Repair instructions SUZUKI SWIFT 2007 2.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Table of Contents 7- i
7
Section 7
CONTENTS
HVAC
Precautions ................................................. 7-1
Precautions............................................................. 7-1
Precautions on HVAC ........................................... 7-1
Heater and Ventilation.... ......................... 7A-1
General Description ............................................. 7A-1
Heater and Ventilation Construction ................... 7A-1
Schematic and Routing Diagram ........................ 7A-2 Heater and Ventilation Wiring Circuit Diagram .... 7A-2
Diagnostic Information and Procedures ............ 7A-3 Heater and Ventilation Symptom Diagnosis........ 7A-3
Repair Instructions .............................................. 7A-4 HVAC Unit Components ..................................... 7A-4
HVAC Unit Removal and Installation .................. 7A-4
Blower Motor Removal and Installation............... 7A-4
Blower Motor Inspection ..................................... 7A-4
Blower Motor Resistor Removal and Installation ......................................................... 7A-5
Blower Motor Resistor Inspection ....................... 7A-5
Blower Motor Relay Inspection ........................... 7A-6
HVAC Control Unit Components ......................... 7A-6
HVAC Control Unit Remova l and Installation ...... 7A-7
Blower Speed Selector In spection ...................... 7A-9
Air Intake Selector Inspec tion ............................. 7A-9
Air Intake Control Actuator Removal and Installation ......................................................... 7A-9
Air Intake Control Actuator Inspection .............. 7A-10
Center Ventilation Louver Removal and Installation ....................................................... 7A-10
Side Ventilation Louver Removal and Installation ....................................................... 7A-11
HVAC Air Filter Removal and Installation (If Equipped)........................................................ 7A-12
HVAC Air Filter Inspection (If Equipped) ........... 7A-12
Air Conditioning System... ...................... 7B-1
Manual Type ............................................................ 7B-1
Precautions........................................................... 7B-1A/C System Caution ............................................ 7B-1
Precautions on Servicing A/C System ................ 7B-1
General Description ............................................. 7B-3 Refrigerant Type Identifica tion ............................ 7B-3
Sub-Cool A/C System Description ...................... 7B-4
A/C Operation Description .................................. 7B-4 Schematic and Routing Diagram ........................7B-5
Major Components of A/C System ...................... 7B-5
A/C System Wiring Diagram ............................... 7B-6
Diagnostic Information and Procedures ............7B-7 A/C System Symptom Diagnosis ........................ 7B-7
Abnormal Noise Sympto m Diagnosis of A/C
System .............................................................. 7B-9
A/C System Performance Inspection ................ 7B-10
A/C System Inspection at ECM ......................... 7B-15
Repair Instructions ........... .................................7B-16
Operation Procedure for Re frigerant Charge .... 7B-16
Condenser Assembly On-Vehicle Inspection .... 7B-21
Condenser Assembly Removal and Installation ....................................................... 7B-21
Receiver/Dryer Removal and Installation .......... 7B-22
HVAC Unit Components ................................... 7B-23
HVAC Unit Removal and In stallation ................ 7B-24
Evaporator Inspection ....................................... 7B-24
Evaporator Thermistor (Evaporator Temperature Sensor) Removal and
Installation ....................................................... 7B-25
Evaporator Thermistor (Evaporator Temperature Sensor) Inspec tion..................... 7B-25
Expansion Valve Removal and Installation ....... 7B-26
Expansion Valve Inspection .............................. 7B-26
A/C Refrigerant Pressure Sensor and Its Circuit Inspection............................................. 7B-26
A/C Refrigerant Pressu re Sensor Removal
and Installation ................................................ 7B-26
A/C Switch Inspection ....................................... 7B-27
Compressor Relay Inspection ........................... 7B-27
Compressor Drive Belt Inspection and Adjustment ...................................................... 7B-27
Compressor Drive Belt Removal and Installation ....................................................... 7B-28
Compressor Assembly Removal and Installation ....................................................... 7B-28
Compressor Assembly Components................. 7B-29
Magnet Clutch Inspection.................................. 7B-29
Magnet Clutch Removal and Installation........... 7B-29
Relief Valve Inspection...................................... 7B-31
Relief Valve Removal and Installation............... 7B-32
Specifications .................... .................................7B-32
Tightening Torque Specifications ...................... 7B-32
Special Tools and Equipmen t ...........................7B-33

Downloaded from www.Manualslib.com manuals search engine 7-ii Table of Contents
Recommended Service Material ....................... 7B-33
Special Tool ...................................................... 7B-33
Automatic Type .................... .................................7B-34
Precautions.........................................................7B-34 A/C System Caution .......................................... 7B-34
Precautions in Diagnosing Trouble ................... 7B-34
Precautions on Servicing A/C System .............. 7B-34
General Description .......... .................................7B-34
Auto A/C System Descript ion ............................ 7B-34
HVAC Control Module Operation Description ... 7B-36
Refrigerant Type Identifica tion .......................... 7B-36
Sub-Cool A/C System Description .................... 7B-36
A/C Operation Description ................................ 7B-36
On-Board Diagnostic System Description ......... 7B-37
Schematic and Routing Diagram ......................7B-37 Major Components of A/C System .................... 7B-37
A/C System Wiring Diagra m ............................. 7B-38
Diagnostic Information and Procedures ..........7B-39 A/C System Symptom Diagnosis ...................... 7B-39
Abnormal Noise Sympto m Diagnosis of A/C
System ............................................................ 7B-42
DTC Check........................................................ 7B-42
DTC Clearance ................................................. 7B-43
DTC Table ......................................................... 7B-44
Fail-Safe Table ................. ................................. 7B-45
Scan Tool Data ................................................. 7B-46
Air Conditioning System Check......................... 7B-47
Visual Inspection ............................................... 7B-49
DTC B1502: Inside Air Temperature Sensor and/or Its Circuit Malfunction .......................... 7B-49
DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction .............. 7B-50
DTC B1504: Sunload Sensor and/or Its Circuit Malfunction ......... ................................. 7B-52
DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit
Malfunction ...................................................... 7B-53
DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit
Malfunction ...................................................... 7B-55
DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction .......................... 7B-57
DTC B1514: Air Flow Co ntrol Actuator and/or
Its Circuit Malfunction ...................................... 7B-60
DTC B1541: HVAC Control Module Back-Up Power Supply Malfunction .............................. 7B-62
DTC B1546: A/C Refrigerant Pressure Malfunction ...................................................... 7B-63
DTC B1551: Serial Communication Circuit Malfunction ...................................................... 7B-63
DTC B1552: Serial Communication Signal Malfunction ...................................................... 7B-64
DTC B1553: CAN Communication Signal Malfunction ...................................................... 7B-65
DTC B1557: Vehicle Speed Sensor Signal Malfunction ...................................................... 7B-65
DTC B1561: Engine Coolant Temperature Sensor Signal Malfunctio n .............................. 7B-66 DTC B1562: Outside Air Temperature Sensor
Signal Malfunction ........................................... 7B-66
DTC B1563: A/C Refr igerant Pressure
Sensor Signal Malfunction .............................. 7B-66
Inspection of HVAC Control Module and Its Circuit .............................................................. 7B-67
A/C System Performance Inspection ................ 7B-70
A/C System Inspection at ECM ......................... 7B-70
Repair Instructions ............ ................................7B-71
Operation Procedure for Refrigerant Charge .... 7B-71
HVAC Unit Components ................................... 7B-72
HVAC Unit Removal and In stallation ................ 7B-73
Temperature Control Actuator Removal and Installation ....................................................... 7B-73
Temperature Control Actuat or Inspection ......... 7B-73
Air Flow Control Actuator Removal and Installation ....................................................... 7B-74
Air Flow Control Actuator Inspection ................. 7B-74
Air Intake Control Actuator Removal and Installation ....................................................... 7B-75
Air Intake Control Actuator Inspection............... 7B-75
Actuator Linkage Inspection .............................. 7B-76
Blower Motor Controller Removal and Installation ....................................................... 7B-76
Blower Motor Controller Inspection ................... 7B-76
HVAC Control Module Removal and Installation ....................................................... 7B-77
Sunload Sensor Removal and Installation ........ 7B-77
Sunload Sensor Inspection ............................... 7B-77
Outside Air Temperature Sensor Removal and Installation ................................................ 7B-77
Outside Air Temperature Sensor Inspection ..... 7B-77
Inside Air Temperature Sensor Removal and Installation ....................................................... 7B-78
Inside Air Temperature Sens or Inspection ........ 7B-78
Condenser Assembly On-Vehicle Inspection .... 7B-78
Condenser Assembly Removal and Installation ....................................................... 7B-78
Receiver/Dryer Removal and Installation .......... 7B-78
Evaporator Inspection ....................................... 7B-78
Evaporator Temperature Sensor Removal and Installation ................................................ 7B-78
Evaporator Temperature Se nsor Inspection ..... 7B-78
Expansion Valve Removal an d Installation ....... 7B-78
Expansion Valve Inspection .............................. 7B-78
A/C Refrigerant Pressure Sensor and Its Circuit Inspection............................................. 7B-78
A/C Refrigerant Pressu re Sensor Removal
and Installation ................................................ 7B-78
Compressor Relay Inspection .
.......................... 7B-78
Compressor Drive Belt Inspection and Adjustment ...................................................... 7B-78
Compressor Drive Belt Removal and Installation ....................................................... 7B-79
Compressor Assembly Removal and Installation ....................................................... 7B-79
Compressor Assembly Components................. 7B-79
Magnet Clutch Removal and Installation........... 7B-79
Magnet Clutch Inspection.................................. 7B-79
Relief Valve Inspection...................................... 7B-79

Downloaded from www.Manualslib.com manuals search engine 7A-4 Heater and Ventilation:
Repair Instructions
HVAC Unit ComponentsS7RS0B7106001
For manual type A/C, refer to “HVAC Unit Components
in Section 7B”.
For automatic type A/C, refer to “HVAC Unit
Components in Section 7B”.
HVAC Unit Removal and InstallationS7RS0B7106002
Removal
1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove cowl top panel from vehicle body referring to “Cowl Top Components in Section 9K”.
4) Drain engine coolant, and then disconnect heater hoses (1) from HVAC unit (2).
5) Remove instrument panel from vehicle body referring to “Instrument Panel Removal and
Installation in Section 9C”.
6) Remove nuts (3).
7) Remove HVAC unit from vehicle body.
Installation
Reverse removal procedure noting the following
instructions.
• Be careful not to catch any cable and wiring harness in inappropriate position.
• Adjust control cables of HVAC control unit referring to “HVAC Control Unit Remo val and Installation”.
• Fill engine coolant to radiator.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Blower Motor Removal and InstallationS7RS0B7106003
Removal
1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Disconnect connector (1) from blower motor (2).
4) Remove blower motor from HVAC unit by removing screws (3).
Installation
Reverse removal procedure noting the following
instruction.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Blower Motor InspectionS7RS0B7106004
• Check for continuity between two terminals as shown. If there is no continuity, replace blower motor.
3
2
3
1
3I4RS0B710004-01
3
1
2
3
3
I4RS0B710005-01
I4RS0A710006-01

Downloaded from www.Manualslib.com manuals search engine 7B-16 Air Conditioning System: Manual Type
Repair Instructions
Operation Procedure for Refrigerant ChargeS7RS0B7216001
WARNING!
• Your eyes should not be exposed to refrigerant (liquid).Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately –
6 °C (21.2 ° F) below freezing point. Should liquid HFC-134a (R-134a) is exposed to your eyes, it may
cause a serious injury. To protect your eyes from such accident, it is necessary to always wear
goggles. Should it occur that HFC-134a (R-134a) is exposed to your eyes, consult a doctor
immediately.
– Do not use your hand to rub the affected eye(s). Instead, use fresh cold water to splash it over the affected area to gradually raise temperature of such area above freezing point.
– Obtain proper treatment as soon as possible from a doctor or eye specialist.
• Should the liquid refrigerant HFC-134a (R-134a) is exposed to your skin, the affected area should be treated in the same manner as when skin is frostbitten or frozen.
• Do not handle refrigerant near any place where welding or steam cleaning is performed.
• Refrigerant should be kept in a cold and dark pl ace. It should never be stored in any place where
temperature is high, e.g. where exposed to direct su n light, close to fire or inside vehicle (including
trunk room).
• Avoid breathing fume produced when HFC-134a (R-134a) is burned. Such fume may be hazardous to your health.

Recovery
When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling
equipment because discharging refrigerant HFC-134a (R-1 34a) into atmosphere would cause adverse effect to
environments.
Start evacuation.Start evacuation.
Stop evacuation.Stop evacuation.
Wait 10 minutesWait 10 minutes
Check A/C system forCheck A/C system for
pressure tighteness.pressure tighteness.
Recharge A/C system withRecharge A/C system withrefrigerant.refrigerant.
Check A/C system for refrigerantCheck A/C system for refrigerantleaks and amount of refrigerantleaks and amount of refrigerantcharged.charged.
Performance testPerformance test
Inspect and repair connections.Inspect and repair connections.
If gauge showsIf gauge showsabnormal conditionsabnormal conditions
Recharge 370 20 g ofRecharge 370 20 g ofrefrigerant.refrigerant.
I5RS0C721005-01

Downloaded from www.Manualslib.com manuals search engine 7B-24 Air Conditioning System: Manual Type
HVAC Unit Removal and InstallationS7RS0B7216006
Removal1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Recover refrigerant from A/C system with recovery and recycling equipment referring to “Recovery” in
“Operation Procedure for Refrigerant Charge”.
4) Remove cowl top panel referring to “Cowl Top Components in Section 9K”.
5) Drain engine coolant, and then disconnect heater hoses (1) from HVAC unit (2).
6) Remove instrument panel from vehicle body referring to “Audio Unit Re moval and Installation in
Section 9C”.
7) Loosen suction hose and liquid pipe bolt (4).
8) Remove nuts (3).
9) Remove HVAC unit from vehicle body. Installation
Reverse removal procedure noting the following
instructions.
• Replenish specified amount of compressor oil to
compressor suction side referring to “Replenishing
Compressor Oil” in “Operation Procedure for
Refrigerant Charge”.
• Install the padding (1) to the installation hole uniformly.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
• Adjust control cables referr ing to “HVAC Control Unit
Removal and Installati on in Section 7A”.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Evaporator InspectionS7RS0B7216007
Check the followings.
• Clog of A/C evaporator fins.If any clogs are found, A/C evaporator fins should be
washed with water, and then should be dried with
compressed air.
• A/C evaporator fins for leakage and breakage. If any defects are found, repair or replace A/C
evaporator.
• A/C evaporator fittings for leakage. If any defects are found, repair or replace A/C
evaporator.
2. Blower upper case 8. Temperature control door assembly 14. Temperature control lever 20. Packing
3. Air intake control actuator 9. Blower motor resistor 15. Airflow control lever21. Filter cover (if equipped)
4. HVAC Air filter (if equipped) 10. Blower lower case 16. Evaporator22. Drain hose
5. Heater unit upper case 11. Blower motor 17. O-ring23. Cable lock clamp
6. Foot duct 12. Heater unit lower case 18. Expansion valve: Do not reuse.
3
2
3
3
1
4
I4RS0B720009-01
1
I4RS0B720010-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-71
ECM Voltage Values Table for Relation of A/C Control
Repair Instructions
Operation Procedure for Refrigerant ChargeS7RS0B7226001
Refer to “Operation Procedure for Refrigerant Charge”.Terminal Wire Color Circuit Normal Value Condition
C37-14 GRY/RED Output of 5 V power
source 4.5 – 5.5 V Ignition switch turned ON
C37-15 BLK Ground for ECM Below 0.3 V Ignition switch turned ON
C37-24 LT GRN Engine coolant temp.
(ETC) sensor signal 3.3 – 3.8 V Ignition switch turned ON, ECT at 0
°C (32 ° F)
1.38 – 1.72 V Ignition switch turned ON, ECT at 50 °C (122 °F)
C37-30 BLK Ground for ECM Below 0.3 V Ignition switch turned ON
C37-55 ORN Ground for sensors Below 0.3 V Ignition switch turned ON
C37-58 BLK/ORN Ground for ECM Below 0.3 V Ignition switch turned ON E23-1 BLK/RED Main power supply 10 – 14 V Ignition switch turned ON
E23-3 RED CAN (high)
communication line
(active high signal)
for BCM and
combination meterRefer to “DTC P2101: Throttle Actu
ator Control Motor Circuit Range /
Performance in Section 1A”
E23-16 BLK/RED Main power supply 10 – 14 V Ignition switch turned ON
E23-18 WHT CAN (low)
communication line
(active low signal) for
BCM and
combination meterRefer to “DTC P2101: Throttle Actu
ator Control Motor Circuit Range /
Performance in Section 1A”
E23-19 BLU/WHT Electric load signal
for blower motor 10 – 14 V
Ignition switch turned ON, blower speed selector
OFF or between 1st and 5th position
0 – 1 V Ignition switch turned ON, blower speed selector
between 6th and HIGH position
E23-46 LT GRN Radiator fan relay
No.1 output 10 – 14 V
Ignition switch turned ON, engine coolant temp.:
below 95
°C (203 ° F), or A/C refrigerant pressure:
below 600 kPa (87 psi).
0 – 2 V Ignition switch turned ON, engine coolant temp.:
97.5
°C (207.5 °F) or higher, or A/C refrigerant
pressure: 1100 kPa (159.5 psi) or higher.
E23-47 GRY A/C compressor relay
output 10 – 14 V Engine running, A/C request signal high input
0 – 1 V Engine running, A/C request signal low input
E23-48 GRN Radiator fan relay
No.2 and No.3 output 10 – 14 V
Ignition switch turned ON, engine coolant temp.:
below 100
°C (212 °F), or A/C refrigerant
pressure: below 1200 kPa (174 psi).
0 – 2 V Ignition switch turned ON, engine coolant temp.:
102.5
°C (216.5 ° F) or higher, or A/C refrigerant
pressure: 1500 kPa (217.5 psi) or higher.
E23-55 RED A/C refrigerant
pressure sensor
signal 1.46 – 1.71 V
Engine running, A/C refrigerant pressure at 0.8
MPa (8.0 kg/cm
2) (A/C refrigerant pressure
measured by manifold gauge)
2.55 – 2.80 V Engine running, A/C refrigerant pressure at 1.6
MPa (16.0 kg/cm
2) (A/C refrigerant pressure
measured by manifold gauge)
E23-60 BRN/WHT Main power supply
relay output 10 – 14 V Ignition switch turned OFF
0 – 2 V Ignition switch turned ON

Downloaded from www.Manualslib.com manuals search engine Table of Contents 8- i
8
Section 8
CONTENTS
Restraint
Precautions ................................................. 8-1
Precautions............................................................. 8-1
Precautions on Restraint ....................................... 8-1
Seat Belts .......... ............................... ........ 8A-1
Precautions........................................................... 8A-1
Precautions on Service a nd Diagnosis of Seat
Belt .................................................................... 8A-1
General Description ............................................. 8A-1 Seat Belt Construction ........................................ 8A-1
Diagnostic Information and Procedures ............ 8A-2 Repair and Inspection Required after Accident ............................................................ 8A-2
Repair Instructions .............................................. 8A-3 Front Seat Belt Components ............................... 8A-3
Front Seat Belt Removal and Installation ............ 8A-4
Front Seat Belt Inspection ................................... 8A-4
Rear Seat Belt Components ............................... 8A-6
Rear Seat Belt Removal and Installation ............ 8A-7
Rear Seat Belt Inspection ................................... 8A-7
Specifications ....................................................... 8A-7
Tightening Torque Specifications ........................ 8A-7
Air Bag System ............... ......................... 8B-1
Precautions........................................................... 8B-1
Precautions on Service and Diagnosis of Air Bag System....................................................... 8B-1
Precautions on Handling and Storage of Air Bag System Components . ................................ 8B-2
Precautions on Disposal of Air Bag and Seat
Belt Pretensioner .............................................. 8B-5
General Description ............................................. 8B-5 Air Bag System Construction .............................. 8B-5
Air Bag System Input / Output Table .................. 8B-6
Schematic and Routing Diagram ........................ 8B-7 Air Bag System Wiring Circuit Diagram .............. 8B-7
Component Locatio n ........................................... 8B-9
Air Bag System Components, Wiring and Connectors Location ......................................... 8B-9
Diagnostic Information and Procedures .......... 8B-10 Air Bag Diagnostic System Check .................... 8B-10
Air Bag Diagnostic System Check Flow ............ 8B-10
DTC Table ......................................................... 8B-11
DTC Check ....................................................... 8B-12 DTC Clearance ................................................. 8B-12
Scan Tool Data ................................................. 8B-13
“AIR BAG” Warning Right Comes ON Steady .. 8B-13
“AIR BAG” Warning Right Does Not Come
ON ................................................................... 8B-15
“AIR BAG” Warning Right Flashes .................... 8B-16
DTC B1013: SDM fault...................................... 8B-17
DTC B1014: “AIR BAG” Warning Right Circuit Failure ............................................................. 8B-17
DTC B1016: Power Source Voltage High ......... 8B-18
DTC B1017: Power Source Voltage Low .......... 8B-20
DTC B1021: Front Air Bag Module Deployed ... 8B-22
DTC B1024 / B1025: Side-Air Bag (Driver / Passenger) Deployed...................................... 8B-22
DTC B1026: Pretensioner Activated ................. 8B-23
DTC B1027: Reusable Number Exceeded ....... 8B-24
DTC B1031: Driver Air Bag Initiator Circuit
Resistance High .............................................. 8B-24
DTC B1032: Driver Air Bag Initiator Circuit
Resistance Low ............................................... 8B-29
DTC B1033: Driver Air Bag Initiator Circuit
Short to Ground............................................... 8B-34
DTC B1034: Driver Air Bag Initiator Circuit
Short to Power Circuit .... ................................. 8B-39
DTC B1041: Passenger Air Bag Initiator Circuit Resistance High ................................... 8B-44
DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low.................................... 8B-47
DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground ................................... 8B-50
DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circ uit .......................... 8B-53
DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance
High ................................................................. 8B-56
DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circu it Resistance Low .. 8B-58
DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground .. 8B-60
DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power
Circuit .............................................................. 8B-62
DTC B1061 / B1065: Driver / Passenger Side- Air Bag Initiator Circuit Resistance High ......... 8B-64

Downloaded from www.Manualslib.com manuals search engine 8-ii Table of Contents
DTC B1062 / B1066: Driver / Passenger Side-Air Bag Initiator Circuit Resistance Low .......... 8B-67
DTC B1063 / B1067: Driver / Passenger Side- Air Bag Initiator Circuit S hort to Ground .......... 8B-70
DTC B1064 / B1068: Driver / Passenger Side- Air Bag Initiator Circu it Short to Power
Circuit .............................................................. 8B-73
DTC B1071: Forward-Sensor Performance Problem ........................................................... 8B-76
DTC B1072: Forward-Sensor Communication Error ................................................................ 8B-76
DTC B1073: Forward-Sensor Circuit Short to Ground ............................................................ 8B-76
DTC B1074: Forward-Sensor Circuit Short to Power Circuit or Open ..................................... 8B-78
DTC B1081 / B1091: Driver / Passenger Side- Sensor Performance Probl em ......................... 8B-80
DTC B1082 / B1092: Driver / Passenger Side- Sensor Communication Erro r .......................... 8B-80
DTC B1083 / B1093: Driver / Passenger Side- Sensor Circuit Short to Ground ....................... 8B-80
DTC B1084 / B1094: Driver / Passenger Side- Sensor Circuit Short to Power Circuit or
Open ............................................................... 8B-81
DTC B1085 / B1095: Wrong Side-Sensor (Driver Side / Passenger) ID ........................... 8B-83
DTC B1361 / B1365: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance
High ................................................................. 8B-84
DTC B1362 / B1366: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance
Low ................................................................. 8B-86
DTC B1363 / B1367: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to
Ground ............................................................ 8B-88
DTC B1364 / B1368: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to
Power Circuit ................................................... 8B-90
Contact Coil Cable and Its Circuit Check .......... 8B-93 Inspection of Intermittent and Poor
Connections .................................................... 8B-95
Repair and Inspection Required after Accident .......................................................... 8B-96
Repair Instructions ............ ................................8B-98
Disabling Air Bag System.................................. 8B-98
Enabling Air Bag System .................................. 8B-99
SDM Removal and Installation ........................ 8B-100
SDM Inspection ............................................... 8B-101
Driver Air Bag (Inflato r) Module Removal and
Installation ..................................................... 8B-101
Driver Air Bag (Inflator) Module Inspection ..... 8B-103
Passenger Air Bag (Inflator) Module Removal and Installation .............................................. 8B-103
Passenger Air Bag (I nflator) Module
Inspection ...................................................... 8B-105
Side-Air Bag (Inflator) Module Removal and
Installation ..................................................... 8B-105
Side-Air Bag (Inflator) Inspection .................... 8B-107
Side Curtain-Air Bag (Inflator) Module Removal and Installation ............................... 8B-107
Side Curtain-Air Bag (Inflator) Module Inspection ...................................................... 8B-109
Forward-Sensor Removal and Installation ...... 8B-109
Forward-Sensor In spection ............................. 8B-110
Side-Sensor Removal and Installation ............ 8B-110
Side-Sensor Inspection ................................... 8B-111
Passenger Air Bag (Inflator) Module Repair
Harness Installation....................................... 8B-112
Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal ................................... 8B-113
Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal.... 8B-124
Specifications .................. .................................8B-125
Tightening Torque Specifications .................... 8B-125
Special Tools and Equipmen t .........................8B-125
Use of Special Tools ....................................... 8B-125
Recommended Service Material ..................... 8B-127
Special Tool .................................................... 8B-127

Downloaded from www.Manualslib.com manuals search engine 8A-3 Seat Belts:
Repair Instructions
Front Seat Belt ComponentsS7RS0B8106001
WARNING!
• Never attempt to disassemble or repair the seat belt pretensioner (retractor assembly). If any abnormality is found, be sure to replace it with new one as an assembly.
• Be sure to read “Precautions on Service and Diagnosis of Seat Belt” before starting to work and observe every precaution during work. Neglecting them may result in personal injury or
unactivation of the seat belt pretensioner when necessary.

(a)
(a)
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1
2
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5
a)
b)
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7
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810
9
7 2 11
9
1012
I6RS0C810001-01
1. Upper anchor
6. Shoulder adjuster mounting bolt
: Tighten upper bolt first, then tighten lower bolt. 11. Spring washer
2. Lower anchor 7. Anchor bolt
: Tighten upper bolt first, then tighten lower bolt. 12. Wave washer
3. Retractor assembly 8. Cushion : 43 N⋅m (4.3 kgf-m, 31.5 lb-ft)
4. Buckle 9. Spacer : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
5. Yellow connector (for seat belt pretensioner) 10. Washer

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-1
Restraint
Air Bag System
Precautions
Precautions on Service and Diagnosis of Air
Bag System
S7RS0B8200001
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/BAG” fuse and air bag (inflator) module(s) (driver,
passenger, side of both si des and curtain of both
sides) 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 S ystem Check” must be the
starting point of any air bag diagnostics. The “Air Bag
Diagnostic System Check” will verify proper “AIR
BAG” warning right operatio n 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, passenger, side of both si des and curtain of both
sides), seat belt pretensio ners (driver and passenger),
SDM, forward-sensor or side-sensor, be careful not to
drop it or apply an impact to it. If an excessive impact
was applied (e.g., SDM, forward-sensor and side-
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, passenger,
side of both sides and curtain of both sides) and seat
belt pretensioner connectors (driver and passenger)
respectively.
• When applying paint around the air bag system related parts, use care so that the harness or
connector will not be expo sed 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.