fuel pressure relief procedure SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 1-iv Table of Contents
Crankshaft Inspection .......................................1D-63
Main Bearings Inspection ..................................1D-65
Sensor Plate Inspection ....................................1D-70
Rear Oil Seal Inspection ...................................1D-70
Flywheel Inspection...........................................1D-70
Cylinder Block Inspection ..................................1D-70
Specifications .....................................................1D-71
Tightening Torque Specifications ......................1D-71
Special Tools and Equipment ...........................1D-73
Recommended Service Material .......................1D-73
Special Tool ......................................................1D-73
Engine Lubrication System.....................1E-1
General Description ............................................. 1E-1
Engine Lubrication Description ........................... 1E-1
Diagnostic Information and Procedures ............ 1E-2
Oil Pressure Check ............................................. 1E-2
Repair Instructions .............................................. 1E-3
Oil Pan and Oil Pump Strainer Components....... 1E-3
Oil Pan and Oil Pump Strainer Removal and
Installation ......................................................... 1E-4
Oil Pan and Oil Pump Strainer Cleaning ............. 1E-5
Oil Pump Components ........................................ 1E-6
Oil Pump Removal and Installation ..................... 1E-6
Oil Pump Disassembly and Reassembly ............ 1E-6
Oil Pump Inspection ............................................ 1E-7
Specifications ....................................................... 1E-9
Tightening Torque Specifications ........................ 1E-9
Special Tools and Equipment ............................. 1E-9
Recommended Service Material ......................... 1E-9
Special Tool ........................................................ 1E-9
Engine Cooling System ........................... 1F-1
General Description ............................................. 1F-1
Cooling System Description ................................ 1F-1
Coolant Description ............................................. 1F-1
Schematic and Routing Diagram ........................ 1F-2
Coolant Circulation .............................................. 1F-2
Diagnostic Information and Procedures ............ 1F-3
Engine Cooling Symptom Diagnosis ................... 1F-3
Repair Instructions .............................................. 1F-4
Cooling System Components.............................. 1F-4
Coolant Level Check ........................................... 1F-5
Engine Cooling System Inspection and
Cleaning ............................................................ 1F-5
Cooling System Draining..................................... 1F-5
Cooling System Flush and Refill ......................... 1F-6
Cooling Water Pipes or Hoses Removal and
Installation ......................................................... 1F-6
Thermostat Removal and Installation.................. 1F-7
Thermostat Inspection......................................... 1F-7
Radiator Cooling Fan Assembly On-Vehicle
Inspection .......................................................... 1F-8
Radiator Cooling Fan Relay Inspection............... 1F-8
Radiator Cooling Fan Assembly Removal and
Installation ......................................................... 1F-8
Radiator Cooling Fan Disassembly and
Reassembly ...................................................... 1F-9
Radiator On-Vehicle Inspection and Cleaning .... 1F-9Radiator Removal and Installation ...................... 1F-9
Water Pump / Generator Drive Belt Tension
Inspection and Adjustment.............................. 1F-10
Water Pump / Generator Drive Belt Removal
and Installation ................................................ 1F-10
Water Pump Removal and Installation .............. 1F-11
Water Pump Inspection ..................................... 1F-12
Specifications ..................................................... 1F-12
Tightening Torque Specifications ...................... 1F-12
Special Tools and Equipment ........................... 1F-12
Recommended Service Material ....................... 1F-12
Fuel System ............................................. 1G-1
Precautions .......................................................... 1G-1
Precautions on Fuel System Service ................. 1G-1
General Description ............................................ 1G-2
Fuel System Description .................................... 1G-2
Fuel Delivery System Description ...................... 1G-2
Fuel Pump Description ....................................... 1G-2
Schematic and Routing Diagram ....................... 1G-3
Fuel Delivery System Diagram........................... 1G-3
Diagnostic Information and Procedures ........... 1G-3
Fuel Pressure Inspection ................................... 1G-3
Fuel Cut Operation Inspection ........................... 1G-4
Repair Instructions ............................................. 1G-5
Fuel System Components .................................. 1G-5
Fuel Hose Disconnecting and Reconnecting ..... 1G-6
Fuel Pressure Relief Procedure ......................... 1G-7
Fuel Leakage Check Procedure......................... 1G-8
Fuel Lines On-Vehicle Inspection ...................... 1G-8
Fuel Pipe Removal and Installation.................... 1G-8
Fuel Injector On-Vehicle Inspection ................... 1G-9
Fuel Injector Removal and Installation ............... 1G-9
Fuel Injector Inspection .................................... 1G-10
Fuel Filler Cap Inspection ................................ 1G-12
Fuel Tank Inlet Valve Removal and
Installation ...................................................... 1G-12
Fuel Tank Inlet Valve Inspection ...................... 1G-12
Fuel Tank Removal and Installation ................. 1G-13
Fuel Tank Inspection ........................................ 1G-14
Fuel Tank Purging Procedure .......................... 1G-15
Fuel Pump On-Vehicle Inspection.................... 1G-15
Fuel Pump Assembly Removal and
Installation ...................................................... 1G-15
Main Fuel Level Sensor Removal and
Installation ...................................................... 1G-16
Fuel Pump Inspection ...................................... 1G-17
Specifications .................................................... 1G-17
Tightening Torque Specifications ..................... 1G-17
Special Tools and Equipment .......................... 1G-18
Special Tool ..................................................... 1G-18
Ignition System ........................................ 1H-1
General Description .............................................1H-1
Ignition System Construction ..............................1H-1
Schematic and Routing Diagram ........................1H-2
Ignition System Wiring Circuit Diagram...............1H-2
Component Location ...........................................1H-3
Ignition System Components Location................1H-3

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-17
Engine Assembly Removal and InstallationS6RW0D1406013
Removal
1) Relieve fuel pressure according to “Fuel Pressure
Relief Procedure in Section 1G”.
2) Disconnect negative and positive cable at battery.
3) Disconnect ECM connectors.
4) Remove battery and battery tray with ECM.
5) Remove right and left side engine under covers.
6) Remove A/C compressor belt by referring to
“Compressor Drive Belt Removal and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
7) Drain engine oil referring to “Engine Oil and Filter
Change in Section 0B”.
8) Drain transaxle oil referring to “Manual Transaxle Oil
Change in Section 5B” or “A/T Fluid Change in
Section 5A”.
9) Drain transfer oil referring to “Transfer Oil Change in
Section 3C”.
10) Drain coolant referring to “Cooling System Draining
in Section 1F”
11) Remove air cleaner assembly referring to “Air
Cleaner Assembly Removal and Installation”.
12) With hose connected, detach A/C compressor from
its bracket referring to “Compressor Assembly
Removal and Installation in Section 7B” or
“Compressor Assembly Removal and Installation in
Section 7B”.
CAUTION!
Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

13) Remove cylinder upper cover (1).14) Disconnect the following electric wires/connectors
and each clamps.
• TP sensor (1)
• MAP sensor (2)
• ECT sensor (3)
•EGR valve (4)
• CMP sensor (5)
• Ignition coil assembly (6)
• Injector (7)
•HO2S (8)
• Oil control valve (9) (for engine with VVT system)
• Engine oil pressure switch (10)
• CKP sensor (12)
• Knock sensor (13)
• Generator (14)
• Starting motor (15)
• Ground terminal (16) from cylinder block
• Battery ground cable (17) from transaxle
• Back-up light switch (18) (for M/T model)
• Torque sensor (19)
• P/S motor (20)
• Output shaft speed sensor (VSS) (29) (for A/T
model)
• Solenoid valve (30) (for A/T model)
• Transmission range sensor (31) (for A/T model)
• Input shaft speed sensor (32) (for A/T model)
15) Disconnect the following cables, and remove control
cable bracket (23)
• Gear select control cable (21) (for M/T model)
• Gear shift control cable (22) (for M/T model)
• A/T select cable (33) (for A/T model)
16) Disconnect the following hoses.
• Brake booster hose (24) from intake manifold
• Radiator inlet and outlet hoses (25) from radiator
• Heater inlet and outlet hoses (26) from heater
core
• Fuel feed hose (27) from fuel feed pipe
• Fuel vapor hose (11) from fuel vapor pipe
• Clutch hose (28) from transaxle (for M/T model)
• A/T fluid cooler hoses (for A/T model)
F: Vehicle forward 8. Engine front mounting bracket : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
1. Engine right mounting bracket 9. Engine front mounting
: Be sure to direct yellow mark to forward.: 95 N⋅m (9.5 kgf-m, 69.0 lb-ft)
2. Engine right mounting 10. Transfer : 65 N⋅m (6.5 kgf-m, 47.0 lb-ft)
3. Engine left mounting bracket 11. Suspension frame : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
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Downloaded from www.Manualslib.com manuals search engine 1G-1 Fuel System:
Engine
Fuel System
Precautions
Precautions on Fuel System ServiceS6RW0D1700001
WARNING!
Before attempting service of any type on fuel system, the following should be always observed in
order to reduce the risk of fire and personal injury.
• Disconnect negative cable at battery.
• Do not smoke, and place no smoking signs near work area.
• Be sure to have CO
2 fire extinguisher handy.
• Be sure to perform work in a well-ventilated area and away from any open flames (such as gas hot
heater).
• Wear safety glasses.
• To relieve fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then
reinstall it.
• As fuel feed line is still under high fuel pressure even after stopping engine, loosening or
disconnecting fuel feed line directly may cause dangerous spout of fuel. Before loosening or
disconnecting fuel feed line, make sure to relieve fuel pressure referring to “Fuel Pressure Relief
Procedure”.
• A small amount of fuel may be released when the fuel line is disconnected. In order to reduce the
risk of personal injury, cover a shop cloth to the fitting to be disconnected. Be sure to put that cloth
in an approved container after disconnecting.
• Never run engine with fuel pump relay disconnected when engine and exhaust system are hot.
• Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each
hose correctly referring to “Fuel Hose Disconnecting and Reconnecting”.
After connecting, make sure that it has no twist or kink.
• When installing injector or fuel feed pipe, lubricate its O-ring with gasoline.
• When servicing the fuel tank, it should be treated with respect, with no contact with sharp edges or
hot surfaces. In addition, the fuel tank should not be dropped since fuel tank, fuel pump and other
components can be damaged by the impact. If dropped, all components should be replaced because
there is a risk of damage.
• The fuel tank is made of resin.
Be sure not to allow solvent (chemical article such as grease and sealant) to attach to the fuel tank
as some chemical reaction may occur, causing the fuel tank to be swollen, hardened or distorted
leakage and resulting in fuel leakage from the fuel tank.

Downloaded from www.Manualslib.com manuals search engine 1G-3 Fuel System:
Schematic and Routing Diagram
Fuel Delivery System DiagramS6RW0D1702001
Diagnostic Information and Procedures
Fuel Pressure InspectionS6RW0D1704001
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

1) Relieve fuel pressure in fuel feed line referring to
“Fuel Pressure Relief Procedure”.
2) Disconnect fuel feed hose from fuel delivery pipe.
3) Connect special tools and hose between fuel feed
hose (1) and fuel delivery pipe as shown in figure,
and clamp hoses securely in order to ensure that no
leaks occur during checking.
Special tool
(A): 09912–58442
(B): 09912–58432
(C): 09912–58490
73 6
1 4
5
8
9
2
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1. Fuel tank 4. Delivery pipe 7. Fuel filter
2. Fuel pump assembly 5. Fuel injector 8. Fuel level sensor (gauge)
3. Fuel pressure regulator 6. Fuel feed line 9. Fuel pump
(C) (B)
(A)
1I5RW0A170002-02

Downloaded from www.Manualslib.com manuals search engine 1G-7 Fuel System:
Clamp other than around fuel tank
For Quick Joint
Disconnecting
1) Remove mud, dust and/or foreign material between
pipe (1) and quick joint (fuel pipe) (2) by blowing
compressed air.
2) Unlock joint lock by inserting special tool between
pipe and quick joint.
Special tool
(A): 09919–47020
3) Disconnect quick joint from pipe.
Reconnecting
Insert quick joint (fuel pipe) to fuel pipe until they lock
securely (a click is heard), and confirm that quick joint
(fuel pipe) is not disconnected by hand.
Fuel Pressure Relief ProcedureS6RW0D1706003
CAUTION!
This work must not be done when engine is
hot. If done so, it may cause adverse effect to
catalyst.

NOTE
If ECM detects DTC(s) after servicing, clear
DTC(s) referring to “DTC Clearance in
Section 1A”.

1) Make sure that engine is cold.
2) Shift transaxle gear shift lever in “Neutral” (shift
select lever in “P” range for A/T model), set parking
brake and block drive wheels.
3) Remove relay / fuse box cover.
4) Disconnect fuel pump relay (1) from relay / fuse box
(2).
5) Remove fuel filler cap in order to release fuel vapor
pressure in fuel tank, and then reinstall it.
[A]: With short pipe, fit hose as far as it reaches pipe joint as shown.
[B]: With the following type pipe, fit hose as far as its peripheral projection
as shown.
[C]: With bent pipe, fit hose as its bent part as shown or till depth “b”.
[D]: With straight pipe, fit hose till depth “b”.
[E]: With red marked pipe, fit hose end reaches red mark on pipe.
[F]: For fuel tank filler hose, insert it to spool or welding-bead.
“a”: Clamp securely at a position 3 – 7 mm (0.12 – 0.27 in.) from hose end.
“b”: 20 – 30 mm (0.79 – 1.18 in.)
“c”: 0 – 5 mm (0 – 0.19 in.)
“d”: 5 – 12 mm (0.2 – 0.47 in.)
“e”: 38 mm (1.50 in.)
I5RW0A170006-01
4. Red mark
1
2
1 2
(A)
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Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-8
6) Start engine and run it until engine stops for lack of
fuel. Repeat cranking engine 2 – 3 times for about 3
seconds each time in order to dissipate fuel pressure
in lines. Fuel connections are now safe for servicing.
7) After servicing, connect fuel pump relay (1) to relay /
fuse box and install relay / fuse box cover.
Fuel Leakage Check ProcedureS6RW0D1706004
After performing any service on fuel system, check to
make sure that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate
fuel pump) and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply
fuel pressure to fuel line until fuel pressure is felt by
hand placed on fuel feed hose.
2) In this state, check to see that there are no fuel
leakages from any part of fuel system.
Fuel Lines On-Vehicle InspectionS6RW0D1706005
CAUTION!
Due to the fact that fuel feed line (1) is under
high pressure, use special care when
servicing it.

Visually inspect fuel lines for evidence of fuel leakage,
hose crack and deterioration or damage.
Make sure all clamps are secure.
Replace parts as needed.
Fuel Pipe Removal and InstallationS6RW0D1706006
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

Removal
1) Relieve fuel pressure in fuel feed line according to
“Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Disconnect fuel hose (3) from fuel pipe (2) at the
front and rear of each fuel pipe referring to “Fuel
Hose Disconnecting and Reconnecting”.
4) Mark the location of clamps (1) on fuel pipes (2), so
that the clamps can be reinstalled to where they
were.
5) Remove clamps (1) from vehicle body, fuel pipes and
brake pipes.
CAUTION!
Be careful not to bent and damage fuel pipes
and brake pipes when removing clamp.

6) Remove fuel pipe (2).
Installation
1) Install clamps to marked location on pipes. If clamp
is deformed, its claw is bent or broken, replace it with
new one.
2) Install pipes with pipe clamps to vehicle.
3) Connect fuel hoses and pipes to each pipe referring
to “Fuel Hose Disconnecting and Reconnecting”.
4) Connect negative cable at battery.
5) With engine OFF, turn ignition switch to ON position
and check for fuel leaks.
1
2
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2
3
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Downloaded from www.Manualslib.com manuals search engine 1G-9 Fuel System:
Fuel Injector On-Vehicle InspectionS6RW0D1706007
1) Using sound scope (1) or such, check operating
sound of injector (2) when engine is running or
cranking.
Cycle of operating sound should vary according to
engine speed.
If no sound or an unusual sound is heard, check
injector circuit (wire or coupler) or injector.
2) Disconnect connector (1) from injector, connect
ohmmeter between terminals of injector and check
resistance.
If resistance is out of reference value greatly,
replace.
Reference resistance of fuel injector
12.0 Ω at 20 °C, 68 °F
3) Connect connector to injector securely.
Fuel Injector Removal and InstallationS6RW0D1706008
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

Removal
1) Relieve fuel pressure according to “Fuel Pressure
Relief Procedure”.
2) Disconnect negative cable at battery.
3) Remove air cleaner case (1) and air suction hose
(2).
4) Disconnect fuel injector couplers.
5) Disconnect fuel feed hose (4) from fuel delivery pipe
(1).
6) Remove fuel delivery pipe bolts (2).
7) Remove fuel injector(s) (3).
I2RH0B170007-01
I2RH0B170008-01
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2
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2
1
4
3
3
I5RW0A170010-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-10
Installation
Reverse removal procedure for installation noting the
following.
• Replace injector O-ring (1) with new one using care
not to damage it.
• Check if cushion (2) is scored or damaged. If it is,
replace with new one.
• Apply thin coat of fuel to O-rings (1), and then install
injectors (3) into delivery pipe (4) and cylinder head.
Make sure that injectors rotate smoothly (6). If not,
probable cause is incorrect installation of O-ring.
Replace O-ring with new one.
• Tighten delivery pipe bolts (5) to specified torque and
make sure that injectors rotate smoothly.
Tightening torque
Fuel delivery pipe bolt (a): 25 N·m (2.5 kgf-m, 18.0
lb-ft)
• After installation, with engine OFF and ignition switch
ON, check for fuel leaks around fuel line connection.Fuel Injector InspectionS6RW0D1706009
WARNING!
• Before starting the following procedure, be
sure to observe “Precautions on Fuel
System Service” in order to reduce the risk
of fire and personal injury.
• Put injector and battery as far away as
possible in order to reduce risk of fire and
personal injury when connecting/
disconnecting test lead to/from battery.

1) Relieve fuel pressure according to “Fuel Pressure
Relief Procedure” if equipped.
2) Disconnect fuel feed hose from delivery pipe.
3) Set special tools as follows.
Special tool
(A): 09912–58421
(B): 09930–88530
(C): 09912–57610
a) Fit washer (1) (inside diameter 13.5 – 14.5
mm(0.532 – 0.570 in.)) to injector (2), and then
install injector to special tool (A).
b) Connect special tool (B) to injector.
c) Install special tool (C) to special tool (A).
d) Connect fuel feed hose to special tool (A).
I3RM0A170011-01
(B)
(A)
(A)(C)
2
1
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Downloaded from www.Manualslib.com manuals search engine 1G-13 Fuel System:
Fuel Tank Removal and InstallationS6RW0D1706011
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

Removal
1) Relieve fuel pressure in fuel feed line according to
“Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Remove fuel filler cap.
4) Insert hose of a hand operated pump into fuel filler
hose (1) and drain fuel in space “A” as shown in
figure.
CAUTION!
Do not force pump hose into fuel tank.

5) Hoist vehicle, and remove clamp (2), fuel filler hose
(1) and breather hose (3) from fuel filler neck.6) Remove exhaust center pipe referring to “Exhaust
Pipe and Muffler Removal and Installation in Section
1K”.
7) Remove propeller shaft (For 4WD model) referring to
“Propeller Shaft Assembly Removal and Installation
in Section 3D”.
8) Due to absence of fuel tank drain plug, drain fuel
tank by pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
CAUTION!
• Do not force pump hose into fuel tank.
• Never store fuel in an open container due
to possibility of fire or explosion.

9) Disconnect quick joint (fuel pipe) (1) from fuel pipes
(2) referring to “Fuel Hose Disconnecting and
Reconnecting”.
10) Support fuel tank (1) with jack (2) and remove its
mounting bolts (3).
11) Lower fuel tank a little as to disconnect wire harness
at connector (1)and ground wire (2), then remove
fuel tank.
2. Inlet check valve
I4RS0B170022-01
1 23
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2
1
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1
2
33
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