2006 SUZUKI SX4 speed

Downloaded from www.Manualslib.com manuals search engine 1C-12 Engine Electrical Devices:
Main Relay, Fuel Pump Relay, Starting Motor
Control Relay, Throttle Actuator Control Relay
and Radiator Cooling Fan Relay Inspection
S6RW0D1306017
1) Disconnect negative cable at battery.
2) Remove main relay (1), fuel pump relay (3), starting
motor control relay (2), throttle actuator control relay
(4) and/or radiator cooling fan relay (5) from
individual circuit fuse box No.1.
3) Check that there is no continuity between terminal
“C” and “D”. If there is continuity, replace relay.
4) Connect battery positive (+) terminal to terminal “B”
of relay. Connect battery negative (–) terminal to
terminal “A” of relay. Check for continuity between
terminal “C” and “D”. If there is no continuity when
relay is connected to the battery, replace relay.
Mass Air Flow (MAF) and Intake Air
Temperature (IAT) Sensor On-Vehicle
Inspection
S6RW0D1306018
NOTE
Before performed this inspection, be sure to
read the “Precautions of ECM Circuit
Inspection in Section 1A”.

1) Disconnect negative cable at battery.
2) Disconnect MAF and IAT sensor connector.
3) Connect voltmeter to “BLK/RED” wire terminal (2) of
MAF and IAT sensor connector (1) disconnected and
ground.
4) Turn ON ignition switch position and check that
voltage is battery voltage.
If not, check if wire harness is open or connection is
poor.
5) Turn OFF ignition switch position and connect
connector to MAF and IAT sensor.
6) Remove ECM from its bracket referring to “Engine
Control Module (ECM) Removal and Installation”.
7) Connect special tool between ECM and ECM
connector referring to “Inspection of ECM and Its
Circuits in Section 1A”.
8) Turn ON ignition switch position and check MAF
signal voltage between “C01-26” terminal circuit and
“C01-27” terminal circuit of special tool.
MAF signal voltage between “C01-26” terminal
circuit and “C01-27” terminal circuit of special
tool
MAF signal voltage of MAF and IAT sensor with
ignition switch turned ON: 0.5 – 1.0 V
9) Start engine and check that voltage is lower than 5 V
and it rises as engine speed increases.
MAF signal voltage between “C01-26” terminal
circuit and “C01-27” terminal circuit of special
tool
MAF signal reference voltage of MAF and IAT
sensor at specified Idle speed: 1.3 – 1.8 V
10) If check result is not as specified above, cause may
lie in wire harness, connector connection, MAF and
IAT sensor or ECM.
"D" "B""A""C"
2
1
4 3
5
I5RW0A130014-01
1. ECM
I3RB0A130009-01
“C01-27” “C01-26”
1
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-3
Camshaft Position Control (VVT Variable Valve Timing) System DescriptionS6RW0D1401002
System Description
The VVT system is an electronic control system which continuously vary and optimize the intake valve timing in
response to the engine operating condition.
The optimized intake valve timing produce such an air intake with high efficiency that both the higher power generation
and lower fuel consumption can be attained in the whole engine speed range from low to high. In the area of the
average engine load, low emission of nitrogen oxides (NOx) and high fuel efficiency can also be attained by making
the valve opening overlap between the intake and exhaust valves longer.
For the brief of the system operation, the intake valve timing is varied by the cam timing sprocket (1) which varies the
rotational phase between the intake camshaft (3) and sprocket. The rotor (2) in the cam timing sprocket is actuated by
switching or adjusting the hydraulic pressure applied to the chambers for the timing advancing (7) and/or retarding (6).
To switch or adjust the hydraulic pressure appropriately, ECM operates the oil control valve (12) with detecting the
engine speed, intake air value, throttle opening, engine coolant temperature and camshaft position (angle).
1
4
5
10
8
9
2
7
6
12
11
3
60˚ (variable angle)
Most retarded timing Most advanced timing
Exhaust valveIntake valve
Crank angle
Overlap of valves
Valve lift
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4. Oil passage to chamber for timing retarding 8. Oil filter 10. Oil pan
5. Oil passage to chamber for timing advancing 9. Oil pump 11. Control signal from ECM

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-5
Targeted Timing Varying Operation
Diagnostic Information and Procedures
Compression CheckS6RW0D1404001
Check compression pressure on all 4 cylinders as
follows:
1) Warm up engine to normal operating temperature.
2) Stop engine after warming up.
NOTE
After warming up engine, place transmission
gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T model), and set
parking brake and block drive wheels.

3) Remove air cleaner assembly with air suction hose
referring to “Air Cleaner Assembly Removal and
Installation”.
4) Remove cylinder head upper cover.
5) Remove ignition coil assemblies and all spark plugs
referring to “Spark Plug Removal and Installation in
Section 1H”.
6) Disconnect fuel injector wires at the coupler.7) Install special tools (Compression gauge) into spark
plug hole.
Special tool
(A): 09915–64512
(B): 09915–64530
(C): 09915–67010 Driving condition Valve timing Target of control Effect
Engine running at idle
speedMost retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to intake manifold.Stabilization of the engine
rotation at idle speed.
Average engine load
rangeTo the advanced
sideTo lengthen the valve opening overlap
in order to enhance the internal
exhaust gas recirculation and reduce
the pumping loss.Improvement of the fuel
efficiency.
Lowering of the exhaust
emission.
Light engine load
rangeTo the retarded sideTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to intake manifold.Keeping of the engine stability.
Low or average
engine speed range
with heavy engine
loadTo the advanced
sideTo advance the closing timing of the
intake valve in order to improve the
volumetric efficiency.Improvement of generating the
engine torque at low and
average engine speed.
High engine speed
range with heavy
engine loadTo the retarded sideTo retard the closing timing of the
intake valve in order to improve the
volumetric efficiency.Improvement of generating the
engine power.
Low engine coolant
temperatureMost retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to intake manifold and
reduce the fuel increasing.
To slow the fast idle speed of the
engine as a result of stabilizing the
engine idling.Stabilization of the fast idling of
the engine.
Improvement of the fuel
efficiency.
At engine starting and
stoppingMost retardedTo shorten the valve opening overlap in
order to prevent the exhaust gas
counterflow to intake manifold.Improvement of start ability.
(A)
(C)
(B)
I3RH0B140009-01

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-7
7) Install air cleaner assembly with air suction hose
referring to “Air Cleaner Assembly Removal and
Installation”.
8) Run engine at specified idle speed and read vacuum
gauge. Vacuum should be within specification.
Vacuum specification (at sea level)
59 – 73 kPa (45 – 55 cmHg, 17.7 – 21.6 in.Hg) at
specified idle speed
9) After checking, disconnect special tool (Vacuum
gauge) from PCV valve.
10) Detach blind cap from PCV valve.
11) Install air cleaner assembly with air suction hose
referring to “Air Cleaner Assembly Removal and
Installation”.
Valve Lash (Clearance) InspectionS6RW0D1404003
1) Remove negative cable at battery.
2) Remove cylinder head cover referring to “Cylinder
Head Cover Removal and Installation”.
3) Remove right side engine under cover, if necessary.
4) Using 17 mm wrench, turn crankshaft pulley (1)
clockwise until cam lobes (2) become perpendicular
to shim faces (3) at valves “1” and “7” as shown in
figure.
5) Check valve lashes with thickness gauge (4)
according to the following procedure.
a) Check valve lashes at valves “1” and “7”.
b) Turn camshafts by 90° (by turning crankshaft
with wrench).
c) Make sure that cam lobes are perpendicular to
shim faces at valves to be checked (in this case,
“3” and “8”), if not, adjust it by turning crankshaft.
Check valve lashes.
d) In the same manner as b) – c), check valve
lashes at valves “4” and “6”.
e) In the same manner as b) – c) again, check
valve lashes at valves “2” and “5”.
If valve lash is out of specification, record valve lash and
adjust it to specification by replacing shim.
Valve clearance specification
When cold (Coolant temperature is 15 – 25 °C (59 –
77 °F)):
• Intake: 0.18 – 0.22 mm (0.007 – 0.009 in.)
• Exhaust: 0.28 – 0.32 mm (0.011 – 0.013 in.)
When hot (Coolant temperature is 60 – 68 °C (140 –
154 °F)):
• Intake: 0.21 – 0.27 mm (0.008 – 0.011 in.)
• Exhaust: 0.30 – 0.36 mm (0.012 – 0.014 in.)Replacement of Shim
1) Close the valve whose shim (2) is to be replaced by
turning crankshaft, then turn tappet (3) till its cut
section (1) faces inside as shown in figure.
I3RM0A140004-01
I2RH0B140006-01

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)
1
I5RW0A140009-01

Downloaded from www.Manualslib.com manuals search engine 1E-2 Engine Lubrication System:
Diagnostic Information and Procedures
Oil Pressure CheckS6RW0D1504001
WARNING!
To avoid the danger of being burned, do not
touch the exhaust system when the system is
hot. Any service on the exhaust system
should be performed when the system is
cool.

NOTE
Prior to checking oil pressure, check the
following.
• Oil level in oil pan
If oil level is low, add oil up to full level
mark (hole) (1) on oil level gauge referring
to “Engine Oil and Filter Change in Section
0B”.
• Oil quality
If oil is discolored or deteriorated, change
it. For particular oil to be used, refer to
“Engine Oil and Filter Change in Section
0B”.
• Oil leaks
If leak is found, repair it.

1) Disconnect oil pressure switch coupler (1).
2) Remove oil pressure switch (2) from cylinder block.3) Install special tools (oil pressure gauge) to vacated
threaded hole of oil pressure switch.
Special tool
(A): 09915–77310
(B): 09915–78211
4) Start engine and warm engine up to normal
operating temperature.
NOTE
Be sure to shift transaxle gear shift lever in
“Neutral”, set parking brake and block drive
wheels.

5) After warming up, raise engine speed to 4,000 r/min.
and measure oil pressure.
Oil pressure specification
More than 270 kPa (2.7 kgf/cm2, 39.8 psi) at 4,000
r/min. (rpm)
6) After checking oil pressure, stop engine and remove
oil pressure gauge and attachment.
7) Before reinstalling oil pressure switch (2), be sure to
wrap its screw threads with sealing tape (1) and
tighten switch to specified torque.
NOTE
If sealing tape edge is bulged out from screw
threads of switch, cut it off.

Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft)
2. Low level mark (hole)
I2RH0B150002-01
I2RH0B150003-01
I2RH0B150004-01
I2RH0B150005-01

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-6
Cooling System Flush and RefillS6RW0D1606005
WARNING!
To help avoid danger of being burned, do not
remove radiator cap while engine and
radiator are still hot. Scalding fluid and steam
can be blown out under pressure if cap is
taken off too soon.

NOTE
For detail of coolant specification, refer to
“Coolant Description”.

1) Remove radiator cap when engine is cool as follows.
a) Turn cap counterclockwise slowly until it reaches
a “stop” (Do not press down while turning it).
b) Wait until pressure is relieved (indicated by a
hissing sound) then press down on cap and
continue to turn it counterclockwise.
2) With radiator cap removed, run engine until upper
radiator hose is hot (this shows that thermostat is
open and coolant is flowing through system).
3) Stop engine and drain coolant from radiator drain
plug (1).
4) Close radiator drain plug. Add water until system is
filled and run engine until upper radiator hose is hot
again.
5) Repeat Steps 3) and 4) several times until drained
liquid is nearly colorless.
6) Close radiator drain plug (1) tightly.7) Remove reservoir cap (2) and reservoir (1).
8) Pour out any fluid, scrub and clean inside of
reservoir with soap and water.
Flush it well with clean water and drain, Reinstall
reservoir.
9) Fill reservoir with coolant up to “FULL” level mark (3).
10) Install reservoir cap (2) on reservoir.
11) Fill radiator with coolant up to bottom of radiator filler
neck and install radiator cap, making sure that the
ear of cap lines is parallel to radiator.
12) Run engine at idle speed.
13) Run engine until radiator fan motor is operated.
14) Stop engine and wait until engine comes cooled
down to help avoid danger of being burned.
15) Add coolant to radiator up to bottom of radiator filler
neck, and install radiator cap, making sure that the
ear of cap lines is parallel to radiator.
16) Repeat Step 12) through 15).
17) Confirm that reservoir coolant level is “FULL” level
mark (3). If coolant is insufficient, repeat Step 9) and
10).
Cooling Water Pipes or Hoses Removal and
Installation
S6RW0D1606006
Removal
1) Drain coolant referring to “Cooling System Draining”.
2) To remove these pipes or hoses, loosen clamp on
each hose and pull hose end off.
Installation
Install removed parts in reverse order of removal
procedure, noting the following.
• Tighten each clamp securely referring to “Cooling
System Components”.
• Refill cooling system referring to Step 7) to 17) of
“Cooling System Flush and Refill”.
1I4RS0A160003-01
2
1
3
I6RW0D160001-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-4
4) Check that battery voltage is 11 V or more.
5) Measure fuel pressure at each condition.
If measured pressure is out of specification, refer to
“Fuel Pressure Check in Section 1A” and check each
possibly defective part. Replace if found defective.
a) Turn ignition switch ON to operate fuel pump and
after 2 seconds turn it OFF. Repeat this 3 or 4
times and then check fuel pressure.
Fuel pressure specification
With fuel pump operating and engine
stopped: 360 – 400 kPa (3.6 – 4.0 kgf/cm2,
51.2 – 56.9 psi)
b) Start engine and warm it up to normal operating
temperature, and measure fuel pressure at
idling.
Fuel pressure specification
At specified idle speed: 360 – 400 kPa (3.6 –
4.0 kgf/cm2, 51.2 – 56.9 psi)
c) Stop engine, and measure fuel pressure at one
minute after stopping.
Fuel pressure specification
With 1 min. after engine (fuel pump) stop
(Pressure reduces as time passes): Over 250
kPa (2.5 kgf/cm
2, 35.6 psi)
6) After checking fuel pressure, remove fuel pressure
gauge.
WARNING!
As fuel feed line is still under high fuel
pressure, make sure to release fuel pressure
according to the following procedures.
• Place fuel container under joint.
• Cover joint with rag (1) and loosen joint nut
slowly in order to release fuel pressure
gradually.

7) Remove special tools from fuel delivery pipe and fuel
feed hose.
8) Connect fuel feed hose to fuel delivery pipe and
clamp it securely.
9) With engine OFF and ignition switch ON, check for
fuel leaks.
Fuel Cut Operation InspectionS6RW0D1704002
NOTE
Before inspection, make sure that gear shift
lever is in neutral position (shift select lever
is “P” range for A/T vehicle), A/C is OFF and
parking brake lever is pulled all the way up.

1) Warm engine up to normal operating temperature.
2) While listening to sound of injector (2) by using
sound scope (1) or such, increase engine speed to
higher than 3,000 r/min.
3) Check to make sure that injector operation sound is
stop when throttle valve is closed instantly and it is
heard again when engine speed is reduced to
approx. 2,000 r/min or less.
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