side impact SUZUKI SX4 2006 1.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-90
• Improperly formed or damaged terminals.
Check each connector terminal in problem circuits
carefully to ensure good contact tension by using the
corresponding mating terminal included in the
connector test adapter kit (special tool).
If contact tension is not enough, reform the terminal to
increase contact tension or replace it.
Special tool
(A): 09932–76010 Connector test adapter kit
• Poor terminal-to-wire connection.
Check each wire harness in problem circuits for poor
connection by shaking it by hand lightly. If any
abnormal condition is found, change the wire harness
assembly or component parts with new ones.
• Wire insulation which is rubbed through, causing an
intermittent short as the bare area touches other
wiring or parts of the vehicle.
• Wire broken inside the insulation. This condition could
cause a continuity check to show a good circuit, but if
only 1 or 2 strands of a multi-strand-type wire are
intact, resistance could be far too high.
Repair and Inspection Required after AccidentS6RW0D8204048
CAUTION!
• All air bag system components, including
the electrical harness (component
mounting points), must be inspected after
an accident. If any components are
damaged or bent, they must be replaced
even if air bag system activation did not
occur.
• Never use air bag system parts from
another vehicle.
• Do not attempt to service the parts below.
Service of these parts is by replacement
only.
– Driver / Passenger air bag (inflator)
modules
– Driver / Passenger side-air bag (inflator)
modules
– Driver / Passenger side curtain-air bag
(inflator) modules
– Driver / Passenger seat belt
pretensioners
– Forward impact-sensor
– Driver / Passenger side impact-sensors
–SDM
– Contact coil and combination switch
assembly
– Air bag wire harness in main harness,
instrument panel harness, floor harness,
passenger air bag harness, side-air bag
harness and side curtain-air bag
harness.
• Proper operation of the sensors and air
bag system requires that any repairs to the
vehicle structure return it to its original
production configuration.

(A)
I4RS0A820045-01
IYSQ01010028-01
IYSQ01820025-01

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 Air Bag System: 8B-92
– Check connector or lead wire of SDM for scorching,
melting or damage.
– Check SDM connector and terminals for tightness.
– Check if SDM sets a DTC and is judged as
malfunctioning according to the diagnostic flow.
• Air bag wire harness and connections
– Check for damages, deformities or poor
connections.
Refer to “Inspection of Intermittent and Poor
Connections”.
– Check wire harness clamps for tightness.
• Forward impact-sensor
– Check sensor (1) and apron-side-member (driver
side) (2) for damage, bend or rust.
– Check connector (3) or lead wire (4) of forward-
sensor for scorching, melting or damage.• Side impact-sensor
– Check sensor (1) and under body (2) for dents,
cracks, deformation or rust.
– Check sensor connector (sensor side and harness
side) (3) or sensor lead wire (4) for damage, crack,
scorching or melting.
• Seat belt pretensioner
– Check for dents, cracks, damage or fitness
– Check harness and connector for damage or
tightness.
• Seat belts and mounting points
– Refer to “Front Seat Belt Components in Section
8A”.
• “AIR BAG” warning light
– After vehicle is completely repaired, perform “Air
Bag Diagnostic System Check”.
• Side-air bag (inflator) module
– Check for dents, cracks, damage or fitness.
– Check trim cover for cracks or deformities.
– Check wire harness and connector for damage or
tightness.
• Side curtain-air bag (inflator) module
– Check for dents, cracks, damage or fitness.
– Check harness wire harness and connector for
damage or tightness.
– Check headlining for cracks or deformation.
1. Main harness 5. Side-air bag harness
2. Grounding point 6. Side curtain-air bag harness
3. Floor harness 7. Side curtain-air bag (inflator)
module
4. Instrument panel harness
I5RH01820092-01
4
1
26
3
5
7
I6RW0C820018-01
1
23
4I5RW0A820059-01
1. Seat belt 2. Retractor assembly
3 2
1
4
I5RW0A820060-01
I3JA01820043-01

Downloaded from www.Manualslib.com manuals search engine 8B-97 Air Bag System:
Driver Air Bag (Inflator) Module InspectionS6RW0D8206006
WARNING!
Never disassemble air bag (inflator) module
or measure its resistance. Otherwise,
personal injury may result.

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 visually and if any of the
following is found, replace it with a new one.
• Air bag being deployed
• Trim cover (pad surface) (1) being cracked
• Inflator case (2) being damaged or having been
exposed to strong impact (dropped)
• Bend or deformity of air bag (inflator) module bracket.
Passenger Air Bag (Inflator) Module Removal
and Installation
S6RW0D8206007
WARNING!
• 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.

Removal
1) Disable air bag system. Refer to “Disabling Air Bag
System”.
2) Remove center ventilation louver with garnish
referring to “Center Ventilation Louver Removal and
Installation in Section 7A”.
3) Pull out glove box while pushing its stopper from
both right and left sides.
4) Remove passenger air bag (inflator) module
attaching bolts (1) and its facing cover bolt (6).
5) Hold up passenger air bag (inflator) module with its
facing cover (5) without extending wire harness (2)
to avoid air bag connector damage and to
disconnect passenger air bag (inflator) module
connector (3) as shown in figure.
a) Unlock lock button (4).
b) With lock button unlocked, disconnect connector.
6) Remove passenger air bag (inflator) module with its
facing cover (5) from instrument panel.
1
2
I5RW0A820067-01
“A”
5
“A”“A”
3
4a)
b)
2
6
1 1
I7RW01821033-01

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 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 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 Air Bag System: 8B-104
Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air
Bag System”.
3) Remove front bumper referring to “Front Bumper
and Rear Bumper Components in Section 9K”.
4) Disconnect forward impact-sensor connector (1)
sliding connector outer (2) as shown.
5) Remove forward impact-sensor bolt (3) and forward
impact-sensor (4) from apron-side-member (driver
side) (5).
Installation
CAUTION!
Proper operation of forward impact-sensor
requires sensor be rigidly attached to vehicle
structure and that the arrow on sensor be
pointing toward the front of the vehicle.

1) Check that none of the following faulty conditions
exists.
• Bend, deformity or rust of front panel.
• Foreign matter on mating surface of sensor.
2) Install forward impact-sensor (1) to apron-side-
member (driver side) (3) and tighten mounting bolt
(2) to specified torque.
Tightening torque
Forward impact-sensor mounting bolt (a): 9 N·m
(0.9 kgf-m, 6.5 lb-ft)3) Connect forward impact-sensor connector (4) by
pushing connector till click is heard from it.
4) Install front bumper referring to “Front Bumper and
Rear Bumper Components in Section 9K”.
5) Enable air bag system referring to “Enabling Air Bag
System”.
6) Connect negative (–) cable at battery.
Forward Impact-Sensor InspectionS6RW0D8206014
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.

CAUTION!
• Never disassemble forward impact-sensor.
• Sensor should be replaced when it was
dropped from a height of 90 cm (3 ft) or
more.

• Check sensor for dents, cracks or deformation.
• Check sensor connector (sensor side and harness
side) and sensor connector lock mechanism for
damage or crack.
• Check connector terminals for bend, corrosion or rust.
4
2
3
5
1
I7RW01821035-01
1
2, (a)
4
3
I6RW0B820038-01

Downloaded from www.Manualslib.com manuals search engine 8B-105 Air Bag System:
Side Impact-Sensor Removal and InstallationS6RW0D8206024
WARNING!
During service procedures, be very careful
when handling a sensor.
• Never strike or jar a sensor.
• A sensor bolt must be carefully torqued to
assure proper operation. Under loose
connection, it could cause improper
operation of the air bag system.

Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system. Refer to “Disabling Air Bag
System”.
3) Remove center pillar lower trim.
4) Turn up floor carpet at front seat side.
5) Disconnect side impact-sensor connector (1) sliding
connector outer (2) as shown.
6) Remove side impact-sensor bolts (3), and side
impact-sensor (4) from side sill inner panel (5).
Installation
CAUTION!
Proper operation of side impact-sensor
requires that sensor is rigidly attached to
specified position.

1) Check that none of following faulty conditions exists.
• Bend, deformity or rust of under body.
• Foreign matter on mating surface of sensor.2) Install side impact-sensor (1) to side sill inner panel
(2) and tighten side impact-sensor bolt (3) to
specified torque.
Tightening torque
Side impact-sensor bolt (a): 9 N·m (0.9 kgf-m,
6.5 lb-ft)
3) Connect side impact-sensor connector (4) by
pushing connector till click is heard from it.
4) Return the carpet, and install center pillar lower trim.
5) Enable air bag system. Refer to “Enabling Air Bag
System”.
6) Connect negative (–) cable at battery.
Side Impact-Sensor InspectionS6RW0D8206025
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.

CAUTION!
• Never disassemble side impact-sensor.
• Sensor should be replaced when it was
dropped from a height of 90 cm (3 ft) or
more.

• Check sensor for dents, crack, deformation.
• Check sensor connector (sensor side and harness
side), lock mechanism or sensor lead wire for
damage, crack, scorching or melting.
• Check connector terminals for bent, corrosion or rust.
If any faulty condition is found in above checks,
replace.
5
4
3
2
1I7RW01822149-01
2
1
3, (a)
4I7RW01822150-01

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-118
Specifications
Tightening Torque SpecificationsS6RW0D8207001
NOTE
The specified tightening torque is also described in the following.
“Side-Air Bag (Inflator) Module Removal and Installation”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Use of Special ToolsS6RW0D8208001
WARNING!
To avoid deployment when troubleshooting
the air bag system, do not use electrical
equipment such as a battery powered or AC
powered voltmeter, ohmmeter, etc., or any
type of electrical equipment other than that
specified. Do not use a non-powered probe
type tester.
Instructions must be followed carefully,
otherwise personal injury may result.

You should be familiar with the tools listed under the
heading “Special Tool”. You should be able to measure
voltage and resistance. You should be familiar with
proper use of a scan tool such as Air Bag Driver /
Passenger Load Tool, Connector Test Adapter Kit and
the Digital Multimeter.
Special tool
(A): 09932–76010 Connector Test Adapter KitThis must be used whenever a diagnostic procedure
requests checking or probing a terminal.
Using the appropriate adapter in the special tool will
ensure that no damage to the terminal will occur from the
multimeter probe, such as spreading or bending. Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
SDM bolt 9 0.9 6.5)
Driver air bag (inflator) module mounting bolt 9 0.9 6.5)
Passenger air bag (inflator) module attaching
bolt23 2.3 17.0)
Sleeve lock nut 2.5 0.25 2.0)
Side curtain-air bag (inflator) module attaching
bolts11 1.1 8.0)
Forward impact-sensor mounting bolt 9 0.9 6.5)
Side impact-sensor bolt 9 0.9 6.5)
I7RW01822127-01