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Suzuki SX4 RW420 2006 2007 2008 2009 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Suzuki Model: SX4 Chassis Code: RW420 Model Years Covered: 2006, 2007, 2008, 2009 Codes Internal Product Code: SUZ-SX4-RW420-2006-2009-WSM 👋 Introduction Market Position Vehicle Segment: Subcompact...
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🏷️ Basic Information
Identification
Make:
Suzuki
Model:
SX4
Chassis Code:
RW420
Model Years Covered:
2006, 2007, 2008, 2009
Codes
Internal Product Code:
SUZ-SX4-RW420-2006-2009-WSM
👋 Introduction
Market Position
Vehicle Segment:
Subcompact Crossover SUV
Target Audience:
Individuals and families seeking a versatile, fuel-efficient, and practical vehicle for urban and light off-road use.
Competitive Analysis
Key Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Nissan Rogue, Mitsubishi Outlander Sport.
Key Features
All-Wheel Drive:
Available i-AWD system provides enhanced traction and stability, a significant differentiator in its class.
Practicality:
Spacious interior for its size, versatile cargo space, and a higher seating position.
Value Proposition:
Often positioned as a more affordable alternative to larger or more premium SUVs.
📋 Manual Details
Coverage Areas
Primary Market:
Global (based on RW420 chassis)
Region Specific Notes:
While the chassis code RW420 is consistent, regional variations in engine options, emissions, and specific equipment may exist. This manual aims for comprehensive coverage of the core RW420 platform.
Page Count
Total Pages:
1500+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
Delivery Method:
Instant Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full engine disassembly, assembly, timing, lubrication, cooling, fuel delivery, emission control systems.
Engine Electrical:
Ignition system, starter motor, charging system, ECU diagnostics, sensor identification and testing.
Transmission:
Manual and Automatic transmission service, overhaul, fluid specifications, torque converter operation.
Drivetrain:
Front-wheel drive (FWD) and All-wheel drive (AWD) systems, driveshafts, differentials, transfer case (if applicable).
Suspension:
Front and rear suspension components, springs, shock absorbers, control arms, steering knuckles, wheel alignment specifications.
Steering:
Power steering system, steering column, steering gear, tie rods, components, and adjustment procedures.
Brakes:
Hydraulic brake system, disc and drum brake components, ABS system, parking brake, bleeding procedures, component replacement.
Body Exterior:
Body panels, doors, hoods, trunk lid, bumpers, glass, seals, hinges, and related hardware.
Body Interior:
Dashboard, seats, door panels, headliner, trim pieces, airbags, seatbelt systems.
Electrical System:
Lighting system, power windows, locks, mirrors, wipers, horn, battery, fuses, relays, wiring diagrams.
HVAC:
Heating, ventilation, and air conditioning system service, component testing, refrigerant handling, and troubleshooting.
Exhaust System:
Exhaust manifold, catalytic converter, muffler, pipes, and hangers.
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel injectors, fuel pressure regulator, EVAP system.
Cooling System:
Radiator, water pump, thermostat, coolant hoses, fan operation, coolant specifications.
Emission Controls:
Emission control devices, EGR system, PCV system, O2 sensors, emissions testing procedures.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement.
Diagnostic Procedures:
Systematic troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnosis.
Removal Installation:
Step-by-step instructions for removing and installing all major and minor vehicle components.
Disassembly Assembly:
Detailed breakdown and reassembly of individual components and sub-assemblies.
Adjustments:
Setting clearances, torque specifications, wheel alignment, clutch adjustment, brake adjustments.
Repair Rebuilding:
Comprehensive guides for repairing and rebuilding worn or damaged components.
Special Tool Usage:
Identification and usage instructions for specialized tools required for specific repair procedures.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission overhauls.
Detail Level:
Step-by-step instructions, detailed illustrations, exploded diagrams, and photos for clarity.
Factory Specifications:
Includes factory-set specifications, allowable limits, and torque values for all critical fasteners and adjustments.
📊 Manual Specifications
File Format
Type:
PDF
Searchability:
Likely searchable text within the PDF, allowing for quick information retrieval.
Print Quality
Printability:
Yes, all pages are printable.
Resolution Notes:
PDF format generally ensures good resolution for printing, assuming original source quality.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
Software Requirements
Reader:
Adobe Reader
Operating Systems:
Windows, Mac OS, Linux OS
⚙️ Engine Specifications
Primary Engine
Engine Code:
M16A (common for this generation)
Engine Type:
Inline 4-cylinder, DOHC, 16-valve
Displacement:
1.6 Liters (1586 cc)
Performance
Horsepower Est:
Approx. 102-110 HP (depending on market and tuning)
Torque Est:
Approx. 145-150 Nm (depending on market and tuning)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU Type:
ECU (Engine Control Unit) with OBD-II diagnostics
Timing System:
Timing Chain
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission
Features
AWD Integration:
Manual and automatic transmissions are available with the i-AWD system.
📐 Dimensions
Exterior
Length Est:
4100-4135 mm
Width Est:
1755-1765 mm
Height Est:
1600-1610 mm
Weights
Curb Weight Est:
1200-1300 kg (depending on drivetrain and trim)
Gross Vehicle Weight Rating Est:
1700-1800 kg
🛡️ Safety Features
Ratings
Crash Test Notes:
Refer to specific regional safety ratings (e.g., Euro NCAP, NHTSA) for detailed crash test performance.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Ebs:
Electronic Brake-force Distribution (EBD)
Esp:
Optional Electronic Stability Program (ESP) on some models/trims.
Passive Features
Airbags:
Front airbags for driver and passenger, optional side airbags and curtain airbags on higher trims.
Seat Belts:
Three-point seat belts with pretensioners for front seats, three-point seat belts for rear seats.
Child Seat Anchors:
ISOFIX/LATCH compatible child seat mounting points.
💡 Technology Features
Infotainment
Head Unit Features:
Base models likely feature a basic AM/FM/CD player with auxiliary input. Higher trims may offer MP3 playback, optional navigation (rare for this era).
Driver Assistance
Cruise Control:
Available on higher trim levels.
Parking Sensors:
Rarely equipped on this generation; may have been an aftermarket option.
Connectivity
Bluetooth:
Not typically factory-equipped on base models of this era; aftermarket integration is common.
Usb Port:
Unlikely to be standard on base models; may be present on higher trims or aftermarket.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 7,500 miles (12,000 km) or 6 months, whichever comes first. Consult manual for specific details.
Air Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed or typically every 30,000 miles (48,000 km).
Spark Plug Replacement:
Iridium spark plugs typically have a lifespan of 60,000-100,000 miles (96,000-160,000 km). Refer to manual for specific type and interval.
Coolant Flush:
Typically every 30,000 miles (48,000 km) or 2-3 years.
Fluid Specifications
Engine Oil Type:
Refer to manual for specific viscosity (e.g., 5W-30, 0W-20 often recommended for modern Suzuki engines). Use API SN/SN PLUS or ILSAC GF-5 compliant oil.
Engine Oil Capacity Est:
Approx. 3.7 - 4.0 Liters (with filter change).
Coolant Type:
Suzuki Super Long Life Coolant (SLLC) or equivalent silicate-free, long-life coolant (typically pink or red).
Transmission Fluid Manual:
API GL-4 SAE 75W-90 Gear Oil.
Transmission Fluid Automatic:
Suzuki ATF 3317 or equivalent Dexron III/Mercon spec fluid (confirm with manual).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
Refer to manual, typically ATF Dexron II/III or a specific Suzuki power steering fluid.
Known Issues
Common Wear Items:
Brake pads and rotors, front suspension components (bushings, ball joints), clutch wear (manual transmission).
Engine Performance Notes:
Can be prone to carbon buildup in older engines if not maintained; regular oil changes are crucial.
AWD System Notes:
Proper maintenance of AWD system fluids and check for leaks. Potential for issues with differentials or transfer case if neglected.
📚 Vehicle History
Brand Heritage
Brand Focus:
Suzuki has a long history of producing reliable and affordable small cars and motorcycles, known for their engineering and value.
Model Evolution
First Generation:
The SX4 (Global) was introduced in 2006 as a joint venture with Fiat, sharing platform elements with the Fiat Sedici. It was designed to be a compact, versatile vehicle with both FWD and AWD options.
Model Codename Notes:
RW420 refers to the five-door hatchback/crossover variant.
Production
Manufacturing Locations:
Primarily manufactured in Japan (Kosai Plant) and Hungary (Magyar Suzuki).
Production Period For This Manual:
2006-2009 (covering the initial launch and early production years of the first generation).
🏆 Awards & Recognition
Recognitions
Segment Awards:
The Suzuki SX4 often received positive reviews for its value, practicality, and available AWD system in compact SUV comparisons of its time. Specific awards vary by region.
Ratings
Fuel Economy Notes:
Generally considered fuel-efficient for its class, with MPG ratings varying by engine, transmission, and FWD/AWD configuration. Consult specific EPA/equivalent ratings.
Certifications
Emissions Compliance:
Meets applicable emissions standards for its model year and region. Manual details specific procedures for emissions system checks and repairs.