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Suzuki SX4 HATCHBACK RW415 RW416 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: SX4 Hatchback Generation Generation Name: First Generation Generation Years: 2006-2011 Codes Chassis Codes: RW415, RW416, RW420 👋 Introduction Market Position Vehicle Segment: Subcompact crossover SUV Target Audience: Budget-conscious buyers, small families, urban commuters. Competitive Analysis Key Competitors: Nissan Versa, Honda Fit, Toyota Yaris (though the SX4 offered a higher stance). Key Features Dvp Features: All-wheel drive (AWD) option, practical hatchback design, fuel efficiency. Manual Advantage: Provides in-depth technical knowledge for DIY repairs, saving significant labor costs at dealerships. 📋 Manual Details Coverage Areas Years Covered: 2006, 2007, 2008, 2009, 2010, 2011 Page Count Total Pages: More than 2900 Manual Type Type: Workshop Service Repair Manual + Owner's Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine block, cylinder head, pistons, connecting rods, crankshaft, camshafts, valve train, timing belts/chains. Lubrication System: Oil pump, oil filter, oil pan, oil pressure, lubrication passages, oil cooler. Fuel System: Fuel tank, fuel pump, fuel filter, fuel injectors, fuel rail, evaporative emission control (EVAP). Cooling System: Radiator, coolant hoses, thermostat, water pump, cooling fan, coolant reservoir. Ignition System: Spark plugs, ignition coils, ignition control module (ICM), wiring. Starting System: Starter motor, starter solenoid, starter circuit. Charging System: Alternator, voltage regulator, battery, charging circuit. Exhaust System: Exhaust manifold, catalytic converter, muffler, exhaust pipes, oxygen sensors. Suspension: Front suspension (struts, control arms, ball joints), rear suspension (torsion beam, shock absorbers), wheel bearings. Driveline Axle: Front-wheel drive components, CV joints, propeller shafts (if AWD equipped), differential. Brakes: Front and rear brakes (discs/drums), brake calipers, brake pads, brake rotors, master cylinder, brake lines, ABS system. Transmission Transaxle: Manual transmission, automatic transmission, clutch assembly, transmission fluid, gear selection. Steering: Power steering system (hydraulic/electric), steering rack, steering column, tie rods, power steering fluid. Heating Ventilation: HVAC system components, heater core, blower motor, air conditioning (A/C) system, refrigerant. Restraint: Airbags, seat belts, SRS system (Supplemental Restraint System). Body Cab Accessories: Body panels, doors, windows, locks, seats, interior trim, exterior trim, bumpers. Wiring Systems: Engine wiring harness, chassis wiring harness, body wiring harness, connectors, fuses, relays. Control System: Engine Control Module (ECM)/Powertrain Control Module (PCM), transmission control module (TCM), body control module (BCM). Body Electrical System: Lighting system (headlights, taillights, interior lights), power windows, power locks, wipers, horn. Cruise Control System: Components, operation, troubleshooting. Immobilizer Control System: Components, operation, troubleshooting. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, brake inspections. Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics. Repair: Step-by-step repair procedures for all covered systems, component removal and installation, adjustments. Rebuild: Engine, transmission, and major component rebuild procedures. Wiring Diagrams: Comprehensive wiring diagrams for all electrical systems. Specifications: Torque specifications, fluid capacities, clearances, measurements. Technical Depth Depth: Comprehensive; covers everything from basic maintenance to full engine and transmission overhauls, including electrical diagnostics and body repairs. 📊 Manual Specifications File Format Required Software: Adobe Acrobat Reader Extraction Required: Yes (ZIP format, requires WinZip or WinRAR) Print Quality Diagram Resolution: High Definition Text Searchability: Searchable (typical for PDF) Printability: Printable Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) Navigation Chapter Bookmarks: Included ⚙️ Engine Specifications Primary Engine 1.5L: M15A, 1.5L DOHC VVT petrol. Approx. 102 hp @ 6000 rpm, 133 Nm @ 4000 rpm torque. 1.6L: M16A, 1.6L DOHC VVT petrol. Approx. 107-120 hp @ 6000 rpm, 145-156 Nm @ 4000 rpm torque (depending on market/tune). 2.0L: J20A, 2.0L DOHC VVT petrol. Approx. 143-150 hp @ 6000 rpm, 185-190 Nm @ 4000 rpm torque. Performance Fuel Type: Unleaded gasoline Fuel System Injection Type: Multi-point fuel injection (MPI) Emission Control: Catalytic converter, O2 sensors, EVAP system. 🔧 Transmission Standard Standard Transmission Type: 5-speed manual Optional Optional Transmission Type: 4-speed automatic Features Drivetrain: Front-Wheel Drive (FWD) standard, All-Wheel Drive (AWD) optional on some trims and engines. 📐 Dimensions Exterior Length: Approx. 4135 mm (162.8 in) Width: Approx. 1755 mm (69.1 in) Height: Approx. 1605 mm (63.2 in) for FWD, 1610 mm (63.4 in) for AWD Cargo Cargo Volume: Approx. 255 - 385 liters (9.0 - 13.6 cu ft) with rear seats up, expandable with seats folded. Weights Curb Weight: Approx. 1200-1350 kg (2645-2976 lbs) depending on configuration. Towing Capacity: Not typically specified for this segment/vehicle, consult local regulations and specific model documentation. 🛡️ Safety Features Ratings NHTSA Rating: Generally received good ratings for its time (e.g., 4 stars frontal, 5 stars side from NHTSA in some configurations). Active Features ABS: Anti-lock Braking System (ABS) usually standard or optional. Ebs: Electronic Brake-force Distribution (EBD) often paired with ABS. Traction Control: Traction Control System (TCS) and Electronic Stability Program (ESP) available on certain models/trims. Passive Features Airbags: Front airbags, side curtain airbags, front-seat side airbags depending on trim and market. Seatbelts: Three-point seatbelts with pretensioners and force limiters. 💡 Technology Features Infotainment Audio System: Base...
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Sku: 481898
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Suzuki SX4 HATCHBACK RW415 RW416 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
SX4 Hatchback
Generation
Generation Name:
First Generation
Generation Years:
2006-2011
Codes
Chassis Codes:
RW415, RW416, RW420
👋 Introduction
Market Position
Vehicle Segment:
Subcompact crossover SUV
Target Audience:
Budget-conscious buyers, small families, urban commuters.
Competitive Analysis
Key Competitors:
Nissan Versa, Honda Fit, Toyota Yaris (though the SX4 offered a higher stance).
Key Features
Dvp Features:
All-wheel drive (AWD) option, practical hatchback design, fuel efficiency.
Manual Advantage:
Provides in-depth technical knowledge for DIY repairs, saving significant labor costs at dealerships.
📋 Manual Details
Coverage Areas
Years Covered:
2006, 2007, 2008, 2009, 2010, 2011
Page Count
Total Pages:
More than 2900
Manual Type
Type:
Workshop Service Repair Manual + Owner's Manual
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine block, cylinder head, pistons, connecting rods, crankshaft, camshafts, valve train, timing belts/chains.
Lubrication System:
Oil pump, oil filter, oil pan, oil pressure, lubrication passages, oil cooler.
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel injectors, fuel rail, evaporative emission control (EVAP).
Cooling System:
Radiator, coolant hoses, thermostat, water pump, cooling fan, coolant reservoir.
Ignition System:
Spark plugs, ignition coils, ignition control module (ICM), wiring.
Starting System:
Starter motor, starter solenoid, starter circuit.
Charging System:
Alternator, voltage regulator, battery, charging circuit.
Exhaust System:
Exhaust manifold, catalytic converter, muffler, exhaust pipes, oxygen sensors.
Suspension:
Front suspension (struts, control arms, ball joints), rear suspension (torsion beam, shock absorbers), wheel bearings.
Driveline Axle:
Front-wheel drive components, CV joints, propeller shafts (if AWD equipped), differential.
Brakes:
Front and rear brakes (discs/drums), brake calipers, brake pads, brake rotors, master cylinder, brake lines, ABS system.
Transmission Transaxle:
Manual transmission, automatic transmission, clutch assembly, transmission fluid, gear selection.
Steering:
Power steering system (hydraulic/electric), steering rack, steering column, tie rods, power steering fluid.
Heating Ventilation:
HVAC system components, heater core, blower motor, air conditioning (A/C) system, refrigerant.
Restraint:
Airbags, seat belts, SRS system (Supplemental Restraint System).
Body Cab Accessories:
Body panels, doors, windows, locks, seats, interior trim, exterior trim, bumpers.
Wiring Systems:
Engine wiring harness, chassis wiring harness, body wiring harness, connectors, fuses, relays.
Control System:
Engine Control Module (ECM)/Powertrain Control Module (PCM), transmission control module (TCM), body control module (BCM).
Body Electrical System:
Lighting system (headlights, taillights, interior lights), power windows, power locks, wipers, horn.
Cruise Control System:
Components, operation, troubleshooting.
Immobilizer Control System:
Components, operation, troubleshooting.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, brake inspections.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics.
Repair:
Step-by-step repair procedures for all covered systems, component removal and installation, adjustments.
Rebuild:
Engine, transmission, and major component rebuild procedures.
Wiring Diagrams:
Comprehensive wiring diagrams for all electrical systems.
Specifications:
Torque specifications, fluid capacities, clearances, measurements.
Technical Depth
Depth:
Comprehensive; covers everything from basic maintenance to full engine and transmission overhauls, including electrical diagnostics and body repairs.
📊 Manual Specifications
File Format
Required Software:
Adobe Acrobat Reader
Extraction Required:
Yes (ZIP format, requires WinZip or WinRAR)
Print Quality
Diagram Resolution:
High Definition
Text Searchability:
Searchable (typical for PDF)
Printability:
Printable
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
Navigation
Chapter Bookmarks:
Included
⚙️ Engine Specifications
Primary Engine
1.5L:
M15A, 1.5L DOHC VVT petrol. Approx. 102 hp @ 6000 rpm, 133 Nm @ 4000 rpm torque.
1.6L:
M16A, 1.6L DOHC VVT petrol. Approx. 107-120 hp @ 6000 rpm, 145-156 Nm @ 4000 rpm torque (depending on market/tune).
2.0L:
J20A, 2.0L DOHC VVT petrol. Approx. 143-150 hp @ 6000 rpm, 185-190 Nm @ 4000 rpm torque.
Performance
Fuel Type:
Unleaded gasoline
Fuel System
Injection Type:
Multi-point fuel injection (MPI)
Emission Control:
Catalytic converter, O2 sensors, EVAP system.
🔧 Transmission
Standard
Standard Transmission Type:
5-speed manual
Optional
Optional Transmission Type:
4-speed automatic
Features
Drivetrain:
Front-Wheel Drive (FWD) standard, All-Wheel Drive (AWD) optional on some trims and engines.
📐 Dimensions
Exterior
Length:
Approx. 4135 mm (162.8 in)
Width:
Approx. 1755 mm (69.1 in)
Height:
Approx. 1605 mm (63.2 in) for FWD, 1610 mm (63.4 in) for AWD
Cargo
Cargo Volume:
Approx. 255 - 385 liters (9.0 - 13.6 cu ft) with rear seats up, expandable with seats folded.
Weights
Curb Weight:
Approx. 1200-1350 kg (2645-2976 lbs) depending on configuration.
Towing Capacity:
Not typically specified for this segment/vehicle, consult local regulations and specific model documentation.
🛡️ Safety Features
Ratings
NHTSA Rating:
Generally received good ratings for its time (e.g., 4 stars frontal, 5 stars side from NHTSA in some configurations).
Active Features
ABS:
Anti-lock Braking System (ABS) usually standard or optional.
Ebs:
Electronic Brake-force Distribution (EBD) often paired with ABS.
Traction Control:
Traction Control System (TCS) and Electronic Stability Program (ESP) available on certain models/trims.
Passive Features
Airbags:
Front airbags, side curtain airbags, front-seat side airbags depending on trim and market.
Seatbelts:
Three-point seatbelts with pretensioners and force limiters.
💡 Technology Features
Infotainment
Audio System:
Base models typically featured a CD player with AM/FM radio and basic speaker system. Higher trims could offer MP3 compatibility, auxiliary input, and more speakers.
Driver Assistance
Cruise Control:
Available on higher trims, operated via steering wheel buttons or stalk. Covered in detail in the manual.
Connectivity
Auxiliary Input:
Common on many models for connecting external audio devices.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-10,000 miles (12,000-16,000 km) or 6-12 months, whichever comes first, depending on driving conditions and oil type (consult manual for specifics).
Timing Belt Replacement:
For engines using a timing belt (e.g., some variants of the M16A), replacement is typically recommended around 60,000-100,000 miles (96,000-160,000 km). Consult manual for exact interval and engine type.
Spark Plug Replacement:
Intervals vary based on plug type (standard vs. iridium), but often around 60,000-100,000 miles (96,000-160,000 km).
Fluid Specifications
Engine Oil Type:
Typically SAE 5W-30 or 0W-20, API SN or higher. Specific viscosity and API rating depend on engine and climate. Consult manual.
Coolant Type:
Suzuki Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant with specific inhibitor package. Typically a pink or red colored coolant. Consult manual for color and specification.
Transmission Fluid Manual:
API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90. Consult manual for exact specification.
Transmission Fluid Automatic:
Suzuki ATF 5D03 or equivalent Dexron III/Mercon equivalent. Consult manual for exact specification.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Always use clean, fresh fluid.
Power Steering Fluid Type:
Typically ATF Dexron II or III for hydraulic systems. Electric power steering systems do not require fluid.
Known Issues
Common Faults:
Occasional reports of water pump leaks, minor electrical gremlins, and potential suspension component wear over time. Timing chain tensioner issues on some higher mileage engines, though less common than belts.
📚 Vehicle History
Brand Heritage
Suzuki Automotive:
Suzuki has a long history of producing reliable, fuel-efficient vehicles, often with a focus on small and compact segments.
Model Evolution
Sx4 Origin:
The SX4 was developed as a collaboration with Fiat, sharing its platform with the Fiat Sedici. It was designed to offer a balance of hatchback practicality and SUV-like styling and ground clearance.
Production
Manufacturing Locations:
Primary manufacturing often in Japan (Kosai) and Hungary (Magyar Suzuki).
🏆 Awards & Recognition
Recognitions
Safety Awards:
Achieved good safety ratings in crash tests by organizations like Euro NCAP and NHTSA for its class, contributing to its appeal.
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