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SUZUKI SX4 RW420 SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
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Description
SUZUKI SX4 RW420 SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
FILE DETAILS:
SUZUKI SX4 RW420 SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Language : English
Pages : 294
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
SUZUKI SX4 RW420 SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
TOP....................................................................................................................................................... 0 MANUAL LIST............................................................................................................................................... 0 IMPORTANT................................................................................................................................................. 1 FOREWORD.................................................................................................................................................. 3 TABLE OF CONTENTS......................................................................................................................................... 5 Precautions............................................................................................................................................... 7 Precautions........................................................................................................................................... 8 Precautions....................................................................................................................................... 8 Precaution for Vehicle Equipped with ESP‚ System.............................................................................................. 8 General Information....................................................................................................................................... 9 General Information................................................................................................................................... 10 General Description............................................................................................................................... 10 Abbreviations................................................................................................................................. 10 Engine.................................................................................................................................................... 13 Engine General Information and Diagnosis.............................................................................................................. 15 Precautions....................................................................................................................................... 15 Precautions on Engine Service................................................................................................................. 15 Precautions in Diagnosing Trouble............................................................................................................. 15 Precautions for DTC Troubleshooting........................................................................................................... 16 Precautions of ECM Circuit Inspection......................................................................................................... 16 Precautions of Electric Throttle Body System Calibration...................................................................................... 16 Precaution on CAN Troubleshooting............................................................................................................. 17 General Description............................................................................................................................... 19 Statement on Cleanliness and Care............................................................................................................. 19 Engine Diagnosis General Description.......................................................................................................... 19 On-Board Diagnostic System Description........................................................................................................ 19 DLC (Data Link Connector)..................................................................................................................... 21 Engine and Emission Control System Description................................................................................................ 21 CAN Communication System Description.......................................................................................................... 22 Air Intake System Description................................................................................................................. 24 Description of Electric Throttle Body System.................................................................................................. 25 Description of Electric Throttle Body System Calibration...................................................................................... 26 Generator Control System Description.......................................................................................................... 26 A/F Sensor Description........................................................................................................................ 27 Electronic Control System Description......................................................................................................... 28 Engine and Emission Control Input / Output Table.............................................................................................. 33 Schematic and Routing Diagram..................................................................................................................... 37 Engine and Emission Control System Diagram.................................................................................................... 37 Component Location................................................................................................................................ 39 Electronic Control System Components Location................................................................................................. 39 Diagnostic Information and Procedures............................................................................................................. 40 Engine and Emission Control System Check...................................................................................................... 40 Malfunction Indicator Lamp (MIL) Check........................................................................................................ 43 DTC Check..................................................................................................................................... 44 DTC Clearance................................................................................................................................. 45 Troubleshooting for Communication Error with Scan Tool Using CAN.............................................................................. 45 DTC Table..................................................................................................................................... 50 Fail-Safe Table............................................................................................................................... 54 Scan Tool Data................................................................................................................................ 56 Visual Inspection............................................................................................................................. 61 Engine Basic Inspection....................................................................................................................... 62 Engine Symptom Diagnosis...................................................................................................................... 63 MIL Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)...................................................... 70 MIL Remains ON after Engine Starts............................................................................................................ 72 DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1, Bank-1).................................................................. 73 DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2, Bank-1).................................................................. 76 DTC P0102 / P0103: Mass or Volume Air Flow Circuit Low / High Input........................................................................... 78 DTC P0112 / P0113: Intake Air Temperature Sensor Circuit Low / High Input..................................................................... 80 DTC P0117 / P0118: Engine Coolant Temperature Circuit Low / High.............................................................................. 81 DTC P0122 / P0123: Throttle / Pedal Position Sensor / Switch “A” Circuit Low / High........................................................... 83 DTC P0131 / P0132: O2 Sensor Circuit Low Voltage / High Voltage (Sensor-1, Bank-1)............................................................ 85 DTC P0134: O2 Sensor Circuit No Activity Detected (Sensor-1, Bank-1).......................................................................... 86 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2, Bank-1)................................................................... 88 DTC P0171 / P0172: System Too Lean / Too Rich (Sensor-1, Bank-1).............................................................................. 89 DTC P0222 / P0223: Throttle Position Sensor (Sub) Circuit Low / High.......................................................................... 91 DTC P0327 / P0328: Knock Sensor Circuit Low / High............................................................................................ 93 DTC P0335: Crankshaft Position Sensor “A” Circuit............................................................................................. 94 DTC P0340: Camshaft Position Sensor “A” Circuit............................................................................................... 96 DTC P0350: Ignition Coil Primary / Secondary Circuit.......................................................................................... 98 DTC P0443: EVAP Emission System Purge Control Valve Circuit...................................................................................100 DTC P0462 / P0463: Fuel Level Sensor Circuit Low / High.......................................................................................102 DTC P0480: Fan 1 Control Circuit..............................................................................................................104 DTC P0481: Fan 2 Control Circuit..............................................................................................................107 DTC P0500: Vehicle Speed Sensor “A”...........................................................................................................109 DTC P0532 / P0533: A/C Refrigerant Pressure Sensor Circuit Low / High.........................................................................110 DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance.....112 DTC P0620: Generator Control Circuit..........................................................................................................113 DTC P0625 / P0626: Generator Field Terminal Circuit Low / High................................................................................115 DTC P0660 / P0662: Intake Manifold Tuning Valve Control Circuit Open / High...................................................................117 DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High............................................................................119 DTC P1510: ECM Back-Up Power Supply Malfunction...............................................................................................121 DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance........................................................................122 DTC P2102: Throttle Actuator Control Motor Circuit Low........................................................................................123 DTC P2103: Throttle Actuator Control Motor Circuit High.......................................................................................124 DTC P2111: Throttle Actuator Control System - Stuck Open......................................................................................125 DTC P2119: Throttle Actuator Control Throttle Body Range / Performance........................................................................125 DTC P2122 / P2123: Throttle / Pedal Position Sensor / Switch “D” Circuit Low / High...........................................................127 DTC P2127 / P2128: Throttle / Pedal Position Sensor / Switch “E” Circuit Low / High Input.....................................................129 DTC P2135: Throttle / Pedal Position Sensor / Switch “A” / “B” Voltage Correction.............................................................131 DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correction..............................................................................132 DTC P2228 / P2229: Barometric Pressure Circuit Low / High.....................................................................................133 DTC U0073: Control Module Communication Bus Off...............................................................................................133 DTC U0101: Lost Communication with TCM........................................................................................................133 DTC U0121: Lost Communication with ABS / ESP‚ Control Module..................................................................................133 DTC U0140: Lost Communication with Body Control Module........................................................................................133 Troubleshooting for CAN-DTC...................................................................................................................134 Inspection of ECM and Its Circuits............................................................................................................139 ECM Power and Ground Circuit Check............................................................................................................158 Fuel Injector Circuit Check...................................................................................................................162 Fuel Pump and Its Circuit Check...............................................................................................................164 Fuel Pressure Check...........................................................................................................................167 A/C Condenser Cooling Fan Control System Inspection...........................................................................................169 A/C System Circuits Check.....................................................................................................................171 Electric Load Signal Circuit Check............................................................................................................174 Radiator Cooling Fan Low Speed Control System Check...........................................................................................176 Radiator Cooling Fan High Speed Control System Check..........................................................................................178 Repair Instructions...............................................................................................................................179 Idle Speed and IAC Throttle Valve Opening Inspection..........................................................................................179 Special Tools and Equipment.......................................................................................................................180 Special Tool..................................................................................................................................180 Engine Electrical Devices.............................................................................................................................181 Repair Instructions...............................................................................................................................181 Electric Load Current Sensor On-Vehicle Inspection............................................................................................181 Charging System.......................................................................................................................................182 General Description...............................................................................................................................182 Generator Description.........................................................................................................................182 Suspension................................................................................................................................................185 Suspension General Diagnosis..........................................................................................................................186 Specifications....................................................................................................................................186 Wheel Alignment Specifications................................................................................................................186 Wheels and Tires......................................................................................................................................187 Specifications....................................................................................................................................187 Wheels and Tires Specifications...............................................................................................................187 Tightening Torque Specifications..............................................................................................................187 Brakes....................................................................................................................................................189 Brake Control System and Diagnosis....................................................................................................................191 General Description...............................................................................................................................191 Front Brake Hose / Pipe Construction..........................................................................................................191 Diagnostic Information and Procedures.............................................................................................................192 Brakes Symptom Diagnosis......................................................................................................................192 Repair Instructions...............................................................................................................................194 Master Cylinder Removal and Installation......................................................................................................194 Specifications....................................................................................................................................195 Tightening Torque Specifications..............................................................................................................195 Electronic Stability Program..........................................................................................................................196 Precautions.......................................................................................................................................196 Precautions in Diagnosing Troubles............................................................................................................196 Precautions in On-Vehicle Service.............................................................................................................196 Precautions in Hydraulic Unit Operation Check.................................................................................................196 Precautions in Sensor Calibration.............................................................................................................196 Precautions in Speedometer Test or Other Tests................................................................................................197 General Description...............................................................................................................................197 Electronic Stability Program Description......................................................................................................197 ESP‚ Hydraulic Unit / Control Module Assembly Description.....................................................................................197 Warning Light, Indicator Light Description....................................................................................................198 CAN Communication System Description..........................................................................................................199 Schematic and Routing Diagram.....................................................................................................................200 Electronic Stability Program Schematic........................................................................................................200 Electronic Stability Program Wiring Circuit Diagram...........................................................................................201 Component Location................................................................................................................................202 Electronic Stability Program Component Location...............................................................................................202 Diagnostic Information and Procedures.............................................................................................................204 Electronic Stability Program Check............................................................................................................204 ESP‚ Warning Light Check......................................................................................................................206 ABS Warning Lamp Check........................................................................................................................206 EBD Warning Lamp (Brake Warning Lamp) Check...................................................................................................206 DTC Check.....................................................................................................................................207 DTC Table.....................................................................................................................................207 DTC Clearance.................................................................................................................................210 Fail-Safe Table...............................................................................................................................211 Scan Tool Data................................................................................................................................213 ESP‚ Warning Light Does Not Come ON at Ignition Switch ON.....................................................................................215 ESP‚ Warning Light Comes ON Steady............................................................................................................216 ABS Warning Lamp Does Not Come ON at Ignition Switch ON.......................................................................................217 ABS Warning Lamp Comes ON Steady..............................................................................................................217 EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady.........................................................................................218 Serial Data Link Circuit Check................................................................................................................220 DTC C1016: Brake Light Switch.................................................................................................................222 DTC C1017 / C1023: Lateral G Sensor / Yaw Rate Sensor.........................................................................................224 DTC C1020 / C1028: Master Cylinder Pressure Sensor Power Supply Failure / Circuit.............................................................224 DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor or Encoder.............................225 DTC C1024: Steering Angle Sensor..............................................................................................................227 DTC C1027: ESP‚ OFF Switch....................................................................................................................227 DTC C1033: Wheel Speed Sensor Deviation.......................................................................................................228 DTC C1034 / C1039: Yaw Rate / G Sensor Power Supply Failure / Internal Failure................................................................230 DTC C1037: Steering Angle Sensor Power Supply Failure.........................................................................................231 DTC C1038: Steering Angle Sensor Detect Rolling Counter.......................................................................................232 DTC C1040: ESP‚ Continuous Operation..........................................................................................................233 DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056: Inlet / Outlet / Cut / Suction Solenoid....233 DTC C1057: Power Supply Voltage Too High / Too Low............................................................................................235 DTC C1061: Pump Motor Circuit.................................................................................................................236 DTC C1063: Solenoid Valve Power Supply Driver Circuit.........................................................................................237 DTC C1071: Control Module Internal Defect.....................................................................................................238 DTC C1075: Steering Angle Sensor Calibration..................................................................................................238 DTC C1091: CAN Invalid Data from ECM..........................................................................................................239 DTC C1096: Yaw Rate / G Sensor Message Counter Error..........................................................................................239 DTC U0073: Control Module Communication Bus Off...............................................................................................240 DTC U0100: Lost Communication with ECM / PCM..................................................................................................240 DTC U0101 Lost Communication with TCM.........................................................................................................240 DTC U0114 Lost Communication with Four-Wheel Drive Clutch Control Module......................................................................240 DTC U0123 Lost Communication with Yaw Rate Sensor Module......................................................................................240 DTC U0126: Lost Communication with Steering Angle Sensor......................................................................................240 ESP‚ Hydraulic Unit / Control Module Assembly Power and Ground Circuit Check..................................................................240 Repair Instructions...............................................................................................................................242 ESP‚ Hydraulic Unit Operation Check...........................................................................................................242 Sensor Calibration............................................................................................................................243 ESP‚ Hydraulic Unit / Control Module Assembly On-Vehicle Inspection...........................................................................243 ESP‚ Hydraulic Unit / Control Module Assembly Removal and Installation........................................................................244 Front Wheel Speed Sensor On-Vehicle Inspection................................................................................................245 Front Wheel Speed Sensor Removal and Installation.............................................................................................245 Front Wheel Speed Sensor Inspection...........................................................................................................245 Rear Wheel Speed Sensor On-Vehicle Inspection.................................................................................................245 Rear Wheel Speed Sensor Removal and Installation..............................................................................................245 Rear Wheel Speed Sensor Inspection............................................................................................................245 Front Wheel Speed Sensor Encoder On-Vehicle Inspection........................................................................................245 Front Wheel Speed Sensor Encoder Removal and Installation.....................................................................................245 Rear Wheel Speed Sensor Encoder On-Vehicle Inspection.........................................................................................245 Rear Wheel Speed Sensor Encoder Removal and Installation......................................................................................245 Master Cylinder Pressure Sensor On-Vehicle Inspection.........................................................................................246 Yaw Rate / G Sensor On-Vehicle Inspection.....................................................................................................246 Yaw Rate / G Sensor Removal and Installation..................................................................................................248 Yaw Rate / G Sensor Inspection................................................................................................................248 Steering Angle Sensor On-Vehicle Inspection...................................................................................................248 Steering Angle Sensor Removal and Installation................................................................................................249 Steering Angle Sensor Inspection..............................................................................................................250 ESP‚ OFF Switch Removal and Installation......................................................................................................250 ESP‚ OFF Switch Inspection....................................................................................................................250 Specifications....................................................................................................................................251 Tightening Torque Specifications..............................................................................................................251 Special Tools and Equipment.......................................................................................................................251 Special Tool..................................................................................................................................251 Restraint.................................................................................................................................................253 Air Bag System........................................................................................................................................254 Diagnostic Information and Procedures.............................................................................................................254 DTC Table.....................................................................................................................................254 Body, Cab and Accessories.................................................................................................................................259 Instrumentation / Driver Info. / Horn.................................................................................................................260 General Description...............................................................................................................................260 CAN Communication System Description..........................................................................................................260 Schematic and Routing Diagram.....................................................................................................................261 Combination Meter Circuit Diagram.............................................................................................................261 Glass / Windows / Mirrors.............................................................................................................................263 Diagnostic Information and Procedures.............................................................................................................263 Deicer Symptom Diagnosis......................................................................................................................263 Repair Instructions...............................................................................................................................263 Rear End Door Window Defogger Relay Inspection................................................................................................263 Deicer Switch Inspection......................................................................................................................263 Deicer Relay Inspection.......................................................................................................................264 Deicer Wire Inspection........................................................................................................................264 Deicer Wire Repair............................................................................................................................264 Power Door Mirror Switch Inspection...........................................................................................................264 Power Door Mirror Actuator Inspection.........................................................................................................265 Seats.................................................................................................................................................266 Diagnostic Information and Procedures.............................................................................................................266 Front Seat Heater Symptom Diagnosis...........................................................................................................266 Repair Instructions...............................................................................................................................267 Front Seat Components.........................................................................................................................267 Front Seat Removal and Installation...........................................................................................................268 Front Seat Heater Switch (Driver and Passenger Side) Inspection...............................................................................268 Front Seat Heater Wire Inspection.............................................................................................................268 Rear Seat Components..........................................................................................................................269 Specifications....................................................................................................................................270 Tightening Torque Specifications..............................................................................................................270 Special Tools and Equipment.......................................................................................................................270 Recommended Service Material..................................................................................................................270 Control Systems...........................................................................................................................................271 Body Electrical Control System........................................................................................................................272 Precautions.......................................................................................................................................272 Precautions in Diagnosing Trouble.............................................................................................................272 General Description...............................................................................................................................272 BCM General Description.......................................................................................................................272 Security Alarm Description (If Equipped)......................................................................................................272 Schematic and Routing Diagram.....................................................................................................................273 Body Electrical Control System Wiring Circuit Diagram.........................................................................................273 Connector Layout Diagram of BCM and Junction Block............................................................................................276 Component Location................................................................................................................................277 BCM and Related System Component Location.....................................................................................................277 Diagnostic Information and Procedures.............................................................................................................278 BCM Self-Diagnosis Function...................................................................................................................278 Scan Tool Data................................................................................................................................280 Inspection of BCM and Its Circuits............................................................................................................282 Repair Instructions...............................................................................................................................290 Security Alarm Mode Selection Procedure (If Equipped).........................................................................................290 Keyless Start System..................................................................................................................................291 Schematic and Routing Diagram.....................................................................................................................291 Keyless Start System Electric Wiring Circuit Diagram..........................................................................................291 Diagnostic Information and Procedures.............................................................................................................292 Precautions in Diagnosing Troubles............................................................................................................292 Door Lock Operation (Keyless Start System)....................................................................................................292 COPYRIGHT.................................................................................................................................................293 BOOKCOVER.................................................................................................................................................294
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