wiring diagram SUZUKI SX4 2006 1.G Service Workshop Manual

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.
33
2 2
1
I4JA01000002-01
1
I4JA01000003-01
I2RH01010038-01
I2RH01010039-01
I2RH01010040-01

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 General Information and Diagnosis: 1A-27
Wiring Diagram
61
2
3
REDWHT
REDWHT
REDWHT
REDWHT
E01-3E01-18
E08-1E08-12
E08-2E08-13
G05-1G05-3
RED
WHT
REDWHTG16-19G16-18
5
REDWHTG05-2G05-4
8
9
REDWHT G26-23G26-22
4
REDWHTG241-9
G241-7
G241-10
G241-67
REDWHT
REDWHT
C06-17C06-7
C01-12C01-13 [B]
61
2
3
REDWHT
REDWHT
REDWHT
REDWHT
REDWHT
E01-3E01-18
E08-1E08-12
E08-2E08-13
E04-1E04-2
G04-4G04-2
REDWHT
REDWHTG16-19G16-18
5
REDWHTG04-3G04-1
8
9
REDWHT G26-23G26-22
4
REDWHTG241-9
G241-7G241-10
G241-67
REDWHT
REDWHT
C06-17C06-7
C01-12C01-13 [A]
87 6543 219 10 11 12 13 14 15 16
[C]
[D]
21
3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53
59
60
582
26 27 28 15
30
56
4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238 3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 5121 22
5216 259
24 14
29
55 57 54 53
59
605826
27
28 15
30
56
4832 31 34 35 36 37 40 42 39 38 44
45 43 41 3312 13
238 E01 C011 2 3 10 11 12
16 17 18 15 14 13 19 20 21 25 24 23 22 2654 6 7 8 9 [E]
G26
65
15 16 14 13 12 1143
24 23 212210 9 8 721
19 20 18 17 C06 [F]1 2 3 4 7 8 9 10 11 14 15 16
36 3435 24 23
21 22 28 27 2526 37 39 38 4018 17 13 12 19 20
[G]
G16
[K]
1
17G2413 2 4 5 6 7 8 9 10111213141516
19 18 20 2122 23 24 25 26 27 28 29 30 31 32 [J]E081 2 3 4 5 6 712 13 14 15 16 17 18 19 20 21 22
8 9 10 11 23 24 25 26
1 2 3 4 5 6 7
1 2 3 4 5 6 7 8 9 10 11
8 9 10 11
12 13 1412 13 14
15 16 17
18 19 20 21 22G04 E04 [H]1 [I]
G05
2 3 4 7 8 9 10 11 14 15 16
36 3435 24 23 2122 28 27 2526 37 39 38 4018 17 13 12 19 2065
33 32 31 30 29
I6RW0D110017-01

Downloaded from www.Manualslib.com manuals search engine 1A-52 Engine General Information and Diagnosis:
Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but
Engine Can Be Started)
S6RW0D1104011
Wiring Diagram
Circuit Description
When the ignition switch is turned ON, ECM causes the main relay to turn ON (close the contact point). Then, ECM
being supplied with the main power, transmits indication ON signal of malfunction indicator lamp (MIL) to combination
meter in order to turn MIL ON. And then, combination meter turns MIL ON. When the engine starts to run and no
malfunction is detected in the system, ECM transmits MIL indication OFF signal to combination meter in order to turn
MIL OFF. And then, combination meter turns MIL OFF, but if a malfunction was or is detected, MIL remains ON even
when the engine is running.
BLK/WHT
BLK/RED
BLK/RED
BLK/RED
WHTBLK/YEL
BLK/YEL
RED/BLK
BLK/YEL
GRN
BRN/WHT
12V5V
2
3 8
6
57
REDWHTREDWHT
REDWHTREDWHT
E01-29
E01-3
E01-1
E01-60
E01-18
E01-16
BLK/ORN49
13
10 12 11G241-31
1414
G241-16
[A]
E01 C01
3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238 3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238G2411 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
[B]
1
C01-58
C01-15 C01-30
BLK/ORN
BLKBLKBLK
15
E01-31
REDWHTREDWHTC01-13 C01-12
1614
I6RW0D110018-02
[A]: ECM connector (viewed from harness side) 5. “IG COIL” fuse 11. Individual circuit fuse box No.1
[B]: Combination meter connector (viewed from harness side) 6. “METER” fuse 12. “IGN” fuse
1. Main fuse box 7. ECM 13. BCM
2. Ignition switch 8. Junction block assembly 14. CAN communication line
3. Main relay 9. ABS control module 15. To other control module (if equipped)
4. Malfunction indicator lamp in combination meter 10. “FI” fuse 16. TCM (for A/T model)

Downloaded from www.Manualslib.com manuals search engine 1A-54 Engine General Information and Diagnosis:
Malfunction Indicator Lamp Remains ON after Engine StartsS6RW0D1104012
Wiring Diagram
Refer to “Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can
Be Started)”.
Circuit Description
When the ignition switch is turned ON, ECM causes the main relay to turn ON (close the contact point). Then, ECM
being supplied with the main power, transmits indication ON signal of malfunction indicator lamp (MIL) to combination
meter in order to turn MIL ON. And then, combination meter turns MIL ON. When the engine starts to run and no
malfunction is detected in the system, ECM transmits MIL indication OFF signal to combination meter in order to turn
MIL OFF. And then, combination meter turns MIL OFF, but if a malfunction was or is detected, MIL remains ON even
when the engine is running.
Troubleshooting
NOTE
• 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”.

Step Action Yes No
1DTC check
1) Start engine and recheck DTC of ECM and TCM (for A/T
model) while engine running.
Is there any DTC(s)?Go to Step 2 of “Engine
and Emission Control
System Check”, Step 2
of “A/T System Check in
Section 5A”.Go to Step 2.
2CAN communication line circuit check
1) Check CAN communication line circuit between control
modules for open, short, high resistance and
connections referring to Step 5 to 10 under
“Troubleshooting for Communication Error with Scan
Tool Using CAN”.
Is circuit in good condition?Substitute a known-
good combination meter
and recheck. If MIL still
remains ON, substitute
a known-good ECM and
recheck.Repair or replace CAN
communication circuit.

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-55
DTC P0010: Camshaft Position Actuator Circuit (for engine with VVT system)S6RW0D1104013
System and Wiring Diagram
Circuit Description
Actual valve timing fails to become close to target advance level of each function although advance control function or
retarded advance control function is at work.
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
1) Clear DTC. Refer to “DTC Clearance”.
2) Start engine and keep it at idle for 10 seconds.
3) Check DTC. Refer to “DTC Check”.
3
7
1
[A]:45
6
C01-58
C01-15
C01-30
E01-31BLK
BLK
BLK/ORN
RED
YEL
GRN/RED
GRN/WHT
C01-60
C01-59
3
2
1
E01C01
3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238 3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238
BLK
I6RW0D110019-01
[A]: Oil flow 2. ECM 4. Oil filter 6. Oil pan
1. Oil control valve 3. Camshaft timing sprocket 5. Oil pump 7. Intake camshaft
DTC detecting condition Trouble area
Monitor signal of oil control valve is different from command signal. (Circuit open or short)
(1 driving cycle detection logic)• Oil control valve
• Oil control valve circuit
•ECM

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DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)S6RW0D1104015
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and warm up to normal operating temperature.
4) Run engine at idle speed for 1 min. or more.
5) Check DTC and pending DTC.
DTC Troubleshooting
NOTE
Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to
“Precautions for DTC Troubleshooting”.

E01C01
3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238 3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238
BLK/WHT
WHT
11
GRN
39
E01-29
WHT
ORN
BLK/WHT
BLKC01-46
C01-10
C01-57
6
7
10
BLK
BLUWHT
BLK/RED
1
4
5
8
12
I6RW0D110020-01
1. Main fuse box 4. Junction block assembly 7. Heater 10. To HO2S-2
2. Shield wire 5. “IG COIL” fuse 8. To HO2S-2 heater 11. Individual circuit fuse box No.1
3. Ignition switch 6. HO2S-1 9. ECM 12. “IGN” fuse
DTC detecting condition Trouble area
Voltage of HO2S-1 heater is more than specified value or lower than specified value for
5 seconds even through its control duty ratio is within 25 – 75%.
(2 driving cycle detection logic)• HO2S-1 heater circuit
• HO2S-1 heater
•ECM
Step Action Yes No
1Was “Engine and Emission Control System Check”
performed?Go to Step 2. Go to “Engine and
Emission Control
System Check”.

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-61
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)S6RW0D1104016
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and warm up to normal operating temperature.
4) Run engine at idle speed for 1 min.
5) Check DTC and pending DTC.
DTC Troubleshooting
NOTE
Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to
“Precautions for DTC Troubleshooting”.

E01C01
3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238 3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238
BLK/WHT
WHT
11
GRN
39
E01-29
BRN
ORN
BLK/WHT
BLKC01-47
C01-11
C01-57
6
2 7
10
BLK
BLUWHT
RED/BLU
1
4
5
8
12
5V
I6RW0D110021-01
1. Main fuse box 4. Junction block assembly 7. Heater 10. To HO2S-1
2. Shield wire 5. “IG COIL” fuse 8. To HO2S-1 heater 11. Individual circuit fuse box No.1
3. Ignition switch 6. HO2S-2 9. ECM 12. “IGN” fuse
DTC detecting condition Trouble area
Voltage of HO2S-2 heater is more than specified value or less than specified value for
5 seconds even through its control duty ratio is within 25 – 75%.
(2 driving cycle detection logic)• HO2S-2 heater
• HO2S-2 heater circuit
•ECM
Step Action Yes No
1Was “Engine and Emission Control System Check”
performed?Go to Step 2. Go to “Engine and
Emission Control
System Check”.

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-63
DTC P0101: Mass Air Flow Circuit Range / PerformanceS6RW0D1104017
Wiring Diagram
DTC Detecting Condition and Trouble Area
E01C01
3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238 3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238
BLK/WHT
BLK/RED
BLK/RED
WHTBLK/YELBLK/YEL
BLK/YEL
GRN
BRN/WHT
12V5V
5V
2
34E01-29
E01-1
E01-60
C01-58
C01-15 C01-30
BLK/ORN
BLKBLK
BLK/REDE01-16
BLK/YEL
GRY/BLU
1BLK/RED
C01-25
C01-55 5
E01-31 BLK
GRY/BLU
GRY
GRN/BLKC01-26
C01-27
I6RW0D110022-02
1. MAF and IAT sensor 3. Main relay 5. To other sensors
2. Ignition switch 4. ECM
DTC detecting condition Trouble area
• MAF volume is greater than specified value after warming up engine with
idling condition.
• MAF volume is lower than specified value at high speed condition.
(2 driving cycle detection logic)• Air intake system (clog or leakage)
• MAF sensor circuit
• MAF sensor
• TP sensor and/or its circuit
• MAP sensor and/or its circuit
•ECM

Downloaded from www.Manualslib.com manuals search engine 1A-66 Engine General Information and Diagnosis:
DTC P0102: Mass Air Flow Circuit Low InputS6RW0D1104018
Wiring Diagram
Refer to “DTC P0101: Mass Air Flow Circuit Range / Performance”.
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and run it for 10 sec.
4) Check DTC and pending DTC.
DTC Troubleshooting
NOTE
Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to
“Precautions for DTC Troubleshooting”.

10MAF sensor signal circuit check
1) Measure resistance between “GRN/BLK” wire terminal
of MAF and IAT sensor connector and “C01-26” terminal
of ECM connector.
Is resistance below 3
Ω?Faulty MAF and IAT
sensor.“GRN/BLK” wire is open
or high resistance
circuit.
11Is DTC P0106 displayed?Go to “DTC P0106:
Manifold Absolute
Pressure Range /
Performance”.Substitute a known-
good ECM and recheck. Step Action Yes No
DTC detecting condition Trouble area
Voltage of MAF sensor output is less than specified value for specified time
with engine running.
(1 driving cycle detection logic)• Open or short in MAF sensor circuit
• MAF sensor
•ECM
Step Action Yes No
1Was “Engine and Emission Control System Check”
performed?Go to Step 2. Go to “Engine and
Emission Control
System Check”.
2MAF sensor and its circuit check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Start engine and check MAF value displayed on scan
tool. (Refer to “Scan Tool Data” for normal value.)
Is normal value indicated?Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.Go to Step 3.
3MAF sensor power supply voltage check
1) Disconnect connector from MAF and IAT sensor with
ignition switch turned OFF.
2) Turn ON ignition switch, measure voltage between
engine ground and “BLK/RED” wire terminal of MAF and
IAT sensor connector.
Is voltage 10 – 14 V?Go to Step 4. “BLK/RED” wire is open
circuit.