Power steer SUZUKI SX4 2006 1.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-41
P/S Control Module Removal and InstallationS6RW0D6306011
Removal
1) Disconnect negative cable at battery.
2) Remove console box.
3) Disconnect connectors (1) from P/S control module.
4) Remove P/S control module and bracket (2) from
floor panel.
5) Separate P/S control module and bracket.
Installation
Reverse removal procedure.
Torque Sensor and Its Circuit InspectionS6RW0D6306012
1) Check that torque sensor circuit is in good condition
referring to Step 2 to 3 of “DTC C1111 / C1113 /
C1115: Torque Sensor Circuit Failure”. If check result
is not satisfactory, repair torque sensor circuit.
2) Remove console box.
3) With ignition switch turned OFF, connect scan tool to
DLC or connect voltage tester between “E11-18” –
“E11-9” (main sensor) or “E11-10” – “E11-9” (sub
sensor) with connected connector to P/S control
module.
4) Set torque wrench to steering wheel referring to
“Steering Force Check” for checking steering force.
1
2
I5RW0A630027-01
[A]: Main sensor [B]: Sub sensor
E11
1818
E11
10
[A]
[B]
9 9
I7RW01632021-01
I3RM0A630022-01

Downloaded from www.Manualslib.com manuals search engine 6C-42 Power Assisted Steering System:
5) Turn ON ignition switch without engine running and
select scan tool “Data List” mode due to checking
“Sensor (Main) Torque” and “Sensor (Sub) Torque”
displayed on scan tool when steering wheel turned
left and right (if used).
6) Check that characteristic of torque sensor (main and
sub) output voltage or scan tool data and steering
force is as following graph when steering wheel is
turned left and right. If sensor voltage or scan tool
data is out of specified value or does not vary linearly
as the following graph, check EPS control module
and its circuit referring to “Inspection of P/S Control
Module and Its Circuits”.
If they are OK, replace steering gear case assembly.P/S Motor and Its Circuit InspectionS6RW0D6306013
1) Check motor circuit referring to Step 2 to 3 of “DTC
C1141 / C1142 / C1143 / C1145: Motor Circuit
Failure”. If check result is not satisfactory, repair
motor circuit.
2) Disconnect motor connector from steering gear case
assembly with ignition switch turned OFF.
3) Check for resistance between terminals of motor
connector.
If check result is not as specified, check P/S motor
harness for continuity. If it is OK, replace steering
gear case assembly.
Motor circuit resistance
4) Check for insulation between each terminal of motor
connector and body ground.
If check result is not as specified, check P/S motor
harness for insulation. If it is OK, replace steering
gear case assembly.
Motor circuit resistance
5) Hoist vehicle
6) Check that steering wheel turns to left and right
smoothly. If steering wheel does not turn smoothly,
inspect and repair defective steering and suspension
parts.
7) Connect “E12” connector with ignition switch turned
OFF.
[A]: Main sensor
[B]: Sub sensor
[C]: Steering force at left turn
[D]: Steering force at right turn
[E]: Steering wheel at free
[F]: “Sensor (Main) Torque” in “Data List” displayed on scan tool
[G]: “Sensor (Sub) Torque” in “Data List” displayed on scan tool
0
[E][N.m]
MAX
MAX [D] [C]
[E][D] [C]
2.33 - 2.68[V] [F]
[G] [A]
[B]
66
1.65 - 1.9
(1.0 - 1.3)3.0 - 3.4 (3.7 - 4.0)
0 5
2.33 - 2.681.65 - 1.9
(1.0 - 1.3)3.0 - 3.4 (3.7 - 4.0)
0 5
0
[N.m]
MAX
MAX
[V]
6 11.76 11.7611.76 11.766
0 11.5
-12.00 -12.0
11.5
I7RW01632011-02
“E12-1” and “E12-2” (For motor) Approx. 1 Ω
Each terminal and body ground No continuity
[A]: Motor connector “E12” (viewed from harness side)
12
[A]
I6RW0C630012-02

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-43
8) Using ammeter (2), check that P/S motor current (1)
is as following table with idling engine. If check result
is not satisfactory, check P/S control module for
torque sensor signal and P/S motor output referring
to “Inspection of P/S Control Module and Its
Circuits”. If they are OK, replace steering gear case
assembly.
NOTE
When P/S motor is cold condition (that is,
armature coil of P/S motor is not heated),
motor current in the following table can be
measured

Motor current at hoisted vehicle (reference
value)
Specifications
Tightening Torque SpecificationsS6RW0D6307001
NOTE
The specified tightening torque is also described in the following.
“Steering Gear Case Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. ConditionWhen
steering
wheel is left
at straight
position: [A]When steering
wheel is turned
left or right by
turning speed
with 90° /sec:
[B]When
steering
wheel is
kept fully
turned left
or right
until it
stops.: [C]
Motor
currentApprox. 0 A Approx. 0 – 5 AApprox.
45 – 60 A
3. P/S control module
1
32
E12-1
E12-2
[C][A]
[B] [B]
I7RW01632012-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Tie-rod end nut 45 4.5 32.5)
Tie-rod end lock nut 45 4.5 32.5)
Wheel bolt 85 8.5 61.5)
Steering gear case mounting bolt 70 7.0 51.0)
Steering lower shaft assembly upper joint bolt 25 2.5 18.5)
Steering lower shaft assembly lower joint bolt 25 2.5 18.5)
Tie-rod 75 7.5 54.5)
Earth cable bolt 4.0 0.4 2.8)
Rack damper screw Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) and
loosen 180° and then tighten 3.9 N⋅m (0.39
kgf-m, 3.0 lb-ft) and turn it back by 10° or
less by the specified procedure.)
Rotation torque of pinion 2.2 0.22 1.5)
Steering rack damper lock nut 60 6.0 43.5)

Downloaded from www.Manualslib.com manuals search engine 6C-44 Power Assisted Steering System:
Special Tools and Equipment
Recommended Service MaterialS6RW0D6308001
NOTE
Required service material is also described in the following.
“Steering Gear Case Assembly Components”

Special ToolS6RW0D6308002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease E P/No.: 99000–25050)
Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250)
09944–18220 SUZUKI scan tool
Pinion torque checking
socket—
)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 8B-1 Air Bag System:
Restraint
Air Bag System
Precautions
Precautions on Service and Diagnosis of Air
Bag System
S6RW0D8200004
WARNING!
• If the air bag system and another vehicle
system both need repair, SUZUKI
recommends that the air bag system be
repaired first, to help avoid unintended air
bag system activation.
• Do not modify the steering wheel,
dashboard, both front seat or any other on
or around air bag system components.
Modifications can adversely affect air bag
system performance and lead to injury.
• Be sure to follow the procedures described
in this section. Failure to follow
procedures could result in possible air bag
system activation, personal injury or
unneeded air bag system repairs.

• WARNING / CAUTION labels are attached on each
part of air bag system components (SDM, air bag
(inflator) modules and seat belt pretensioners). Be
sure to follow the instructions.
• Many of service procedures require disconnection of
“A/B” fuse and air bag (inflator) module(s) (driver
module, passenger module, side modules and curtain
modules) from initiator circuit to avoid an accidental
deployment.
• Do not apply power to the air bag system unless all
components are connected or a diagnostic flow
requests it, as this will set a DTC.
• The “Air Bag Diagnostic System Check” must be the
starting point of any air bag diagnostics. The “Air Bag
Diagnostic System Check” will verify proper “AIR
BAG” warning light operation and will lead you to the
correct flow to diagnose any air bag malfunctions.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacements.
• Never use air bag component parts from another
vehicle.
• If the vehicle will be exposed to temperatures over 93
°C (200 °F) (for example, during a paint baking
process), remove the air bag system components
beforehand to avoid component damage or
unintended system activation.• When handling the air bag (inflator) modules (driver
module, passenger module, side modules and curtain
modules), seat belt pretensioners (driver module and
passenger module), SDM, forward impact-sensor or
side impact-sensor be careful not to drop it or apply
an impact to it. If an excessive impact was applied
(e.g., SDM, forward impact-sensor are dropped, air
bag (inflator) module is dropped from a height of 90
cm (3 ft) or more, seat belt pretensioner (retractor
assembly) is dropped from a height of 30 cm (1 ft) or
more), never attempt disassembly or repair but
replace it with a new one.
• When using electric welding, be sure to disconnect air
bag (inflator) module connectors (driver module,
passenger module, side modules and curtain
modules) and seat belt pretensioner connectors
(driver module and passenger module) respectively.
• When applying paint around the air bag system
related parts, use care so that the harness or
connector will not be exposed to the paint mist.
• Never expose air bag system component parts
directly to hot air (drying or baking the vehicle after
painting) or flames.
WARNING!
When performing service on or around air
bag system components or air bag wiring,
follow the procedures listed in “Disabling Air
Bag System” to temporarily disable the air
bag system.
Failure to follow procedures could result in
possible air bag system activation, personal
injury or unneeded air bag system repairs.

Precautions on Handling and Storage of Air Bag
System Components
S6RW0D8200002
SDM
WARNING!
Never power up air bag system when SDM is
not rigidly attached to the vehicle. Otherwise,
personal injury may result.

CAUTION!
After detecting one time of such collision as
to meet deployment conditions, SDM must
not be used. Refer to “Air Bag Diagnostic
System Check” when checking SDM.

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-12
Diagnostic Information and Procedures
Air Bag Diagnostic System CheckS6RW0D8204001
WARNING!
To avoid deployment when troubleshooting
the air bag system, do not use electrical test
equipment such as a battery powered or AC
powered voltmeter, ohmmeter, etc., or any
type of electrical equipment other than that
specified in this manual. Do not use a non-
powered probe type tester.
Instructions in this manual must be followed
carefully, otherwise personal injury may
result.

CAUTION!
• The order in which DTCs are diagnosed is
very important. Failure to diagnose the
DTCs in the order specified may result in
extended diagnostic time, incorrect
diagnosis and incorrect parts replacement.
• When measurement of resistance or
voltage is required in the flow, use a tester
along with a correct terminal adapter from
special tool (Connector test adapter kit).
• When a check for proper connection is
required, refer to “Inspection of
Intermittent and Poor Connections”.
• If an open circuit in the air bag wire
harness damaged, connector or terminal is
found, replace the wire harness,
connectors and terminals as an assembly.

The diagnostic procedures used are designed to find
and repair air bag system malfunctions.
To get the best results, it is important to use the
diagnostic flow and follow the sequence in the following.
1) Perform the “Air Bag Diagnostic System Check
Flow”.
(The “Air Bag Diagnostic System Check Flow” must
be the starting point of any air bag system diagnosis.
The “Air Bag Diagnostic System Check Flow” checks
for proper “AIR BAG” warning light operation through
“AIR BAG” warning light and whether air bag DTCs
exist.)
2) Refer to the proper diagnostic flow as directed by the
“Air Bag Diagnostic System Check Flow”.
(The “Air Bag Diagnostic System Check Flow” will
lead you to the correct flow to diagnose any air bag
system malfunctions. Bypassing these procedures
may result in extended diagnostic time, incorrect
diagnosis and incorrect parts replacement.)
3) Repeat the “Air Bag Diagnostic System Check Flow”
after any repair or diagnostic procedures have been
performed.
(Performing the “Air Bag Diagnostic System Check
Flow” after all repair or diagnostic procedures will
ensure that the repair has been made correctly and
that no other malfunctions exist.)
A: Combination meter 6. Side curtain-air bag (inflator) module (8-
channel system)14. “A/B” fuse in junction block assembly
B: Steering wheel 7. Contact coil assembly 15. Air bag harness in main harness
C: Seat 8. Forward impact-sensor 16. Air bag harness in instrument panel harness
1. “AIR BAG” warning light 9. Apron-side-member (driver side) 17. Air bag harness in floor harness
2. Driver air bag (inflator) module 10. Side impact-sensor (8-channel system) 18. Side-air bag harness (8-channel system)
3. Passenger air bag facing cover 11. Side sill inner panel 19. Side curtain-air bag harness (8-channel
system)
4. Passenger air bag (inflator) module 12. SDM 20. Ground for air bag system
5. Side-air bag (inflator) module (8-channel
system)13. Seat belt pretensioner

Downloaded from www.Manualslib.com manuals search engine 8B-37 Air Bag System:
NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs referring to “DTC Clearance”, if any.
• Repeat “Air Bag Diagnostic System Check” to confirm that the trouble has been corrected.

DTC B1034: Driver Air Bag Circuit Shorted to Power SupplyS6RW0D8204021
Wiring Diagram
Refer to “DTC B1031: Driver Air Bag Circuit High Resistance”.
DTC Detecting Condition and Trouble Area4Contact coil circuit check
1) Connect contact coil connector “G347” located under the
steering column.
2) Remove driver air bag (inflator) module from steering
column referring to “Driver Air Bag (Inflator) Module
Removal and Installation”.
3) Check for proper connection to driver air bag (inflator)
module at terminal in connector (2).
4) If OK, release shorting bar in SDM connector inserting
release tool (1) included in special tool (A).
Special tool
(A): 09932–76010
5) Measure resistance between each terminals of driver air
bag (inflator) module connector (2) and body ground.
Is each measured resistance infinity?Substitute a known-
good SDM and recheck.Replace contact coil
assembly referring to
“Contact Coil Cable
Assembly Removal and
Installation in Section
6B”. Step Action Yes No
“L04-4” “L04-3”
1,(A)
(A)
2
I7RW01821021-01
DTC detecting condition Trouble area
Driver air bag circuit has been shorted to power supply for
more than 4 sec.• Driver air bag circuit
•SDM

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-38
DTC Troubleshooting
Step Action Yes No
1Was “Air Bag Diagnostic System Check Flow” performed?Go to Step 2. Go to “Air Bag
Diagnostic System
Check Flow”.
2Driver air bag circuit check
1) With ignition switch turned OFF, disconnect contact coil
connector “G347” located under the steering column.
2) Disconnect SDM connector “L04”.
3) Check for proper connection to contact coil connector at
terminal in “G347” connector.
4) Check for proper connection to SDM connector at
terminal “L04-3” and “L04-4”.
5) If OK, release shorting bar in SDM connector inserting
release tool (1) included in special tool (A).
Special tool
(A): 09932–76010
6) With ignition switch turned ON, measure voltage
between “G347-1” terminal and body ground, and
between “G347-2” terminal and body ground.
Is each measured voltage 0 V?Go to Step 4. Go to Step 3.
3Floor harness circuit check
1) Disconnect “L378” connector located near the driver side
front pillar lower trim.
2) If OK, release shorting bar in SDM connector inserting
release tool (1) included in special tool (A).
Special tool
(A): 09932–76010
3) With ignition switch turned ON, measure voltage
between “L378-1” terminal and body ground, and
between “L378-2” terminal and body ground.
Is each measured voltage 0 V?Repair “GRN/RED”
circuit or “GRN” circuit
for short to power
supply circuit at
instrument panel
harness.Repair “GRN/RED”
circuit or “GRN” circuit
for short to power
supply circuit at floor
harness.
“L04-4” “L04-3”
1,(A)
(A)
I7RW01821022-01
“L04-4” “L04-3”
1,(A)
(A)
I7RW01821022-01

Downloaded from www.Manualslib.com manuals search engine 8B-47 Air Bag System:
NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Clear DTCs referring to “DTC Clearance”, if any.
• Repeat “Air Bag Diagnostic System Check” to confirm that the trouble has been corrected.

2Passenger air bag circuit check
1) Remove passenger air bag (inflator) module from
steering column referring to “Passenger Air Bag (Inflator)
Module Removal and Installation”.
2) Disconnect SDM connector “L04”.
3) Check for proper connection to SDM connector at
terminal “L04-5” and “L04-6”.
4) Check for proper connection to passenger air bag
(inflator) module at terminals in “G259” connector.
5) If OK, release shorting bar in SDM connector inserting
release tool (1) included in special tool (A).
Special tool
(A): 09932–76010
6) With ignition switch turned ON, measure voltage
between “L04-5” terminal and body ground, and
between “L04-6” terminal and body ground.
Is each measured voltage 0 V?Substitute a known-
good SDM and recheck.Go to Step 3.
3Floor harness circuit check
1) Disconnect “L377” connector located near the
passenger side front pillar lower trim.
2) Check for proper connection to floor harness connector
at terminal in “L377” connector.
3) If OK, release shorting bar in SDM connector inserting
release tool (1) included in special tool (A).
Special tool
(A): 09932–76010
4) With ignition switch turned ON, measure voltage
between “L377-1” terminal and body ground, and
between “L377-2” terminal and body ground.
Is each measured voltage 0 V?Repair “BLU/RED”
circuit or “YEL/RED”
circuit for short to power
supply circuit at
instrument panel
harness.Repair “BLU/RED”
circuit or “YEL/RED”
circuit for short to power
supply circuit at floor
harness. Step Action Yes No
1, (A)
“L04-6” “L04-5”(A)
I7RW01822047-01
1, (A)
“L04-6” “L04-5”(A)
I7RW01822047-01

Downloaded from www.Manualslib.com manuals search engine 9-ii Table of Contents
B-9 Keyless Start System Circuit Diagram...... 9A-103
C-1 Combination Meter Circuit Diagram
(Meter) .......................................................... 9A-104
C-2 Combination Meter Circuit Diagram
(Indicator) ...................................................... 9A-105
C-3 Combination Meter Circuit Diagram
(Warning Light) ............................................. 9A-106
D-1 Headlight System Circuit Diagram
(Except Taiwan) ............................................ 9A-108
D-1 Headlight System Circuit Diagram
(Taiwan) ........................................................ 9A-110
D-2 Position, Tail and Licence Plate Light
System Circuit Diagram (Except Taiwan) ..... 9A-111
D-2 Position, Tail and Licence Plate Light
System Circuit Diagram (Taiwan) ................. 9A-112
D-3 Front Fog Light System Circuit Diagram
(Except Taiwan) ............................................ 9A-113
D-3 Front Fog Light System Circuit Diagram
(Taiwan) ........................................................ 9A-114
D-4 Illumination Light System Circuit Diagram
(Except Taiwan) ............................................ 9A-115
D-4 Illumination Light System Circuit Diagram
(Taiwan) ........................................................ 9A-116
D-5 Interior Light System Circuit Diagram
(Except Taiwan) ............................................ 9A-117
D-5 Interior Light System Circuit Diagram
(Taiwan) ........................................................ 9A-118
D-6 Turn Signal and Hazard Warning Light
System Circuit Diagram (Except Taiwan) ..... 9A-119
D-6 Turn Signal and Hazard Warning Light
System Circuit Diagram (Taiwan) ................. 9A-121
D-7 Brake Light System Circuit Diagram ........ 9A-123
D-8 Back-Up Light System Circuit Diagram .... 9A-124
D-9 Headlight Beam Leveling System Circuit
Diagram (Manual Leveling)........................... 9A-125
D-10 Rear Fog Light Circuit Diagram .............. 9A-126
E-1 Heater System Circuit Diagram ................ 9A-127
E-2 Auto A/C System Circuit Diagram ............ 9A-129
F-1 Air-Bag System Circuit Diagram (4ch) ...... 9A-131
F-1 Air-Bag System Circuit Diagram (8ch) ...... 9A-132
F-2 Anti-Lock Brake System Circuit Diagram.. 9A-134
F-4 Power Steering System Circuit Diagram .. 9A-136
G-1 Audio System Circuit Diagram ................. 9A-138
G-2 Multi Information Display / Accessory
Socket System Circuit Diagram .................... 9A-140
G-4 Navigation System Circuit Diagram ......... 9A-141
List of Connector .............................................9A-143
List of Connectors ........................................... 9A-143
C Connector .................................................... 9A-143
E Connector .................................................... 9A-145
G Connector .................................................... 9A-146
J Connector ..................................................... 9A-149
K Connector .................................................... 9A-149
L Connector..................................................... 9A-150
O Connector .................................................... 9A-152
Q Connector (8ch)........................................... 9A-152
R Connector .................................................... 9A-152
S Connector .................................................... 9A-152
Lighting Systems .................................... 9B-1
Precautions ...........................................................9B-1
Precautions for Discharge Headlight Service
(If Equipped)...................................................... 9B-1
Precautions in Diagnosing Troubles
(Headlight Auto Leveling System) ..................... 9B-1
General Description .............................................9B-1
Discharge Headlight Description (If
Equipped) .......................................................... 9B-1
Headlight Auto Leveling System Description
(If Equipped)...................................................... 9B-2
Auto-On Headlight System Description (If
Equipped) .......................................................... 9B-4
Schematic and Routing Diagram ........................9B-5
Headlight Auto Leveling System Wiring
Circuit Diagram ................................................. 9B-5
Component Location ...........................................9B-6
Lighting System Components Location............... 9B-6
Interior Light System Location............................. 9B-7
Diagnostic Information and Procedures ............9B-7
Self-Diagnosis Function for Headlight Auto
Leveling System ................................................ 9B-7
Headlight Leveling Warning Light Check ............ 9B-8
Headlight Symptom Diagnosis (Discharge
Headlight Model) ............................................... 9B-8
Headlight Symptom diagnosis (Other than
Discharge Headlight Model) .............................. 9B-9
Auto-On Headlight System Symptom
Diagnosis (If Equipped) ..................................... 9B-9
DRL System Symptom Diagnosis (If
Equipped) ........................................................ 9B-10
Headlight Auto Leveling System Symptom
Diagnosis (If Equipped) ................................... 9B-10
Headlight Manual Leveling System Symptom
Diagnosis (If Equipped) ................................... 9B-10
Turn Signal and Hazard Warning Light
Symptom Diagnosis ........................................ 9B-11
Clearance, Tail and License Plate Light
Symptom Diagnosis ........................................ 9B-11
Back-Up Light Symptom Diagnosis................... 9B-12
Brake Light Symptom Diagnosis ....................... 9B-12
Front Fog Light Symptom Diagnosis (If
Equipped) ........................................................ 9B-12
Rear Fog Light Symptom Diagnosis (If
Equipped) ........................................................ 9B-12
Illumination Cancel System Symptom
Diagnosis (If Equipped) ................................... 9B-13
Interior Light Symptom Diagnosis ..................... 9B-13
DRL Operation Inspection (If Equipped) ........... 9B-13
Inspection of DRL Controller and Its Circuits
(If Equipped).................................................... 9B-13
Auto-On Headlight Operation Inspection (If
Equipped) ........................................................ 9B-15
Inspection of Auto-On Headlight Controller
and Its Circuit (If Equipped)............................. 9B-15
Inspection of Headlight Leveling Control
Module and Its Circuit (Headlight Auto
Leveling System)............................................. 9B-16
Repair Instructions ............................................9B-18
Headlight Housing Removal and Installation .... 9B-18