Oil ring SUZUKI SX4 2006 1.G Service Service Manual

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-119
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive DetectedS6RW0D1104043
System and Wiring Diagram7CMP sensor check
1) Check CMP sensor and signal rotor tooth referring to
“Camshaft Position (CMP) Sensor Inspection in Section
1C”.
Is check result satisfactory?Substitute a known-
good ECM and recheck.Replace CMP sensor
and/or intake camshaft. Step Action Yes No
I6RW0D110034-01
1. EGR valve 4. Sensed information 7. “IG COIL” fuse 10. Main relay
2. Intake manifold 5. Fresh air 8. Main fuse box 11. “FI” fuse
3. ECM 6. Exhaust gas 9. Ignition switch 12. “IGN” fuse

Downloaded from www.Manualslib.com manuals search engine 1A-122 Engine General Information and Diagnosis:
DTC P0403: Exhaust Gas Recirculation Control CircuitS6RW0D1104044
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

1) With ignition switch turned OFF, connect scan tool to DLC.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and warm it up to normal operating temperature.
4) Drive vehicle in 2000 – 3500 rpm of engine speed.
5) Keep above vehicle speed for 1 min. (Throttle valve opening is kept constant in this step.)
6) Stop vehicle and check DTC and pending DTC.
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
BLK/WHT
BLK/RED
BLK/RED
WHTBLK/YELBLK/YEL
BLK/YEL
GRN
BRN/WHT
12V5V
4
1 65E01-29
E01-1
E01-60
C01-58
C01-15 C01-30
BLK/ORN
BLKBLK
E01-16 2BLK/RED
C01-4
C01-3
C01-19
C01-18
BLK/RED
BLK/RED
BLK/RED
GRN/RED
GRN/ORN
WHT/RED
BRN/YEL
37 8
E01-31 BLK
I6RW0D110037-01
1. Main relay 3. Main fuse box 5. ECM 7. “FI” fuse
2. EGR valve 4. Ignition switch6. “IG COIL” fuse 8. “IGN” fuse
DTC detecting condition Trouble area
EGR valve output voltage is different from output command with more than one pole
out of 4 poles.
(1 driving cycle detection logic)• EGR valve circuit open
• EGR valve
•ECM

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-123
DTC Troubleshooting
NOTE
Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to
“Precautions for DTC Troubleshooting”.

Step Action Yes No
1Was “Engine and Emission Control System Check”
performed?Go to Step 2. Go to “Engine and
Emission Control
System Description”.
2EGR valve power supply circuit check
1) Remove air intake pipe.
2) With ignition switch turned OFF, disconnect EGR valve
connector.
3) With ignition switch turned ON, measure voltage
between “BLK/RED” wire terminal of EGR valve
connector and vehicle body ground.
Is check voltage 10 – 14 V?Go to Step 3. “BLK/RED” wire is open
circuit.
3Wire circuit check
1) Disconnect connectors from ECM with ignition switch
turned OFF.
2) Turn ON ignition switch.
3) Measure voltage between engine ground and each
“GRN/RED”, “GRN/ORN”, “WHT/RED”, “BRN/YEL” wire
terminals of EGR valve connector.
Is each voltage 0 V?Go to Step 4. Faulty wire(s) are
shorted to other circuit.
If wires are OK,
substitute a known-
good ECM and recheck.
4Wire circuit check
1) With ignition switch turned OFF, measure resistance
between engine ground and each “GRN/RED”, “GRN/
ORN”, “WHT/RED”, “BRN/YEL” wire terminals of EGR
valve connector.
Is resistance infinity?Go to Step 5. Faulty wire(s) are
shorted to ground
circuit.
If wires are OK,
substitute a known-
good ECM and recheck.
5Short circuit check for EGR valve control circuit
1) With ignition turned OFF, measure resistance between
each EGR valve control circuit wire (“GRN/RED”, “GRN/
ORN”, “WHT/RED” and “BRN/YEL” wire) and each EGR
valve control circuit wire.
Is each resistance infinity?Go to Step 6. Faulty wire(s) are short
circuit.
6EGR valve stepper motor coil circuit check
1) With ignition switch turned OFF, connect EGR valve
connector.
2) Measure resistance between “E01-1/16” and each “C01-
4”, “C013”, “C01-19”, “C01-18” terminals of ECM
connector.
Is each resistance 20 – 31
Ω at 20 °C, 68 °F?Faulty ECM. Substitute
a known-good ECM and
recheck.Go to Step 7.
7EGR valve check
1) Check EGR valve resistance referring to “EGR Valve
Inspection (If Equipped) in Section 1B”.
Is resistance within specified value?Faulty wire(s) are open
or high resistance
circuit. If wires are OK,
substitute a known-
good ECM and recheck.Faulty EGR valve.

Downloaded from www.Manualslib.com manuals search engine 1A-126 Engine General Information and Diagnosis:
DTC P0443: Evaporative Emission System Purge Control Valve CircuitS6RW0D1104046
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

1) With ignition switch OFF, connect scan tool to DLC.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and warm up normal operating temperature.
4) Drive vehicle at more than 40 km/h, 25 mph for 5 min. or more.
5) Check DTC and pending DTC.
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
BLK/WHT
BLK/RED
BLK/RED
WHTBLK/YELBLK/YEL
BLK/YEL
GRN
BRN/WHT
12V5V
5
42 36E01-29
E01-1
E01-60
C01-58
C01-15 C01-30
BLK/ORN
BLKBLK
7 8
BLK/REDBLK/REDE01-16
1
C01-29 BLU/BLK
BLKE01-31
I6RW0D110039-01
1. EVAP canister purge valve 3. “IG COIL” fuse 5. Ignition switch 7. “FI” fuse
2. Main relay 4. Main fuse box 6. ECM 8. “IGN” fuse
DTC detecting condition Trouble area
Monitor signal of EVAP canister purge valve is different from command signal.
(Circuit open or short)
(2 driving cycle detection logic)• EVAP canister purge valve
• EVAP canister purge valve circuit
•ECM

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-131
DTC P0481: Cooling Fan 2 (A/C Condenser Fan) Control CircuitS6RW0D1104049
Wiring Diagram
Circuit Description
A/C condenser cooling fan motor is turned ON and OFF by its relay which ECM controls. A/C condenser cooling fan
motor is turned ON when ECM outputs A/C ON signal or when engine coolant temp. is 110 °C, 230 °F or more.
DTC Detecting Condition and Trouble Area7Radiator cooling fan control check
1) Run engine until ECT is over 100 °C, 212 °F.
2) Measure voltage between vehicle body ground and
“E01-46” terminal of ECM connector.
Is voltage lower than 1.5 V?Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”. If OK, substitute a
known-good ECM and
recheck.Faulty ECM.
Substitute a known-
good ECM and recheck. Step Action Yes No
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
BLK/WHT
WHT
1
GRN
27
E01-29
10
89
REDBLK
3
5BLK/WHT
RED/BLKE01-58
WHT
4E01-47 GRY
BLU/YEL
6
C01-58
C01-15 C01-30
BLK/ORN
BLKBLKE01-31BLK
I6RW0D110042-01
1. Individual circuit fuse box No.1 5. A/C condenser cooling fan motor 9. “A/C” fuse
2. Ignition switch 6. A/C compressor 10. “IG COIL” fuse
3. A/C condenser cooling fan relay 7. ECM
4. A/C compressor relay 8. “FI” fuse
DTC detecting condition Trouble area
Monitor signal of A/C condenser cooling fan relay is different
from command signal.
(1 driving cycle detection logic but MIL does not light up)• A/C condenser cooling fan relay circuit malfunction
• A/C condenser cooling fan relay malfunction
• ECM malfunction

Downloaded from www.Manualslib.com manuals search engine 1A-140 Engine General Information and Diagnosis:
DTC Troubleshooting
NOTE
Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to
“Precautions for DTC Troubleshooting”.

DTC P0616: Starter Relay Circuit LowS6RW0D1104054
Wiring DiagramStep Action Yes No
1DTC recheck
1) Clear DTC referring to “DTC Clearance”.
2) Turn OFF ignition switch.
3) Turn ON ignition switch and check DTC.
Is DTC P0601 or P0607 still indicated?Go to Step 2. Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.
2ECM reprogramming check
Was reprogramming of ECM executed?Execute reprogramming
of ECM correctly once
again.Go to step 3.
3ECM power and ground circuit check
1) Check that ECM power supply circuit and ECM ground
circuit is in good condition referring to “ECM Power and
Ground Circuit Check”.
Are check results OK?Substitute a known-
good ECM and recheck.Repair ECM power or
ground circuit.
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
3
461E01-29
C01-58
C01-15 C01-30
BLK/ORN
BLKBLK
5
RED/WHTGRN/WHT
GRN
RED
E01-30
C01-48
BLK/WHT
YEL/GRN
YEL/GRN
WHT
2 7
8 9WHT
WHT/BLU
BLKE01-31
I6RW0D110045-01
1. ECM 4. Main fuse box 7. “ST SIG” fuse
2. Starter motor 5. Starting motor control relay 8. “ST MOT” fuse
3. Ignition switch 6. “IG COIL” fuse 9. “IGN” fuse

Downloaded from www.Manualslib.com manuals search engine 1A-144 Engine General Information and Diagnosis:
DTC P2101: Throttle Actuator Control Motor Circuit Range / PerformanceS6RW0D1104057
Wiring Diagram2Battery voltage supply circuit check
1) Turn OFF ignition switch.
2) Remove ECM from its bracket with ECM connectors
connected.
3) With engine running, measure voltage between “E01-2”
terminal of ECM connector and engine ground.
Is voltage 10 – 14 V?Poor “E01-2”
connection or
intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.
If wire and connections
are OK, substitute a
known-good ECM and
recheck.“DOME” fuse blown,
“WHT” or “WHT/RED”
wire is circuit open or
short circuit. Step Action Yes No
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
12V
5VBLK/REDBLK/RED
BLK/YEL
12BLK/YEL
BLK/YEL
BRN/WHT
E01-1
E01-60
C01-58
C01-15 C01-30
BLK/ORN
BLKBLKE01-31 BLK
BLK/RED
RED
BRN
BLU
GRN
GRNGRY
WHT
BLK
GRY
BLK/REDE01-16
E01-45
E01-32
C01-45
C01-44
C01-43
C01-54
C01-40
C01-42
C01-41
1-1
1-2
1-33
45
867
109
E01-29 GRNBLK/WHT
WHT
YEL
I6RW0D110047-01
1. Electric throttle body assembly 3. ECM 8. “IGN” fuse
1-1. Throttle actuator 4. Main relay 9. “IG COIL” fuse
1-2. Throttle position sensor (main) 5. Individual circuit fuse box No.1 10. Ignition switch
1-3. Throttle position sensor (sub) 6. “THR MOT” fuse
2. Throttle actuator control relay 7. “FI” fuse

Downloaded from www.Manualslib.com manuals search engine 1A-160 Engine General Information and Diagnosis:
DTC P2135: Throttle Position Sensor (Main / Sub) Voltage CorrelationS6RW0D1104066
Wiring Diagram9Ground circuit check
1) Remove ECM from its bracket with ECM connectors
connected.
2) Check for proper connection of ECM connector at “E01-
51” terminal.
3) If OK, measure resistance between “E01-51” terminal of
ECM connector and engine ground.
Is resistance below 5
Ω?“WHT” wire is open or
high resistance circuit.Faulty ECM ground
circuit. If circuit is OK,
substitute a known-
good ECM and recheck.
10APP sensor assembly check
1) Check APP sensor (sub) referring to “Accelerator Pedal
Position (APP) Sensor Assembly Inspection in Section
1C”.
Is output voltage within specified value?Substitute a known-
good ECM and recheck.Replace APP sensor
assembly. Step Action Yes No
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
12V
5VBLK/REDBLK/RED
BLK/YEL
12BLK/YEL
BLK/YEL
BRN/WHT
E01-1
E01-60
C01-58
C01-15 C01-30
BLK/ORN
BLKBLKE01-31 BLK
BLK/RED
RED
BRN
BLU
GRN
GRNGRY
WHT
BLK
GRY
BLK/REDE01-16
E01-45
E01-32
C01-45
C01-44
C01-43
C01-54
C01-40
C01-42
C01-41
1-1
1-2
1-33
45
867
109
E01-29 GRNBLK/WHT
WHT
YEL
I6RW0D110049-02
1. Electric throttle body assembly 3. ECM 8. “IGN” fuse
1-1. Throttle actuator 4. Main relay 9. “IG COIL” fuse
1-2. Throttle position sensor (main) 5. Individual circuit fuse box No.1 10. Ignition switch
1-3. Throttle position sensor (sub) 6. “THR MOT” fuse
2. Throttle actuator control relay 7. “FI” fuse

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-179
E01-26RED/
BLUEPS signal10 – 14 V Ignition switch turned ON.
—
0 – 1 VWith engine running at idle
speed, and steering wheel
turned to the right or left as
far as it stops.
E01-27 — — — — —
E01-28YEL/
BLKSerial
communication line
for immobilizer coil
antenna10 – 14 V Ignition switch turned ON. —
E01-29BLK/
WHTIgnition switch
signal0 – 1 V Ignition switch turned OFF.
—
10 – 14 V Ignition switch turned ON.
E01-30 WHTStarting motor
control relay output0 – 1 V Ignition switch turned ON.
—
0 – 1 VIgnition switch is turned to
ST (engine cranking)
position.
E01-31 BLK Ground for ECM Below 0.3 V Ignition switch turned ON. —
E01-32 GRNPower supply of
throttle actuator
drive circuit10 – 14 V Ignition switch turned ON. —
E01-33 — — — — —
E01-34 REDOutput for 5 V
power source of
APP sensor (sub)4.5 – 5.5 V Ignition switch turned ON. —
E01-35 BRNOutput for 5 V
power source of
APP sensor (main)4.5 – 5.5 V Ignition switch turned ON. —
E01-36 YELAPP sensor (sub)
signal0.37 – 0.38 VIgnition switch turned ON
and accelerator pedal at
idle position after warmed
up engine.
—
1.70 – 2.00 V
(“Reference
waveform No.30: ”)Ignition switch turned ON
and accelerator pedal at
full depressed position
after warmed up engine.
E01-37 GRNAPP sensor (main)
signal0.75 – 0.85 VIgnition switch turned ON
and accelerator pedal at
idle position after warmed
up engine.
—
3.46 – 4.24 V
(“Reference
waveform No.30: ”)Ignition switch turned ON
and accelerator pedal at
full depressed position
after warmed up engine.
E01-38 — — — — —
E01-39 — — — — —
E01-40 — — — — —
E01-41 — — — — —
E01-42 — — — — —
E01-43 — — — — —
E01-44 — — — — —
E01-45 BRNThrottle actuator
control relay output0 – 1 V Ignition switch turned ON. — Terminal
No.Wire
colorCircuit Normal voltage Condition Remarks

Downloaded from www.Manualslib.com manuals search engine 1A-192 Engine General Information and Diagnosis:
Resistance Check
1) Remove ECM from its bracket referring to “Engine Control Module (ECM) Removal and Installation in Section 1C”.
CAUTION!
Never touch terminals of ECM itself or connect voltmeter or ohmmeter (2).

2) Connect special tool to ECM connectors (1) securely.
NOTE
Do not connect the other connector of special tool to ECM.

Special tool
(A): 09933–06320
3) Check resistance between each pair of terminals of special tool connectors (1) as listed in the following table.
CAUTION!
• Be sure to connect ohmmeter probe from wire harness side of coupler.
• Be sure to turn OFF ignition switch for this check.
• Resistance in the following table represents that measured when parts temperature is 20 °C (68 °F).

1
(A)
2
3
I7RW01110032-02
Terminals Circuit Standard resistance Condition
C01-47 to E01-29 Heater of HO2S-2 4 – 15 Ω—
E01-46 to E01-1/16 Radiator cooling fan relay No.1 160 – 240 Ω—
E01-60 to E01-29 Main relay 160 – 240 ΩBattery disconnected and
ignition switch turned ON
E01-15 to E01-29 Fuel pump relay 160 – 240 Ω—
C01-16 to E01-1/16No.3 fuel injector
10.8 – 18.2 Ω—
C01-17 to E01-1/16No.4 fuel injector
C01-4 to E01-1/16EGR valve (stepping motor No.1 coil) (if
equipped)20 – 31 Ω—
C01-29 to E01-1/16 EVAP canister purge valve 28 – 35 Ω—
C01-2 to E01-1/16 No.2 fuel injector 10.8 – 18.2 Ω—
C01-3 to E01-1/16EGR valve (stepping motor No.2 coil) (if
equipped)
20 – 31 Ω— C01-18 to E01-1/16EGR valve (stepping motor No.4 coil) (if
equipped)
C01-19 to E01-1/16EGR valve (stepping motor No.3 coil) (if
equipped)
C01-46 to E01-29 Heater of HO2S-1 2 – 11 Ω—
C01-1 to E01-1/16 No.1 fuel injector 10.8 – 18.2 Ω—
E01-29 to E01-47 A/C compressor relay (if equipped with A/C) 160 – 240 Ω—
E01-58 to E01-1/16A/C condenser cooling fan relay
(if equipped with A/C)160 – 240 Ω—
C01-60 to C01-59 Oil control valve (for engine with VVT system) 6 – 15 Ω—
E01-45 to E01-1/16 Throttle actuator control relay 160 – 240 Ω—