2006 SUZUKI SX4 Shift switch

Downloaded from www.Manualslib.com manuals search engine 1A-36 Engine General Information and Diagnosis:
For Vehicle Equipped with A/TS6RW0D1104081
NOTE
There are two types of OBD system depending on the vehicle specification.
For identification, refer to “Precaution on On-Board Diagnostic (OBD) System”.

When using CAN communication OBD generic scan tool, not only the previous star (*) marked ECM DTC(s) but also
the following DTC(s) is displayed on CAN communication OBD generic scan tool simultaneously.
Fail-Safe TableS6RW0D1104006
When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction continues to exist but
that mode is cancelled when ECM detects normal condition after that. DTC No. Detecting itemDetecting condition
(DTC will set when detecting)
P0705 Transmission range sensor circuit malfunction (PRNDL input)
Refer to “DTC Table in Section 5A”. P0707 Transmission range sensor circuit low
P0711Transmission fluid temperature sensor “A” circuit range/
performance
P0712 Transmission fluid temperature sensor circuit low
P0713 Transmission fluid temperature sensor circuit high
P0717 Input/Turbine speed sensor circuit no signal
P0722 Output speed sensor (VSS) circuit no signal
P0741 Torque converter clutch circuit performance or stuck off
P0742 Torque converter clutch circuit stuck on
P0751 Shift solenoid-A (No.1) performance or stuck off
P0752 Shift solenoid-A (No.1) stuck on
P0756 Shift solenoid-B (No.2) performance or stuck off
P0757 Shift solenoid-B (No.2) stuck on
P0787 Shift/Timing solenoid control circuit low
P0788 Shift/Timing solenoid control circuit high
P0961 Pressure control solenoid “A” control circuit range/performance
P0962 Pressure control solenoid control circuit low
P0963 Pressure control solenoid control circuit high
P0973 Shift solenoid-A (No.1) control circuit low
P0974 Shift solenoid-A (No.1) control circuit high
P0976 Shift solenoid-B (No.2) control circuit low
P0977 Shift solenoid-B (No.2) control circuit high
P1702 Internal control module memory check sum error
P1723 Range select switch malfunction
P1878 Torque converter clutch shudder
P2762Torque converter clutch (TCC) pressure control solenoid control
circuit range/performance
P2763Torque converter clutch pressure control solenoid control circuit
high
P2764Torque converter clutch pressure control solenoid control circuit
low
U0100 Lost communication with ECM/PCM “A”
DTC No. Detected item Fail-safe operation
) P0102 Mass air flow circuit low input • ECM controls injector drive time (fuel injection
volume) according to throttle valve opening
(closed throttle position or not).
• ECM stops EGR control. ) P0103 Mass air flow circuit high input
) P0112 Intake air temperature sensor circuit low ECM controls actuators assuming that intake air
temperature is 20 °C (68 °F). ) P0113 Intake air temperature sensor circuit high
) P0117 Engine coolant temperature circuit low • ECM controls actuators assuming that engine
coolant temperature is 80 °C (176 °F).
• ECM operates radiator cooling fan. ) P0118 Engine coolant temperature circuit high

Downloaded from www.Manualslib.com manuals search engine 1A-38 Engine General Information and Diagnosis:
Scan Tool DataS6RW0D1104007
As the data values are standard values estimated on the basis of values obtained from the normally operating vehicles
by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases
where the checked value does not fall within each specified data range. Therefore, judgment as abnormal should not
be made by checking with these data alone.
Also, conditions that can be checked by the scan tool are those detected by ECM and output from ECM as commands
and there may be cases where the engine or actuator is not operating (in the condition) as indicated by the scan tool.
Be sure to use the timing light to check the ignition timing.
NOTE
• There are two types of OBD system depending on the vehicle specification.
For identification, refer to “Precaution on On-Board Diagnostic (OBD) System”.
• With the CAN communication generic scan tool, only star (*) marked data in the following table can
be read.
• When checking the data with the engine running at idle or racing, be sure to shift M/T gear to the
neutral position and A/T gear to the “Park” position and pull the parking brake fully. Also, if nothing
or “no load” is indicated, turn OFF A/C (if equipped with A/C), all electric loads, P/S and all the other
necessary switches.

Scan tool data Vehicle conditionNormal condition /
reference values
*) COOLANT TEMP
(ENGINE COOLANT TEMP.)At specified idle speed after warming up 80 – 100 °C, 176 – 212 °F
*) INTAKE AIR TEMP. At specified idle speed after warming up–5 °C (23 °F) + environmental
temp. to 40 °C (104 °F) +
environmental temp.
*) ENGINE SPEED It idling with no load after warming up Desired idle speed ± 50 rpm
) DESIRED IDLE
(DESIRED IDLE SPEED)It idling with radiator cooling fan stopped and all
electrical parts turned OFF after warming up, M/T at
neutral700 rpm
*) MAF
(MASS AIR FLOW RATE)At specified idle speed with no load after warming up1.0 – 4.0 g/s 0.14 – 0.52 lb/
min.
At 2500 r/min. with no load after warming up4.0 – 9.0 g/s 0.53 – 1.58 lb/
min.
*) CALC LOAD
(CALCULATED LOAD
VA L U E )At specified idle speed with no load after warming up 16 – 36%
At 2500 r/min. with no load after warming up 10 – 30%
*) MAP
(INTAKE MANIFOLD
ABSOLUTE PRESSURE) (if
equipped)At specified idle speed with no load after warming up 24 – 38 kPa, 7.1 – 11.2 in.Hg
*) THROTTLE POSITION
(RELATIVE THROTTLE
POSITION)Ignition switch ON /
warmed up engine
stoppedAccelerator pedal released 0 – 12%
Accelerator pedal depressed
fully90 – 100%
*) BAROMETRIC PRES —Barometric pressure is
displayed
) FUEL TANK LEVEL Ignition switch ON 0 – 100%
*) BATTERY VOLTAGE Ignition switch ON / engine at stop 10 – 14 V
) BRAKE SWITCH Ignition switch ONBrake pedal is released OFF
Brake pedal is depressed ON
*) FUEL SYSTEM B1
(FUEL SYSTEM STATUS)At specified idle speed after warming up CLSD (closed loop)
*) O2S B1 S1
(HEATED OXYGEN
SENSOR-1)At specified idle speed after warming up 0.1 – 0.95 V
*)
O2S B1 S2
(HEATED OXYGEN
SENSOR-2) (if equipped)At 2000 r/min. for 3 min. or longer after warming up 0.1 – 0.95 V

Downloaded from www.Manualslib.com manuals search engine 1A-212 Engine General Information and Diagnosis:
Repair Instructions
Idle Speed and IAC Throttle Valve Opening
Inspection
S6RW0D1106001
Before idle speed check, make sure of the following.
• Lead wires and hoses of electronic fuel injection and
engine and emission control systems are connected
securely.
• Valve lash is checked according to maintenance
schedule.
• Ignition timing is within specification.
• All accessories (wipers, heater, lights, A/C, etc.) are
out of service.
• Air cleaner has been properly installed and is in good
condition.
• No abnormal air drawn in from air intake system.After all items are confirmed, check idle speed and IAC
throttle opening as follows.NOTE
Before starting engine, place transmission
gear shift lever in “Neutral”, and set parking
brake and block drive wheels.

Step Action Yes No
1Is there DTC(s) of ECT sensor circuit (DTC P0116 / P0117 /
P0118) and/or radiator cooling fan circuit (DTC P0480)?Go to corresponding
DTC flow.Go to Step 2.
2Radiator cooling fan control circuit check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Start engine and select “Data List” on scan tool.
3) Warm up engine until coolant temp. is 100 °C, 212 °F or
higher and A/C switch turns OFF (if equipped with A/C).
(If engine coolant temp. dose not rise, check engine
cooling system or ECT sensor.)
Is radiator cooling fan started when engine coolant temp.
reached above temp.?Radiator cooling fan
control system is in
good condition.Perform from Step 2 to
Step 7 in DTC P0480
diag. flow. If OK, Go to
Ste p 3.
3Radiator cooling fan control check
1) Disconnect radiator cooling fan motor connector with
ignition switch turned OFF.
2) Run engine when ECT is over 100 °C, 212 °F.
3) Measure voltage between vehicle body ground and
“BLU/RED” wire terminal of disconnected radiator
cooling fan motor connector.
Is voltage 10 – 14 V?Go to Step 4. “BLU/RED” wire is open
or high resistance
circuit.
4Check radiator cooling fan wire circuit check
1) Turn ignition switch to OFF position.
2) Measure resistance between “BLK” wire terminal of
disconnected radiator cooling fan motor connector and
vehicle body ground.
Is resistance below 1
Ω?Go to Step 5. “BLK” wire is open or
high resistance circuit.
5Radiator cooling fan check
1) Check radiator cooling fan referring to “Radiator Cooling
Fan Assembly On-Vehicle Inspection in Section 1F”.
Is it in good condition?Substitute a known-
good ECM and recheck.Faulty radiator cooling
fan.

Downloaded from www.Manualslib.com manuals search engine 1B-1 Aux. Emission Control Devices:
Engine
Aux. Emission Control Devices
Diagnostic Information and Procedures
EGR System Inspection (If Equipped)S6RW0D1204001
1) Connect SUZUKI scan tool to data link connector
(DLC) (1) with ignition switch turned OFF.
2) Turn ON ignition switch and erase DTC using
“Delete” in “DTC” menu of scan tool.
3) Start engine and warm it up to normal operating
temperature, then select “Data List” mode on scan
tool.
4) Make sure that vehicle condition is as follows.
• Vehicle speed = 0 km/h (0 KPH)
• Engine speed ≤ 900 rpm
• Engine coolant temp. ≥ 90 °C, 164 °F5) With engine idling (without depressing accelerator
pedal), open EGR valve by using “Step EGR
Control” mode in “Engine / Active Test” menu. In this
state, as EGR valve opening increases engine idle
speed drops. If not, possible cause is clogged EGR
gas passage, stuck or faulty EGR valve.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
Repair Instructions
EVAP Canister Purge InspectionS6RW0D1206001
NOTE
Before inspection, check to make sure that
gear shift lever is in neutral position and that
parking brake lever is pulled all the way up.

1) Disconnect purge hose (1) from purge pipe.
2) Place finger against the end of disconnected hose
and check that vacuum is not felt there when engine
is cool and running at idle speed. If check result is
not satisfactory, check EVAP canister purge valve,
wire harness and ECM.
EVAP Canister Purge Valve and Its Circuit
Inspection
S6RW0D1206002
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.

(A) 1I5RW0C110011-01
1
I5RW0A120006-01

Downloaded from www.Manualslib.com manuals search engine 1D-6 Engine Mechanical:
8) Disengage clutch (1) (to lighten starting load on
engine) for M/T vehicle, and depress accelerator
pedal (2) all the way to make throttle fully open.
9) Crank engine with fully charged battery, and read the
highest pressure on compression gauge.
NOTE
• For measuring compression pressure,
crank engine at least 250 r/min. by using
fully charged battery.
• If measured compression pressure is
lower than limit value, check installation
condition of special tool. If it is properly
installed, possibility is compression
pressure leakage from where piston ring
and valve contact.

Compression pressure
Standard: 1400 kPa (14.0 kgf/cm2, 199.0 psi)
Limit: 1100 kPa (11.0 kgf/cm2, 156.0 psi)
Max. difference between any two cylinders: 100
kPa (1.0 kgf/cm
2, 14.2 psi)
10) Carry out Steps 7) through 9) on each cylinder to
obtain 4 readings.
11) After checking, install spark plugs and ignition coil
assemblies with high-tension cord referring to “Spark
Plug Removal and Installation in Section 1H”.
12) Connect ignition coil couplers.
13) Connect fuel injector wires at the coupler.
14) Install cylinder head upper cover.
15) Install air cleaner assembly with air section hose
referring to “Air Cleaner Assembly Removal and
Installation”.
Engine Vacuum CheckS6RW0D1404002
The engine vacuum that develops in the intake line is a
good indicator of the condition of the engine. The
vacuum checking procedure is as follows:
1) Warm up engine to normal operating temperature.
NOTE
After warming up engine, place transmission
gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T model), and set
parking brake and block drive wheels.

2) Stop engine and turn off the all electric switches.
3) Remove air cleaner assembly with air suction hose
referring to “Air Cleaner Assembly Removal and
Installation”.
4) Remove PCV hose (1) from PCV valve (2).
5) Connect special tool (Vacuum gauge) to PCV hose
(1).
Special tool
(A): 09915–67311
6) Blind PCV valve (2) using tape (3) or the like.I2RH0B140005-01
12
I5RW0C140038-01
(A)
1
2
3
I5RW0A140003-02

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-17
Engine Assembly Removal and InstallationS6RW0D1406013
Removal
1) Relieve fuel pressure according to “Fuel Pressure
Relief Procedure in Section 1G”.
2) Disconnect negative and positive cable at battery.
3) Disconnect ECM connectors.
4) Remove battery and battery tray with ECM.
5) Remove right and left side engine under covers.
6) Remove A/C compressor belt by referring to
“Compressor Drive Belt Removal and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
7) Drain engine oil referring to “Engine Oil and Filter
Change in Section 0B”.
8) Drain transaxle oil referring to “Manual Transaxle Oil
Change in Section 5B” or “A/T Fluid Change in
Section 5A”.
9) Drain transfer oil referring to “Transfer Oil Change in
Section 3C”.
10) Drain coolant referring to “Cooling System Draining
in Section 1F”
11) Remove air cleaner assembly referring to “Air
Cleaner Assembly Removal and Installation”.
12) With hose connected, detach A/C compressor from
its bracket referring to “Compressor Assembly
Removal and Installation in Section 7B” or
“Compressor Assembly Removal and Installation in
Section 7B”.
CAUTION!
Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

13) Remove cylinder upper cover (1).14) Disconnect the following electric wires/connectors
and each clamps.
• TP sensor (1)
• MAP sensor (2)
• ECT sensor (3)
•EGR valve (4)
• CMP sensor (5)
• Ignition coil assembly (6)
• Injector (7)
•HO2S (8)
• Oil control valve (9) (for engine with VVT system)
• Engine oil pressure switch (10)
• CKP sensor (12)
• Knock sensor (13)
• Generator (14)
• Starting motor (15)
• Ground terminal (16) from cylinder block
• Battery ground cable (17) from transaxle
• Back-up light switch (18) (for M/T model)
• Torque sensor (19)
• P/S motor (20)
• Output shaft speed sensor (VSS) (29) (for A/T
model)
• Solenoid valve (30) (for A/T model)
• Transmission range sensor (31) (for A/T model)
• Input shaft speed sensor (32) (for A/T model)
15) Disconnect the following cables, and remove control
cable bracket (23)
• Gear select control cable (21) (for M/T model)
• Gear shift control cable (22) (for M/T model)
• A/T select cable (33) (for A/T model)
16) Disconnect the following hoses.
• Brake booster hose (24) from intake manifold
• Radiator inlet and outlet hoses (25) from radiator
• Heater inlet and outlet hoses (26) from heater
core
• Fuel feed hose (27) from fuel feed pipe
• Fuel vapor hose (11) from fuel vapor pipe
• Clutch hose (28) from transaxle (for M/T model)
• A/T fluid cooler hoses (for A/T model)
F: Vehicle forward 8. Engine front mounting bracket : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
1. Engine right mounting bracket 9. Engine front mounting
: Be sure to direct yellow mark to forward.: 95 N⋅m (9.5 kgf-m, 69.0 lb-ft)
2. Engine right mounting 10. Transfer : 65 N⋅m (6.5 kgf-m, 47.0 lb-ft)
3. Engine left mounting bracket 11. Suspension frame : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
1
I5RW0A140009-01

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 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.
I5RW0A170003-01
I2RH0B170004-01