2006 SUZUKI SX4 PPL

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-4
Diagnostic Information and Procedures
Ignition System Symptom DiagnosisS6RW0D1804001
Reference Waveform of Ignition SystemS6RW0D1804002
Refer to “Reference waveform No.5”, “Reference waveform No.6” and “Reference waveform No.7” under “Inspection
of ECM and Its Circuits in Section 1A” for waveform of Ignition trigger signal.
Ignition System CheckS6RW0D1804003
Condition Possible cause Correction / Reference Item
Engine cranks, but will
not start or hard to start
(No spark)Blown fuse for ignition coilReplace.
Loose connection or disconnection of
lead wire or high-tension cord(s)Connect securely.
Faulty high-tension cord(s)Replace.
Faulty spark plug(s)Replace.
Faulty ignition coilReplace ignition coil assembly.
Faulty CKP sensor or CKP sensor plateClean, tighten or replace.
Faulty CMP sensor or sensor rotor tooth
of camshaftClean, tighten or replace.
Faulty ECMReplace.
Poor fuel economy or
engine performanceIncorrect ignition timingCheck related sensors and CKP sensor plate.
Faulty spark plug(s) or high-tension
cord(s)Adjust, clean or replace.
Faulty ignition coil assemblyReplace.
Faulty CKP sensor or CKP sensor plateClean, tighten or replace.
Faulty CMP sensor or sensor rotor tooth
of camshaftClean, tighten or replace.
Faulty knock sensorReplace.
Faulty ECMReplace.
Step Action Yes No
1Was “Engine and Emission Control System Check”
performed?Go to Step 2. Go to “Engine and
Emission Control
System Check in
Section 1A”.
2Ignition spark test
1) Check all spark plugs for condition and type referring to
“Spark Plug Inspection”.
2) If OK, perform ignition spark test referring to “Ignition
Spar k Tes t”.
Is spark emitted from all spark plugs?Go to Step 12. Go to Step 3.
3DTC check
1) Perform DTC check referring to “DTC Check in Section
1A”.
Is DTC stored in ECM?Go to applicable DTC
diag. flow.Go to Step 4.
4Electrical connection check
1) Check ignition coil assemblies and high-tension cords
for electrical connection.
Are they connected securely?Go to Step 5. Connect securely.
5High-tension cords check
1) Check high-tension cord for resistance referring to
“High-Tension Cord Inspection”.
Is check result satisfactory?Go to Step 6. Replace high-tension
cord(s).

Downloaded from www.Manualslib.com manuals search engine 1H-5 Ignition System:
6Ignition coil assembly power supply and ground circuit
check
1) Check ignition coil assembly power supply and ground
circuits for open and short.
Are circuits in good condition?Go to Step 7. Repair or replace.
7Ignition coil assembly check
1) Check ignition coil for resistance referring to “Ignition
Coil Assembly (Including Ignitor) Inspection”.
Is check result satisfactory?Go to Step 8. Replace ignition coil
assembly.
8CKP sensor check
1) Check CKP sensor referring to “Crankshaft Position
(CKP) Sensor Inspection in Section 1C”.
Is check result satisfactory?Go to Step 9. Tighten CKP sensor
bolt, replace CKP
sensor or CKP sensor
plate.
9CMP sensor check
1) Check CMP sensor referring to “Camshaft Position
(CMP) Sensor Inspection in Section 1C”.
Is check result satisfactory?Go to Step 10. Tighten CMP sensor
bolt, replace CMP
sensor or intake
camshaft.
10Ignition trigger signal circuit check
1) Check ignition trigger signal wire for open, short and
poor connection.
Is circuit in good condition?Go to Step 11. Repair or replace.
11A known-good ignition coil assembly substitution
1) Substitute a known-good ignition coil assembly and then
repeat Step 2.
Is check result of Step 2 satisfactory?Go to Step 12. Substitute a known-
good ECM and then
repeat Step 2.
12Ignition timing check
1) Check initial ignition timing and ignition timing advance
referring to “Ignition Timing Inspection”.
Is check result satisfactory?System is in good
condition.Go to Step 13.
13Knock sensor check
1) Confirm that knock sensor circuit is in good condition
referring to “DTC P0327 / P0328: Knock Sensor Circuit
Low / High in Section 1A”.
2) Check oscilloscope waveform of knock sensor signal
referring to “Reference waveform No.19” and
“Reference waveform No.20” under “Inspection of ECM
and Its Circuits in Section 1A”.
Is check result satisfactory?Check CMP sensor,
CMP sensor rotor tooth
of camshaft, CKP
sensor, CKP sensor
plate and/or input
signals related to this
system.Substitute a known-
good knock sensor and
recheck. Step Action Yes No

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-10
Specifications
Tightening Torque SpecificationsS6RW0D1807001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Special ToolS6RW0D1808001
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Spark plug 25 2.5 18.0)
Ignition coil bolt 11 1.1 8.0)
09930–76420 SUZUKI scan tool (SUZUKI-
SDT)
Timing-light (dry cell type) —
)This kit includes following
items. 1. SUZUKI-SDT 2.
DLC3 cable 3. USB cable 4.
AC/DC power supply 5.
Voltage meter probe 6.
Storage case )
1
2
34
56

Downloaded from www.Manualslib.com manuals search engine 1I-5 Starting System:
Starting Motor ComponentsS6RW0D1906002
I4RS0A190003-01
1. Front housing 7. Plate 13. Planetary gear 19. Rear bush
2. Bush 8. Seal rubber 14. Packing 20. Starting motor battery cable nut
3. Pinion stop ring 9. Magnetic switch 15. Yoke : 9.8 N⋅m (0.98 kgf-m, 7.0 lb-ft)
4. Over-running clutch 10. Ball 16. Armature : Do not reuse.
5. Lever 11. Internal gear 17. Brush assembly : Apply grease 99000-25011 to sliding surface of each part.
6. Plunger 12. Planetary carrier shaft 18. Rear bracket

Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-5
Charging Indicator Lamp Operation
Generator Test (Undercharged Battery Check)S6RW0D1A04003
This condition, as evidenced by slow cranking or low
specific gravity can be caused by one or more of the
following conditions even though indicator lamp may be
operating normal. The following procedure also applies
to cars with voltmeter and ammeter.
• Make sure that undercharged condition has not been
caused by accessories left on for extended period of
time.
• Check drive belt for proper tension.
• If battery defect is suspected, refer to “Battery
Description”.
• Inspect wiring for defects. Check all connections for
tightness and cleanliness, battery cable connections
at battery, starting motor and ignition ground cable.
No-Load Check
1) Connect voltmeter and ammeter as shown in figure.
NOTE
Use fully charged battery.

2) Run engine from idling up to 2,000 rpm with all
accessories turned off and read meters.
If voltage is higher than standard value, check
ground of brushes.
If brushes are not grounded, replace IC regulator.
If voltage is lower than standard value, proceed to
the following check.
Specification for undercharged battery (No-load
check)
Current: 10 A
Voltage: 14.2 – 14.8 V at Hi (H) (at 25 °C, 77 °F)
Voltage: 12.5 – 13.1 V at Lo (L) (at 25 °C, 77 °F)
NOTE
Consideration should be taken that voltage
will differ somewhat with regulator case
temperature as shown in figure.

Condition Possible cause Correction / Reference Item
Charge light does not
light with ignition ON and
engine offFuse blownCheck fuse.
Indicator lamp (LED) faultyCheck BCM, combination meter and/or CAN
communication line.
Wiring connection looseTighten loose connection.
IC regulator or field coil faultyCheck generator.
Poor contact between brush and slip
ringRepair or replace.
Charge light does not go
out with engine running
(battery requires frequent
recharging)Drive belt loose or wornAdjust or replace drive belt.
IC regulator or generator faultyCheck charging system.
Wiring faultyRepair wiring.
1. Generator
2. Ammeter (between generator “B” terminal and battery (+) terminal)
3. Voltmeter (between generator “B” terminal and ground)
4. Battery
5. Load
6. Switch
I2RH011A0006-01
[A]: Regulated voltage (V)
[B]: Heatsink temperature (°C)
16.0
12.0
14.2 15.3
14.8
14.2
13.3 14.8
15.0
11.0 14.0
13.0 [A]
12.5 13.6
13.1
12.5
11.613.1
[B] -30 0 25 135
H
L
I2RH0B1A0005-01

Downloaded from www.Manualslib.com manuals search engine 2B-3 Front Suspension:
Adjustment
1) Loosen right and left tie-rod end lock nuts (1) first.
2) Rotate right and left tie-rods (2) by the same amount
to align toe to specification. In this adjustment, the
lengths “A” of both right and left tie-rod should be
equal.
NOTE
Before rotating tie-rods (2), apply grease
between tie-rods and rack boots so that
boots won’t be twisted.

3) After adjustment, tighten lock nuts (1) to specified
torque.
Tightening torque
Tie-rod end lock nut (a): 45 N·m (4.5 kgf-m, 32.5
lb-ft)
NOTE
Make sure that rack boots are not twisted.

Steering Angle Check and Adjustment
When tie-rod or tie-rod end was replaced, check toe and
then also steering angle with turning radius gauge (1).
If steering angle is not correct, check whether right and
left tie-rods length “A” are equal.
NOTE
If tie-rod lengths were changed to adjust
steering angle, reinspect toe-in.

Steering angle
Inside: 36.0° ± 2°
Outside: 32.1° (Reference)
Reference Information
Side slip
When checked with side slip tester, side slip should
satisfy following specification.
Side slip
0 to IN 3.0 mm/m (0 to IN 0.118 in/3.3 ft)
If side slip is greatly difference, toe or front wheel
alignment may not be correct.
I3RH0A220002-01
I3RH0A220003-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-8
3) Install bump stopper and strut dust cover onto strut
rod. For installing direction, refer to the figure in
“Front Strut Assembly Components”.
4) Pull strut rod as far up as possible and use care not
to allow it to retract into strut.
5) Install spring seat on coil spring and then spring
upper seat (1) aligning “OUT” mark (3) on spring
upper seat and center of strut bracket (2).
6) Install bearing (3), strut support (2) and strut support
lower nut (1) in this sequence.
Tighten strut support lower nut (1) to specified
torque.
When tightening strut support lower nut, hold stud
with hexagon wrench.
Tightening torque
Strut support lower nut (a): 55 N·m (5.5 kgf-m,
40.0 lb-ft)Front Strut Assembly CheckS6RW0D2206005
• Inspect strut for oil leakage, damage or deformation.
If defect is found, replace strut as an assembly unit,
because it can not be disassembled.
• Inspect strut function referring to the following
procedures:
1) Check and adjust tire pressures as specified.
2) Bounce vehicle body up and down 3 or 4 times
continuously by pushing front end of the vehicle side
body to check strut.
Also, note how many times vehicle body rebounds to
stop after force application.
3) Repeat the same procedure to the other strut to
confirm that the both side struts equally respond.
If conditions of struts are in doubt, compare them with
known-good vehicle or strut.
• Inspect bearing for wear, abnormal noise or gripping.
If defective, replace.
• Inspect coil spring seat for cracks or deformation.
If defective, replace.
• Inspect bump stopper for deterioration.
If defective, replace.
• Inspect rebound stopper and strut mount for wear,
cracks or deformation.
If defective, replace.
I4RS0A220012-01
3
2
1,(a)
I5RW0A220010-02
I4RS0A220014-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-12
4) Drive in dust cover so that dimensions “a” and “b”
become equal as shown in the figure.
CAUTION!
When drive in dust cover, be careful not to
deform it.

5) Caulk more than 6 places with a punch.
6) Using special tool and hydraulic press, press fit
wheel hub (1) into wheel bearing (2) (Face grooved
rubber seal side to wheel hub).
Special tool
(A): 09913–75510 7) Apply grease lightly to end face of inner ring (1).
“A”: Grease 99000–25121 (SUZUKI Super
Grease H)
NOTE
Do not apply the grease to the encoder
section to avoid the encoder malfunction.

8) Install steering knuckle with wheel hub and bearing
(1) so that foreign material should not enter wheel
speed sensing point “a”.I2RH01220038-01
I2RH01220039-01
I7RW01220007-01
2. Wheel encoder
3. Drive shaft
I5RW0B220001-01
I7RW01220008-02