2006 SUZUKI SX4 Switch

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-213
1) Connect SUZUKI scan tool to DLC (1) with ignition
switch turned OFF.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)2) Warm up engine to normal operating temperature.
3) Check engine idle speed and “IAC throttle opening”
by using “Data List” mode on scan tool to check “IAC
throttle opening”.
4) If check result is out of specification, inspect electric
throttle body assembly referring to “Electric Throttle
Body Assembly On-Vehicle Inspection in Section
1C”.
Engine idle speed
A/C OFF: 700 ± 50 rpm (IAC duty: 5 – 25%)
A/C ON: 750 ± 50 rpm
5) Check that specified engine idle speed is obtained
with A/C turned ON if vehicle is equipped with A/C.
If not, check A/C system referring to “A/C System
Circuits Check”.
Special Tools and Equipment
Special ToolS6RW0D1108001
(A) 1I5RW0C110011-01
09912–58432 09912–58442
Fuel pressure gauge hose Fuel pressure gauge
This tool is included in fuel
pressure gauge set (09912-
58413). )This tool is included in fuel
pressure gauge set (09912-
58413). )
09912–58490 09933–06320
3-way joint & hose ECM check harness (120P)
)) / )
SUZUKI scan tool (SUZUKI-
SDT)
—
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 1B-1 Aux. Emission Control Devices:
Engine
Aux. Emission Control Devices
Diagnostic Information and Procedures
EGR System Inspection (If Equipped)S6RW0D1204001
1) Connect SUZUKI scan tool to data link connector
(DLC) (1) with ignition switch turned OFF.
2) Turn ON ignition switch and erase DTC using
“Delete” in “DTC” menu of scan tool.
3) Start engine and warm it up to normal operating
temperature, then select “Data List” mode on scan
tool.
4) Make sure that vehicle condition is as follows.
• Vehicle speed = 0 km/h (0 KPH)
• Engine speed ≤ 900 rpm
• Engine coolant temp. ≥ 90 °C, 164 °F5) With engine idling (without depressing accelerator
pedal), open EGR valve by using “Step EGR
Control” mode in “Engine / Active Test” menu. In this
state, as EGR valve opening increases engine idle
speed drops. If not, possible cause is clogged EGR
gas passage, stuck or faulty EGR valve.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
Repair Instructions
EVAP Canister Purge InspectionS6RW0D1206001
NOTE
Before inspection, check to make sure that
gear shift lever is in neutral position and that
parking brake lever is pulled all the way up.

1) Disconnect purge hose (1) from purge pipe.
2) Place finger against the end of disconnected hose
and check that vacuum is not felt there when engine
is cool and running at idle speed. If check result is
not satisfactory, check EVAP canister purge valve,
wire harness and ECM.
EVAP Canister Purge Valve and Its Circuit
Inspection
S6RW0D1206002
WARNING!
Do not apply vacuum by mouth; otherwise
harmful fuel vapor can be breathed in.

CAUTION!
Do not apply vacuum more than –86 kPa (–
12.47 psi); otherwise EVAP canister purge
valve could be damaged.

(A) 1I5RW0C110011-01
1
I5RW0A120006-01

Downloaded from www.Manualslib.com manuals search engine Aux. Emission Control Devices: 1B-2
1) Prepare to operate EVAP canister purge valve as
follows.
a) When using SUZUKI scan tool:
i) Connect SUZUKI scan tool to DLC (1) with
ignition switch turned OFF and disconnect
purge valve vacuum hoses from intake
manifold and EVAP canister.
ii) Turn ON ignition switch, clear DTC and
select “Engine / Active Test” mode on
SUZUKI scan tool.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
b) When not using SUZUKI scan tool:
NOTE
Before performed this check, be sure to read
the “Precautions of ECM Circuit Inspection in
Section 1A”.

i) Disconnect purge valve vacuum hoses from
intake manifold and purge pipe.
ii) Remove ECM from its bracket referring to
“Engine Control Module (ECM) Removal and
Installation in Section 1C”.
iii) Connect special tool between ECM and ECM
connector referring to “Inspection of ECM
and Its Circuits in Section 1A”.
iv) Turn ON ignition switch.
Using service wire, ground “C01-29” terminal
circuit of special tool (valve ON: “B”) and
unground it (valve OFF: “A”).2) Check purge valve for operation and vacuum
passage for clog when valve is switched ON and
OFF by using SUZUKI scan tool or service wire.
If check result is not satisfactory, check vacuum
hoses, EVAP canister purge valve, wire harness and
connections.
EVAP canister purge valve specification
[A] Valve OFF: When vacuum (–60 kPa (–8.7 psi))
is applied to hose (1), vacuum can be applied.
[B] Valve ON: When vacuum is applied to hose
(1), vacuum can not be applied.
Special tool
(A): 09917–47011
Vacuum Passage InspectionS6RW0D1206003
Start engine and run it at idle speed. Disconnect vacuum
hose (1) from EVAP canister purge valve (2). With finger
placed against disconnected hose, check that vacuum is
applied.
If it is not applied, clean vacuum passage by blowing
compressed air.
(A) 1I5RW0C110011-01
“C01-29”
“A”
“B”
I6RW0D120001-01
[A]
1 (A)
[B]
1 (A)
I5RW0A120008-01
1
2
I5RW0A120003-01

Downloaded from www.Manualslib.com manuals search engine 1B-3 Aux. Emission Control Devices:
Vacuum Hose InspectionS6RW0D1206004
Check hoses for connection, leakage, clog and
deterioration.
Replace as necessary.
EVAP Canister Purge Valve InspectionS6RW0D1206005
WARNING!
Do not apply vacuum by mouth; otherwise
harmful fuel vapor can be breathed in.

CAUTION!
Do not apply vacuum more than –86 kPa (–
12.47 psi); otherwise EVAP canister purge
valve could be damaged.

1) With ignition switch turned OFF, disconnect coupler
and vacuum hoses from canister purge valve.
2) Remove EVAP canister purge valve from air cleaner
assembly.3) Check resistance between two terminals of EVAP
canister purge valve.
If resistance is not as specified, replace EVAP
canister purge valve.
EVAP canister resistance
30 – 34 Ω at 20 °C (68 °F)
4) With coupler disconnected, apply vacuum (–60 kPa
(–8.7 psi)) to pipe (1). If vacuum can be applied, go
to next step. If vacuum can not be applied, replace
EVAP canister purge valve.
5) In this state, connect 12 V-battery to EVAP canister
purge valve terminals. If vacuum can not be applied,
EVAP canister purge valve is in good condition.
If applied, replace EVAP canister purge valve.
WARNING!
Do not suck the air through valve. Fuel vapor
inside valve is harmful.

Special tool
(A): 09917–47011
6) Install EVAP canister purge valve to air cleaner
assembly.1. Purge hose (EVAP canister purge valve side)
2. Purge pipe (EVAP canister side)
I6RW0D120002-02
I3RM0A120008-01
1
1(A)
(A)
I3RB0A120007-01

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