2006 SUZUKI SX4 Hvac

Downloaded from www.Manualslib.com manuals search engine FOREWORD
This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service
operations, replacement of components (Service) and for disassembly and assembly of major components (Unit
Repair-Overhaul).
VOLUME 1 contains General information, Engine, Suspension, Drive/Axle and Brakes sections (Sections 0 – 5).
VOLUME 2 contains Transmission/Transaxle, Steering, HVAC, Restraint, Body/Cab/Accessories and
Control Systems sections (Sections 6 – 10).
Applicable Model:
SX4 (RW415/RW416) produced at KOSAI plant in Japan with following vehicle identification number
(VIN)
The contents are classified into sections each of which is given a section number as indicated in the Table of
Contents on following page. And on the first page of each individual section is an index of that section.
This manual should be kept in a handy place for ready reference of the service work.
Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials as specified in each description.
All information, illustrations and specifications contained in this literature are based on the latest product infor-
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2006JSAGY############ ~
JS2Y#############~

Downloaded from www.Manualslib.com manuals search engine 00
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Vo l u m e 1
Precautions............................................................... 00-i
Precautions ............................................................ 00-1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubrication ................................. 0B-1
Engine ......................................................................... 1-i
Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1
Aux. Emission Control Devices .............................. 1B-1
Engine Electrical Devices....................................... 1C-1
Engine Mechanical ................................................. 1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System .......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System....................................................... 1H-1
Starting System ....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System ..................................................... 1K-1
Suspension ................................................................. 2-i
Precautions .............................................................. 2-1
Suspension General Diagnosis .............................. 2A-1
Front Suspension ................................................... 2B-1
Rear Suspension.................................................... 2C-1
Wheels and Tires ................................................... 2D-1
Driveline / Axle ........................................................... 3-i
Precautions .............................................................. 3-1
Drive Shaft / Axle ................................................... 3A-1
Differential .............................................................. 3B-1
Transfer .................................................................. 3C-1
Propeller Shafts...................................................... 3D-1
Brakes ......................................................................... 4-i
Precautions .............................................................. 4-1
Brake Control System and Diagnosis .................... 4A-1
Front Brakes........................................................... 4B-1
Rear Brakes ........................................................... 4C-1
Parking Brake......................................................... 4D-1
ABS ........................................................................ 4E-1
Transmission / Transaxle .......................................... 5-i
Precautions .............................................................. 5-1
Automatic Transmission/Transaxle ........................ 5A-1
Manual Transmission/Transaxle ............................ 5B-1
Clutch ..................................................................... 5C-1
Vo l u m e 2
Precautions ............................................................... 00-i
Precautions ............................................................ 00-1
Steering ....................................................................... 6-i
Precautions .............................................................. 6-1
Steering General Diagnosis ................................... 6A-1
Steering Wheel and Column .................................. 6B-1
Power Assisted Steering System ...........................6C-1
HVAC ........................................................................... 7-i
Precautions .............................................................. 7-1
Heater and Ventilation............................................ 7A-1
Air Conditioning System ......................................... 7B-1
Restraint ...................................................................... 8-i
Precautions .............................................................. 8-1
Seat Belts ............................................................... 8A-1
Air Bag System ...................................................... 8B-1
Body, Cab and Accessories ...................................... 9-i
Precautions .............................................................. 9-1
Wiring Systems ...................................................... 9A-1
Lighting Systems .................................................... 9B-1
Instrumentation / Driver Info. / Horn .......................9C-1
Wipers / Washers ...................................................9D-1
Glass / Windows / Mirrors ...................................... 9E-1
Security and Locks ................................................. 9F-1
Seats ..................................................................... 9G-1
Interior Trim ............................................................9H-1
Hood / Fenders / Doors .......................................... 9J-1
Body Structure ....................................................... 9K-1
Paint / Coatings ...................................................... 9L-1
Exterior Trim .......................................................... 9M-1
Control Systems ....................................................... 10-i
Precautions ............................................................ 10-1
Body Electrical Control System ............................ 10B-1
Immobilizer Control System .................................10C-1
Keyless Start System ........................................... 10E-1
TABLE OF CONTENTS

Downloaded from www.Manualslib.com manuals search engine Precautions: 00-4
WARNING!
• Whenever raising a vehicle for service, be
sure to follow the instructions under
“Vehicle Lifting Points in Section 0A”.
• When it is necessary to do service work
with the engine running, make sure that
the parking brake is set fully and the
transmission is in Neutral (for manual
transmission vehicles) or Park (for
automatic transmission vehicles), Keep
hands, hair, clothing, tools, etc. away from
the fan and belts when the engine is
running.
• When it is necessary to run the engine
indoors, make sure that the exhaust gas is
forced outdoors.
• Do not perform service work in areas
where combustible materials can come in
contact with a hot exhaust system. When
working with toxic or flammable materials
(such as gasoline and refrigerant), make
sure that the area you work in is well-
ventilated.
• To avoid getting burned, keep away from
hot metal parts such as the radiator,
exhaust manifold, tail pipe, muffler, etc.
• New and used engine oil can be
hazardous. Children and pets may be
harmed by swallowing new or used oil.
Keep new and used oil and used engine oil
filters away from children and pets.
Continuous contact with used engine oil
has been found to cause [skin] cancer in
laboratory animals. Brief contact with used
oil may irritate skin. To minimize your
exposure to used engine oil, wear a long-
sleeve shirt and moisture-proof gloves
(such as dish washing gloves) when
changing engine oil. If engine oil contacts
your skin, wash thoroughly with soap and
water. Launder any clothing or rags if wet
with oil, recycle or properly dispose of
used oil and filters.
• Be sure to observe following instructions
when handling service materials such as
fuel, oil, fluid, coolant, grease, sealant,
thread lock cement, etc. Otherwise, your
health may be ruined.
– Whenever handling any of these service
materials, wear safety glasses to protect
your eyes. If it gets into your eye, it may
cause inflammation.
– Whenever handling any of these service
materials, wear moisture-proof gloves to
protect your skin. If it adheres to your
skin, it may cause inflammation.– Do not swallow any of these service
materials. It would cause diarrhea or
nausea.
– Keep all these materials out of children’s
reach.
• Make sure the bonnet is fully closed and
latched before driving. If it is not, it can fly
up unexpectedly during driving,
obstructing your view and resulting in an
accident.

• Before starting any service work, cover fenders, seats
and any other parts that are likely to get scratched or
stained during servicing. Also, be aware that what you
wear (e.g., buttons) may cause damage to the
vehicle’s finish.
• When performing service to electrical parts that does
not require use of battery power, disconnect the
negative cable of the battery.
• When disconnecting the negative cable from the
battery, be careful to the following.
– Check and record DTCs in ECM, HVAC control
module and/or PS control module if necessary
before disconnecting.
– Record displayed contents of the clock and/or
audio system, etc. before disconnecting and reset it
as before after connecting.
– For vehicle equipped with electric throttle body
system, perform electric throttle body system
calibration referring to “Electric Throttle Body
System Calibration in Section 1C” after
reconnecting the negative cable to the battery.
I2RH01010025-01
I2RH01010026-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 0- i
0
Section 0
CONTENTS
General Information
General Information ................................ 0A-1
General Description ............................................. 0A-1
Abbreviations ...................................................... 0A-1
Symbols .............................................................. 0A-2
Wire Color Symbols ............................................ 0A-2
Fasteners Information ......................................... 0A-3
Vehicle Lifting Points ........................................... 0A-5
Vehicle Identification Number ............................. 0A-6
Engine Identification Number .............................. 0A-6
Transmission Identification Number .................... 0A-6
Component Location ........................................... 0A-7
Warning, Caution and Information Labels
Location ............................................................ 0A-7
Maintenance and Lubrication ................. 0B-1
Precautions........................................................... 0B-1
Precautions for Maintenance and Lubrication ..... 0B-1
Scheduled Maintenance ...................................... 0B-1
Maintenance Schedule under Normal Driving
Conditions ......................................................... 0B-1
Maintenance Recommended under Severe
Driving Conditions ............................................. 0B-2
Repair Instructions .............................................. 0B-3
Accessory Drive Belt Inspection.......................... 0B-3
Accessory Drive Belt Replacement ..................... 0B-3
Valve Lash (Clearance) Inspection ..................... 0B-3
Engine Oil and Filter Change .............................. 0B-4
Engine Coolant Change ...................................... 0B-5
Exhaust System Inspection ................................. 0B-5
Spark Plug Replacement .................................... 0B-5
Air Cleaner Filter Inspection ................................ 0B-6
Air Cleaner Filter Replacement ........................... 0B-6
Fuel Lines and Connections Inspection .............. 0B-6
Fuel Filter Replacement ...................................... 0B-6
Fuel Tank Inspection ........................................... 0B-6PCV Valve Inspection ......................................... 0B-6
Fuel Evaporative Emission Control System
Inspection .......................................................... 0B-6
Brake Discs and Pads (Front) Inspection............ 0B-7
Brake Drums and Shoes (Rear) Inspection ........ 0B-7
Brake Hoses and Pipes Inspection ..................... 0B-7
Brake Fluid Replacement .................................... 0B-7
Brake Lever and Cable Inspection ...................... 0B-7
Clutch Fluid Inspection ........................................ 0B-8
Tires Inspection ................................................... 0B-8
Wheel Discs Inspection ....................................... 0B-8
Wheel Bearing Inspection ................................... 0B-8
Suspension System Inspection ........................... 0B-9
Steering System Inspection ................................ 0B-9
Drive Shaft (Axle) Boots Inspection .................... 0B-9
Propeller Shaft (4WD) Inspection...................... 0B-10
Manual Transaxle Oil Inspection ....................... 0B-10
Manual Transaxle Oil Replacement .................. 0B-10
Automatic Transaxle Fluid Level Inspection...... 0B-10
Automatic Transaxle Fluid Replacement .......... 0B-10
Automatic Transaxle Fluid Cooler Hose
Inspection ........................................................ 0B-10
Transfer Oil Inspection (4WD)........................... 0B-10
Transfer Oil Replacement (4WD) ...................... 0B-10
Rear Deferential Oil Inspection (4WD) .............. 0B-10
Rear Deferential Oil Replacement (4WD) ......... 0B-10
All Latches, Hinges and Locks Inspection......... 0B-10
HVAC Air Filter (If Equipped) Inspection ........... 0B-11
HVAC Air Filter (If Equipped) Replacement ...... 0B-11
Final Inspection for Maintenance Service ......... 0B-11
Specifications .....................................................0B-12
Tightening Torque Specifications ...................... 0B-12
Special Tools and Equipment ...........................0B-12
Recommended Fluids and Lubricants............... 0B-12
Special Tool ...................................................... 0B-12

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-2
NOTE
• “R”: Replace or change
• “I”: Inspect and correct, replace or lubricate if necessary
• For spark plugs, replace every 50,000 km if the local law requires.
• Nickel spark plug: BKR6E-11 (NGK) or K20PR-U11 (DENSO)
• Iridium spark plug: IFR6J11 (NGK)
• Periodic replacement of fuel filter is not necessary if it is not instructed in “Periodic Maintenance
Schedule” section of the Owner’s manual. The scheduled maintenance varies depending on the
vehicle specification.

Maintenance Recommended under Severe Driving ConditionsS6RW0D0205002
If the vehicle is usually used under the conditions corresponding to any severe condition code given below, IT IS
RECOMMENDED that applicable maintenance operation be performed at the particular interval as shown in the
following table.
Severe condition code:
A: Repeated short trips
B: Driving on rough and/or muddy roads
C: Driving on dusty roads
D: Driving in extremely cold weather and/or salted roads
E: Repeated short trips in extremely cold weather
F: Leaded fuel use
G: – – – – –
H: Towing a trailer (if admitted)Automatic transaxle fluidFluid level (I: ))—I—I—I
Fluid change (R: ))Replace every 165,000 km (99,000
miles)
Fluid hose (i: ))———I——
Transfer oil (4WD) (leakage, level) (I: )) I—I—I—
Rear differential oil (4WD) (leakage, level) (I: )) (R: ) 1st 15,000 km only) R or I — I — I —
All latches, hinges and locks (I: ))—I—I—I
HVAC air filter (if equipped) (I: )) (R: ))—IR—IR
Severe
condition codeMaintenanceMaintenance
operationMaintenance interval
– B C D – – – – Accessory drive belt) IEvery 15,000 km
(9,000 miles) or 12 months
) REvery 45,000 km
(27,000 miles) or 36 months
A – C D E F – H Engine oil and oil filter) REvery 7,500 km
(4,500 miles) or 6 months
– – C – – – – – Air cleaner filter *1) IEvery 2,500 km
(1,500 miles)
) REvery 30,000 km
(18,000 miles) or 24 months
A B C – E F – H Spark plugsNickel plug
) REvery 10,000 km (6,000 miles) or 8
months
Iridium plug
(Highly recommended)Every 30,000 km (18,000 miles) or
24 months
– B C D – – – H Wheel bearings) IEvery 15,000 km
(9,000 miles) or 12 months
– B – D E – – HDrive shaft boots / Propeller shaft
(4WD)) / ) IEvery 15,000 km
(9,000 miles) or 12 months IntervalKm (x 1,000) 15 30 45 60 75 90
Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72

Downloaded from www.Manualslib.com manuals search engine 0B-3 Maintenance and Lubrication:
NOTE
• “I”: Inspect and correct or replace if necessary
• “R”: Replace or change
• *1: Inspect or replace more frequently if the vehicle is used under dusty conditions.
• *2: Clean or replace more frequently if the air from the air conditioning decreases.

Repair Instructions
Accessory Drive Belt InspectionS6RW0D0206001
WARNING!
All inspection and replacement are to be
performed with ENGINE NOT RUNNING.

Water Pump and Generator Drive Belt
Inspect belt for cracks, cuts, deformation, wear and
cleanliness. If any defect exists, replace.
Check belt for tension referring to “Water Pump /
Generator Drive Belt Tension Inspection and Adjustment
in Section 1J”.
A/C Compressor Drive Belt (If Equipped)
Inspect belt for cracks, cuts, deformation, wear and
cleanliness. If any defect exists, replace.
Check belt for tension referring to “Compressor Drive
Belt Inspection and Adjustment in Section 7B” or
“Compressor Drive Belt Inspection and Adjustment in
Section 7B”.
Accessory Drive Belt ReplacementS6RW0D0206002
Water Pump and Generator Drive Belt
Replace belt with new one referring to “Water Pump /
Generator Drive Belt Removal and Installation in Section
1J”.
A/C Compressor Drive Belt (If Equipped)
Replace belt with new one referring to “Compressor
Drive Belt Removal and Installation in Section 7B” or
“Compressor Drive Belt Removal and Installation in
Section 7B”.
Valve Lash (Clearance) InspectionS6RW0D0206003
Inspect intake and exhaust valve lash and adjust as
necessary.
Refer to “Valve Lash (Clearance) Inspection in Section
1D” for valve lash inspection and adjustment procedure. – B – – E – – HManual transaxle oil
Transfer oil (4WD)
Differential oil (4WD)) / ) / ) RFirst time only:
15,000 km (9,000 miles) or 12
months
Second time and after:
Every 30,000 km (18,000 miles) or
24 months reckoning from 0 km (0
mile) or 0 month
– B – – E – – H Automatic transaxle fluid)R Every 30,000 km (18,000 miles) or
24 months
– – C D – – – – HVAC air filter (if equipped) *2) IEvery 15,000 km (9,000 miles) or
12 months
) REvery 45,000 km (27,000 miles) or
36 months Severe
condition codeMaintenanceMaintenance
operationMaintenance interval
1. Camshaft 2. Thickness gauge
I2RH0B020003-02

Downloaded from www.Manualslib.com manuals search engine 0B-11 Maintenance and Lubrication:
HVAC Air Filter (If Equipped) InspectionS6RW0D0206034
Check HVAC air filter for dirt and dust referring to “HVAC
Air Filter Inspection (If Equipped) in Section 7A”. If air
filter is dirty, clean or replace air filter with new one.
HVAC Air Filter (If Equipped) ReplacementS6RW0D0206035
Replace HVAC air filter with new one referring to “HVAC
Air Filter Removal and Installation (If Equipped) in
Section 7A”.
Final Inspection for Maintenance ServiceS6RW0D0206036
WARNING!
When carrying out road tests, select a safe
place where no man or no running vehicle is
seen so as to prevent any accident.

Seats
Check that seat slides smoothly and locks securely at
any position. Also check that reclining mechanism of
front seat back allows it to be locked at any angle.
Seat Belt
Inspect belt system including webbing, buckles, latch
plates, retractors and anchors for damage or wear.
Check that seat belt is securely locked. If “REPLACE
BELT” label on seat belt is visible, replace belt.
Battery Electrolyte Level Check
Check that the electrolyte level of all battery cells is
between the upper and lower level lines on the case. If
battery is equipped with built-in indicator, check battery
condition by the indicator.
Accelerator Pedal Operation
Check that pedal operates smoothly without getting
caught or interfered by any other part.
Engine Start
Check engine start for readiness.
WARNING!
Before performing the following check, be
sure to have enough room around the
vehicle. Then, firmly apply both the parking
brake and the regular brakes. Do not use the
accelerator pedal. If the engine starts, be
ready to turn off the ignition promptly. Take
these precautions because the vehicle could
move without warning and possibly cause
personal injury or property damage.

On automatic transaxle vehicles, try to start the engine in
each select lever position. The starting motor should
crank only in “P” (Park) or “N” (Neutral).
On manual transaxle vehicles, place the shift lever in
“Neutral,” depress clutch pedal fully and try to start.
Exhaust System Check
Check for leakage, cracks or loose supports.
Clutch (for Manual Transaxle)
Check for the following.
• Clutch is completely released when depressing clutch
pedal,
• No slipping clutch occurs when releasing pedal and
accelerating.
• Clutch itself is free from any abnormal condition.
Gearshift or Select Lever
Check gear shift or select lever for smooth shifting to all
positions and for good performance of transaxle in any
position.
With automatic transaxle equipped vehicle, also check
that shift indicator indicates properly according to which
position select lever is shifted to.
With automatic transaxle equipped vehicle, make sure
that vehicle is at complete stop when shifting select lever
to “P” range position and release all brakes.
Brake
Foot brake
Check the following:
• that brake pedal has proper travel,
• that brake works properly,
• that it is free from noise,
• that vehicle does not pull to one side when brake is
applied.
• and that brake do not drag.
Parking brake
Check that lever has proper travel.
WARNING!
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property
damage. Be prepared to apply regular brake
quickly even if vehicle should start to move.

Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and brake
lever is pulled all the way.

Downloaded from www.Manualslib.com manuals search engine 1A-26 Engine General Information and Diagnosis:
• The MIL is turned on when the ECM and/or
TCM detect malfunction(s). Each ECM and
TCM stores diagnostic information as the
diagnostic trouble code (DTC) in its
memory and outputs the DTC to the scan
tool.
Therefore, check both of the ECM and TCM
for any DTC with the scan tool because the
DTC stored in ECM and TCM is not read
and displayed at a time. However, each of
the ECM and TCM needs not to be checked
with the generic scan tool because the
DTC stored in ECM and TCM is read and
displayed at a time.

1) Prepare CAN communication OBD generic scan tool
or SUZUKI scan tool.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
2) With ignition switch OFF, connect it to DLC (1)
located on underside of instrument panel at driver’s
seat side.
3) Turn ignition switch ON and confirm that MIL lights.
4) Read DTC and freeze frame data according to
instructions displayed on scan tool and print them or
write them down. Refer to scan tool operator’s
manual for details.
If communication between scan tool and ECM is not
possible, go to “Troubleshooting for Communication
Error with Scan Tool Using CAN”.
5) After completing the check, turn ignition switch off
and disconnect scan tool from DLC.
DTC ClearanceS6RW0D1104004
NOTE
There are two types of OBD system
depending on the vehicle specification.
For identification, refer to “Precaution on On-
Board Diagnostic (OBD) System”.

1) Connect SUZUKI scan tool or CAN communication
OBD generic scan tool to data link connector in the
same manner as when making this connection for
DTC check.2) Turn ignition switch OFF and then ON.
3) Erase DTC and pending DTC according to
instructions displayed on scan tool. Freeze frame
data is cleared with the DTC. Refer to scan tool
operator’s manual for further details.
If communication between scan tool and ECM is not
possible, go to “Troubleshooting for Communication
Error with Scan Tool Using CAN”.
4) After completing the clearance, turn ignition switch
OFF and disconnect scan tool from data link
connector.
NOTE
DTC and freeze frame data stored in ECM
memory are also cleared in the following
cases. Be careful not to clear them before
keeping their record.
• When power to ECM is cut off (by
disconnecting battery cable, removing
fuse or disconnecting ECM connectors).
• When the same malfunction (DTC) is not
detected again during 40 engine warm-up
cycles. (See “Warm-Up Cycle” of “On-
Board Diagnostic System Description”.)

Troubleshooting for Communication Error with
Scan Tool Using CAN
S6RW0D1104083
Perform this troubleshooting when it is not possible to
communicate between scan tool and ECM/TCM.
NOTE
• When performing this troubleshooting, be
sure to have full understanding of
“Precaution on CAN Troubleshooting” and
observe it.
• It may be possible that CAN system has
trouble because of fuse blown or low
battery voltage. Before troubleshooting,
check to make sure that fuse, battery
voltage and generator status are normal.
• When disconnecting each control module
connector in this troubleshooting, various
DTCs will be detected. Be sure to clear
DTCs in the following control modules
after completing this troubleshooting.
–ECM
–BCM
–TCM
– Keyless start control module
– 4WD control module
– HVAC control module (Auto A/C model)
– P/S control module

(A) 1I5RW0C110011-01