AIR SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 9H-2 Interior Trim:
Head Lining Removal and InstallationS6RW0D9806002
WARNING!
Refer to “Air Bag System Service Warning in
Section 00” before starting service work.

Removal
1) Remove sun visor (1).
2) Remove dome lights of front (1) and center (2).3) Remove front pillar upper trims (1) rear side sill
scuffs (2), center pillar inner lower trims (3), center
pillar inner upper trims (4), back panel trim (5), rear
quarter lower trims (6) and rear quarter upper trims
(7).
1
I5RW0A980001-01
12
I5RW0A980002-01
[A]: With curtain air bag [B]: Without curtain air bag
32
4
B
B
B
C
A
A
AB
B
A
B
B
[A] [B]
7
6
BBBA
A
AAA
B
B
B
CCC
5
C
BC
BB
B
11
C
I5RW0A980004-03

Downloaded from www.Manualslib.com manuals search engine Hood / Fenders / Doors: 9J-1
Body, Cab and Accessories
Hood / Fenders / Doors
Repair Instructions
Hood Removal and InstallationS6RW0D9A06001
Removal
CAUTION!
Place cloth to prevent body from any
damage.

1) Remove hood silencer (4).
2) Disconnect window washer hose (1) from hood.
3) Remove 4 mounting bolts (3) to detach hood (2).
Installation
Reverse removal procedure noting the following.
• Apply sealant to contact face “A” of hood hinge.
Specified sealant.
“A”: Sealant 99000–31110 (SUZUKI Bond
No.1215)
• Adjust hood lock position if necessary referring to
“Hood Inspection and Adjustment”.
Hood Inspection and AdjustmentS6RW0D9A06002
Inspection
• Check that hood opens and closes smoothly and
properly. Lubricate if necessary.
• Check that hood stops in the secondary latched
position properly (preventing hood from opening
freely) and that hood closes completely in the fully
latched position.
• Adjust hood locks position, if necessary.Adjustment
Adjust the following point:
• Hood position adjustment.
Fore-and-aft and right-and-left adjustment.
Adjust hood clearance by loosening hood mounting
bolts. Refer to “Panel Clearance in Section 9K”.
• Vertical adjustment
If only one side (right or left) of hood is not level with
front fender, make it level by tightening or loosening
hood cushion (1).
• Hood lock position adjustment
a. Loosen hood lock bolts.
b. Adjust hood lock height position so the hood is
locked without looseness.
c. Tighten hood latch bolts to specified torque.
Tightening torque
Hood latch bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-
ft)
d. Make sure the hood is locked smoothly and
securely.
2
4
1
3 “A”
“A”
I5RW0A9A0001-01
1
I5RW0A9A0002-01
(a)(a)
I5RW0A9A0003-01

Downloaded from www.Manualslib.com manuals search engine Body Structure: 9K-1
Body, Cab and Accessories
Body Structure
Repair Instructions
Front Bumper and Rear Bumper ComponentsS6RW0D9B06001
1 24
5
6
3
78
9
10
I6RW0C9B0003-01
1. Front bumper 5. Front bumper lower member 9. Reflector
2. Radiator upper grill 6. Front bumper holder 10. License garnish(if equipped)
3. Retainer(if equipped) 7. Rear bumper holder

Downloaded from www.Manualslib.com manuals search engine Body Structure: 9K-5
Side Body
Hole to hole distance
o
dek
fl
im
n
g
j
h
o
ac
b
dek
fl
im
n
g
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h
ac
b
I5RW0A9B0005-02
a. Instrumental panel upper mounting bolt hole f. Front shoulder adjuster bracket installation
upper holek. Curtain-air bag module installation hole
b. Front door lower hinge installation upper hole g. Front door switch mounting screw hole l. Rear seat belt upper anchor installation hole
c. Front pillar inner trim installation hole h. Bleeding hole (φ 15 mm) m. Rear door switch mounting screw hole
d. Curtain-air bag module installation hole i. Rear door upper hinge installation upper hole n. Side sill scuff installation rear hole (φ 7 mm)
e. Curtain-air bag module installation hole j. Rear door lower hinge installation front hole o. Parking brake cable bracket installation front hole
a-f: 1,144 mm (45.039 in.) f-h: 1,242 mm (48.898 in.) d-o: 1,236 mm (48.661 in.)
a-g: 862 mm (33.937 in.) f-l: 864 mm (34.016 in.) e-o: 1,221 mm (48.071 in.)
a-i: 938 mm (36.929 in.) i-l: 1,020 mm (40.157 in.) f-o: 1,139 mm (44.843 in.)
b-g: 965 mm (37.992 in.) i-m: 885 mm (34.843 in.) g-o: 784 mm (30.866 in.)
b-j: 1,001 mm (39.409 in.) j-m: 1,022 mm (40.236 in.) h-o: 978 mm (38.504 in.)
c-h: 959 mm (37.756 in.) k-n: 1,089 mm (42.874 in.) k-o: 1,315 mm (51.772 in.)
d-f: 415 mm (16.339 in.) l-n: 910 mm (35.827 in.) l-o: 1,445 mm (56.890 in.)
d-g: 848 mm (33.386 in.) a-o: 1,285 mm (50.591 in.) m-o: 1,276 mm (50.236 in.)
d-h: 1,195 mm (47.047 in.) b-o: 1,278 mm (50.315 in.) n-o: 913 mm (35.945 in.)
e-h: 1,334 mm (52.520 in.) c-o: 1,303 mm (51.299 in.)

Downloaded from www.Manualslib.com manuals search engine Paint / Coatings: 9L-1
Body, Cab and Accessories
Paint / Coatings
General Description
Anti-Corrosion Treatment ConstructionS6RW0D9C01001
WARNING!
Standard shop practices, particularly eye protection, should be followed during the performance of the
following operations to avoid personal injury.

As rust proof treatment, steel sheets are given corrosion resistance on the interior and/or exterior.
These corrosion resistance steel sheet materials are called one of two-side galvanized steel sheets.
It is for the sake of rust protection that these materials are selected and given a variety of treatments as described
blow.
• Steel sheets are treated with cathodic electro primer which is excellent in corrosion resistance.
• Rust proof wax coatings are applied to door and side sill insides where moisture is liable to stay.
• Vinyl coating is applied to body underside and wheel housing inside.
• Sealer is applied to door hem, engine compartment steel sheet-to-steel sheet joint, and the like portions to prevent
water penetration and resulting in rust occurrence.
In panel replacement or collision damage repair, leaving the relevant area untreated as it is in any operation which
does disturb the rust proof treatment will cause corrosion to that area. Therefore, it is the essential function of any
repair operation to correctly recoat the related surfaces of the relevant area.
All the metal panels are coated with metal conditioners and primer coating during vehicle production. Following the
repair and/or replacement parts installation, every accessible bare metal surface should be cleaned and coated with
rust proof primer. Perform this operation prior to the application of sealer and rust proof wax coating.
Sealer is applied to the specific joints of a vehicle during production. The sealer is intended to prevent dust from
entering the vehicle and serves also as an anticorrosion barrier. The sealer is applied to the door and hood hem areas
and between panels. Correct and reseal the originally sealed joints if damaged. Reseal the attaching joints of a new
replacement panel and reseal the hem area of a replacement door or hood.
Use a quality sealer to seal the flanged joints, overlap joints and seams. The sealer must have flexible characteristics
and paint ability after it’s applied to repair areas.
For the sealer to fill open joints, use caulking material. Select a sealer in conformance with the place and purpose of a
specific use. Observe the manufacturer’s label-stand instructions when using the sealer.
In many cases, repaired places require color painting. When this is required, follow the ordinary techniques specified
for the finish preparation, color painting and undercoating build-up.
Rust proof wax, a penetrative compound, is applied to the metal-to-metal surfaces (door and side sill insides) where it
is difficult to use ordinary undercoating material for coating. Therefore, when selecting the rust proof wax, it may be the
penetrative type.
During the undercoating (vinyl coating) application, care should be taken that sealer is not applied to the engine-
related parts and shock absorber mounting or rotating parts. Following the under coating, make sure that body drain
holes are kept open.
The sequence of the application steps of the anti-corrosion materials are as follows:
1) Clean and prepare the metal surface.
2) Apply primer.
3) Apply sealer (all joints sealed originally).
4) Apply color in areas where color is required such as hem flanges, exposed joints and under body components.
5) Apply anticorrosion compound (penetrative wax).
6) Apply undercoating (rust proof material).

Downloaded from www.Manualslib.com manuals search engine 9L-2 Paint / Coatings:
Plastic Parts FinishingS6RW0D9C01002
Painting
Rigid or hard ABS plastic needs no primer coating.
General acrylic lacquers can be painted properly over hard ABS plastic in terms of adherence.
1) Use cleaning solvent for paint finish to wash each part.
2) Apply conventional acrylic color lacquer to part surface.
3) Follow lacquer directions for required drying time. (Proper drying temperature range is 60 – 70 °C (140 – 158 °F)).
Reference
Plastic parts employ not only ABS (Acrylonitrile Butadiene Styrene) plastic but also polypropylene, vinyl, or the like
plastic. Burning test method to identify ABS plastic is described below.
1) Use a sharp blade to cut off a plastic sliver from the part at its hidden backside.
2) Hold sliver with pincers and set it on fire.
3) Carefully observe condition of the burning plastic.
4) ABS plastic must raise readily distinguishable back smoke while burning with its residue suspended in air
temporarily.
5) Polypropylene must raise no readily distinguishable smoke while burning.

Downloaded from www.Manualslib.com manuals search engine 9M-1 Exterior Trim:
Body, Cab and Accessories
Exterior Trim
Repair Instructions
Roof Molding Removal and InstallationS6RW0D9D06001
2
312
3
44 [A]
A
B
[B]
5
6
(a)
(a)
I5RW0C9D0002-04
[A]: Roof molding installation Position roof molding with touching A to B. 3. Roof rail nut (if equipped)
[B]: Roof molding clip installation position 4. Roof molding
A: Positioning rib 5. Roof molding clip (Push-in type)
: Install roof molding clip to specified position on body with epoxy
adhesive applied.
B: Positioning for roof molding (Edge of panel flange) 6. Groove
1. Roof rail (if equipped) : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
2. Roof rail cap (if equipped)

Downloaded from www.Manualslib.com manuals search engine Table of Contents 10- i
10
Section 10
CONTENTS
Control Systems
Precautions ............................................... 10-1
Precautions........................................................... 10-1
Precautions for Control Systems......................... 10-1
Body Electrical Control System ........... 10B-1
Precautions......................................................... 10B-1
Precautions in Diagnosing Trouble ................... 10B-1
General Description ........................................... 10B-1
BCM General Description ................................. 10B-1
CAN Communication System Description......... 10B-1
Theft Deterrent Light ......................................... 10B-2
Security Alarm Description (If Equipped) .......... 10B-2
Schematic and Routing Diagram ...................... 10B-3
Body Electrical Control System Wiring Circuit
Diagram .......................................................... 10B-3
Connector Layout Diagram of BCM and
Junction Block ................................................. 10B-6
Component Location ......................................... 10B-7
BCM and Related System Component
Location .......................................................... 10B-7
Diagnostic Information and Procedures .......... 10B-8
BCM Self-Diagnosis Function ........................... 10B-8
Body Electrical Control System Check.............. 10B-9
Scan Tool Data ............................................... 10B-11
DTC Table ....................................................... 10B-13
DTC Check ..................................................... 10B-14
DTC Clearance ............................................... 10B-15
BCM Power Circuit and Ground Circuit Check 10B-16
DTC B1133 (DTC No. 1133): Battery Voltage
Too High ....................................................... 10B-17
DTC B1141 / DTC B1142 (No. 1141 / No.
1142) Outside Air Temperature (Ambient
Temp.) Sensor Circuit Malfunction ................ 10B-18
DTC B1150 (No. 1150): Air Bag
Communication Circuit Malfunction .............. 10B-19
DTC B1157 (No. 1157) Air Bag Deployment
Signal Input ................................................... 10B-20
DTC B1170 (No. 1170): EEPROM Access
Error .............................................................. 10B-20
DTC U0073 (No. 0073): Control Module
Communication Bus Off ................................ 10B-20
DTC U0100 (No. 0100): Lost Communication
with ECM....................................................... 10B-20DTC U0101 (No. 0101): Lost Communication
with TCM ....................................................... 10B-20
DTC U0155 (No. 0155): Lost Communication
with Instrument Panel Cluster (IPC) Control
Module .......................................................... 10B-20
DTC U1144 (No. 1144): Lost Communication
with Keyless Start Control Module ................ 10B-20
Inspection of BCM and Its Circuits .................. 10B-21
Repair Instructions ..........................................10B-28
BCM (Included in Junction Block) Removal
and Installation .............................................. 10B-28
Security Alarm Mode Selection Procedure (If
Equipped) ...................................................... 10B-29
Outside Air Temperature Sensor Removal
and Installation .............................................. 10B-29
Outside Air Temperature Sensor Inspection ... 10B-29
Special Tools and Equipment .........................10B-29
Special Tool .................................................... 10B-29
Immobilizer Control System ................. 10C-1
Precautions.........................................................10C-1
Precautions in Diagnosing Troubles .................10C-1
Precaution in Replacing ECM ...........................10C-1
Precaution in Replacing Ignition Key ................10C-1
Precautions in Handling Immobilizer Control
System ............................................................10C-1
General Description ...........................................10C-2
Immobilizer Control System Introduction ..........10C-2
On-Board Diagnostic System Description
(Self-diagnosis Function)................................10C-2
Schematic and Routing Diagram ......................10C-3
Immobilizer Control System Wiring Circuit
Diagram...........................................................10C-3
Component Location .........................................10C-5
Immobilizer Control System Components
Location...........................................................10C-5
Diagnostic Information and Procedures ..........10C-5
Immobilizer Control System Check ...................10C-5
DTC Check........................................................10C-6
DTC Clearance .................................................10C-6
DTC Table .........................................................10C-7
Scan Tool Data .................................................10C-8
Immobilizer Indicator Light Does Not Come
ON with Ignition Switch ON and Engine Stop ..10C-9

Downloaded from www.Manualslib.com manuals search engine 10-ii Table of Contents
Immobilizer Indicator Light Remains ON after
Engine Start ..................................................10C-10
DTC P1614: Transponder Response Error .....10C-10
DTC P1615: Steering Lock Unit
Communication Error ....................................10C-11
DTC P1616: Unregistered Keyless Start
Control Module ..............................................10C-12
DTC P1618: Keyless Start Control Module
CAN Communication Error............................10C-13
DTC P1621: Immobilizer Communication
Line Error ......................................................10C-13
DTC P1622: EEPROM Reading / Writing
Error ..............................................................10C-14
DTC P1623: Unregistered Transponder .........10C-14
DTC P1625: Immobilizer Antenna Error..........10C-15
DTC P1636: Immobilizer Information
Registration Failure .......................................10C-15
DTC P1638: Immobilizer Information
Mismatched ...................................................10C-16
Inspection of ICM and Its Circuit .....................10C-17
Repair Instructions ..........................................10C-19
ICM Removal and Installation .........................10C-19
Registration of the Ignition Key .......................10C-19
Procedure after ECM Replacement ................10C-19
Special Tools and Equipment .........................10C-20
Special Tool ....................................................10C-20
Keyless Start System .............................10E-1
General Description ........................................... 10E-1
Keyless Start System Description ..................... 10E-1
Parts and Functions .......................................... 10E-2
Keyless Engine Start Function .......................... 10E-3
Door Lock Function of Keyless Start System .... 10E-4
Operation Area of Remote Controller................ 10E-5
Alarm Function .................................................. 10E-6
CAN Communication System Description......... 10E-6
Schematic and Routing Diagram ...................... 10E-7
Keyless Start System Electric Wiring Circuit
Diagram .......................................................... 10E-7
Diagnostic Information and Procedures .......... 10E-8
Precautions in Diagnosing Troubles ................. 10E-8
Self-Diagnosis Function .................................... 10E-8
Keyless Start System Diagnosis Introduction ... 10E-8
Keyless Start System Check ............................. 10E-9
Customer Questionnaire (Example) ................ 10E-10Key Indicator Light Check ............................... 10E-10
DTC Check...................................................... 10E-11
DTC Table ....................................................... 10E-12
DTC Clearance ............................................... 10E-12
Keyless Start System Symptom Diagnosis ..... 10E-13
Keyless Start System Operation Inspection .... 10E-14
Door Lock Operation (Keyless Start System) . 10E-14
Inspection of Keyless Start Control Module
and Its Circuits .............................................. 10E-14
No DTC Detection After Performing DTC
Check ............................................................ 10E-20
Key Indicator Light Circuit Check (Key
Indicator Light Doesn’t Light when Ignition
Knob Switch is Pushed) ................................ 10E-21
Keyless Start Control Module Power and
Ground Circuit Check .................................... 10E-23
DTC No. 11: Communication Error with
Steering Lock Unit ......................................... 10E-24
DTC No. 13 / No. 14: Release Signal Error
from Steering Lock Unit / Steering Lock Unit
Malfunction .................................................... 10E-25
DTC No. 21 / No. 22: Internal Error of Keyless
Start Control Module (EEPROM Reading
Error) / (EEPROM Writing Error) ................... 10E-25
DTC No. 31: Lost Communication with BCM .. 10E-26
DTC No. 33: Control Module Communication
Bus Off .......................................................... 10E-26
DTC No. 51 / No. 52 / No. 53: Driver Side /
Passenger Side / Rear End Door Request
Switch Failure................................................ 10E-26
Repair Instructions .......................................... 10E-27
Antennas and Request Switches Removal
and Installation .............................................. 10E-27
Front Door (Driver and Passenger Side), Rear
End Door Request Switch Inspection............ 10E-28
Steering Lock Unit Removal and Installation .. 10E-28
Steering Lock Unit Inspection ......................... 10E-28
Front Door Lock Switch Inspection ................. 10E-28
Keyless Start Control Module Removal and
Installation ..................................................... 10E-29
Remote Controller Inspection.......................... 10E-29
Replacement of Remote Controller Battery .... 10E-29
Registration Procedure for Remote Controller
ID Code ......................................................... 10E-30
Keyless Start Registration ............................... 10E-31

Downloaded from www.Manualslib.com manuals search engine Precautions: 10-1
Control Systems
Precautions
Precautions
Precautions for Control SystemsS6RW0DA000001
Air Bag Warning
Refer to “Air Bag Warning in Section 00”.
Precaution of Troubleshooting for CAN
Refer to “Precaution on CAN Troubleshooting in Section 1A”.