602 SUZUKI SX4 2006 1.G Service Repair 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 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-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-120
Special ToolS6RW0D8208002
09932–75010 09932–75031
Air bag load tool Air bag deployment harness
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / )) / ) / )
09932–75041 09932–76010
Passenger air bag (inflator)
module deployment fixtureConnector test adapter set
) / )This set includes the
following items. 1.
Connector test adapter kit
(09932-75020), 2.
Connector test adapter &
shorting bar release tool
(09932-76020) ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) /
) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / ) / ) / ) /
) / ) / ) / ) / )
09932–76510 09932–77310
Deployment adapter cable Deployment adapter cable
4P
) / ) / ))
09932–78310 09932–78332
Adapter cable Deployment adapter cable
) / ) / ) / ) / ) / ) / ) /
))
09932–78340 SUZUKI scan tool
Deployment adapter cable —
) / )This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12. ) / )

Downloaded from www.Manualslib.com manuals search engine 9B-19 Lighting Systems:
Headlight Bulb Replacement (Discharge
Headlight Model)
S6RW0D9206002
WARNING!
• To avoid danger of being burned, don’t
touch when the bulb is hot.
• Don’t touch glass surface of bulb, to avoid
deteriorate as the case may be unclear
when bulb light on at dirty condition.
• Be sure to read “Precautions for Discharge
Headlight Service (If Equipped)” before
starting to service work.

1) Check to ensure that lighting switch is at OFF
position.
2) Disconnect negative (–) cable at battery.
3) Remove headlight housing referring to “Headlight
Housing Removal and Installation”.
4) Remove cover (1) from headlight housing by turning
it counterclockwise.
5) Remove igniter (2) from discharge headlight bulb by
turning it counterclockwise.
6) Replace bulb (1) from headlight housing.
7) Install igniter to discharge headlight bulb by turning it
clockwise.
8) Install cover to headlight housing by turning it
clockwise.
9) Install headlight housing to vehicle body referring to
“Headlight Housing Removal and Installation”.
10) Connect negative (–) cable at battery.
11) After installation, be sure to inspect and adjust
aiming referring to “Headlight Aiming Adjustment
with Screen”.
Ballast Removal and Installation (Discharge
Headlight Model)
S6RW0D9206023
WARNING!
Be sure to read “Precautions for Discharge
Headlight Service (If Equipped)” carefully
before working. Neglecting them may result
in personal injury.

Removal
1) Check to ensure that lighting switch is at OFF
position.
2) Disconnect negative (–) cable at battery.
3) Remove headlight housing referring to “Headlight
Housing Removal and Installation”.
4) Remove ballast (1) from headlight housing (2).
5) Disconnect connector (3) from ballast.
Installation
Reverse removal procedure noting the following.
• Connect connectors securely.
• After installation, be sure to inspect and adjust aiming
referring to “Headlight Aiming Adjustment with
Screen”.
1 2
I6RW0C920014-02
1
I6RW0C920015-02
2
1
3
I6RW0C920016-02

Downloaded from www.Manualslib.com manuals search engine Lighting Systems: 9B-20
Igniter Removal and Installation (Discharge
Headlight Model)
S6RW0D9206024
WARNING!
Be sure to read “Precautions for Discharge
Headlight Service (If Equipped)” carefully
before working. Neglecting them may result
in personal injury.

Removal
1) Remove ballast referring to “Ballast Removal and
Installation (Discharge Headlight Model)”.
2) Remove cover (1) from headlight housing by turning
it counterclockwise.
3) Remove igniter (2) from discharge headlight bulb by
turning it counterclockwise.
4) After disconnecting ground wire (3), pull out igniter
(2) from headlight housing.Installation
Reverse removal procedure noting the following.
• Connect connectors securely.
• After installation, be sure to inspect and adjust aiming
referring to “Headlight Aiming Adjustment with
Screen”.
Headlight Aiming Adjustment with ScreenS6RW0D9206003
NOTE
• Unless otherwise obligated by local regulations, adjust headlight aiming according to the following
procedure.
• After replacing headlight housing, be sure to adjust aiming.
• When inspecting and adjusting headlight with leveling system, make sure to set the leveling switch
to “0” position with ignition switch turned ON.

1) Make sure the following items.
• Place vehicle on a flat surface in front of blank wall (screen) (1) ahead of headlight surface.
Distance “a”
10 m (32.8 ft.)
• Adjust air pressure of all tires to the specified value respectively.
• Bounce vehicle body up and down by hand to stabilize suspension.
• Carry out aiming with a driver aboard.
Driver’s weight
75 kg (165 lb)
2) Check to see if hot spot (high intensity zone) of each low beam axis falls as shown in figure.
NOTE
If the headlights interfere each other and make it hard to see the cut line clearly, cover the headlight on
one side. This helps to make aiming adjustment easier.

Hot spot specification
Angle “b”: 0.75° (Specification)
Calculated distance “H”: Approx. 130 mm (5.15 in.)
3) Align headlight aiming to specification by adjusting aiming gear if it is not set properly.
2
1 3
I6RW0C920017-01

Downloaded from www.Manualslib.com manuals search engine Lighting Systems: 9B-22
Headlight Switch (in Lighting Switch) Removal
and Installation
S6RW0D9206004
Removal
1) Disconnect negative (–) cable at battery.
2) Remove steering column hole cover (3).
3) Remove steering column covers (1).
Turn steering wheel to access steering column cover
screws (2).
4) Remove lighting switch (1) from combination switch
assembly (2) and disconnect its coupler (3).
Installation
Reverse removal procedure for installation.
Headlight Switch (in Lighting Switch)
Inspection
S6RW0D9206025
Check for continuity between terminals at each switch
position. If check result is not as specified, replace
switch.Without rear fog light switch and auto-on headlight
switch
With rear fog light switch
1
2
3
I5RW0A920007-02
2
1
3
I5RW0A920008-01
[A]: LHD [D]: Shaft condition
[B]: RHD *: If equipped
[C]: Terminal
[A]: Terminal
[B]: Shaft condition
[C]
[D]3 5
LOW
PASS
HI
LOW
PASS
HI LOW
PASS
HI
[A] [B]
1
6*2 3 4 5123 4 5
1246*
I6JB0B920003-02
[A]
[B]14 356
LOW
PASS
HI
LOW
PASS
HI LOW
PASS
HI
2
5 4 3 2 16
I5JB0D920011-04

Downloaded from www.Manualslib.com manuals search engine 9B-27 Lighting Systems:
2) Check to see if hot spot (high intensity zone) of each
front fog light axis falls as shown in the figure.
NOTE
If the fog lights interfere each other and make
it hard to see the cut line clearly, cover the
fog light on one side. This helps to make
aiming adjustment easier.

Hot spot specification
Angle “b”: 1.14° (Specification)
Calculated distance “H”: Approx. 199 mm (7.83
in.)
3) If it is not set properly, align front fog light to
specification by rotating aiming gear.
Rear Fog Light Switch Inspection (If Equipped)S6RW0D9206021
NOTE
• Rear fog light switch can be turned to ON
position only when headlight switch is
turned to HEADLIGHT position (low or high
beams).
• Rear fog light switch turns OFF
automatically when headlight switch is
turned to OFF position.

Check for continuity between terminals at each switch
position.
If check result is not as specified, replace switch.
2. Bounding line
3. Hot spot
4. Aiming gear (for up / down adjustment)
5. Turning (for up adjustment)
6. Turning (for down adjustment)
7. Front fog light assembly
X-X: Horizontal center line of front fog light bulb
A-A: Vertical center line of left front fog light bulb
B-B: Vertical center line of right front fog light bulb
[A]: Left front fog light
[B]: Right front fog light
32
2
AB AB
[A] [B]X X
1
“H”
“H” “H” “b”
“a”
54
7
67I6RW0C920020-01
Terminal
Shaft condition12
OFF
ON
ON
OFF
2 1
I4RS0B920013-01