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2006-2012 Suzuki SX4 Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: SX4 Model Codes: RW415, RW416 Generation Generation: First Generation (GY/RW) Codes Chassis Codes: RW (Global Hatchback), GY (Global Sedan - less common in some markets) 👋 Introduction Market Position Market Segment: Subcompact hatchback/sedan, offering affordability, practicality, and a degree of sporty styling. Competitive Analysis Key Competitors: Ford Focus, Honda Civic, Toyota Corolla, Mazda3, Chevrolet Aveo. Key Features Vehicle Appeal: Designed as an affordable and versatile global car, often praised for its AWD option (in certain markets), fuel efficiency, and practical interior for its size. Manual Advantage: Enables DIY maintenance and repair, potentially saving significant costs compared to dealership or independent mechanic services. 📋 Manual Details Coverage Areas Applicable Model Years: 2006, 2007, 2008, 2009, 2010, 2011, 2012 Covered Models: All SX4 models, all engine variants Page Count Estimated Page Count: Likely exceeds 1500 pages (typical for comprehensive factory service manuals) Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Mechanical Systems: Engine mechanical (1.5L, 1.6L), Driveline/Axle, Suspension (front & rear), Brakes (hydraulic, ABS), Steering (power steering system), Transmission (automatic & manual gearboxes) Electrical Systems: Restraint systems (airbags, seatbelts), HVAC (heating, ventilation, air conditioning), Body electrical, Control systems (ECU, sensors, actuators), Lighting, Instrumentation Procedures Included Diagnostic Procedures: Troubleshooting guides, diagnostic trouble codes (DTCs) interpretation, electrical schematic analysis, component testing Repair Procedures: Step-by-step repair instructions for all major components and systems, including engine overhaul, transmission service, brake caliper replacement, suspension component repair, body panel repair Maintenance Procedures: Scheduled maintenance tasks, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, tune-up procedures Installation Procedures: Instructions for replacing components, including torque specifications and alignment procedures Technical Depth Technical Depth: Comprehensive, covering basic maintenance to advanced diagnostics and full component rebuilds. Includes detailed specifications, diagrams, and exploded views. 📊 Manual Specifications File Format Compatibility: All Versions of Windows & Mac Requirements: Adobe PDF Reader, WinZip Print Quality Printability: All pages are printable Binding Type Binding Type: Digital (PDF) - No physical binding Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Displacement 1: 1.5 Liters (1490 cc) Engine Code 1: M15A (common) Engine Type 1: Inline 4-cylinder, DOHC, 16-valve, VVT (Variable Valve Timing) Bore X Stroke 1: 73.0 mm x 83.2 mm (approx.) Compression Ratio 1: 10.0:1 (approx.) Fuel Delivery 1: Multi-point Fuel Injection (MPI) Horsepower 1: 100-110 HP @ 6000-6200 RPM (market dependent) Torque 1: 130-140 Nm @ 4000-4200 RPM (market dependent) Secondary Engine Engine Displacement 2: 1.6 Liters (1586 cc) Engine Code 2: M16A (common) Engine Type 2: Inline 4-cylinder, DOHC, 16-valve, VVT (Variable Valve Timing) Bore X Stroke 2: 78.0 mm x 83.0 mm (approx.) Compression Ratio 2: 10.4:1 (approx.) Fuel Delivery 2: Multi-point Fuel Injection (MPI) Horsepower 2: 110-120 HP @ 6000-6200 RPM (market dependent) Torque 2: 150-156 Nm @ 4000-4400 RPM (market dependent) 🔧 Transmission Standard Transmission Type Std: 5-Speed Manual Optional Transmission Type Opt: 4-Speed Automatic (with overdrive) Features Drivetrain Options: Front-Wheel Drive (FWD) and All-Wheel Drive (AWD - particularly common on hatchback models). Fluid Specs Manual Transmission Fluid: API GL-4, SAE 75W-90 (verify specific Suzuki part number/spec) Automatic Transmission Fluid: Suzuki ATF 3317 or equivalent (verify specific Suzuki part number/spec) 📐 Dimensions Exterior Length: Hatchback: ~4135 mm / Sedan: ~4490 mm (varies slightly by market) Width: ~1755 mm Height: Hatchback: ~1565 mm / Sedan: ~1545 mm (varies slightly by market) Wheelbase: ~2500 mm Weights Curb Weight: 1100-1250 kg (approx., depending on configuration and drivetrain) Cargo Cargo Volume: Hatchback: ~290-300 liters (rear seats up) 🛡️ Safety Features Ratings NHTSA Overall Rating: Mixed (4-star front, 5-star side in some tests, but varied by year and testing body) IIHS Rating: Good in front and side impacts for many configurations. Active Features Available Active Safety: ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), Brake Assist, available ESP (Electronic Stability Program) on some models. Passive Features Standard Passive Safety: Front airbags, side airbags (optional/standard depending on trim), curtain airbags (optional/standard depending on trim), pretensioner seatbelts. 💡 Technology Features Infotainment Infotainment System: Base models featured basic AM/FM/CD players. Higher trims offered options like MP3 compatibility, auxiliary input, and eventually Bluetooth and navigation systems in later years/facelifts. Driver Assistance Available Driver Assistance: Key driver assistance features include ABS, EBD, and optional ESP. Limited advanced driver-assistance systems (ADAS) were available during this generation compared to modern vehicles. Connectivity Connectivity Options: Auxiliary audio input jack, USB ports (on later models/higher trims), Bluetooth hands-free calling (on some models). 🔧 Maintenance Service Intervals Engine Oil Change: Every 7,500 miles (12,000 km) or 6 months, whichever comes first (under normal driving conditions). Air Filter Replacement: Every 15,000 miles (24,000 km) or 12 months. Spark Plug Replacement: iridium spark plugs: ~60,000 - 75,000 miles (verify specific type/spec). Fluid Specifications Engine Oil Type: API SN or SP, ILSAC...
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2006-2012 Suzuki SX4 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
SX4
Model Codes:
RW415, RW416
Generation
Generation:
First Generation (GY/RW)
Codes
Chassis Codes:
RW (Global Hatchback), GY (Global Sedan - less common in some markets)
👋 Introduction
Market Position
Market Segment:
Subcompact hatchback/sedan, offering affordability, practicality, and a degree of sporty styling.
Competitive Analysis
Key Competitors:
Ford Focus, Honda Civic, Toyota Corolla, Mazda3, Chevrolet Aveo.
Key Features
Vehicle Appeal:
Designed as an affordable and versatile global car, often praised for its AWD option (in certain markets), fuel efficiency, and practical interior for its size.
Manual Advantage:
Enables DIY maintenance and repair, potentially saving significant costs compared to dealership or independent mechanic services.
📋 Manual Details
Coverage Areas
Applicable Model Years:
2006, 2007, 2008, 2009, 2010, 2011, 2012
Covered Models:
All SX4 models, all engine variants
Page Count
Estimated Page Count:
Likely exceeds 1500 pages (typical for comprehensive factory service manuals)
Manual Type
Manual Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Mechanical Systems:
Engine mechanical (1.5L, 1.6L), Driveline/Axle, Suspension (front & rear), Brakes (hydraulic, ABS), Steering (power steering system), Transmission (automatic & manual gearboxes)
Electrical Systems:
Restraint systems (airbags, seatbelts), HVAC (heating, ventilation, air conditioning), Body electrical, Control systems (ECU, sensors, actuators), Lighting, Instrumentation
Procedures Included
Diagnostic Procedures:
Troubleshooting guides, diagnostic trouble codes (DTCs) interpretation, electrical schematic analysis, component testing
Repair Procedures:
Step-by-step repair instructions for all major components and systems, including engine overhaul, transmission service, brake caliper replacement, suspension component repair, body panel repair
Maintenance Procedures:
Scheduled maintenance tasks, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, tune-up procedures
Installation Procedures:
Instructions for replacing components, including torque specifications and alignment procedures
Technical Depth
Technical Depth:
Comprehensive, covering basic maintenance to advanced diagnostics and full component rebuilds. Includes detailed specifications, diagrams, and exploded views.
📊 Manual Specifications
File Format
Compatibility:
All Versions of Windows & Mac
Requirements:
Adobe PDF Reader, WinZip
Print Quality
Printability:
All pages are printable
Binding Type
Binding Type:
Digital (PDF) - No physical binding
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Displacement 1:
1.5 Liters (1490 cc)
Engine Code 1:
M15A (common)
Engine Type 1:
Inline 4-cylinder, DOHC, 16-valve, VVT (Variable Valve Timing)
Bore X Stroke 1:
73.0 mm x 83.2 mm (approx.)
Compression Ratio 1:
10.0:1 (approx.)
Fuel Delivery 1:
Multi-point Fuel Injection (MPI)
Horsepower 1:
100-110 HP @ 6000-6200 RPM (market dependent)
Torque 1:
130-140 Nm @ 4000-4200 RPM (market dependent)
Secondary Engine
Engine Displacement 2:
1.6 Liters (1586 cc)
Engine Code 2:
M16A (common)
Engine Type 2:
Inline 4-cylinder, DOHC, 16-valve, VVT (Variable Valve Timing)
Bore X Stroke 2:
78.0 mm x 83.0 mm (approx.)
Compression Ratio 2:
10.4:1 (approx.)
Fuel Delivery 2:
Multi-point Fuel Injection (MPI)
Horsepower 2:
110-120 HP @ 6000-6200 RPM (market dependent)
Torque 2:
150-156 Nm @ 4000-4400 RPM (market dependent)
🔧 Transmission
Standard
Transmission Type Std:
5-Speed Manual
Optional
Transmission Type Opt:
4-Speed Automatic (with overdrive)
Features
Drivetrain Options:
Front-Wheel Drive (FWD) and All-Wheel Drive (AWD - particularly common on hatchback models).
Fluid Specs
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (verify specific Suzuki part number/spec)
Automatic Transmission Fluid:
Suzuki ATF 3317 or equivalent (verify specific Suzuki part number/spec)
📐 Dimensions
Exterior
Length:
Hatchback: ~4135 mm / Sedan: ~4490 mm (varies slightly by market)
Width:
~1755 mm
Height:
Hatchback: ~1565 mm / Sedan: ~1545 mm (varies slightly by market)
Wheelbase:
~2500 mm
Weights
Curb Weight:
1100-1250 kg (approx., depending on configuration and drivetrain)
Cargo
Cargo Volume:
Hatchback: ~290-300 liters (rear seats up)
🛡️ Safety Features
Ratings
NHTSA Overall Rating:
Mixed (4-star front, 5-star side in some tests, but varied by year and testing body)
IIHS Rating:
Good in front and side impacts for many configurations.
Active Features
Available Active Safety:
ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), Brake Assist, available ESP (Electronic Stability Program) on some models.
Passive Features
Standard Passive Safety:
Front airbags, side airbags (optional/standard depending on trim), curtain airbags (optional/standard depending on trim), pretensioner seatbelts.
💡 Technology Features
Infotainment
Infotainment System:
Base models featured basic AM/FM/CD players. Higher trims offered options like MP3 compatibility, auxiliary input, and eventually Bluetooth and navigation systems in later years/facelifts.
Driver Assistance
Available Driver Assistance:
Key driver assistance features include ABS, EBD, and optional ESP. Limited advanced driver-assistance systems (ADAS) were available during this generation compared to modern vehicles.
Connectivity
Connectivity Options:
Auxiliary audio input jack, USB ports (on later models/higher trims), Bluetooth hands-free calling (on some models).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first (under normal driving conditions).
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Spark Plug Replacement:
iridium spark plugs: ~60,000 - 75,000 miles (verify specific type/spec).
Fluid Specifications
Engine Oil Type:
API SN or SP, ILSAC GF-5 or GF-6A, Viscosity 0W-20 or 5W-30 (verify owner's manual for specific engine/climate recommendations)
Coolant Type:
Suzuki Super Long Life Coolant (SLLC) or equivalent (pre-mixed, P-HOAT type)
Brake Fluid Type:
DOT 3 or DOT 4 (verify specific requirement)
Known Issues
Common Wear Items:
Front struts/shocks, brake pads and rotors, exhaust system components (rust), wheel bearings, catalytic converter (can be prone to failure if engine issues are neglected).
Engine Specific Concerns:
Occasional issues with ignition coils, oil consumption if not maintained, and potential for timing chain wear on higher mileage vehicles (though generally reliable).
Transmission Concerns:
Automatic transmission can be less responsive than modern CVTs or dual-clutches; proper fluid maintenance is crucial. Manual transmissions are generally robust.
Electrical Issues:
Minor electrical gremlins can occur, such as power window motor failures or sensor issues, typically resolvable with proper diagnosis.
📚 Vehicle History
Brand Heritage
Suzuki Automotive Focus:
Suzuki has a long history of producing small, efficient, and often rugged vehicles, including motorcycles and kei cars, before expanding into global markets with models like the SX4.
Model Evolution
Sx4 Development:
Developed in collaboration with Fiat, it was positioned as a compact, high-riding hatchback or sedan with an emphasis on all-weather capability, especially with its optional AWD system.
Production
Production Period:
2006-2014 (globally, with facelifts during its run)
Manufacturing Locations:
Japan (Saitama), Hungary (Magyar Suzuki), India (Maruti Suzuki - as Maruti Suzuki SX4).
🏆 Awards & Recognition
Recognitions
Industry Awards:
The SX4 often received praise for its value proposition, fuel economy, and the availability of AWD in a segment where it was less common.
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