2006 SUZUKI SX4 coolant temperature

Downloaded from www.Manualslib.com manuals search engine 0A-1 General Information:
General Information
General Information
General Description
AbbreviationsS6RW0D0101001
A:
ABDC: After Bottom Dead Center
ABS: Anti-lock Brake System
AC: Alternating Current
A/C: Air Conditioning
A-ELR: Automatic-Emergency Locking Retractor
A/F: Air Fuel Mixture Ratio
ALR: Automatic Locking Retractor
API: American Petroleum Institute
APP sensor: Accelerator Pedal Position Sensor
A/T: Automatic Transmission, Automatic Transaxle
AT D C : After Top Dead Center
ATF: Automatic Transmission Fluid, Automatic
Transaxle Fluid
B:
B+: Battery Positive Voltage
BBDC: Before Bottom Dead Center
BCM: Body Electrical Control Module
BTDC: Before Top Dead Center
C:
CAN: Controller Area Network
CKT: Circuit
CKP Sensor: Crankshaft Position Sensor
CMP Sensor: Camshaft Position Sensor
CO: Carbon Monoxide
CPP Switch: Clutch Pedal Position Switch (Clutch
Switch, Clutch Start Switch)
CPU: Central Processing Unit
CRS: Child Restraint System
D:
DC: Direct Current
DLC: Data Link Connector (Assembly Line Diag. Link,
ALDL, Serial Data Link, SDL)
DOHC: Double Over Head Camshaft
DOJ: Double Offset Joint
DRL: Daytime Running Light
DTC: Diagnostic Trouble Code (Diagnostic Code)
E:
EBCM: Electronic Brake Control Module, ABS Control
Module
EBD: Electronic Brake Force Distribution
ECM: Engine Control Module
ECT Sensor: Engine Coolant Temperature Sensor
(Water Temp. Sensor, WTS)
EFE Heater: Early Fuel Evaporation Heater (Positive
Temperature Coefficient, PTC Heater)
EGR: Exhaust Gas Recirculation
EGRT Sensor: EGR Temperature Sensor (Recirculated
Exhaust Gas Temp. Sensor, REGTS)
EPS: Electronic Power Steering
EVAP: Evaporative Emission
EVAP Canister: Evaporative Emission Canister
(Charcoal Canister)F:
4WD: 4 Wheel Drive
G:
GEN: Generator
GND: Ground
GPS: Global Positioning System
H:
HAVC: Heating, Ventilating and Air Conditioning
HC: Hydrocarbons
HO2S: Heated Oxygen Sensor
I:
IAC Valve: Idle Air Control Valve (Idle Speed Control
Solenoid Valve, ISC Solenoid Valve)
IAT Sensor: Intake Air Temperature Sensor (Air
temperature Sensor, ATS)
ICM: Immobilizer Control Module
IG: Ignition
ISC Actuator: Idle Speed Control Actuator
L:
LH: Left Hand
LHD: Left Hand Drive vehicle
LSPV: Load Sensing Proportioning Valve
M:
MAF Sensor: Mass Air Flow Sensor (Air Flow Sensor,
AFS, Air Flow Meter, AFM)
MAP Sensor: Manifold Absolute Pressure Sensor
(Pressure Sensor, PS)
Max: Maximum
MFI: Multiport Fuel Injection (Multipoint Fuel Injection)
Min: Minimum
MIL: Malfunction Indicator Lamp (“SERVICE ENGINE
SOON” Light)
M/T: Manual Transmission, Manual Transaxle
N:
NOx: Nitrogen Oxides
O:
OBD: On-Board Diagnostic System (Self-Diagnosis
Function)
O/D: Overdrive
OHC: Over Head Camshaft
O2S: Oxygen Sensor
P:
PCM: Powertrain Control Module
PCV: Positive Crankcase Ventilation
PNP: Park / Neutral Position
P/S: Power Steering
PSP Switch: Power Steering Pressure Switch (P/S
Pressure Switch)
R:
RH: Right Hand
RHD: Right Hand Drive vehicle

Downloaded from www.Manualslib.com manuals search engine 0B-5 Maintenance and Lubrication:
6) Replenish oil until oil level is brought to FULL level
mark on dipstick (oil pan and oil filter capacity). The
filler inlet is at the top of the cylinder head cover. It is
recommended to use engine oil of SG, SH, SJ, SL or
SM grade. Select the appropriate oil viscosity
according to the proper engine oil viscosity chart [A].
NOTE
Engine oil capacity is specified as the
following.
However, note that the amount of oil required
when actually changing oil may somewhat
differ from the data depending on various
conditions (temperature, viscosity, etc.).

Engine oil specification
Oil pan capacity: About 3.7 liters (7.8 / 6.5 US /
lmp pt.)
Oil filter capacity: About 0.2 liter (0.4 / 0.3 US /
lmp pt.)
Others: About 0.3 liter (0.6 / 0.5 US / lmp pt.)
Total: About 4.2 liters (8.9 / 7.4 US / lmp pt.)
7) Check oil filter and drain plug for oil leakage.
8) Start engine and run it for 3 minutes. Stop it and wait
another 5 minutes before checking oil level. Add oil,
as necessary, to bring oil level to FULL level mark (1)
on dipstick.
Engine Coolant ChangeS6RW0D0206005
Change engine coolant with new one referring to
“Cooling System Flush and Refill in Section 1F”.
Exhaust System InspectionS6RW0D0206006
WARNING!
To avoid danger of being burned, do not
touch exhaust system when it is still hot.
Any service on exhaust system should be
performed when it is cool.

When carrying out periodic maintenance, or the vehicle
is raised for other service, check exhaust system as
follows:
• Check rubber mountings for damage, deterioration,
and out of position.
• Check exhaust system for leakage, loose
connections, dents and damages.
If bolts or nuts are loose, tighten them to specification.
• Check nearby body areas for damaged, missing or
mispositioned parts, open seams, holes, loose
connections or other defects which could permit
exhaust fumes to seep into the vehicle.
• Make sure that exhaust system components have
enough clearance from the underbody to avoid
overheating and possible damage to floor carpet.
• Any defects should be fixed at once.
Spark Plug ReplacementS6RW0D0206007
Replace spark plugs with new ones referring to “Spark
Plug Removal and Installation in Section 1H”.
2. Low level mark (hole)
C
Fo o-30
-22-20
-4-10
14 32 50 68 86 104010203040
5W-30
20W-40, 20W-50
10W-30
15W-40, 15W-50
10W-40, 10W-50
[A]
I4RS0A020002-01
IYSQ01020012-01
I4RS0A020003-01

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-12
Steering
• Check to ensure that steering wheel is free from
instability, or abnormally heavy feeling.
• Check that the vehicle does not wander or pull to one
side.
Engine
• Check that engine responds readily at all speeds.
• Check that engine is free from abnormal noise and
abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting system
are free from abnormal noise and abnormal vibration or
any other abnormal condition.Meters and Gauge
Check that speedometer, odometer, fuel meter,
temperature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan
switch lever to highest position for this check.
Specifications
Tightening Torque SpecificationsS6RW0D0207001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Fluids and LubricantsS6RW0D0208001
Special ToolS6RW0D0208002
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Engine oil drain plug 35 3.5 25.5)
Oil filter 14 1.4 10.5 for reference )
Engine oil SG, SH, SJ, SL or SM grade (Refer to “Engine Oil and Filter Change” for engine
oil viscosity.)
Engine coolant
(Ethylene glycol base coolant)“Antifreeze/Anticorrosion coolant”
Brake fluid Refer to reservoir cap of brake master cylinder.
Manual transaxle oil Refer to “Manual Transaxle Oil Change in Section 5B”.
Automatic transaxle fluid Refer to “A/T Fluid Change in Section 5A”.
Transfer oil (4WD) Refer to “Transfer Oil Change in Section 3C”.
Rear differential (4WD) Refer to “Rear Differential Oil Change in Section 3B”.
Door hinges Engine oil or water resistance chassis grease
Hood latch assembly Engine oil or water resistance chassis grease
Key lock cylinder Spray lubricant
09915–47331
Oil filter wrench
)

Downloaded from www.Manualslib.com manuals search engine Table of Contents 1- i
1
Section 1
CONTENTS
Engine
Precautions ................................................. 1-1
Precautions............................................................. 1-1
Precautions for Engine .......................................... 1-1
Engine General Information and
Diagnosis ................................................. 1A-1
Precautions........................................................... 1A-1
Precautions on Engine Service ........................... 1A-1
Precaution on On-Board Diagnostic (OBD)
System .............................................................. 1A-1
Precautions in Diagnosing Trouble ..................... 1A-1
Precautions for DTC Troubleshooting ................. 1A-2
Precautions of ECM Circuit Inspection................ 1A-2
Precautions of Electric Throttle Body System
Calibration ......................................................... 1A-2
Precaution on CAN Troubleshooting .................. 1A-3
General Description ............................................. 1A-5
Statement on Cleanliness and Care ................... 1A-5
Engine Diagnosis General Description ............... 1A-5
On-Board Diagnostic System Description ........... 1A-5
Data Link Connector (DLC) ................................. 1A-8
Engine and Emission Control System
Description ........................................................ 1A-8
CAN Communication System Description........... 1A-9
Air Intake System Description ........................... 1A-11
Description of Electric Throttle Body System
Calibration ....................................................... 1A-11
Description of Electric Throttle Body System .... 1A-11
Engine and Emission Control Input / Output
Table ............................................................... 1A-18
Schematic and Routing Diagram ...................... 1A-19
Engine and Emission Control System
Diagram .......................................................... 1A-19
Component Location ......................................... 1A-21
Electronic Control System Components
Location .......................................................... 1A-21
Diagnostic Information and Procedures .......... 1A-22
Engine and Emission Control System Check.... 1A-22
Malfunction Indicator Lamp (MIL) Check .......... 1A-25
DTC Check ....................................................... 1A-25
DTC Clearance ................................................. 1A-26
Troubleshooting for Communication Error
with Scan Tool Using CAN.............................. 1A-26
DTC Table ......................................................... 1A-32For Vehicle Equipped with A/T .......................... 1A-36
Fail-Safe Table .................................................. 1A-36
Scan Tool Data ................................................. 1A-38
Visual Inspection ............................................... 1A-43
Engine Basic Inspection .................................... 1A-43
Engine Symptom Diagnosis .............................. 1A-45
Malfunction Indicator Lamp Does Not Come
ON with Ignition Switch ON and Engine Stop
(but Engine Can Be Started) ........................... 1A-52
Malfunction Indicator Lamp Remains ON after
Engine Starts................................................... 1A-54
DTC P0010: Camshaft Position Actuator
Circuit (for engine with VVT system) ............... 1A-55
DTC P0011 / P0012: Camshaft Position -
Timing Over-Advanced or System
Performance / Retarded (for engine with
VVT system).................................................... 1A-57
DTC P0031 / P0032: HO2S Heater Control
Circuit Low / High (Sensor-1) .......................... 1A-59
DTC P0037 / P0038: HO2S Heater Control
Circuit Low / High (Sensor-2) .......................... 1A-61
DTC P0101: Mass Air Flow Circuit Range /
Performance.................................................... 1A-63
DTC P0102: Mass Air Flow Circuit Low Input ... 1A-66
DTC P0103: Mass Air Flow Circuit High Input .. 1A-67
DTC P0106: Manifold Absolute Pressure
Range / Performance ...................................... 1A-69
DTC P0107: Manifold Absolute Pressure
Circuit Low Input ............................................. 1A-70
DTC P0108: Manifold Absolute Pressure
Circuit High Input............................................. 1A-72
DTC P0111: Intake Air Temperature Circuit
Range / Performance ...................................... 1A-74
DTC P0112: Intake Air Temperature Sensor
Circuit Low ...................................................... 1A-76
DTC P0113: Intake Air Temperature Sensor
Circuit High...................................................... 1A-78
DTC P0116: Engine Coolant Temperature
Circuit Range / Performance ........................... 1A-80
DTC P0117: Engine Coolant Temperature
Circuit Low ...................................................... 1A-83
DTC P0118: Engine Coolant Temperature
Circuit High...................................................... 1A-85
DTC P0122: Throttle Position Sensor (Main)
Circuit Low ...................................................... 1A-87

Downloaded from www.Manualslib.com manuals search engine Table of Contents 1-iii
EGR Valve Removal and Installation (If
Equipped).......................................................... 1B-4
EGR Valve Inspection (If Equipped) ................... 1B-4
PCV Hose Inspection .......................................... 1B-5
PCV Valve Inspection ......................................... 1B-5
Special Tools and Equipment ............................. 1B-5
Special Tool ........................................................ 1B-5
Engine Electrical Devices ....................... 1C-1
Repair Instructions .............................................. 1C-1
Engine Control Module (ECM) Removal and
Installation ......................................................... 1C-1
Manifold Absolute Pressure (MAP) Sensor
Inspection (If Equipped) .................................... 1C-2
Electric Throttle Body Assembly On-Vehicle
Inspection.......................................................... 1C-2
Electric Throttle Body System Calibration ........... 1C-5
Accelerator Pedal Position (APP) Sensor
Assembly On-Vehicle Inspection ...................... 1C-5
Accelerator Pedal Position (APP) Sensor
Assembly Removal and Installation .................. 1C-5
Accelerator Pedal Position (APP) Sensor
Assembly Inspection ......................................... 1C-6
Engine Coolant Temperature (ECT) Sensor
Removal and Installation................................... 1C-7
Engine Coolant Temperature (ECT) Sensor
Inspection.......................................................... 1C-7
Heated Oxygen Sensor (HO2S-1 and HO2S-
2) Heater On-Vehicle Inspection (If
Equipped).......................................................... 1C-8
Heated Oxygen Sensor (HO2S-1 and HO2S-
2) Removal and Installation (If Equipped) ......... 1C-8
Camshaft Position (CMP) Sensor Removal
and Installation .................................................. 1C-9
Camshaft Position (CMP) Sensor Inspection ...... 1C-9
Crankshaft Position (CKP) Sensor Removal
and Installation ................................................ 1C-10
Crankshaft Position (CKP) Sensor Inspection .. 1C-11
Knock Sensor Removal and Installation ........... 1C-11
Main Relay, Fuel Pump Relay, Starting Motor
Control Relay, Throttle Actuator Control
Relay and Radiator Cooling Fan Relay
Inspection........................................................ 1C-12
Mass Air Flow (MAF) and Intake Air
Temperature (IAT) Sensor On-Vehicle
Inspection........................................................ 1C-12
Mass Air Flow (MAF) and Intake Air
Temperature (IAT) Sensor Removal and
Installation ....................................................... 1C-13
Intake Air Temperature (IAT) Sensor
Inspection........................................................ 1C-13
Specifications..................................................... 1C-14
Tightening Torque Specifications ...................... 1C-14
Engine Mechanical .................................. 1D-1
General Description ............................................. 1D-1
Engine Construction Description ......................... 1D-1
Camshaft Position Control (VVT Variable
Valve Timing) System Description .................... 1D-3Diagnostic Information and Procedures ............1D-5
Compression Check ............................................1D-5
Engine Vacuum Check........................................1D-6
Valve Lash (Clearance) Inspection .....................1D-7
Repair Instructions ............................................1D-10
Air Intake System Components.........................1D-10
Air Cleaner Filter Removal and Installation .......1D-10
Air Cleaner Filter Inspection and Cleaning........1D-10
Air Cleaner Assembly Removal and
Installation .......................................................1D-11
Cylinder Head Cover Removal and
Installation .......................................................1D-11
Throttle Body and Intake Manifold
Components ....................................................1D-13
Throttle Body On-Vehicle Inspection.................1D-14
Electric Throttle Body Assembly Removal and
Installation .......................................................1D-14
Throttle Body Cleaning......................................1D-14
Intake Manifold Removal and Installation .........1D-15
Engine Mountings Components ........................1D-16
Engine Assembly Removal and Installation ......1D-17
Timing Chain Cover Components .....................1D-22
Timing Chain Cover Removal and Installation ..1D-23
Timing Chain Cover Inspection .........................1D-25
Oil Control Valve Removal and Installation
(For Engine with VVT) .....................................1D-26
Oil Control Valve Inspection (For Engine with
VVT) ................................................................1D-26
Timing Chain and Chain Tensioner
Components ....................................................1D-27
Timing Chain and Chain Tensioner Removal
and Installation ................................................1D-27
Timing Chain and Chain Tensioner Inspection ..1D-31
Camshaft, Tappet and Shim Components ........1D-32
Camshaft, Tappet and Shim Removal and
Installation .......................................................1D-33
Camshaft, Tappet and Shim Inspection ............1D-36
Valves and Cylinder Head Components ...........1D-39
Valves and Cylinder Head Removal and
Installation .......................................................1D-40
Valves and Cylinder Head Disassembly and
Assembly.........................................................1D-42
Valves and Valve Guides Inspection.................1D-45
Cylinder Head Inspection ..................................1D-47
Valve Spring Inspection ....................................1D-48
Pistons, Piston Rings, Connecting Rods and
Cylinders Components ....................................1D-49
Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation .................1D-49
Pistons, Piston Rings, Connecting Rods and
Cylinders Disassembly and Assembly ............1D-51
Cylinders, Pistons and Piston Rings
Inspection ........................................................1D-52
Piston Pins and Connecting Rods Inspection ...1D-54
Crank Pin and Connecting Rod Bearings
Inspection ........................................................1D-55
Main Bearings, Crankshaft and Cylinder
Block Components ..........................................1D-59
Main Bearings, Crankshaft and Cylinder
Block Removal and Installation .......................1D-60

Downloaded from www.Manualslib.com manuals search engine 1A-6 Engine General Information and Diagnosis:
• As a condition for detecting a malfunction in some
areas in the system being monitored by ECM and
turning ON the malfunction indicator lamp (1) due to
that malfunction, 2 driving cycle detection logic is
adopted to prevent erroneous detection.
• When a malfunction is detected, engine and driving
conditions then are stored in ECM memory as freeze
frame data. (For the details, refer to description on
“Freeze Frame Data: ”.)
• It is possible to communicate via DLC (3) by using not
only SUZUKI scan tool (2) but also CAN
communication OBD generic scan tool. (Diagnostic
information can be accessed by using a scan tool.)
Warm-Up Cycle
A warm-up cycle means sufficient vehicle operation such
that the coolant temperature has risen by at least 22 °C
(40 °F) from engine starting and reaches a minimum
temperature of 70 °C (160 °F).
Driving Cycle
A “Driving Cycle” consists of engine startup and engine
shutoff.2 Driving Cycle Detection Logic
The malfunction detected in the first driving cycle is
stored in ECM memory (in the form of pending DTC) but
the malfunction indicator lamp does not light at this time.
It lights up at the second detection of same malfunction
also in the next driving cycle.
Pending DTC
Pending DTC means a DTC detected and stored
temporarily at 1 driving cycle of the DTC which is
detected in the 2 driving cycle detection logic.
Freeze Frame Data
ECM stores the engine and driving conditions (in the
form of data as shown in the figure) at the moment of the
detection of a malfunction in its memory. This data is
called “Freeze frame data”.
Therefore, it is possible to know engine and driving
conditions (e.g., whether the engine was warm or not,
where the vehicle was running or stopped, where air/fuel
mixture was lean or rich) when a malfunction was
detected by checking the freeze frame data. Also, ECM
has a function to store each freeze frame data for three
different malfunctions in the order as each malfunction is
detected. Utilizing this function, it is possible to know the
order of malfunctions that have been detected. Its use is
helpful when rechecking or diagnosing a trouble.
For example
1
2 3
I5RW0C110001-01
I5RW0C110028-03

Downloaded from www.Manualslib.com manuals search engine 1A-10 Engine General Information and Diagnosis:
ECM Transmission Data
ECM Reception Data
BCM TCMCombination
Meter
DATA ECM Transmit
Brake pedal switch signal
Vehicle speed signal
Engine speed signal
Engine torque signal
Accelerator pedal position signal
4WD Control
ModuleKeyless Start
Control
Module
A/C refrigerant pressure
signal
A/C compressor clutch signal
Engine type signal
Immobilizer indicator light control
signal
MIL control signal
Engine coolant temperature signal
Fuel level signal
Fuel consumption signal
Throttle position signal
Driving cycle active
Warm up cycle active
Odometer signal
I6RW0D110003-02
DATA ECM Receive
ABS control
module
Transmission oil temperature signal
Transmission warning light signal Vehicle speed pulse signal A/T selector lever position signal
Transmission actual gear position signal
Wheel speed signal (front right)
Wheel speed signal (front left)
ABS indication signal
A/C switch ON signal
Electric load signalBCM
4WD mode status
Torque request signalTCM
MIL control signal4WD control
module
I6RW0D110013-02

Downloaded from www.Manualslib.com manuals search engine 1A-32 Engine General Information and Diagnosis:
DTC TableS6RW0D1104005
NOTE
• There are two types of OBD system depending on the vehicle specification.
For identification, refer to “Precaution on On-Board Diagnostic (OBD) System”.
• For non-Euro-OBD model, some of DTC No. with delta (U) mark in the following table can not be
detected by ECM depending on vehicle specification.
• With the CAN communication generic scan tool, only star (*) marked DTC No. in the following table
can be read.
• 1 driving cycle: MIL lights up when DTC is detected during 1 driving cycle.
• 2 driving cycles: MIL lights up when the same DTC is detected also in the next driving cycle after
DTC is detected and stored temporarily in the first driving cycle.
• *2 driving cycles:
MIL blinks or lights up. Refer to “DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire
Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected” for details.

DTC No. Detecting itemDetecting condition
(DTC will set when detecting:)MIL
) *P0010Camshaft position actuator circuit
(for engine with VVT system)Oil control valve circuit open or short.1 driving
cycle
) *P0011Camshaft position – timing over-
advanced or system performance
(for engine with VVT system)Actual value of advanced valve timing does not reach
target value, or valve timing is advanced although ECM
command is most retarding.2 driving
cycles
) *P0012Camshaft position – timing over-
retarded
(for engine with VVT system)2 driving
cycles
) *P0031HO2S heater control circuit low
(Sensor-1)Heater current is less than specification while heater ON.2 driving
cycles
) *P0032HO2S heater control circuit high
(Sensor-1)Heater current is more than specification while heater ON.2 driving
cycles
)
U*P0037HO2S heater control circuit low
(Sensor-2)Heater current is less than specification while heater ON.2 driving
cycles
)
U*P0038HO2S heater control circuit high
(Sensor-2)Heater current is more than specification while heater ON.2 driving
cycles
)
U*P0101Mass air flow circuit range/
performanceMAF sensor volume is more than specification or less
than specification.2 driving
cycles
) *P0102 Mass air flow circuit low input Output voltage of MAF sensor is less than specification.1 driving
cycle
) *P0103 Mass air flow circuit high input Output voltage of MAF sensor is more than specification.1 driving
cycle
)
U*P0106Manifold absolute pressure circuit
range/performanceDifference between Max. manifold absolute pressure
value and Min. manifold pressure value is less than
specification or difference between barometric pressure
value and manifold pressure value is less than
specification2 driving
cycles
)
U*P0107Manifold absolute pressure circuit
low inputOutput voltage of MAP sensor is less than specification.
1 driving
cycle
)
U*P0108Manifold absolute pressure circuit
high inputOutput voltage of MAP sensor is more than specification.1 driving
cycle
)
U* P 0 111Intake air temperature sensor circuit
range/performanceVariation of intake air temperature from engine start is
less than specification.2 driving
cycles
) *P0112Intake air temperature sensor circuit
lowCircuit voltage of IAT sensor is less than specification.1 driving
cycle
) *P0113Intake air temperature sensor circuit
highCircuit voltage of IAT sensor is more than specification.1 driving
cycle
)
U*P0116Engine coolant temperature circuit
range/performanceEngine coolant temperature is less than specified
temperature for specified time from engine start.2 driving
cycles