SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-14
Installation
CAUTION!
• When connecting joint, clean outside
surfaces of pipe where joint is to be
inserted, push joint into pipe till joint lock
clicks and check to ensure that pipes are
connected securely, or fuel leak may
occur.
• Never let the fuel hoses touch the ABS
sensor harness (if equipped).

1) If parts have been removed from fuel tank, install
them before installing fuel tank to vehicle.
2) Raise fuel tank (1) with jack (2) and connect fuel
pump connector (3), ground wire (4) and clamp wire
harness.
Tightening torque
Ground wire bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Install fuel tank to vehicle.
Tightening torque
Fuel tank bolt (b): 45 N·m (4.5 kgf-m, 33.0 lb-ft)4) Connect fuel filler hose (1) and breather hose (2) to
filler neck (3) as shown in figure, and clamp them
securely.
Tightening torque
Fuel filler hose clamp (a): 1.5 N·m (0.15 kgf-m,
1.0 lb-ft)
5) Connect fuel feed hose (1) and vapor hose (2) to
each pipe as shown in figure, and clamp them
securely.
6) Install exhaust center pipe referring to “Exhaust Pipe
and Muffler Removal and Installation in Section 1K”.
7) Install propeller shaft (For 4WD model) referring to
“Propeller Shaft Assembly Removal and Installation
in Section 3D”.
8) Connect negative cable at battery.
9) With engine OFF, turn ignition switch to ON position
and check for fuel leaks.
Fuel Tank InspectionS6RW0D1706012
After removing fuel tank, check hoses and pipes
connected to fuel tank for leaks, loose connections,
deterioration or damage. Also check fuel pump
assembly gaskets for leaks, visually inspect fuel tank for
leaks and damage.
Replace any damaged or malconditioned parts.
(b)(b)
1
2
3
4
(a)
I7RW01170010-01
1(a)2
3
I5RW0A170017-01
1
2
I5RW0A170018-01

Downloaded from www.Manualslib.com manuals search engine 1G-15 Fuel System:
Fuel Tank Purging ProcedureS6RW0D1706013
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.
• This purging procedure will not remove all
fuel vapor.
Do not attempt any repair on tank using
heat of flame as an explosion resulting in
personal injury could occur.

CAUTION!
Never remain water in fuel tank after washing,
or fuel tank inside will get corrosion.

The following procedure are used for purging fuel tank.
1) After removing fuel tank, remove all hoses, pipes
and fuel pump assembly from fuel tank.
2) Drain all remaining fuel from tank.
3) Place fuel tank to flushing area.
4) Fill tank with warm water or tap water, and agitate
vigorously and drain. Repeat this washing until
inside of tank is clean. Replace tank if its inside is
rusty.
5) Completely flush out remaining water after washing.
6) Be sure to dry fuel tank assembly thoroughly out of
direct sunlight after washing.
Fuel Pump On-Vehicle InspectionS6RW0D1706014
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.

NOTE
The fuel pressure regulator is incorporated
with the fuel pump assembly so individual
inspection of it is impossible.

1) Remove filler cap and turn ON ignition switch (2).
Then fuel pump operating sound should be heard
from fuel filler (1) for about 2 seconds and stop. Be
sure to reinstall fuel filler cap after checking.
If the check result is not satisfactory, go to “Fuel
Pump and Its Circuit Check in Section 1A”.2) Turn OFF ignition switch and leave over 10 minutes
as it is.
3) Fuel pressure should be felt at fuel feed hose (1) for
about 2 seconds after ignition switch ON.
If fuel pressure is not felt, go to “Fuel Pressure
Check in Section 1A”.
Fuel Pump Assembly Removal and InstallationS6RW0D1706015
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) Remove fuel tank from vehicle referring to “Fuel
Tank Removal and Installation”.
2) Disconnect fuel pipe (1) from fuel pump assembly (2)
referring to “Fuel Hose Disconnecting and
Reconnecting”.
3) Remove fuel pump assembly and earth bracket from
fuel tank.
IVSY01170013-01
1I5RW0A170019-01
1
2
I7RW01170011-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-16
Installation
CAUTION!
When connecting joint, clean outside surface
of pipe where joint is to be inserted, push
joint into pipe till joint lock clicks and check
to ensure that pipes are connected securely,
or fuel leak may occur.

1) Clean mating surfaces of fuel pump assembly and
fuel tank.
2) Put plate (2) on fuel pump assembly (1) by matching
the protrusion of fuel pump assembly (3) to plate
hole (4) as shown.
3) Install new gasket (2), fuel pump assembly (1) and
earth bracket (5) with plate (3) to fuel tank (4).
Tightening torque
Fuel pump assembly bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)
4) Connect fuel feed pipe (1) to fuel pump assembly
(2).5) Install fuel tank to vehicle. Refer to “Fuel Tank
Removal and Installation”.
Main Fuel Level Sensor Removal and
Installation
S6RW0D1706019
CAUTION!
• Do not touch resister plate (1) and deform
arm (2). It may cause main fuel level sensor
to fail.
• Be very careful not to cause damage to
fuel tube installed section (sealed section
in bore). If it be damaged, replace it with
new one, or fuel will leak from the part.

Removal
1) Remove fuel pump assembly from fuel tank referring
to “Fuel Pump Assembly Removal and Installation”.
2) Disconnect main fuel level sensor connector (3).
3) With pressing snap-fit part (2), remove main fuel
level sensor (1) by sliding it in the arrow direction as
shown in figure.
Installation
Reverse removal procedure for installation.
3
1 2 4
I5JB0A171025-01
3
1
2
(a)
4
5
I7RW01170012-01
1
2
I7RW01170011-01
1
2I4RS0A170016-01
1 3
12
I5JB0A171026-01

Downloaded from www.Manualslib.com manuals search engine 1G-17 Fuel System:
Fuel Pump InspectionS6RW0D1706016
• Check fuel pump assembly for damage.
• Check fuel suction filter for evidence of dirt and
contamination.
If present, replace or clean and check for presence of
dirt in fuel tank.
• For electrical circuit, refer to “Fuel Pump and Its
Circuit Check in Section 1A”.
• For inspection of fuel level gauge (1), refer to “Fuel
Level Sensor Inspection in Section 9C”.
Specifications
Tightening Torque SpecificationsS6RW0D1707001
NOTE
The specified tightening torque is also described in the following.
“Fuel System Components”
“Fuel Hose Disconnecting and Reconnecting”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
1
I5JB0A171027-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Fuel delivery pipe bolt 25 2.5 18.0)
Ground wire bolt 11 1.1 8.0)
Fuel tank bolt 45 4.5 33.0)
Fuel filler hose clamp 1.5 0.15 1.0)
Fuel pump assembly bolt 11 1.1 8.0)

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Special Tools and Equipment
Special ToolS6RW0D1708001
09912–57610 09912–58421
Injector checking tool plate Checking tool set
)This kit includes the
following items. 1. Tool body
and washer, 2. Body plug, 3.
Body attachment-1, 4.
Holder, 5. Return hose and
clamp, 6. Body attachment-2
and washer, 7. Hose
attachment-1, 8. Hose
attachment-2 )
09912–58432 09912–58442
Fuel pressure gauge hose Fuel pressure gauge
This tool is included in fuel
pressure gauge set (09912-
58413). )This tool is included in fuel
pressure gauge set (09912-
58413). )
09912–58490 09919–47020
3-way joint & hose Quick joint remover
))
09930–88530 SUZUKI scan tool (SUZUKI-
SDT)
Injector test lead —
)This kit includes following
items. 1. SUZUKI-SDT 2.
DLC3 cable 3. USB cable 4.
AC/DC power supply 5.
Voltage meter probe 6.
Storage case )
1
2
34
56

Downloaded from www.Manualslib.com manuals search engine 1H-1 Ignition System:
Engine
Ignition System
General Description
Ignition System ConstructionS6RW0D1801001
The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below.
•ECM
It detects the engine and vehicle conditions through the signals from the sensors, determines the most suitable
ignition timing and time for electricity to flow to the primary coil and sends a signal to the ignitor (power unit) in the
ignition coil assembly.
•Ignition coil assembly (including an ignitor)
The ignition coil assembly has a built-in ignitor which turns ON and OFF the current flow to the primary coil
according to the signal from ECM. When the current flow to the primary coil is turned OFF, a high voltage is induced
in the secondary coil.
•High-tension cords and spark plugs
•CMP sensor (Camshaft position sensor) and CKP sensor (Crankshaft position sensor)
Using signals from these sensors, ECM identifies the specific cylinder whose piston is in the compression stroke,
detects the crank angle and adjusts initial ignition timing automatically.
•TP sensor, ECT sensor, MAP sensor, MAF sensor, IAT sensor, knock sensor and other sensors / switches
Although this ignition system does not have a distributor, it has two ignition coil assemblies (one is for No.1 and No.4
spark plugs and the other is for No.2 and No.3 spark plugs). When an ignition signal is sent from ECM to the ignitor in
the ignition coil assembly for No.1 and No.4 spark plugs, a high voltage is induced in the secondary coil and that
passes through the high-tension cords and causes No.1 and No.4 spark plugs to spark simultaneously. Likewise,
when an ignition signal is sent to the ignitor in the other ignition coil assembly, No.2 and No.3 spark plugs spark
simultaneously.

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Schematic and Routing Diagram
Ignition System Wiring Circuit DiagramS6RW0D1802001
E01-60
E01-29
12V5V
5V
E01-1
E01-16
BLK/WHT
BLK/RED
BLK/RED
BLK/RED
80A
BLK/YELBLK/YEL
BLK/YEL
GRN
BLK
WHT
BRN/WHT
BLK/ORN
BLK
BLK
BLK
C01-20
BLK/RED
PNK
BLK/ORN
5V
C01-21
BLK/WHT
7
34
1
125
6 2
11 89 10
GRN/YEL
GRN/WHT
C01-6
C01-55V
5V
RED/YEL
C01-58
C01-15
C01-30
E01-31
E01C01
3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238 3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238
13
14
15
16
17
BLK
I6RW0D180001-01
1. Ignition switch 7. No.1 spark plug 13. Relay box
2. Main relay 8. No.2 spark plug 14. “IG ACC” fuse
3. Ignition coil assembly for No.1 and No.4 spark plugs 9. No.3 spark plug 15. “FI” fuse
4. Ignition coil assembly for No.2 and No.3 spark plugs 10. No.4 spark plug 16. Junction block assembly
5. CMP sensor 11. Sensed information 17. “IG COIL” fuse
6. CKP sensor 12. Battery fuse box

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Component Location
Ignition System Components LocationS6RW0D1803001
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

12*
15*
13
1 689
11
10
74
5
14
2 3
16
I5RW0C180002-01
1. ECM 7. ECT sensor 13. Battery fuse box
2. Ignition coil assembly for No.1 and No.4 spark plugs 8. MAF and IAT sensor 14. Relay box
3. Ignition coil assembly for No.2 and No.3 spark plugs 9. Electric throttle body assembly 15. Junction block assembly
4. CMP sensor (VVT model) 10. High-tension cords 16. CMP sensor (VVT model)
5. CKP sensor 11. Knock sensor
6. MAP sensor (if equipped) 12. Data link connector

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).

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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