Suzuki SX4 2006-2008 Workshop Service Repair Manual

IMPORTANT WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the words , and NOTE have special meanings. Pay special attention to the messages high- lighted by these signal words. The circle with a slash in this manual means “Don’t do this” or “Don’t let this happen”. WARNING ! CAUTION ! Indicates a potential hazard that could result in death or injury. WARNING ! Indicates a potential hazard that could result in vehicle damage. CAUTION ! NOTE: Indicates special information to make maintenance easier or instructions clearer. This service manual is intended for authorized Suzuki dealers and qualified service technicians only. Inexperienced technicians or technicians without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the technician and may render the vehicle unsafe for the driver and passengers. WARNING ! For vehicles equipped with a Supplemental Restraint (Air Bag) System: • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser- vice Precautions” under “On-Vehicle Service” in air bag system section before performing service on or around the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative. Either of these two conditions may result in severe injury. • 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, instrument panel or any other air bag system component on or around air bag system components or wiring. 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, that is air bag (inflator) modules, SDM and/or seat belt with pretensioner, beforehand to avoid component damage or unintended activation. WARNING !

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 information 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. © 2007 SUZUKI MOTOR CORPORATION All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of Suzuki Motor Corporation. RW415 (Hatchback) JSAGYA11S######## ~ JSAGYB11S######## ~ RW416 (Hatchback) JSAGYA21S######## ~ JS2YA21S######### ~ RW416 (Sedan) JSAGYC21S######## ~ JS2YC21S######### ~

RECOMMENDATI ON OF GENUINE SUZUKI PARTS AND ACCESSORIES USE SUZUKI strongly recommends the use of genuine SUZUKI parts* and accessories. Genuine SUZUKI parts and accessories are built to the highest standards of quality and performance, and are designed to fit the vehicle’s exact specifications. A wide variety of non-genuine replacement parts and accessories for SUZUKI vehicles are currently available in the market. Using these parts and accessories can affect the vehicle performance and shorten its useful life. Therefore, installation of non-genuine SUZUKI parts and accessories is not covered under warranty. Non-Genuine SUZUKI Parts and Accessories Some parts and accessories may be approved by certain authorities in your country. Some parts and accessories are sold as SUZUKI authorized replacement parts and accessories. Some genuine SUZUKI parts and accessories are sold as re-use parts and accessories. These parts and accessories are non-genuine Suzuki parts and accessories and use of these parts are not covered under warranty. Re-use of Genuine SUZUKI Parts and Accessories The resale or re-use of the following items which could give rise to safety hazards for users is expressly forbid- den: 1) Airbag components and all other pyrotechnic items, including their components (e.g. cushion, control devices and sensors) 2) Seatbelt system, including their components (e.g. webbing, buckles, and retractors) The air bag and seat belt pretensioner components contain explosive chemicals. These components should be removed and disposed of properly by SUZUKI authorized service shop or scrap yard to avoid unintended explo- sion before scrapping. *The parts remanufactured under SUZUKI's approval can be used as genuine SUZUKI parts in Europe.

00 0 1 2 3 4 5 6 7 8 9 10 11 Volume 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 Shaft ....................................................... 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 Electronic Stability Program ................................... 4F-1 Transmission / Transaxle .......................................... 5-i Precautions .............................................................. 5-1 Automatic Transmission/Transaxle ........................ 5A-1 Manual Transmission/Transaxle ............................ 5B-1 Clutch ..................................................................... 5C-1 Volume 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

Table of Contents 00- i 00 Section 00 CONTENTS Precautions Precautions ............................................... 00-1 Precautions........................................................... 00-1 Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System ........ 00-1 General Precautions ........................................... 00-4 Warning for Wheel (with tire) Removal ............... 00-6 Precautions in Servicing 4WD Model .................. 00-7 Precautions for Catalytic Converter .................... 00-7 Precautions for Installing Mobile Communication Equipment ............................... 00-8 Precaution for CAN Communication System ...... 00-8 Precautions for Electrical Circuit Service ............ 00-8 Air Bag Warning ................................................ 00-10 Air Bag System Service Warning ...................... 00-10 Fastener Caution............................................... 00-11 Suspension Caution .......................................... 00-11 Wheels and Tires Caution ................................. 00-11 ABS Caution...................................................... 00-11 Precaution for Vehicle Equipped with ESP® System ............................................................ 00-11 Brake Caution ................................................... 00-11 Repair Instructions ............................................ 00-12 Electrical Circuit Inspection Procedure ............. 00-12 Intermittent and Poor Connection Inspection .... 00-14

00-1 Precautions: Precautions Precautions Precautions Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System S7RW0A0000001 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) module 7. 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) 2 3 7 8 4 10 10 4 7 9 1 5 6 I5RW0A000001-01 I4RS0A000002-02

Precautions: 00-2 Servicing and Handling WARNING ! Many of service procedures require disconnection of “A/B” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver, Passenger, Side and Curtain Air Bag (Inflator) Modules • For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65 °C (150 °F), without high humidity and away from electric noise. • When carrying a live air bag (inflator) module, make sure the bag opening is pointed away from you. In case of an accidental deployment, the bag will then deploy with minimal chance of injury. Never carry the air bag (inflator) module by the wires or connector on the underside of the module. When placing a live air bag (inflator) module on a bench or other surface, always face the bag up, away from the surface. As the live passenger air bag (inflator) module must be placed with its bag (trim cover) facing up, place it on the workbench with a slit (1) or use the workbench vise (2) to hold it securely at its lower mounting bracket (3). It is also prohibited to place anything on top of the trim cover and stack air bag (inflator) modules. This is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental deployment. Otherwise, personal injury may result. • Never dispose of live (undeployed) air bag (inflator) modules (driver, passenger, side and curtain). If disposal is necessary, be sure to deploy them according to deployment procedures described in “Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal in Section 8B” before disposal. • The air bag (inflator) module immediately after deployment is very hot. Wait for at least half an hour to cool it off before proceeding the work. • After an air bag (inflator) module has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by- products of the chemical reaction. As with many service procedures, gloves and safety glasses should be worn. [A]: Always carry air bag (inflator) module with trim cover (air bag opening) away from body. [B]: Always place air bag (inflator) module on workbench with trim cover (air bag opening) up, away from loose objects. 1 2 3 [A] [B] I4RS0A000003-02

00-3 Precautions: WARNING ! SDM • For handling and storage of a SDM, select a place where the ambient temperature below 65 °C (150 °F), without high humidity and away from electric noise. • During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. • Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system. The SDM could be activated when powered while not rigidly attached to the vehicle which could cause deployment and result in personal injury. WARNING ! Driver and Passenger Seat Belt Pretensioners • For handling and storage of a live seat belt pretensioner, select a place where the ambient temperature below 65 °C (150 °F), without high humidity and away from electric noise. • Never carry seat belt pretensioner by wire or connector of pretensioner. When placing a live seat belt pretensioner on the workbench or some place like that, never put something on seat belt pretensioner. Otherwise, personal injury may result. • Never dispose of live (inactivated) seat belt pretensioners (drive and passenger). If disposal is necessary, be sure to activate them according to activation procedures described in “Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal in Section 8B” before disposal. • The seat belt pretensioner immediately after activation is very hot. Wait for at least half an hour to cool it off before proceeding the work. • With many service procedures, gloves and safety glasses should be worn to prevent any possible irritation of the skin or eyes. • Even when the accident was light enough not to cause air bags to activate, be sure to inspect system parts and other related parts according to instructions under “Repair and Inspection Required after Accident in Section 8B”. • When servicing parts other than air bag system, if shocks may be applied to air bag system component parts, remove those parts beforehand. • When handling the air bag (inflator) modules (driver, passenger, side and curtain), seat belt pretensioners (driver and passenger), forward sensor, side sensors or SDM, be careful not to drop it or apply an impact to it. If an excessive impact was applied, never attempt disassembly or repair but replace it with a new one. • When grease, cleaning agent, oil, water, etc. has got onto air bag (inflator) modules (driver, passenger, side and curtain) or seat belt pretensioners (drive and passenger), wipe off immediately with a dry cloth. • Air bag wire harness is included in floor and instrument panel wire harnesses. Air bag wire harness branched off from floor and instrument panel wire harnesses can be identified easily as it is covered with a yellow protection tube and it has yellow connectors. Be very careful when handling it. • When an open in air bag wire harness, damaged wire harness, connector or terminal is found, replace wire harness, connectors and terminals as an assembly. • Do not apply power to the air bag system unless all components are connected or a diagnostic flow requests it, as this will set a DTC. • Never use air bag system component parts from another vehicle. • When using electric welding, be sure to disconnect all air bag (inflator) module connectors and pretensioner connectors from air bag wire harness respectively. • Never expose air bag system component parts directly to hot air (drying or baking the vehicle after painting) or flames. • WARNING / CAUTION labels are attached on each part of air bag system components. Be sure to follow the instructions. • After vehicle is completely repaired, perform “Air Bag Diagnostic System Check in Section 8B”.

Suzuki SX4 2006-2008 Workshop Service Repair Manual

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