Precautions SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 8B-99 Air Bag System:
Passenger Air Bag (Inflator) Module InspectionS6RW0D8206008
WARNING!
• Never measure resistance of passenger air
bag (inflator) module or disassemble it.
Otherwise personal injury may result.
• Never attempt to disassemble or repair the
passenger 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.
• Wire harness or connector is damaged.
• Air bag (inflator) module is damaged or a strong
impact was applied to it.
• Bend or deformity of air bag (inflator) module bracket.
Side-Air Bag (Inflator) Module Removal and
Installation
S6RW0D8206020
WARNING!
• Never attempt to disassemble or repair the
side-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.

I5RW0A820072-03
1. Side-air bag (inflator) module 6. Sleeve
2. Seat back frame bracket 7. Sleeve lock nut
3. Side-air bag (inflator) module
connector8. Fastener
4. Seat back : 2.5 N⋅m (0.25 kgf-m, 2.0
lb-ft)
5. Air bag harness in floor harness : Do not reuse.
12
3
4
5
(a)7 6
8
2
1
I7RW01822144-01

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-100
Removal
1) Disable air bag system. Refer to “Disabling Air Bag
System”.
2) Loosen seat back surface fastener (1) and roll up
backside of seat back surface.
3) Remove sleeve lock nut (1) from side-air bag
(inflator) module (2).
4) Remove side-air bag (inflator) module from seat
back.
5) Disconnect side-air bag (inflator) module connector
(1) as shown in the figure.
a) Unlock lock button (2).
b) With lock button unlocked, disconnect connector.WARNING!
• When carrying a live air bag (inflator)
module, make sure the bag opening is
pointed away from you.
Never carry air bag (inflator) module by
wires or connector on the side of the
module. In case of an accidental
deployment, the bag will then deploy with
minimal chance of injury.
• As the live side-air bag (inflator) module
must be kept with its bag (trim cover)
facing up while being stored or left
standing. This is necessary so that a free
space is provided to allow the air bag to
expand in the unlikely event of accidental
deployment.
• Observe “Precautions on Handling and
Storage of Air Bag System Components”
for handling and storing it.
Otherwise, personal injury may result.

6) Remove fastener (1) with sleeve (2) from seat back.
Installation
1) Install new fastener (1) to seat back.
2. Seat back
2
1
I7RW01822145-01
21
2
I7RW01822146-01
2
1
a)
b)
I4RS0A820068-01
12
I7RW01822147-01
1
I7RW01822148-01

Downloaded from www.Manualslib.com manuals search engine 8B-101 Air Bag System:
2) Install new sleeve (1) and sleeve lock nut (2) to side-
air bag (inflator) module, then tighten nut to specified
torque.
Tightening torque
Sleeve lock nut (a): 2.5 N·m (0.25 kgf-m, 2.0 lb-
ft)
3) Connect side-air bag (inflator) module connector (1)
securely as shown in the figure.
a) Connect connector.
b) Lock connector with lock button (2).
4) Insert claw (1) of side-air bag (inflator) module on
installation hole (2).
5) Install side-air bag (inflator) module by pushing it into
fastener (3) securely.
6) Roll down backside seat back surface and fix seat
back surface fastener securely.Side-Air Bag (Inflator) InspectionS6RW0D8206021
WARNING!
• Never attempt to disassemble or repair the
side-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” 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.
• There is a crack in trim cover (pad surface).
• Wire harness or connector is damaged.
• Air bag (inflator) module is damaged or a strong
impact was applied to it.
• Bend or deformity of air bag (inflator) module bracket.
12, (a)
I4RS0A820073-02
1
2
a) b)
I4RS0A820070-01
1
2
3
I4RS0A820074-02
I4RS0A820075-02

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-102
Side Curtain-Air Bag (Inflator) Module Removal
and Installation
S6RW0D8206022
WARNING!
• 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.

Removal
1) Disable air bag system. Refer to “Disabling Air Bag
System”.
2) Remove head lining referring to “Head Lining
Removal and Installation in Section 9H”.
3) Disconnect side curtain-air bag (inflator) module
connector (1) as shown in figure.
a) Unlock lock button (2).
b) With lock button unlocked, disconnect connector.
4) Remove side curtain-air bag (inflator) module fixing
bolts (1) and clips (2).5) Remove side curtain-air bag (inflator) module.
WARNING!
• When carrying a live air bag (inflator)
module, make sure the bag opening is
pointed away from you.
Never carry air bag (inflator) module by
wires or connector on the side of the
module. In case of an accidental
deployment, the bag will then deploy with
minimal chance of injury.
• As the live curtain air bag (inflator) module
must be kept with its bag facing up while
being stored or left standing. This is
necessary so that a free space is provided
to allow the air bag to expand in the
unlikely event of accidental deployment.
• Observe “Precautions on Handling and
Storage of Air Bag System Components”
for handling and storing it.
Otherwise, personal injury may result.

Installation
WARNING!
Do not install side curtain-air bag (inflator)
module while twisted or bent. Otherwise, side
curtain-air bag (inflator) module may not
deploy and injury may result.

1) Install side curtain-air bag (inflator) module (1) with
clips (2) and new bolts (3).
2) Tighten side curtain-air bag (inflator) module
attaching bolts (4) to specified torque.
Tightening torque
Side curtain-air bag (inflator) module attaching
bolts (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
1
2
a)
b)
I5RW0A820075-01
1111
22I5RW0A820076-01
4, (a)
333
34, (a)
1
22
I5RW0A820077-01

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 8B-107 Air Bag System:
7) Install passenger air bag (inflator) module referring
to “Passenger Air Bag (Inflator) Module Removal
and Installation”.
8) Enabling air bag system referring to “Enabling Air
Bag System”.
9) Confirm that there is no DTC detected to SDM with
ignition switch turned ON.
Air Bag (Inflator) Module and Seat Belt
Pretensioner Disposal
S6RW0D8206018
WARNING!
Failure to follow proper air bag (inflator)
module and seat belt pretensioner disposal
procedures can result in air bag deployment
and pretensioner activation which may cause
personal injury. Do not dispose of live
(undeployed) air bag (inflator) modules and
seat belt pretensioners. Because undeployed
air bag (inflator) module / inactivated seat
belt pretensioner must not be disposed of
through normal refuse channels. Undeployed
air bag (inflator) module and inactivated seat
belt pretensioner contain substances that
can cause severe illness or personal injury if
sealed container is damaged during disposal.

Air bag (inflator) module / seat belt pretensioner can be
deployed / activated inside or outside of vehicle.
Deployment / Activation method used depends upon
final disposition of vehicle. Review the following
instructions in order to determine which will work best in
a given situation.
Deployment / Activation Outside of Vehicle: When you
intend to return the vehicle to service, deploy the air bag
(inflator) module(s) and/or activate seat belt
pretensioner(s) outside of the vehicle.
Deployment / Activation Inside of Vehicle: When the
vehicle will be destroyed, or salvaged for component
parts, deploy the air bag module(s) and/or activate seat
belt pretensioner(s) installed on vehicle.
WARNING!
The following precautions must be observed
for this work. Failure to observe any of them
may result in personal injury.
• Procedure should be followed strictly as
described here.
• Be sure to read “Precautions on Service
and Diagnosis of Air Bag System”
beforehand.
• To avoid accidental deployment /
activation, this work should be performed
by no more than one person.
• Since smoke is produced when air bag
(inflator) module is deployed and
pretensioner is activated, select well-
ventilated area.
• Air bag (inflator) module and seat belt
pretensioner will immediately deploy /
activate when 12 volts vehicle battery is
connected to it. Wear safety glasses
throughout this entire deployment /
activation and disposal procedure.
• Wear suitable ear protection when
deploying air bag (inflator) module /
activating seat belt pretensioner. Also,
advise those who are in area close to
deployment / activation site to wear
suitable ear protection.
• Do not deploy / activate two or more air
bag system components (air bag (inflator)
modules and seat belt pretensioners) at
the same time.
• Never connect deployment harness to any
12 volts vehicle battery before connecting
deployment harness to air bag (inflator)
module and seat belt pretensioner.
Deployment harness shall remain shorted
and not be connected to 12 volts vehicle
battery till you are ready to deploy air bag
(inflator) module or activate seat belt
pretensioner.

Downloaded from www.Manualslib.com manuals search engine 8B-113 Air Bag System:
12) Notify all people in immediate area that you intend to
deploy / activate air bag (inflator) module or seat belt
pretensioner.
NOTE
• When air bag (inflator) module deploys and
seat belt pretensioner activates, rapid gas
expansion will create substantial report.
Wear suitable ear protection. Notify all
people in immediate area that you intend
to deploy air bag (inflator) module or
activate seat belt pretensioner and suitable
ear protection should be worn.
• When driver air bag (inflator) module
deploys, driver air bag (inflator) module
may jump about 30 cm (1 ft) vertically. This
is normal reaction to force of rapid gas
expansion inside of drive air bag (inflator)
module.
• After air bag (inflator) module has been
deployed, surface of air bag (inflator) may
contain powdery residue. This powder
consists primarily of cornstarch (used to
lubricate bag (inflator) as it inflates) and by
products of chemical reaction.

WARNING!
• Do not place deployed air bag (inflator)
module and activated seat belt
pretensioner near any flammable objects.
• Do not apply water, oil, etc. to deployed air
bag (inflator) module and activated seat
belt pretensioner.
• Wait for about 30 minutes before touching
any metal surface of air bag (inflater)
module or seat belt pretensioner module.
Disregarding these precautions may cause
fire or personal injury.
Failure to follow procedures may result in fire
or personal injury.

13) Separate two banana plugs (1) on deployment
harness.
14) Connect deployment harness to 12 volts vehicle
battery (2). This will immediately deploy or activate
air bag (inflator) module or seat belt pretensioner.
15) Disconnect deployment harness from 12 volts
vehicle battery (2) and short two deployment
harness leads together by fully seating one banana
plug into the other.16) In the unlikely event that air bag (inflator) module or
seat belt pretensioner did not deploy / activate after
following these procedures, proceed immediately
with Step 22) through 25). If air bag (inflator) module
or seat belt pretensioner did deploy or activate,
proceed with Steps 18) through 21).
17) Put on pair of shop gloves to protect your hands from
possible irritation and heat when handling deployed
air bag (inflator) module or activated seat belt
pretensioner.
18) Disconnect adapter cable (special tool) from air bag
(inflator) module or seat belt pretensioner as soon as
possible. This will prevent adapter cable (special
tool) from damage due to possible contact with hot
air bag (inflator) module or hot seat belt
pretensioner.
19) Check adapter cable as follows.
• For air bag (inflator) module
Be sure to check air bag (inflator) module adapter
cable (special tool) for damage after deployment
and replace it with new adapter cable (special
tool), if it is damaged.
• For seat belt pretensioner
Be sure to check seat belt pretensioner adapter
cable (special tool) for damage after seat belt
pretensioner is activated. Replace it with spare
connector (special tool) or new adapter, if
necessary.
20) Dispose of deployed air bag (inflator) module (1) or
activated seat belt pretensioner (2) through normal
refuse channels after it has cooled for at least 30
minutes and tightly seal air bag (inflator) module (1)
or seat belt pretensioner (2) in strong vinyl bag.
Refer to “Deployed Air Bag (Inflator) Module and
Activated Seat Belt Pretensioner Disposal” for
details.
I2RH01820069-01
I3JA01820116-01

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 Air Bag System: 8B-116
8) Route deployment harness (1) out of vehicle.
9) Check that inside of vehicle and area surrounding
vehicle are clear of all people and loose or
flammable objects.
10) Stretch deployment harness (1) to its full length 10 m
(33 ft).
11) Place 12 volts vehicle battery (2) near shorted end of
deployment harness (1).
12) Completely cover windshield area and front door
window openings with drop cloth, a blanket or any
similar item. This reduces possibility of injury due to
possible fragmentation of vehicle’s glass or interior.
13) Notify all people in immediate area that you intend to
deploy air bag (inflator) module or activate seat belt
pretensioners.
NOTE
• When air bag (inflator) module deploys or
seat belt pretensioners activate, rapid gas
expansion will create substantial report.
Wear suitable ear protection. Notify all
people in immediate area that you intend
to deploy air bag (inflator) module or to
activate seat belt pretensioner and suitable
ear protection should be worn.
• After air bag (inflator) module has been
deployed, surface of air bag may contain
powdery residue. This powder consists
primarily of cornstarch (used to lubricate
air bag (inflator) module as it inflates) and
by-products of chemical reaction.

WARNING!
• Do not place deployed air bag (inflator)
module and activated seat belt
pretensioners near any flammable objects.
• Do not apply water, oil, etc. to deployed air
bag (inflator) module and activated seat
belt pretensioners.
• Wait for about 30 minutes before touching
any metal surface of air bag (inflater)
module or seat belt pretensioner modules.
Disregarding these precautions may cause
fire or personal injury.
Failure to follow procedures may result in fire
or personal injury.

14) Separate two banana plugs (1) on deployment
harness (2).
15) Connect deployment harness (2) to 12 volts vehicle
battery (3). This will immediately deploy or activate
air bag (inflator) module or seat belt pretensioners.
16) Disconnect deployment harness (2) from 12 volts
vehicle battery (3) and short two deployment
harness leads together by fully seating one banana
plug into the other.
17) Repeat Steps 3) through 16) to deploy / activate air
bag (inflator) modules and seat belt pretensioners
which has not been deployed / activated, if any.
18) In the unlikely event that air bag (inflator) module
and seat belt pretensioners after following these
procedures, proceed immediately with Step 24)
through 26). If air bag (inflator) module and seat belt
pretensioners did deploy / activate, proceed with
Steps 19) through 23).
19) Carefully remove drop cloth from vehicle and clean
off any fragments or discard it entirely.
20) Put on pair of shop gloves to protect your hands from
possible irritation and heat when handling deployed
air bag (inflator) module and activated seat belt
pretensioners.
10 m (33 ft)
1
2
I5RW0A820089-01
1
3 2
I5RW0A820090-01

Downloaded from www.Manualslib.com manuals search engine 8B-117 Air Bag System:
21) Disconnect adapter cable (special tool) from air bag
(inflator) module or seat belt pretensioner as soon as
possible. This will prevent adapter cable (special
tool) from damage due to possible contact with hot
air bag (inflator) module or hot seat belt
pretensioner.
22) Check adapter cable connector as follows.
Adapter cable connector (special tool) is designed to
be reused. However it should be inspected for
damage after deployment and replaced if necessary.
23) With air bag (inflator) modules deployed and seat
belt pretensioners activated, vehicle may be
scrapped in the same manner as non-air bag system
/ seat belt pretensioner equipped vehicle.
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.

24) Remove undeployed air bag (inflator) module(s) and/
or inactivated seat belt pretensioner(s) from vehicle.
For driver air bag (inflator) module, refer to “Driver
Air Bag (Inflator) Module Removal and Installation”.
For passenger air bag (inflator) module, refer to
“Passenger Air Bag (Inflator) Module Removal and
Installation”. For side air bag (inflator) module, refer
to “Side-Air Bag (Inflator) Module Removal and
Installation”. For side curtain-air bag (inflator)
module, refer to “Side Curtain-Air Bag (Inflator)
Module Removal and Installation”. For seat belt
pretensioner, refer to “Front Seat Belt Removal and
Installation in Section 8A”.
25) Temporarily store undeployed air bag (inflator)
module referring to “Precautions on Service and
Diagnosis of Air Bag System” for details.
26) Contact your local distributor for further assistance.
Deployed Air Bag (Inflator) Module and
Activated Seat Belt Pretensioner Disposal
S6RW0D8206019
WARNING!
Failure to follow proper air bag (inflator)
module and seat belt pretensioner disposal
procedures can result in air bag deployment
and pretensioner activation which may cause
personal injury. The undeployed air bag
(inflator) module and the inactivated seat belt
pretensioner must not be disposed of
through normal refuse channels.
The undeployed air bag (inflator) module and
the inactivated seat belt pretensioner
contains substances that can cause severe
illness or personal injury if the sealed
container is damaged during disposal.

Deployed air bag (inflator) module and the activated seat
belt pretensioner can be disposed of through normal
refuse channels just like any other parts. For their
disposal, however, the following points should be noted.
• The air bag (inflator) module and the seat belt
pretensioner immediately after deployment / activation
is very hot. Wait for 30 minutes to cool it off before
handling it.
• Never apply water, oil, etc. to deployed air bag
(inflator) module and the activated seat belt
pretensioner to cool it off and be careful so that water,
oil etc. does not get on the deployed air bag (inflator)
module and the activated seat belt pretensioner.
• After the air bag (inflator) module has been deployed,
the surface of the air bag may contain a powdery
residue. This powder consists primarily of cornstarch
(used to lubricate the bag as it inflates) and by-
products of the chemical reaction. As with many
service procedures, you should wear gloves and
safety glasses.
• When disposing of the deployed air bag (inflator)
module and the activated seat belt pretensioner, be
sure to seal it in a vinyl bag.
• When air bag (inflator) module and seat belt
pretensioner have been deployed / activated inside
the vehicle which is going to be scrapped, leave them
as installed to the vehicle.
• Be sure to wash your hands with mild soap and water
after handling them.
IYSQ01820095-01
I3JA01820119-01