seat 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 RECOMMENDATON OF GENUINE SUZUKI PARTS AND ACCESSORIES USE
SUZUKI strongly recommends the use of genuine SUZUKI parts* and accessories. Genuine SUZUKI parts and
accessories are built to the highest standards of quality and performance, and are designed to fit the vehicle’s
exact specifications.
A wide variety of non-genuine replacement parts and accessories for SUZUKI vehicles are currently available in
the market. Using these parts and accessories can affect the vehicle performance and shorten its useful life.
Therefore, installation of non-genuine SUZUKI parts and accessories is not covered under warranty.
Non-Genuine SUZUKI Parts and Accessories
Some parts and accessories may be approved by certain authorities in your country.
Some parts and accessories are sold as SUZUKI authorized replacement parts and accessories. Some genu-
ine SUZUKI parts and accessories are sold as re-use parts and accessories. These parts and accessories are
non-genuine Suzuki parts and accessories and use of these parts are not covered under warranty.
Re-use of Genuine SUZUKI Parts and Accessories
The resale or re-use of the following items which could give rise to safety hazards for users is expressly forbid-
den:
1) Airbag components and all other pyrotechnic items, including their components (e.g. cushion, control
devices and sensors)
2) Seatbelt system, including their components (e.g. webbing, buckles, and retractors)
The air bag and seat belt pretensioner components contain explosive chemicals. These components should be
removed and disposed of properly by SUZUKI authorized service shop or scrap yard to avoid unintended explo-
sion before scrapping.
*The parts remanufactured under SUZUKI's approval can be used as genuine SUZUKI parts in Europe.

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 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)
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I5RW0A000001-01
I4RS0A000002-02

Downloaded from www.Manualslib.com manuals search engine Precautions: 00-2
Servicing and Handling
WARNING!
Many of service procedures require
disconnection of “A/B” fuse and all air bag
(inflator) module(s) from initiator circuit to
avoid an accidental deployment.
Driver, Passenger, Side and Curtain Air Bag
(Inflator) Modules
• For handling and storage of a live air bag
(inflator) module, select a place where the
ambient temperature below 65 °C (150 °F),
without high humidity and away from
electric noise.
• When carrying a live air bag (inflator)
module, make sure the bag opening is
pointed away from you. In case of an
accidental deployment, the bag will then
deploy with minimal chance of injury.
Never carry the air bag (inflator) module by
the wires or connector on the underside of
the module. When placing a live air bag
(inflator) module on a bench or other
surface, always face the bag up, away from
the surface. As the live passenger air bag
(inflator) module must be placed with its
bag (trim cover) facing up, place it on the
workbench with a slit (1) or use the
workbench vise (2) to hold it securely at its
lower mounting bracket (3). It is also
prohibited to place anything on top of the
trim cover and stack air bag (inflator)
modules. This is necessary so that a free
space is provided to allow the air bag to
expand in the unlikely event of accidental
deployment. Otherwise, personal injury
may result.
• Never dispose of live (undeployed) air bag
(inflator) modules (driver, passenger, side
and curtain). If disposal is necessary, be
sure to deploy them according to
deployment procedures described in “Air
Bag (Inflator) Module and Seat Belt
Pretensioner Disposal in Section 8B”
before disposal.
• The air bag (inflator) module immediately
after deployment is very hot. Wait for at
least half an hour to cool it off before
proceeding the work.• After an air bag (inflator) module has been
deployed, the surface of the air bag may
contain a powdery residue. This powder
consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by-
products of the chemical reaction. As with
many service procedures, gloves and
safety glasses should be worn.

[A]: Always carry air bag (inflator) module with trim cover (air bag opening)
away from body.
[B]: Always place air bag (inflator) module on workbench with trim cover (air
bag opening) up, away from loose objects.
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[B]
I4RS0A000003-02

Downloaded from www.Manualslib.com manuals search engine 00-3 Precautions:
WARNING!
SDM
• For handling and storage of a SDM, select
a place where the ambient temperature
below 65 °C (150 °F), without high humidity
and away from electric noise.
• During service procedures, be very careful
when handling a Sensing and Diagnostic
Module (SDM). Never strike or jar the SDM.
• Never power up the air bag system when
the SDM is not rigidly attached to the
vehicle. All SDM and mounting bracket
fasteners must be carefully torqued and
the arrow must be pointing toward the
front of the vehicle to ensure proper
operation of the air bag system.
The SDM could be activated when powered
while not rigidly attached to the vehicle
which could cause deployment and result
in personal injury.

WARNING!
Driver and Passenger Seat Belt
Pretensioners
• For handling and storage of a live seat belt
pretensioner, select a place where the
ambient temperature below 65 °C (150 °F),
without high humidity and away from
electric noise.
• Never carry seat belt pretensioner by wire
or connector of pretensioner. When
placing a live seat belt pretensioner on the
workbench or some place like that, never
put something on seat belt pretensioner.
Otherwise, personal injury may result.
• Never dispose of live (inactivated) seat belt
pretensioners (drive and passenger). If
disposal is necessary, be sure to activate
them according to activation procedures
described in “Air Bag (Inflator) Module and
Seat Belt Pretensioner Disposal in Section
8B” before disposal.
• The seat belt pretensioner immediately
after activation is very hot. Wait for at least
half an hour to cool it off before
proceeding the work.
• With many service procedures, gloves and
safety glasses should be worn to prevent
any possible irritation of the skin or eyes.

• Even when the accident was light enough not to
cause air bags to activate, be sure to inspect system
parts and other related parts according to instructions
under “Repair and Inspection Required after Accident
in Section 8B”.
• When servicing parts other than air bag system, if
shocks may be applied to air bag system component
parts, remove those parts beforehand.
• When handling the air bag (inflator) modules (driver,
passenger, side and curtain), seat belt pretensioners
(driver and passenger), forward sensor, side sensors
or SDM, be careful not to drop it or apply an impact to
it. If an excessive impact was applied, never attempt
disassembly or repair but replace it with a new one.
• When grease, cleaning agent, oil, water, etc. has got
onto air bag (inflator) modules (driver, passenger, side
and curtain) or seat belt pretensioners (drive and
passenger), wipe off immediately with a dry cloth.
• Air bag wire harness is included in floor and
instrument panel wire harnesses. Air bag wire
harness branched off from floor and instrument panel
wire harnesses can be identified easily as it is covered
with a yellow protection tube and it has yellow
connectors. Be very careful when handling it.
• When an open in air bag wire harness, damaged wire
harness, connector or terminal is found, replace wire
harness, connectors and terminals as an assembly.
• Do not apply power to the air bag system unless all
components are connected or a diagnostic flow
requests it, as this will set a DTC.
• Never use air bag system component parts from
another vehicle.
• When using electric welding, be sure to disconnect all
air bag (inflator) module connectors and pretensioner
connectors from air bag wire harness respectively.
• Never expose air bag system component parts
directly to hot air (drying or baking the vehicle after
painting) or flames.
• WARNING / CAUTION labels are attached on each
part of air bag system components. Be sure to follow
the instructions.
• After vehicle is completely repaired, perform “Air Bag
Diagnostic System Check in Section 8B”.
General PrecautionsS6RW0D0000002
The WARNING and CAUTION describe some general
precautions that you should observe when servicing a
vehicle. These general precautions apply to many of the
service procedures, and they will not necessarily be
repeated with each procedure to which they apply.

Downloaded from www.Manualslib.com manuals search engine Precautions: 00-4
WARNING!
• Whenever raising a vehicle for service, be
sure to follow the instructions under
“Vehicle Lifting Points in Section 0A”.
• When it is necessary to do service work
with the engine running, make sure that
the parking brake is set fully and the
transmission is in Neutral (for manual
transmission vehicles) or Park (for
automatic transmission vehicles), Keep
hands, hair, clothing, tools, etc. away from
the fan and belts when the engine is
running.
• When it is necessary to run the engine
indoors, make sure that the exhaust gas is
forced outdoors.
• Do not perform service work in areas
where combustible materials can come in
contact with a hot exhaust system. When
working with toxic or flammable materials
(such as gasoline and refrigerant), make
sure that the area you work in is well-
ventilated.
• To avoid getting burned, keep away from
hot metal parts such as the radiator,
exhaust manifold, tail pipe, muffler, etc.
• New and used engine oil can be
hazardous. Children and pets may be
harmed by swallowing new or used oil.
Keep new and used oil and used engine oil
filters away from children and pets.
Continuous contact with used engine oil
has been found to cause [skin] cancer in
laboratory animals. Brief contact with used
oil may irritate skin. To minimize your
exposure to used engine oil, wear a long-
sleeve shirt and moisture-proof gloves
(such as dish washing gloves) when
changing engine oil. If engine oil contacts
your skin, wash thoroughly with soap and
water. Launder any clothing or rags if wet
with oil, recycle or properly dispose of
used oil and filters.
• Be sure to observe following instructions
when handling service materials such as
fuel, oil, fluid, coolant, grease, sealant,
thread lock cement, etc. Otherwise, your
health may be ruined.
– Whenever handling any of these service
materials, wear safety glasses to protect
your eyes. If it gets into your eye, it may
cause inflammation.
– Whenever handling any of these service
materials, wear moisture-proof gloves to
protect your skin. If it adheres to your
skin, it may cause inflammation.– Do not swallow any of these service
materials. It would cause diarrhea or
nausea.
– Keep all these materials out of children’s
reach.
• Make sure the bonnet is fully closed and
latched before driving. If it is not, it can fly
up unexpectedly during driving,
obstructing your view and resulting in an
accident.

• Before starting any service work, cover fenders, seats
and any other parts that are likely to get scratched or
stained during servicing. Also, be aware that what you
wear (e.g., buttons) may cause damage to the
vehicle’s finish.
• When performing service to electrical parts that does
not require use of battery power, disconnect the
negative cable of the battery.
• When disconnecting the negative cable from the
battery, be careful to the following.
– Check and record DTCs in ECM, HVAC control
module and/or PS control module if necessary
before disconnecting.
– Record displayed contents of the clock and/or
audio system, etc. before disconnecting and reset it
as before after connecting.
– For vehicle equipped with electric throttle body
system, perform electric throttle body system
calibration referring to “Electric Throttle Body
System Calibration in Section 1C” after
reconnecting the negative cable to the battery.
I2RH01010025-01
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Downloaded from www.Manualslib.com manuals search engine Precautions: 00-14
Intermittent and Poor Connection InspectionS6RW0D0006002
Most intermittent are caused by faulty electrical
connections or wiring, although a sticking relay or
solenoid can occasionally be at fault. When checking it
for proper connection, perform careful check of suspect
circuits for:
• Poor mating of connector halves, or terminals not fully
seated in the connector body (backed out).
• Dirt or corrosion on the terminals. The terminals must
be clean and free of any foreign material which could
impede proper terminal contact. However, cleaning
the terminal with a sand paper or the like is prohibited.
• Damaged connector body, exposing the terminals to
moisture and dirt, as well as not maintaining proper
terminal orientation with the component or mating
connector.
• Improperly formed or damaged terminals.
Check each connector terminal in problem circuits
carefully to ensure good contact tension by using the
corresponding mating terminal.
If contact tension is not enough, reform it to increase
contact tension or replace.• Poor terminal-to-wire connection.
Check each wire harness in problem circuits for poor
connection by shaking it by hand lightly. If any
abnormal condition is found, repair or replace.
• Wire insulation which is rubbed through, causing an
intermittent short as the bare area touches other
wiring or parts of the vehicle.
• Wiring broken inside the insulation. This condition
could cause continuity check to show a good circuit,
but if only 1 or 2 strands of a multi-strand-type wire
are intact, resistance could be far too high.
If any abnormality is found, repair or replace.
1. Check contact tension by inserting and removing just once.
2. Check each terminal for bend and proper alignment.
I2RH01010057-01
I5RH01000007-01
I2RH01010059-01
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Downloaded from www.Manualslib.com manuals search engine General Information: 0A-8
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I6RW0D010001-01
1. Air bag label on driver air bag (inflator) module 6. Air bag label on SDM
2. Air bag label on contact coil assembly 7. Pretensioner label on seat belt retractor
3. Air bag label on passenger air bag (inflator) module 8. Side/Curtain air bag label on pillar (both right and left sides) (if equipped)
4. Air bag label on side air bag (inflator) module (if equipped) [A]: These labels are attached on vehicle equipped with air bag system only.
5. Air bag label on curtain air bag (inflator) module

Downloaded from www.Manualslib.com manuals search engine 0B-11 Maintenance and Lubrication:
HVAC Air Filter (If Equipped) InspectionS6RW0D0206034
Check HVAC air filter for dirt and dust referring to “HVAC
Air Filter Inspection (If Equipped) in Section 7A”. If air
filter is dirty, clean or replace air filter with new one.
HVAC Air Filter (If Equipped) ReplacementS6RW0D0206035
Replace HVAC air filter with new one referring to “HVAC
Air Filter Removal and Installation (If Equipped) in
Section 7A”.
Final Inspection for Maintenance ServiceS6RW0D0206036
WARNING!
When carrying out road tests, select a safe
place where no man or no running vehicle is
seen so as to prevent any accident.

Seats
Check that seat slides smoothly and locks securely at
any position. Also check that reclining mechanism of
front seat back allows it to be locked at any angle.
Seat Belt
Inspect belt system including webbing, buckles, latch
plates, retractors and anchors for damage or wear.
Check that seat belt is securely locked. If “REPLACE
BELT” label on seat belt is visible, replace belt.
Battery Electrolyte Level Check
Check that the electrolyte level of all battery cells is
between the upper and lower level lines on the case. If
battery is equipped with built-in indicator, check battery
condition by the indicator.
Accelerator Pedal Operation
Check that pedal operates smoothly without getting
caught or interfered by any other part.
Engine Start
Check engine start for readiness.
WARNING!
Before performing the following check, be
sure to have enough room around the
vehicle. Then, firmly apply both the parking
brake and the regular brakes. Do not use the
accelerator pedal. If the engine starts, be
ready to turn off the ignition promptly. Take
these precautions because the vehicle could
move without warning and possibly cause
personal injury or property damage.

On automatic transaxle vehicles, try to start the engine in
each select lever position. The starting motor should
crank only in “P” (Park) or “N” (Neutral).
On manual transaxle vehicles, place the shift lever in
“Neutral,” depress clutch pedal fully and try to start.
Exhaust System Check
Check for leakage, cracks or loose supports.
Clutch (for Manual Transaxle)
Check for the following.
• Clutch is completely released when depressing clutch
pedal,
• No slipping clutch occurs when releasing pedal and
accelerating.
• Clutch itself is free from any abnormal condition.
Gearshift or Select Lever
Check gear shift or select lever for smooth shifting to all
positions and for good performance of transaxle in any
position.
With automatic transaxle equipped vehicle, also check
that shift indicator indicates properly according to which
position select lever is shifted to.
With automatic transaxle equipped vehicle, make sure
that vehicle is at complete stop when shifting select lever
to “P” range position and release all brakes.
Brake
Foot brake
Check the following:
• that brake pedal has proper travel,
• that brake works properly,
• that it is free from noise,
• that vehicle does not pull to one side when brake is
applied.
• and that brake do not drag.
Parking brake
Check that lever has proper travel.
WARNING!
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property
damage. Be prepared to apply regular brake
quickly even if vehicle should start to move.

Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and brake
lever is pulled all the way.