2006 SUZUKI SX4 battery

Downloaded from www.Manualslib.com manuals search engine 1H-3 Ignition System:
Component Location
Ignition System Components LocationS6RW0D1803001
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

12*
15*
13
1 689
11
10
74
5
14
2 3
16
I5RW0C180002-01
1. ECM 7. ECT sensor 13. Battery fuse box
2. Ignition coil assembly for No.1 and No.4 spark plugs 8. MAF and IAT sensor 14. Relay box
3. Ignition coil assembly for No.2 and No.3 spark plugs 9. Electric throttle body assembly 15. Junction block assembly
4. CMP sensor (VVT model) 10. High-tension cords 16. CMP sensor (VVT model)
5. CKP sensor 11. Knock sensor
6. MAP sensor (if equipped) 12. Data link connector

Downloaded from www.Manualslib.com manuals search engine Ignition System: 1H-8
Ignition Coil Assembly (Including Ignitor)
Removal and Installation
S6RW0D1806005
Removal
1) Disconnect negative cable at battery.
2) Remove air cleaner assembly with air intake pipe
and cylinder head upper cover.
3) Disconnect ignition coil coupler.
4) Disconnect high-tension cord (3) from ignition coil
assembly (2).
5) Remove ignition coil bolts (1) and then pull out
ignition coil assembly.
Installation
1) Install ignition coil assembly (2).
2) Tighten ignition coil bolts (1) to specified torque, and
then connect ignition coil coupler.
Tightening torque
Ignition coil bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Install high-tension cord (3) to ignition coil assembly
while gripping its cap.
4) Install cylinder head upper cover and air cleaner
assembly with air intake pipe.
5) Connect negative cable to battery.
Ignition Coil Assembly (Including Ignitor)
Inspection
S6RW0D1806006
Measure secondary coil for resistance.
If resistance is out of specification, replace ignition coil
assembly.
Secondary coil resistance
7.6 – 10.2 kΩ at 20 ° (68 °F)
Ignition Timing InspectionS6RW0D1806007
NOTE
• Ignition timing is not adjustable. If ignition
timing is out of specification, check
system related parts.
• Before starting engine, place transmission
gear shift lever in “Neutral”, and set
parking brake.

1) Connect scan tool to DLC (1) with ignition switch
OFF.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
I2RH0B180006-01
I3RM0A180004-01
I2RH0B180007-01
(A) 1I 5 R W 0 C 11 0 0 11 - 0 1

Downloaded from www.Manualslib.com manuals search engine 1I-1 Starting System:
Engine
Starting System
Schematic and Routing Diagram
Cranking System Circuit DiagramS6RW0D1902001
Diagnostic Information and Procedures
Cranking System Symptom DiagnosisS6RW0D1904001
Possible symptoms due to starting system trouble would be as follows:
• Starting motor does not run (or runs slowly)
• Starting motor runs but fails to crank engine
• Abnormal noise is heard
Proper diagnosis must be made to determine exactly where the cause of each trouble lies in battery, wiring harness,
(including starting motor switch), starting motor or engine.
Do not remove motor just because starting motor does not run. Check the following items and narrow down scope of
possible causes.
1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine side) and starting motor terminals
3) Discharge of battery
4) Mounting of starting motor
I4RS0A190001-01
1. Pinion drive lever 6. Magnetic switch contacts 11. Ignition & Starter switch
2. Pinion & Over-running clutch 7. Pull-in coil 12. Battery
3. Magnetic switch 8. Starting motor 13. To ECM
4. Hold-in coil 9. Starting motor control relay
5. Plunger 10. A/T: Transmission range sensor (shift switch)

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-2
Condition Possible cause Correction / Reference Item
Motor not running (No
operating sound of
magnetic switch)Transmission range sensor is not in P or
N, or not adjusted (A/T model)Shift in P or N, or adjust sensor. (A/T model)
Battery run downRecharge battery.
Battery voltage too low due to battery
deteriorationReplace battery.
Poor contact in battery terminal
connectionRetighten or replace.
Loose grounding cable connectionRetighten.
Fuse set loose or blown offTighten or replace.
Poor contacting action of ignition switch
and magnetic switchReplace.
Lead wire coupler loose in placeRetighten.
Open-circuit between ignition switch and
magnetic switchRepair.
Open-circuit in pull-in coilReplace magnetic switch.
Brushes are seating poorly or worn
downRepair or replace.
Poor sliding of plunger and/or pinionRepair.
Faulty starting motor control relay“Main Relay, Fuel Pump Relay, Starting Motor
Control Relay, Throttle Actuator Control Relay
and Radiator Cooling Fan Relay Inspection in
Section 1C”.
Faulty ECM and its circuit“Inspection of ECM and Its Circuits in Section
1A”.
Motor not running
(Operating sound of
magnetic switch heard)Battery run downRecharge battery.
Battery voltage too low due to battery
deteriorationReplace battery.
Loose battery cable connectionsRetighten.
Burnt main contact point, or poor
contacting action of magnetic switchReplace magnetic switch.
Brushes are seating poorly or worn
downRepair or replace.
Weakened brush springReplace.
Burnt commutatorReplace armature.
Layer short-circuit of armatureReplace.
Crankshaft rotation obstructedRepair.
Starting motor running
but too slow (small
torque) (If battery and
wiring are satisfactory,
inspect starting motor)Insufficient contact of magnetic switch
main contactsReplace magnetic switch.
Layer short-circuit of armatureReplace.
Disconnected, burnt or worn
commutatorRepair commutator or replace armature.
Worn brushesReplace brush.
Weakened brush springsReplace spring.
Burnt or abnormally worn end bushReplace bush.
Starting motor running,
but not cranking engineWorn pinion tipReplace over-running clutch.
Poor sliding of over-running clutchRepair.
Over-running clutch slippingReplace over-running clutch.
Worn teeth of ring gearReplace flywheel (M/T model) or drive plate (A/
T model).
NoiseAbnormally worn bushReplace bush.
Worn pinion or worn teeth of ring gearReplace over-running clutch, flywheel (M/T
model) or drive plate (A/T model).
Poor sliding of pinion (failure in return
movement)Repair or replace.
Worn internal or planetary gear teethReplace.
Lack of oil in each partLubricate.

Downloaded from www.Manualslib.com manuals search engine 1I-3 Starting System:
Cranking System TestS6RW0D1904002
CAUTION!
Each test must be performed within 3 – 5
seconds to avoid coil from burning.

Pull-In Test
Connect battery to the magnetic switch as shown.
Check that plunger and pinion move outward.
If plunger and pinion don’t move, replace the magnetic
switch.
NOTE
Before testing, disconnect lead wire from
terminal “M” (2).

Hold-In Test
While connected as the figure with plunger out,
disconnect negative lead from terminal “M”.
Check that plunger and pinion remain out.
If plunger and pinion return inward, replace the magnetic
switch.Plunger and Pinion Return Test
Disconnect negative lead from starting motor body.
Check that plunger and pinion return inward.
If plunger and pinion don’t return, replace the magnetic
switch.
No-Load Performance Test
Connect battery and ammeter to starter as shown.
Check that starter rotates smoothly and steadily with
pinion moving out. Check that ammeter indicates
specified current.
Specified current (No-load performance test)
90 A MAX. at 11 V Starting motor does not
stop runningFused contact points of magnetic switchReplace magnetic switch.
Short-circuit between turns of magnetic
switch coil (layer short-circuit)Replace magnetic switch.
Failure of returning action in ignition
switchReplace. Condition Possible cause Correction / Reference Item
1. Terminal “S”
3. Lead wire (switch to motor)
I2RH01190002-01
I2RH01190003-01
I2RH01190004-01
I2RH01190005-01

Downloaded from www.Manualslib.com manuals search engine Starting System: 1I-4
Repair Instructions
Starting Motor Dismounting and RemountingS6RW0D1906001
Dismounting
1) Disconnect negative (–) battery lead at battery.
2) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals.
3) Detach shift & select control cable bracket from transaxle. (M/T model only)
4) Remove starting motor mount bolt (3) and nut (4).
5) Remove starting motor (5).
Remounting
Reverse the dismounting procedure noting the following.
• Tighten battery cable nut (6) to specified torque.
Tightening torque
Starting motor battery cable nut (a): 9.8 N·m (0.98 kgf-m, 7.0 lb-ft)
I4RS0A190002-01
: 9.8 N⋅m (0.98 kgf-m, 7.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 1I-5 Starting System:
Starting Motor ComponentsS6RW0D1906002
I4RS0A190003-01
1. Front housing 7. Plate 13. Planetary gear 19. Rear bush
2. Bush 8. Seal rubber 14. Packing 20. Starting motor battery cable nut
3. Pinion stop ring 9. Magnetic switch 15. Yoke : 9.8 N⋅m (0.98 kgf-m, 7.0 lb-ft)
4. Over-running clutch 10. Ball 16. Armature : Do not reuse.
5. Lever 11. Internal gear 17. Brush assembly : Apply grease 99000-25011 to sliding surface of each part.
6. Plunger 12. Planetary carrier shaft 18. Rear bracket

Downloaded from www.Manualslib.com manuals search engine 1I-9 Starting System:
Front Housing Bush
Inspect the bush for wear or damage. Replace if
necessary.
Specifications
Cranking System SpecificationsS6RW0D1907002
Tightening Torque SpecificationsS6RW0D1907003
NOTE
The specified tightening torque is also described in the following.
“Starting Motor Dismounting and Remounting”
“Starting Motor Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS6RW0D1908001
NOTE
Required service material is also described in the following.
“Starting Motor Components”

I2RH01190024-01
Voltage 12 volts
Output 1.2 kW
Rating 30 seconds
Direction of rotation Clockwise as viewed from pinion side
Brush length Standard: 12.3 mm (0.48 in.) Limit: 7.0 mm (0.28 in.)
Number of pinion teeth 8
Performance Condition Guarantee
Around at 20 °C
(68 °F)No load characteristic 11.0 V90 A maximum
2370 r/min minimum
Load characteristic7.5 V
300 A10.65 N⋅m (1.065 kgf-m, 7.70 lb-ft) minimum
840 r/min minimum
Locked characteristic 4.0 V780 A maximum
20 N⋅m (2.0 kgf-m, 14.5 lb-ft) minimum
Magnetic switch operating voltage 8 volts maximum
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Starting motor battery cable nut 9.8 0.98 7.0)