2006 SUZUKI SX4 electrical

Downloaded from www.Manualslib.com manuals search engine 1C-14 Engine Electrical Devices:
Specifications
Tightening Torque SpecificationsS6RW0D1307001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
ECM mounting bolt 8 0.8 6.0)
ECT sensor 15 1.5 11.0)
Heated oxygen sensor 45 4.5 32.5)
CMP sensor bolt (non-VVT model) 10 1.0 7.5)
CMP sensor bolt (VVT model) 11 1.1 8.0)
CKP sensor bolt 11 1.1 8.0)
Knock sensor 22 2.2 16.0)
MAF and IAT sensor screw 1.5 0.15 1.1)

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 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-9 Ignition System:
2) Start engine and warm it up to normal operating
temperature.
3) Make sure that all of electrical loads except ignition
are switched off.
4) Check to be sure that idle speed is within
specification.
5) Fix ignition timing by using “Fixed Spark Control” of
“Engine / Active Test” mode on scan tool.
6) Set timing light (1) to high-tension cord for No.1
cylinder and check that ignition timing is within
specification.
Initial ignition timing
fixed with SUZUKI scan tool: 5 ± 3° BTDC (at
specified idle speed)
Ignition order
1 – 3 – 4 – 2
Special tool
(A): 09930–764207) If ignition timing is out of specification, check the
followings.
• CKP sensor
• CKP sensor plate
• TP sensor
• CMP sensor
• CMP sensor rotor tooth of camshaft
• Vehicle speed signal from ABS hydraulic unit /
control module
• Knock sensor
• Timing chain cover installation
8) After checking initial ignition timing, release ignition
timing fixation by using scan tool.
9) With engine idling (throttle opening at closed position
and vehicle stopped), check that ignition timing is
about 5° – 15° BTDC (Constant variation within a
few degrees from 5° – 15° BTDC indicates no
abnormality but proves operation of electronic timing
control system.) Also, check that increasing engine
speed advances ignition timing.
If the check results are not satisfactory, check CKP
sensor and ECM.
1, (A)10
0I3RB0A180004-01

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Engine
Charging System
General Description
Battery DescriptionS6RW0D1A01001
The battery has three major functions in the electrical
system.
• It is a source of electrical energy for cranking the
engine.
• It acts as a voltage stabilizer for the electrical system.
• It can, for a limited time, provide energy when the
electrical load exceeds the output of the generator.
Carrier and Hold-Down
The battery carrier should be in good condition so that it
will support the battery securely and keep it level. Before
installing the battery, the battery carrier and hold-down
clamp should be clean and free from corrosion and
make certain there are no parts in carrier.
To prevent the battery from shaking in its carrier, the
hold-down bolts should be tight enough but not over-
tightened.
Electrolyte Freezing
The freezing point of electrolyte depends on its specific
gravity. Since freezing may ruin a battery, it should be
protected against freezing by keeping it in a fully
charged condition. If a battery is frozen accidentally, it
should not be charged until it is warmed.
Sulfation
If the battery is allowed to stand for a long period in
discharged condition, the lead sulfate becomes
converted into a hard, crystalline substance, which will
not easily turn back to the active material again during
the subsequent recharging. “Sulfation” means the result
as well as the process of that reaction. Such a battery
can be revived by very slow charging and may be
restored to usable condition but its capacity is lower than
before.Built-In Indicator (If Equipped)
The battery has a built-in temperature compensated
indicator in the top of the battery. This indicator is to be
used with the following diagnostic procedure. When
checking the indicator, make sure that the battery has a
clean top. A light may be needed in some poorly-lit
areas.
Three types of indication available under normal
operation are as follows.
•Green dot
Battery is sufficiently charged for testing.
•Dark
Battery must be charged before testing. If there is a
cranking complaint, battery should be tested as
described in “Battery Inspection”. Charging and
electrical systems should also be checked at this time.
•Clear or light yellow
This means that fluid level is below the bottom of
hydrometer. Its possible cause is excessive or
prolonged charging, a broken case, excessive tipping
or normal battery deterioration. When the battery is
found in such condition, it is possible that high
charging voltage is caused by the faulty charging
system and therefore, charging and electrical systems
need to be checked. If there is a trouble in cranking
and its cause lies in the battery, it should be replaced.
I2RH011A0001-01

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Generator DescriptionS6RW0D1A01002
The basic charging system is the IC integral regulator charging system. The internal components are connected
electrically as shown below.
Charging System Circuit
The generator features a solid state regulator that is mounted inside the generator. All regulator components are
enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the rear housing. The
regulator voltage is being controlled by ECM under some conditions while driving. Refer to “Generator Control System
Description in Section 1A” in related manual.
The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication.
Two brushes carry current through the two slip rings to the field coil mounted on the rotor, and under normal conditions
will provide long period of attention-free service.
The stator windings are assembled inside a laminated core that forms part of the generator frame.
A rectifier bridge connected to the stator windings contains diodes, and electrically changes that stator AC. voltages to
a D.C. voltage which appears at the generator output terminal.
1 26345
4
3B
7
8
9
10E FFRCIG
L
I6RW0D1A0002-01
1. Pulley 6. Field coil B: Generator output (Battery terminal) L: Lamp terminal
2. Pulley nut 7. Regulator C: Generator cut FR: Field duty monitor
3. Rotor fan 8. Brush E: Ground
4. Stator coil 9. Rear end frame F: Field coil terminal
5. Stator core 10. Drive end frame IG: Ignition terminal
B
IG
L
C
E
7
2 4
3
5
FR
610
11
12 13 1
[A]
IG1 9
14
8
I6RW0D1A0001-03
[A]: If equipped with electric load current sensor 4. Diode 8. Battery 12. Combination meter
1. Generator with regulator assembly 5. Field coil (rotor coil) 9. Electric load current sensor (if equipped) 13. CAN driver
2. I.C. regulator 6. Charge indicator light 10. ECM 14. Main fuse box
3. Stator coil 7. Main switch 11. BCM

Downloaded from www.Manualslib.com manuals search engine 1J-4 Charging System:
Diagnostic Information and Procedures
Battery InspectionS6RW0D1A04001
Common Causes of Failure
A battery is not designed to last indefinitely; however,
with proper care, it will provide many years of service. If
the battery performs satisfactorily during test buy fails to
operate properly for no apparent reason, the following
are some factors that may point to the cause of trouble:
• Accessories left on overnight or for an extended
period without the generator operating.
• Slow average driving speed for short periods.
• Electrical load exceeding generator output particularly
with addition of aftermarket equipment.
• Defects in charging system such as high resistance,
slipping drive belt, loose generator output terminal,
faulty generator or voltage regulator. Refer to
“Generator Symptom Diagnosis”.
• Battery abuse, including failure to keep battery cable
terminals clean and tight or loose battery hold down.
• Mechanical problems in electrical system such as
shorted or pinched wires.
Visual Inspection
Check for obvious damage, such as cracked or broken
case or cover, that could permit loss of electrolyte. If
obvious damage is noted, replace battery. Determine
cause of damage and correct as needed.
Generator Symptom DiagnosisS6RW0D1A04002
CAUTION!
• Do not mistake polarities of “IG” terminal
and “L” terminal.
• Do not create short circuit between “IG”
and “L” terminals. Always connect these
terminals through a lamp.
• Do not connect any load between “L” and
“E” terminals.
• When connecting charger or booster
battery to vehicle battery, refer to “Jump
Starting in Case of Emergency”.

Trouble in charging system will show up as one or more
of the following conditions:
1) Faulty indicator lamp operation.
2) An undercharged battery as evidenced by slow
cranking or indicator dark.
3) An overcharged battery as evidenced by excessive
spewing of electrolyte from vents.
Noise from generator may be caused by loose drive
pulley, loose mounting bolts, worn or dirty bearings,
defective diode, or defective stator.
B: Generator output (Battery terminal) IG: Ignition terminal
C: C terminal L: Lamp terminal
E: Ground FR: Field duty monitor
F: Field coil terminal
E FFRC
B
IG
L
I6RW0D1A0003-01

Downloaded from www.Manualslib.com manuals search engine 1J-6 Charging System:
3) Ground “F” terminal and start engine, then measure
voltage at “B” terminal as shown in figure.
• Voltage is higher than standard value. It is
considered that generator itself is good but IC
regulator has been damaged, replace IC
regulator.
• Voltage is lower than standard value. It is
considered that generator itself has problem,
check the generator.
Load Check
1) Run engine at 2,000 rpm and turn on head light and
heater motor.
2) Measure current and if it is less than 20 A, repair or
replace generator.Generator Test (Overcharged Battery Check)S6RW0D1A04004
1) To determine battery condition, refer to “Battery
Description”.
2) If obvious overcharged condition exists as evidenced
by excessive spewing of electrolyte, measure
generator “B” terminal voltage at engine 2000 rpm.
3) If measured voltage is higher than upper limit value,
disassemble generator.
4) Check ground of brushes. If brushes are not
grounded, replace IC regulator. Then check field coil
for grounds and shorts.
Repair Instructions
Jump Starting in Case of EmergencyS6RW0D1A06001
With Auxiliary (Booster) Battery
CAUTION!
If vehicle is manual transaxle model and has
a catalytic converter, do not push or tow it to
start. Damage to its emission system and/or
to other parts may result.

Both booster and discharged battery should be treated
carefully when using jumper cables. Follow the
procedure outlined as follows, being careful not to cause
sparks.
WARNING!
• Departure from these conditions or
procedure described as follows could
result in:
– Serious personal injury (particularly to
eyes) or property damage from such
causes as battery explosion, battery
acid, or electrical burns.
– Damage to electronic components of
either vehicle.
• Remove rings, watches, and other jewelry.
Wear approved eye protection.
• Be careful so that metal tools or jumper
cables do not contact positive battery
terminal (or metal in contact with it) and
any other metal on vehicle, because a
short circuit could occur.
• Do not connect negative cable directly to
negative terminal of dead battery.

I2RH011A0008-01
[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