section 1l SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 9E-3 Glass / Windows / Mirrors:
Diagnostic Information and Procedures
Rear End door Window Defogger Symptom DiagnosisS6RW0D9504001
NOTE
• Use of SUZUKI scan tool makes it easy to check whether a faulty condition is on the input side or
output side of BCM. For checking procedure, refer to “Diagnosis Using Output Test Function of
SUZUKI Scan Tool” under “Scan Tool Data in Section 10B”.
• Check each part in the order from the top of the following list.

Power Window Control System Symptom DiagnosisS6RW0D9504002
Condition Possible cause Correction / Reference Item
Rear end door window
defogger does not
operateCircuit fuse blownReplace fuse and check for short circuit.
Rear end door window defogger switch
faultyCheck rear end door window defogger switch
referring to “Rear End Door Window Defogger
Switch Inspection”.
Rear end door window defogger relay
faultyCheck rear end door window defogger relay
referring to “Rear End Door Window Defogger
Relay Inspection”.
Defogger wire faultyCheck defogger wire referring to “Rear End
Door Window Defogger Wire Inspection”.
Wiring or grounding faultyRepair circuit.
BCM faultyReplace after making sure that none of above
parts is faulty.
Condition Possible cause Correction / Reference Item
All power windows do not
operateCircuit fuse blownReplace fuse and check for short circuit.
Power window main switch faultyCheck power window main switch referring to
“Power Window Main Switch Inspection”.
Ignition switch faultyCheck ignition switch referring to “Ignition
Switch Inspection in Section 9C”.
Wiring or grounding faultyRepair circuit.
Only one power window
does not operatePower window main switch faultyCheck power window main switch referring to
“Power Window Main Switch Inspection”.
Power window sub switch faultyCheck power window sub switch referring to
“Power Window Sub Switch Inspection”.
Wiring and/or coupler faultyCheck wiring and/or coupler.
Power window regulator faultyCheck window regulator.
Power window motor faultyCheck power window motor.
Wiring or grounding faultyRepair circuit.
Driver side door glass
fails to perform auto-up /
auto-down function
(Pinching Prevention
Function Model)Power window main switch faultyCheck power window main switch referring to
“Power Window Main Switch Inspection”.
Power window motor faultyCheck power window motor referring to “Pulse
Sensor and Its Circuit Inspection (Pinching
Prevention Function Model)”.
Wiring or grounding faultyRepair circuit.
Driver side door glass
fails to lower back even
when a foreign matter is
pinched (Pinching
Prevention Function
Model)Power window main switch has not been
initializedExecute the initial setting of power window
main switch referring to “Power Window Main
Switch Initialization (Pinching Prevention
Function Model)”.
Power window main switch faultyCheck power window main switch referring to
“Power Window Main Switch Inspection”.
Power window motor faultyCheck power window motor referring to “Pulse
Sensor and Its Circuit Inspection (Pinching
Prevention Function Model)”.

Downloaded from www.Manualslib.com manuals search engine 9E-5 Glass / Windows / Mirrors:
Door Mirror Heater Symptom Diagnosis (If Equipped)S6RW0D9504004
NOTE
• Use of SUZUKI scan tool makes it easy to check whether a faulty condition is on the input side or
output side of BCM. For checking procedure, refer to “Diagnosis Using Output Test Function of
SUZUKI Scan Tool” under “Scan Tool Data in Section 10B”.
• Check each part in the order from the top of the following list.

Repair Instructions
Windshield ComponentsS6RW0D9506001
Condition Possible cause Correction / Reference Item
All door mirror heaters
does not operateCircuit fuse blownReplace fuse and check for short circuit.
Rear end door window defogger switch
faultyCheck rear end door window defogger switch
referring to “Rear End Door Window Defogger
Switch Inspection”.
Rear end door window defogger relay
faultyCheck rear end door window defogger relay
referring to “Rear End Door Window Defogger
Relay Inspection”.
Wiring or grounding faultyRepair circuit.
BCM faultyReplace after making sure that none of above
parts is faulty.
Only one door mirror
heater does not operateDoor mirror heater faultyCheck door mirror heater refiring to “Door
Mirror Heater Inspection (If Equipped)”.
Wiring or grounding faultyRepair circuit.
3 31
2
44
4
I5RW0A950001-02
1. Windshield glass 3. Windshield glass stopper : Do not reuse.
2. Windshield molding 4. Spacer

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Windshield Removal and InstallationS6RW0D9506002
Preparation
The windshield is installed by using a special type of
adhesive (that is, one component urethane adhesive
used with primer). For the windshield replacement, it is
important to use an adhesive which provides sufficient
adhesion strength and follow the proper procedure.
CAUTION!
• Described is the glass replacement by
using 3 types of primers and 1 type of
adhesive made by YOKOHAMA (one
component urethane adhesive to be used
with primer in combination). When using
primer and adhesive made by other
manufacturers, be sure to refer to handling
instructions supplied with them.
Negligence in following such procedure or
misuse of the adhesive in any way hinders
its inherent adhesive property. Therefore,
before the work, make sure to read
carefully the instruction and description
given by the maker of the adhesive to be
used and be sure to follow the procedure
and observe each precaution throughout
the work.
• Should coated surface be scratched or
otherwise damaged, be sure to repair
damaged part, or corrosion may start from
there.

Use the specific adhesive which has the following
property.
Glass adhesive shearing strength
40 kg/cm2 (569 lb/in2) or moreAdhesive materials and tools required for removal and
installation.
• One component urethane adhesive and primers used
in combination (For one sheet of windshield).
– Adhesive (470 g (15.7 oz.))
– Primer for glass (30 g (1.0 oz.))
– Primer for body (30 g (1.0 oz.))
– Primer for molding (30 g (1.0 oz.))
• Eyeleteer
•Piano string
• Windshield knife
• Brush for primer application (2 pcs)
•Knife
• Rubber sucker grip
• Sealant gun (for filling adhesive)
• Putty spatula (for correcting adhered parts)
Removal
1) Clean both inside and outside of glass and around it.
2) Remove wiper arms and cowl top garnish.
3) Using tape, cover body surface around glass to
prevent any damage.
4) Remove rear view mirror, sun visor and front pillar
trims (right & left).
5) If necessary, remove instrument panel. Refer to
“Instrument Panel Removal and Installation in
Section 9C”.
6) If necessary, remove head lining. Refer to “Head
Lining Removal and Installation in Section 9H”.
7) Remove (or cut) windshield molding.
8) Drill hole with eyeleteer (1) through adhesive and let
piano string through it.
I2RH01950040-01

Downloaded from www.Manualslib.com manuals search engine 9E-9 Glass / Windows / Mirrors:
10) Apply adhesive (1) referring to figure.
NOTE
• Press glass (2) against fittings surface of
body panel quickly after adhesive (1) is
applied.
• Use of rubber sucker grip is helpful to hold
and carry glass after adhesive (1) is
applied.
• Perform steps 8) to 9) within 10 min. to
ensure sufficient adhesion.
• Be sure to refer to adhesive maker’s
instruction for proper handling and drying
time.
• Start from bottom side of glass (2).
• Be careful not to damage primer.

Adhesive amount specifications and position for
windshield
Width “a”: Approx. 7 mm (0.27 in.)
Height “b”: Approx. 15 mm (0.59 in.)
Position “c”: Approx. 10 mm (0.39 in.) for right,
left and upper sections
Position “d”: Approx. 50 mm (1.97 in.) for bottom
section11) Holding rubber sucker grips (1), place glass onto
body by aligning mating marks marked in step 3) and
press it.
12) Check for water leakage by pouring water over
windshield through hose. If leakage is found, dry
windshield and fill leaky point with adhesive. If water
still leaks even after that, remove glass and start
installation procedure all over again.
NOTE
• Do not use high pressure water.
• Do not blow compressed air directly at
adhesive applied part when drying.
• Do not use infrared light or like for drying.

3. Molding 4. Windshield glass spacer
2
“b”
“c”
2
3
1
“a”
3
2
1
“b”
“c”
“a”
2
4
1“b”
“d”
“a”
I5RW0A950006-01
I2RH01950050-01
I2RH01950051-01

Downloaded from www.Manualslib.com manuals search engine Glass / Windows / Mirrors: 9E-18
Rear Door Window Regulator Removal and
Installation
S6RW0D9506015
Removal
1) Remove door glass referring to “Rear Door Glass
Removal and Installation”.
2) Disconnect power window motor lead wire at
coupler.
3) Loosen regulator mounting screws, and then remove
rear window regulator (1).
Installation
Reverse removal procedure noting the following.
• Apply grease to sliding and rotating portions of
window regulator.
: Grease 99000–25011 (SUZUKI Super Grease A)
• Tighten rear door window regulator attaching screws.
Rear door window regulator screw tightening
order
(1) → (2)
Rear Door Window Regulator InspectionS6RW0D9506016
Check the following point:
• Check regulator sliding and rotating parts.
• Check rollers for wear and damage.
Rear End Door Window Defogger Switch
Inspection
S6RW0D9506017
1) Check rear end door window defogger switch for
operation as follows.
a) Rear end door window defogger switch is built in
HVAC control unit.
Remove HVAC control module (unit) referring to
“HVAC Control Unit Removal and Installation in
Section 7A” or “HVAC Control Module Removal
and Installation in Section 7B”.
b) Check that there is continuity between terminal
(1) and terminal (2) of HVAC control module
(unit) when rear end door window defogger
switch is at ON position. (Rear end door window
defogger switch is kept in push.)
c) Check that there is no continuity between
terminal (1) and terminal (2) of HVAC control
module (unit) when rear end door window
defogger switch is at OFF position.
If check result does not meet the above conditions,
replace HVAC control module (unit).
1
I5RW0A950031-01
2
2
1
I5RW0A950032-01[A]: Manual A/C model
[B]: Auto A/C model
1
1 2
2[A]
[B]
I5RW0A950033-01

Downloaded from www.Manualslib.com manuals search engine 9F-3 Security and Locks:
Diagnostic Information and Procedures
Power Door Lock System Symptom Diagnosis (If Equipped)S6RW0D9604001
NOTE
• Use of SUZUKI scan tool makes it easy to check whether a faulty condition is on the input side or
output side of BCM. For checking procedure, refer to “Diagnosis Using Output Test Function of
SUZUKI Scan Tool” under “Scan Tool Data in Section 10B”.
• Check each part in the order from the top of the following list.

Power Door Lock System Operation Inspection (If Equipped)S6RW0D9604002
1) Check the following operation:
a) Turn the driver side key cylinder is turned LOCK once, check all doors lock.
b) Turn the driver side door key cylinder is turned UNLOCK position with door key twice, check all doors unlock.
c) With all doors unlocked, insert key in key cylinder of driver side door and turn it to lock side, turn it again to lock
side within 3 seconds and check that no door can be opened even when door lock knob is moved to unlock
side (dead lock function, if equipped).
If malfunction is found, go to “Power Door Lock System Symptom Diagnosis (If Equipped)”. Condition Possible cause Correction / Reference Item
All door can not be locked
/ unlocked by all of
switchesCircuit fuse blownReplace fuse and check for short circuit.
Wiring or grounding faultyRepair circuit.
BCM faultyReplace after making sure that none of above
parts is faulty.
All door can not be locked
/ unlocked by only power
door lock switchCircuit fuse blownReplace fuse and check for short circuit.
Power door lock switch faultyCheck power door lock switch referring to
“Power Door Lock Switch Inspection (If
Equipped)”.
Wiring harness connected to power door
lock switch faultyRepair.
Wiring or grounding faultyRepair circuit.
BCM faultyReplace after making sure that none of above
parts is faulty.
All door can not be locked
/ unlocked by only key
cylinder switchCircuit fuse blownReplace fuse and check for short circuit.
Key cylinder switch faultyCheck key cylinder switch referring to “Door
Key Cylinder Switch Inspection (If Equipped)”.
Wiring or grounding faultyRepair circuit.
BCM faultyReplace after making sure that none of above
parts is faulty.
Only one door can not be
locked / unlockedPower door lock actuator faultyCheck actuator referring to “Power Door Lock
Actuator Inspection (If Equipped)”.
Wiring harness connected to applicable
door lock actuator faultyRepair.
BCM faultyReplace after making sure that none of above
parts is faulty.

Downloaded from www.Manualslib.com manuals search engine Security and Locks: 9F-4
Keyless Entry System Symptom Diagnosis (If Equipped)S6RW0D9604003
NOTE
• Confirm that power door lock system is in good condition before referring to the following possible
causes.
• Check each part in the order from the top of the following list.

Condition Possible cause Correction / Reference Item
All door can not be locked
/ unlocked by only
keyless entry transmitterTransmitter battery deadReplace battery referring to “Replacement of
Transmitter Battery (Other than Keyless Start
Model)”.
Door switch faultyCheck door switch referring to “Door Switch
(Front / Rear Door) Inspection in Section 9C”
and/or “Rear End Door Switch Inspection in
Section 9C”.
Transmitter faultyReplace transmitter.
Key reminder switch in ignition switch
faultyCheck ignition switch referring to “Ignition
Switch Inspection in Section 9C”.
Wiring or grounding faultyRepair circuit.
Keyless entry receiver faultyCheck keyless entry receiver referring to
“Keyless Entry Receiver and Its Circuit
Inspection (If Equipped)”.
BCM faultyReplace after making sure that none of above
parts is faulty.
Turn signal lights can not
be flashed when doors
are locked / unlocked by
keyless entry transmitterTurn signal and hazard warning relay
faultyCheck turn signal and hazard warning relay
referring to “Turn Signal and Hazard Warning
Relay Inspection in Section 9B”.
Wiring or grounding faultyRepair circuit.
BCM faultyReplace after making sure that none of above
parts is faulty.
Interior light does not
light when doors are
unlocked by keyless entry
transmitterWiring or grounding faultyRepair circuit.
BCM faultyReplace after making sure that none of above
parts is faulty.
Hazard warning lights do
not light when doors are
locked/unlocked by
keyless entry transmitterTurn signal and hazard warning relay
faultyCheck turn signal and hazard warning relay
referring to “Turn Signal and Hazard Warning
Relay Inspection in Section 9B”.
Wiring or grounding faultyRepair circuit.
BCM faultyReplace after making sure that none of above
parts is faulty.
Transmitter code can not
be programmed to BCMDoor switch faultyCheck door switch referring to “Door Switch
(Front / Rear Door) Inspection in Section 9C”
and/or “Rear End Door Switch Inspection in
Section 9C”.
Keyless entry receiver faultyCheck keyless entry receiver referring to
“Keyless Entry Receiver and Its Circuit
Inspection (If Equipped)”.
Key reminder switch in ignition switch
faultyCheck ignition switch referring to “Ignition
Switch Inspection in Section 9C”.
Wiring or grounding faultyRepair circuit.
BCM faultyReplace after making sure that none of above
parts is faulty.

Downloaded from www.Manualslib.com manuals search engine 9F-5 Security and Locks:
Keyless Entry System Operation Inspection (If
Equipped)
S6RW0D9604004
NOTE
When performing the this inspection, make
sure to have any of the door once opened /
closed after the ignition key has been
removed from the ignition key cylinder.

1) Confirm that power door lock system operates
normally, refer to “Power Door Lock System
Operation Inspection (If Equipped)”.
2) All doors are closed and unlocked.
3) Check the following operation:
a) Push “lock” button (1) on transmitter (2) or
remote controller once, and check all doors lock
and hazard waning lights flash once.b) Push “unlock” button (3) on transmitter (2) or
remote controller twice, and check all doors
unlock and hazard waning lights flash twice and
interior light turns on several seconds with the
interior light switch in the middle position.
If malfunction is found, go to “Keyless Entry System
Symptom Diagnosis (If Equipped)”.
Door Lock Function of Keyless Start System
Symptom Diagnosis (If Equipped)
S6RW0D9604005
Proceed to “Keyless Start System Symptom Diagnosis in
Section 10E” in case that doors cannot be locked and
unlocked by operating the request switch at the outside
door handle.
Rear End Door Opener System Symptom Diagnosis (If Equipped)S6RW0D9604006
NOTE
• Use of SUZUKI scan tool makes it easy to check whether a faulty condition is on the input side or
output side of BCM. For checking procedure, refer to “Diagnosis Using Output Test Function of
SUZUKI Scan Tool” under “Scan Tool Data in Section 10B”.
• Check each part in the order from the top of the following list.

Rear End Door Opener System Operation Inspection (If Equipped)S6RW0D9604007
1) Unlock all doors by using manual lock switch, keyless entry transmitter, or key cylinder switch.
2) Make sure that latch of rear end door is released from striker when rear end door opener switch is pushed.
If malfunction is found, go to “Rear End Door Opener System Symptom Diagnosis (If Equipped)”.
1
3
2I4RS0B960013-01
Condition Possible cause Correction / Reference Item
Rear end door can not be
openedCircuit fuse blownReplace fuse and check for short circuit.
Rear end door opener switch faultyCheck rear end door opener switch referring to
“Rear End Door Opener Switch Inspection (If
Equipped)”.
Rear end door actuator faultyCheck rear end door actuator referring to
“Power Door Lock Actuator Inspection (If
Equipped)”.
Wiring or grounding faultyRepair circuit.
BCM faultyReplace after making sure that none of above
parts is faulty.

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Repair Instructions
Front Door Lock Assembly ComponentsS6RW0D9606001
Front Door Lock Assembly Removal and
Installation
S6RW0D9606002
Removal
1) Remove door trim and door sealing cover referring to
step 1) to 6) of “Front Door Glass Removal and
Installation in Section 9E”.
2) Raise window all the way up.
3) Remove door sash (1).4) Remove key cylinder mounting bolt (1), and then
remove key cylinder (2).
5) Disconnect door opening control rod (1) from outside
handle.
6) Disconnect door lock motor lead wire at coupler (if
equipped).
(a)
(b)
5
3
6
1 4
2
I5RW0A960003-01
1. Front door latch assembly
: Apply lithium grease 99000-25011 to sliding and rotating parts and spring if any.4. Latch striker : 5.0 N⋅m
(0.5 kgf-m, 4.0 lb-ft)
2. Outside handle assembly
: Apply lithium grease 99000-25011 to sliding part.5. Key cylinder : 10 N⋅m
(1.0 kgf-m, 7.5 lb-ft)
3. Outside handle frame
: Apply lithium grease 99000-25011 to sliding part and spring.6. Inside handle bezel
1
I4RS0A960007-01
12
I4RS0B960005-01

Downloaded from www.Manualslib.com manuals search engine 9F-7 Security and Locks:
7) Remove door latch screws (2) and remove door lock
assembly (3).
Installation
Reverse removal procedure to install front door lock
assembly noting the following instructions.
• Apply grease to sliding parts of door latch assembly.
: Grease 99000–25011 (SUZUKI Super Grease A)
• Tighten door latch screws to specified torque.
Tightening torque
Door latch screw (a): 5.0 N·m (0.5 kgf-m, 4.0 lb-ft)
• Move door latch striker (2) up or down so its center
aligns with the center of groove “A” on the door lock
assembly (1) as shown.
Striker should be moved vertically and placed level.
Do not adjust door lock (1).
Tightening torque
Door latch striker screw (a): 10 N·m (1.0 kgf-m, 7.5
lb-ft)• Move door latch striker (1) sideways to adjust door
outer panel surface (2) flush with rear door outer
panel or body outer panel surface (3) as shown.
• Install door trim referring to “Front Door Glass
Removal and Installation in Section 9E”.
3. Shaft
1
2 3
I4RS0A960006-01
(a)
I4RS0A960008-01
1
2
3
(a)“A”
I5RW0A960005-01
[A]: Front door
[B]: Rear door
I5RW0A960012-01