200 SUZUKI SX4 2006 1.G Service Service Manual

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-9
6) Select new shim No. (1) with a thickness as close as
possible to calculated value.
Available new shims No.
7) Install new shim facing shim No. side with tappet.8) Lift valve by turning crankshaft counterclockwise (in
opposite direction against above Step 4)) and
remove special tool.
Special tool
(A): 09916–67020
(A): 09916–67021
9) Install camshaft housing (1) and tighten bolts to
specified torque.
Tightening torque
Camshaft housing bolt (a): Tighten 11 N⋅m (1.1
kgf-m, 8.0 lb-ft) by the specified procedure
10) Check valve clearance again after adjusting it.
11) After checking and adjusting all valves.
12) Install cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”. Thickness mm
(in.)Shim No.Thickness mm
(in.)Shim No.
2.175 (0.0856) 218 2.600 (0.1024) 260
2.200 (0.0866) 220 2.625 (0.1033) 263
2.225 (0.0876) 223 2.650 (0.1043) 265
2.250 (0.0886) 225 2.675 (0.1053) 268
2.275 (0.0896) 228 2.700 (0.1063) 270
2.300 (0.0906) 230 2.725 (0.1073) 273
2.325 (0.0915) 233 2.750 (0.1083) 275
2.350 (0.0925) 235 2.775 (0.1093) 278
2.375 (0.0935) 238 2.800 (0.1102) 280
2.400 (0.0945) 240 2.825 (0.1112) 283
2.425 (0.0955) 243 2.850 (0.1122) 285
2.450 (0.0965) 245 2.875 (0.1132) 288
2.475 (0.0974) 248 2.900 (0.1142) 290
2.500 (0.0984) 250 2.925 (0.1152) 293
2.525 (0.0994) 253 2.950 (0.1161) 295
2.550 (0.1004) 255 2.975 (0.1171) 298
2.575 (0.1014) 258 3.000 (0.1181) 300
I2RH0B140015-01
1. Tappet 2. Camshaft
(A)2
1
I3RM0A140006-01
I2RH0B140149-01

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-2
Schematic and Routing Diagram
Coolant CirculationS6RW0D1602001
While the engine is warmed up (thermostat closed), coolant circulates as follows.
When coolant is warmed up to normal temperature and the thermostat opens, coolant passes through the radiator
core to be cooled as follows.
7
5
6
4
3
2
81
I5RW0C160001-02
1. Radiator inlet hose 3. Thermostat 5. Throttle body 7. Heater core
2. Radiator outlet hose 4. Water pump 6. Engine 8. Radiator
7
5
6
4
3
2
81
I5RW0C160002-02
1. Radiator inlet hose 3. Thermostat 5. Throttle body 7. Heater core
2. Radiator outlet hose 4. Water pump 6. Engine 8. Radiator

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 Ignition System: 1H-2
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

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 1J-2 Charging System:
Care of battery
WARNING!
• Never expose battery to open flame or electric spark because of battery generate gas which is
flammable and explosive.
• Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive
acid. Flush any contacted area with water immediately and thoroughly.
• Batteries should always be kept out of reach of children.

1) The battery is a very reliable component, but needs periodical attentions.
• Keep the battery carrier clean.
• Prevent rust formation on the terminal posts.
• Keep the electrolyte up to the upper level uniformly in all cells.
• When keeping battery on vehicle over a long period of time, follow instructions given below.
– Weekly, start the engine and run it until it reaches normal operating temperature with engine speed of 2000 to
3000 rpm. Make sure all electric switches are off before storing the vehicle.
– Recharge the battery twice a month to prevent it from discharging excessively. This is especially important
when ambient temperature is low.
The battery discharges even when it is not used, while vehicles are being stored. Battery electrolyte can
freeze and battery case can crack at cold ambient condition if battery is not properly charged.
2) Keep the battery cable connections clean.
The cable connections, particularly at the positive (+) terminal post, tend to become corroded. The product of
corrosion, or rust, on the mating faces of conductors resists the flow of current.
Clean the terminals and fittings periodically to ensure good metal-to-metal contact, and grease the connections
after each cleaning to protect them against rusting.
3) Be always in the know as to the state of charge of the battery. The simplest way to tell the state of charge is to
carry out a hydrometer test. The hydrometer is an instrument for measuring the specific gravity (S.G.) of the
battery electrolyte. The S.G. of the electrolyte is indicative of the state of charge. Refer to “Battery Inspection”.

Downloaded from www.Manualslib.com manuals search engine 1J-6 Charging System:
3) Ground “F” terminal and start engine, then measure
voltage at “B” terminal as shown in figure.
• Voltage is higher than standard value. It is
considered that generator itself is good but IC
regulator has been damaged, replace IC
regulator.
• Voltage is lower than standard value. It is
considered that generator itself has problem,
check the generator.
Load Check
1) Run engine at 2,000 rpm and turn on head light and
heater motor.
2) Measure current and if it is less than 20 A, repair or
replace generator.Generator Test (Overcharged Battery Check)S6RW0D1A04004
1) To determine battery condition, refer to “Battery
Description”.
2) If obvious overcharged condition exists as evidenced
by excessive spewing of electrolyte, measure
generator “B” terminal voltage at engine 2000 rpm.
3) If measured voltage is higher than upper limit value,
disassemble generator.
4) Check ground of brushes. If brushes are not
grounded, replace IC regulator. Then check field coil
for grounds and shorts.
Repair Instructions
Jump Starting in Case of EmergencyS6RW0D1A06001
With Auxiliary (Booster) Battery
CAUTION!
If vehicle is manual transaxle model and has
a catalytic converter, do not push or tow it to
start. Damage to its emission system and/or
to other parts may result.

Both booster and discharged battery should be treated
carefully when using jumper cables. Follow the
procedure outlined as follows, being careful not to cause
sparks.
WARNING!
• Departure from these conditions or
procedure described as follows could
result in:
– Serious personal injury (particularly to
eyes) or property damage from such
causes as battery explosion, battery
acid, or electrical burns.
– Damage to electronic components of
either vehicle.
• Remove rings, watches, and other jewelry.
Wear approved eye protection.
• Be careful so that metal tools or jumper
cables do not contact positive battery
terminal (or metal in contact with it) and
any other metal on vehicle, because a
short circuit could occur.
• Do not connect negative cable directly to
negative terminal of dead battery.

I2RH011A0008-01
[A]: Regulated voltage (V)
[B]: Heatsink temperature (°C)
16.0
12.0
14.2 15.3
14.8
14.2
13.3 14.8
15.0
11.0 14.0
13.0 [A]
12.5 13.6
13.1
12.5
11.613.1
[B] -30 0 25 135
H
L
I2RH0B1A0005-01

Downloaded from www.Manualslib.com manuals search engine 2-1 Precautions:
Suspension
Precautions
Precautions
Precautions on SuspensionS6RW0D2000001
Suspension Caution
Refer to “Suspension Caution in Section 00”.
Wheels and Tires Caution
Refer to “Wheels and Tires Caution in Section 00”.
General Precautions
Refer to “General Precautions in Section 00”.
Vehicle Lifting Points
Refer to “Vehicle Lifting Points in Section 0A”.
Fastener Caution
Refer to “Fastener Caution in Section 00”.
Fastener Information
Refer to “Fasteners Information in Section 0A”.
Brake Caution
Refer to “Brake Caution in Section 00”.

Downloaded from www.Manualslib.com manuals search engine 2B-1 Front Suspension:
Suspension
Front Suspension
General Description
Front Suspension ConstructionS6RW0D2201001
1
4 3
2
7
6
8
))
5
9(a)
(b)
(b)
(b)
(b)
(c)
(c)
(d)
(d)
(e)(f)
(g)
(h)
(i)
(h)
F
I7RW01220002-03
1. Front strut assembly 8. Front suspension frame : 200 N⋅m (20.0 kgf-m, 145.0 lb-ft)
2. Front drive shaft 9. Suspension control arm : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
3. Steering knuckle : 140 N⋅m (14.0 kgf-m, 101.5 lb-ft) : 95 N⋅m (9.5 kgf-m, 69.0 lb-ft)
4. Front wheel hub : 150 N⋅m (15.0 kgf-m, 108.5 lb-ft) : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
5. Stabilizer joint : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) : Do not reuse.
6. Stabilizer bar : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft) F: Forward
7. Tie-rod : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-2
Front Wheel Alignment ConstructionS6RW0D2201002
Among factors for front wheel alignment, only toe setting
can be adjusted. Camber and caster are not adjustable.
Therefore, should camber or caster be out of
specification due to the damage caused by hazardous
road conditions or collision, whether the damage is in
body or in suspension should be determined and
damaged body should be repaired or damaged
suspension should be replaced.
Preliminary Checks Prior to Adjustment Front Wheel
Alignment
Steering and vibration complaints are not always the
result of improper wheel alignment. An additional item to
be checked is the possibility of tire lead due to worn or
improperly manufactured tires. “Lead” is the vehicle
deviation from a straight path on a level road without
hand pressure on the steering wheel. Refer to “Radial
Tire Lead / Pull Description in Section 2D” in order to
determine if the vehicle has a tire lead problem. Before
making any adjustment affecting wheel alignment, the
following checks and inspections should be made to
ensure correctness of alignment readings and alignment
adjustments:• Check all tires for proper inflation pressures and
approximately the same tread wear.
• Check for loose of ball joints. Check tie-rod ends; if
excessive looseness is noted, it must be corrected
before adjusting.
• Check for run-out of wheels and tires.
• Check vehicle trim heights; if it is out of limit and a
correction is needed, it must be done before adjusting
toe.
• Check for loose of suspension control arms.
• Check for loose or missing stabilizer bar attachments.
• Consideration must be given to excess loads, such as
tool boxes. If this excess load is normally carried in
vehicle, it should remain in vehicle during alignment
checks.
• Consider condition of equipment being used to check
alignment and follow manufacturer’s instructions.
• Regardless of equipment used to check alignment,
vehicle must be placed on a level surface.
NOTE
To prevent possible incorrect reading of toe,
camber or caster, vehicle front and rear end
must be moved up and down a few times
before inspection.

Repair Instructions
Front Wheel Alignment Inspection and
Adjustment
S6RW0D2206001
Toe Inspection and Adjustment
Preparation for toe inspection and adjustment.
• Place vehicle in unloaded state on level surface.
• Set steering wheel in straight state.
• Check that inflation pressure of each tire is adjusted
properly and wheel is free from deflection.
• Check that each suspension part is free from bend,
dent, wear or damage in any other form.
• Check that ground clearance at the right and left is
just about the same.Inspection
Measure toe with toe-in gauge (1).
Toe should be within following specifications.
If toe is out of the specification, adjust toe properly.
To e
IN 1.0 ± 1.0 mm (0.0394 ± 0.0394 in.)
I2RH01220062-01