PDF Service Manual Suzuki SX4 RW420 - 3 MB
This two-volume service manual provides complete repair and maintenance information for the Suzuki SX4 (RW420).
It is the same comprehensive guide used by Suzuki dealership technicians.
The manual covers every system in detail, including the engine, transmission, suspension, brakes, and electrical systems.
It's the ultimate resource for anyone performing in-depth service or repairs on their SX4.
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--- Page 1 ---
IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
! WARNING , ! CAUTION and NOTE have special meanings. Pay special attention to the messages high-
lighted by these signal words.
! WARNING
Indicates a potential hazard that could result in death or injury.
! CAUTION
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
! WARNING
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 ser-
vice 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.
The circle with a slash in this manual means “Don’t do this” or “Don’t let this happen”.
--- Page 3 ---
00-9 Precautions:
• When disconnecting connectors, never pull the wiring • To avoid damage to the harness, protect its part which
harness. Unlock the connector lock first and then pull may contact against a part forming a sharp angle by
them apart by holding connectors themselves. winding tape or the like around it.
I2RH01010044-01
• Be careful not to touch the electrical terminals of parts
which use microcomputers (e.g. electronic control unit
I2RH01010040-01
like as ECM, PCM, P/S controller, etc.). The static
• When connecting connectors, also hold connectors electricity from your body can damage these parts.
and put them together until they lock securely (a click
is heard).
I2RH01010041-01 I3RM0A000004-01
• When installing the wiring harness, fix it with clamps • Never connect any tester (voltmeter, ohmmeter, or
so that no slack is left. whatever) to electronic control unit when its coupler is
disconnected. Attempt to do it may cause damage to
it.
• Never connect an ohmmeter to electronic control unit
with its coupler connected to it. Attempt to do it may
cause damage to electronic control unit and sensors.
• Be sure to use a specified voltmeter / ohmmeter.
Otherwise, accurate measurements may not be
obtained or personal injury may result. If not specified,
use a voltmeter with high impedance (M Ω/V
I2RH01010042-01 minimum) or a digital type voltmeter.
• When installing vehicle parts, be careful so that the • When taking measurements at electrical connectors
wiring harness is not interfered with or caught by any using a tester probe, be sure to insert the probe (2)
other part. from the wire harness side (backside) of the
connector (1).
I2RH01010043-01
I2RH01010046-01
--- Page 4 ---
General Information: 0A-8
[A] [B] 5
3
5
[C]
1
2
8
4 7
8 6
I7RW0A010001-01
1. Air bag label on driver air bag (inflator) module 7. Pretensioner label on seat belt retractor
2. Air bag label on contact coil assembly 8. Side/Curtain air bag label on pillar (both right and left sides) (if equipped)
3. Air bag label on passenger air bag (inflator) module [A]: These labels are attached on vehicle equipped with air bag system only.
4. Air bag label on side air bag (inflator) module (if equipped) [B]: Sedan model
5. Air bag label on curtain air bag (inflator) module [C]: Hatchback model
6. Air bag label on SDM
--- Page 5 ---
1A-2 Engine General Information and Diagnosis:
• Therefore, check both ECM and TCM for DTC when Precautions for DTC Troubleshooting
MIL lights on. S7RW0C1100004
• When checking ECM for DTC, keep in mind that DTC • Before performed trouble shooting, be sure to read
is displayed on the scan tool as follows depending on the “Precautions of ECM Circuit Inspection”.
the scan tool used. • When measuring circuit voltage, resistance and/or
– SUZUKI scan tool displays DTC detected by ECM. pulse signal at ECM connector, connect the special
tool to ECM and/or the ECM connectors referring to
– CAN communication OBD generic scan tool “Inspection of ECM and Its Circuits”.
displays DTC detected by each of ECM and TCM
simultaneously. • Upon completion of inspection and repair work,
perform “DTC Confirmation Procedure” and confirm
• Priorities for diagnosing troubles that the trouble has been corrected.
If two or more diagnostic trouble codes (DTCs) are
stored, proceed to the flow of the DTC which has
detected earliest in the order and follow the instruction
Precautions of ECM Circuit Inspection
S7RW0C1100005
in that table. • ECM connectors are waterproofed. Each terminal of
If no instructions are given, DTCs according to the the ECM connectors is sealed up with the grommet.
following priorities. Therefore, when measuring circuit voltage, resistance
a. Diagnostic trouble codes (DTCs) other than DTC and/or pulse signal at ECM connector, do not insert
P0171 / P0172 (Fuel system too lean/too rich) and the tester’s probe into the sealed terminal at the
DTC P0300 / P0301 / P0302 / P0303 / P0304 harness side. When measuring circuit voltage,
(Misfire detected) resistance and/or pulse signal at ECM connector,
b. DTC P0171 / P0172 (Fuel system too lean/too connect the special tool to the ECM connectors. And,
rich) insert the tester’s probe into the special tool’s
c. DTC P0300 / P0301 / P0302 / P0303 / P0304 connectors at the harness side, and then measure
(Misfire detected) voltage, resistance and/or pulse signal. Or, ECM and
its circuits may be damaged by water.
• Be sure to read “Precaution for CAN Communication
System in Section 00” before inspection and observe • Wire colors of the special tool’s connectors are
what is written there. different from the ones of the ECM connectors.
However, the circuit arrangement of the special tool’s
• ECM Replacement connectors is same as the one of the ECM
When substituting a known-good ECM, check for the connectors. Therefore, measure circuit voltage and
following conditions. Neglecting this check may cause resistance by identifying the terminal location subject
damage to known good ECM. to the measurement.
– Resistance value of all relays, actuators is as
specified respectively. Precautions of Electric Throttle Body System
– APP sensor, TP sensor and A/C refrigerant Calibration
pressure sensor are in good condition and none of S7RW0C1100006
power circuits of these sensors is shorted to After performing one of works described below, it is
ground. necessary to re-register the completely closed throttle
valve reference position stored in memory of ECM. (For
• Communication of ECM, BCM, combination meter,
detailed information, refer to “Description of Electric
keyless start control module, ABS / control module,
Throttle Body System Calibration”.) For the procedure to
4WD control module and TCM, is established by CAN
register such data in ECM, refer to “Electric Throttle
(Controller Area Network). (For more detail of CAN
Body System Calibration in Section 1C”.
communication for ECM, refer to “CAN
Communication System Description”). Therefore, • To shut off backup power of ECM for such purposes of
handle CAN communication line with care referring to battery replacement or “DOME” fuse removal.
“Precaution for CAN Communication System in • To erase DTCs P0607, P0122, P0123, P0222, P0223,
Section 00”. P2101, P2102, P2103, P2111, P2119, P2122, P2123,
• Immobilizer transponder code registration after P2127, P2128, P2135 and/or P2138.
replacing ECM (Immobilizer model) • To replace ECM.
When ECM is replaced with new one or with another • To replace throttle body and/or APP sensor assembly.
one, make sure to register immobilizer transponder
code to ECM correctly according to “Procedure after
ECM Replacement in Section 10C”.
--- Page 6 ---
Engine General Information and Diagnosis: 1A-17
Schematic and Routing Diagram
Engine and Emission Control System Diagram
S7RW0C1102001
36
25
26
27
28
29
30
31
32
37
41
42
24
38
40
23
39
35
34
22
33
18
19
21
17
20
15
2
12
16
14
13
1
3
11
10
4
5
9
6
7
8
I6RW0C110008-01
--- Page 7 ---
1A-32 Engine General Information and Diagnosis:
Step Action Yes No
4 DTC Check Go to applicable Go to Step 5.
1) Turn ignition switch to OFF position. troubleshooting of DTC
other than CAN-DTC.
2) Connect scan tool to DLC.
3) Check DTC in the following control modules that
communicate with scan tool by K-line.
• BCM
• Keyless start control module
• 4WD control module
Is there any DTC other than CAN-DTC?
5 CAN line check between DLC and BCM Go to Step 6. Repair CAN line.
1) Turn ignition switch to OFF position.
2) Disconnect BCM connector from BCM.
3) Check for proper connection to all terminals of BCM
connector.
4) If OK, check CAN lines between DLC and BCM
connector for open, short to power circuit, short to
ground circuit, short to other CAN line and high
resistance.
Are CAN lines between DLC and BCM connector in good
condition?
6 Control module connector check Intermittent trouble. Go to Step 7.
1) Turn ignition switch to OFF position. Check for intermittent
referring to “Intermittent
2) Disconnect all the following control module connectors.
and Poor Connection
• Control modules communicated by CAN Inspection in Section
– ECM 00”.
– TCM
– ABS control module
– BCM
– Combination meter
– Keyless start control module
– 4WD control module
3) Check for proper connection to each CAN line terminal
of all control module (communicated by CAN)
connectors.
4) If OK, connect connectors of all control module/sensor
communicated by CAN securely.
5) Check communication between scan tool and ECM/TCM
by DTC check in ECM/TCM.
Is it possible to check DTC in ECM and TCM?
--- Page 8 ---
Engine General Information and Diagnosis: 1A-47
Visual Inspection
S7RW0C1104009
Visually check the following parts and systems.
Inspection Item Referring section
Engine oil Level, leakage “Engine Oil and Filter Change in Section 0B”
Engine coolant Level, leakage “Coolant Level Check in Section 1F”
“Fuel Leakage Check Procedure in Section
Fuel Level, leakage
1G”
“Automatic Transaxle Fluid Level Inspection
A/T fluid Level, leakage
in Section 0B”
“Accessory Drive Belt Inspection in Section
Air cleaner element Dirt, clogging
0B”
Fluid level, corrosion of
Battery “Battery Description in Section 1J”
terminal
“Accessory Drive Belt Inspection in Section
Water pump belt Tension, damage
0B”
“Electric Throttle Body Assembly On-Vehicle
Throttle valve Operating sound
Inspection in Section 1C”
Disconnection, looseness, “Vacuum Hose and Purge Valve Chamber
Vacuum hoses of air intake system
deterioration, bend Inspection in Section 1B”
Connectors of electric wire harness Disconnection, friction
“Intermittent and Poor Connection Inspection
Fuses Burning
in Section 00”
Parts Installation, deformation —
Bolt Looseness —
Other parts that can be checked visually —
Also add the following items at engine start, if possible
MIL Operation “Malfunction Indicator Lamp (MIL) Check”
“Generator Symptom Diagnosis in Section
Charging light Operation
1J”
“Oil Pressure Switch Inspection in Section
Engine oil pressure light Operation
9C”
“Engine Coolant Temperature (ECT) Sensor
Engine coolant temp. meter Operation
Inspection in Section 9C”
Fuel level meter Operation “Fuel Level Sensor Inspection in Section 9C”
Tachometer Operation —
Exhaust system Leakage of exhaust gas, noise —
Abnormal air being inhaled from air intake system —
Other parts that can be checked visually —
Engine Basic Inspection
S7RW0C1104010
This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found
in “Visual Inspection”.
Follow the flow carefully.
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”.
2 Check battery voltage Go to Step 3. Charge or replace
battery.
Is it 11 V or more?
3 Is vehicle equipped with keyless start control system? Go to Step 4. Go to Step 5.
4 Check keyless start control system for operation Go to Step 5. Keyless start control
1) Check keyless start control system referring to “Keyless system malfunction.
Start System Operation Inspection in Section 10E”.
Is check result satisfactory?
--- Page 9 ---
1A-62 Engine General Information and Diagnosis:
Step Action Yes No
4 HO2S heater circuit check Go to Step 5. Repair or replace
1) Disconnect connectors from ECM and check for proper defective wiring harness
terminal connection to ECM connector. / connector.
2) If connections are OK, check that HO2S heater circuit is
as follows.
• Insulation resistance of wire harness is infinity
between “Control circuit of HO2S heater” terminal and
each other terminal at HO2S connector.
• Wiring harness resistance of “Control circuit of HO2S
heater” is less than 1 Ω.
• Insulation resistance between “Control circuit of
HO2S heater” and vehicle body ground is infinity.
Is it in good condition?
5 HO2S heater check Substitute a known- Replace HO2S.
1) Check heater resistance of HO2S referring to “Heated good ECM and recheck.
Oxygen Sensor (HO2S) Heater On-Vehicle Inspection in
Section 1C”.
Is HO2S heater in good condition?
DTC P0101: Mass or Volume Air Flow Circuit Range / Performance
S7RW0C1104017
Wiring Diagram
4
6
GRN BLK/WHT E01-29
2
C01-15 BLK
C01-30 BLK
3
WHT C01-29 BLK
BLK/YEL BLK/YEL BRN/WHT E01-60 C01-48 BLK/ORN
C01-58 BLK/ORN
12V 5V
BLK/YEL BLK/RED BLK/RED E01-1
7 8 9
A1
1 BLK/RED E01-16
BLK/RED
A2
PNK/BLK C01-26
A3
GRY C01-27
B2 B1 5V
LT GRN/BLK C01-25
GRY/BLU
5 GRY/BLU C01-57
E01 C01
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
I7RW01110046-03
A1: MAF sensor power supply circuit B2: IAT sensor ground circuit 4. ECM 8. “IGN” fuse
A2: MAF sensor signal circuit 1. MAF and IAT sensor 5. To other sensors 9. “FI” fuse
A3: MAF sensor ground circuit 2. Ignition switch 6. “IG COIL” fuse
B1: IAT sensor signal circuit 3. Main relay 7. Fuse box No.2
--- Page 10 ---
Engine General Information and Diagnosis: 1A-77
DTC P0134: O2 Sensor Circuit No Activity Detected (Sensor-1, Bank-1)
S7RW0C1104026
Wiring Diagram
Refer to “DTC P0030: HO2S Heater Control Circuit (Sensor-1, Bank-1)”.
A/F Sensor Description
Refer to “A/F Sensor Description”.
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
Impedance of A/F sensor element is higher than 500 Ω for 15 sec. • A/F sensor and/or its circuit
even though A/F sensor heater is turned ON for specified time with • ECM
engine running.
(2 driving cycle detection logic)
DTC Confirmation Procedure
NOTE
Check to make sure that the following conditions are satisfied when using this “DTC Confirmation
Procedure”.
• The following DTCs are not detected: DTCs related to A/F sensor heater
1) With ignition switch OFF, connect scan tool to DLC.
2) Turn ON ignition switch and clear DTC.
3) Start engine and warm up to normal operating temperature.
4) Run engine at idle speed for 2 min. or more.
5) Check DTC and pending DTC.
DTC Troubleshooting
Step Action Yes No
1 Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and
performed? Emission Control
System Check”.
2 A/F sensor signal check Intermittent trouble. Go to Step 3.
1) Connect scan tool with ignition switch turned OFF. Check for intermittent
2) Warm up engine to normal operating temperature and referring to “Intermittent
keep it at 2000 r/min. for 60 sec. and Poor Connection
Inspection in Section
3) Repeat racing engine (Repeat depressing accelerator
00”.
pedal 5 to 6 times continuously to enrich A/F mixture and
take foot off from pedal to enlean it).
4) Check for A/F sensor output current displayed on scan
tool.
Does A/F sensor output current between –0.2 mA and 0.2
mA?
--- Page 11 ---
1A-92 Engine General Information and Diagnosis:
Step Action Yes No
6 CMP sensor check Substitute a known- Replace CMP sensor
1) Check CMP sensor and sensor rotor referring to good ECM and recheck. and/or sensor rotor.
“Camshaft Position (CMP) Sensor Inspection in Section
1C”.
Are they in good condition?
DTC P0420: Catalyst System Efficiency Below Threshold (Bank-1)
S7RW0C1104035
System and Wiring Diagram
5
5V
WHT C01-38
BLK C01-37
BLK/RED C01-39 5V
BRN C01-11
BLU WHT WHT BLU