ECU SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 8B-103 Air Bag System:
3) Connect side curtain-air bag (inflator) module
connector (1) securely as shown in figure.
a) Connect connector.
b) Lock connector with lock button (2).
4) Install head lining referring to “Head Lining Removal
and Installation in Section 9H”.
5) Enable air bag system. Refer to “Enabling Air Bag
System”.
Side Curtain-Air Bag (Inflator) Module
Inspection
S6RW0D8206023
WARNING!
• Never measure resistance of side curtain-
air bag (inflator) module or disassemble it.
Otherwise personal injury may result.
• Never attempt to disassemble or repair the
side curtain-air bag (inflator) module. 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 Air Bag System”,
“Precautions on Handling and Storage of
Air Bag System Components” and
“Precautions on Disposal of Air Bag and
Seat Belt Pretensioner” before starting to
work and observe every precaution during
work. Neglecting them may result in
personal injury or undeployment of the air
bag when necessary.

CAUTION!
If air bag (inflator) module was dropped from
a height of 90 cm (3 ft) or more, it should be
replaced.

Check air bag (inflator) module appearance visually for
the following symptoms and if any one of them is found,
replace with a new one.
• Air bag has deployed.
• Inflator case being damaged or having been exposed
to strong impact (dropped).
Forward Impact-Sensor Removal and
Installation
S6RW0D8206013
WARNING!
During service procedures, be very careful
when handling a sensor.
• Never strike or jar a sensor.
• A sensor and mounting bracket bolts must
be carefully torqued to assure proper
operation. Under loose connection, it
could cause improper operation of the air
bag system.

1
2
b)
a)
I5RW0A820078-01
I5JB0A820089-02

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-106
Passenger Air Bag (Inflator) Module Repair
Harness Installation
S6RW0D8206017
Replace passenger air bag (inflator) module repair
harness (2) according to the following procedure when
the harness (9) connected with passenger air bag
(inflator) module of the air bag harness included in
instrument panel harness (7) and passenger air bag
(inflator) module connector (1) is damaged.
1) Disable air bag system. Refer to “Disabling Air Bag
System”.
2) Remove passenger air bag (inflator) module
referring to “Passenger Air Bag (Inflator) Module
Removal and Installation” if it has installed.
3) Disconnect floor harness joint (yellow) connector (1)
with passenger air bag (inflator) module of air bag
harness included in instrument panel harness from
floor harness located near the glove box.4) Cut off passenger air bag (inflator) module connector
(1) and floor harness joint (yellow) connector (2) with
passenger air bag (inflator) module of air bag
harness included in instrument panel harness as
shown, and then fasten it to instrument panel
harness with vinyl tape for avoiding interference with
other parts.
5) Fix passenger air bag (inflator) module repair
harness (1) to instrument panel harness (2).
CAUTION!
To avoid interference with other parts, fasten
the repair harness to instrument panel
harness with a clamp (3) as shown in figure.

6) Connect passenger air bag (inflator) module repair
harness connector (4) to floor harness securely till
click is heard.
3. Driver air bag (inflator) module
4. Passenger air bag (inflator) module
5. Floor harness
6. Vinyl tape
7. Instrument panel harness
8. Floor harness joint (yellow) connector with passenger air bag (inflator)
module of air bag harness included in instrument panel harness
10. Floor harness joint (yellow) connector of passenger air bag (inflator)
module repair harness
5
2
4
4
7
7
1
3
3
5
66
8
10
9
I5RW0C820001-01
1
I5RW0C820002-01
[A]: Viewed from dash panel side
1
2
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3
4 213
[A]
I5RW0C820004-01

Downloaded from www.Manualslib.com manuals search engine 8B-109 Air Bag System:
WARNING!
• For handling and storage of seat belt
pretensioner, select place where ambient
temperature is below 65 °C (150 °F),
without high humidity and away from
electric noise.
• Never carry seat belt pretensioner by
webbing.
• When placing seat belt pretensioner on
workbench or other surface, be sure to lay
it with its exhaust hole (1) side facing up. It
is also prohibited to put something on seat
belt pretensioner.
Otherwise, personal injury may result.

6) Set air bag (inflator) module or seat belt pretensioner
as follows.
• For driver air bag (inflator) module
a. Clear space (3) on ground about 185 cm (6 ft)
in diameter where driver air bag (inflator)
module (1) is set for deployment. 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 deployment area.
b. Place driver air bag (inflator) module (1) with
its vinyl trim cover facing up (2) on ground in
St ep a .• For passenger air bag (inflator) module
a. Clear space (3) on ground about 185 cm (6 ft)
in diameter where passenger air bag (inflator)
module (1) is set for deployment. 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 deployment area.
b. Place deployment fixture (A) on ground in
Step a.
Special tool
(A): 09932–75041
c. Fill plastic reservoir in deployment fixture (A)
with water or sand. This is necessary to
provide sufficient stabilization of fixture during
deployment.
d. Attach passenger air bag (inflator) module (1)
in deployment fixture (A) securely using M8
bolt (2).
CAUTION!
Be sure to use M8 size and 7T strength bolt
for fixing passenger air bag (inflator) module
(1) to deployment fixture (A).

1
I4JA01822118-01
I3JA01820036-01
31
2
(A)
I5RW0A820085-02

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-112
10) Connect adapter cable (B) as follows.
Special tool
(B): 09932–76510
• For driver air bag (inflator) module [A]:
Check that driver air bag (inflator) module is
placed with its vinyl trim cover facing up, and
connect adapter cable (B) to driver air bag
(inflator) module.
• For passenger air bag (inflator) module [B]:
Check that passenger air bag (inflator) module is
firmly and properly secured on deployment fixture
(special tool), and connect adapter cable (B) to
passenger air bag (inflator) module.
NOTE
Wind wire harness (5) around at least 2 times.

• For side-air bag (inflator) module [C]:
Verify that side-air bag (inflator) module is firmly
and properly on deployment fixture (special tool),
and connect adapter cable (B) to side-air bag
(inflator) module.
• For side curtain-air bag (inflator) module [D]:
a. Connect adapter cable (B) to side curtain-air
bag (inflator) module.
b. Pile 2 tires (2) and wheel-installed tire (3) on
top of tire with side curtain-air bag (inflator)
(4), and tie them with wire harness (5) 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 (5) around at least 2 times.

• For seat belt pretensioner [E]:
a. Connect adapter cable (B) to seat belt
pretensioner.
b. Pile 2 wheel-installed tires (3) on top of tire
with seat belt pretensioner (6), and tie them
with wire harness (5) 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 (5) around at least 2 times.

c. Drape blanket (7) over those tires.
11) Connect adapter cable (B) to deployment harness
(A) connector and lock connectors with lock lever.
[A]
10 m (33 ft)
(A)
(B)
1
10 m (33 ft)
(A)
(B)1
5
3
2
4
(A)
[B]
[C]
[D]
[E]
7
3
6
5 (A)(B)
1
10 m (33 ft)
10 m (33 ft) (A)
(B)
1
1
10 m (33 ft)
I5JB0A820102-01

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 9-iv Table of Contents
Front Speaker Removal and Installation (If
Equipped) ........................................................9C-19
Rear Speaker Removal and Installation (If
Equipped) ........................................................9C-19
GPS Antenna Removal and Installation (If
Equipped) ........................................................9C-20
Horn Removal and Installation ..........................9C-20
Horn Inspection .................................................9C-20
Horn Relay Inspection .......................................9C-20
Antenna Base Removal and Installation ...........9C-21
Remote Audio Control Switch Removal and
Installation (If Equipped) .................................9C-21
Remote Audio Control Switch Inspection (If
Equipped) ........................................................9C-22
Vehicle Speed Signal Inspection (For Audio
Unit) (If Equipped) ...........................................9C-22
Specifications .....................................................9C-22
Tightening Torque Specifications ......................9C-22
Wipers / Washers .................................... 9D-1
Diagnostic Information and Procedures ............ 9D-1
Front Wiper and Washer Symptom Diagnosis ....9D-1
Rear Wiper and Washer Symptom Diagnosis..... 9D-1
Repair Instructions ..............................................9D-2
Wipers and Washers Components .....................9D-2
Washer Tank and Washer Pump Removal
and Installation ..................................................9D-3
Washer Pump Inspection ....................................9D-3
Windshield Wiper Removal and Installation ........9D-3
Windshield Wiper Motor Inspection.....................9D-4
Rear Wiper Removal and Installation.................. 9D-6
Rear Wiper Motor Inspection ..............................9D-7
Windshield Wiper and Washer Switch
Removal and Installation ................................... 9D-8
Windshield Wiper and Washer Switch
Inspection .......................................................... 9D-8
Rear Wiper and Washer Switch Removal and
Installation .......................................................9D-10
Rear Wiper and Washer Switch Inspection.......9D-10
Rear Wiper Relay Removal and Installation .....9D-10
Rear Wiper Relay Inspection ............................9D-10
Specifications .....................................................9D-11
Tightening Torque Specifications ......................9D-11
Glass / Windows / Mirrors .......................9E-1
Precautions........................................................... 9E-1
Precautions for Power Window Service
(Pinching Prevention Function Model) .............. 9E-1
General Description ............................................. 9E-1
Rear End Door Window Defogger System
Description ........................................................ 9E-1
Schematic and Routing Diagram ........................ 9E-2
Power Window Circuit Diagram (Pinching
Prevention Function Model) .............................. 9E-2
Diagnostic Information and Procedures ............ 9E-3
Rear End door Window Defogger Symptom
Diagnosis .......................................................... 9E-3
Power Window Control System Symptom
Diagnosis .......................................................... 9E-3Inspection of Pinching Prevention Function
(Pinching Prevention Function Model) .............. 9E-4
Power Door Mirror Control System Symptom
Diagnosis .......................................................... 9E-4
Door Mirror Heater Symptom Diagnosis (If
Equipped) .......................................................... 9E-5
Repair Instructions .............................................. 9E-5
Windshield Components ..................................... 9E-5
Windshield Removal and Installation .................. 9E-6
Front Pillar Window Components...................... 9E-10
Front Pillar Window Removal and Installation... 9E-10
Rear Quarter Window Components .................. 9E-11
Rear Quarter Window Removal and
Installation ....................................................... 9E-11
Rear End Door Window Components ............... 9E-12
Rear End Door Glass Removal and
Installation ....................................................... 9E-12
Front Door Window Components ...................... 9E-13
Front Door Glass Removal and Installation ...... 9E-14
Front Door Window Regulator Removal and
Installation ....................................................... 9E-15
Front Door Window Regulator Inspection ......... 9E-15
Rear Door Window Components ...................... 9E-16
Rear Door Glass Removal and Installation ....... 9E-16
Rear Door Window Regulator Removal and
Installation ....................................................... 9E-18
Rear Door Window Regulator Inspection .......... 9E-18
Rear End Door Window Defogger Switch
Inspection ........................................................ 9E-18
Rear End Door Window Defogger Relay
Inspection ........................................................ 9E-19
Rear End Door Window Defogger Wire
Inspection ........................................................ 9E-19
Rear End Door Window Defogger Wire
Repair.............................................................. 9E-20
Power Window Main Switch Inspection ............ 9E-20
Power Window Sub Switch Inspection .............. 9E-22
Pulse Sensor and Its Circuit Inspection
(Pinching Prevention Function Model) ............ 9E-23
Power Window Main Switch Initialization
(Pinching Prevention Function Model) ............ 9E-24
Door Mirror Components................................... 9E-24
Door Mirror Removal and Installation................ 9E-25
Power Door Mirror Switch Inspection ................ 9E-25
Power Door Mirror Actuator Inspection ............. 9E-25
Door Mirror Heater Inspection (If Equipped) ..... 9E-26
Door Mirror Heater Switch Inspection (If
Equipped) ........................................................ 9E-26
Special Tools and Equipment ........................... 9E-26
Recommended Service Material ....................... 9E-26
Security and Locks...................................9F-1
General Description ............................................. 9F-1
Key Coding Construction .................................... 9F-1
Rear End Door Opener System Description ....... 9F-1
Component Location ........................................... 9F-2
Power Door Lock and Keyless Entry System
Component Location (If Equipped) ................... 9F-2
Diagnostic Information and Procedures ............ 9F-3

Downloaded from www.Manualslib.com manuals search engine 9A-23 Wiring Systems:
G: Instrument panel harness, Instrument panel antenna wire / S: Contact coil (LHD)
G: Instrument panel harness
G146G141
G309
G34
G253
G266G255
G144
G241
G17G311
G153 G63
G248
G310
G61
G259G243
G267
G355
(TO L409)
1311
14
G16
G341
(TO L374)
G354
(TO K154)
G342
(TO L375)
G348
(TO K153)
G352
(TO L402)
G254
G04
G271
G272
G307
12
G211
G343
(TO L376)G349
(TO L399)
G344
(TO L377)G147G345
(TO L378)
G334
(TO E382)
G333
(TO E381)
G20
S121S61
G32 G155 G154 G64
G62G214
G65 G273
G151
G152 G150
G05 G06
G308
G306 G265
G35
G251
G347
S172
G346
S171
G S S
Instrument panel
antenna wire
I6RW0D910902-01
No./Color Connective position No./Color Connective position
G04/N or BLU BCM G248/BLU Audio (Navigation)
G05/N (Taiwan) BCM G251/N ACC socket
G06/BLK
(Taiwan)BCM G253/GRN Multi information display
G16/N (IF
EQPD)KLS ECMG254/N (IF
EQPD)Keyless receiver
G17/BLK ICMG255/BLK
(Auto A/C)Diode #1
G20/GRN
(Auto A/C)Auto A/C unit G259/ORN Passenger inflator
G32/N EVAP thermistorG265/N
(Taiwan)Security option
G34/N (Auto A/
C)Room temperature sensor G271/N J/B
G35/N (Auto A/
C)Sunlight sensor G272/N J/B
G61/N Heater fan motor G273/N J/B
G62/BLK Fresh/Recircle actuator G306/N J/C
G63/BLK (Auto
A/C)Mode selecting actuatorG307/N (IF
EQPD)J/C
G64/BLK (Auto
A/C)Temperature control actuator G308/N J/C
G65/N Fan driver G309/GRY J/C
G141/BLK COMB switchG310/N (Auto
A/C)J/C
G144/N COMB switch G311/GRY J/C
G146/N Main switch (key) G333/GRY or N Main harness (To E381)
G147/N IG switch G334/BRN Main harness (To E382)

Downloaded from www.Manualslib.com manuals search engine Wiring Systems: 9A-84
38 39
"D-5""D-1"
BLK/BLU
3 AA BBG042
BLU/YEL
BLU/YEL
J/C
G307
1G265
J/C
G308
G146
1 4
Main switch
(Key switch)
DOME
G2715 15A
37ACC
G2725 15A
23
WHT/REDWHT/BLK
WHT/RED
YEL/RED
YEL/RED
YEL/BLK
YEL/BLK
1E37
2
Ambient
temperature
sensor
"B-5" Switch
840
37362726
RED/BLUBRN/YELLT GRN/BLKBRNGRY/WHTGRY/RED
Parking
brake
switchSeat
belt
switch
"C-3"
RBBY
97
RED/BLK
BB
GR
Oil
pressure
switchBrake
fluid
level
switch
Security
option
GRB
G05G0617
PNK
G04
24
GRY/RED
9G0521
LgBBGWGR
Main switch
"B-5"
Sub switch
"B-5"
Front door
switch
"D-3"Switch
Front door
switch
"D-5"
BRBR
BLK/RED
R
12
RED
BLK/BLUBLK/RED
BLK/REDBLK/REDBLK/RED
J/B
FF
Rear door
switch
"D-5"
BR
DD
J/CJ/C
L346
L347
BCM
GRY
E381
G33334
G343
L3761511
I6RW0C910956-01

Downloaded from www.Manualslib.com manuals search engine 9B-19 Lighting Systems:
Headlight Bulb Replacement (Discharge
Headlight Model)
S6RW0D9206002
WARNING!
• To avoid danger of being burned, don’t
touch when the bulb is hot.
• Don’t touch glass surface of bulb, to avoid
deteriorate as the case may be unclear
when bulb light on at dirty condition.
• Be sure to read “Precautions for Discharge
Headlight Service (If Equipped)” before
starting to service work.

1) Check to ensure that lighting switch is at OFF
position.
2) Disconnect negative (–) cable at battery.
3) Remove headlight housing referring to “Headlight
Housing Removal and Installation”.
4) Remove cover (1) from headlight housing by turning
it counterclockwise.
5) Remove igniter (2) from discharge headlight bulb by
turning it counterclockwise.
6) Replace bulb (1) from headlight housing.
7) Install igniter to discharge headlight bulb by turning it
clockwise.
8) Install cover to headlight housing by turning it
clockwise.
9) Install headlight housing to vehicle body referring to
“Headlight Housing Removal and Installation”.
10) Connect negative (–) cable at battery.
11) After installation, be sure to inspect and adjust
aiming referring to “Headlight Aiming Adjustment
with Screen”.
Ballast Removal and Installation (Discharge
Headlight Model)
S6RW0D9206023
WARNING!
Be sure to read “Precautions for Discharge
Headlight Service (If Equipped)” carefully
before working. Neglecting them may result
in personal injury.

Removal
1) Check to ensure that lighting switch is at OFF
position.
2) Disconnect negative (–) cable at battery.
3) Remove headlight housing referring to “Headlight
Housing Removal and Installation”.
4) Remove ballast (1) from headlight housing (2).
5) Disconnect connector (3) from ballast.
Installation
Reverse removal procedure noting the following.
• Connect connectors securely.
• After installation, be sure to inspect and adjust aiming
referring to “Headlight Aiming Adjustment with
Screen”.
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1
I6RW0C920015-02
2
1
3
I6RW0C920016-02

Downloaded from www.Manualslib.com manuals search engine Lighting Systems: 9B-20
Igniter Removal and Installation (Discharge
Headlight Model)
S6RW0D9206024
WARNING!
Be sure to read “Precautions for Discharge
Headlight Service (If Equipped)” carefully
before working. Neglecting them may result
in personal injury.

Removal
1) Remove ballast referring to “Ballast Removal and
Installation (Discharge Headlight Model)”.
2) Remove cover (1) from headlight housing by turning
it counterclockwise.
3) Remove igniter (2) from discharge headlight bulb by
turning it counterclockwise.
4) After disconnecting ground wire (3), pull out igniter
(2) from headlight housing.Installation
Reverse removal procedure noting the following.
• Connect connectors securely.
• After installation, be sure to inspect and adjust aiming
referring to “Headlight Aiming Adjustment with
Screen”.
Headlight Aiming Adjustment with ScreenS6RW0D9206003
NOTE
• Unless otherwise obligated by local regulations, adjust headlight aiming according to the following
procedure.
• After replacing headlight housing, be sure to adjust aiming.
• When inspecting and adjusting headlight with leveling system, make sure to set the leveling switch
to “0” position with ignition switch turned ON.

1) Make sure the following items.
• Place vehicle on a flat surface in front of blank wall (screen) (1) ahead of headlight surface.
Distance “a”
10 m (32.8 ft.)
• Adjust air pressure of all tires to the specified value respectively.
• Bounce vehicle body up and down by hand to stabilize suspension.
• Carry out aiming with a driver aboard.
Driver’s weight
75 kg (165 lb)
2) Check to see if hot spot (high intensity zone) of each low beam axis falls as shown in figure.
NOTE
If the headlights interfere each other and make it hard to see the cut line clearly, cover the headlight on
one side. This helps to make aiming adjustment easier.

Hot spot specification
Angle “b”: 0.75° (Specification)
Calculated distance “H”: Approx. 130 mm (5.15 in.)
3) Align headlight aiming to specification by adjusting aiming gear if it is not set properly.
2
1 3
I6RW0C920017-01