2006 SUZUKI SX4 sensor

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 1C-2 Engine Electrical Devices:
Manifold Absolute Pressure (MAP) Sensor
Inspection (If Equipped)
S6RW0D1306002
1) Remove air cleaner assembly.
2) Disconnect connector from MAP sensor.
3) Remove MAP sensor.
4) Arrange 3 new 1.5 V batteries (2) in series (check
that total voltage is 4.5 – 5.0 V) and connect its
positive terminal to “Vin” terminal of sensor and
negative terminal to “Ground” terminal. Then check
voltage between “Vout” and “Ground”. Also, check if
voltage reduces when vacuum is applied up to 400
mmHg by using vacuum pump (3).
If check result is not satisfactory, replace MAP
sensor (1).
Output voltage (When input voltage is 4.5 – 5.5 V,
ambient temp. 20 – 30 °C, 68 – 86 °F)
5) Install MAP sensor securely.
6) Connect MAP sensor connector securely.
7) Install air cleaner assembly.
Electric Throttle Body Assembly On-Vehicle
Inspection
S6RW0D1306003
WARNING!
Never touch throttle valve with finger while
ignition switch is turned ON and accelerator
pedal is depressed. Otherwise, injury may
result by pinching the finger between throttle
valve and throttle body housing.

CAUTION!
• Do not disassemble electric throttle body
assembly.
• Do not expose electric throttle body
assembly to excessive shock like a
dropping it. If electric throttle body
assembly has been exposed to excessive
shock, it should be replaced.
• Be careful not to accrete a foreign material
(like dust and/or metallic particle) to the
throttle body housing and/or throttle valve.
Otherwise, the throttle body assembly is
breaking down by throttle valve accretion.
• Do not apply excessive moving force to
throttle valve for throttle valve operation
check and/or TP sensor performance
check.
Otherwise, the throttle body assembly is
breaking down by damaging the internal
resinous gear of throttle valve actuator.

NOTE
After replacing electric throttle body
assembly, perform calibration of electric
throttle body assembly referring to “Electric
Throttle Body System Calibration”.

Altitude
(Reference)Barometric pressureOutput
voltage
(ft) (m) (mmHg) (kPa) (V)
0 – 2000 0 – 610 760 – 707 100 – 94 3.3 – 4.3
2001 –
5000611 –
1524Under 707
over 63494 – 85 3.0 – 4.1
5001 –
80001525 –
2438Under 634
over 56785 – 76 2.7 – 3.7
8001 –
100002439 –
3048Under 567
over 52676 – 70 2.5 – 3.3
I3RM0A130005-01

Downloaded from www.Manualslib.com manuals search engine Engine Electrical Devices: 1C-3
Throttle Valve Visual Check
1) Remove air cleaner outlet hose.
2) Check that there isn’t any foreign matter caught
between throttle valve and throttle body housing. If
there is, take it out after removing throttle body
referring to “Electric Throttle Body Assembly
Removal and Installation in Section 1D” and clean
inside of throttle body thoroughly.
Throttle Valve Operation Check
1) Remove air cleaner outlet hose.
2) Turn OFF ignition switch.
3) Move throttle valve with finger to its full open position
and check that it moves smoothly.
4) Take off finger from opened throttle valve (1) which is
at full open position and check that it moves
smoothly by its return spring and open spring force
back to default position (position where throttle valve
is open by 7° (2) from completely closed position).
5) Move throttle valve with finger to its completely
closed position and check that it moves smoothly.
6) Take off finger from closed throttle valve (1) which is
at completely closed position and check that it
moves smoothly by its return spring and open spring
force back to default position.
If check result is not satisfactory, replace electric
throttle body assembly.Electric Throttle Body Assembly Operation Check
1) Remove air cleaner outlet hose.
2) Turn ON ignition switch.
3) Depress accelerator pedal gradually and check that
throttle valve moves smoothly until it opens fully.
4) Release accelerator pedal depressed in Step 3) and
check that throttle valve (1) moves back to default
position (position where throttle valve is open by 7°
(2) from its completely closed position).
If check result is satisfactory, electric throttle body
system is in good condition.If check result is not
satisfactory, proceed to next step.
5) Perform “Accelerator Pedal Position (APP) Sensor
Assembly On-Vehicle Inspection”, “Throttle Actuator
(Motor) Check” and “Throttle Position Sensor
Performance Check”.
If check results are not satisfactory, replace electric
throttle body assembly.
If check results are satisfactory, wire circuit and/or
ECM are faulty.
Throttle Actuator (Motor) Check
1) Turn OFF ignition switch.
2) Disconnect connector from electric throttle body
assembly.
3) Measure resistance between “M1” terminal (1) and
“M2” terminal (2) of electric throttle body assembly.
If measured resistance is out of specified value,
replace electric throttle body assembly.
Throttle actuator (motor) resistance
0.3 – 100 Ω at 20 °C (68 °F)
I4RS0B130004-01
1
2
I4RS0B130005-01
1
2
I4RS0B130005-01
21
I4RS0B130023-01

Downloaded from www.Manualslib.com manuals search engine 1C-4 Engine Electrical Devices:
Throttle Position Sensor Performance Check
1) Remove air cleaner outlet hose.
2) Turn OFF ignition switch.
3) Disconnect connector from electric throttle body
assembly.
4) Check throttle position sensor (main and sub) output
voltage as following steps.
a) For throttle position sensor (main), arrange 3
new 1.5 V batteries (1) in series (check that total
voltage is 4.5 – 5.0 V) and connect its positive
terminal to “Vin” terminal (2) and negative
terminal to “Ground” terminal (3) of sensor. Then
using voltmeter, connect positive terminal to
“Vout 1” terminal (4) of sensor and negative
terminal to battery.
b) For throttle position sensor (sub), arrange 3 new
1.5 V batteries (1) in series (check that total
voltage is 4.5 – 5.0 V) and connect its positive
terminal to “Vin” terminal (2) and negative
terminal to “Ground” terminal (3) of sensor. Then
using voltmeter, connect positive terminal to
“Vout 2” terminal (4) of sensor and negative
terminal to battery.
c) Measure output voltage variation while throttle
valve is opened and closed as following
specification.If sensor voltage is out of specified value and linear
variation as the following graph, replace electric throttle
body assembly.
TP sensor output voltage
TP sensor (main) [A]: 0.45 – 4.88 V, varying
according to throttle valve opening by finger
(Voltage should vary by 0.04 V for each 1° valve
opening)
TP sensor (sub) [B]: 1.33 – 5.007 V, varying
according to throttle valve opening by finger
(Voltage should vary by about 0.032 V for each 1°
valve opening)
1 42 3
I4RS0B130007-02
1
3
24
I4RS0B130008-01
[C]: TP sensor (main) output voltage
[D]: TP sensor (sub) output voltage
[E]: Throttle valve opening
[F]: Position where throttle valve is open by 7° from completely closed
position (default position)
[G]: Angel obtained when accelerator pedal is depressed fully (84°)
[H]: Angle obtained when throttle valve is fully opened with finger (96°)
[B]
[A][D]
(V) [C]
(V)
[F]
[G][E] 0.45 - 0.75 0.724 - 1.036 3.675 - 4.245 4.000 - 4.880
1.33 - 1.63 1.604 - 1.9163.883 - 4.453 4.097 - 5.007
[H]
I7RW01130019-05

Downloaded from www.Manualslib.com manuals search engine Engine Electrical Devices: 1C-5
Electric Throttle Body System CalibrationS6RW0D1306004
NOTE
If the service described under the
“Precautions of Electric Throttle Body
System Calibration in Section 1A” is
performed, calibrate electric throttle body
system as follows.

1) If electric throttle body assembly and/or accelerator
pedal position (APP) sensor assembly are replaced,
perform following steps.
a) Disconnect negative cable at battery for 20
seconds or more for the purpose of clearing
calibration data of closed throttle position from
memory in ECM.
b) Connect negative cable to battery.
2) Keep ignition switch at ON position for 5 seconds or
more without running engine.
Accelerator Pedal Position (APP) Sensor
Assembly On-Vehicle Inspection
S6RW0D1306005
1) Check that APP sensor assembly has been mounted
to vehicle body properly (no pinched floor carpet,
etc.).
If mounting is not properly, reinstall APP sensor
assembly properly referring to “Accelerator Pedal
Position (APP) Sensor Assembly Removal and
Installation”.
2) Connect scan tool to DLC with ignition switch turned
OFF.
3) Turn ON ignition switch and select “Data List” mode
on scan tool.4) Check that accelerator pedal position sensor voltage
varies as the following graph.
If sensor voltage is out of specified value or does not
vary linearly as the following graph, check APP
sensor assembly referring to “Accelerator Pedal
Position (APP) Sensor Assembly Inspection”.
Accelerator Pedal Position (APP) Sensor
Assembly Removal and Installation
S6RW0D1306006
CAUTION!
• Do not expose APP sensor assembly to
excessive shock like a dropping it. If APP
sensor assembly has been exposed to
excessive shock, it should be replaced.
• Be careful not to expose sensor section of
APP sensor assembly to water.

NOTE
After replacing APP sensor assembly,
perform calibration of throttle valve referring
to “Electric Throttle Body System
Calibration”.

[A]: APP sensor (main) voltage
[B]: APP sensor (sub) voltage
[C]: Voltage
[D]: Idle position of accelerator pedal
[E]: Full depressed position of accelerator pedal
[C]
[D] [E]
3.50 - 4.27 V
1.74 - 2.17 V
0.65 - 0.82 V
0.30 - 0.44 V
[A]
[B]
I7RW01130020-01

Downloaded from www.Manualslib.com manuals search engine 1C-6 Engine Electrical Devices:
Removal
1) Disconnect negative cable at battery.
2) Disconnect connector from APP sensor assembly.
3) Remove APP sensor assembly from its bracket.
Installation
Reverse removal procedure for installation noting the
following.
• Tighten APP sensor assembly upper nut (1) first and
then lower nuts (2) to specified torque.
Tightening torque
APP sensor assembly nut (a): 6 N⋅m (0.6 kgf-m, 4.5
lb-ft)
• Connect connector to APP sensor assembly securely.
Accelerator Pedal Position (APP) Sensor
Assembly Inspection
S6RW0D1306007
Check APP sensor (main and sub) output voltage as
following steps.
1) For APP sensor (main), arrange 3 new 1.5 V
batteries (1) in series (check that total voltage is 4.5
– 5.0 V) and connect its positive terminal to “Vin 1”
terminal (2) and negative terminal to “Ground 1”
terminal (3) of sensor. Then using voltmeter, connect
positive terminal to “Vout 1” terminal (4) of sensor
and negative terminal to battery.2) For APP sensor (sub), arrange 3 new 1.5 V batteries
(1) in series (check that total voltage is 4.5 – 5.0 V)
and connect its positive terminal to “Vin 2” terminal
(2) and negative terminal to “Ground 2” terminal (3)
of sensor. Then using voltmeter, connect positive
terminal to “Vout 2” terminal (4) of sensor and
negative terminal to battery.
3) Measure output voltage variation while accelerator
pedal is no depressed and fully depressed as
following graph.
If sensor voltage is out of specified value or does not
vary linearly as the following graph, replace APP sensor
assembly.
1, (a)
2, (a)
I5RW0A130004-01
1 2 34I5RW0A130005-01
[C]: Voltage
[D]: Idle position of accelerator pedal
[E]: Fully depressed position of accelerator pedal
1 2 3 4I5RW0A130006-02
[C]
[D] [E]
3.50 - 4.27 V
1.74 - 2.17 V
0.65 - 0.82 V
0.30 - 0.44 V
[A]
[B]
I7RW01130020-01

Downloaded from www.Manualslib.com manuals search engine Engine Electrical Devices: 1C-7
Engine Coolant Temperature (ECT) Sensor
Removal and Installation
S6RW0D1306008
Removal
1) Disconnect negative cable at battery.
2) Drain coolant referring to “Cooling System Draining
in Section 1F”.
WARNING!
To 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.

3) Remove air intake pipe.
4) Disconnect connector from ECT sensor (1).
5) Remove ECT sensor from water outlet.
Installation
Reverse removal procedure noting the following.
• Clean mating surfaces of ECT sensor and water
outlet.
• Check O-ring for damage and replace, if necessary.
• Tighten ECT sensor (1) to specified torque.
Tightening torque
ECT sensor (a): 15 N·m (1.5 kgf-m, 11.0 lb-ft)
• Connect connector to ECT sensor securely.
• Refill coolant referring to “Cooling System Flush and
Refill in Section 1F”.
Engine Coolant Temperature (ECT) Sensor
Inspection
S6RW0D1306009
Immerse temperature sensing part of ECT sensor (1) in
water (or ice) and measure resistance between sensor
terminals while heating water gradually.
If measured resistance doesn’t show such characteristic
as shown, replace ECT sensor.
1
I2RH0B130008-01
1,(a)
I2RH0B130009-01
I5RW0A130007-01

Downloaded from www.Manualslib.com manuals search engine 1C-8 Engine Electrical Devices:
Heated Oxygen Sensor (HO2S-1 and HO2S-2)
Heater On-Vehicle Inspection (If Equipped)
S6RW0D1306010
1) Disconnect sensor connector.
2) Using ohmmeter, measure resistance between
terminals “V
B” and “GND” of sensor connector.
If found faulty, replace oxygen sensor.
NOTE
Temperature of sensor affects resistance
value largely. Make sure that sensor heater is
at correct temperature.

Resistance of oxygen sensor heater
HO2S-1: 5.0 – 6.4 Ω at 20 °C (68 °F)
HO2S-2: 11.7 – 14.5 Ω at 20 °C (68 °F)
Viewed from terminal side
3) Connect sensor connector securely.
Heated Oxygen Sensor (HO2S-1 and HO2S-2)
Removal and Installation (If Equipped)
S6RW0D1306011
Removal
WARNING!
To avoid danger of being burned, do not
touch exhaust system when system is hot.
Oxygen sensor removal should be performed
when system is cool.

1) Disconnect negative cable at battery.
2) Disconnect connector of heated oxygen sensor and
release its wire harness from clamps.
3) Perform following items before removing heated
oxygen sensor.
a) For HO2S-1, remove exhaust manifold referring
to “Exhaust Manifold Removal and Installation in
Section 1K”, if necessary.
b) For HO2S-2, hoist vehicle.
4) Remove heated oxygen sensor from exhaust pipe or
exhaust manifold.Installation
Reverse removal procedure noting the following.
• Tighten heated oxygen sensor (1) to specified torque.
Tightening torque
Heated oxygen sensor (a): 45 N·m (4.5 kgf-m,
32.5 lb-ft)
• Install exhaust manifold referring to “Exhaust Manifold
Removal and Installation in Section 1K”, if removed.
• Connect connector of heated oxygen sensor (1) and
clamp wire harness securely.
• After installing heated oxygen sensor, start engine
and check that no exhaust gas leakage exists.
[A]: HO2S-1 [B]: HO2S-2
I4RS0A130006-01
[A]: HO2S-1 [B]: HO2S-2
[A]
[B]
1, (a)
1, (a)
I3RM0A130007-01