warning SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 6C-28 Power Assisted Steering System:
DTC Troubleshooting
DTC C1155: P/S Control Module Internal FailureS6RW0D6304018
Wiring Diagram
Refer to “DTC C1153: P/S Control Module Power Supply Circuit”.
DTC Detecting Condition and Trouble Area
DTC TroubleshootingStep Action Yes No
1Was “EPS System Check” performed?Go to Step 2. Go to “EPS System
Check”.
2Battery voltage check
1) Check circuit fuse for P/S control module.
2) If OK, measure voltage between positive (+) battery
terminal and vehicle body ground with engine running.
Is voltage 10 V or more?Go to Step 3. Check charging system
referring to “Generator
Test (Undercharged
Battery Check) in
Section 1J”.
3P/S control module power supply circuit check
Check power supply circuit and ground circuit for P/S control
module referring to “P/S Control Module Power Supply and
Ground Circuit Check”.
Is check result in good condition?Substitute a known-
good P/S control
module and recheck.Repair defective circuit.
DTC detecting condition Trouble area
Internal memory (EEPROM) is data error.
(In this case, “EPS” warning light does not light up)
or
Internal circuit is faulty.
or
Power supply voltage of P/S control module exceeded
17.5 V
(1 driving cycle detection logic)• Generator
• P/S control module
Step Action Yes No
1Was “EPS System Check” performed?Go to Step 2. Go to “EPS System
Check”.
2P/S control module power supply and ground circuit
check
Check power supply circuit and ground circuit for P/S control
module referring to “P/S Control Module Power Supply and
Ground Circuit Check”.
Is check result in good condition?Go to Step 3. Repair or replace
defective circuit.
3Battery voltage check
1) Check voltage between positive (+) battery terminal and
vehicle body ground with engine speed at 3000 rpm.
Is voltage 15.5 V or less?Replace P/S control
module.Check charging system
referring to “Generator
Test (Overcharged
Battery Check) in
Section 1J”.

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-31
Terminal Wire color Circuit Normal voltage Condition
E11-1 LT GRN/BLKIgnition switch signal for P/S
control module10 – 14 V Ignition switch ON
E11-2 — — — —
E11-3 — — — —
E11-4 PPL Vehicle speed signal*0 – 1 V
↑↓
8 – 14 V
(“Reference
waveform No.7”
under “Inspection
of BCM and Its
Circuits in
Section 10B”)• Ignition switch ON
• Front left tire turned quickly with right
tire locked
E11-5 GRY “EPS” warning light0 V Ignition switch ON
0 – 14 V Engine running
E11-6 — — — —
E11-7 — — — —
E11-8 GRN9 V power supply for torque
sensorAbout 9 V• Ignition switch ON
• Voltage between “E11-8” and “E11-9”
terminals
E11-9 BLK Ground for torque sensors — —
E11-10 WHT Torque sensor signal (Sub)About 2.5 – 4.0 V• Steering wheel with left turn
• Out put voltage varies linearly
depending on steering force
About 2.5 V Steering wheel at free
About 1.0 – 2.5 V• Steering wheel with right turn
• Out put voltage varies linearly
depending on steering force
E11-11 BLUSerial communication circuit for
data link connector——
E11-12 BRN Engine speed signal*0 – 1 V
↑↓
8 – 14 V
(“Reference
waveform No.24
and No.25” under
“Inspection of
ECM and Its
Circuits in
Section 1A”)Engine idling
E11-13 — — — —
E11-14 RED/BLU P/S active signal (idle up signal)About 12 V Ignition switch ON
0 – 1 VEngine idling and turned steering wheel
to the right or left until it stops
E11-15 — — — —
E11-16 — — — —
E11-17 — — — —
E11-18 YEL Torque sensor signal (Main)About 1.0 – 2.5 V• Steering wheel with left turn
• Out put voltage varies linearly
depending on steering force
About 2.5 V Steering wheel at free
About 2.5 – 4.0 V• Steering wheel with right turn
• Out put voltage varies linearly
depending on steering force
E11-19 GRY Ground for shield wire — —

Downloaded from www.Manualslib.com manuals search engine 7-1 Precautions:
HVAC
Precautions
Precautions
Precautions on HVACS6RW0D7000001
Air Bag Warning
Refer to “Air Bag Warning in Section 00”.
A/C System Caution
Refer to “A/C System Caution in Section 7B” or “A/C System Caution in Section 7B”.
Precautions on Servicing A/C System
Refer to “Precautions on Servicing A/C System in Section 7B” or “Precautions on Servicing A/C System in Section
7B”.
Precaution in Diagnosing Trouble (Automatic Type)
Refer to “Precautions in Diagnosing Trouble in Section 7B”.

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-1
HVAC
Air Conditioning System
Manual Type
Precautions
A/C System CautionS6RW0D7210001
CAUTION!
The A/C system of this vehicle uses HFC-134a (R-134a) refrigerant, specified compressor oil and
specified parts.
Do not use CFC-12 (R-12) refrigerant, R-12 exclusive use compressor oil and R-12 exclusive parts in
this A/C system, do not attempt to use R-12 servicing equipment. Otherwise, use of it will result in
leakage of refrigerant, damage or other faulty condition of A/C system and damage or other faulty
condition of servicing equipment.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.

Precautions on Servicing A/C SystemS6RW0D7210002
WARNING!
Should refrigerant HFC-134a (R-134a) is exposed to your eye(s), consult a doctor immediately.
• Do not reuse your hand to rub affected eye(s). Instead, use fresh cold water to splash it over
affected area to thus gradually raise its temperature above the freezing point.
• Obtain proper treatment as soon as possible from a doctor or eye specialist. Should liquid
refrigerant HFC-134a (R-134a) is exposed to your skin, such affected part should be treated in the
same manner as when skin is frostbitten or frozen.

Handling Refrigerant HFC-134a (R-134a)
• Always wear goggles to protect your eyes.
• Avoid direct contact to liquid refrigerant.
• Do not heat refrigerant container higher than 40 °C (104 °F).
• Do not discharge refrigerant into atmosphere.
• Do not expose bright metals to liquid refrigerant. Refrigerant combined with moisture is corrosive and tarnishes
surfaces of bright metals including chrome.
• Never use heat for bending pipes. When bending a pipe, try to make its bending angle as smooth as possible.
• Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system, install
a blind plug or cap to the fitting immediately.
• When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.
• Check local governmental regulations regarding working with refrigerator systems and its tooling.
• When connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to O-ring.
• Replace O-ring with new one once hoses, pipes and parts disconnected.
• When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.
• Route drain hose so that drained water does not make any contact to vehicle components.
• If pipes or hoses are replaced, replenish specified amount of compressor oil to compressor suction side referring to
“Replenishing Compressor Oil” in “Operation Procedure for Refrigerant Charge”.

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-17
Repair Instructions
Operation Procedure for Refrigerant ChargeS6RW0D7216001
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 place. It should never be stored in any place where
temperature is high, e.g. where exposed to direct sun 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.

Start evacuation.Start evacuation.
Stop evacuation.Stop evacuation.
15 minutes (above -100 kPa)15 minutes (above -100 kPa)
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 430 20 g ofRecharge 430 20 g ofrefrigerant.refrigerant.
I5RW0A721011-01

Downloaded from www.Manualslib.com manuals search engine 7B-20 Air Conditioning System: Manual Type
Charge
CAUTION!
• Because the sight glass is not used for this
A/C system, do not perform an additional
charge to the A/C system. To charge the
proper amount of refrigerant, recover and
evacuate the A/C system first. And then,
charge the proper amount of refrigerant
into the A/C system.
• Always charge refrigerant through low
pressure side of A/C system after the initial
charge is performed from the high
pressure side with the engine stopped.
• Never charge refrigerant through high
pressure side of A/C system with engine
running.
• Do not charge refrigerant while
compressor is hot.
• When installing tap valve to refrigerant
container to make a hole there through,
carefully follow directions given by
manufacturer.
• A pressure gauge should always be used
before and during refrigerant charge.
• The refrigerant container should be
emptied of refrigerant when discarding it.
• The refrigerant container should not be
heated up to 40 °C (104 °F) or over.
• Refrigerant container should not be
reversed in direction during refrigerant
charge. Reversing in direction causes
liquid refrigerant to enter compressor,
causing troubles, such as compression of
liquid refrigerant and the like.

NOTE
The air conditioning system contains HFC-
134a (R-134a).
Described here is a method to charge the air
conditioning system with refrigerant from the
refrigerant service container.
When charging refrigerant recovered by
using the refrigerant and recycling
equipment (when recycling refrigerant),
follow the procedure described in the
equipment manufacturer’s instruction
manual.

The initial charge of the A/C system is performed
through the high pressure side with the engine stopped.
And next, this method must be followed by charging from
the low pressure side with the engine running.
1) Check if hoses are routed properly after evacuating
the system.
2) Connect low charging hose (1) and high charging
hose (2) of the manifold gauge set (3) in position.
Then, open refrigerant container valve (4) to purge
the charging line.
3) Open the high pressure side valve (5) and charge
refrigerant to system.
4) After a while, open the low pressure side valve (6)
and close the high pressure side valve.
WARNING!
Make sure that high pressure side valve is
closed securely.

5) Start engine and keep engine speed at 1500 r/min,
and then operate A/C system.
6) Charge A/C system with refrigerant in vapor state. At
this time, refrigerant container should be held
upright.
4
3
6
2
1 5
I7RW01721012-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-21
7) When refrigerant container (1) is emptied, use the
following procedure to replace it with a new
refrigerant container.
a) Close low pressure valve.
b) Replace empty container with a refrigerant
container which has been charged with
refrigerant. When using refrigerant container tap
valve (2), use the following procedure for
replacement.
i) Retract needle (3) and remove refrigerant
container tap valve by loosening its plate nut
(4).
ii) Install the refrigerant container tap valve to a
new refrigerant container.
c) Purge any air existing in center charging hose.
When using refrigerant container tap valve, use
the following procedure to purge air.
i) Once fully tighten refrigerant container tap
valve (1), and then loosen (open) plate nut
(2) slightly.
ii) Open low pressure side valve (3) of manifold
gauge set (4) a little.
iii) As soon as refrigerant comes out with a
“hiss” through a clearance between
refrigerant container and tap valve, tighten
plate nut as well as low pressure side valve.
iv) Turn handle of tap valve clockwise so that its
needle is screwed into the new container to
make a hole for refrigerant flow.8) After the system has been charged with specified
amount of refrigerant or when low pressure gauge
(1) and high pressure gauge (2) have indicated the
following specified value, close low pressure side
valve (3) on manifold gauge set (4).
Specified amount of refrigerant
430 ± 20 g (15.2 ± 0.7 oz))
Low side and high side pressure example
Removal of Manifold Gauge Set
WARNING!
High pressure side is under high pressure.
Therefore, be careful not to get injured
especially on your eyes and skin.

For the A/C system charged with the specified amount of
refrigerant, remove manifold gauge set as follows:
1) Close low pressure side valve of manifold gauge set.
(The high pressure side valve is closed continuously
during the process of charging.)
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service
valves. This operation must be performed quickly.
5) Put caps on service valves.
I2RH01720018-01
I2RH01720019-01
Gauges should read as follows when ambient
temperature is 30 °C (86 °F).
Pressure
on high pressure gauge1130 – 1560 kPa
(11.4 – 15.6 kgf/cm
2)
(162.3 – 221.8 psi)
Pressure
on low pressure gauge270 – 390 kPa
(2.7 – 3.9 kgf/cm
2)
(38.8 – 56.0 psi)
4
2
1
3
I7RW01721013-02

Downloaded from www.Manualslib.com manuals search engine 7B-22 Air Conditioning System: Manual Type
Check A/C System for Refrigerant Leaks
Whenever a refrigerant leak is suspected in the system
or any service operation has been performed which may
result in malfunction of lines and connections, it is
advisable to check for leaks.
Common sense should be used during refrigerant leak
test, since the need and extent of any such test will, in
general, depend upon the nature of a complaint and the
type of a service performed on the system.
Liquid leak detector
WARNING!
• To prevent explosions and fires, make sure
that there are no flammables in the vicinity.
• When the refrigerant exposed to fire, it
turns into a poisonous gas (phosgene). Do
not inhale this gas.

There is a number of fittings and places throughout the
A/C system where a liquid leak detector solution may be
used to pinpoint refrigerant leaks.
By merely applying the solution to the area in question
with a swab, such as attached to the cap of a vial,
bubbles will form within seconds if there is a leak.
For confined areas, such as sections of the evaporator
and condenser, an electronic (refrigerant) leak detector
is more practical for determining leaks.
Special tool
(A): 09990–86012
Condenser Cooling Fan Removal and
Installation
S6RW0D7216002
CAUTION!
Be careful not to damage fins of radiator. If
radiator fin is bent, straighten it by using flat
head screwdriver or pair of pliers.

Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect condenser cooling fan motor coupler.
3) Remove reservoir (1) from radiator.
4) Remove condenser cooling fan (2) from radiator (3).
Installation
Reverse removal procedure to install condenser cooling
fan.
(A)
I5RW0A721054-01
13
2
I5RW0A721017-01

Downloaded from www.Manualslib.com manuals search engine 7B-38 Air Conditioning System: Automatic Type
Automatic Type
Precautions
A/C System CautionS6RW0D7220001
Refer to “A/C System Caution”.
Precautions in Diagnosing TroubleS6RW0D7220002
• Do not disconnect couplers from HVAC control module, battery cable from battery, HVAC control module ground
wire harness from body or main fuse before confirming diagnostic information (diagnostic trouble code) stored in
HVAC control module memory.
• Diagnostic information (diagnostic trouble code) stored in HVAC control module can be checked by display of HVAC
control module. Also, it can be checked by using SUZUKI scan tool. Before checking diagnostic information
(diagnostic trouble code), read this manual and operator's manual for SUZUKI scan tool to know how to read
diagnostic information (diagnostic trouble code).
• When trouble is diagnosed using diagnostic information (diagnostic trouble code) on display of HVAC control
module, keep in your mind that each diagnostic information (diagnostic trouble code) has priority, and only
diagnostic information (diagnostic trouble code) which has the highest priority is indicated. Therefore, after
troubleshooting the malfunction, make sure if there exists any other diagnostic information (diagnostic trouble
code).
• Be sure to read “Air Bag Warning in Section 00” before inspection.
Precautions on Servicing A/C SystemS6RW0D7220003
Refer to “Precautions on Servicing A/C System”.

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 and Diagnosis of Seat
Belt .................................................................... 8A-1
General Description ............................................. 8A-2
Seat Belt Construction ........................................ 8A-2
Diagnostic Information and Procedures ............ 8A-3
Repair and Inspection Required after
Accident ............................................................ 8A-3
Repair Instructions .............................................. 8A-4
Front Seat Belt Components ............................... 8A-4
Front Seat Belt Removal and Installation ............ 8A-5
Front Seat Belt Inspection................................... 8A-6
Rear Seat Belt Components ............................... 8A-7
Rear Seat Belt Removal and Installation ............ 8A-8
Rear Seat Belt Inspection ................................... 8A-8
Specifications....................................................... 8A-8
Tightening Torque Specifications ........................ 8A-8
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-1
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 Block Diagram ........................... 8B-6
Air Bag System Input / Output Table .................. 8B-7
Schematic and Routing Diagram ........................ 8B-8
Air Bag System Wiring Circuit Diagram .............. 8B-8
Component Location ......................................... 8B-11
Air Bag System Components, Wiring and
Connectors Location ....................................... 8B-11
Diagnostic Information and Procedures .......... 8B-12
Air Bag Diagnostic System Check .................... 8B-12
Air Bag Diagnostic System Check Flow ............ 8B-13
DTC Table ......................................................... 8B-14DTC Check........................................................ 8B-18
DTC Clearance ................................................. 8B-18
Scan Tool Data ................................................. 8B-18
“AIR BAG” Warning Light Comes ON Steady ... 8B-19
“AIR BAG” Warning Light Does Not Come ON .. 8B-22
Serial Data Link Circuit Check .......................... 8B-23
DTC B1013: SDM Internal Failure .................... 8B-25
DTC B1014: “AIR BAG” Warning Light Circuit .. 8B-26
DTC B1016: Power Supply Voltage too High.... 8B-26
DTC B1017: Power Supply Voltage too Low .... 8B-27
DTC B1021: Front Air Bag Deployment
Record............................................................. 8B-28
DTC B1024 / B1025: Side Air-Bag
Deployment Record ........................................ 8B-29
DTC B1026: Seat Belt Pretensioner
Activation Record ............................................ 8B-29
DTC B1027: Number of Deployment Times
Exceeded Limit................................................ 8B-30
DTC B1031: Driver Air Bag Circuit High
Resistance ...................................................... 8B-31
DTC B1032: Driver Air Bag Circuit Low
Resistance ...................................................... 8B-33
DTC B1033: Driver Air Bag Circuit Shorted to
Ground ............................................................ 8B-35
DTC B1034: Driver Air Bag Circuit Shorted to
Power Supply .................................................. 8B-37
DTC B1041: Passenger Air Bag Circuit High
Resistance ...................................................... 8B-40
DTC B1042: Passenger Air Bag Circuit Low
Resistance ...................................................... 8B-43
DTC B1043: Passenger Air Bag Circuit
Shorted to Ground........................................... 8B-45
DTC B1044: Passenger Air Bag Circuit
Shorted to Power Supply ................................ 8B-46
DTC B1051 / B1055: Seat Belt Pretensioner
Circuit High Resistance ................................... 8B-48
DTC B1052 / B1056: Seat Belt Pretensioner
Circuit Low Resistance.................................... 8B-51
DTC B1053 / B1057: Seat Belt Pretensioner
Shorted to Ground........................................... 8B-52
DTC B1054 / B1058: Seat Belt Pretensioner
Circuit Shorted to Power Supply ..................... 8B-54
DTC B1061 / B1065: Side-Air Bag Circuit
High Resistance .............................................. 8B-55