steering SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-76
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 / passenger curtain-air bag circuit check
1) With ignition switch turned OFF, remove rear quarter
upper trim of applicable side and disconnect applicable
side curtain-air bag (inflator) module connector.
2) Check for proper connection to applicable side curtain-
air bag (inflator) module at terminals in “Q102” or “Q103”
connector.
3) If OK, then connect special tools (A), (B) and (C) to
applicable side curtain-air bag (inflator) module
connector.
Special tool
(A): 09932–76010
(B): 09932–75010
(C): 09932–78310
4) Check SDM for DTC.
With ignition switch turned ON, is DTC B1361 or B1365 still
indicated?Go to Step 3. Replace side curtain-air
bag (inflator) module
referring to “Side
Curtain-Air Bag
(Inflator) Module
Removal and
Installation”.
STEERING WHEEL(B)(C)
(A)“Q102”, “Q103”
I7RW01822087-02

Downloaded from www.Manualslib.com manuals search engine 8B-79 Air Bag System:
DTC B1362 / B1366: Curtain-Air Bag Circuit Low ResistanceS6RW0D8204063
DTC B1362: Driver Curtain-Air Bag Circuit Low Resistance
DTC B1366: Passenger Curtain-Air Bag Circuit Low Resistance
Wiring Diagram
Refer to “DTC B1361 / B1365: Curtain-Air Bag Circuit High Resistance”.
DTC Detecting Condition and Trouble Area
DTC TroubleshootingDTC detecting condition Trouble area
DTC B1362:
Driver curtain-air bag circuit is less than 1.0 Ω for more
than 4 sec.
DTC B1366:
Passenger curtain-air bag circuit is less than 1.0 Ω for
more than 4 sec.• Driver / passenger curtain-air bag circuit
• Driver / passenger curtain-air bag module
•SDM
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 / passenger curtain-air bag circuit check
1) With ignition switch turned OFF, remove rear quarter
upper trim of applicable side and disconnect applicable
side curtain-air bag (inflator) module connector.
2) Check for proper connection to applicable side curtain-
air bag (inflator) module at terminals in “Q102” or “Q103”
connector.
3) If OK, then connect special tools (A), (B) and (C) to
applicable side curtain-air bag (inflator) module
connector.
Special tool
(A): 09932–76010
(B): 09932–75010
(C): 09932–78310
4) Check SDM for DTC.
With ignition switch turned ON, is DTC B1362 or B1366 still
indicated?Go to Step 3. Replace side curtain-air
bag (inflator) module
referring to “Side
Curtain-Air Bag
(Inflator) Module
Removal and
Installation”.
STEERING WHEEL(B)(C)
(A)“Q102”, “Q103”
I7RW01822087-02

Downloaded from www.Manualslib.com manuals search engine 8B-91 Air Bag System:
CAUTION!
After detecting one time of such collision as
to meet deployment conditions, the SDM
must not be used.
Refer to “Air Bag Diagnostic System Check”
when checking the SDM.

Accident with Deployment / Activation – Component
Replacement
When driver and passenger air bags are deployed, the
following components must be replaced.
• Driver and passenger air bag (inflator) modules
• Driver and passenger seat belt pretensioners
• SDM after detecting such collision as to meet
deployment conditions
• Forward impact-sensor
• Instrument panel
When side-air bag and side curtain-air bag are deployed,
the following components must be replaced.
• Deployed side-air bag (inflator) module
• Deployed side curtain-air bag (inflator) module
• Side impact-sensor
•SDM
Accident with or without Deployment / Activation –
Component Inspections
Certain air bag and restraint system components must
be inspected after any crash, whether the air bag system
activated or not. If any faulty condition is found in the
following checks, replace faulty part.
Those components are:
• Steering column (1) and shaft joints
– Check for length, damage and bend according to
“Checking Steering Column for Accident Damage in
Section 6B”.
• Steering column bracket (2) and capsules
– Check for damage and bent.
• Steering wheel and driver air bag (inflator) module
– Check for damage or air bag (inflator) module
fitness.
– Check trim cover (pad surface) for cracks.
– Check wire harness and connector for damage or
tightness.• Contact coil assembly
– Check wire harness and connectors for damage or
tightness.
– Check contact coil case for damage.
– Check contact coil circuit referring to “Contact Coil
Cable and Its Circuit Check”.
• Instrument panel member and reinforcement
– Check for any distortion, bending, cracking or other
damage.
– Check instrument panel for cracks or deformities.
• Passenger air bag (inflator) module
– Check for dents, cracks, damage or fitness.
– Check harness and connector for damage or
tightness.
•SDM
– Check for external damage such as deformation,
scratch, crack, peeled paint, etc.
– Check SDM for a cause in itself preventing its
proper installation. (There is a gap between SDM
and SDM plate, or it cannot be fixed securely.)
1
2
I6RW0B820015-01
I5JB0A820062-01
I4RS0A820048-01
I5RW0A820058-03

Downloaded from www.Manualslib.com manuals search engine 8B-93 Air Bag System:
Repair Instructions
Disabling Air Bag SystemS6RW0D8206001
1) Turn steering wheel so that vehicle’s wheels (front
tires) are pointing straight ahead.
2) Disconnect negative (–) cable at battery.
3) Turn ignition switch to “LOCK” position and remove
key.
4) Remove “A/B” fuse from junction block assembly.
5) Remove driver side front pillar lower trim and
disconnect yellow connector (1) for driver air bag as
follows.
a) Release locking of lock slider (2).
b) After unlocked, disconnect connector.
6) Remove passenger side front pillar lower trim and
disconnect yellow connector (3) for passenger air
bag as follows.
a) Release locking of lock slider (2).
b) After unlocked, disconnect connector.
7) Side-air bag (inflator) model:
Disconnect yellow connector of side-air bag (inflator)
module under front seat cushion (1).
a) Release locking of lock slider (2).
b) After unlocked, disconnect connector.8) Side curtain-air bag (inflator) model:
Remove quarter inner trim and disconnect yellow
connector (1) of side curtain-air bag (inflator)
module.
a) Release locking of lock slider (2).
b) After unlocked, disconnect connector.
NOTE
With “A/B” fuse removed and ignition switch
ON, “AIR BAG” warning light will be ON.
This is normal operation and does not
indicate air bag system malfunction.

Enabling Air Bag SystemS6RW0D8206002
1) Confirm that battery negative (–) cable is
disconnected.
2) Turn ignition switch to “LOCK” position and remove
key.
3) Connect yellow connector (1) of driver air bag
(inflator) module by pushing connector till click is
heard from it.
4) Connect yellow connector (1) of passenger air bag
(inflator) module by pushing connector till click is
heard from it.
1
a)
b)
2
3
I7RW01821012-01
1
2
a)
b)
I6RW0B820017-01
1
I5RW0A820091-01
1
I5RW0A820062-02

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-96
Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system. Refer to “Disabling Air Bag
System”.
3) Loosen driver air bag (inflator) module mounting
bolts (1) till it turns freely, pull them out and fix them
to bolt clamps.
4) Remove air bag (inflator) module from steering
wheel.
5) Disconnect driver air bag (inflator) module connector
(1) of driver air bag (inflator) module and horn
connector (2) (if equipped) as shown in figure.
a) Unlock lock button (3).
b) With lock button unlocked, disconnect connector.
WARNING!
Special care is necessary when handling and
storing a live (undeployed) air bag (inflator)
module. Observe “Precautions on Handling
and Storage of Air Bag System
Components”. Otherwise, personal injury
may result.

Installation
1) Connect horn connector (1) securely (if equipped).
2) Connect driver air bag (inflator) module connector
(2) to driver air bag (inflator) module (3) securely as
shown in figure.
a) Connect connector.
b) Lock connector with lock button.
3) Install driver air bag (inflator) module (1) to steering
wheel (2), taking care so that no part of wire harness
is caught between them.
4) Make sure that clearance between module (1) and
steering wheel (2) is uniform all the way.
5) Tighten driver air bag (inflator) module mounting bolt
(left side) (3) to specified torque first and then driver
air bag (inflator) module mounting bolt (right side) (4)
to specified torque.
Tightening torque
Driver air bag (inflator) module mounting bolt
(a): 9 N·m (0.9 kgf-m, 6.5 lb-ft)
6) Enable air bag system. Refer to “Enabling Air Bag
System”.
7) Connect negative (–) cable at battery.
I3JA01820031-01
1
2
a)
b)3
I5RW0A820065-01
2
1
b)
a)3
I5RW0A820066-01
I5RH01820103-01

Downloaded from www.Manualslib.com manuals search engine 8B-119 Air Bag System:
The adapter (1) will also give an idea of whether or not
contact tension is sufficient, helping to find an open or
intermittent open due to poor terminal contact. An SDM
short bar release tool (2) is included in the connector test
adapter kit. Inserting it into the SDM connector (3) will
releases the shorting bar.
Special tool
(B): 09932–75010 Air bag driver / passenger load
tool
This tool is used as a diagnostic aid and safety device to
prevent inadvertent air bag (inflator) module deployment.
The load tool has three connectors attached to its case
which are electrically functional and serve as resistive
load substitutions.
No more than two connectors are used at any time.
One of connectors (“STEERING WHEEL”) is used to
substitute the load of the followings.
• Driver air bag (inflator) module when it is connected at
the top of the column to the contact coil assembly.
• Passenger air bag (inflator) module when it is
connected to the air bag harness connector in
instrument panel harness for passenger air bag
(inflator) module.
• Each of driver and passenger seat belt pretensioners
when it is connected to air bag harness connector in
instrument panel harness for driver and passenger
seat belt pretensioners.
• Side-air bag (inflator) module when it is connected to
the floor harness connector for side-air bag (inflator)
module.
• Side curtain-air bag (inflator) module when it is
connected to the floor harness connector for side
curtain-air bag (inflator) module.Another connector (“BASE OF COLUMN”) is used to
substitute the load of the driver air bag (inflator) module
and the contact coil assembly when it is connected at the
base of the column to the air bag wire harness.
The third connector (“PASSENGER INFLATOR”) is not
used.
By substituting the resistance of the load tool when
called for, a determination can be made as to whether an
inflator circuit component is causing system malfunction
and which component is causing the malfunction.
The load tool should be used only when specifically
called for in the diagnostic procedures.
1
2
3
I4RS0A820108-01
1. Connector for contact coil and driver air bag (inflator) module
(Located near the base of the steering column)
2. Connector for driver, passenger air bag (inflator) module, side-air bag
(inflator) module and driver and passenger seat belt pretensioners
3. Not used
I1JA01820004-01

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

Downloaded from www.Manualslib.com manuals search engine 9A-3 Wiring Systems:
Ignition switch Keyless entry Immobilizer system Combination meter Lighting switch
Headlight leveling Hazard warning light Front fog light Rear fog light Spark plug
Radiator fan Fuel pump Injector XX control module Windshield wiper
Windshield washer Rear wiper Rear washer Rear defogger Power window
Power door lock Power mirror A/B Pretensioner Passenger side
Driver side Seat heater A/C Power steering Side air-bag (R)
Side air-bag (L) Side curtain air-bag (R) Side curtain air bag (L) Glow plug
I2RH01910912-01I3JA01910902-01I5RH01910901-01I2RH01910915-01I2RH01910916-01
I3JA01910904-01I3JA01910905-01I3JA01910906-01I3JA01910907-01I2RH01910921-01
I2RH01910922-01I3JA01910908-01I5RW0A910987-01
XX
Cont M
I2RH01910925-01I3JA01910909-01
I3JA01910910-01I3JA01910911-01I3JA01910912-01I2RH01910930-01I3JA01910913-01
I3JA01910914-01I3JA01910915-01I3JA01910916-01I3JA01910917-01I3JA01910918-01
I3JA01910919-01I2RH01910938-01I3JA01910920-01I3JA01910921-01I4JA01910901-01
I4JA01910902-01I5RS0A910958-01I5RS0A910959-01
I5RW0A910986-01

Downloaded from www.Manualslib.com manuals search engine 9A-19 Wiring Systems:
Instrument PanelS6RW0D910A003
E: Main harness, power steering wire (RHD)
E: Main harness
E: Power steering wireE159/GRY Front turn signal light (R)E247/BLK
(Taiwan)Headlight LO relay (R)
E160/GRY Front turn signal light (L)E248/BLK
(Taiwan)Headlight LO relay (L)
E161/N Front position light (R) E281/BLK Horn
E162/N Front position light (L) E311/BLK Main fuse box
E163/BLK Front fog light (R) E312/N Main fuse box
E164/BLK Front fog light (L) E371/N Engine harness (To C343)
E165/N Side turn signal light (R) No./Color Connective position No./Color Connective position
E12E13E11E387
(TO L371)E04E388
(TO L372)
E31E61
E377
E378
E325
E323
E324
E381
(TO G333)
E382
(TO G334)
E191E181E192
10
Power steering wire
E
I6RW0C910908-04
No./Color Connective position No./Color Connective position
E04/BLU BCM E325/N J/B
E13/BLK P/S control module E377/BLU Power steering wire (To E378)
E181/N Brake light switch E381/GRY Instrument panel harness (To G333)
E191/BLK APP (Acceleration pedal) sensor E382/BRN Instrument panel harness (To G334)
E192/N CPP (clutch pedal) cut switchE383/GRN
(IF EQPD)Instrument panel harness (To G335)
E323/BRN J/B E387/N Floor harness (To L371)
E324/N J/B E388/YEL Floor harness (To L372)
No./Color Connective position No./Color Connective position
E11/BLK P/S control module E61/GRY P/S motor
E12/BLU P/S control module E378/BLU Main harness (To E377)
E31/GRY Torque sensor

Downloaded from www.Manualslib.com manuals search engine Wiring Systems: 9A-20
E: Main harness, power steering wire (LHD)
E: Main harness
E: Power steering wire
E12E13E11E387
(TO L371)E04E388
(TO L372)
E31E61
E377
E378
E325
E323
E324
E381
(TO G333)
E382
(TO G334)
E191E181
10 Power steering wire
E
I6RW0C910909-02
No./Color Connective position No./Color Connective position
E04/BLU
(Except
Taiwan)BCM E325/N J/B
E13/BLK P/S control module E377/BLU Power steering wire (To E378)
E181/N Brake light switch E381/GRY Instrument panel harness (To G333)
E191/BLK APP (Acceleration pedal) sensor E382/BRN Instrument panel harness (To G334)
E323/BRN J/B E387/N Floor harness (To L371)
E324/N J/B E388/YEL Floor harness (To L372)
No./Color Connective position No./Color Connective position
E11/BLK P/S control module E61/GRY P/S motor
E12/BLU P/S control module E378/BLU Main harness (To E377)
E31/GRY Torque sensor