ig coil SUZUKI SX4 2006 1.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-6
Ignition Spark TestS6RW0D1804004
1) Remove air cleaner assembly with air intake pipe.
2) Disconnect all injector couplers from injectors.
WARNING!
Without disconnection of injector couplers,
combustible gas may come out from spark
plug holes during this test and may get
ignited in engine room.

3) Remove spark plug and check it for condition and
type referring to “Spark Plug Inspection”.
4) If OK, connect ignition coil coupler to ignition coil
assembly and connect spark plug to ignition coil
assembly or high-tension cord. Ground spark plug.5) Crank engine and check if each spark plug sparks.
6) If no spark is emitted, inspect the related parts as
described in “Ignition System Symptom Diagnosis”.
Repair Instructions
High-Tension Cord Removal and InstallationS6RW0D1806001
Removal
1) Remove air cleaner assembly with air intake pipe
and cylinder head upper cover.
2) Disconnect No.1 cylinder (2) and No.3 cylinder (3)
high-tension cords from ignition coil assemblies (1)
while gripping each cap.
3) Pull out high-tension cords from spark plugs while
gripping each cap.
CAUTION!
• Removal of high-tension cords together
with clamps will be recommended so as
not to damage their inside wire (resistive
conductor).
• For the same reason, pull out each
connection by gripping cap portion.

Installation
1) Install No.1 cylinder (2) and No.3 cylinder (3) high-
tension cords to spark plugs and ignition coil
assemblies (1) while gripping each cap.
CAUTION!
• Never attempt to use metal conductor
high-tension cords as replacing parts.
• Insert each cap portion fully when
installing high-tension cords.

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I4RS0A180003-01
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Downloaded from www.Manualslib.com manuals search engine 1H-7 Ignition System:
High-Tension Cord InspectionS6RW0D1806002
Measure resistance of high-tension cord (1) by using
ohmmeter.
If resistance exceeds specification, replace high-tension
cord(s).
High-tension cord resistance
No.1 cylinder high-tension cord resistance: 1.4 – 4.0
kΩ
No.3 cylinder high-tension cord resistance: 0.6 – 2.0
kΩ
Spark Plug Removal and InstallationS6RW0D1806003
Removal
1) Remove air cleaner assembly with air intake pipe
and cylinder head upper cover.
2) Pull out high-tension cords by gripping their caps
and then remove ignition coil assemblies referring to
“Ignition Coil Assembly (Including Ignitor) Removal
and Installation”.
3) Remove spark plugs.
Installation
1) Install spark plugs and tighten them to specified
torque.
Tightening torque
Spark plug: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
2) Install ignition coil assemblies referring to “Ignition
Coil Assembly (Including Ignitor) Removal and
Installation”.
3) Install high-tension cords securely by gripping their
caps.
4) Install cylinder head upper cover and air cleaner
assembly with air intake pipe.
Spark Plug InspectionS6RW0D1806004
CAUTION!
• When servicing the iridium / platinum
spark plugs (slender center electrode type
plugs), do not touch the center electrode
to avoid damage to it. The electrode is not
strong enough against mechanical force
as it is slender and its material is not
mechanically tough.
• Do not clean or adjust gap for the iridium /
platinum spark plugs.

Inspect spark plug for:
• Electrode wear
• Carbon deposits
• Insulator damage
If any abnormality is found for nickel spark plugs, adjust
air gap, clean with spark plug cleaner or replace it with
specified new plug.
For iridium / platinum spark plugs, replace it with new
plug.
Spark plug air gap
“a”
: 1.0 – 1.1 mm (0.040 – 0.043 in.)
Spark plug type
NGK: BKR6E-11 (Nickel) / IFR6J11 (Iridium)
DENSO: K20PR-U11 (Nickel)
NOTE
NGK IFR6J11 is highly recommended for
better engine starting performance under –25
°C (–13 °F).

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Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-8
Ignition Coil Assembly (Including Ignitor)
Removal and Installation
S6RW0D1806005
Removal
1) Disconnect negative cable at battery.
2) Remove air cleaner assembly with air intake pipe
and cylinder head upper cover.
3) Disconnect ignition coil coupler.
4) Disconnect high-tension cord (3) from ignition coil
assembly (2).
5) Remove ignition coil bolts (1) and then pull out
ignition coil assembly.
Installation
1) Install ignition coil assembly (2).
2) Tighten ignition coil bolts (1) to specified torque, and
then connect ignition coil coupler.
Tightening torque
Ignition coil bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Install high-tension cord (3) to ignition coil assembly
while gripping its cap.
4) Install cylinder head upper cover and air cleaner
assembly with air intake pipe.
5) Connect negative cable to battery.
Ignition Coil Assembly (Including Ignitor)
Inspection
S6RW0D1806006
Measure secondary coil for resistance.
If resistance is out of specification, replace ignition coil
assembly.
Secondary coil resistance
7.6 – 10.2 kΩ at 20 ° (68 °F)
Ignition Timing InspectionS6RW0D1806007
NOTE
• Ignition timing is not adjustable. If ignition
timing is out of specification, check
system related parts.
• Before starting engine, place transmission
gear shift lever in “Neutral”, and set
parking brake.

1) Connect scan tool to DLC (1) with ignition switch
OFF.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
I2RH0B180006-01
I3RM0A180004-01
I2RH0B180007-01
(A) 1I 5 R W 0 C 11 0 0 11 - 0 1

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-10
Specifications
Tightening Torque SpecificationsS6RW0D1807001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Special ToolS6RW0D1808001
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Spark plug 25 2.5 18.0)
Ignition coil bolt 11 1.1 8.0)
09930–76420 SUZUKI scan tool (SUZUKI-
SDT)
Timing-light (dry cell type) —
)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 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 Starting System: 1I-2
Condition Possible cause Correction / Reference Item
Motor not running (No
operating sound of
magnetic switch)Transmission range sensor is not in P or
N, or not adjusted (A/T model)Shift in P or N, or adjust sensor. (A/T model)
Battery run downRecharge battery.
Battery voltage too low due to battery
deteriorationReplace battery.
Poor contact in battery terminal
connectionRetighten or replace.
Loose grounding cable connectionRetighten.
Fuse set loose or blown offTighten or replace.
Poor contacting action of ignition switch
and magnetic switchReplace.
Lead wire coupler loose in placeRetighten.
Open-circuit between ignition switch and
magnetic switchRepair.
Open-circuit in pull-in coilReplace magnetic switch.
Brushes are seating poorly or worn
downRepair or replace.
Poor sliding of plunger and/or pinionRepair.
Faulty starting motor control relay“Main Relay, Fuel Pump Relay, Starting Motor
Control Relay, Throttle Actuator Control Relay
and Radiator Cooling Fan Relay Inspection in
Section 1C”.
Faulty ECM and its circuit“Inspection of ECM and Its Circuits in Section
1A”.
Motor not running
(Operating sound of
magnetic switch heard)Battery run downRecharge battery.
Battery voltage too low due to battery
deteriorationReplace battery.
Loose battery cable connectionsRetighten.
Burnt main contact point, or poor
contacting action of magnetic switchReplace magnetic switch.
Brushes are seating poorly or worn
downRepair or replace.
Weakened brush springReplace.
Burnt commutatorReplace armature.
Layer short-circuit of armatureReplace.
Crankshaft rotation obstructedRepair.
Starting motor running
but too slow (small
torque) (If battery and
wiring are satisfactory,
inspect starting motor)Insufficient contact of magnetic switch
main contactsReplace magnetic switch.
Layer short-circuit of armatureReplace.
Disconnected, burnt or worn
commutatorRepair commutator or replace armature.
Worn brushesReplace brush.
Weakened brush springsReplace spring.
Burnt or abnormally worn end bushReplace bush.
Starting motor running,
but not cranking engineWorn pinion tipReplace over-running clutch.
Poor sliding of over-running clutchRepair.
Over-running clutch slippingReplace over-running clutch.
Worn teeth of ring gearReplace flywheel (M/T model) or drive plate (A/
T model).
NoiseAbnormally worn bushReplace bush.
Worn pinion or worn teeth of ring gearReplace over-running clutch, flywheel (M/T
model) or drive plate (A/T model).
Poor sliding of pinion (failure in return
movement)Repair or replace.
Worn internal or planetary gear teethReplace.
Lack of oil in each partLubricate.

Downloaded from www.Manualslib.com manuals search engine 1I-3 Starting System:
Cranking System TestS6RW0D1904002
CAUTION!
Each test must be performed within 3 – 5
seconds to avoid coil from burning.

Pull-In Test
Connect battery to the magnetic switch as shown.
Check that plunger and pinion move outward.
If plunger and pinion don’t move, replace the magnetic
switch.
NOTE
Before testing, disconnect lead wire from
terminal “M” (2).

Hold-In Test
While connected as the figure with plunger out,
disconnect negative lead from terminal “M”.
Check that plunger and pinion remain out.
If plunger and pinion return inward, replace the magnetic
switch.Plunger and Pinion Return Test
Disconnect negative lead from starting motor body.
Check that plunger and pinion return inward.
If plunger and pinion don’t return, replace the magnetic
switch.
No-Load Performance Test
Connect battery and ammeter to starter as shown.
Check that starter rotates smoothly and steadily with
pinion moving out. Check that ammeter indicates
specified current.
Specified current (No-load performance test)
90 A MAX. at 11 V Starting motor does not
stop runningFused contact points of magnetic switchReplace magnetic switch.
Short-circuit between turns of magnetic
switch coil (layer short-circuit)Replace magnetic switch.
Failure of returning action in ignition
switchReplace. Condition Possible cause Correction / Reference Item
1. Terminal “S”
3. Lead wire (switch to motor)
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I2RH01190005-01

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-6
Starting Motor InspectionS6RW0D1906003
Plunger
Inspect plunger for wear. Replace if necessary.
Magnetic Switch
Push in plunger and release it. The plunger should
return quickly to its original position. Replace if
necessary.
Pull-in coil open circuit test
Check for continuity across magnetic switch “S” terminal
(1) and “M” terminal (2). If no continuity, coil is open and
should be replaced.Hold-in coil open circuit test
Check for continuity across magnetic switch “S” terminal
(1) and coil case. If no continuity, coil is open and should
be replaced.
Rear Bracket Bush
Inspect bush for wear or damage. Replace if necessary.
Brush
• Check brushes for wear.
Measure length of brushes and if below the limit,
replace the brush.
Brush length
Standard: 12.3 mm (0.48 in.)
Limit: 7.0 mm (0.28 in.)
• Install brushes to each brush holder and check for
smooth movement.
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I2RH01190009-01
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Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-3
Generator DescriptionS6RW0D1A01002
The basic charging system is the IC integral regulator charging system. The internal components are connected
electrically as shown below.
Charging System Circuit
The generator features a solid state regulator that is mounted inside the generator. All regulator components are
enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the rear housing. The
regulator voltage is being controlled by ECM under some conditions while driving. Refer to “Generator Control System
Description in Section 1A” in related manual.
The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication.
Two brushes carry current through the two slip rings to the field coil mounted on the rotor, and under normal conditions
will provide long period of attention-free service.
The stator windings are assembled inside a laminated core that forms part of the generator frame.
A rectifier bridge connected to the stator windings contains diodes, and electrically changes that stator AC. voltages to
a D.C. voltage which appears at the generator output terminal.
1 26345
4
3B
7
8
9
10E FFRCIG
L
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1. Pulley 6. Field coil B: Generator output (Battery terminal) L: Lamp terminal
2. Pulley nut 7. Regulator C: Generator cut FR: Field duty monitor
3. Rotor fan 8. Brush E: Ground
4. Stator coil 9. Rear end frame F: Field coil terminal
5. Stator core 10. Drive end frame IG: Ignition terminal
B
IG
L
C
E
7
2 4
3
5
FR
610
11
12 13 1
[A]
IG1 9
14
8
I6RW0D1A0001-03
[A]: If equipped with electric load current sensor 4. Diode 8. Battery 12. Combination meter
1. Generator with regulator assembly 5. Field coil (rotor coil) 9. Electric load current sensor (if equipped) 13. CAN driver
2. I.C. regulator 6. Charge indicator light 10. ECM 14. Main fuse box
3. Stator coil 7. Main switch 11. BCM

Downloaded from www.Manualslib.com manuals search engine 1J-4 Charging System:
Diagnostic Information and Procedures
Battery InspectionS6RW0D1A04001
Common Causes of Failure
A battery is not designed to last indefinitely; however,
with proper care, it will provide many years of service. If
the battery performs satisfactorily during test buy fails to
operate properly for no apparent reason, the following
are some factors that may point to the cause of trouble:
• Accessories left on overnight or for an extended
period without the generator operating.
• Slow average driving speed for short periods.
• Electrical load exceeding generator output particularly
with addition of aftermarket equipment.
• Defects in charging system such as high resistance,
slipping drive belt, loose generator output terminal,
faulty generator or voltage regulator. Refer to
“Generator Symptom Diagnosis”.
• Battery abuse, including failure to keep battery cable
terminals clean and tight or loose battery hold down.
• Mechanical problems in electrical system such as
shorted or pinched wires.
Visual Inspection
Check for obvious damage, such as cracked or broken
case or cover, that could permit loss of electrolyte. If
obvious damage is noted, replace battery. Determine
cause of damage and correct as needed.
Generator Symptom DiagnosisS6RW0D1A04002
CAUTION!
• Do not mistake polarities of “IG” terminal
and “L” terminal.
• Do not create short circuit between “IG”
and “L” terminals. Always connect these
terminals through a lamp.
• Do not connect any load between “L” and
“E” terminals.
• When connecting charger or booster
battery to vehicle battery, refer to “Jump
Starting in Case of Emergency”.

Trouble in charging system will show up as one or more
of the following conditions:
1) Faulty indicator lamp operation.
2) An undercharged battery as evidenced by slow
cranking or indicator dark.
3) An overcharged battery as evidenced by excessive
spewing of electrolyte from vents.
Noise from generator may be caused by loose drive
pulley, loose mounting bolts, worn or dirty bearings,
defective diode, or defective stator.
B: Generator output (Battery terminal) IG: Ignition terminal
C: C terminal L: Lamp terminal
E: Ground FR: Field duty monitor
F: Field coil terminal
E FFRC
B
IG
L
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