2006 SUZUKI SX4 ig coil

Downloaded from www.Manualslib.com manuals search engine 00-1 Precautions:
Precautions
Precautions
Precautions
Precautions for Vehicles Equipped with a
Supplemental Restraint (Air Bag) System
S6RW0D0000001
WARNING!
• The configuration of air bag system parts
are as shown in the figure. When it is
necessary to service (remove, reinstall and
inspect) these parts, be sure to follow
procedures described in Air Bag System
section. Failure to follow proper
procedures could result in possible air bag
system activation, personal injury, damage
to parts or air bag system being unable to
activate when necessary.
• If the air bag system and another vehicle
system both need repair, SUZUKI
recommends that the air bag system be
repaired first, to help avoid unintended air
bag system activation.
• Do not modify the steering wheel,
dashboard, or any other air bag system
components. Modifications can adversely
affect air bag system performance and
lead to injury.
• If the vehicle will be exposed to
temperatures over 93 °C (200 °F) (for
example, during a paint baking process),
remove the air bag system components
beforehand to avoid component damage
or unintended air bag system activation.

Diagnosis
• When troubleshooting air bag system, be sure to
follow “Diagnosis” in Air Bag System section.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacement.
• Never use electrical test equipment other than that
specified.
WARNING!
Never attempt to measure the resistance of
the air bag (inflator) modules (driver,
passenger, side and curtain) and seat belt
pretensioners (driver and passenger). It is
very dangerous as the electric current from
the tester may deploy the air bag or activate
the pretensioner.

1. Air bag wire harness (in floor, main
and instrument panel harness)6. Driver air bag (inflator) module
2. Passenger air bag (inflator)
module7. Side air bag (inflator) module
(if equipped)
3. SDM 8. Curtain air bag (inflator)
module (if equipped)
4. Seat belt pretensioner 9. Forward sensor
5. Contact coil 10. Side sensor (if equipped)
23
7
8
4
10
10
4 7 9156
I5RW0A000001-01
I4RS0A000002-02

Downloaded from www.Manualslib.com manuals search engine General Information: 0A-8
1
2
4
8
6 97 3 [A]
5
I6RW0D010001-01
1. Air bag label on driver air bag (inflator) module 6. Air bag label on SDM
2. Air bag label on contact coil assembly 7. Pretensioner label on seat belt retractor
3. Air bag label on passenger air bag (inflator) module 8. Side/Curtain air bag label on pillar (both right and left sides) (if equipped)
4. Air bag label on side air bag (inflator) module (if equipped) [A]: These labels are attached on vehicle equipped with air bag system only.
5. Air bag label on curtain air bag (inflator) module

Downloaded from www.Manualslib.com manuals search engine Table of Contents 1-v
Diagnostic Information and Procedures ............ 1H-4
Ignition System Symptom Diagnosis................... 1H-4
Reference Waveform of Ignition System............. 1H-4
Ignition System Check ........................................ 1H-4
Ignition Spark Test .............................................. 1H-6
Repair Instructions .............................................. 1H-6
High-Tension Cord Removal and Installation...... 1H-6
High-Tension Cord Inspection ............................ 1H-7
Spark Plug Removal and Installation .................. 1H-7
Spark Plug Inspection ......................................... 1H-7
Ignition Coil Assembly (Including Ignitor)
Removal and Installation................................... 1H-8
Ignition Coil Assembly (Including Ignitor)
Inspection.......................................................... 1H-8
Ignition Timing Inspection ................................... 1H-8
Specifications..................................................... 1H-10
Tightening Torque Specifications ...................... 1H-10
Special Tools and Equipment ........................... 1H-10
Special Tool ...................................................... 1H-10
Starting System ......................................... 1I-1
Schematic and Routing Diagram ......................... 1I-1
Cranking System Circuit Diagram ........................ 1I-1
Diagnostic Information and Procedures ............. 1I-1
Cranking System Symptom Diagnosis ................. 1I-1
Cranking System Test.......................................... 1I-3
Repair Instructions ............................................... 1I-4
Starting Motor Dismounting and Remounting ...... 1I-4
Starting Motor Components ................................. 1I-5
Starting Motor Inspection ..................................... 1I-6
Specifications........................................................ 1I-9
Cranking System Specifications........................... 1I-9
Tightening Torque Specifications ......................... 1I-9
Special Tools and Equipment.............................. 1I-9
Recommended Service Material .......................... 1I-9
Charging System ...................................... 1J-1
General Description ............................................. 1J-1
Battery Description .............................................. 1J-1
Generator Description ......................................... 1J-3
Diagnostic Information and Procedures ............ 1J-4
Battery Inspection ............................................... 1J-4
Generator Symptom Diagnosis ........................... 1J-4
Generator Test (Undercharged Battery
Check) ............................................................... 1J-5
Generator Test (Overcharged Battery Check) .... 1J-6
Repair Instructions .............................................. 1J-6
Jump Starting in Case of Emergency.................. 1J-6
Battery Dismounting and Remounting ................ 1J-7
Water Pump / Generator Drive Belt Tension
Inspection and Adjustment ................................ 1J-7
Water Pump / Generator Drive Belt Removal
and Installation .................................................. 1J-8
Generator Dismounting and Remounting............ 1J-9
Generator Components..................................... 1J-10
Generator Inspection......................................... 1J-11
Specifications ..................................................... 1J-13
Charging System Specifications ....................... 1J-13
Tightening Torque Specifications ...................... 1J-13
Exhaust System ....................................... 1K-1
General Description .............................................1K-1
Exhaust System Description ............................... 1K-1
Diagnostic Information and Procedures ............1K-1
Exhaust System Check ....................................... 1K-1
Repair Instructions ..............................................1K-2
Exhaust System Components ............................. 1K-2
Exhaust Manifold Removal and Installation ........ 1K-3
Exhaust Pipe and Muffler Removal and
Installation ......................................................... 1K-4
Specifications .......................................................1K-5
Tightening Torque Specifications ........................ 1K-5

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-13
Engine and Emission Control System Flow Diagram
Intake manifoldExhaust
manifold
Exhaust gas Air
Fuel Vapor
War m up
catalystExhaust
pipe
EVAP canister
purge valve
Fuel injector
ECT
sensor
ECM
Heater
control
Heater
control
(if equipped)
Barometric pressure sensor HO2S-1HO2S-2
(if equipped) Engine
CMP
sensorCKP
sensor
Knock
sensorIgnition
coil with
igniter
APP sensor
A/C compressor
clutch
Generator
Immobilizer
coil antenna
P/S control
module
Brake light
switch
Air cleaner
IAT
sensorMAF
sensor
A/C refrigerant
pressure sensor
TP
sensor Throttle body
assembly
Throttle
actuator
A/C condenser
fan
DLC
Radiator
fan
Combination meter
· MIL
· Coolant Temp.
· Immobilizer indicator light
· Tachometer
· Speedometer
· Fuel level
· Odometer4WD
control module
Wheel speed
sensor (VSS)
(M/T)
· Electric load
· A/C switch ON
BCM
Keyless start
control module
ABS control module
Blower speed
selector
MAP sensor
(if equipped)EGR valve
(if equipped)
Check
valve
EVAP
canister
Fuel level sensorFuel tankFuel
pump
CMP actuator
oil control valve
(VVT model)
TCM
Output shaft speed
(VSS) sensor (A/T)
Three way
catalyst (if
equipped)
I6RW0D110004-03

Downloaded from www.Manualslib.com manuals search engine 1A-14 Engine General Information and Diagnosis:
ECM Input / Output Circuit Diagram
51 50
+B
54
IG1+BB
ST64
65
67
BLK/WHTWHT/RED
BRN/WHTBLK/RED
BLK/RED
57
: 71
: 72 : 5V : 12V68 IG1
BLK
WHT
GRY
YEL/GRNWHT
66
58
61
62
63 55
70
60 59
53
WHT
4+B
5
PNK
RED/YEL
BLK/ORN
C01-20
C01-21
8RED62C01-56
13WHT/BLKE01-57
ORNE01-54
21
23WHTRED
WHTRED
22
E01-3E01-18
C01-13C01-12
YEL/RED 24E01-24
YEL/BLK
YEL/RED 25E01-28E01-13
E01-30
E01-16
E01-60E01-1
E01-29
GRN/WHTE01-20
C01-48
E01-2
GRN/YEL47
48
GRN/WHTC01-5
C01-6
44
45RED/BLKE01-58
42
43GRY46E01-47
40LT GRN41BLU/REDE01-46
38
39
PNKBLKGRN/WHTE01-15
GRN/REDGRN/WHT37YELREDC01-59C01-60
35BLU/BLKC01-29
31
32
33
34BLU/YELBLU/WHT
BLU/REDBLU/ORNC01-17C01-16
C01-1C01-2
BLK/ORNBLKC01-30
C01-58C01-15
E01-31BLKBLK
49RED/BLU
BRNE01-4
E01-26 9
GRY
BLK/YELGRY/BLU
GRN/BLKC01-26C01-27
C01-25 +B
IG16
7WHT
BRNRED/BLU
BLK/WHT
3 3
ORN
BLK/RED
C01-57
C01-10
C01-11
C01-46
C01-47
GRY/REDC01-14
11LT GRNGRY/BLUGRY/BLU12RED/BLU
C01-55
E01-55
C01-24
10
RED/BLKGRY/BLUC01-53
IG2
IG2
69RED/WHTC01-52
26
RED
BRNGRN
BLU
GRN
WHTBLK
28
30 2927
3YEL
GRYC01-41C01-42C01-40
C01-43C01-44
C01-45
E01-45E01-32
C01-54
BRN/YELWHT/RED
GRN/REDGRN/ORN
C01-18C01-1936C01-3C01-4
56
1
52
IG2+BB
BLU/WHT
BLU/WHT
14
15
17
16
E01-19
E01-19
18
19
BRNGRNBLU
REDYELWHT
E01-353
BLK
E01-37E01-52
E01-34E01-36E01-51
E01-50
2
20BLU/YELC01-28
I6RW0D110005-03
1. ECM 25. Immobilizer coil antenna 49. P/S control module
2. APP sensor assembly 26. Throttle actuator control relay 50. Brake light
3. Shield wire 27. “THR MOT” fuse 51. Brake light switch
4. CMP sensor 28. Electric throttle body assembly 52. To ABS control module
5. CKP sensor 29. Throttle actuator 53. “STOP” fuse
6. HO2S-1 30. TP sensor 54. Main relay

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-15
Terminal Arrangement of ECM Coupler (Viewed from Harness Side)
7. HO2S-2 (if equipped) 31. Fuel injector No.1 55. Starting motor control relay
8. Knock sensor 32. Fuel injector No.2 56. Transmission range switch (A/T
model)
9. MAF and IAT sensor 33. Fuel injector No.3 57. Starting motor
10. MAP sensor (if equipped) 34. Fuel injector No.4 58. “DOME” fuse
11. ECT sensor 35. EVAP canister purge valve 59. “IG COIL” fuse
12. A/C refrigerant pressure sensor 36. EGR valve (if equipped) 60. “IG2 SIG” fuse
13. A/C evaporator outlet air temp. sensor (Manual A/C
model)37. Oil control valve (Camshaft position control) (VVT
model)61. “FI” fuse
14. Blower motor relay 38. Fuel pump relay 62. “ST SIG” fuse
15. Blower motor 39. Fuel pump 63. “ST” fuse
16. Blower speed selector (Auto A/C model) 40. Radiator cooling fan motor relay 64. Ignition switch
17. Blower speed selector (Manual A/C model) 41. Radiator cooling fan motor 65. “IGN” fuse
18. A/C switch 42. A/C compressor relay 66. “RDTR” fuse
19. To BCM 43. A/C compressor 67. Main fuse box
20. Generator 44. A/C condenser cooling fan motor relay 68. Battery
21. ABS control module 45. A/C condenser cooling fan motor 69. Shield ground
22. TCM 46. A/C fuse 70. Barometric pressure sensor
23. To other control module and DLC connected CAN 47. Ignition coil assembly (for No.1 and No.4 spark plugs) 71. Engine ground
24. Fuel level sensor 48. Ignition coil assembly (for No.2 and No.3 spark plugs) 72. Body ground
E01C01
3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238 3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238
I6RW0D110014-01

Downloaded from www.Manualslib.com manuals search engine 1A-16 Engine General Information and Diagnosis:
Connector: C01
Terminal Wire color Circuit Terminal Wire color Circuit
1 BLU/YEL Fuel injector No.1 output 31 — —
2 BLU/WHT Fuel injector No.2 output 32 — —
3 GRN/ORNEGR valve (stepper motor coil 2)
output33 — —
4 GRN/REDEGR valve (stepper motor coil 1)
output34 — —
5 GRN/WHTIgnition coil No.2 and No.3
output35 — —
6 GRN/YELIgnition coil No.1 and No.4
output36 — —
7— — 37— —
8— — 38— —
9— — 39— —
10 WHTOxygen signal of heated oxygen
sensor-140 WHTThrottle position sensor (sub)
signal
11 B R NOxygen signal of heated oxygen
sensor-2 (if equipped)41 GRYGround for shield wire of TP
sensor circuit
12 WHTCAN communication line (active
low signal) to TCM (for A/T
model)42 BLKGround for throttle position
sensor
13 REDCAN communication line (active
high signal) to TCM (for A/T
model) 43 REDOutput for 5 V power source of
throttle position sensor
14 GRY/REDOutput of 5 V power source for
MAP sensor (if equipped) and A/
C refrigerant pressure sensor
(A/C model)44 YEL Output of throttle actuator
15 BLK Ground for ECM 45 BLU Output of throttle actuator
16 BLU/RED Fuel injector No.3 output 46 BLK/REDHeater output of heated
oxygen sensor-1
17 BLU/ORN Fuel injector No.4 output 47 RED/BLUHeater output of heated
oxygen sensor-2 (if equipped)
18 BRN/YELEGR valve (stepper motor coil 4)
output (if equipped)48 YEL/GRN Starting motor signal
19 WHT/REDEGR valve (stepper motor coil 3)
output (if quipped)49 — —
20 RED/YEL CMP sensor signal 50 WHT/BLU Ground of ECM for shield wire
21 PNK CKP sensor signal 51 — —
22 — — 52 — —
23 — — 53 RED/BLKManifold absolute pressure
(MAP) sensor signal (if
equipped)
24 LT GRNEngine coolant temp. (ECT)
sensor signal54 GRNThrottle position sensor (main)
signal
25 BLK/YELIntake air temp. (IAT) sensor
signal55 GRY/BLU Ground for sensors
26 GRN/BLKMass air flow (MAF) sensor
signal56 RED Knock sensor signal
27 GRY Ground for MAF sensor 57 ORN Ground for sensors
28 BLU/YEL Generator control output 58 BLK/ORN Ground for ECM
29 BLU/BLKEVAP canister purge valve
output59 GRN/WHTOil control valve ground
(for engine with VVT system)
30 BLK Ground for ECM 60 GRN/REDOil control valve output
(for engine with VVT system)

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-17
Connector: E01
Terminal Wire color Circuit Terminal Wire color Circuit
1 BLK/RED Main power supply 31 BLK Ground for ECM
2WHT/REDPower source for ECM internal
memory32 GRNPower supply of throttle
actuator drive circuit.
3REDCAN communication line (active
high signal) to ABS control
module assembly33 — —
4BRNEngine revolution signal output
for EPS control module34 REDOutput for 5 V power source of
APP sensor (sub)
5— — 35BRNOutput for 5 V power source of
APP sensor (main)
6 — — 36 YEL APP sensor (sub) signal
7 — — 37 GRN APP sensor (main) signal
8— — 38— —
9— — 39— —
10 — — 40 — —
11 — — 4 1 — —
12 — — 42 — —
13 YEL/REDClock signal for immobilizer coil
antenna43 — —
14 — — 44 — —
15 GRN/WHT Fuel pump relay output 45 BRNThrottle actuator control relay
output
16 BLK/RED Main power supply 46 LT GRNRadiator cooling fan relay
output
17 — — 47 GRYA/C compressor relay output
(if equipped with A/C)
18 WHTCAN communication line (active
low signal) to ABS control
module assembly48 — —
19 BLU/WHTElectric load signal for heater
blower motor49 — —
20 GRN/WHT Brake light switch signal 50 BLKGround for shield wire of APP
sensor
21 — — 51 WHTGround for APP sensor (sub)
signal
22 — — 52 BLUGround for APP sensor (main)
signal
23 — — 53 — —
24 YEL/RED Fuel level sensor signal 54 ORN Ground for sensors
25 — — 55 RED/BLUA/C refrigerant pressure
sensor signal
(if equipped with A/C)
26 RED/BLU EPS signal 56 WHT/GRN —
27 — — 57 WHT/BLKA/C evaporator outlet air temp.
sensor signal
(if equipped with A/C)
28 YEL/BLKSerial communication line for
immobilizer coil antenna58 RED/BLK —
29 BLK/WHT Ignition switch signal 59 — —
30 WHTStarting motor control relay
output60 BRN/WHT Main power supply relay output