engine and emission control check SUZUKI SX4 2006 1.G Service Manual PDF

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 1B-3 Aux. Emission Control Devices:
Vacuum Hose InspectionS6RW0D1206004
Check hoses for connection, leakage, clog and
deterioration.
Replace as necessary.
EVAP Canister Purge Valve InspectionS6RW0D1206005
WARNING!
Do not apply vacuum by mouth; otherwise
harmful fuel vapor can be breathed in.

CAUTION!
Do not apply vacuum more than –86 kPa (–
12.47 psi); otherwise EVAP canister purge
valve could be damaged.

1) With ignition switch turned OFF, disconnect coupler
and vacuum hoses from canister purge valve.
2) Remove EVAP canister purge valve from air cleaner
assembly.3) Check resistance between two terminals of EVAP
canister purge valve.
If resistance is not as specified, replace EVAP
canister purge valve.
EVAP canister resistance
30 – 34 Ω at 20 °C (68 °F)
4) With coupler disconnected, apply vacuum (–60 kPa
(–8.7 psi)) to pipe (1). If vacuum can be applied, go
to next step. If vacuum can not be applied, replace
EVAP canister purge valve.
5) In this state, connect 12 V-battery to EVAP canister
purge valve terminals. If vacuum can not be applied,
EVAP canister purge valve is in good condition.
If applied, replace EVAP canister purge valve.
WARNING!
Do not suck the air through valve. Fuel vapor
inside valve is harmful.

Special tool
(A): 09917–47011
6) Install EVAP canister purge valve to air cleaner
assembly.1. Purge hose (EVAP canister purge valve side)
2. Purge pipe (EVAP canister side)
I6RW0D120002-02
I3RM0A120008-01
1
1(A)
(A)
I3RB0A120007-01

Downloaded from www.Manualslib.com manuals search engine Aux. Emission Control Devices: 1B-4
EVAP Canister InspectionS6RW0D1206006
WARNING!
DO NOT SUCK nozzles on EVAP canister.
Fuel vapor inside EVAP canister is harmful.

1) Check outside of EVAP canister visually.
2) Disconnect vacuum hoses from EVAP canister.
3) Check that there is no restriction of flow through
purge pipe (1) and air pipe (2) when air is blown (4)
into tank pipe (3).
If any faulty condition is found in this inspection,
replace EVAP canister.
EGR Valve Removal and Installation (If
Equipped)
S6RW0D1206007
Removal
1) Disconnect negative cable at battery.
2) Remove air intake pipe.
3) Remove EGR pipe and gaskets.
4) Disconnect EGR valve connector.
5) Remove EGR valve and gasket from cylinder head.
Installation
Reverse removal procedure noting the following.
• Clean mating surface of valve and cylinder head.
• Use new gaskets.
EGR Valve Inspection (If Equipped)S6RW0D1206008
1) Check resistance between following terminals of
EGR valve (1) in each pair.
If found faulty, replace EGR valve assembly.
EGR valve resistance (A – B, C – B, F – E, D – E
terminal)
20 – 24 Ω
2) Remove carbon from EGR valve gas passage.
CAUTION!
Do not use any sharp-edged tool to remove
carbon.
Be careful not to damage or bend EGR valve
(1), valve seat (3) and rod.

3) Inspect valve (2), valve seat and rod for fault, cracks,
bend or other damage.
If found faulty, replace EGR valve assembly.
4
3 1
2
I6RW0D120003-01
I2RH0B120005-01
I2RH0B120006-01

Downloaded from www.Manualslib.com manuals search engine 1B-5 Aux. Emission Control Devices:
PCV Hose InspectionS6RW0D1206009
NOTE
Be sure to check that there is no obstruction
in PCV valve or its hoses before checking
IAC throttle valve opening, for obstructed
PCV valve or hose hampers its accurate
adjustment.

Check hoses for connection, leakage, clog and
deterioration.
Replace as necessary.
PCV Valve InspectionS6RW0D1206010
NOTE
Be sure to check that there is no obstruction
in PCV valve or its hoses before checking
IAC throttle valve opening, for obstructed
PCV valve or hose hampers its accurate
adjustment.

1) Detach air cleaner assembly.
2) Disconnect PCV valve from cylinder head cover and
install plug to head cover hole.
3) Install air cleaner assembly temporarily.
4) Run engine at idle.5) Place your finger over end of PCV valve (1) to check
for vacuum.
If there is no vacuum, check for clogged valve.
Replace as necessary.
6) After checking vacuum, stop engine and remove
PCV valve (1).
Shake valve and listen for rattle of check needle
inside the valve. If valve does not rattle, replace PCV
valve.
7) After checking, remove plug and install PCV valve.
8) Install air cleaner assembly securely.
Special Tools and Equipment
Special ToolS6RW0D1208001
I2RH0B120007-01
I2RH0B120008-01
09917–47011 SUZUKI scan tool (SUZUKI-
SDT)
Vacuum pump gauge —
) / )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 Engine Mechanical: 1D-5
Targeted Timing Varying Operation
Diagnostic Information and Procedures
Compression CheckS6RW0D1404001
Check compression pressure on all 4 cylinders as
follows:
1) Warm up engine to normal operating temperature.
2) Stop engine after warming up.
NOTE
After warming up engine, place transmission
gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T model), and set
parking brake and block drive wheels.

3) Remove air cleaner assembly with air suction hose
referring to “Air Cleaner Assembly Removal and
Installation”.
4) Remove cylinder head upper cover.
5) Remove ignition coil assemblies and all spark plugs
referring to “Spark Plug Removal and Installation in
Section 1H”.
6) Disconnect fuel injector wires at the coupler.7) Install special tools (Compression gauge) into spark
plug hole.
Special tool
(A): 09915–64512
(B): 09915–64530
(C): 09915–67010 Driving condition Valve timing Target of control Effect
Engine running at idle
speedMost retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to intake manifold.Stabilization of the engine
rotation at idle speed.
Average engine load
rangeTo the advanced
sideTo lengthen the valve opening overlap
in order to enhance the internal
exhaust gas recirculation and reduce
the pumping loss.Improvement of the fuel
efficiency.
Lowering of the exhaust
emission.
Light engine load
rangeTo the retarded sideTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to intake manifold.Keeping of the engine stability.
Low or average
engine speed range
with heavy engine
loadTo the advanced
sideTo advance the closing timing of the
intake valve in order to improve the
volumetric efficiency.Improvement of generating the
engine torque at low and
average engine speed.
High engine speed
range with heavy
engine loadTo the retarded sideTo retard the closing timing of the
intake valve in order to improve the
volumetric efficiency.Improvement of generating the
engine power.
Low engine coolant
temperatureMost retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to intake manifold and
reduce the fuel increasing.
To slow the fast idle speed of the
engine as a result of stabilizing the
engine idling.Stabilization of the fast idling of
the engine.
Improvement of the fuel
efficiency.
At engine starting and
stoppingMost retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to intake manifold.Improvement of start ability.
(A)
(C)
(B)
I3RH0B140009-01

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).

Downloaded from www.Manualslib.com manuals search engine 1K-1 Exhaust System:
Engine
Exhaust System
General Description
Exhaust System DescriptionS6RW0D1B01001
The exhaust system consists of an exhaust manifold, three-way catalytic converter (TWC) in catalyst case, exhaust
pipes, a muffler and seals, gasket and etc.
The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of
Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
Diagnostic Information and Procedures
Exhaust System CheckS6RW0D1B04001
WARNING!
To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any
service on the exhaust system should be performed when the system is cool.

At every interval of periodic maintenance service, and when vehicle is raised for other service, check exhaust system
as follows:
• Check rubber mountings for damage, deterioration, and out of position.
• Check exhaust system for leakage, loose connection, dent and damage.
• If bolts or nuts are loosened, tighten them to specified torque referring to “Exhaust System Components”.
• Check nearby body areas damaged, missing, or mispositioned part, open seam, hole connection or any other
defect which could permit exhaust fumes to seep into vehicle.
• Make sure that exhaust system components have enough clearance from underbody to avoid overheating and
possible damage to vehicle underbody.
• Any defect should be fixed at once.
IYSY011B0003-01

Downloaded from www.Manualslib.com manuals search engine 10C-2 Immobilizer Control System:
• Do not leave ignition key in a place where
temperature is high. High temperature may cause
damage to the transponder built in the ignition key.• Do not turn ignition switch to ON position by bringing
radio antenna close to coil antenna. Or, the
immobilizer control system may detect some
abnormal condition and prevent the engine from
starting.
General Description
Immobilizer Control System IntroductionS6RW0DA301001
The immobilizer control system is an anti-theft device that immobilizes the vehicle. It stops the engine from working
and prevents the vehicle from being stolen. It mainly consists of the following components. For immobilizer control
system components location, refer to “Immobilizer Control System Components Location”.
•ECM
• ICM with the built-in coil antenna
• Ignition key with the built-in transponder
A code called the transponder code is memorized in the transponder. And, the code is registered with ECM. Basically,
when the ignition switch is turned ON, ECM reads the code by the coil antenna. Then, if the code in transponder in the
ignition key does not match with the one registered with ECM, ECM stops the operation of the fuel injection so as not
to start up the engine and turns the immobilizer indicator light ON and OFF using CAN communication lines. (In
addition to the above operation, ECM also turns the immobilizer indicator light ON and OFF when some trouble is
detected in the keyless start system.)
On-Board Diagnostic System Description (Self-diagnosis Function)S6RW0DA301002
ECM diagnoses if there is any trouble with the immobilizer control system. The diagnostic information is stored as the
diagnostic trouble code (DTC) in ECM. To read the diagnostic information, use SUZUKI scan tool referring to “DTC
Check”.
With the ignition switch turned ON (but the engine at stop) regardless of the condition of the engine and emission
control system, ECM indicates whether there is any trouble with the immobilizer control system or not by either lighting
ON or flashing ON and OFF the immobilizer indicator light.
Immobilizer indicator light lights ON:
No trouble exists in the immobilizer control system. (After starting up the engine, the light turns OFF.)
Immobilizer indicator light flashes ON and OFF:
There is some trouble in the immobilizer control system or in the keyless start system. Its diagnostic information is
stored in ECM.
I3RH0AA30003-01
I3RH0AA30004-01

Downloaded from www.Manualslib.com manuals search engine Immobilizer Control System: 10C-5
Component Location
Immobilizer Control System Components LocationS6RW0DA303001
Diagnostic Information and Procedures
Immobilizer Control System CheckS6RW0DA304001
3
4567
1
2
2
13
I6RW0BA30001-01
1. ECM 5. Ignition key (non keyless entry model)
2. Immobilizer indicator light 6. Ignition key (keyless start model)
3. ICM 7. Transponder
4. Ignition key (keyless entry model)
Step Action Yes No
1Immobilizer indicator light check
1) Turn ignition switch to ON position using ignition key.
Does immobilizer indicator light come on?Go to Step 2. Check if DTC P1636
and/or P1638 are
detected by ECM
referring to “DTC
Check”. If detected, go
to applicable DTC diag.
flow. If not detected, go
to “Immobilizer Indicator
Light Does Not Come
ON with Ignition Switch
ON and Engine Stop”.
2Immobilizer indicator light check
Does immobilizer indicator light flash on and off continuously
in Step 1?Check ECM for DTC
referring to “DTC
Check”. Then, go to
applicable DTC diag.
flow.Go to Step 3.
3Engine start check
1) Start engine using ignition key.
Does engine start?Go to Step 4. Go to “Engine and
Emission Control
System Check in
Section 1A”.
4Immobilizer indicator light check
1) Check if immobilizer indicator light remains ON after
engine start.
Does immobilizer indicator light remains ON after engine
start?Go to “Immobilizer
Indicator Light Remains
ON after Engine Start”.Immobilizer control
system is in good
condition. Then, go to
“Keyless Start System
Check in Section 10E”
for keyless start model.