2006 SUZUKI SX4 Engine Mechanical

Downloaded from www.Manualslib.com manuals search engine 1J-4 Charging System:
Diagnostic Information and Procedures
Battery InspectionS6RW0D1A04001
Common Causes of Failure
A battery is not designed to last indefinitely; however,
with proper care, it will provide many years of service. If
the battery performs satisfactorily during test buy fails to
operate properly for no apparent reason, the following
are some factors that may point to the cause of trouble:
• Accessories left on overnight or for an extended
period without the generator operating.
• Slow average driving speed for short periods.
• Electrical load exceeding generator output particularly
with addition of aftermarket equipment.
• Defects in charging system such as high resistance,
slipping drive belt, loose generator output terminal,
faulty generator or voltage regulator. Refer to
“Generator Symptom Diagnosis”.
• Battery abuse, including failure to keep battery cable
terminals clean and tight or loose battery hold down.
• Mechanical problems in electrical system such as
shorted or pinched wires.
Visual Inspection
Check for obvious damage, such as cracked or broken
case or cover, that could permit loss of electrolyte. If
obvious damage is noted, replace battery. Determine
cause of damage and correct as needed.
Generator Symptom DiagnosisS6RW0D1A04002
CAUTION!
• Do not mistake polarities of “IG” terminal
and “L” terminal.
• Do not create short circuit between “IG”
and “L” terminals. Always connect these
terminals through a lamp.
• Do not connect any load between “L” and
“E” terminals.
• When connecting charger or booster
battery to vehicle battery, refer to “Jump
Starting in Case of Emergency”.

Trouble in charging system will show up as one or more
of the following conditions:
1) Faulty indicator lamp operation.
2) An undercharged battery as evidenced by slow
cranking or indicator dark.
3) An overcharged battery as evidenced by excessive
spewing of electrolyte from vents.
Noise from generator may be caused by loose drive
pulley, loose mounting bolts, worn or dirty bearings,
defective diode, or defective stator.
B: Generator output (Battery terminal) IG: Ignition terminal
C: C terminal L: Lamp terminal
E: Ground FR: Field duty monitor
F: Field coil terminal
E FFRC
B
IG
L
I6RW0D1A0003-01

Downloaded from www.Manualslib.com manuals search engine 4A-1 Brake Control System and Diagnosis:
Brakes
Brake Control System and Diagnosis
Precautions
Precautions on BrakeS6RW0D4100001
Air Bag Warning
Refer to“Air Bag Warning in Section 00”.
Brakes Diagnosis Note
Refer to “Brakes Diagnosis Note”.
General Description
Brakes ConstructionS6RW0D4101001
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two
in front and four in rear).
The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make two
independent circuits. One connects front right & rear left brakes and the other connects front left & rear right brakes.
In this brake system, the disc brake is used for the front wheel brake and drum brake (leading / trailing shoes) for the
rear brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and
mechanical linkage system. The same brake shoes of rear drum brake are used for both parking and foot brakes.
NOTE
• The figures show LH steering vehicle.
• The difference between RH steering vehicle and LH steering vehicle is the location of the brake
master cylinder, the brake booster and ABS hydraulic unit / control module assembly.

A
421
37
7
658
I7RW01410001-01
1. Brake booster 4. Primary side 7. Parking brake cable
2. Master cylinder 5. ABS hydraulic unit / control module assembly 8. 4-way joint
3. Secondary side 6. Parking brake lever A: Forward

Downloaded from www.Manualslib.com manuals search engine 5A-30 Automatic Transmission/Transaxle:
Manual Road TestS6RW0D5104011
WARNING!
Carry out test in very little traffic area to prevent an accident.
Test requires 2 persons, a driver and a tester.

The purpose of this test is to judge whether causal factor of trouble which occurred in automatic transaxle is electrical
or mechanical by disconnecting valve body harness connector (1) and fixing automatic transaxle gear position.
1) Start engine and warm it up to normal operating temperature.
2) Turn ignition switch to OFF position and disconnect valve body harness connector (1).
3) Turn OFF all electrical loads.
With select lever shifted to each range (“L”, “2”, “3” and “D”), drive vehicle at 1,000 rpm engine speed and then
check vehicle speed by referring to “Fixed gear position”.
If vehicle speed is not as specified in “Fixed gear position” table, go to troubleshooting.
4) Connect valve body harness connector and clear DTC.
Fixed gear position
Troubleshooting
Engine Brake TestS6RW0D5104012
WARNING!
Before test, make sure that there is no vehicle behind so as to prevent rear-end collision.

1) While driving vehicle in 3rd gear of “D” range, shift select lever down to “2” range and check if engine brake
operates.
2) In the same way as in Step 1), check engine brake for operation when select lever is shifted down to “L” range.
3) Engine brake should operate in the test.
TroubleshootingSelect lever position Fixed gear position Vehicle speed
L range
3rd gear Approx. 25.0 km/h (15.5 mile/h) 2 range
3 range
D range
R range Reverse gear Approx. 10.9 km/h (6.8 mile/h)
1
I5RW0C510010-01
Condition Possible cause Correction / Reference Item
Operated gear is not
correctFaulty valve body componentReplace valve body assembly.
Faulty clutch or brakeInspect clutch and brake. If any parts are faulty,
replace them.
Condition Possible cause Correction / Reference Item
Failure to operate when
shifted down to “2” rangeFaulty valve body componentReplace valve body assembly.
Faulty O/D and 2nd coast brakeInspect. If NG, replace.
Failure to operate when
shifted down to “L” rangeFaulty valve body componentReplace valve body assembly.
Faulty 1st and reverse brakeInspect. If NG, replace.

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-53
DTC P0741 / P0742: TCC Circuit Performance or Stuck OFF / TCC Circuit Stuck ONS6RW0D5104026
DTC Detecting Condition and Trouble Area
DTC P0741
DTC P0742
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out with 2 persons, a driver and a tester, on a level road.

1) Connect scan tool to DLC with ignition switch OFF, if available.
2) Clear DTC in TCM memory.
3) Start engine and warm it up to normal operating temperature.
4) Shift select lever to “N” and “D” range for each 10 seconds.
5) Drive vehicle with 3rd or 4th gear in “D” range and lock-up ON for 2 seconds or longer referring to “Automatic Gear
Shift Table”.
6) Shift select lever to “3” range.
7) Drive vehicle with 2nd or 3rd gear in “3” range, 15 – 30% throttle opening and at vehicle speed of 25 – 40 km/h (16
– 25 mile/h) at least for 1 second.
8) Stop vehicle and turn ignition switch OFF.
9) Repeat Step 3) to 7) one time.
10) Stop vehicle and check DTC.7Check output shaft speed sensor (VSS) gears visually
1) Check output shaft speed sensor gears for the
followings.
• No damage in drive gear on differential case
• No damage in driven gear in output shaft speed
sensor
Is result satisfactory?Intermittent trouble or
faulty TCM.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.
If OK, substitute a
known-good TCM and
recheck.Replace drive gear and/
or driven gear of output
shaft speed sensor. Step Action Yes No
DTC detecting condition Trouble area
When driving vehicle with 3rd or 4th gear in “D” range,
difference in revolution between engine and A/T input (input
shaft speed) is larger than specification although TCM
commanded TCC solenoid valve to turn ON.• Mechanical malfunction of TCC solenoid valve
• Malfunction of valve body assembly
• Fluid passage clogged or leaking
• Torque converter clutch malfunction
DTC detecting condition Trouble area
When driving vehicle with 2nd, 3rd or 4th gear in “D” range,
difference in revolution between engine and A/T input (input
shaft speed) is smaller than specification although TCM
commanded TCC solenoid valve to turn OFF.• Mechanical malfunction of TCC solenoid valve
• Malfunction of valve body assembly
• Fluid passage clogged or leaking
• Torque converter clutch malfunction

Downloaded from www.Manualslib.com manuals search engine 5A-54 Automatic Transmission/Transaxle:
DTC Troubleshooting
DTC P0751 / P0752 / P0756 / P0757: Shift Solenoid MalfunctionS6RW0D5104027
DTC P0751: Shift Solenoid-A (No.1) Performance or Stuck OFF
DTC P0752: Shift Solenoid-A (No.1) Stuck ON
DTC P0756: Shift Solenoid-B (No.2) Performance or Stuck OFF
DTC P0757: Shift Solenoid-B (No.2) Stuck ON
DTC Detecting Condition and Trouble Area
DTC P0751
DTC P0752
DTC P0756
DTC P0757Step Action Yes No
1Was “A/T System Check” performed?Go to Step 2. Go to “A/T System
Check”.
2 1) Check TCC solenoid valve for operation referring to
“Solenoid Valves (Shift Solenoid Valves and Timing
Solenoid Valve) Inspection”.
Are they in good condition?Clean fluid passage or
replace valve body
assembly.Replace TCC solenoid
valve.
DTC detecting condition Trouble area
3rd gear ratio is detected although TCM command is for 2nd
gear while vehicle running at 20 km/h (12 mile/h) or more in
“D” range after engine being warmed up.• Mechanical malfunction of shift solenoid valve-A
(No.1)
• Malfunction of valve body assembly
• Fluid passage clogged or leaking
• Mechanical malfunction of automatic transaxle
(clutch, brake or gear etc.)
DTC detecting condition Trouble area
2nd gear ratio is detected although TCM command is for 3rd
gear while vehicle running at 20 km/h (12 mile/h) or more in
“D” range after engine being warmed up.• Mechanical malfunction of shift solenoid valve-A
(No.1)
• Malfunction of valve body assembly
• Fluid passage clogged or leaking
• Mechanical malfunction of automatic transaxle
(clutch, brake or gear etc.)
DTC detecting condition Trouble area
3rd gear ratio is detected although TCM command is for 4th
gear while vehicle running at 20 km/h (12 mile/h) or more in
“D” range after engine being warmed up.• Mechanical malfunction of shift solenoid valve-B
(No.2)
• Malfunction of valve body assembly
• Fluid passage clogged or leaking
• Mechanical malfunction of automatic transaxle
(clutch, brake or gear etc.)
DTC detecting condition Trouble area
4th gear ratio is detected although TCM command is for 3rd
gear while vehicle running at 20 km/h (12 mile/h) or more in
“D” range after engine being warmed up.• Mechanical malfunction of shift solenoid valve-B
(No.2)
• Malfunction of valve body assembly
• Fluid passage clogged or leaking
• Mechanical malfunction of automatic transaxle
(clutch, brake or gear etc.)

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-6
The air bag system is designed to activate only in severe
frontal “a” and sideward “b” collisions. It is not designed
to activate in rear impacts, rollovers, or minor frontal and
sideward collisions, since it would offer no protection in
those types of accidents.
Air Bag System Block DiagramS6RW0D8201004
I6RW0C820019-01
Battery Voltage
Forward Impact-Sensor
Driver Side Impact-Sensor
Passenger Side Impact-Sensor
DC / DC Converter
Back Up Capacitor
Safing Power Driver
Mechanical Longitudinal G Sensor (switch)
X-Y G sensor
(Longitudinal /
Lateral Acceleration)
Driver Side-Air Bag
Driver Side Curtain-Air Bag
Passenger Side Curtain-Air Bag
Passenger Side-Air Bag
Passenger Seat Belt Pretensioner
Driver Seat Belt Pretensioner
Passenger Air Bag
Driver Air Bag
INPUTOUTPUTSDM
Front Air
Bag and
Seat Belt
Preten-
tioner
Deploy-
ment
Driver
Side
Air Bag
Deploy-
ment
Driver
Side
Curtain
Air Bag
Deploy-
ment
Driver
Main CPU
BCM and Cmbination Meter
I6RW0C820001-01

Downloaded from www.Manualslib.com manuals search engine 8B-9 Air Bag System:
Terminal arrangement of SDM (viewed from harness side)
[A]: Shorting bar 11. BCM 25. Driver seat belt pretensioner
[B]: Connector 12. Combination meter 26. Passenger seat belt pretensioner
[C]: Junction block with BCM model 13. “AIR BAG” warning light27. Driver side-air bag (inflator) module (8-channel system)
[D]: Junction block without BCM model 14. Light driver 28. Passenger side-air bag (inflator) module (8-channel system)
1. Battery 15. SDM 29. Driver side curtain-air bag (inflator) module (8-channel
system)
2. Main fuse 16. To HVAC control module (auto A/C model) 30. Passenger side curtain-air bag (inflator) module (8-channel
system)
3. Fuse 17. Data link connector (DLC) 31. Safing power driver
4. Individual circuit fuse box No.1 18. Forward impact-sensor 32. X-Y-G (longitudinal / lateral acceleration)
5. “IGN” fuse 19. Driver side impact-sensor (8-channel
system)33. DC / DC converter
6. Ignition switch 20. Passenger side impact-sensor (8-channel
system)34. Mechanical longitudinal G sensor (switch)
7. Junction block assembly 21. Ground for air bag system 35. Back up capacitor
8. “DOME” fuse 22. Contact coil assembly
9. “METER” fuse 23. Driver air bag (inflator) module
10. “A/B” fuse 24. Passenger air bag (inflator) module
1
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 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
1
I7RW01822003-02
1. SDM Connector “L04”

Downloaded from www.Manualslib.com manuals search engine 8B-31 Air Bag System:
NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Repeat “Air Bag Diagnostic System Check” to confirm that the trouble has been corrected.
• Clear DTC B1157 (air bag deployed) of BCM referring to “DTC Clearance in Section 10B”, if any.

DTC B1031: Driver Air Bag Circuit High Resistance S6RW0D8204018
Wiring Diagram
DTC Detecting Condition and Trouble Area
“L04”“L04”[A]
BLK
L04-28
6 8
7
RED
GRN“L313”L04-27
910
L04-3 L04-4
1
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 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
12 [L04]
[G347]12 [L378]
15
13
16
12V5V30V 30V
141112
GRN/RED GRN/RED
GRN GRN
“G347” “S172” “L378” “G345”
1
2 BLKWHT3
4
5
I6RW0C820008-01
[A]: Shorting bar 6. Ignition switch 12. Driver air bag (inflator) module
1. Battery 7. “A/B” fuse 13. DC / DC converter
2. Fuse 8. Junction block assembly 14. Back up capacitor
3. Main fuse box 9. Ground for air bag system 15. Safing power driver
4. “IGN” fuse 10. SDM 16. Mechanical longitudinal G sensor (switch)
5. Individual circuit fuse box No.1 11. Contact coil assembly
DTC detecting condition Trouble area
Driver air bag circuit is more than 5.2 Ω for more than 4
sec.• Driver air bag circuit
• Contact coil assembly
• Driver air bag module
•SDM