battery SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 8B-111 Air Bag System:
• For seat belt pretensioner
a. Cut webbing (1) at tongue plate stopper (3) of
seat belt pretensioner (2) side as shown.
NOTE
Hold seat belt pretensioner (2) vertically in
the same condition as it is installed.
Otherwise, webbing can’t be pulled out.

b. Remove tongue plate (4) and shoulder anchor
(5) from webbing.
c. Tie webbing (1) tightly at 10 cm (3.9 in.) from
cutting edge as shown.
d. Tie seat belt pretensioner (2) with wire
harness (3) to wheel-installed tire (4) as
shown.
Wire harness specifications
Stripped wire harness section 1.25 mm2
(0.0019 in.2) or more (Stripped wire harness
diameter 1.25 mm (0.05 in.) or more)
NOTE
Wind wire harness (3) around at least 3 times.

e. Clear space (5) on ground about 185 cm (6 ft)
in diameter where seat belt pretensioner (2) is
to be activated. Paved, outdoor location where
there is no activity is preferred. If outdoor
location is not available, use space on shop
floor where there is no activity and sufficient
ventilation is provided. Ensure no loose or
flammable object exists within activation area.
f. Place wheel-installed tire (4) with seat belt
pretensioner (2) on ground in Step e.
7) Stretch deployment harness (A) from air bag
(inflator) module or seat belt pretensioner to its full
length 10 m (33 ft).
Special tool
(A): 09932-75031
8) Place 12 volts vehicle battery (1) near the shorted
end of deployment harness (A).
9) Check that area around air bag (inflator) module or
seat belt pretensioner is clear of all people and loose
or flammable objects.
31452I3JA01820037-01
10 cm (3.9 in.)
1
I4RS0A820104-01
1. Webbing
4 3
3
25
I4RS0A820105-01

Downloaded from www.Manualslib.com manuals search engine 8B-113 Air Bag System:
12) Notify all people in immediate area that you intend to
deploy / activate air bag (inflator) module or seat belt
pretensioner.
NOTE
• When air bag (inflator) module deploys and
seat belt pretensioner activates, rapid gas
expansion will create substantial report.
Wear suitable ear protection. Notify all
people in immediate area that you intend
to deploy air bag (inflator) module or
activate seat belt pretensioner and suitable
ear protection should be worn.
• When driver air bag (inflator) module
deploys, driver air bag (inflator) module
may jump about 30 cm (1 ft) vertically. This
is normal reaction to force of rapid gas
expansion inside of drive air bag (inflator)
module.
• After air bag (inflator) module has been
deployed, surface of air bag (inflator) may
contain powdery residue. This powder
consists primarily of cornstarch (used to
lubricate bag (inflator) as it inflates) and by
products of chemical reaction.

WARNING!
• Do not place deployed air bag (inflator)
module and activated seat belt
pretensioner near any flammable objects.
• Do not apply water, oil, etc. to deployed air
bag (inflator) module and activated seat
belt pretensioner.
• Wait for about 30 minutes before touching
any metal surface of air bag (inflater)
module or seat belt pretensioner module.
Disregarding these precautions may cause
fire or personal injury.
Failure to follow procedures may result in fire
or personal injury.

13) Separate two banana plugs (1) on deployment
harness.
14) Connect deployment harness to 12 volts vehicle
battery (2). This will immediately deploy or activate
air bag (inflator) module or seat belt pretensioner.
15) Disconnect deployment harness from 12 volts
vehicle battery (2) and short two deployment
harness leads together by fully seating one banana
plug into the other.16) In the unlikely event that air bag (inflator) module or
seat belt pretensioner did not deploy / activate after
following these procedures, proceed immediately
with Step 22) through 25). If air bag (inflator) module
or seat belt pretensioner did deploy or activate,
proceed with Steps 18) through 21).
17) Put on pair of shop gloves to protect your hands from
possible irritation and heat when handling deployed
air bag (inflator) module or activated seat belt
pretensioner.
18) Disconnect adapter cable (special tool) from air bag
(inflator) module or seat belt pretensioner as soon as
possible. This will prevent adapter cable (special
tool) from damage due to possible contact with hot
air bag (inflator) module or hot seat belt
pretensioner.
19) Check adapter cable as follows.
• For air bag (inflator) module
Be sure to check air bag (inflator) module adapter
cable (special tool) for damage after deployment
and replace it with new adapter cable (special
tool), if it is damaged.
• For seat belt pretensioner
Be sure to check seat belt pretensioner adapter
cable (special tool) for damage after seat belt
pretensioner is activated. Replace it with spare
connector (special tool) or new adapter, if
necessary.
20) Dispose of deployed air bag (inflator) module (1) or
activated seat belt pretensioner (2) through normal
refuse channels after it has cooled for at least 30
minutes and tightly seal air bag (inflator) module (1)
or seat belt pretensioner (2) in strong vinyl bag.
Refer to “Deployed Air Bag (Inflator) Module and
Activated Seat Belt Pretensioner Disposal” for
details.
I2RH01820069-01
I3JA01820116-01

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-114
21) Wash your hands with mild soap and water
afterward.
NOTE
Remaining steps are to be followed in the
unlikely event that air bag (inflator) module
did not deploy or seat belt pretensioner did
not activate.

22) Ensure that deployment harness has been
disconnected from 12 volts vehicle battery and that
its two banana plugs have been shorted together by
fully seating one banana plug into the other.
23) Disconnect deployment harness and adapter cable
from air bag (inflator) module or seat belt
pretensioner.
24) Temporarily store undeployed air bag (inflator)
module referring to “Precautions on Service and
Diagnosis of Air Bag System” for details.
25) Contact your local distributor for further assistance.
Deployment / Activation Inside of Vehicle
When the vehicle will be destroyed, or salvaged for
component parts, deploy the air bag modules and/or
activate seat belt pretensioners installed on vehicle.
NOTE
If equipped with the seat belt pretensioners,
activate both side of seat belt pretensioners
at the same time when using special tool (C).

1) Turn ignition switch to LOCK position, remove key
and put on safety glasses.
2) Remove all loose objects from front seats and
instrument panel.
3) Disconnect air bag (inflator) module or seat belt
pretensioner connector as follows.
• For driver air bag (inflator) module [A]
Remove driver side front pillar lower trim and
disconnect driver air bag (inflator) module
connector (1).
• For passenger air bag (inflator) module [B]
Remove passenger side front pillar lower trim and
disconnect passenger air bag (inflator) module
connector (2).
• For side-air bag (inflator) module [C]
Disconnect side-air bag (inflator) module
connectors (3) under front seat cushion.
• For side curtain-air bag (inflator) module [D]
Remove right-side rear quarter lower trim and
disconnect side curtain-air bag (inflator) module
connector (4).
• For seat belt pretensioners (right and left) [E]
Remove both side (driver and passenger side)
center pillar lower trim and disconnect seat belt
pretensioner connectors (5).4) Confirm that each air bag (inflator) module and/or
seat belt pretensioners is securely mounted.
1
3
4
2
1
21
2
21
2
15 [A]
[B]
[C]
[D]
[E]
I5RW0A820087-02

Downloaded from www.Manualslib.com manuals search engine 8B-115 Air Bag System:
5) Check that there is no open, short or damage in
special tools (deployment harness (A), adapter cable
(B), (C) and (D)). If any faulty condition is found, do
not use it and be sure to use new special tool. And
connect adapter cable (B), (C) or (D) to deployment
harness (A) and lock connectors with lock slider.
Special tool
(A): 09932–75031
(B): 09932–78332
(C): 09932–77310
(D): 09932–76510
6) Short two deployment harness leads together by
fully seating one banana plug into the other.
WARNING!
Deployment harness (A) shall remain shorted
and not be connected to 12 volts vehicle
battery until you are ready to deploy air bag
(inflator) module or activate seat belt
pretensioner.

7) Connect adapter cable (B), (C) or (D) in series with
deployment harness (A) to air bag (inflator) module
or seat belt pretensioner as follows.
• For driver air bag (inflator) module [A]
Connect adapter cable (B) in series with
deployment harness (A) and push adapter cable
(B) connector to air bag (inflator) module
connector till click can be heard.
• For passenger air bag (inflator) module [B]
Connect adapter cable (B) in series with
deployment harness (A) and push adapter cable
(B) connector to air bag (inflator) module
connector till click can be heard.
• For side-air bag (inflator) module [C]
Connect adapter cable (B) in series with
deployment harness (A) and push adapter cable
(B) connector to side bag (inflator) module
connector till click can be heard.
• For side curtain-air bag (inflator) module [D]
Connect adapter cable (C) in series with
deployment harness (A) and push adapter cable
(C) connector to air bag (inflator) module
connector till click can be heard.
• For seat belt pretensioners [E]
Connect adapter cable (D) in series with
deployment harness (A) to seat belt pretensioner
and lock connector with lock part.
[C] [B]
[D]
[E] [A]
12
(D)
(A)1
1
(A)
(B)
1 (C)
(A)
1
(B)
(A)
1
(B)
(A)
I5RW0A820088-02

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-116
8) Route deployment harness (1) out of vehicle.
9) Check that inside of vehicle and area surrounding
vehicle are clear of all people and loose or
flammable objects.
10) Stretch deployment harness (1) to its full length 10 m
(33 ft).
11) Place 12 volts vehicle battery (2) near shorted end of
deployment harness (1).
12) Completely cover windshield area and front door
window openings with drop cloth, a blanket or any
similar item. This reduces possibility of injury due to
possible fragmentation of vehicle’s glass or interior.
13) Notify all people in immediate area that you intend to
deploy air bag (inflator) module or activate seat belt
pretensioners.
NOTE
• When air bag (inflator) module deploys or
seat belt pretensioners activate, rapid gas
expansion will create substantial report.
Wear suitable ear protection. Notify all
people in immediate area that you intend
to deploy air bag (inflator) module or to
activate seat belt pretensioner and suitable
ear protection should be worn.
• After air bag (inflator) module has been
deployed, surface of air bag may contain
powdery residue. This powder consists
primarily of cornstarch (used to lubricate
air bag (inflator) module as it inflates) and
by-products of chemical reaction.

WARNING!
• Do not place deployed air bag (inflator)
module and activated seat belt
pretensioners near any flammable objects.
• Do not apply water, oil, etc. to deployed air
bag (inflator) module and activated seat
belt pretensioners.
• Wait for about 30 minutes before touching
any metal surface of air bag (inflater)
module or seat belt pretensioner modules.
Disregarding these precautions may cause
fire or personal injury.
Failure to follow procedures may result in fire
or personal injury.

14) Separate two banana plugs (1) on deployment
harness (2).
15) Connect deployment harness (2) to 12 volts vehicle
battery (3). This will immediately deploy or activate
air bag (inflator) module or seat belt pretensioners.
16) Disconnect deployment harness (2) from 12 volts
vehicle battery (3) and short two deployment
harness leads together by fully seating one banana
plug into the other.
17) Repeat Steps 3) through 16) to deploy / activate air
bag (inflator) modules and seat belt pretensioners
which has not been deployed / activated, if any.
18) In the unlikely event that air bag (inflator) module
and seat belt pretensioners after following these
procedures, proceed immediately with Step 24)
through 26). If air bag (inflator) module and seat belt
pretensioners did deploy / activate, proceed with
Steps 19) through 23).
19) Carefully remove drop cloth from vehicle and clean
off any fragments or discard it entirely.
20) Put on pair of shop gloves to protect your hands from
possible irritation and heat when handling deployed
air bag (inflator) module and activated seat belt
pretensioners.
10 m (33 ft)
1
2
I5RW0A820089-01
1
3 2
I5RW0A820090-01

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-118
Specifications
Tightening Torque SpecificationsS6RW0D8207001
NOTE
The specified tightening torque is also described in the following.
“Side-Air Bag (Inflator) Module Removal and Installation”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Use of Special ToolsS6RW0D8208001
WARNING!
To avoid deployment when troubleshooting
the air bag system, do not use electrical
equipment such as a battery powered or AC
powered voltmeter, ohmmeter, etc., or any
type of electrical equipment other than that
specified. Do not use a non-powered probe
type tester.
Instructions must be followed carefully,
otherwise personal injury may result.

You should be familiar with the tools listed under the
heading “Special Tool”. You should be able to measure
voltage and resistance. You should be familiar with
proper use of a scan tool such as Air Bag Driver /
Passenger Load Tool, Connector Test Adapter Kit and
the Digital Multimeter.
Special tool
(A): 09932–76010 Connector Test Adapter KitThis must be used whenever a diagnostic procedure
requests checking or probing a terminal.
Using the appropriate adapter in the special tool will
ensure that no damage to the terminal will occur from the
multimeter probe, such as spreading or bending. Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
SDM bolt 9 0.9 6.5)
Driver air bag (inflator) module mounting bolt 9 0.9 6.5)
Passenger air bag (inflator) module attaching
bolt23 2.3 17.0)
Sleeve lock nut 2.5 0.25 2.0)
Side curtain-air bag (inflator) module attaching
bolts11 1.1 8.0)
Forward impact-sensor mounting bolt 9 0.9 6.5)
Side impact-sensor bolt 9 0.9 6.5)
I7RW01822127-01

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-120
Special ToolS6RW0D8208002
09932–75010 09932–75031
Air bag load tool Air bag deployment harness
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / )) / ) / )
09932–75041 09932–76010
Passenger air bag (inflator)
module deployment fixtureConnector test adapter set
) / )This set includes the
following items. 1.
Connector test adapter kit
(09932-75020), 2.
Connector test adapter &
shorting bar release tool
(09932-76020) ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) /
) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / )
09932–76510 09932–77310
Deployment adapter cable Deployment adapter cable
4P
) / ) / ))
09932–78310 09932–78332
Adapter cable Deployment adapter cable
) / ) / ) / ) / ) / ) / ) /
))
09932–78340 SUZUKI scan tool
Deployment adapter cable —
) / )This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12. ) / )

Downloaded from www.Manualslib.com manuals search engine Table of Contents 9-v
Power Door Lock System Symptom
Diagnosis (If Equipped)..................................... 9F-3
Power Door Lock System Operation
Inspection (If Equipped) .................................... 9F-3
Keyless Entry System Symptom Diagnosis (If
Equipped).......................................................... 9F-4
Keyless Entry System Operation Inspection
(If Equipped) ..................................................... 9F-5
Door Lock Function of Keyless Start System
Symptom Diagnosis (If Equipped) .................... 9F-5
Rear End Door Opener System Symptom
Diagnosis (If Equipped)..................................... 9F-5
Rear End Door Opener System Operation
Inspection (If Equipped) .................................... 9F-5
Repair Instructions .............................................. 9F-6
Front Door Lock Assembly Components ............ 9F-6
Front Door Lock Assembly Removal and
Installation ......................................................... 9F-6
Front Door Lock Assembly Inspection ................ 9F-8
Power Door Lock Switch Inspection (If
Equipped).......................................................... 9F-8
Door Key Cylinder Switch Inspection (If
Equipped).......................................................... 9F-8
Power Door Lock Actuator Inspection (If
Equipped).......................................................... 9F-9
Rear Door Lock Assembly Components ........... 9F-10
Rear Door Lock Assembly Removal and
Installation ....................................................... 9F-10
Rear Door Lock Assembly Inspection ............... 9F-10
Rear End Door Lock Assembly Components.... 9F-11
Rear End Door Lock Assembly Removal and
Installation ....................................................... 9F-12
Rear End Door Lock Assembly Inspection........ 9F-12
Rear End Door Opener Switch Inspection (If
Equipped)........................................................ 9F-12
Replacement of Transmitter Battery (Other
than Keyless Start Model) ............................... 9F-13
Programming Transmitter Code for Keyless
Entry System (Other than Keyless Start
Model) ............................................................. 9F-13
Keyless Entry Answer Back Function
Change-over Procedure (If Equipped) ............ 9F-14
Keyless Entry Receiver Removal and
Installation (If Equipped)................................. 9F-14
Keyless Entry Receiver and Its Circuit
Inspection (If Equipped) .................................. 9F-15
Specifications..................................................... 9F-16
Tightening Torque Specifications ...................... 9F-16
Special Tools and Equipment ........................... 9F-16
Recommended Service Material ....................... 9F-16
Seats ......................................................... 9G-1
Diagnostic Information and Procedures ............9G-1
Front Seat Heater Symptom Diagnosis (If
Equipped)..........................................................9G-1
Repair Instructions ..............................................9G-2
Front Seat Components ......................................9G-2
Front Seat Removal and Installation ...................9G-3Front Seat Heater Switch (Driver and
Passenger Side) Inspection (If Equipped)........ 9G-3
Front Seat Heater Wire Inspection (If
Equipped) ......................................................... 9G-3
Rear Seat Components...................................... 9G-4
Rear Seat Removal and Installation................... 9G-4
Specifications ...................................................... 9G-5
Tightening Torque Specifications ....................... 9G-5
Special Tools and Equipment ............................ 9G-5
Recommended Service Material ........................ 9G-5
Interior Trim ............................................. 9H-1
Repair Instructions ..............................................9H-1
Floor Carpet Removal and Installation ................9H-1
Head Lining Removal and Installation.................9H-2
Console Box Components ..................................9H-3
Specifications .......................................................9H-4
Tightening Torque Specifications ........................9H-4
Hood / Fenders / Doors ............................ 9J-1
Repair Instructions .............................................. 9J-1
Hood Removal and Installation ........................... 9J-1
Hood Inspection and Adjustment ........................ 9J-1
Front Fender Components .................................. 9J-2
Front Fender Removal and Installation ............... 9J-2
Front Door Assembly Components ..................... 9J-3
Front Door Assembly Removal and
Installation ......................................................... 9J-3
Rear Door Assembly Components...................... 9J-5
Rear Door Assembly Removal and
Installation ......................................................... 9J-5
Rear End Door Assembly Components .............. 9J-6
Rear End Door Assembly Removal and
Installation ......................................................... 9J-6
Specifications ....................................................... 9J-8
Tightening Torque Specifications ........................ 9J-8
Special Tools and Equipment ............................. 9J-8
Recommended Service Material ......................... 9J-8
Body Structure......................................... 9K-1
Repair Instructions ..............................................9K-1
Front Bumper and Rear Bumper Components .... 9K-1
Cowl Top and Front Lower Crossmember
Components ...................................................... 9K-2
Specifications .......................................................9K-3
Body Dimensions ................................................ 9K-3
Panel Clearance................................................ 9K-10
Tightening Torque Specifications ...................... 9K-10
Paint / Coatings ........................................9L-1
General Description ............................................. 9L-1
Anti-Corrosion Treatment Construction............... 9L-1
Plastic Parts Finishing ......................................... 9L-2
Component Location ........................................... 9L-3
Sealant Application Areas ................................... 9L-3
Under Coating Application Areas ...................... 9L-10
Anti-Corrosion Compound Application Area ..... 9L-12
Exterior Trim ............................................ 9M-1

Downloaded from www.Manualslib.com manuals search engine Wiring Systems: 9A-2
Symbols and MarksS6RW0D9101003
Battery Ground Normal fuse Slow blow fuse
Circuit breaker Coil, Solenoid Heater Bulb
Cigarette lighter Motor Pump Horn Speaker
Buzzer Chime Condenser Thermistor Reed switch
Resistance Variable resistance Transistor
NPN PNP
Photo transistor Diode Zener diode Light emitting diode Photo diode
Piezoelectric element Harness Ring terminal Connector
Connected Not connected
Relay Switch
Normal open Normal closed Open switch Closed switch
I2RH01910910-01IYSQ01910915-01IYSQ01910916-01
IYSQ01910917-01IYSQ01910918-01
IYSQ01910919-01IYSQ01910920-01IYSQ01910921-01IYSQ01910922-01IYSQ01910923-01
IYSQ01910924-01
IYSQ01910925-01IYSQ01910926-01
H
I2RH01910911-01I5JB0B910995-02
IYSQ01910929-01IYSQ01910930-01IYSQ01910931-01IYSQ01910932-01IYSQ01910933-01
IYSQ01910934-01IYSQ01910935-01IYSQ01910936-01IYSQ01910937-01IYSQ01910938-01
IYSQ01910939-01IYSQ01910940-01IYSQ01910941-01IYSQ01910942-01IYSQ01910943-01
IYSQ01910944-01IYSQ01910945-01IYSQ01910946-01IYSQ01910947-01IYSQ01910948-01
I5RW0A910982-01I5RW0A910983-01I5RW0A910984-01I5RW0A910985-01

Downloaded from www.Manualslib.com manuals search engine Wiring Systems: 9A-4
How to Read Connector Layout DiagramS6RW0D9101004
[A-1]: Harness symbol and corresponding harness name
A: Battery harness
B: A/C harness
C: Engine harness
D: Injector harness
E: Main harness, Oil pressure switch wire, Console wire
G: Instrument panel harness
J: Side door wire (Power window)
K: Interior light harness, Rear speaker wire, Roof wire
L: Floor harness, G sensor wire (Fuel pump harness)
M: Rear bumper harness
O: Rear end door harness
Q: Air bag/Pretensioner harness
R: (Fuel pump wire)
[A-2]: Connector Number
[B]: Ground point No.
12
11
[B][B]
Connector code
[A-1] [A-2]L 36
L13L15
R01 L14L12L11L10 L09 L36
R02 L24 L25 L33
L28 L20 L26 (TO O01)
{
L05
L16
L32 L19 L01 (TO G01)
L02 (TO E04)
L03 (TO E05) L42
R05 R04
L07 (TO K02)
I2RH01910901-01