2006 SUZUKI SX4 warning

Downloaded from www.Manualslib.com manuals search engine 1F-5 Engine Cooling System:
Coolant Level CheckS6RW0D1606002
WARNING!
To help 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 radiator
cap is taken off too soon.

To check level, lift hood and look at “see-through”
coolant reservoir.
It is not necessary to remove radiator cap to check
coolant level.
When engine is cool, check coolant level in reservoir (1).
A normal coolant level should be between FULL mark
(2) and LOW mark (3) on reservoir (1).
If coolant level is below LOW mark (3), remove reservoir
cap (4) and add proper coolant to reservoir to bring
coolant level up to FULL mark (2).
NOTE
If proper quality antifreeze is used, there is
no need to add extra inhibitors or additives
that claim to improve system. They may be
harmful to proper operation of system, and
are unnecessary expense.

Engine Cooling System Inspection and
Cleaning
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WARNING!
To help 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.

1) Check cooling system for leakage or damage.
2) Wash radiator cap and filler neck with clean water by
removing radiator cap when engine is cold.
3) Check coolant for proper level and freeze protection.
4) Using a pressure tester (1), check system and
radiator cap (2) for proper pressure holding capacity.
If replacement of cap is required, use a proper cap
for this vehicle.
NOTE
After installing radiator cap to radiator, make
sure that the ear of cap lines is parallel to
radiator.

Cooling system and radiator cap holding
pressure (for inspection)
110 kPa (1.1 kgf/cm2, 15.6 psi)
5) Tighten hose clamps and inspect all hoses. Replace
hoses whenever cracked, swollen or otherwise
deteriorated.
6) Clean frontal area of radiator core.
Cooling System DrainingS6RW0D1606004
WARNING!
To help 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.

1) Remove radiator cap.
2) Drain coolant from radiator drain plug (1).
3) After draining coolant, be sure to tighten drain plug
(1) securely.
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Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-6
Cooling System Flush and RefillS6RW0D1606005
WARNING!
To help 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.

NOTE
For detail of coolant specification, refer to
“Coolant Description”.

1) Remove radiator cap when engine is cool as follows.
a) Turn cap counterclockwise slowly until it reaches
a “stop” (Do not press down while turning it).
b) Wait until pressure is relieved (indicated by a
hissing sound) then press down on cap and
continue to turn it counterclockwise.
2) With radiator cap removed, run engine until upper
radiator hose is hot (this shows that thermostat is
open and coolant is flowing through system).
3) Stop engine and drain coolant from radiator drain
plug (1).
4) Close radiator drain plug. Add water until system is
filled and run engine until upper radiator hose is hot
again.
5) Repeat Steps 3) and 4) several times until drained
liquid is nearly colorless.
6) Close radiator drain plug (1) tightly.7) Remove reservoir cap (2) and reservoir (1).
8) Pour out any fluid, scrub and clean inside of
reservoir with soap and water.
Flush it well with clean water and drain, Reinstall
reservoir.
9) Fill reservoir with coolant up to “FULL” level mark (3).
10) Install reservoir cap (2) on reservoir.
11) Fill radiator with coolant up to bottom of radiator filler
neck and install radiator cap, making sure that the
ear of cap lines is parallel to radiator.
12) Run engine at idle speed.
13) Run engine until radiator fan motor is operated.
14) Stop engine and wait until engine comes cooled
down to help avoid danger of being burned.
15) Add coolant to radiator up to bottom of radiator filler
neck, and install radiator cap, making sure that the
ear of cap lines is parallel to radiator.
16) Repeat Step 12) through 15).
17) Confirm that reservoir coolant level is “FULL” level
mark (3). If coolant is insufficient, repeat Step 9) and
10).
Cooling Water Pipes or Hoses Removal and
Installation
S6RW0D1606006
Removal
1) Drain coolant referring to “Cooling System Draining”.
2) To remove these pipes or hoses, loosen clamp on
each hose and pull hose end off.
Installation
Install removed parts in reverse order of removal
procedure, noting the following.
• Tighten each clamp securely referring to “Cooling
System Components”.
• Refill cooling system referring to Step 7) to 17) of
“Cooling System Flush and Refill”.
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Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-10
Water Pump / Generator Drive Belt Tension
Inspection and Adjustment
S6RW0D1606014
WARNING!
• Disconnect negative cable at battery
before checking and adjusting belt
tension.
• To help 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.

1) Inspect belt for cracks, cuts, deformation, wear and
cleanliness. If it is necessary to replace belt, refer to
“Water Pump / Generator Drive Belt Removal and
Installation”.
2) Check belt for tension. Belt is in proper tension when
it deflects the following specification under thumb
pressure (about 100 N (10kgf, 22 lbs.).
If belt tension is out of specification, go to next steps.
Water pump / generator drive belt tension
“a”: 4.5 – 5.5 mm (0.18 – 0.22 in.) as deflection /
100 N (10kgf, 22lbs)
NOTE
When replacing belt with a new one, adjust
belt tension to 4.0 – 4.5 mm (0.16 – 0.18 in.).

3) After loosening generator bracket bolts (2) and pivot
bolt (3), adjust belt tension to specification described
at step 2) by loosening / tightening generator adjust
bolt (1).
4) Tighten generator bracket bolts and pivot bolt as
specified torque.
Tightening torque
Generator bracket bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Generator pivot bolt (b): 50 N·m (5.0 kgf-m, 36.0
lb-ft)5) Check belt tension for specification after turning
crankshaft two rotations clockwise.
6) Tighten generator adjusting bolt (1) as specified
torque.
Tightening torque
Generator adjusting bolt (c): Tighten 7.0 N⋅m
(0.7 kgf-m, 5.0 lb-ft) by the specified procedure.
7) Connect negative cable at battery.
Water Pump / Generator Drive Belt Removal and
Installation
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Removal
1) Disconnect negative cable at battery.
2) If vehicle equipped with A/C, remove compressor
drive belt before removing water pump belt (1).
Refer to “Compressor Drive Belt Removal and
Installation in Section 7B” or “Compressor Drive Belt
Removal and Installation in Section 7B”.
3) Loosen generator bracket bolts (2) and generator
pivot bolt (3).
4) Loosen generator adjusting bolt (4), and then
remove water pump belt.
a
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1, (c)
2, (a)
3, (b)
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Downloaded from www.Manualslib.com manuals search engine 1G-1 Fuel System:
Engine
Fuel System
Precautions
Precautions on Fuel System ServiceS6RW0D1700001
WARNING!
Before attempting service of any type on fuel system, the following should be always observed in
order to reduce the risk of fire and personal injury.
• Disconnect negative cable at battery.
• Do not smoke, and place no smoking signs near work area.
• Be sure to have CO
2 fire extinguisher handy.
• Be sure to perform work in a well-ventilated area and away from any open flames (such as gas hot
heater).
• Wear safety glasses.
• To relieve fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then
reinstall it.
• As fuel feed line is still under high fuel pressure even after stopping engine, loosening or
disconnecting fuel feed line directly may cause dangerous spout of fuel. Before loosening or
disconnecting fuel feed line, make sure to relieve fuel pressure referring to “Fuel Pressure Relief
Procedure”.
• A small amount of fuel may be released when the fuel line is disconnected. In order to reduce the
risk of personal injury, cover a shop cloth to the fitting to be disconnected. Be sure to put that cloth
in an approved container after disconnecting.
• Never run engine with fuel pump relay disconnected when engine and exhaust system are hot.
• Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each
hose correctly referring to “Fuel Hose Disconnecting and Reconnecting”.
After connecting, make sure that it has no twist or kink.
• When installing injector or fuel feed pipe, lubricate its O-ring with gasoline.
• When servicing the fuel tank, it should be treated with respect, with no contact with sharp edges or
hot surfaces. In addition, the fuel tank should not be dropped since fuel tank, fuel pump and other
components can be damaged by the impact. If dropped, all components should be replaced because
there is a risk of damage.
• The fuel tank is made of resin.
Be sure not to allow solvent (chemical article such as grease and sealant) to attach to the fuel tank
as some chemical reaction may occur, causing the fuel tank to be swollen, hardened or distorted
leakage and resulting in fuel leakage from the fuel tank.

Downloaded from www.Manualslib.com manuals search engine 1G-3 Fuel System:
Schematic and Routing Diagram
Fuel Delivery System DiagramS6RW0D1702001
Diagnostic Information and Procedures
Fuel Pressure InspectionS6RW0D1704001
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.

1) Relieve fuel pressure in fuel feed line referring to
“Fuel Pressure Relief Procedure”.
2) Disconnect fuel feed hose from fuel delivery pipe.
3) Connect special tools and hose between fuel feed
hose (1) and fuel delivery pipe as shown in figure,
and clamp hoses securely in order to ensure that no
leaks occur during checking.
Special tool
(A): 09912–58442
(B): 09912–58432
(C): 09912–58490
73 6
1 4
5
8
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1. Fuel tank 4. Delivery pipe 7. Fuel filter
2. Fuel pump assembly 5. Fuel injector 8. Fuel level sensor (gauge)
3. Fuel pressure regulator 6. Fuel feed line 9. Fuel pump
(C) (B)
(A)
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Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-4
4) Check that battery voltage is 11 V or more.
5) Measure fuel pressure at each condition.
If measured pressure is out of specification, refer to
“Fuel Pressure Check in Section 1A” and check each
possibly defective part. Replace if found defective.
a) Turn ignition switch ON to operate fuel pump and
after 2 seconds turn it OFF. Repeat this 3 or 4
times and then check fuel pressure.
Fuel pressure specification
With fuel pump operating and engine
stopped: 360 – 400 kPa (3.6 – 4.0 kgf/cm2,
51.2 – 56.9 psi)
b) Start engine and warm it up to normal operating
temperature, and measure fuel pressure at
idling.
Fuel pressure specification
At specified idle speed: 360 – 400 kPa (3.6 –
4.0 kgf/cm2, 51.2 – 56.9 psi)
c) Stop engine, and measure fuel pressure at one
minute after stopping.
Fuel pressure specification
With 1 min. after engine (fuel pump) stop
(Pressure reduces as time passes): Over 250
kPa (2.5 kgf/cm
2, 35.6 psi)
6) After checking fuel pressure, remove fuel pressure
gauge.
WARNING!
As fuel feed line is still under high fuel
pressure, make sure to release fuel pressure
according to the following procedures.
• Place fuel container under joint.
• Cover joint with rag (1) and loosen joint nut
slowly in order to release fuel pressure
gradually.

7) Remove special tools from fuel delivery pipe and fuel
feed hose.
8) Connect fuel feed hose to fuel delivery pipe and
clamp it securely.
9) With engine OFF and ignition switch ON, check for
fuel leaks.
Fuel Cut Operation InspectionS6RW0D1704002
NOTE
Before inspection, make sure that gear shift
lever is in neutral position (shift select lever
is “P” range for A/T vehicle), A/C is OFF and
parking brake lever is pulled all the way up.

1) Warm engine up to normal operating temperature.
2) While listening to sound of injector (2) by using
sound scope (1) or such, increase engine speed to
higher than 3,000 r/min.
3) Check to make sure that injector operation sound is
stop when throttle valve is closed instantly and it is
heard again when engine speed is reduced to
approx. 2,000 r/min or less.
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Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-6
Fuel Hose Disconnecting and ReconnectingS6RW0D1706002
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.

For Connection Other Than Quick Joint
• Clamp around fuel tank
NOTE
Be sure to install hose to spool of pipe surely.

9. Fuel tank bolt 19. Grommet
10. Fuel tank belt 20. O-ring
I7RW01170005-01
[A]: Connection A “b”: 30 mm (1.18 in.) 1. Pipe
[B]: Connection B “c”: 38 mm (1.50 in.) 2. Hose
[C]: Connection C “d”: 5 – 12 mm (0.20 – 0.48 in.) 3. Clamp
[D]: Connection D “e”: 7 – 14 mm (0.28 – 0.55 in.) : 1.5 N⋅m (0.15 kgf-m, 1.0 lb-ft)
“a”: 3 – 7 mm (0.12 – 0.28 in.) “f”: 2 mm (0.08 in.)

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-8
6) Start engine and run it until engine stops for lack of
fuel. Repeat cranking engine 2 – 3 times for about 3
seconds each time in order to dissipate fuel pressure
in lines. Fuel connections are now safe for servicing.
7) After servicing, connect fuel pump relay (1) to relay /
fuse box and install relay / fuse box cover.
Fuel Leakage Check ProcedureS6RW0D1706004
After performing any service on fuel system, check to
make sure that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate
fuel pump) and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply
fuel pressure to fuel line until fuel pressure is felt by
hand placed on fuel feed hose.
2) In this state, check to see that there are no fuel
leakages from any part of fuel system.
Fuel Lines On-Vehicle InspectionS6RW0D1706005
CAUTION!
Due to the fact that fuel feed line (1) is under
high pressure, use special care when
servicing it.

Visually inspect fuel lines for evidence of fuel leakage,
hose crack and deterioration or damage.
Make sure all clamps are secure.
Replace parts as needed.
Fuel Pipe Removal and InstallationS6RW0D1706006
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) Disconnect fuel hose (3) from fuel pipe (2) at the
front and rear of each fuel pipe referring to “Fuel
Hose Disconnecting and Reconnecting”.
4) Mark the location of clamps (1) on fuel pipes (2), so
that the clamps can be reinstalled to where they
were.
5) Remove clamps (1) from vehicle body, fuel pipes and
brake pipes.
CAUTION!
Be careful not to bent and damage fuel pipes
and brake pipes when removing clamp.

6) Remove fuel pipe (2).
Installation
1) Install clamps to marked location on pipes. If clamp
is deformed, its claw is bent or broken, replace it with
new one.
2) Install pipes with pipe clamps to vehicle.
3) Connect fuel hoses and pipes to each pipe referring
to “Fuel Hose Disconnecting and Reconnecting”.
4) Connect negative cable at battery.
5) With engine OFF, turn ignition switch to ON position
and check for fuel leaks.
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