2006 SUZUKI SX4 warning

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 Aux. Emission Control Devices: 1B-4
EVAP Canister InspectionS6RW0D1206006
WARNING!
DO NOT SUCK nozzles on EVAP canister.
Fuel vapor inside EVAP canister is harmful.

1) Check outside of EVAP canister visually.
2) Disconnect vacuum hoses from EVAP canister.
3) Check that there is no restriction of flow through
purge pipe (1) and air pipe (2) when air is blown (4)
into tank pipe (3).
If any faulty condition is found in this inspection,
replace EVAP canister.
EGR Valve Removal and Installation (If
Equipped)
S6RW0D1206007
Removal
1) Disconnect negative cable at battery.
2) Remove air intake pipe.
3) Remove EGR pipe and gaskets.
4) Disconnect EGR valve connector.
5) Remove EGR valve and gasket from cylinder head.
Installation
Reverse removal procedure noting the following.
• Clean mating surface of valve and cylinder head.
• Use new gaskets.
EGR Valve Inspection (If Equipped)S6RW0D1206008
1) Check resistance between following terminals of
EGR valve (1) in each pair.
If found faulty, replace EGR valve assembly.
EGR valve resistance (A – B, C – B, F – E, D – E
terminal)
20 – 24 Ω
2) Remove carbon from EGR valve gas passage.
CAUTION!
Do not use any sharp-edged tool to remove
carbon.
Be careful not to damage or bend EGR valve
(1), valve seat (3) and rod.

3) Inspect valve (2), valve seat and rod for fault, cracks,
bend or other damage.
If found faulty, replace EGR valve assembly.
4
3 1
2
I6RW0D120003-01
I2RH0B120005-01
I2RH0B120006-01

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-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

Downloaded from www.Manualslib.com manuals search engine 1D-8 Engine Mechanical:
2) Lift down the valve by turning crankshaft to 360°.
3) Hold tappet at that position using special tool as
follows.
a) Remove its housing bolts.
b) Check housing No. and select special tool
corresponding to housing No., referring to
“Special tool selection table”.
Special tool selection table
c) Hold down the tappet so as not to contact the
shim by installing special tool on camshaft
housing with housing bolt (1) tighten housing
bolts by hand.
Special tool
(A): 09916–67020
(A): 09916–670214) Turn camshaft by approximately 90° clockwise and
remove shim (3).
WARNING!
Never put in the hand between camshaft and
tappet.

5) Using a micrometer (2), measure the thickness of
the removed shim (1), and determine replacement
shim by calculating the thickness of new shim with
the following formula and table.
Shim thickness specification
Intake side:
A = B + C – 0.20 mm (0.008 in.)
Exhaust side:
A = B + C – 0.30 mm (0.012 in.)
A: Thickness of new shim
B: Thickness of removed shim
C: Measured valve clearance
For example of intake side:
When thickness of removed shim is 2.40 mm (0.094
in.), and measured valve clearance is 0.45 mm
(0.018 in.).
A = 2.40 mm (0.094 in.) + 0.45 mm (0.018 in.) – 0.20
mm (0.008 in.) = 2.65 mm (0.104 in.)
Calculated thickness of new shim = 2.65 mm (0.104
in.) No. on camshaft
housingEmbossed mark on special
tool
I2 IN2
I3, I4, I5 IN345
E2 EX2
E3, E4, E5 EX345A: I: Intake side or E: Exhaust side
B: Position from timing chain side
C: Pointing to timing chain side
I2RH0B140011-01
I5RW0C140003-01
1. Special tool 2. Magnet
I2RH0B140013-01
I2RH0B140014-01

Downloaded from www.Manualslib.com manuals search engine 1E-2 Engine Lubrication System:
Diagnostic Information and Procedures
Oil Pressure CheckS6RW0D1504001
WARNING!
To avoid the danger of being burned, do not
touch the exhaust system when the system is
hot. Any service on the exhaust system
should be performed when the system is
cool.

NOTE
Prior to checking oil pressure, check the
following.
• Oil level in oil pan
If oil level is low, add oil up to full level
mark (hole) (1) on oil level gauge referring
to “Engine Oil and Filter Change in Section
0B”.
• Oil quality
If oil is discolored or deteriorated, change
it. For particular oil to be used, refer to
“Engine Oil and Filter Change in Section
0B”.
• Oil leaks
If leak is found, repair it.

1) Disconnect oil pressure switch coupler (1).
2) Remove oil pressure switch (2) from cylinder block.3) Install special tools (oil pressure gauge) to vacated
threaded hole of oil pressure switch.
Special tool
(A): 09915–77310
(B): 09915–78211
4) Start engine and warm engine up to normal
operating temperature.
NOTE
Be sure to shift transaxle gear shift lever in
“Neutral”, set parking brake and block drive
wheels.

5) After warming up, raise engine speed to 4,000 r/min.
and measure oil pressure.
Oil pressure specification
More than 270 kPa (2.7 kgf/cm2, 39.8 psi) at 4,000
r/min. (rpm)
6) After checking oil pressure, stop engine and remove
oil pressure gauge and attachment.
7) Before reinstalling oil pressure switch (2), be sure to
wrap its screw threads with sealing tape (1) and
tighten switch to specified torque.
NOTE
If sealing tape edge is bulged out from screw
threads of switch, cut it off.

Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft)
2. Low level mark (hole)
I2RH0B150002-01
I2RH0B150003-01
I2RH0B150004-01
I2RH0B150005-01

Downloaded from www.Manualslib.com manuals search engine 1F-1 Engine Cooling System:
Engine
Engine Cooling System
General Description
Cooling System DescriptionS6RW0D1601001
The cooling system consists of the radiator cap, radiator,
coolant reservoir, hoses, water pump, cooling fan and
thermostat. The radiator is of tube-and-fin type.
Coolant DescriptionS6RW0D1601002
WARNING!
• Do not remove radiator cap to check
engine coolant level; check coolant
visually at the see-through coolant
reservoir. Coolant should be added only to
reservoir as necessary.
• As long as there is pressure in the cooling
system, the temperature can be
considerably higher than the boiling
temperature of the solution in the radiator
without causing the solution to boil.
Removal of the radiator cap while engine is
hot and pressure is high will cause the
solution to boil instantaneously and
possibly with explosive force, spewing the
solution over engine, fenders and person
removing cap. If the solution contains
flammable anti-freeze such as alcohol (not
recommended for use at any time), there is
also the possibility of causing a serious
fire.
• Check to make sure that engine coolant
temperature is cold before removing any
part of cooling system.
• Also be sure to disconnect negative cable
from battery terminal before removing any
part.

The coolant recovery system is standard. The coolant in
the radiator expands with heat, and the coolant is
overflowed to the reservoir.
When the system cools down, the coolant is drawn back
into the radiator.
The cooling system has been filled with a quality coolant
that is a 50/50 mixture of water and ethylene glycol
antifreeze.
This 50/50 mixture coolant solution provides freezing
protection to –36 °C (–33 °F).
• Maintain cooling system freeze protection at –36 °C (–
33 °F) to ensure protection against corrosion and loss
of coolant from boiling. This should be done even if
freezing temperatures are not expected.
• Add ethylene glycol base coolant when coolant has to
be added because of coolant loss or to provide added
protection against freezing at temperature lower than
–36 °C (–33 °F).
NOTE
• Alcohol or methanol base coolant or plain
water alone should not be used in cooling
system at any time as damage to cooling
system could occur.
• Coolant must be mixed with demineralized
water or distilled water.

Anti-freeze proportioning table
Coolant capacity
M/T:
• Engine, radiator and heater: 6.8 liters (14.37/11.97
US/lmp pt.)
• Reservoir: 0.7 liters (1.48/1.23 us/lmp pt.)
• Total: 7.5 liters (15.85/13.20 US/lmp pt.)
A/T:
• Engine, radiator and heater: 6.9 liters (14.58/16.63
US/lmp pt.)
• Reservoir: 0.7 liters (1.48/1.23 us/lmp pt.)
• Total: 7.6 liters (16.06/13.38 US/lmp pt.)For M/T
modelFor A/T
model
Freezing
temperature°C–36–36
°F–33–33
Anti-freeze / Anti-
corrosion coolant
concentration%5050
Ratio of compound
to cooling waterltr. 3.75/3.75 3.8/3.8
US pt. 7.92/7.92 8.03/8.03
Imp pt. 6.60/6.60 6.69/6.69