2006 SUZUKI SX4 check engine

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-12
Fuel Filler Cap InspectionS6RW0D1706010
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

Remove cap (1), and check gasket for even filler neck
imprint, and deterioration or any damage. If gasket (2) is
in malcondition, replace cap.
NOTE
If cap requires replacement, only a cap with
the same features should be used. Failure to
use correct cap can result in fire and
personal injury.

Fuel Tank Inlet Valve Removal and InstallationS6RW0D1706017
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal
1) Remove fuel tank referring to “Fuel Tank Removal
and Installation”.
2) Remove fuel tank inlet valve (1) using flat head rod
(2) or the like.
CAUTION!
Be careful not to damage fuel tank inlet
valve(1) with flat head rod (2) or the like.

Installation
1) Install fuel tank inlet valve (1) to fuel tank.
2) Install fuel tank referring to “Fuel Tank Removal and
Installation”.
Fuel Tank Inlet Valve InspectionS6RW0D1706018
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Check fuel tank inlet valve for the following.
If any damage or malfunction is found, replace.
•Damage
• Smooth opening and closing
I2RH01170008-01
I7RW01170013-01
I2RH0B170018-01
I2RH0B170019-01

Downloaded from www.Manualslib.com manuals search engine 1G-13 Fuel System:
Fuel Tank Removal and InstallationS6RW0D1706011
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

Removal
1) Relieve fuel pressure in fuel feed line according to
“Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Remove fuel filler cap.
4) Insert hose of a hand operated pump into fuel filler
hose (1) and drain fuel in space “A” as shown in
figure.
CAUTION!
Do not force pump hose into fuel tank.

5) Hoist vehicle, and remove clamp (2), fuel filler hose
(1) and breather hose (3) from fuel filler neck.6) Remove exhaust center pipe referring to “Exhaust
Pipe and Muffler Removal and Installation in Section
1K”.
7) Remove propeller shaft (For 4WD model) referring to
“Propeller Shaft Assembly Removal and Installation
in Section 3D”.
8) Due to absence of fuel tank drain plug, drain fuel
tank by pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
CAUTION!
• Do not force pump hose into fuel tank.
• Never store fuel in an open container due
to possibility of fire or explosion.

9) Disconnect quick joint (fuel pipe) (1) from fuel pipes
(2) referring to “Fuel Hose Disconnecting and
Reconnecting”.
10) Support fuel tank (1) with jack (2) and remove its
mounting bolts (3).
11) Lower fuel tank a little as to disconnect wire harness
at connector (1)and ground wire (2), then remove
fuel tank.
2. Inlet check valve
I4RS0B170022-01
1 23
I5RW0A170012-01
2
1
I5RW0A170014-02
1
2
33
I5RW0A170013-01
1
2
I7RW01170009-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-14
Installation
CAUTION!
• When connecting joint, clean outside
surfaces of pipe where joint is to be
inserted, push joint into pipe till joint lock
clicks and check to ensure that pipes are
connected securely, or fuel leak may
occur.
• Never let the fuel hoses touch the ABS
sensor harness (if equipped).

1) If parts have been removed from fuel tank, install
them before installing fuel tank to vehicle.
2) Raise fuel tank (1) with jack (2) and connect fuel
pump connector (3), ground wire (4) and clamp wire
harness.
Tightening torque
Ground wire bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Install fuel tank to vehicle.
Tightening torque
Fuel tank bolt (b): 45 N·m (4.5 kgf-m, 33.0 lb-ft)4) Connect fuel filler hose (1) and breather hose (2) to
filler neck (3) as shown in figure, and clamp them
securely.
Tightening torque
Fuel filler hose clamp (a): 1.5 N·m (0.15 kgf-m,
1.0 lb-ft)
5) Connect fuel feed hose (1) and vapor hose (2) to
each pipe as shown in figure, and clamp them
securely.
6) Install exhaust center pipe referring to “Exhaust Pipe
and Muffler Removal and Installation in Section 1K”.
7) Install propeller shaft (For 4WD model) referring to
“Propeller Shaft Assembly Removal and Installation
in Section 3D”.
8) Connect negative cable at battery.
9) With engine OFF, turn ignition switch to ON position
and check for fuel leaks.
Fuel Tank InspectionS6RW0D1706012
After removing fuel tank, check hoses and pipes
connected to fuel tank for leaks, loose connections,
deterioration or damage. Also check fuel pump
assembly gaskets for leaks, visually inspect fuel tank for
leaks and damage.
Replace any damaged or malconditioned parts.
(b)(b)
1
2
3
4
(a)
I7RW01170010-01
1(a)2
3
I5RW0A170017-01
1
2
I5RW0A170018-01

Downloaded from www.Manualslib.com manuals search engine 1G-15 Fuel System:
Fuel Tank Purging ProcedureS6RW0D1706013
WARNING!
• Before starting the following procedure, be
sure to observe “Precautions on Fuel
System Service” in order to reduce the risk
of fire and personal injury.
• This purging procedure will not remove all
fuel vapor.
Do not attempt any repair on tank using
heat of flame as an explosion resulting in
personal injury could occur.

CAUTION!
Never remain water in fuel tank after washing,
or fuel tank inside will get corrosion.

The following procedure are used for purging fuel tank.
1) After removing fuel tank, remove all hoses, pipes
and fuel pump assembly from fuel tank.
2) Drain all remaining fuel from tank.
3) Place fuel tank to flushing area.
4) Fill tank with warm water or tap water, and agitate
vigorously and drain. Repeat this washing until
inside of tank is clean. Replace tank if its inside is
rusty.
5) Completely flush out remaining water after washing.
6) Be sure to dry fuel tank assembly thoroughly out of
direct sunlight after washing.
Fuel Pump On-Vehicle InspectionS6RW0D1706014
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

NOTE
The fuel pressure regulator is incorporated
with the fuel pump assembly so individual
inspection of it is impossible.

1) Remove filler cap and turn ON ignition switch (2).
Then fuel pump operating sound should be heard
from fuel filler (1) for about 2 seconds and stop. Be
sure to reinstall fuel filler cap after checking.
If the check result is not satisfactory, go to “Fuel
Pump and Its Circuit Check in Section 1A”.2) Turn OFF ignition switch and leave over 10 minutes
as it is.
3) Fuel pressure should be felt at fuel feed hose (1) for
about 2 seconds after ignition switch ON.
If fuel pressure is not felt, go to “Fuel Pressure
Check in Section 1A”.
Fuel Pump Assembly Removal and InstallationS6RW0D1706015
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

Removal
1) Remove fuel tank from vehicle referring to “Fuel
Tank Removal and Installation”.
2) Disconnect fuel pipe (1) from fuel pump assembly (2)
referring to “Fuel Hose Disconnecting and
Reconnecting”.
3) Remove fuel pump assembly and earth bracket from
fuel tank.
IVSY01170013-01
1I5RW0A170019-01
1
2
I7RW01170011-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-16
Installation
CAUTION!
When connecting joint, clean outside surface
of pipe where joint is to be inserted, push
joint into pipe till joint lock clicks and check
to ensure that pipes are connected securely,
or fuel leak may occur.

1) Clean mating surfaces of fuel pump assembly and
fuel tank.
2) Put plate (2) on fuel pump assembly (1) by matching
the protrusion of fuel pump assembly (3) to plate
hole (4) as shown.
3) Install new gasket (2), fuel pump assembly (1) and
earth bracket (5) with plate (3) to fuel tank (4).
Tightening torque
Fuel pump assembly bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)
4) Connect fuel feed pipe (1) to fuel pump assembly
(2).5) Install fuel tank to vehicle. Refer to “Fuel Tank
Removal and Installation”.
Main Fuel Level Sensor Removal and
Installation
S6RW0D1706019
CAUTION!
• Do not touch resister plate (1) and deform
arm (2). It may cause main fuel level sensor
to fail.
• Be very careful not to cause damage to
fuel tube installed section (sealed section
in bore). If it be damaged, replace it with
new one, or fuel will leak from the part.

Removal
1) Remove fuel pump assembly from fuel tank referring
to “Fuel Pump Assembly Removal and Installation”.
2) Disconnect main fuel level sensor connector (3).
3) With pressing snap-fit part (2), remove main fuel
level sensor (1) by sliding it in the arrow direction as
shown in figure.
Installation
Reverse removal procedure for installation.
3
1 2 4
I5JB0A171025-01
3
1
2
(a)
4
5
I7RW01170012-01
1
2
I7RW01170011-01
1
2I4RS0A170016-01
1 3
12
I5JB0A171026-01

Downloaded from www.Manualslib.com manuals search engine 1G-17 Fuel System:
Fuel Pump InspectionS6RW0D1706016
• Check fuel pump assembly for damage.
• Check fuel suction filter for evidence of dirt and
contamination.
If present, replace or clean and check for presence of
dirt in fuel tank.
• For electrical circuit, refer to “Fuel Pump and Its
Circuit Check in Section 1A”.
• For inspection of fuel level gauge (1), refer to “Fuel
Level Sensor Inspection in Section 9C”.
Specifications
Tightening Torque SpecificationsS6RW0D1707001
NOTE
The specified tightening torque is also described in the following.
“Fuel System Components”
“Fuel Hose Disconnecting and Reconnecting”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
1
I5JB0A171027-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Fuel delivery pipe bolt 25 2.5 18.0)
Ground wire bolt 11 1.1 8.0)
Fuel tank bolt 45 4.5 33.0)
Fuel filler hose clamp 1.5 0.15 1.0)
Fuel pump assembly bolt 11 1.1 8.0)

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-18
Special Tools and Equipment
Special ToolS6RW0D1708001
09912–57610 09912–58421
Injector checking tool plate Checking tool set
)This kit includes the
following items. 1. Tool body
and washer, 2. Body plug, 3.
Body attachment-1, 4.
Holder, 5. Return hose and
clamp, 6. Body attachment-2
and washer, 7. Hose
attachment-1, 8. Hose
attachment-2 )
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 09919–47020
3-way joint & hose Quick joint remover
))
09930–88530 SUZUKI scan tool (SUZUKI-
SDT)
Injector test lead —
)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 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).