ABS SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 00
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Vo l u m e 1
Precautions............................................................... 00-i
Precautions ............................................................ 00-1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubrication ................................. 0B-1
Engine ......................................................................... 1-i
Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1
Aux. Emission Control Devices .............................. 1B-1
Engine Electrical Devices....................................... 1C-1
Engine Mechanical ................................................. 1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System .......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System....................................................... 1H-1
Starting System ....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System ..................................................... 1K-1
Suspension ................................................................. 2-i
Precautions .............................................................. 2-1
Suspension General Diagnosis .............................. 2A-1
Front Suspension ................................................... 2B-1
Rear Suspension.................................................... 2C-1
Wheels and Tires ................................................... 2D-1
Driveline / Axle ........................................................... 3-i
Precautions .............................................................. 3-1
Drive Shaft / Axle ................................................... 3A-1
Differential .............................................................. 3B-1
Transfer .................................................................. 3C-1
Propeller Shafts...................................................... 3D-1
Brakes ......................................................................... 4-i
Precautions .............................................................. 4-1
Brake Control System and Diagnosis .................... 4A-1
Front Brakes........................................................... 4B-1
Rear Brakes ........................................................... 4C-1
Parking Brake......................................................... 4D-1
ABS ........................................................................ 4E-1
Transmission / Transaxle .......................................... 5-i
Precautions .............................................................. 5-1
Automatic Transmission/Transaxle ........................ 5A-1
Manual Transmission/Transaxle ............................ 5B-1
Clutch ..................................................................... 5C-1
Vo l u m e 2
Precautions ............................................................... 00-i
Precautions ............................................................ 00-1
Steering ....................................................................... 6-i
Precautions .............................................................. 6-1
Steering General Diagnosis ................................... 6A-1
Steering Wheel and Column .................................. 6B-1
Power Assisted Steering System ...........................6C-1
HVAC ........................................................................... 7-i
Precautions .............................................................. 7-1
Heater and Ventilation............................................ 7A-1
Air Conditioning System ......................................... 7B-1
Restraint ...................................................................... 8-i
Precautions .............................................................. 8-1
Seat Belts ............................................................... 8A-1
Air Bag System ...................................................... 8B-1
Body, Cab and Accessories ...................................... 9-i
Precautions .............................................................. 9-1
Wiring Systems ...................................................... 9A-1
Lighting Systems .................................................... 9B-1
Instrumentation / Driver Info. / Horn .......................9C-1
Wipers / Washers ...................................................9D-1
Glass / Windows / Mirrors ...................................... 9E-1
Security and Locks ................................................. 9F-1
Seats ..................................................................... 9G-1
Interior Trim ............................................................9H-1
Hood / Fenders / Doors .......................................... 9J-1
Body Structure ....................................................... 9K-1
Paint / Coatings ...................................................... 9L-1
Exterior Trim .......................................................... 9M-1
Control Systems ....................................................... 10-i
Precautions ............................................................ 10-1
Body Electrical Control System ............................ 10B-1
Immobilizer Control System .................................10C-1
Keyless Start System ........................................... 10E-1
TABLE OF CONTENTS

Downloaded from www.Manualslib.com manuals search engine Precautions: 00-12
Repair Instructions
Electrical Circuit Inspection ProcedureS6RW0D0006001
While there are various electrical circuit inspection
methods, described here is a general method to check
its open and short circuit by using an ohmmeter and a
voltmeter.
Open Circuit Check
Possible causes for the open circuit are as follows. As
the cause is in the connector or terminal in many cases,
they need to be checked particularly carefully.
• Loose connection of connector
• Poor contact of terminal (due to dirt, corrosion or rust
on it, poor contact tension, entry of foreign object etc.)
• Wire harness being open
When checking system circuits including an electronic
control unit such as ECM, TCM, ABS control module,
etc., it is important to perform careful check, starting with
items which are easier to check.
1) Disconnect negative (–) cable from battery
2) Check each connector at both ends of the circuit
being checked for loose connection. Also check lock
condition of connector if equipped with connector
lock.
3) Using a test male terminal, check both terminals of
the circuit being checked for contact tension of its
female terminal. Check each terminal visually for
poor contact (possibly caused by dirt, corrosion, rust
entry of foreign object, etc.). At the same time, check
to make sure that each terminal is locked in the
connector fully.4) Using continuity check or voltage check the following
procedure, check the wire harness for open circuit
and poor connection with its terminals. Locate
abnormality, if any.
Continuity Check
1) Measure resistance between connector terminals at
both ends of the circuit being checked (between “A-
1” and “C-1” in the figure). If no continuity is indicated
(infinity or over limit), that means that the circuit is
open between terminals “A-1” and “C-1”.
2) Disconnect the connector included in the circuit
(connector-B in the figure) and measure resistance
between terminals “A-1” and “B-1”.
If no continuity is indicated, that means that the
circuit is open between terminals “A-1” and “B-1”. If
continuity is indicated, there is an open circuit
between terminals “B-1” and “C-1” or an abnormality
in connector-B.
1. Check contact tension by inserting and removing just for once.
I2RH01010049-01
I2RH01010050-01
1. Looseness of crimping
2. Open
3. Thin wire (single strand of wire)
I2RH01010051-01
I2RH01010052-01
I2RH01010053-01

Downloaded from www.Manualslib.com manuals search engine 0A-1 General Information:
General Information
General Information
General Description
AbbreviationsS6RW0D0101001
A:
ABDC: After Bottom Dead Center
ABS: Anti-lock Brake System
AC: Alternating Current
A/C: Air Conditioning
A-ELR: Automatic-Emergency Locking Retractor
A/F: Air Fuel Mixture Ratio
ALR: Automatic Locking Retractor
API: American Petroleum Institute
APP sensor: Accelerator Pedal Position Sensor
A/T: Automatic Transmission, Automatic Transaxle
AT D C : After Top Dead Center
ATF: Automatic Transmission Fluid, Automatic
Transaxle Fluid
B:
B+: Battery Positive Voltage
BBDC: Before Bottom Dead Center
BCM: Body Electrical Control Module
BTDC: Before Top Dead Center
C:
CAN: Controller Area Network
CKT: Circuit
CKP Sensor: Crankshaft Position Sensor
CMP Sensor: Camshaft Position Sensor
CO: Carbon Monoxide
CPP Switch: Clutch Pedal Position Switch (Clutch
Switch, Clutch Start Switch)
CPU: Central Processing Unit
CRS: Child Restraint System
D:
DC: Direct Current
DLC: Data Link Connector (Assembly Line Diag. Link,
ALDL, Serial Data Link, SDL)
DOHC: Double Over Head Camshaft
DOJ: Double Offset Joint
DRL: Daytime Running Light
DTC: Diagnostic Trouble Code (Diagnostic Code)
E:
EBCM: Electronic Brake Control Module, ABS Control
Module
EBD: Electronic Brake Force Distribution
ECM: Engine Control Module
ECT Sensor: Engine Coolant Temperature Sensor
(Water Temp. Sensor, WTS)
EFE Heater: Early Fuel Evaporation Heater (Positive
Temperature Coefficient, PTC Heater)
EGR: Exhaust Gas Recirculation
EGRT Sensor: EGR Temperature Sensor (Recirculated
Exhaust Gas Temp. Sensor, REGTS)
EPS: Electronic Power Steering
EVAP: Evaporative Emission
EVAP Canister: Evaporative Emission Canister
(Charcoal Canister)F:
4WD: 4 Wheel Drive
G:
GEN: Generator
GND: Ground
GPS: Global Positioning System
H:
HAVC: Heating, Ventilating and Air Conditioning
HC: Hydrocarbons
HO2S: Heated Oxygen Sensor
I:
IAC Valve: Idle Air Control Valve (Idle Speed Control
Solenoid Valve, ISC Solenoid Valve)
IAT Sensor: Intake Air Temperature Sensor (Air
temperature Sensor, ATS)
ICM: Immobilizer Control Module
IG: Ignition
ISC Actuator: Idle Speed Control Actuator
L:
LH: Left Hand
LHD: Left Hand Drive vehicle
LSPV: Load Sensing Proportioning Valve
M:
MAF Sensor: Mass Air Flow Sensor (Air Flow Sensor,
AFS, Air Flow Meter, AFM)
MAP Sensor: Manifold Absolute Pressure Sensor
(Pressure Sensor, PS)
Max: Maximum
MFI: Multiport Fuel Injection (Multipoint Fuel Injection)
Min: Minimum
MIL: Malfunction Indicator Lamp (“SERVICE ENGINE
SOON” Light)
M/T: Manual Transmission, Manual Transaxle
N:
NOx: Nitrogen Oxides
O:
OBD: On-Board Diagnostic System (Self-Diagnosis
Function)
O/D: Overdrive
OHC: Over Head Camshaft
O2S: Oxygen Sensor
P:
PCM: Powertrain Control Module
PCV: Positive Crankcase Ventilation
PNP: Park / Neutral Position
P/S: Power Steering
PSP Switch: Power Steering Pressure Switch (P/S
Pressure Switch)
R:
RH: Right Hand
RHD: Right Hand Drive vehicle

Downloaded from www.Manualslib.com manuals search engine 0A-5 General Information:
Vehicle Lifting PointsS6RW0D0101005
WARNING!
• Before applying hoist to underbody, always take vehicle balance throughout service into
consideration. Vehicle balance on hoist may change depending on what part to be removed.
• Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe,
fuel pipe, bracket or any other part.
• When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up
the vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by
trying to move vehicle body in both ways. Work can be started only after this confirmation.
• Make absolutely sure to lock hoist after vehicle is hoisted up.

When Using Frame Contact Hoist
When Using Floor Jack
WARNING!
If the vehicle to be jacked up only at the front
or rear end, be sure to block the wheels on
ground in order to ensure safety.
After the vehicle is jacked up, be sure to
support it on stands. It is extremely
dangerous to do any work on the vehicle
raised on jack alone.

CAUTION!
Never apply jack against rear suspension
parts (i.e., torsion beam, etc.) or vehicle floor,
or it may get deformed.

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I5RW0A010001-02
1. Vehicle front3. Floor jack position 5. Cap
2. Support position for frame contact hoist and safety stand 4. Body mounting stay

Downloaded from www.Manualslib.com manuals search engine 0B-9 Maintenance and Lubrication:
Suspension System InspectionS6RW0D0206023
• Inspect front struts and rear shock absorbers for
evidence of oil leakage, dents or any other damage on
sleeves; and inspect anchor ends for deterioration.
Replace defective parts, if any.
• Check front and rear suspension systems for
damaged, loose or missing parts; also for parts
showing signs of wear or lack of lubrication.
Repair or replace defective parts, if any.
• Check front suspension arm ball joint stud dust seals
for leakage, detachment, tear or any other damage.
Replace defective boot, if any.
Steering System InspectionS6RW0D0206024
1) Check steering wheel for play and rattle, holding
vehicle straight on ground.
Steering wheel play
“a”: 0 – 30 mm (0 – 1.1 in.)2) Check bolts and nuts for tightness and retighten
them as necessary. Repair or replace defective
parts, if any.
3) Check steering linkage for looseness and damage.
Repair or replace defective parts, if any.
4) Check boots (1) and (2) of steering linkage and
steering gear case for damage (leak, detachment,
tear, etc.). If damage is found, replace defective boot
with new one.
If any dent is found on steering gear case boots,
correct it to original shape by turning steering wheel
to the right or left as far as it stops and holding it for a
few seconds.
5) Check universal joints (3) of steering shaft for rattle
and damage. If rattle or damage is found, replace
defective part with a new one.
6) Check that steering wheel can be turned fully to the
right and left. Repair or replace defective parts, if
any.
7) If equipped with power steering system, check also,
in addition to check items, that steering wheel can be
turned fully to the right and left more lightly when
engine is running at idle speed than when it is
stopped. Repair, if found faulty.
8) Check wheel alignment referring to “Front Wheel
Alignment Inspection and Adjustment in Section 2B”.
Drive Shaft (Axle) Boots InspectionS6RW0D0206025
Check drive shaft boots (wheel side and differential side)
for leaks, detachment, tear or other damage.
Replace defective parts as necessary.
I4RS0A020011-01
I4RS0A020012-01
I2RH01020026-01
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I4RS0B020007-01
I2RH01310001-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 1- i
1
Section 1
CONTENTS
Engine
Precautions ................................................. 1-1
Precautions............................................................. 1-1
Precautions for Engine .......................................... 1-1
Engine General Information and
Diagnosis ................................................. 1A-1
Precautions........................................................... 1A-1
Precautions on Engine Service ........................... 1A-1
Precaution on On-Board Diagnostic (OBD)
System .............................................................. 1A-1
Precautions in Diagnosing Trouble ..................... 1A-1
Precautions for DTC Troubleshooting ................. 1A-2
Precautions of ECM Circuit Inspection................ 1A-2
Precautions of Electric Throttle Body System
Calibration ......................................................... 1A-2
Precaution on CAN Troubleshooting .................. 1A-3
General Description ............................................. 1A-5
Statement on Cleanliness and Care ................... 1A-5
Engine Diagnosis General Description ............... 1A-5
On-Board Diagnostic System Description ........... 1A-5
Data Link Connector (DLC) ................................. 1A-8
Engine and Emission Control System
Description ........................................................ 1A-8
CAN Communication System Description........... 1A-9
Air Intake System Description ........................... 1A-11
Description of Electric Throttle Body System
Calibration ....................................................... 1A-11
Description of Electric Throttle Body System .... 1A-11
Engine and Emission Control Input / Output
Table ............................................................... 1A-18
Schematic and Routing Diagram ...................... 1A-19
Engine and Emission Control System
Diagram .......................................................... 1A-19
Component Location ......................................... 1A-21
Electronic Control System Components
Location .......................................................... 1A-21
Diagnostic Information and Procedures .......... 1A-22
Engine and Emission Control System Check.... 1A-22
Malfunction Indicator Lamp (MIL) Check .......... 1A-25
DTC Check ....................................................... 1A-25
DTC Clearance ................................................. 1A-26
Troubleshooting for Communication Error
with Scan Tool Using CAN.............................. 1A-26
DTC Table ......................................................... 1A-32For Vehicle Equipped with A/T .......................... 1A-36
Fail-Safe Table .................................................. 1A-36
Scan Tool Data ................................................. 1A-38
Visual Inspection ............................................... 1A-43
Engine Basic Inspection .................................... 1A-43
Engine Symptom Diagnosis .............................. 1A-45
Malfunction Indicator Lamp Does Not Come
ON with Ignition Switch ON and Engine Stop
(but Engine Can Be Started) ........................... 1A-52
Malfunction Indicator Lamp Remains ON after
Engine Starts................................................... 1A-54
DTC P0010: Camshaft Position Actuator
Circuit (for engine with VVT system) ............... 1A-55
DTC P0011 / P0012: Camshaft Position -
Timing Over-Advanced or System
Performance / Retarded (for engine with
VVT system).................................................... 1A-57
DTC P0031 / P0032: HO2S Heater Control
Circuit Low / High (Sensor-1) .......................... 1A-59
DTC P0037 / P0038: HO2S Heater Control
Circuit Low / High (Sensor-2) .......................... 1A-61
DTC P0101: Mass Air Flow Circuit Range /
Performance.................................................... 1A-63
DTC P0102: Mass Air Flow Circuit Low Input ... 1A-66
DTC P0103: Mass Air Flow Circuit High Input .. 1A-67
DTC P0106: Manifold Absolute Pressure
Range / Performance ...................................... 1A-69
DTC P0107: Manifold Absolute Pressure
Circuit Low Input ............................................. 1A-70
DTC P0108: Manifold Absolute Pressure
Circuit High Input............................................. 1A-72
DTC P0111: Intake Air Temperature Circuit
Range / Performance ...................................... 1A-74
DTC P0112: Intake Air Temperature Sensor
Circuit Low ...................................................... 1A-76
DTC P0113: Intake Air Temperature Sensor
Circuit High...................................................... 1A-78
DTC P0116: Engine Coolant Temperature
Circuit Range / Performance ........................... 1A-80
DTC P0117: Engine Coolant Temperature
Circuit Low ...................................................... 1A-83
DTC P0118: Engine Coolant Temperature
Circuit High...................................................... 1A-85
DTC P0122: Throttle Position Sensor (Main)
Circuit Low ...................................................... 1A-87

Downloaded from www.Manualslib.com manuals search engine 1-ii Table of Contents
DTC P0123: Throttle Position Sensor (Main)
Circuit High ..................................................... 1A-89
DTC P0131 / P0132: O2 Sensor (HO2S)
Circuit Low Voltage / High Voltage (Sensor-
1) ..................................................................... 1A-92
DTC P0133: O2 Sensor (HO2S) Circuit Slow
Response (Sensor-1) ...................................... 1A-95
DTC P0134: O2 Sensor (HO2S) Circuit No
Activity Detected (Sensor-1) ........................... 1A-96
DTC P0137 / P0138: O2 Sensor (HO2S)
Circuit Low Voltage / High Voltage (Sensor-
2) ..................................................................... 1A-98
DTC P0140: O2 Sensor (HO2S) Circuit No
Activity Detected (Sensor-2) ......................... 1A-101
DTC P0171 / P0172: Fuel System Too Lean /
Rich ............................................................... 1A-103
DTC P0222: Throttle Position Sensor (Sub)
Circuit Low .................................................... 1A-105
DTC P0223: Throttle Position Sensor (Sub)
Circuit High ................................................... 1A-107
DTC P0300 / P0301 / P0302 / P0303 / P0304:
Random Misfire Detected / Cylinder 1 /
Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire
Detected ........................................................ 1A-110
DTC P0327 / P0328: Knock Sensor Circuit
Low / High ..................................................... 1A-112
DTC P0335: Crankshaft Position (CKP)
Sensor Circuit ............................................... 1A-114
DTC P0340: Camshaft Position (CMP)
Sensor Circuit ............................................... 1A-116
DTC P0401 / P0402: Exhaust Gas
Recirculation Flow Insufficient Detected /
Excessive Detected ...................................... 1A-119
DTC P0403: Exhaust Gas Recirculation
Control Circuit ............................................... 1A-122
DTC P0420: Catalyst System Efficiency
below Threshold ............................................ 1A-124
DTC P0443: Evaporative Emission System
Purge Control Valve Circuit........................... 1A-126
DTC P0462 / P0463: Fuel Level Sensor
Circuit Low / High .......................................... 1A-128
DTC P0480: Fan 1 (Radiator Cooling Fan)
Control Circuit ............................................... 1A-129
DTC P0481: Cooling Fan 2 (A/C Condenser
Fan) Control Circuit ....................................... 1A-131
DTC P0500: Vehicle Speed Sensor (VSS)
Malfunction .................................................... 1A-134
DTC P0532: A/C Refrigerant Pressure
Sensor Circuit Low ........................................ 1A-136
DTC P0533: A/C Refrigerant Pressure
Sensor Circuit High ....................................... 1A-138
DTC P0601 / P0602 / P0607: Internal Control
Module Memory Check Sum Error / Control
Module Programming Error / Control Module
Performance ................................................. 1A-139
DTC P0616: Starter Relay Circuit Low............ 1A-140
DTC P0617: Starter Relay Circuit High ........... 1A-141
DTC P1510: ECM Back-Up Power Supply
Malfunction .................................................... 1A-143DTC P2101: Throttle Actuator Control Motor
Circuit Range / Performance ......................... 1A-144
DTC P2102: Throttle Actuator Control Motor
Circuit Low .................................................... 1A-146
DTC P2103: Throttle Actuator Control Motor
Circuit High.................................................... 1A-147
DTC P2111: Throttle Actuator Control System
- Stuck Open ................................................. 1A-148
DTC P2119: Throttle Actuator Control Throttle
Body Range / Performance ........................... 1A-149
DTC P2122: Pedal Position Sensor (Main)
Circuit Low Input ........................................... 1A-151
DTC P2123: Pedal Position Sensor (Main)
Circuit High Input........................................... 1A-153
DTC P2127: Pedal Position Sensor (Sub)
Circuit Low Input ........................................... 1A-155
DTC P2128: Pedal Position Sensor (Sub)
Circuit High Input........................................... 1A-158
DTC P2135: Throttle Position Sensor (Main /
Sub) Voltage Correlation ............................... 1A-160
DTC P2138: Pedal Position Sensor (Main /
Sub) Voltage Correlation ............................... 1A-163
DTC P2227 / P2228 / P2229: Barometric
Pressure Circuit Malfunction ......................... 1A-165
DTC U0073: Control Module Communication
Bus Off .......................................................... 1A-166
DTC U0101: Lost Communication with TCM .. 1A-166
DTC U0121: Lost Communication with ABS
Control Module .............................................. 1A-166
DTC U0140: Lost Communication with Body
Control Module .............................................. 1A-166
Troubleshooting for CAN-DTC ........................ 1A-167
Inspection of ECM and Its Circuits .................. 1A-172
ECM Power and Ground Circuit Check........... 1A-193
Fuel Injector Circuit Check .............................. 1A-196
Fuel Pump and Its Circuit Check..................... 1A-198
Fuel Pressure Check....................................... 1A-201
A/C Condenser Cooling Fan Control System
Inspection ...................................................... 1A-202
A/C System Circuits Check ............................. 1A-205
Electric Load Signal Circuit Check .................. 1A-209
Radiator Cooling Fan Control System Check . 1A-211
Repair Instructions ..........................................1A-212
Idle Speed and IAC Throttle Valve Opening
Inspection ...................................................... 1A-212
Special Tools and Equipment .........................1A-213
Special Tool .................................................... 1A-213
Aux. Emission Control Devices ............. 1B-1
Diagnostic Information and Procedures ............1B-1
EGR System Inspection (If Equipped) ................ 1B-1
Repair Instructions ..............................................1B-1
EVAP Canister Purge Inspection ........................ 1B-1
EVAP Canister Purge Valve and Its Circuit
Inspection .......................................................... 1B-1
Vacuum Passage Inspection............................... 1B-2
Vacuum Hose Inspection .................................... 1B-3
EVAP Canister Purge Valve Inspection .............. 1B-3
EVAP Canister Inspection ................................... 1B-4

Downloaded from www.Manualslib.com manuals search engine Table of Contents 1-iii
EGR Valve Removal and Installation (If
Equipped).......................................................... 1B-4
EGR Valve Inspection (If Equipped) ................... 1B-4
PCV Hose Inspection .......................................... 1B-5
PCV Valve Inspection ......................................... 1B-5
Special Tools and Equipment ............................. 1B-5
Special Tool ........................................................ 1B-5
Engine Electrical Devices ....................... 1C-1
Repair Instructions .............................................. 1C-1
Engine Control Module (ECM) Removal and
Installation ......................................................... 1C-1
Manifold Absolute Pressure (MAP) Sensor
Inspection (If Equipped) .................................... 1C-2
Electric Throttle Body Assembly On-Vehicle
Inspection.......................................................... 1C-2
Electric Throttle Body System Calibration ........... 1C-5
Accelerator Pedal Position (APP) Sensor
Assembly On-Vehicle Inspection ...................... 1C-5
Accelerator Pedal Position (APP) Sensor
Assembly Removal and Installation .................. 1C-5
Accelerator Pedal Position (APP) Sensor
Assembly Inspection ......................................... 1C-6
Engine Coolant Temperature (ECT) Sensor
Removal and Installation................................... 1C-7
Engine Coolant Temperature (ECT) Sensor
Inspection.......................................................... 1C-7
Heated Oxygen Sensor (HO2S-1 and HO2S-
2) Heater On-Vehicle Inspection (If
Equipped).......................................................... 1C-8
Heated Oxygen Sensor (HO2S-1 and HO2S-
2) Removal and Installation (If Equipped) ......... 1C-8
Camshaft Position (CMP) Sensor Removal
and Installation .................................................. 1C-9
Camshaft Position (CMP) Sensor Inspection ...... 1C-9
Crankshaft Position (CKP) Sensor Removal
and Installation ................................................ 1C-10
Crankshaft Position (CKP) Sensor Inspection .. 1C-11
Knock Sensor Removal and Installation ........... 1C-11
Main Relay, Fuel Pump Relay, Starting Motor
Control Relay, Throttle Actuator Control
Relay and Radiator Cooling Fan Relay
Inspection........................................................ 1C-12
Mass Air Flow (MAF) and Intake Air
Temperature (IAT) Sensor On-Vehicle
Inspection........................................................ 1C-12
Mass Air Flow (MAF) and Intake Air
Temperature (IAT) Sensor Removal and
Installation ....................................................... 1C-13
Intake Air Temperature (IAT) Sensor
Inspection........................................................ 1C-13
Specifications..................................................... 1C-14
Tightening Torque Specifications ...................... 1C-14
Engine Mechanical .................................. 1D-1
General Description ............................................. 1D-1
Engine Construction Description ......................... 1D-1
Camshaft Position Control (VVT Variable
Valve Timing) System Description .................... 1D-3Diagnostic Information and Procedures ............1D-5
Compression Check ............................................1D-5
Engine Vacuum Check........................................1D-6
Valve Lash (Clearance) Inspection .....................1D-7
Repair Instructions ............................................1D-10
Air Intake System Components.........................1D-10
Air Cleaner Filter Removal and Installation .......1D-10
Air Cleaner Filter Inspection and Cleaning........1D-10
Air Cleaner Assembly Removal and
Installation .......................................................1D-11
Cylinder Head Cover Removal and
Installation .......................................................1D-11
Throttle Body and Intake Manifold
Components ....................................................1D-13
Throttle Body On-Vehicle Inspection.................1D-14
Electric Throttle Body Assembly Removal and
Installation .......................................................1D-14
Throttle Body Cleaning......................................1D-14
Intake Manifold Removal and Installation .........1D-15
Engine Mountings Components ........................1D-16
Engine Assembly Removal and Installation ......1D-17
Timing Chain Cover Components .....................1D-22
Timing Chain Cover Removal and Installation ..1D-23
Timing Chain Cover Inspection .........................1D-25
Oil Control Valve Removal and Installation
(For Engine with VVT) .....................................1D-26
Oil Control Valve Inspection (For Engine with
VVT) ................................................................1D-26
Timing Chain and Chain Tensioner
Components ....................................................1D-27
Timing Chain and Chain Tensioner Removal
and Installation ................................................1D-27
Timing Chain and Chain Tensioner Inspection ..1D-31
Camshaft, Tappet and Shim Components ........1D-32
Camshaft, Tappet and Shim Removal and
Installation .......................................................1D-33
Camshaft, Tappet and Shim Inspection ............1D-36
Valves and Cylinder Head Components ...........1D-39
Valves and Cylinder Head Removal and
Installation .......................................................1D-40
Valves and Cylinder Head Disassembly and
Assembly.........................................................1D-42
Valves and Valve Guides Inspection.................1D-45
Cylinder Head Inspection ..................................1D-47
Valve Spring Inspection ....................................1D-48
Pistons, Piston Rings, Connecting Rods and
Cylinders Components ....................................1D-49
Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation .................1D-49
Pistons, Piston Rings, Connecting Rods and
Cylinders Disassembly and Assembly ............1D-51
Cylinders, Pistons and Piston Rings
Inspection ........................................................1D-52
Piston Pins and Connecting Rods Inspection ...1D-54
Crank Pin and Connecting Rod Bearings
Inspection ........................................................1D-55
Main Bearings, Crankshaft and Cylinder
Block Components ..........................................1D-59
Main Bearings, Crankshaft and Cylinder
Block Removal and Installation .......................1D-60

Downloaded from www.Manualslib.com manuals search engine 1A-2 Engine General Information and Diagnosis:
• When checking ECM for DTC, keep in mind that DTC
is displayed on the scan tool as follows depending on
the scan tool used.
– SUZUKI scan tool displays DTC detected by ECM.
– CAN communication OBD generic scan tool
displays DTC detected by each of ECM and TCM
(for A/T model) simultaneously.
• Priorities for diagnosing troubles
If two or more DTCs are stored, proceed to the DTC
flow which has been detected earliest in the order and
follow the instruction in that flow.
If no instructions are given, troubleshoot DTCs
according to the following priorities.
a. DTCs other than DTC P0171 / P0172 (Fuel
system too lean / too rich), DTC P0300 / P0301 /
P0302 / P0303 / P0304 (Misfire detected) and
DTC P0401 / P0402 (EGR flow malfunction)
b. DTC P0171 / P0172 (Fuel system too lean / too
rich) and DTC P0401 / P0402 (EGR flow
malfunction)
c. DTC P0300 / P0301 / P0302 / P0303 / P0304
(Misfire detected)
• Be sure to read “Precautions for Electrical Circuit
Service in Section 00” before inspection and observe
what is written there.
• ECM replacement:
When substituting a known-good ECM, check for the
following conditions. Neglecting this check may cause
damage to a known-good ECM.
– Resistance value of all relays, actuators is as
specified respectively.
– MAP sensor, A/C refrigerant pressure sensor (if
equipped with A/C), accelerator pedal position
(APP) sensor and TP sensor are in good condition
and none of power circuits of these sensors is
shorted to ground.
• Communication of ECM, BCM, combination meter,
keyless start control module (if equipped with keyless
start control system), 4WD control module (if
equipped), TCM (for A/T model) and ABS control
module, is established by CAN (Controller Area
Network). (For more detail of CAN communication for
ECM, refer to “CAN Communication System
Description”). Therefore, handle CAN communication
line with care referring to “Precaution for CAN
Communication System in Section 00”.
• Immobilizer transponder code registration after
replacing ECM (Immobilizer model)
When ECM is replaced with new one or with another
one, make sure to register immobilizer transponder
code to ECM correctly according to “Procedure after
ECM Replacement in Section 10C”.Precautions for DTC TroubleshootingS6RW0D1100003
• Before performed trouble shooting, be sure to read
the “Precautions of ECM Circuit Inspection”.
• When measuring circuit voltage, resistance and/or
pulse signal at ECM connector, connect the special
tool to ECM and/or the ECM connectors referring to
“Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work,
perform “DTC Confirmation Procedure” and confirm
that the trouble has been corrected.
Precautions of ECM Circuit InspectionS6RW0D1100004
• ECM connectors are waterproofed. Each terminal of
the ECM connectors is sealed up with the grommet.
Therefore, when measuring circuit voltage, resistance
and/or pulse signal at ECM connector, do not insert
the tester’s probe into the sealed terminal at the
harness side. When measuring circuit voltage,
resistance and/or pulse signal at ECM connector,
connect the special tool to the ECM connectors. And,
insert the tester’s probe into the special tool’s
connectors at the harness side, and then measure
voltage, resistance and/or pulse signal. Or, ECM and
its circuits may be damaged by water.
• Wire colors of the special tool’s connectors are
different from the ones of the ECM connectors.
However, the circuit arrangement of the special tool’s
connectors is same as the one of the ECM
connectors. Therefore, measure circuit voltage and
resistance by identifying the terminal location subject
to the measurement.
Precautions of Electric Throttle Body System
Calibration
S6RW0D1100005
After performing one of works described below, it is
necessary to re-register the completely closed throttle
valve reference position stored in memory of ECM. (For
detailed information, refer to “Description of Electric
Throttle Body System Calibration”.) For the procedure to
register such data in ECM, refer to “Electric Throttle
Body System Calibration in Section 1C”.
• To shut off backup power of ECM for such purposes of
battery replacement or “DOME” fuse removal
• To erase DTCs P0122, P0123, P0222, P0223, P2101,
P2102, P2103, P2111, P2112, P2119 and/or P2135
• To replace ECM
• To replace throttle body and/or accelerator pedal
position (APP) sensor assembly

Downloaded from www.Manualslib.com manuals search engine 1A-4 Engine General Information and Diagnosis:
Outline of troubleshooting
When there is a trouble with CAN, perform “Troubleshooting for Communication Error with Scan Tool Using CAN” and/
or “Troubleshooting for CAN-DTC”. Not using this procedure or performing troubleshooting in any other way may skip
some check points resulting in misdiagnosis or take a longer time than necessary.
1) Checking connector related to CAN
2) Checking CAN line
3) Checking each control module/sensor using “DTC check” or “Bus Check”
4) Checking power and ground connection of each control module/sensor
CAN-DTC
Even when DTC related to CAN (= CAN-DTC) as described below is detected, it is not possible to point out the
specific trouble point by CAN-DTC itself. Be sure to troubleshoot according to “Troubleshooting for CAN-DTC”.
CAN-DTC table
Communication with scan tool
• K line or CAN line is used for communication between each control module and scan tool.
Refer to “CAN schematic and routing diagram: ” to determine which line is used for communication between each
control module and scan tool.
• ECM and TCM use CAN line for communication with scan tool. Even if CAN has a trouble other than between DLC
and BCM, communication may also fail between scan tool and these control modules. In such case, perform
troubleshooting according to “Troubleshooting for Communication Error with Scan Tool Using CAN”.
• BCM, ABS control module and 4WD control module use K-line for communication with scan tool. Even if CAN has a
trouble, it is possible to communicate between scan tool and these control modules.
Bus check with SUZUKI scan tool
SUZUKI scan tool (SUZUKI-SDT) efficiently diagnoses a CAN bus malfunction by “Communication Bus Check” and
“Communication Malfunction DTC” under “Bus check”.
“Communication Bus Check” can display all control modules/sensors name communicated by CAN.
Also, “Communication Malfunction DTC” can display only CAN-DTC which is detected by the control modules (ECM
and TCM) communicating with scan tool using CAN line.
[A]: Non-Taiwan model [C]: CAN high line (RED) [E]: K-line
[B]: Taiwan model [D]: CAN low line (WHT)
No. Part Name Communication with scan tool Monitor of CAN-DTC
1. ABS control module K-line Not available
2. ECM CAN Available
3. TCM CAN Available
4. BCM K-line Available
5. Keyless start control module Not available Available
6. 4WD control module K-line Available
7. Combination meter Not available Not available
8. CAN junction connector — —
9. DLC — —
Detected Control Module CAN-DTC
ECM U0073/U0101/U0121/U0140/P1618
TCM U0073/U0100
BCM U0073/U0100/U0101/U0155/U1144
4WD control module U0073/U0100/U0121/U0155
Keyless start control module No.31/No.33