2006 SUZUKI SX4 Lights

Downloaded from www.Manualslib.com manuals search engine 1A-212 Engine General Information and Diagnosis:
Repair Instructions
Idle Speed and IAC Throttle Valve Opening
Inspection
S6RW0D1106001
Before idle speed check, make sure of the following.
• Lead wires and hoses of electronic fuel injection and
engine and emission control systems are connected
securely.
• Valve lash is checked according to maintenance
schedule.
• Ignition timing is within specification.
• All accessories (wipers, heater, lights, A/C, etc.) are
out of service.
• Air cleaner has been properly installed and is in good
condition.
• No abnormal air drawn in from air intake system.After all items are confirmed, check idle speed and IAC
throttle opening as follows.NOTE
Before starting engine, place transmission
gear shift lever in “Neutral”, and set parking
brake and block drive wheels.

Step Action Yes No
1Is there DTC(s) of ECT sensor circuit (DTC P0116 / P0117 /
P0118) and/or radiator cooling fan circuit (DTC P0480)?Go to corresponding
DTC flow.Go to Step 2.
2Radiator cooling fan control circuit check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Start engine and select “Data List” on scan tool.
3) Warm up engine until coolant temp. is 100 °C, 212 °F or
higher and A/C switch turns OFF (if equipped with A/C).
(If engine coolant temp. dose not rise, check engine
cooling system or ECT sensor.)
Is radiator cooling fan started when engine coolant temp.
reached above temp.?Radiator cooling fan
control system is in
good condition.Perform from Step 2 to
Step 7 in DTC P0480
diag. flow. If OK, Go to
Ste p 3.
3Radiator cooling fan control check
1) Disconnect radiator cooling fan motor connector with
ignition switch turned OFF.
2) Run engine when ECT is over 100 °C, 212 °F.
3) Measure voltage between vehicle body ground and
“BLU/RED” wire terminal of disconnected radiator
cooling fan motor connector.
Is voltage 10 – 14 V?Go to Step 4. “BLU/RED” wire is open
or high resistance
circuit.
4Check radiator cooling fan wire circuit check
1) Turn ignition switch to OFF position.
2) Measure resistance between “BLK” wire terminal of
disconnected radiator cooling fan motor connector and
vehicle body ground.
Is resistance below 1
Ω?Go to Step 5. “BLK” wire is open or
high resistance circuit.
5Radiator cooling fan check
1) Check radiator cooling fan referring to “Radiator Cooling
Fan Assembly On-Vehicle Inspection in Section 1F”.
Is it in good condition?Substitute a known-
good ECM and recheck.Faulty radiator cooling
fan.

Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-7
1) Set parking brake and place automatic transaxle in
PARK (NEUTRAL on manual transaxle). Turn off
ignition, turn off lights and all other electrical loads.
2) Check electrolyte level. If it is below low level line,
add distilled water.
3) Attach end of one jumper cable to positive terminal
of booster battery and the other end of the same
cable to positive terminal of discharged battery. (Use
12-volt battery only to jump start engine).
4) Attach one end of the remaining negative cable to
negative terminal of booster battery, and the other
end to a solid engine ground (such as exhaust
manifold) at least 45 cm (18 in.) away from battery of
vehicle being started.
5) Start engine of vehicle with booster battery and turn
off electrical accessories. Then start engine of the
vehicle with discharged battery.
6) Disconnect jumper cables in the exact reverse order.
With Charging Equipment
CAUTION!
When jump starting engine with charging
equipment, be sure equipment used is 12-
volt and negative ground. Do not use 24-volt
charging equipment. Using such equipment
can cause serious damage to electrical
system or electronic parts.

Battery Dismounting and RemountingS6RW0D1A06002
Dismounting
1) Disconnect negative cable (3).
2) Disconnect positive cable (2).
3) Remove retainer (4).
4) Remove battery (1).
Handling
When handling battery, the following safety precautions
should be followed:
• Hydrogen gas is produced by battery. A flame or
spark near battery may cause the gas to ignite.
• Battery fluid is highly acidic. Avoid spilling on clothing
or other fabric. Any spilled electrolyte should be
flushed with large quantity of water and cleaned
immediately.Remounting
1) Reverse removal procedure.
2) Tighten battery cables securely.
NOTE
Check to be sure that ground cable has
enough clearance to hood panel by terminal.

Water Pump / Generator Drive Belt Tension
Inspection and Adjustment
S6RW0D1A06006
WARNING!
• Disconnect negative cable at battery
before checking and adjusting belt
tension.
• 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.

1) Inspect belt for cracks, cuts, deformation, wear and
cleanliness. If it is necessary to replace belt, refer to
“Water Pump / Generator Drive Belt Removal and
Installation”.
2) Check belt for tension. Belt is in proper tension when
it deflects the following specification under thumb
pressure (about 10kg or 22 lb.).
If belt tension is out of specification, go to next steps.
Water pump / generator drive belt tension
“a”
Existing belt: 4.5 – 5.5 mm (0.18 – 0.22 in.) as
deflection / 10 kg (22 lbs)
New belt: 4.0 – 4.5mm (0.16 – 0.18 in.) as
deflection / 10 kg (22 lbs)
1. Battery 4. Retainer
2. Positive cable 5. Nut
3. Negative cable
21
4
3
5I7RW011A0005-01

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-12
DTC TableS6RW0D3204007
NOTE
“O” in transfer position indicator column of the above table means indicator lights up when DTC is
detected.

Fail-Safe TableS6RW0D3204008
This function is provided by the safe mechanism that assures safe driveability even when the coupling assembly,
switch, sensor or its circuit fails. The following table shows the fail safe function for each fail condition of sensor,
coupling assembly, switch, 4WD control module or its circuit. DTC No. Detecting itemDetecting condition
(DTC will set when detecting)4WD
position
Indicator
) C12404WD control module power
supply circuit malfunctionBattery voltage is lower than lower limit voltage for
4WD control module diagnosis.{
) C1243Internal circuit malfunction of
4WD control moduleInternal power supply malfunction of 4WD control
module{
) C1250Coupling air temperature sensor
openSensor output voltage too high{
) C1251Coupling air temperature sensor
shortSensor output voltage too low{
) C1252 Coupling assembly open2WD/4WD switch is changed of 4WD lock position,
and then vehicle is not changed for more than 5
seconds.{
) C1253 Coupling assembly short2WD/4WD switch is changed of 4WD lock position,
and then vehicle is not changed for more than 5
seconds.{
) C1254 2WD/4WD switch malfunctionDifferent switch combination from specification is
detected more than 5 seconds.{
) U0073Control module communication
bus offTransmitting and receiving error of 4WD control
module for specified time continuously{
) U0100 Lost communication with ECMReceiving error of 4WD control module from ECM
for specified time continuously{
) U0121Lost communication with ABS /
ESP® control moduleReceiving error of 4WD control module from ABS /
ESP® control module for specified time
continuously{
) U0155Lost communication with
instrument panel cluster control
moduleReceiving error of 4WD control module from
combination meter for specified time continuously{
DTC No. Trouble Area Fail-Safe Operation
)C12404WD control module power supply circuit
malfunction4WD control module controls the current and
fixed the vehicle to 2WD position.
)C1243Internal circuit malfunction of 4WD control
module
)C1250 Coupling air temperature sensor open
)C1251 Coupling air temperature sensor short
)C1252 Coupling assembly open
)C1253 Coupling assembly short
)C1254 2WD/4WD switch malfunction
)U0073 Control module communication bus off
)U0100 Lost communication with ECM
)U0121Lost communication with ABS / ESP® control
module
)U0155Lost communication with instrument panel
cluster control module

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-6
Dragging brakes (Without
a very light drag is
present in all brakes
immediately after pedal is
released)Master cylinder pistons not returning
correctlyReplace master cylinder.
Restricted brake pipes or hosesCheck for soft hoses or damaged pipes and
replace with new hoses and/or new brake
piping.
Incorrect parking brake adjustment on
rear brakesCheck and adjust to correct specifications.
Weakened or broken return springs in
the drum brakeReplace.
Sluggish parking brake cables or linkageRepair or replace.
Wheel cylinder or caliper piston stickingRepair as necessary.
Badly worn piston seal in caliperReplace piston seal.
Improper brake pedal free heightCheck brake pedal free height.
Pedal pulsation (Pedal
pulsates when depressed
for braking)Damaged wheel bearingsReplace wheel bearings.
Distorted steering knuckle or rear wheel
spindle or rear axle shaftReplace knuckle or rear wheel spindle or rear
axle shaft.
Excessive disc lateral runoutCheck per instructions. If not within
specifications, replace or machine disc.
Rear drums out of roundCheck runout.
Repair or replace drum as necessary.
Braking noiseGlazed brake pad and/or brake shoeRepair or replace brake pad and/or brake
shoe.
Worn or distorted brake shoeReplace brake shoe.
Loose front wheel bearingsReplace wheel hub.
Distorted backing plates or loose
mounting boltsReplace or retighten securing bolts.
Contact wear indicator to brake discReplace brake pads.
Brake warning light lights
after engine startParking brake appliedRelease parking brake and check that brake
warning light turns off.
Insufficient amount of brake fluidInvestigate leaky point, correct it and add
brake fluid.
Brake fluid leakingInvestigate leaky point, correct it and add
brake fluid.
Brake warning light circuit faultyRepair circuit.
Malfunctioning EBD systemCheck system referring to “EBD Warning Light
(Brake Warning Light) Comes ON Steady in
Section 4E”.
Brake warning light turns
on when brake is appliedBrake fluid leakingInvestigate leaky point, correct it and add
brake fluid.
Insufficient amount of brake fluidInvestigate leaky point, correct it and add
brake fluid.
Brake warning light fails
to turn on even when
parking brake is appliedBrake warning light circuit faultyReplace bulb or repair circuit.
ABS warning light turns
on after engine startMalfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light turns
on when brake is appliedMalfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light after
ignition switch has turned
ON Bulb burnt outReplace bulb.
Malfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light flashesNew ABS hydraulic unit / control module
assembly installed.Perform “ABS Hydraulic Unit Operation Check
in Section 4E”. Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-8
Brake Fluid Level InspectionS6RW0D4106004
CAUTION!
Do not use shock absorber fluid or any other
fluid which contains mineral oil. Do not use a
container which has been used for mineral oil
or a container which is wet from water.
Mineral oil will cause swelling and distortion
of rubber parts in hydraulic brake system and
water mixed into brake fluid will lower fluid
boiling point. Keep all fluid containers
capped to prevent contamination.

NOTE
Be sure to use particular brake fluid either as
indicated on reservoir cap of that vehicle or
recommended in owner’s manual which
comes along with that vehicle. Use of any
other fluid is strictly prohibited.
Fluid level should be between MIN and MAX
lines marked on reservoir.
When brake warning light lights sometimes
during driving, replenish fluid to MAX level.
When fluid decreases quickly, inspect brake
system for leakage. Correct leaky points and
then refill to specified level.

1) Check master cylinder, reservoir and reservoir hose
(if equipped) for crack, damage and brake fluid
leakage. If any faulty condition exists, correct or
replace.
2) Check that brake fluid level is between MAX (1) and
MIN marks (2) on reservoir.
Brake Light Switch AdjustmentS6RW0D4106005
Adjustment should be made as follows. Pull up brake
pedal toward you and while holding it there, adjust
switch position so that clearance between end of thread
and brake pedal is as specified. Then lock it by turning
clockwise.
Clearance between brake pedal and brake light
switch
“a”: 0.5 – 1.5 mm (0.02 – 0.05 in.)
Air Bleeding of Brake SystemS6RW0D4106006
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

Bleeding operation is necessary to remove air whenever
it entered hydraulic brake system.
Hydraulic lines of brake system are based on the
diagonal split system. When a brake pipe or hose was
disconnected at the wheel, bleeding operation must be
performed at both ends of the line of the removed pipe or
hose. When any joint part of the master cylinder of other
joint part between the master cylinder and each brake
(wheel) was removed, the hydraulic brake system must
be bled at all 4 wheel brakes.
NOTE
Perform bleeding operation starting with rear
brake caliper or wheel cylinder farthest from
master cylinder and then at front caliper of
the same brake line. Do the same on the
other brake line.

1
2
I7RW01410004-01
1. Right front brake caliper 3. Right rear wheel cylinder
2. Left front brake caliper 4. Left rear wheel cylinder
I5RW0A410005-01
I7RW01410005-01

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-2
General Description
ABS DescriptionS6RW0D4501001
The ABS (Antilock Brake System) controls the fluid
pressure applied to the wheel cylinder of each brake
from the master cylinder so that each wheel is not locked
even when hard braking is applied.
This ABS has also the following function.
While braking is applied, but before ABS control
becomes effective, braking force is distributed between
the front and rear so as to prevent the rear wheels from
being locked too early for better stability of the vehicle.
The main component parts of this ABS include the
following parts in addition to those of the conventional
brake system.
• Wheel speed sensor which senses revolution speed
of each wheel and outputs its signal.
Rear wheel speed sensor of 4WD vehicle is
integrated in rear wheel hub assembly and supplied
as rear wheel hub assembly part.
Front wheel speed sensor and rear wheel speed
sensor of 2WD model are separated from wheel hub
assembly and supplied as spare parts.
• ABS warning light which lights to inform abnormality
when system fails to operate properly.• ABS hydraulic unit / control module assembly is
incorporated ABS control module, ABS hydraulic unit
(actuator assembly), solenoid valve power supply
driver (transistor), solenoid valve driver (transistor),
pump motor driver (transistor).
– ABS control module which sends operation signal
to ABS hydraulic unit to control fluid pressure
applied to each wheel cylinder based on signal
from each wheel speed sensor so as to prevent
wheel from locking.
– ABS hydraulic unit which operates according to
signal from ABS control module to control fluid
pressure applied to wheel cylinder of each 4
wheels.
– Solenoid valve power supply driver (transistor)
which supplies power to solenoid valve in ABS
hydraulic unit.
– Solenoid valve driver (transistor) which controls
each solenoid valves in ABS hydraulic unit.
– Pump motor driver (transistor) which supplies
power to pump motor in ABS hydraulic unit.
• G sensor which detects body deceleration speed for
4WD model.
This ABS is equipped with Electronic Brake force
Distribution (EBD) system that controls a fluid pressure
of rear wheels to best condition, which is the same
function as that of proportioning valve, by the signal from
wheel sensor independently of change of load due to
load capacity and so on. And if the EBD system fails to
operate properly, the brake warning light lights to inform
abnormality.

Downloaded from www.Manualslib.com manuals search engine 4E-3 ABS:
ABS Hydraulic Unit / Control Module Assembly
Description
S6RW0D4501002
ABS control module is a component of ABS hydraulic
unit / control module assembly and has the following
functions.
Self-Diagnosis Function
ABS control module diagnoses conditions of the system
component parts (whether or not there is any
abnormality) all the time and indicates the results
(warning of abnormality occurrence and DTC) through
the ABS warning light as described.• When ignition switch is turned ON, ABS warning light
lights for 2 seconds to check its circuit.
• When no abnormality has been detected (the system
is in good condition), ABS warning light turns OFF
after 2 seconds.
• When an abnormality in the system is detected, ABS
warning light lights and the area where that
abnormality lies is stored in the memory of EEPROM
in ABS control module.
CAN Communication System DescriptionS6RW0D4501003
Refer to “CAN Communication System Description in Section 1A” for CAN communication system description. ABS
control module communicates control data with each control module as follows.
ABS Control Module Transmission Data
1
I4RS0A450001-01
Wheel speed signal (Front-right)
Wheel speed signal (Front-left)
Wheel speed signal (Rear-right)
Wheel speed signal (Rear-left)
ABS active
ABS indication
EBD indicationCombination Meter
TransmitDATA
ABS control module ECM 4WD control module
I7RW01450001-06

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-10
Problem symptom confirmation
Check if what the customer claimed in “Customer
Questionnaire” is actually found in the vehicle and if that
symptom is found, whether it is identified as a failure.
(This step should be shared with the customer if
possible.) Check warning lights related to brake system
referring to “EBD Warning Light (Brake Warning Light)
Check” and “ABS Warning Light Check”.
DTC check, record and clearance
Perform “DTC Check” procedure, record it and then
clear it referring to “DTC Clearance”.
Recheck DTC referring to “DTC Check”.
When DTC which is recorded at DTC check procedure is
detected again after performing DTC clearance, go to
“Step 4: ABS Check: ” to proceed the diagnosis.
When DTC which is recorded at DTC check procedure is
not indicated anymore after performing DTC clearance,
ABS control module does not perform the system
diagnosis, or temporary abnormality may occur,
therefore go to “Step 2: Driving Test: ” to proceed the
diagnosis.
Step 2: Driving Test
Test drive the vehicle at 40 km/h (25 MPH) for more than
a minute and check if any trouble symptom (such as
abnormal lighting of ABS warning light) exists.
If the malfunction DTC is confirmed again at ignition
switch ON, driving test as described is not necessary.
Proceed to Step 3.
Step 3: DTC Check
Recheck DTC referring to “DTC Check”.
Step 4: ABS Check
According to ABS Check for the DTC confirmation in
Step 3, locate the cause of the trouble, namely in a
sensor, switch, wire harness, connector, actuator
assembly or other part and repair or replace faulty parts.
Step 5: Brakes Diagnosis
Check the parts or system suspected as a possible
cause referring to “Brakes Symptom Diagnosis in
Section 4A” and based on symptoms appearing on the
vehicle (symptom obtained through Steps 1 and 2 and
repair or replace faulty parts, if any).
Step 6: Check for Intermittent Problem
Check parts where an intermittent trouble is easy to
occur (e.g., wire harness, connector, etc.), referring to
“Intermittent and Poor Connection Inspection in Section
00” and related circuit of trouble code recorded in Step 1
to 3.
Step 7: Final Confirmation Test
Confirm that the problem symptom has gone and the
ABS is free from any abnormal conditions. If what has
been repaired is related to the malfunction DTC, clear
the DTC once referring to “DTC Clearance” and perform
test driving and confirm that no DTC is indicated.ABS Warning Light CheckS6RW0D4504002
1) Turn ignition switch ON.
2) Check that ABS warning light (1) comes ON for
about 2 seconds and then goes off.
If any faulty condition is found, advance to “ABS
Warning Light Does Not Come ON at Ignition Switch
ON” or “ABS Warning Light Comes ON Steady”.
EBD Warning Light (Brake Warning Light)
Check
S6RW0D4504003
NOTE
Perform this check on a level place.

1) Turn ignition switch ON with parking brake applied.
2) Check that EBD warning light (brake warning light)
(1) is turned ON.
3) Release parking brake with ignition switch ON and
check that EBD warning light (brake warning light)
goes off.
If it doesn’t go off, go to “EBD Warning Light (Brake
Warning Light) Comes ON Steady”.
11
I4RS0A450007-01
BRAKE
1
I4RS0A450008-01