2006 SUZUKI SX4 engine overheat

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 Engine General Information and Diagnosis: 1A-47
Engine overheatingInoperative thermostat“Thermostat Inspection in Section 1F”
Poor water pump performance“Water Pump Inspection in Section 1F”
Clogged or leaky radiator“Radiator On-Vehicle Inspection and Cleaning
in Section 1F”
Improper engine oil grade“Engine Oil and Filter Change in Section 0B”
Clogged oil filter or oil strainer“Oil Pressure Check in Section 1E”
Poor oil pump performance“Oil Pressure Check in Section 1E”
Faulty radiator cooling fan control
system“Radiator Cooling Fan Control System Check”
Dragging brakesCondition “Dragging brakes” in “Brakes
Symptom Diagnosis in Section 4A”
Slipping clutch (for M/T model)Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis in Section 5C” for M/T
model
Blown cylinder head gasket“Cylinder Head Inspection in Section 1D”
Air mixed in cooling system
Poor gasoline mileageLeaks or loose connection of high-
tension cord“High-Tension Cord Removal and Installation
in Section 1H”
Faulty spark plug (improper gap, heavy
deposits and burned electrodes, etc.)“Spark Plug Inspection in Section 1H”
Malfunctioning EGR valve“EGR Valve Inspection (If Equipped) in Section
1B”
High idle speedCondition “Improper engine idling or engine
fails to idle”
Poor performance of ECT sensor, MAF
sensor“Engine Coolant Temperature (ECT) Sensor
Inspection in Section 1C”, or “Intake Air
Temperature (IAT) Sensor Inspection in
Section 1C”
Faulty electric throttle body assembly“Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly“Accelerator Pedal Position (APP) Sensor
Assembly Inspection in Section 1C”
Faulty fuel injector(s)“Fuel Injector Circuit Check”
Faulty ECM
Low compression“Compression Check in Section 1D”
Poor valve seating“Valves and Valve Guides Inspection in
Section 1D”
Dragging brakesCondition “Dragging brakes” in “Brakes
Symptom Diagnosis in Section 4A”
Slipping clutch (for M/T model)Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis in Section 5C” for M/T
model
Thermostat out of order“Thermostat Inspection in Section 1F”
Improper tire pressure“Tires Description in Section 2D”
Camshaft position control (VVT) system
out of order (for engine with VVT
system)“Oil Control Valve Inspection (For Engine with
VVT) in Section 1D”
Excessive engine oil
consumption – Oil
leakageBlown cylinder head gasket“Cylinder Head Inspection in Section 1D”
Leaky camshaft oil seals“Camshaft, Tappet and Shim Inspection in
Section 1D” Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 1A-48 Engine General Information and Diagnosis:
Excessive engine oil
consumption – Oil
entering combustion
chamberSticky piston ring“Cylinders, Pistons and Piston Rings
Inspection in Section 1D”
Worn piston and cylinder“Cylinders, Pistons and Piston Rings
Inspection in Section 1D”
Worn piston ring groove and ring“Cylinders, Pistons and Piston Rings
Inspection in Section 1D”
Improper location of piston ring gap“Pistons, Piston Rings, Connecting Rods and
Cylinders Disassembly and Assembly in
Section 1D”
Worn or damaged valve stem seal“Valves and Valve Guides Inspection in
Section 1D”
Worn valve stem“Valves and Valve Guides Inspection in
Section 1D”
Engine hesitates –
Momentary lack of
response as accelerator
is depressed. Can occur
at all vehicle speeds.
Usually most severe when
first trying to make
vehicle move, as from a
stop sign.Spark plug faulty or plug gap out of
adjustment“Spark Plug Inspection in Section 1H”
Leaky high-tension cord“High-Tension Cord Inspection in Section 1H”
Fuel pressure out of specification“Fuel Pressure Check”
Malfunctioning EGR valve“EGR Valve Inspection (If Equipped) in Section
1B”
Poor performance of ECT sensor or
MAF sensor, “Engine Coolant Temperature (ECT) Sensor
Inspection in Section 1C” or “Intake Air
Temperature (IAT) Sensor Inspection in
Section 1C”
Faulty electric throttle body assembly“Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly“Accelerator Pedal Position (APP) Sensor
Assembly Inspection in Section 1C”
Faulty fuel injector“Fuel Injector Circuit Check”
Faulty ECM
Engine overheatingCondition “Engine overheating”
Low compression“Compression Check in Section 1D”
Camshaft position control (VVT) system
out of order (for engine with VVT
system)“Oil Control Valve Inspection (For Engine with
VVT) in Section 1D”
Surge – Engine power
variation under steady
throttle or cruise. Feels
like vehicle speeds up
and down with no change
in accelerator pedal.Leaky or loosely connected high-tension
cord“High-Tension Cord Removal and Installation
in Section 1H”
Faulty spark plug (excess carbon
deposits, improper gap, burned
electrodes, etc.)“Spark Plug Inspection in Section 1H”
Variable fuel pressure“Fuel Pressure Check”
Kinky or damaged fuel hose and lines
Faulty fuel pump (clogged fuel filter)
Malfunctioning EGR valve“EGR Valve Inspection (If Equipped) in Section
1B”
Poor performance of MAF sensor“Intake Air Temperature (IAT) Sensor
Inspection in Section 1C”
Faulty fuel injector“Fuel Injector Circuit Check”
Faulty ECM
Faulty electric throttle body assembly“Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly“Accelerator Pedal Position (APP) Sensor
Assembly Inspection in Section 1C” Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-49
Excessive detonation –
Engine makes
continuously sharp
metallic knocks that
change with throttle
opening. Sounds like pop
corn popping.Faulty spark plug“Spark Plug Inspection in Section 1H”
Loose connection of high-tension cord“High-Tension Cord Removal and Installation
in Section 1H”
Engine overheatingCondition “Engine overheating”
Clogged fuel filter (faulty fuel pump) or
fuel lines“Fuel Pressure Check” or “Fuel Pump and Its
Circuit Check”
Air drawn in through intake manifold or
throttle body gasket
Malfunctioning EGR valve“EGR Valve Inspection (If Equipped) in Section
1B”
Poor performance of knock sensor, ECT
sensor or MAF sensor“DTC P0327 / P0328: Knock Sensor Circuit
Low / High”, “Engine Coolant Temperature
(ECT) Sensor Inspection in Section 1C” or
“Intake Air Temperature (IAT) Sensor
Inspection in Section 1C”
Faulty fuel injector(s)“Fuel Injector Circuit Check”
Faulty ECM
Excessive combustion chamber
deposits“Cylinders, Pistons and Piston Rings
Inspection in Section 1D” and/or “Piston Pins
and Connecting Rods Inspection in Section
1D”
Camshaft position control (VVT) system
out of order (for engine with VVT
system)“Oil Control Valve Inspection (For Engine with
VVT) in Section 1D”
Engine has no powerFaulty spark plug“Spark Plug Inspection in Section 1H”
Faulty ignition coil with ignitor“Ignition Coil Assembly (Including Ignitor)
Inspection in Section 1H”
Leaks, loose connection or
disconnection of high-tension cord“High-Tension Cord Removal and Installation
in Section 1H”
Faulty knock sensor“DTC P0327 / P0328: Knock Sensor Circuit
Low / High”
Clogged fuel hose or pipe“Fuel Pressure Check”
Malfunctioning fuel pump“Fuel Pump and Its Circuit Check”
Air drawn in through intake manifold
gasket or throttle body gasket
Engine overheatingCondition “Engine overheating”
Malfunctioning EGR valve“EGR Valve Inspection (If Equipped) in Section
1B”
Poor performance of ECT sensor or
MAF sensor“Engine Coolant Temperature (ECT) Sensor
Inspection in Section 1C” or “Intake Air
Temperature (IAT) Sensor Inspection in
Section 1C”
Faulty electric throttle body assembly“Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly“Accelerator Pedal Position (APP) Sensor
Assembly Inspection in Section 1C”
Faulty fuel injector(s)“Fuel Injector Circuit Check”
Faulty ECM
Dragging brakesCondition “Dragging brakes” in “Brakes
Symptom Diagnosis in Section 4A”
Slipping clutch (for M/T model)Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis in Section 5C” (for M/T
model)
Low compression“Compression Check in Section 1D”
Camshaft position control (VVT) system
out of order (for engine with VVT
system)“Oil Control Valve Inspection (For Engine with
VVT) in Section 1D” Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 1A-50 Engine General Information and Diagnosis:
Improper engine idling or
engine fails to idleFaulty spark plug“Spark Plug Inspection in Section 1H”
Leaky or disconnected high-tension cord“High-Tension Cord Removal and Installation
in Section 1H”
Faulty ignition coil with ignitor“Ignition Coil Assembly (Including Ignitor)
Inspection in Section 1H”
Fuel pressure out of specification“Fuel Pressure Check”
Leaky manifold, throttle body, or cylinder
head gasket
Malfunctioning EGR valve“EGR Valve Inspection (If Equipped) in Section
1B”
Faulty evaporative emission control
system“EVAP Canister Purge Inspection in Section
1B”
Faulty EGR system“EGR System Inspection (If Equipped) in
Section 1B”
Faulty fuel injector(s)“Fuel Injector Circuit Check”
Poor performance of ECT sensor or
MAF sensor“Engine Coolant Temperature (ECT) Sensor
Inspection in Section 1C”, or “Intake Air
Temperature (IAT) Sensor Inspection in
Section 1C”
Faulty electric throttle body assembly“Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly“Accelerator Pedal Position (APP) Sensor
Assembly Inspection in Section 1C”
Faulty ECM
Loose connection or disconnection of
vacuum hoses
Malfunctioning PCV valve“PCV Valve Inspection in Section 1B”
Engine overheatingCondition “Engine overheating”
Low compression“Compression Check in Section 1D”
Camshaft position control (VVT) system
out of order (for engine with VVT
system)“Oil Control Valve Inspection (For Engine with
VVT) in Section 1D” Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 1A-110 Engine General Information and Diagnosis:
DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 /
Cylinder 3 / Cylinder 4 Misfire Detected
S6RW0D1104039
System Description
ECM measures the angle of the crankshaft based on the pulse signal from the CKP sensor and CMP sensor for each
cylinder. If it detects a large change in the angle speed of the crankshaft, it concludes occurrence of a misfire. When
the number of misfire is counted by ECM beyond the DTC detecting condition, it determines the cylinder where the
misfire occurred and output it as DTC.
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic
accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

NOTE
Check to make sure that following conditions are satisfied when using this “DTC Confirmation
Procedure”.
• Intake air temp.: –7 °C, 19.4 °F or more
• Engine coolant temp.: –10 °C, 14 °F or more
• Altitude (barometric pressure): 2500 m, 8200 ft or less (560 mmHg, 74.4 kPa or more)

1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and print Freeze Frame Data or write them down using scan tool.
3) Clear DTC using scan tool.
4) Drive vehicle under freeze frame data condition as noted for 1 min. or more.
5) Stop vehicle and check DTC and pending DTC.DTC detecting condition Trouble area
DTC P0300:
• Misfire, which causes catalyst to overheat during 200 engine revolutions, is detected
at 2 or more cylinders. (MIL flashes as long as this misfire occurs continuously.)
or
• Misfire, which affects exhaust emission adversely during 1000 engine revolution, is
detected at 2 or more cylinders. (2 driving cycle detection logic)• Ignition system
• Fuel injector and its circuit
• Fuel pressure
• EGR system
• Abnormal air drawn in
• Engine compression
• Valve lash adjuster
• Valve timing
• Fuel shortage
• Exhaust system
• Fuel of poor quality DTC P0301, P0302, P0303, P0304:
• Misfire, which causes catalyst to overheat during 200 engine revolutions, is detected
at 1 cylinder. (MIL flashes as long as this misfire occurs continuously.)
or
• Misfire, which affects exhaust emission adversely during 1000 engine revolution, is
detected at 1 cylinder. (2 driving cycle detection logic)

Downloaded from www.Manualslib.com manuals search engine 1F-3 Engine Cooling System:
Diagnostic Information and Procedures
Engine Cooling Symptom DiagnosisS6RW0D1604001
Condition Possible cause Correction / Reference Item
Engine overheats
(Radiator fan operates)Loose or broken water pump beltAdjust or replace.
Not enough coolantCheck coolant level and add as necessary.
Faulty thermostatReplace.
Faulty water pumpReplace.
Dirty or bent radiator finsClean or remedy.
Coolant leakage on cooling systemRepair.
Clogged radiatorCheck and replace radiator as necessary.
Faulty radiator capReplace.
Dragging brakesAdjust brake.
Slipping clutchReplace.
Poor charge batteryCheck and replace as necessary.
Poor generation generatorCheck and repair.
ECT sensor faultyCheck and replace as necessary.
Radiator fan motor faultyCheck and replace as necessary.
ECM faultyCheck and replace as necessary.
Wiring or grounding faultyRepair as necessary.
Equipped with too much electric load
part(s)Dismount.
Engine overheats
(Radiator fan does not
operate)Fuse blownCheck fuse of relay/fuse box and check for
short circuit to ground.
Radiator cooling fan relay faultyCheck and replace as necessary.
ECT sensor faultyCheck and replace as necessary.
Radiator cooling fan motor faultyCheck and replace as necessary.
Wiring or grounding faultyRepair as necessary.
ECM faultyCheck and replace as necessary.

Downloaded from www.Manualslib.com manuals search engine 1F-7 Engine Cooling System:
Thermostat Removal and InstallationS6RW0D1606007
Removal
1) Drain coolant referring to “Cooling System Draining”.
2) Remove intake manifold referring to “Intake Manifold
Removal and Installation in Section 1D”.
3) Disconnect water hose (1) and heater hose (2) from
each pipe.
4) Remove thermostat case (3) with thermostat cap (4)
and water inlet pipe (5).
5) Remove water inlet pipe with thermostat cap from
thermostat case.
6) Remove thermostat from thermostat case (3).
Installation
Reverse removal procedure for installation noting the
following points.
• Install thermostat (5) to thermostat case (2) by
aligning air bleed valve (4) of thermostat with mark (3)
of thermostat case and, then install thermostat cap (1)
to thermostat case.
• Use new O-rings when installing.
• Refill cooling system referring to Step 7) to 17) of
“Cooling System Flush and Refill”.
• Verify that there is no coolant leakage at each
connection.
Thermostat InspectionS6RW0D1606008
• Make sure that air bleed valve (1) of thermostat is
clean.
• Check to make sure that valve seat (2) is free from
foreign matters which would prevent valve from
seating tight.
• Check thermostat seal (3) for breakage, deterioration
or any other damage.
• Check thermostatic movement of wax pellet as
follows:
a. Immerse thermostat (1) in water, and heat water
gradually.
b. Check that valve starts to open at specific
temperature.
Temperature at which valve begins to open
80 – 84 °C (176 – 183 °F)
Temperature at which valve become fully open
95 – 97 °C (203 – 206 °F)
Va l v e l i ft
More than 8 mm (0.31 in.) at 95 °C (203 °F)
If valve starts to open at a temperature substantially
below or above specific temperature, thermostat unit
should be replaced with a new one. Such a unit, if
reused, will bring about overcooling or overheating
tendency.
I6RW0B160007-01
4
53
12
I6RW0B160008-01
2. Thermometer 3. Heater
I3RM0A160008-01
I2RH01160012-01