
Ω?Faulty fuel pump. “BLK” wire is open
circuit. Step Action Yes No

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 Aux. Emission Control Devices: 1B-2
1) Prepare to operate EVAP canister purge valve as
follows.
a) When using SUZUKI scan tool:
i) Connect SUZUKI scan tool to DLC (1) with
ignition switch turned OFF and disconnect
purge valve vacuum hoses from intake
manifold and EVAP canister.
ii) Turn ON ignition switch, clear DTC and
select “Engine / Active Test” mode on
SUZUKI scan tool.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
b) When not using SUZUKI scan tool:
NOTE
Before performed this check, be sure to read
the “Precautions of ECM Circuit Inspection in
Section 1A”.

i) Disconnect purge valve vacuum hoses from
intake manifold and purge pipe.
ii) Remove ECM from its bracket referring to
“Engine Control Module (ECM) Removal and
Installation in Section 1C”.
iii) Connect special tool between ECM and ECM
connector referring to “Inspection of ECM
and Its Circuits in Section 1A”.
iv) Turn ON ignition switch.
Using service wire, ground “C01-29” terminal
circuit of special tool (valve ON: “B”) and
unground it (valve OFF: “A”).2) Check purge valve for operation and vacuum
passage for clog when valve is switched ON and
OFF by using SUZUKI scan tool or service wire.
If check result is not satisfactory, check vacuum
hoses, EVAP canister purge valve, wire harness and
connections.
EVAP canister purge valve specification
[A] Valve OFF: When vacuum (–60 kPa (–8.7 psi))
is applied to hose (1), vacuum can be applied.
[B] Valve ON: When vacuum is applied to hose
(1), vacuum can not be applied.
Special tool
(A): 09917–47011
Vacuum Passage InspectionS6RW0D1206003
Start engine and run it at idle speed. Disconnect vacuum
hose (1) from EVAP canister purge valve (2). With finger
placed against disconnected hose, check that vacuum is
applied.
If it is not applied, clean vacuum passage by blowing
compressed air.
(A) 1I5RW0C110011-01
“C01-29”
“A”
“B”
I6RW0D120001-01
[A]
1 (A)
[B]
1 (A)
I5RW0A120008-01
1
2
I5RW0A120003-01

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