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Suzuki SX4 2006/2007/2008/2009 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: SX4 Model Years Covered: 2006, 2007, 2008, 2009 Codes Platform Code: GY (Global/Japanese Market), RW (North American Market) 👋 Introduction Market Position Segment:...
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Tipo: Car
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SKU: 260636
Suzuki SX4 2006/2007/2008/2009 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
SX4
Model Years Covered:
2006, 2007, 2008, 2009
Codes
Platform Code:
GY (Global/Japanese Market), RW (North American Market)
👋 Introduction
Market Position
Segment:
Subcompact crossover SUV
Target Audience:
Individuals seeking a practical, fuel-efficient, and versatile vehicle for urban and light off-road use.
Competitive Analysis
Key Competitors:
Toyota RAV4, Honda CR-V, Nissan Rogue, Ford Escape, Kia Sportage, Hyundai Tucson.
Key Features
Design:
Sporty and somewhat aggressive styling, higher ground clearance than a typical car, available All-Wheel Drive (AWD).
Versatility:
Practical interior space, split-folding rear seats for cargo flexibility, available AWD for enhanced traction in various conditions.
Value Proposition:
Offers a blend of SUV utility and car-like handling at a competitive price point.
📋 Manual Details
Coverage Areas
Primary Regions Covered:
Global
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, pistons, crankshaft, camshafts, valve train, lubrication system, cooling system, fuel system (mechanical), intake manifold, exhaust manifold.
Engine Electrical:
Ignition system, starting system, charging system, engine control module (ECM) operation, sensors, actuators, emissions control systems (PCV, EVAP), wiring diagrams.
Transmission:
Manual transmission (M16A, J20A), automatic transmission (4AT), clutch system, driveline components (axles, driveshafts), transfer case (AWD models).
Brakes:
Front disc brakes, rear drum/disc brakes, parking brake system, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake fluid specifications.
Suspension Steering:
Front MacPherson strut suspension, rear torsion beam/multi-link suspension (depending on market/drivetrain), power steering system (hydraulic/electric), steering gear, wheel alignment specifications.
Body Interior:
Body structure, exterior panels, doors, hood, trunk lid, interior trim, seats, HVAC (Heating, Ventilation, Air Conditioning) system, power windows, power locks, mirrors.
Electrical Chassis:
Lighting system (headlights, taillights, interior), horn, wipers/washers, instrument cluster, audio system, SRS (Supplemental Restraint System) / Airbags, body control module (BCM).
Procedures Included
Maintenance:
Oil and filter changes, fluid checks and top-offs (coolant, brake fluid, power steering fluid, transmission fluid), spark plug replacement, air filter replacement, cabin air filter replacement, battery maintenance, tire rotation.
Engine Repair:
Engine removal/installation, cylinder head overhaul, piston ring replacement, crankshaft bearing replacement, camshaft timing, valve adjustment, fuel injector testing/replacement, EGR valve cleaning/replacement.
Transmission Repair:
Manual transmission disassembly/assembly, clutch replacement, automatic transmission fluid and filter change, valve body inspection, torque converter service.
Brake Service:
Brake pad/shoe replacement, brake rotor/drum resurfacing/replacement, brake caliper service, bleeding the brake system, ABS component testing.
Suspension Steering Repair:
Strut/shock absorber replacement, ball joint replacement, tie rod end replacement, power steering pump/rack replacement, wheel bearing replacement.
Bodywork Collision:
Panel replacement, dent repair, rust repair, glass replacement, door mechanism repair, bumper repair/replacement.
Electrical Diagnostics:
Troubleshooting electrical faults, testing sensors and actuators, wiring harness repair, diagnosing ECM faults, airbag system diagnosis and repair.
Troubleshooting:
Diagnostic flowcharts for common problems, symptom-based troubleshooting guides, fault code interpretation.
Technical Depth
Depth:
Comprehensive: Covers basic maintenance, routine service, in-depth diagnostics, component-level repair, and full system overhauls. Suitable for professional technicians and advanced DIYers.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High resolution, clear diagrams, searchable text
Binding Type
Type:
Not applicable (Digital Download)
Paper Type
Type:
Not applicable (Digital Download)
Compatibility
Operating Systems:
Windows (95/98/ME/XP/Vista/7), Linux, macOS
⚙️ Engine Specifications
Primary Engine
Engine Code Usdm:
J20A
Engine Code Global:
M16A
Configuration:
Inline 4-cylinder, DOHC, 16-valve
Displacement J20A:
2.0 Liters (1998 cc)
Displacement M16A:
1.6 Liters (1586 cc)
Performance
Horsepower J20A:
143 hp @ 6000 rpm
Torque J20A:
137 lb-ft @ 4000 rpm
Horsepower M16A:
100 hp @ 6000 rpm (approx.)
Torque M16A:
108 lb-ft @ 4000 rpm (approx.)
Fuel System
Injection:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Recommended Octane:
87 AKI (Anti-Knock Index)
🔧 Transmission
Standard
Transmission Type Usdm:
4-Speed Automatic
Transmission Type Global:
5-Speed Manual
Optional
Transmission Type Optional:
4-Speed Automatic (available with 1.6L engine in some markets)
Features
Drivetrain:
Front-Wheel Drive (FWD) standard, All-Wheel Drive (AWD) optional
Manual Transmission Gear Ratios:
Refer to manual for specific ratios (e.g., 1st: 3.583, 2nd: 1.947, 3rd: 1.322, 4th: 0.971, 5th: 0.805, Reverse: 3.182)
Automatic Transmission Fluid Spec:
Dexron III or equivalent
📐 Dimensions
Exterior
Length:
Approx. 162.0 inches (4115 mm)
Width:
Approx. 68.7 inches (1745 mm)
Height:
Approx. 64.2 inches (1630 mm)
Wheelbase:
Approx. 100.0 inches (2540 mm)
Ground Clearance:
Approx. 7.2 inches (183 mm)
Weights
Curb Weight FWD Manual:
Approx. 2779 lbs (1261 kg)
Curb Weight AWD Auto:
Approx. 3075 lbs (1395 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5-star
NHTSA Front Impact Passenger:
5-star
NHTSA Side Impact Front Seat Passenger:
5-star
NHTSA Side Impact Rear Seat Passenger:
5-star
NHTSA Rollover:
4-star
Active Features
ABS:
Standard
Ebd:
Standard
Brake Assist:
Available on some trims
Passive Features
Airbags Front:
Standard (Driver and Passenger)
Airbags Side:
Available (Front Side Airbags)
Airbags Curtain:
Available (Front and Rear Side Curtain Airbags)
Seatbelts:
3-point seatbelts with pretensioners and load limiters
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player with MP3 playback, auxiliary audio input jack. Higher trims offered premium audio systems and/or navigation.
Connectivity:
Bluetooth hands-free calling and audio streaming available on some higher trims.
Driver Assistance
Cruise Control:
Available on most trims
Keyless Entry:
Available on some trims
Smart Key Push Button Start:
Available on top trims
🔧 Maintenance
Service Intervals
Oil Change Recommendation:
Every 4,500 miles (7,500 km) or 6 months, whichever comes first, using synthetic or synthetic blend oil.
Engine Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on inspection.
Cabin Air Filter Replacement:
Every 15,000 miles (24,000 km) or annually.
Spark Plug Replacement:
Iridium-tipped spark plugs: 75,000 miles (120,000 km). Platinum-tipped: 30,000 miles (48,000 km).
Coolant Flush:
Every 50,000 miles (80,000 km) or 5 years.
Transmission Fluid Change Auto:
Every 60,000 miles (96,000 km) or as per severe service schedule.
Fluid Specifications
Engine Oil SAE:
SAE 0W-20 (preferred) or 5W-30
Engine Oil API:
API SM or SN certified, ILSAC GF-4 or GF-5
Coolant:
Suzuki Super Long Life Coolant (or equivalent ethylene glycol-based coolant with deionized water, 50/50 mix)
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
Dexron III or equivalent
Known Issues
Catalytic Converter:
Some models experienced premature catalytic converter failure, often due to engine misfires or oil consumption.
Oxygen Sensors:
Oxygen sensors can fail over time, leading to poor fuel economy and check engine lights.
Cv Joints:
Front CV joints can wear out, especially in AWD models subjected to harsh use, leading to clicking noises during turns.
Rear Wheel Bearings:
Rear wheel bearings can sometimes develop noise and require replacement.
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation, a Japanese multinational automotive manufacturer known for compact cars and SUVs.
Model Evolution
First Generation:
The Suzuki SX4 was first introduced in 2006 in Japan, and globally in 2007. It was designed as a joint venture with Fiat, sharing its platform with the Fiat Sedici.
Body Styles:
Initially launched as a 5-door hatchback. A 4-door sedan version was also introduced in certain markets (e.g., North America).
Production
Production Years:
2006-2014 (First Generation)
Manufacturing Locations:
Japan, Hungary, India
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
Awarded a 'Good' rating in front and side impact crash tests by the IIHS (Insurance Institute for Highway Safety), making it a potential Top Safety Pick for its era.
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