service SUZUKI SX4 2006 1.G Service Workshop Manual

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

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

Downloaded from www.Manualslib.com manuals search engine 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 Table of Contents 00- i
00
Section 00
CONTENTS
Precautions
Precautions ............................................... 00-1
Precautions........................................................... 00-1
Precautions for Vehicles Equipped with a
Supplemental Restraint (Air Bag) System ........ 00-1
General Precautions ........................................... 00-3
Warning for Wheel (with tire) Removal ............... 00-6
Precautions in Servicing 4WD Model .................. 00-7
Precautions for Catalytic Converter .................... 00-7
Precautions for Installing Mobile
Communication Equipment ............................... 00-8
Precaution for CAN Communication System ...... 00-8Precautions for Electrical Circuit Service ............ 00-8
Air Bag Warning ................................................ 00-10
Air Bag System Service Warning ...................... 00-10
Fastener Caution............................................... 00-11
Suspension Caution .......................................... 00-11
Wheels and Tires Caution ................................. 00-11
Brake Caution ................................................... 00-11
Repair Instructions ............................................ 00-12
Electrical Circuit Inspection Procedure ............. 00-12
Intermittent and Poor Connection Inspection .... 00-14

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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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.
1
2
3
[A]
[B]
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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.
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Downloaded from www.Manualslib.com manuals search engine 00-7 Precautions:
Precautions in Servicing 4WD ModelS6RW0D0000014
CAUTION!
• Never perform any of the following [A], [B]
and [C] types of service work.
If it is performed while 4WD-auto mode or
4WD-lock mode is selected, front wheels
(or rear wheels) drive rear wheels (or front
wheels) and vehicle accident, drivetrain
damage and personal injury may result.
Also, if it is performed while 2WD mode is
selected, the coupling may be damaged
because of the difference in revolution
speed between front wheels and rear
wheels.
• When testing with 2-wheel chassis
dynamometer or speedometer tester, be
sure to select 4WD system to 4WD-auto
mode or 4WD-lock mode and use 2-wheel
free roller together or make the vehicle as
front wheel drive by removing propeller
shaft.• When testing with 2-wheel brake tester, be
sure to observe the following instructions.
Otherwise, drivetrain damage and personal
injury may result.
– Shift transaxle to N (Neutral) position.
– Select 4WD system to 2WD mode.
– Run engine at specified idle speed.
– Rotate wheels (tires) by brake tester at
vehicle speed below 5 km/h (3 mile/h).
– Do not rotate wheels (tires) for 1 min. or
more.
• When using On-vehicle type wheel
balancing equipment (1), be sure to select
4WD system to 4WD-auto mode or 4WD-
lock mode and jack up all four wheels, off
the ground completely and support vehicle
with safety stands (2).
Be careful of other wheels, which will
rotate at the same time.
Using it with 2WD mode may damage
coupling.
• This vehicle should be towed under one of
the following conditions:
– With all wheels on a flatbed truck.
– With all wheels on the ground.

Precautions for Catalytic ConverterS6RW0D0000004
For vehicles equipped with a catalytic converter, use
only unleaded gasoline and be careful not to let a large
amount of unburned gasoline enter the converter or it
can be damaged.
• Conduct a spark jump test only when necessary,
make it as short as possible, and do not open the
throttle.
• Conduct engine compression checks within the
shortest possible time.
• Avoid situations which can result in engine misfire
(e.g. starting the engine when the fuel tank is nearly
empty.)[A]: Testing with 2-wheel chassis dynamometer or speedometer tester.
[B]: Driving front wheels, which are jacked up.
[C]: Towing under the condition where either front or rear wheels can not
rotate.
[A]
[B]
[C]
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Downloaded from www.Manualslib.com manuals search engine Precautions: 00-8
Precautions for Installing Mobile
Communication Equipment
S6RW0D0000005
When installing mobile communication equipment such
as CB (Citizens-Band)-radio or cellular-telephone, be
sure to observe the following precautions.
Failure to follow cautions may adversely affect electronic
control system.
• Keep the antenna as far away as possible from the
vehicle’s electronic control unit.
• Keep the antenna feeder more than 20 cm (7.9 in.)
away from electronic control unit and its wire
harnesses.
• Do not run the antenna feeder parallel with other wire
harnesses.
• Confirm that the antenna and feeder are correctly
adjusted.
Precaution for CAN Communication SystemS6RW0D0000006
• The loose (1) in the wire harnesses twist of the CAN
lines except around the connector (3) should be within
100 mm (3.9 in.). Refer to the wiring diagram for the
CAN lines discrimination. Excessively-loosed lines
may be influenced by the electric noise.
• Do not connect terminals of the CAN line using a
bypass wire (1). Otherwise, the CAN line may be
influenced by the electric noise.
Precautions for Electrical Circuit ServiceS6RW0D0000007
• When replacing a fuse, make sure to use a fuse of the
specified capacity. Use of a fuse with a larger capacity
will cause a damage to the electrical parts and a fire.
• When disconnecting and connecting coupler, make
sure to turn ignition switch OFF, or electronic parts
may get damaged.
• When disconnecting connectors, never pull the wiring
harness. Unlock the connector lock first and then pull
them apart by holding connectors themselves.
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