200 SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
, and NOTE have special meanings. Pay special attention to the messages high-
lighted by these signal words.
The circle with a slash in this manual means “Don’t do this” or “Don’t let this happen”.
WARNING!CAUTION!
Indicates a potential hazard that could result in death or injury.
WARNING!
Indicates a potential hazard that could result in vehicle damage.
CAUTION!
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
This service manual is intended for authorized Suzuki dealers and qualified service technicians only.
Inexperienced technicians or technicians without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the technician and may render the vehicle unsafe for the driver
and passengers.
WARNING!
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
 If the air bag system and another vehicle system both need repair, Suzuki recommends that the air
bag system be repaired first, to help avoid unintended air bag system activation.
 Do not modify the steering wheel, instrument panel or any other air bag system component on or
around air bag system components or wiring. Modifications can adversely affect air bag system
performance and lead to injury.
 If the vehicle will be exposed to temperatures over 93 °C (200 °F), for example, during a paint baking
process, remove the air bag system components, that is air bag (inflator) modules, SDM and/or seat
belt with pretensioner, beforehand to avoid component damage or unintended activation.
WARNING!

Downloaded from www.Manualslib.com manuals search engine FOREWORD
This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service
operations, replacement of components (Service) and for disassembly and assembly of major components (Unit
Repair-Overhaul).
VOLUME 1 contains General information, Engine, Suspension, Drive/Axle and Brakes sections (Sections 0 – 5).
VOLUME 2 contains Transmission/Transaxle, Steering, HVAC, Restraint, Body/Cab/Accessories and
Control Systems sections (Sections 6 – 10).
Applicable Model:
SX4 (RW415/RW416) produced at KOSAI plant in Japan with following vehicle identification number
(VIN)
The contents are classified into sections each of which is given a section number as indicated in the Table of
Contents on following page. And on the first page of each individual section is an index of that section.
This manual should be kept in a handy place for ready reference of the service work.
Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials as specified in each description.
All information, illustrations and specifications contained in this literature are based on the latest product infor-
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2006JSAGY############ ~
JS2Y#############~

Downloaded from www.Manualslib.com manuals search engine 00-1 Precautions:
Precautions
Precautions
Precautions
Precautions for Vehicles Equipped with a
Supplemental Restraint (Air Bag) System
S6RW0D0000001
WARNING!
• The configuration of air bag system parts
are as shown in the figure. When it is
necessary to service (remove, reinstall and
inspect) these parts, be sure to follow
procedures described in Air Bag System
section. Failure to follow proper
procedures could result in possible air bag
system activation, personal injury, damage
to parts or air bag system being unable to
activate when necessary.
• If the air bag system and another vehicle
system both need repair, SUZUKI
recommends that the air bag system be
repaired first, to help avoid unintended air
bag system activation.
• Do not modify the steering wheel,
dashboard, or any other air bag system
components. Modifications can adversely
affect air bag system performance and
lead to injury.
• If the vehicle will be exposed to
temperatures over 93 °C (200 °F) (for
example, during a paint baking process),
remove the air bag system components
beforehand to avoid component damage
or unintended air bag system activation.

Diagnosis
• When troubleshooting air bag system, be sure to
follow “Diagnosis” in Air Bag System section.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacement.
• Never use electrical test equipment other than that
specified.
WARNING!
Never attempt to measure the resistance of
the air bag (inflator) modules (driver,
passenger, side and curtain) and seat belt
pretensioners (driver and passenger). It is
very dangerous as the electric current from
the tester may deploy the air bag or activate
the pretensioner.

1. Air bag wire harness (in floor, main
and instrument panel harness)6. Driver air bag (inflator) module
2. Passenger air bag (inflator)
module7. Side air bag (inflator) module
(if equipped)
3. SDM 8. Curtain air bag (inflator)
module (if equipped)
4. Seat belt pretensioner 9. Forward sensor
5. Contact coil 10. Side sensor (if equipped)
23
7
8
4
10
10
4 7 9156
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Downloaded from www.Manualslib.com manuals search engine 0B-1 Maintenance and Lubrication:
General Information
Maintenance and Lubrication
Precautions
Precautions for Maintenance and LubricationS6RW0D0200001
Air Bag Warning
Refer to “Air Bag Warning in Section 00”.
Scheduled Maintenance
Maintenance Schedule under Normal Driving ConditionsS6RW0D0205001
NOTE
• This interval should be judged by odometer reading or months, whichever comes first.
• This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km
(54,000 miles), carry out the same services at the same intervals respectively.

IntervalKm (x 1,000) 15 30 45 60 75 90
Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
Engine
Accessory drive belt (I: ), R: ))——I——R
Valve lash (clearance) (I: ))—I—I—I
Engine oil and oil filter (R: )) RRRRRR
Engine coolant (R: ))——R——R
Exhaust system (I: ))—I—I—I
Ignition system
Spark plugs (R: ))When unleaded fuel is usedNickel Plug — — R — — R
Iridium Plug
(Highly recommended)Replace every 105,000 km (63,000
miles) or 84 months
When leaded fuel is used, refer to “Maintenance Recommended under Severe Driving
Conditions”.
Fuel system
Air cleaner filter (R: ), I: ))Paved-road I I R I I R
Dusty conditionsRefer to “Maintenance Recommended
under Severe Driving Conditions”.
Fuel lines and connections (I: ))—I—I—I
Fuel filter (see NOTE below) (R: ))Replace every 105,000 km (63,000
miles)
Fuel tank (I: ))——I——I
Emission control system
PCV valve (I: )) ————— I
Fuel evaporative emission control system (I: )) ————— I
Brake
Brake discs and pads (thickness, wear, damage) (I: )) IIIIII
Brake drums and shoes (wear, damage) (I: ))—I—I—I
Brake hoses and pipes (leakage, damage, clamp) (I: ))—I—I—I
Brake fluid (R: ))—R—R—R
Brake lever and cable (damage, stroke, operation) (I: ))Inspect at first 15,000 km (9,000 miles
only)
Chassis and body
Clutch (fluid leakage, level) (I: ))—I—I—I
Tires (wear, damage, rotation) / wheels (damage) (I: ) / )) IIIIII
Suspension system (tightness, damage, rattle, breakage) (I: ))—I—I—I
Steering system (tightness, damage, breakage, rattle) (I: ))—I—I—I
Drive shaft (axle) boots / Propeller shaft (4WD) (I: )) (I: ))——I——I
Manual transaxle oil (leakage, level) (I: ) 1st 15,000 km only) (R: ))I—R——R

Downloaded from www.Manualslib.com manuals search engine 0B-3 Maintenance and Lubrication:
NOTE
• “I”: Inspect and correct or replace if necessary
• “R”: Replace or change
• *1: Inspect or replace more frequently if the vehicle is used under dusty conditions.
• *2: Clean or replace more frequently if the air from the air conditioning decreases.

Repair Instructions
Accessory Drive Belt InspectionS6RW0D0206001
WARNING!
All inspection and replacement are to be
performed with ENGINE NOT RUNNING.

Water Pump and Generator Drive Belt
Inspect belt for cracks, cuts, deformation, wear and
cleanliness. If any defect exists, replace.
Check belt for tension referring to “Water Pump /
Generator Drive Belt Tension Inspection and Adjustment
in Section 1J”.
A/C Compressor Drive Belt (If Equipped)
Inspect belt for cracks, cuts, deformation, wear and
cleanliness. If any defect exists, replace.
Check belt for tension referring to “Compressor Drive
Belt Inspection and Adjustment in Section 7B” or
“Compressor Drive Belt Inspection and Adjustment in
Section 7B”.
Accessory Drive Belt ReplacementS6RW0D0206002
Water Pump and Generator Drive Belt
Replace belt with new one referring to “Water Pump /
Generator Drive Belt Removal and Installation in Section
1J”.
A/C Compressor Drive Belt (If Equipped)
Replace belt with new one referring to “Compressor
Drive Belt Removal and Installation in Section 7B” or
“Compressor Drive Belt Removal and Installation in
Section 7B”.
Valve Lash (Clearance) InspectionS6RW0D0206003
Inspect intake and exhaust valve lash and adjust as
necessary.
Refer to “Valve Lash (Clearance) Inspection in Section
1D” for valve lash inspection and adjustment procedure. – B – – E – – HManual transaxle oil
Transfer oil (4WD)
Differential oil (4WD)) / ) / ) RFirst time only:
15,000 km (9,000 miles) or 12
months
Second time and after:
Every 30,000 km (18,000 miles) or
24 months reckoning from 0 km (0
mile) or 0 month
– B – – E – – H Automatic transaxle fluid)R Every 30,000 km (18,000 miles) or
24 months
– – C D – – – – HVAC air filter (if equipped) *2) IEvery 15,000 km (9,000 miles) or
12 months
) REvery 45,000 km (27,000 miles) or
36 months Severe
condition codeMaintenanceMaintenance
operationMaintenance interval
1. Camshaft 2. Thickness gauge
I2RH0B020003-02

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Engine Oil and Filter ChangeS6RW0D0206004
WARNING!
• New and used engine oil can be
hazardous.
Be sure to read “WARNING” in “General
Precautions in Section 00” and observe
what is written there.
• Step 1) – 7) outlined below must be
performed with ENGINE NOT RUNNING.
For Step 8), be sure to have adequate
ventilation while engine is running.

Before draining engine oil, check engine for oil leakage.
If any evidence of leakage is found, make sure to correct
defective part before proceeding to the following work.
1) Drain engine oil by removing drain plug.
2) After draining oil, wipe drain plug clean. Reinstall
drain plug.
Tightening torque
Engine oil drain plug (a): 35 N·m (3.5 kgf-m, 25.5
lb-ft)
3) Loosen oil filter by using oil filter wrench (special
tool).
Special tool
(A): 09915–47331
NOTE
Before fitting new oil filter, be sure to oil its
O-ring. Use engine oil for this purpose.

4) Screw new filter on oil filter stand by hand until the
filter O-ring contacts mounting surface.
CAUTION!
To tighten oil filter properly, it is important to
accurately identify the position at which filter
O-ring first contacts mounting surface.

5) Tighten the filter (1) 3/4 turn from the point of contact
with the mounting surface using an oil filter wrench
(2).
Tightening torque
Oil filter (b): 14 N·m (1.4 kgf-m, 10.5 lb-ft) for
reference
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Downloaded from www.Manualslib.com manuals search engine 0B-5 Maintenance and Lubrication:
6) Replenish oil until oil level is brought to FULL level
mark on dipstick (oil pan and oil filter capacity). The
filler inlet is at the top of the cylinder head cover. It is
recommended to use engine oil of SG, SH, SJ, SL or
SM grade. Select the appropriate oil viscosity
according to the proper engine oil viscosity chart [A].
NOTE
Engine oil capacity is specified as the
following.
However, note that the amount of oil required
when actually changing oil may somewhat
differ from the data depending on various
conditions (temperature, viscosity, etc.).

Engine oil specification
Oil pan capacity: About 3.7 liters (7.8 / 6.5 US /
lmp pt.)
Oil filter capacity: About 0.2 liter (0.4 / 0.3 US /
lmp pt.)
Others: About 0.3 liter (0.6 / 0.5 US / lmp pt.)
Total: About 4.2 liters (8.9 / 7.4 US / lmp pt.)
7) Check oil filter and drain plug for oil leakage.
8) Start engine and run it for 3 minutes. Stop it and wait
another 5 minutes before checking oil level. Add oil,
as necessary, to bring oil level to FULL level mark (1)
on dipstick.
Engine Coolant ChangeS6RW0D0206005
Change engine coolant with new one referring to
“Cooling System Flush and Refill in Section 1F”.
Exhaust System InspectionS6RW0D0206006
WARNING!
To avoid danger of being burned, do not
touch exhaust system when it is still hot.
Any service on exhaust system should be
performed when it is cool.

When carrying out periodic maintenance, or the 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
connections, dents and damages.
If bolts or nuts are loose, tighten them to specification.
• Check nearby body areas for damaged, missing or
mispositioned parts, open seams, holes, loose
connections or other defects which could permit
exhaust fumes to seep into the vehicle.
• Make sure that exhaust system components have
enough clearance from the underbody to avoid
overheating and possible damage to floor carpet.
• Any defects should be fixed at once.
Spark Plug ReplacementS6RW0D0206007
Replace spark plugs with new ones referring to “Spark
Plug Removal and Installation in Section 1H”.
2. Low level mark (hole)
C
Fo o-30
-22-20
-4-10
14 32 50 68 86 104010203040
5W-30
20W-40, 20W-50
10W-30
15W-40, 15W-50
10W-40, 10W-50
[A]
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Air Cleaner Filter InspectionS6RW0D0206008
1) Remove air cleaner case clamps.
2) Take air cleaner filter out of case.
3) Check that filter is not excessively dirty, damaged or
oily, clean filter with compressed air from air outlet
side of filter.
4) Install air cleaner filter and clamp cap securely.
Air Cleaner Filter ReplacementS6RW0D0206009
Replace air cleaner filter with new one according to
Steps 1), 2) and 4) of “Air Cleaner Filter Inspection”.
Fuel Lines and Connections InspectionS6RW0D0206010
Visually inspect fuel lines and connections for evidence
of fuel leakage, hose cracking and damage. Make sure
all clamps are secure.
Repair leaky joints, if any.
Replace hoses that are suspected of being cracked.
Fuel Filter ReplacementS6RW0D0206041
Fuel filter is installed in fuel pump assembly in fuel tank.
Replace fuel filter or fuel pump assembly with new one,
referring to “Fuel Pump Assembly Removal and
Installation in Section 1G” for proper procedure.
Fuel Tank InspectionS6RW0D0206011
Check fuel tank damage, cracks, fuel leakage, corrosion
and tank bolts looseness.
If a problem is found, repair or replace.
PCV Valve InspectionS6RW0D0206012
Check crankcase ventilation hose and PCV hose for
leaks, cracks or clog, and PCV valve for stick or clog.
Refer to “PCV Valve Inspection in Section 1B” for PCV
valve checking procedure.
Fuel Evaporative Emission Control System
Inspection
S6RW0D0206013
1) Visually inspect hoses for cracks, damage, or
excessive bends. Inspect all clamps for damage and
proper position.
2) Check EVAP canister for operation and clog,
referring to “EVAP Canister Inspection in Section
1B”.
If a malfunction is found, repair or replace.
I2RH01140007-01
I5RW0A020001-01
I5RW0A020002-01
I4RS0B020002-02
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Brake Discs and Pads (Front) InspectionS6RW0D0206014
1) Remove wheel and caliper but don’t disconnect
brake hose from caliper.
2) Check front disc brake pads and discs for excessive
wear, damage and deflection. Replace parts as
necessary. For details, refer to “Front Disc Brake
Pad Inspection in Section 4B” and “Front Brake Disc
Inspection in Section 4B”.
Be sure to torque caliper pin bolts to specification.
Brake Drums and Shoes (Rear) InspectionS6RW0D0206015
1) Remove wheel and brake drum.
2) Check rear brake drums and brake linings for
excessive wear and damage, while wheels and
drums are removed. At the same time, check wheel
cylinders for leaks. Replace these parts as
necessary.
For details, refer to “Rear Brake Drum and Shoe
Inspection in Section 4C”.
Brake Hoses and Pipes InspectionS6RW0D0206016
Perform this inspection where these is enough light and
use a mirror as necessary.
• Check brake hoses and pipes for proper hookup,
leaks, cracks, chafing and other damage.
• Check that hoses and pipes are clear of sharp edges
and moving parts.
Repair or replace any of these parts as necessary.
CAUTION!
After replacing any brake pipe or hose, be
sure to carry out air purge operation.

Brake Fluid ReplacementS6RW0D0206017
Change brake fluid as follows.
Drain existing fluid from brake system completely, fill
system with specified fluid and carry out air purge
operation.
For air purging procedure, refer to “Air Bleeding of Brake
System in Section 4A”.
Brake Lever and Cable InspectionS6RW0D0206018
1) Inspect brake cable for damage and smooth
movement.
Replace cable if it is in deteriorated condition.
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Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-8
2) Check tooth tip of each notch for damage or wear. If
any damage or wear is found, replace parking lever.
3) Check parking brake lever for proper operation and
stroke, and adjust it if necessary.
For checking and adjusting procedures, refer to
“Parking Brake Inspection and Adjustment in Section
4D”.
Parking brake lever stroke
“a”: 4 – 9 notches (with 200 N (20 kg, 44 lbs) of pull
pressure)
Clutch Fluid InspectionS6RW0D0206019
1) Check clutch system for evidence of fluid leakage.
Repair leaky point if any.
2) Check reservoir for fluid level referring to “Clutch
Fluid Level Inspection in Section 5C”.
If fluid is lower than minimum level (1) of reservoir,
refill reservoir with specified brake fluid indicated on
reservoir cap (2).
Tires InspectionS6RW0D0206020
1) Check tires for uneven or excessive wear, or
damage. If defective, replace.
Refer to “Irregular and/or Premature Wear
Description in Section 2D” and “Wear Indicators
Description in Section 2D” for details.
2) Check inflating pressure of each tire and adjust
pressure to specification as necessary.
NOTE
• Tire inflation pressure should be checked
when tires are cool.
• Specified tire inflation pressure should be
found on tire placard or in owner’s manual
which came with the vehicle.

3) Rotate tires. For details, refer to “Tire Rotation in
Section 2D”.
Wheel Discs InspectionS6RW0D0206021
Inspect each wheel disc for dents, distortion and cracks.
A disc in badly damaged condition must be replaced.
Wheel Bearing InspectionS6RW0D0206022
1) Check front wheel bearing for wear, damage,
abnormal noise or rattles. For details, refer to “Front
Wheel Hub, Disc, Bolt and Bearing Check in Section
2B”.
2) Check rear wheel bearing for wear, damage,
abnormal noise or rattles. For details, refer to “Rear
Wheel Disc, Bolt and Bearing Inspection in Section
2C”.
I4RS0B020005-01
1
2
I5RW0A020005-01
1. Wear indicator
I2RH01020022-01
I2RH01020023-01