200 SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 8B-111 Air Bag System:
• For seat belt pretensioner
a. Cut webbing (1) at tongue plate stopper (3) of
seat belt pretensioner (2) side as shown.
NOTE
Hold seat belt pretensioner (2) vertically in
the same condition as it is installed.
Otherwise, webbing can’t be pulled out.

b. Remove tongue plate (4) and shoulder anchor
(5) from webbing.
c. Tie webbing (1) tightly at 10 cm (3.9 in.) from
cutting edge as shown.
d. Tie seat belt pretensioner (2) with wire
harness (3) to wheel-installed tire (4) 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 (3) around at least 3 times.

e. Clear space (5) on ground about 185 cm (6 ft)
in diameter where seat belt pretensioner (2) is
to be activated. 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 activation area.
f. Place wheel-installed tire (4) with seat belt
pretensioner (2) on ground in Step e.
7) Stretch deployment harness (A) from air bag
(inflator) module or seat belt pretensioner to its full
length 10 m (33 ft).
Special tool
(A): 09932-75031
8) Place 12 volts vehicle battery (1) near the shorted
end of deployment harness (A).
9) Check that area around air bag (inflator) module or
seat belt pretensioner is clear of all people and loose
or flammable objects.
31452I3JA01820037-01
10 cm (3.9 in.)
1
I4RS0A820104-01
1. Webbing
4 3
3
25
I4RS0A820105-01

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 8B-115 Air Bag System:
5) Check that there is no open, short or damage in
special tools (deployment harness (A), adapter cable
(B), (C) and (D)). If any faulty condition is found, do
not use it and be sure to use new special tool. And
connect adapter cable (B), (C) or (D) to deployment
harness (A) and lock connectors with lock slider.
Special tool
(A): 09932–75031
(B): 09932–78332
(C): 09932–77310
(D): 09932–76510
6) Short two deployment harness leads together by
fully seating one banana plug into the other.
WARNING!
Deployment harness (A) shall remain shorted
and not be connected to 12 volts vehicle
battery until you are ready to deploy air bag
(inflator) module or activate seat belt
pretensioner.

7) Connect adapter cable (B), (C) or (D) in series with
deployment harness (A) to air bag (inflator) module
or seat belt pretensioner as follows.
• For driver air bag (inflator) module [A]
Connect adapter cable (B) in series with
deployment harness (A) and push adapter cable
(B) connector to air bag (inflator) module
connector till click can be heard.
• For passenger air bag (inflator) module [B]
Connect adapter cable (B) in series with
deployment harness (A) and push adapter cable
(B) connector to air bag (inflator) module
connector till click can be heard.
• For side-air bag (inflator) module [C]
Connect adapter cable (B) in series with
deployment harness (A) and push adapter cable
(B) connector to side bag (inflator) module
connector till click can be heard.
• For side curtain-air bag (inflator) module [D]
Connect adapter cable (C) in series with
deployment harness (A) and push adapter cable
(C) connector to air bag (inflator) module
connector till click can be heard.
• For seat belt pretensioners [E]
Connect adapter cable (D) in series with
deployment harness (A) to seat belt pretensioner
and lock connector with lock part.
[C] [B]
[D]
[E] [A]
12
(D)
(A)1
1
(A)
(B)
1 (C)
(A)
1
(B)
(A)
1
(B)
(A)
I5RW0A820088-02

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

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 9A-143 Wiring Systems:
List of Connector
List of ConnectorsS6RW0D910F001
Refer to “C Connector”.
Refer to “E Connector”.
Refer to “G Connector”.
Refer to “J Connector”.
Refer to “K Connector”.
Refer to “L Connector”.
Refer to “O Connector”.
Refer to “Q Connector (8ch)”.
Refer to “R Connector”.
Refer to “S Connector”.
C ConnectorS6RW0D910F002
C01 C06
A/T
C07 C31 C31 C32 C32
A/TM15A engine,
M16A engineJ20A engine With OCV Without OCV
C32 C34 C36 C37 C39 C40
J20A engine A/TM15A engine,
M16A engineM15A engine
C40 C42 C42 C43 C44 C45
J20A engine M15A engineM16A engine,
J20A engineM16A engine A/T J20A engine A/T
C46 C47 C47 C48 C64
M15A engine,
J20A engineM15A engine,
M16A engineJ20A engine J20A engine
12 3456
20 21 16 17 18 1978910
22 23 24 2512
27 2613
28
31 32 33 34 35 36
50 51 46 47 48 4937 38 39 40
52 53 54 5511
41
5642
5743
5814 15
29 30
44
60 45
59
MCONF600002-01
17181920
7
1256
89101113141516
21222324
12
34
MCONF240020-01
181920 21
712345 68910
22232425
13141516
26
171112
MCONF260020-01
123
MCONF030103-02
123
MCONF030038-01
123
MCONF030123-01
123
MCONF030103-02
123
MCONF030053-01
123
MCONF030103-02
123
MCONF030030-01
1
MCONF010054-01
12MCONF020042-01
1
2
3
4
MCONF040102-02
1
2
3
4
MCONF040024-01
1
2
3
4
MCONF040024-01
1
2
3
4
MCONF040102-02
1
2
3
4
MCONF040024-01
1
2
MCONF020150-01
1
2
MCONF020150-01
123
MCONF030040-01
14325
MCONF050025-01
12345
MCONF050050-01
1234 56
MCONF060068-01
1
2
MCONF020150-01

Downloaded from www.Manualslib.com manuals search engine Wiring Systems: 9A-144
C91 C92 C93 C94 C101 C101
M15A engine,
M16A engineJ20A engine
C102 C102 C103 C104 C122 C123
M15A engine,
M16A engineJ20A engine J20A engine J20A engine IF EQPDM15A engine,
M16A engine
C123 C124 C139 C139 C141 C162
J20A engine IF EQPDM15A engine A/T,
M16A engine A/TJ20A engine A/T
C163 C165 C166 C166 C192 C194
J20A engine M/TM15A engine A/T,
M16A engine A/TJ20A engine A/T
C195 C196 C282 C283 C311 C312
M15A engine,
M16A engine
C313 C343 (TO E371)
M16A engine
12
MCONF020266-01
12
MCONF020266-01
12
MCONF020266-01
12
MCONF020266-01
123
MCONF030055-01
123
MCONF030103-02
123
MCONF030055-01
123
MCONF030103-02
123
MCONF030103-02
123
MCONF030103-02
123
456
MCONF060018-01
12MCONF020042-01
1
2
MCONF020150-01
2
1
MCONM020033-01
1
2
65
10 74
93
8
MCONF100049-01
1
2
54
8 63
7
MCONF080028-02
1
MCONF010076-01
1
MCONF010030-01
1
MCONF010001-01
12
MCONF020176-0169
12345
78
MCONF090011-01
546
213
879
1110MCONF110011-02
1
MCONF010057-03
21
43
MCONF040127-01
1MCONF010021-01
1
MCONF010057-03
1
MCONF010078-01
1
MCONF010074-01
24
9
131415
1
101112
56378
MCONF150008-01
24
9
131415
1
101112
56378
MCONF150008-01
24
9
131415
1
101112
56378
MCONF150008-01
21
8
3
9765
131211
1819
4
10
14
20171615MCONF200011-01

Downloaded from www.Manualslib.com manuals search engine 9A-145 Wiring Systems:
E ConnectorS6RW0D910F003
E01 E04
Except Taiwan
E08 E11 E12
E13 E31 E33 E35 E36 E37
E40 E61 E62 E63 E64 E65
M16A engine
E65 E68 E69 E70 E151 E152
J20A engine IF EQPD IF EQPD
E159 E160 E161 E162 E163 E164
E165 E166 E181 E183 E191
E192 E221 E222 E223 E224 E225
J20A engine J20A engine J20A engine
12 3456
20 21 16 17 18 1978910
22 23 24 2512
27 2613
28
31 32 33 34 35 36
50 51 46 47 48 4937 38 39 40
52 53 54 5511
41
5642
5743
5814 15
29 30
44
60 45
59
MCONF600002-01
12567
8
9 1011121314
34
MCONF140012-01
210
13242521
1345678911
1214152326161718192022
MCONF260018-01
123456789
11 12 13 14 15 16 17 18 1910
20
MCONF200029-01
1
2
MCONF020204-01
1
2
MCONF020185-01
3 2 1
6 5 4
MCONF060052-01
2
1
MCONM020033-01
2
1
MCONM020033-01
123
MCONF030062-01
1
2
MCONF020200-01
12
MCONF020199-01
12
MCONF020205-01
1
2
MCONF020008-01
1
2
MCONF020008-01
12
54
3
MCONF050027-01
21
MCONF020183-01
21
43
MCONF040130-01
3
12
MCONF030128-01
3
12
MCONF030128-01
21
MCONF020183-01
12
3
MCONF030101-01
12
3
MCONF030101-01
1
2
MCONF020289-01
1
2
MCONF020289-01
1
2
MCONF020013-01
1
2
MCONF020013-01
2 1
MCONF020162-01
2 1
MCONF020162-01
2 1
MCONF020196-01
2 1
MCONF020196-01
1
34
2
MCONF040045-012 1
MCONF020115-01
1234 56
MCONF060068-01
2 1
MCONF020151-01
21
4
3
MCONF040131-01
312
5
4
MCONF050044-01
312
5
4
MCONF050044-01
312
5
4
MCONF050044-01
21
4
3
MCONF040131-01