Suzuki SX4 & SX4 Crossover RW415 RW416 RW420 2006-2016 Workshop Service Repair Manual PDF - MSZKSX40616OPMK.zip
A full factory-style service and repair guide, complete with Electrical Wiring Diagrams, covering the 2006-2016 Suzuki SX4 and SX4 Crossover. It contains every technical detail needed to service, troubleshoot, fix, and rebuild your vehicle the way professional technicians do.
Inside the Suzuki SX4 and SX4 Crossover workshop service repair manual, you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
MAKE: Suzuki
YEAR: 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
MODEL: SX4/SX4 Crossover (RW415, RW416, RW420 Series)
FORMAT: PDF
LANGUAGE: EN/DE/FR/ES/HU/IT/NL/SK
PRODUCT DETAILS:
Total Pages: 3,442 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: EN/DE/FR/ES/HU/IT/NL/SK
TABLE OF CONTENTS
IMPORTANT...1
FOREWORD...3
TABLE OF CONTENTS...5
Precautions...7
Precautions...8
Precautions...8
Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System...8
General Precautions...11
Warning for Wheel (with tire) Removal...13
Precautions in Servicing 4WD Model...14
Precautions for Catalytic Converter...14
Precautions for Installing Mobile Communication Equipment...15
Precaution for CAN Communication System...15
Precautions for Electrical Circuit Service...15
Air Bag Warning...17
Air Bag System Service Warning...17
Fastener Caution...18
Suspension Caution...18
Wheels and Tires Caution...18
ABS Caution...18
Precaution for Vehicle Equipped with ESP‚ System...18
Brake Caution...18
Repair Instructions...19
Electrical Circuit Inspection Procedure...19
Intermittent and Poor Connection Inspection...21
General Information...23
General Information...24
General Description...24
Abbreviations...24
Symbols...25
Wire Color Symbols...25
Fasteners Information...26
Vehicle Lifting Points...28
Vehicle Identification Number...29
Engine Identification Number...29
Transmission Identification Number...29
Component Location...30
Warning, Caution and Information Labels Location...30
Maintenance and Lubrication...32
Precautions...32
Precautions for Maintenance and Lubrication...32
Scheduled Maintenance...32
Maintenance Schedule under Normal Driving Conditions...32
Maintenance Recommended under Severe Driving Conditions...33
Repair Instructions...34
Accessory Drive Belt Inspection...34
Accessory Drive Belt Replacement...35
Valve Lash (Clearance) Inspection...35
Engine Oil and Filter Change...35
Engine Coolant Change...36
Exhaust System Inspection...37
Spark Plug Replacement...37
Air Cleaner Filter Inspection...37
Air Cleaner Filter Replacement...37
Fuel Lines and Connections Inspection...37
Fuel Filter Replacement...37
Fuel Tank Inspection...38
PCV Valve Inspection...38
Fuel Evaporative Emission Control System Inspection...38
Brake Discs and Pads (Front) Inspection...38
Brake Drums and Shoes (Rear) Inspection...38
Brake Hoses and Pipes Inspection...39
Brake Fluid Replacement...39
Brake Lever and Cable Inspection...39
Clutch Pedal Inspection...39
Clutch Fluid Inspection...39
Tires Inspection...40
Wheel Discs Inspection...40
Wheel Bearing Inspection...40
Suspension System Inspection...40
Steering System Inspection...40
Drive Shaft (Axle) Boots Inspection...41
Propeller Shaft (4WD) Inspection...41
Manual Transaxle Oil Inspection...41
Manual Transaxle Oil Replacement...41
Automatic Transaxle Fluid Level Inspection...41
Automatic Transaxle Fluid Replacement...41
Automatic Transaxle Fluid Cooler Hose Inspection...41
Transfer Oil Inspection (4WD)...42
Transfer Oil Replacement (4WD)...42
Rear Deferential Oil Inspection (4WD)...42
Rear Deferential Oil Replacement (4WD)...42
All Latches, Hinges and Locks Inspection...42
HVAC Air Filter (If Equipped) Inspection...42
HVAC Air Filter (If Equipped) Replacement...42
Final Inspection for Maintenance Service...42
Specifications...43
Tightening Torque Specifications...43
Special Tools and Equipment...44
Recommended Fluids and Lubricants...44
Special Tool...44
Engine...45
Precautions...50
Precautions...50
Precautions for Engine...50
Engine General Information and Diagnosis...51
Precautions...51
Precautions on Engine Service...51
Precaution on On-Board Diagnostic (OBD) System...51
Precautions in Diagnosing Trouble...51
Precautions for DTC Troubleshooting...52
Precautions of ECM Circuit Inspection...52
Precautions of Electric Throttle Body System Calibration...52
Precaution on CAN Troubleshooting...53
General Description...55
Statement on Cleanliness and Care...55
Engine Diagnosis General Description...55
On-Board Diagnostic System Description...55
Data Link Connector (DLC) Description...58
Engine and Emission Control System Description...58
CAN Communication System Description...59
Air Intake System Description...61
Description of Electric Throttle Body System Calibration...61
Electric Throttle Body System Description...61
Electronic Control System Description...62
Engine and Emission Control Input / Output Table...63
Schematic and Routing Diagram...64
ECM Input / Output Circuit Diagram...64
Engine and Emission Control System Flow Diagram...68
Engine and Emission Control System Diagram...69
Component Location...71
Electronic Control System Components Location...71
Diagnostic Information and Procedures...72
Engine and Emission Control System Check...72
Malfunction Indicator Lamp (MIL) Check...75
DTC Check...75
DTC Clearance...76
Troubleshooting for Communication Error with Scan Tool Using CAN...76
DTC Table...82
Fail-Safe Table...86
Scan Tool Data...88
Visual Inspection...93
Engine Basic Inspection...93
Engine Symptom Diagnosis...95
Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)...102
Malfunction Indicator Lamp Remains ON after Engine Starts...104
DTC P0010: Camshaft Position Actuator Circuit (for engine with VVT system)...105
DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / Retarded (for engine with VVT system)...107
DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)...109
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)...111
DTC P0101: Mass Air Flow Circuit Range / Performance...113
DTC P0102: Mass Air Flow Circuit Low Input...116
DTC P0103: Mass Air Flow Circuit High Input...117
DTC P0106: Manifold Absolute Pressure Range / Performance...119
DTC P0107: Manifold Absolute Pressure Circuit Low Input...120
DTC P0108: Manifold Absolute Pressure Circuit High Input...122
DTC P0111: Intake Air Temperature Circuit Range / Performance...124
DTC P0112: Intake Air Temperature Sensor Circuit Low...126
DTC P0113: Intake Air Temperature Sensor Circuit High...128
DTC P0116: Engine Coolant Temperature Circuit Range / Performance...130
DTC P0117: Engine Coolant Temperature Circuit Low...133
DTC P0118: Engine Coolant Temperature Circuit High...134
DTC P0122: Throttle Position Sensor (Main) Circuit Low...137
DTC P0123: Throttle Position Sensor (Main) Circuit High...139
DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)...142
DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)...145
DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1)...146
DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)...148
DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2)...151
DTC P0171 / P0172: Fuel System Too Lean / Rich...153
DTC P0222: Throttle Position Sensor (Sub) Circuit Low...155
DTC P0223: Throttle Position Sensor (Sub) Circuit High...157
DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected...160
DTC P0327 / P0328: Knock Sensor Circuit Low / High...162
DTC P0335: Crankshaft Position (CKP) Sensor Circuit...164
DTC P0340: Camshaft Position (CMP) Sensor Circuit...166
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected...169
DTC P0403: Exhaust Gas Recirculation Control Circuit...172
DTC P0420: Catalyst System Efficiency below Threshold...174
DTC P0443: Evaporative Emission System Purge Control Valve Circuit...176
DTC P0462 / P0463: Fuel Level Sensor Circuit Low / High...178
DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit...179
DTC P0481: Cooling Fan 2 (A/C Condenser Fan) Control Circuit...181
DTC P0500: Vehicle Speed Sensor (VSS) Malfunction...184
DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low...186
DTC P0533: A/C Refrigerant Pressure Sensor Circuit High...188
DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance...189
DTC P0616: Starter Relay Circuit Low...190
DTC P0617: Starter Relay Circuit High...191
DTC P1510: ECM Back-Up Power Supply Malfunction...193
DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance...194
DTC P2102: Throttle Actuator Control Motor Circuit Low...196
DTC P2103: Throttle Actuator Control Motor Circuit High...197
DTC P2111: Throttle Actuator Control System - Stuck Open...198
DTC P2119: Throttle Actuator Control Throttle Body Range / Performance...199
DTC P2122: Pedal Position Sensor (Main) Circuit Low Input...201
DTC P2123: Pedal Position Sensor (Main) Circuit High Input...203
DTC P2127: Pedal Position Sensor (Sub) Circuit Low Input...205
DTC P2128: Pedal Position Sensor (Sub) Circuit High Input...208
DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation...210
DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation...213
DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction...215
DTC U0073: Control Module Communication Bus Off...216
DTC U0101: Lost Communication with TCM...216
DTC U0121: Lost Communication with ABS Control Module...216
DTC U0140: Lost Communication with Body Control Module...216
Troubleshooting for CAN-DTC...217
Inspection of ECM and Its Circuits...222
ECM Power and Ground Circuit Check...244
Fuel Injector Circuit Check...247
Fuel Pump and Its Circuit Check...249
Fuel Pressure Check...252
A/C Condenser Cooling Fan Control System Inspection...253
A/C System Circuits Check...256
Electric Load Signal Circuit Check...260
Radiator Cooling Fan Control System Check...262
Repair Instructions...263
Idle Speed and IAC Throttle Valve Opening Inspection...263
Special Tools and Equipment...264
Special Tool...264
Aux. Emission Control Devices...265
Diagnostic Information and Procedures...265
EGR System Inspection (If Equipped)...265
Repair Instructions...265
EVAP Canister Purge Inspection...265
EVAP Canister Purge Valve and Its Circuit Inspection...265
Vacuum Passage Inspection...266
Vacuum Hose Inspection...267
EVAP Canister Purge Valve Inspection...267
EVAP Canister Inspection...268
EGR Valve Removal and Installation (If Equipped)...268
EGR Valve Inspection (If Equipped)...268
PCV Hose Inspection...269
PCV Valve Inspection...269
Special Tools and Equipment...269
Special Tool...269
Engine Electrical Devices...270
Repair Instructions...270
Engine Control Module (ECM) Removal and Installation...270
Manifold Absolute Pressure (MAP) Sensor Inspection (If Equipped)...271
Electric Throttle Body Assembly On-Vehicle Inspection...271
Electric Throttle Body System Calibration...273
Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection...274
Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation...274
Accelerator Pedal Position (APP) Sensor Assembly Inspection...274
Engine Coolant Temperature (ECT) Sensor Removal and Installation...275
Engine Coolant Temperature (ECT) Sensor Inspection...276
Heated Oxygen Sensor (HO2S-1 and HO2S-2) Heater On-Vehicle Inspection (If Equipped)...276
Heated Oxygen Sensor (HO2S-1 and HO2S-2) Removal and Installation (If Equipped)...276
Camshaft Position (CMP) Sensor Removal and Installation...277
Camshaft Position (CMP) Sensor Inspection...278
Crankshaft Position (CKP) Sensor Removal and Installation...278
Crankshaft Position (CKP) Sensor Inspection...279
Knock Sensor Removal and Installation...279
Main Relay, Fuel Pump Relay, Starting Motor Control Relay, Throttle Actuator Control Relay and Radiator Cooling Fan Relay Inspection...280
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection...280
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation...281
Intake Air Temperature (IAT) Sensor Inspection...281
Specifications...282
Tightening Torque Specifications...282
Engine Mechanical...283
General Description...283
Engine Construction Description...283
Camshaft Position Control (VVT Variable Valve Timing) System Description...285
Diagnostic Information and Procedures...287
Compression Check...287
Engine Vacuum Check...288
Valve Lash (Clearance) Inspection...289
Repair Instructions...292
Air Intake System Components...292
Air Cleaner Filter Removal and Installation...292
Air Cleaner Filter Inspection and Cleaning...292
Air Cleaner Assembly Removal and Installation...293
Cylinder Head Cover Removal and Installation...293
Throttle Body and Intake Manifold Components...295
Throttle Body On-Vehicle Inspection...296
Electric Throttle Body Assembly Removal and Installation...296
Throttle Body Cleaning...296
Intake Manifold Removal and Installation...297
Engine Mountings Components...298
Engine Assembly Removal and Installation...299
Timing Chain Cover Components...304
Timing Chain Cover Removal and Installation...305
Timing Chain Cover Inspection...307
Oil Control Valve Removal and Installation (For Engine with VVT)...308
Oil Control Valve Inspection (For Engine with VVT)...308
Timing Chain and Chain Tensioner Components...309
Timing Chain and Chain Tensioner Removal and Installation...309
Timing Chain and Chain Tensioner Inspection...313
Camshaft, Tappet and Shim Components...314