SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Lighting Systems: 9B-12
Back-Up Light Symptom DiagnosisS6RW0D9204020
Brake Light Symptom DiagnosisS6RW0D9204007
Front Fog Light Symptom Diagnosis (If Equipped)S6RW0D9204008
Rear Fog Light Symptom Diagnosis (If Equipped)S6RW0D9204009
Condition Possible cause Correction / Reference Item
Back-up lights do not
light upBulb(s) blownReplace bulb(s).
Circuit fuse blownReplace fuse and check for short circuit.
Back-up light switch (M/T model) or
transmission range sensor (A/T model)
faultyCheck back-up light switch or transmission
range sensor referring to “Back Up Light
Switch Inspection in Section 5B” or
“Transmission Range Sensor Inspection and
Adjustment in Section 5A”.
Wiring or grounding faultyRepair circuit.
Back-up lights stay onBack-up light switch (M/T model) or
transmission range sensor (A/T model)
faultyCheck back-up light switch or transmission
range sensor referring to “Back Up Light
Switch Inspection in Section 5B” or
“Transmission Range Sensor Inspection and
Adjustment in Section 5A”.
Condition Possible cause Correction / Reference Item
Brake light do not light upBulb(s) blownReplace bulb(s).
Circuit fuse blownReplace fuse and check for short circuit.
Brake light switch faultyCheck brake light switch referring to “Brake
Light Switch Inspection”.
Wiring or grounding faultyRepair circuit.
Brake light stay onBrake light switch faultyCheck or adjust brake light switch referring to
“Brake Light Switch Inspection” or “Brake Light
Switch Adjustment in Section 4A”.
Condition Possible cause Correction / Reference Item
Only one light does not
lightBulb blownReplace bulb.
Wiring or grounding faultyRepair circuit.
Front fog lights do not
lightCircuit fuse blownReplace fuse and check for short circuit.
Bulb blownReplace bulb.
Front fog light switch faultyCheck front fog light switch referring to “Front
Fog Light Switch Inspection (If Equipped)”.
Front fog light relay faultyCheck front fog light relay referring to “Tail
Light Relay, Headlight Relay, Front Fog Light
Relay Inspection (If Equipped)”.
Wiring or grounding faultyRepair circuit.
Condition Possible cause Correction / Reference Item
Rear fog light do not lightCircuit fuse blownReplace fuse and check for short circuit.
Bulb blownReplace bulb.
Rear fog light switch faultyCheck rear fog light switch referring to “Rear
Fog Light Switch Inspection (If Equipped)”.
Wiring or grounding faultyRepair circuit.

Downloaded from www.Manualslib.com manuals search engine 9B-13 Lighting Systems:
Illumination Cancel System Symptom Diagnosis (If Equipped)S6RW0D9204010
Interior Light Symptom DiagnosisS6RW0D9204011
NOTE
• Use of SUZUKI scan tool makes it easy to check whether a faulty condition is on the input side or
output side of BCM. For checking procedure, refer to “Diagnosis Using Output Test Function of
SUZUKI Scan Tool” under “Scan Tool Data in Section 10B”.
• Check each part in the order from the top of the following list.

DRL Operation Inspection (If Equipped)S6RW0D9204012
1) Confirm that lighting switch is in OFF position.
2) Confirm that dimmer and passing switch is in low beam position.
3) Check DRL for operation as follows.
a) Turn ignition switch to ON position and check headlights remain OFF.
b) Start engine and run it at idle speed. Check headlights turn ON at low beam.
c) Switch dimmer and passing switch to high beam position and check headlights remain turning ON at low
beam.
4) If check result is not as satisfied, go to “Inspection of DRL Controller and Its Circuits (If Equipped)”.
Inspection of DRL Controller and Its Circuits (If Equipped)S6RW0D9204013
1) Confirm that lighting switch is in good condition referring to “Headlight Switch (in Lighting Switch) Inspection”.
2) Confirm that oil pressure switch is in good condition referring to “Oil Pressure Switch Inspection in Section 9C”.
3) Remove glove box.
4) Remove DRL controller (1) from steering support member.
5) Connect connector to DRL controller.Condition Possible cause Correction / Reference Item
Illumination cancel do not
normal operationCircuit fuse blownReplace fuse and check for short circuit.
Illumination cancel switch faultyCheck illumination cancel switch referring to
“Illumination Cancel Switch Inspection (If
Equipped)”.
Combination meter and/or information
display faultyReplace combination meter and/or information
display.
Wiring or grounding faultyRepair circuit.
Condition Possible cause Correction / Reference Item
Dome light does not light
upBulb blownReplace bulb.
Circuit fuse blownReplace fuse and check for short circuit.
Dome light switch faultyCheck dome light switch.
Door switch faultyCheck door switch referring to “Door Switch
(Front / Rear Door) Inspection in Section 9C”.
Wiring or grounding faultyRepair circuit.
BCM faultyReplace after making sure that none of above
parts is faulty.
Luggage compartment
light does not light up (if
equipped)Bulb blownReplace bulb.
Rear end door switch faultyCheck switch referring to “Rear End Door
Switch Inspection in Section 9C”.
Wiring or grounding faultyRepair circuit.

Downloaded from www.Manualslib.com manuals search engine Lighting Systems: 9B-14
6) Check that the voltage between the following terminals and vehicle body ground are specifications under each
condition.
7) Check that voltage between the following terminals and body ground are as specification under each condition.
If measuring voltage is not within specification, check applicable circuit for open or short. If circuits are normal,
replace DRL controller.
If measuring voltage is within specification, DRL controller and its circuits are good condition.
54321
10987 6
V
1
1[A]
I5RW0A920003-01
[A]: DRL controller connector viewed from harness side
Terminal Circuit Specification Condition
1 To clearance lamp0 – 1 V Engine is at stop and lighting switch is at OFF position.
10 – 14 V Engine is at running and lighting switch is at OFF position.
2 To ignition switch0 – 1 V Ignition switch is at OFF position.
10 – 14 V Ignition switch is at ON position.
3To lighting switch
(CLEARANCE)0 – 1 V Lighting switch is at OFF position.
10 – 14 VLighting switch is at CLEARANCE position or HEAD
position.
4 Ground 0 – 1 V —
5 Ground 0 – 1 V —
6 To head lamp0 – 1 V• Lighting switch is at HEAD position and dimmer switch
is at LOW position.
• Engine is running and lighting switch is at OFF position.
10 – 14 VLighting switch is at HEAD position and dimmer switch is
at HI position.
7 To oil pressure switch8 – 10 VEngine is at running (Oil pressure warning lamp is turned
OFF).
0 – 1 V Engine is at stop.
8 Main fuse 10 – 14 V —
9 To lighting switch (HEAD)6 – 8 V• Engine is at running and lighting switch is at OFF
position.
• Engine is running and lighting switch is CLEARANCE
position.
0 – 1 V• Engine is at running and dimmer switch is at HEAD
position.
• Engine is at stop.
10 To lighting switch (LOW)0 – 1 V• Engine is at running and lighting switch is at OFF
position.
• Lighting switch is at HEAD position and dimmer switch
is at LOW position.
10 – 14 VLighting switch is at HEAD position and dimmer switch is
at HI position.

Downloaded from www.Manualslib.com manuals search engine 9B-15 Lighting Systems:
Auto-On Headlight Operation Inspection (If
Equipped)
S6RW0D9204021
1) Turn ignition switch to ON position and then turn
lighting switch to “AUTO” position.
2) Check headlights for operation as follows. If
headlights do not turn ON or OFF, go to “Inspection
of Auto-On Headlight Controller and Its Circuit (If
Equipped)”.
a) Cover auto-on headlight sensor by hand and
check that headlights light up then.
b) Light over auto-on headlight sensor vertically
with on incandescent lamp of approx, 100 W
apart from about 100 mm (3.94 in.) (1) and check
that headlights go off then.
Inspection of Auto-On Headlight Controller and Its Circuit (If Equipped)S6RW0D9204022
1) Confirm that lighting switch is in good condition referring to “Headlight Switch (in Lighting Switch) Inspection”.
2) Remove steering column hole cover.
3) Remove auto-on headlight controller (1) from steering support member.
4) Connect connector to auto-on headlight control module.
5) Check that the voltage between the following terminals and vehicle body ground are specifications under each
condition.
If measuring voltage is not within specification, check applicable circuit for open or short. If circuits are normal,
replace auto-on headlight controller.
If measuring voltage is within specification, auto-on headlight controller and its circuits are good condition.
[A]: Fig. for Step a) [B]: Fig. for Step b)
[A] [B]
1
I6RW0C920010-02
1
4321
8765
V
[A]
I6RW0C920011-01
[A]: Auto-on headlight controller connector viewed from harness side
Terminal Circuit Specification Condition
1 Tail light control signal0 VLighting switch at “AUTO”
position, tail / position light at
ON.
10 – 14 VIgnition switch is at ON
position, lighting switch at
“OFF” position.
2 Headlight control signal0 VLighting switch at “AUTO”
position, headlight at ON.
10 – 14 VIgnition switch is at ON
position, lighting switch at
“OFF” position.
3Power supply for auto-on
headlight sensorAbout 5 VIgnition switch is at OFF
position.

Downloaded from www.Manualslib.com manuals search engine Lighting Systems: 9B-16
Inspection of Headlight Leveling Control Module and Its Circuit (Headlight Auto Leveling System)S6RW0D9204023
Headlight auto leveling control module and its circuits can be checked at headlight auto leveling control module wiring
couplers by measuring voltage and pulse signal.
CAUTION!
Headlight auto leveling control module cannot be checked by itself. It is strictly prohibited to connect
voltmeter or ohmmeter to headlight auto leveling control module with couplers disconnected from it.

Voltage Check
Check voltage between each terminal of headlight auto leveling control module and vehicle body ground under each
condition. If measured voltage is out of standard value, check circuit (including switch and sensor) of terminal where
voltage was measured.
NOTE
• As each terminal voltage is affected by the battery voltage, confirm that it is 11 V or more when
ignition switch is ON.
• Voltage with asterisk (*) cannot be measured by voltmeter because it is pulse signal. Check it with
oscilloscope if necessary.

4Auto-on headlight sensor
signal3 – 4.5 VLight the sensor lens with
incandescent lamp 100 W
Less than 1 VCover the sensor lens with
hand.
5Ground for auto-on headlight
controller0 V —
6Ground for auto-on headlight
sensor0 V —
7 Lighting switch signal0 VIgnition switch is at ON
position, lighting switch at
“AUTO” position.
1.0 – 5.0 VIgnition switch is at ON
position, lighting switch at other
than “AUTO” position.
8 Ignition switch signal 10 – 14 VIgnition switch is at ON
position. Terminal Circuit Specification Condition
V
10 11 12 13 16 17 18 19 2031 5 6 9
21 22 23 24
[A]
I6RW0C920012-01
[A]: Headlight leveling control module connector (viewed from harness side)

Downloaded from www.Manualslib.com manuals search engine 9B-17 Lighting Systems:
Terminal Circuit Specification Condition
1 Power source 10 – 14 VIgnition switch is at ON
position.
2———
3 Lighting switchLess than 1.5 VLighting switch is at “HEAD”
position.
10 – 14 VLighting switch is at OFF
position.
4———
5 Diagnosis switch terminal About 5 VIgnition switch is at ON
position.
6Headlight auto leveling
indicatorLess than 1.5 VFor about 3 seconds after
ignition switch is turned on (i.e.,
headlight auto leveling
indicator is lit up).
10 – 14 VMore than about 3 seconds
after ignition switch is turned
on (i.e., headlight auto leveling
indicator is not lit up).
7———
8———
9Ground for headlight auto
leveling control unit0 VIgnition switch is at ON
position.
10Power supply for right
headlight leveling actuator10 – 14 VIgnition switch is at ON
position.
11Power supply for left headlight
leveling actuator10 – 14 VIgnition switch is at ON
position.
12Power supply for rear height
sensorAbout 5 VIgnition switch is at ON
position.
13Power supply for front height
sensorAbout 5 VIgnition switch is at ON
position.
14———
15———
16 Vehicle speed signal Refer to “Reference waveform No.1: ”.
17Signal for right headlight
leveling actuatorLess than 1 VLighting switch is at OFF
position.
1.0 – 12.6 VFor 17 seconds after turning
lighting switch to ON position.
18Signal for left headlight leveling
actuatorLess than 1 VLighting switch is at OFF
position.
1.0 – 12.6 VFor 17 seconds after turning
lighting switch to ON position.
19Input signal for rear height
sensorAbout 2.5 VIgnition switch is at ON
position.
20Input signal for front height
sensorAbout 2.5 VIgnition switch is at ON
position.
21 Ground for rear height sensor 0 VIgnition switch is at ON
position.
22 Ground for front height sensor 0 VIgnition switch is at ON
position.
23Ground for right headlight
leveling actuator0 VIgnition switch is at ON
position.
24
Ground for left headlight
leveling actuator0 VIgnition switch is at ON
position.

Downloaded from www.Manualslib.com manuals search engine Lighting Systems: 9B-18
Reference waveform No.1
Vehicle speed signal (1).
Vehicle speed signal is pulse. Pulse frequency varies
depending on vehicle speed.
Repair Instructions
Headlight Housing Removal and InstallationS6RW0D9206001
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.

Removal
1) Disconnect negative (–) cable at battery.
2) Remove front bumper. Refer to “Front Bumper and
Rear Bumper Components in Section 9K”.
3) Remove headlight mounting bolts.
4) Detach headlight housing (1) from vehicle.
5) Disconnect couplers (2) from headlight housing (1).Installation
Reverse removal procedure noting the following.
• Install headlight mounting bolts and clip (1), and then
tighten headlight mounting bolts (“1” – “2”) according
to numerical order as shown in figure.
• After installation, be sure to inspect and adjust aiming
referring to “Headlight Aiming Adjustment with
Screen”. Measurement terminal CH 1: “G14-16” to “G14-9”
Oscilloscope setting CH 1: 2 V
TIME: 20 ms/DIV
Measurement condition Engine is running and
vehicle speed 40 km/h (24
mph)
I6RW0C920013-02
2
1I5RW0A920004-01
1
“2”
“1”
I5RW0A920005-01

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”.
1 2
I6RW0C920014-02
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

Downloaded from www.Manualslib.com manuals search engine 9B-21 Lighting Systems:
1
“H”“b”
“a”
2
10
[G] [F] [E]
7
8
9
6
7
5
10
11 8 9
7
6
5
A
A4
3
B B
A
A4
B B
“H”
“H” “H”
“H” [C]
[D]
A
A4
B B
[A][B]
“H”“H”
XX XX XX
A
A4
B B
[A][B]
“H” “H” [I] [H]
[I] [H]
3
33
3
333
XX
[A][B]
[A][B]
6
5
8
9
I6RW0C920018-02
2. Headlight bulb 10. Headlight housing [D]: LH steering vehicle shown
3. Cut line (bounding line) 11. Headlight leveling actuator [E]: Without headlight leveling actuator
4. Hot spot X-X: Horizontal center line of headlight bulbs [F]: Headlight manual leveling model
5. Turning (for up adjustment) A-A: Vertical center line of left headlight bulb [G]: Headlight auto leveling model
6. Turning (for down adjustment) B-B: Vertical center line of right headlight bulb [H]: Other than discharge headlight model
7. Aiming gear (for right / left adjustment) [A]: Left headlight [I]: Discharge headlight model
8. Turning (for right adjustment) [B]: Right headlight
9. Turning (for left adjustment) [C]: RH steering vehicle shown