2005 SUZUKI SWIFT Engine harness

Downloaded from www.Manualslib.com manuals search engine 8B-102 Air Bag System:
4) Remove air bag (inflator) module from steering wheel.
5) Disconnect driver air bag (inflator) module connector (1) of driver air bag (inflator) module and horn
connector (2) as shown in figure.
a) Unlock lock button (3).
b) With lock button unlocked, disconnect connector.
WARNING!
Special care is necessary when handling and
storing a live (undeployed) air bag (inflator)
module. Observe “Precautions on Handling
and Storage of Air Bag System
Components”. Otherwise, personal injury
may result.

Installation
1) Connect horn connector (1) securely.
2) Connect driver air bag (inflator) module connector (2) to driver air bag (inflator) module (3) securely as
shown in figure.
a) Connect connector.
b) Lock connector with lock button.
3) Install driver air bag (inflator) module (1) to steering wheel (2), taking care so t hat no part of wire harness
is caught between them.
4) Make sure that clearance between module (1) and steering wheel (2) is uniform all the way.
5) Tighten driver air bag (inflator) module mounting bolt (left side) (3) to specified torque first and then driver
air bag (inflator) module mounting bolt (right side) (4)
to specified torque.
Tightening torque
Driver air bag (inflator) module mounting bolt
(a): 9 N·m (0.9 kgf-m, 6.5 lb-ft)
6) Enable air bag system. Refer to “Enabling Air Bag System”.
7) Connect negative cable at battery.
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Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-105
4) Connect passenger air bag (inflator) module connector (1) securely as shown in figure.
a) Connect connector.
b) Lock connector with lock button (2).
5) Enable air bag system. Refer to “Enabling Air Bag System”.
Passenger Air Bag (Inflator) Module InspectionS7RS0B8206008
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
S7RS0B8206009
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.

Removal
1) Disable air bag system. Re fer to “Disabling Air Bag
System”.
2) Roll up the seat surface of the seat back.
3) Remove sleeve lock nut (1) from seat back (2).
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b)
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Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-107
Side-Air Bag (Inflator) InspectionS7RS0B8206010
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.
Side Curtain-Air Bag (Inflator) Module Removal
and Installation
S7RS0B8206011
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. Re fer to “Disabling Air Bag
System”.
2) Remove head lining referring to “Head Lining Removal and Installati on 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.
I4RS0A820075-02
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Downloaded from www.Manualslib.com manuals search engine 8B-110 Air Bag System:
Installation
CAUTION!
Proper operation of forward-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) Apply thread lock cement to mounting bolts thread. Install forward-sensor (1) on front panel and tighten
mounting bolt (2) to specified torque.
“A”: Thread lock cement 99000–32100 (Thread
Lock Cement 1305)
Tightening torque
Forward-sensor mounting bolt (a): 9 N·m (0.9
kgf-m, 6.5 lb-ft)
3) Connect forward-sensor connector by pushing connector till click is heard from it.
4) Connect negative cable at battery.
5) Enable air bag system referring to “Enabling Air Bag System”.
Forward-Sensor InspectionS7RS0B8206014
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-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.
Side-Sensor Removal and InstallationS7RS0B8206015
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. Re fer to “Disabling Air Bag
System”.
3) Remove center pillar lowe r trim and side sill scuff.
4) Turn up floor carpet at front seat side.
5) Remove side-sensor bolt (1), and side-sensor (2) from under body (3).
2,"A",(a)
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Downloaded from www.Manualslib.com manuals search engine 8B-112 Air Bag System:
• Check sensor (1) 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.
Passenger Air Bag (Inflator) Module Repair
Harness Installation
S7RS0B8206017
Replace passenger air bag (inflator) module repair
harness (4) according to the following procedure when
the harness (1) connect ed with passenger air bag
(inflator) module of the air bag harness included in
instrument panel harness (2) and passenger air bag
(inflator) module connector (3) is damaged. 1) Disable air bag system. Re
fer to “Disabling Air Bag
System”.
2) Disconnect “L32” connector from floor harness located near the glove box.
3) Cut off passenger air bag (inflator) module harness (1) included in instrument panel harness (2) as
shown, and then fasten it to instrument panel
harness with vinyl tape for avoiding interference with
other parts.
4) Install passenger air bag (inflator) module repair harness (1) to floor harness (2), instrument panel
harness (3) and passenger air bag (inflator) module.CAUTION!
To avoid interference with other parts, fasten
the repair harness to in strument wire harness
with a clamp or vinyl tape as shown in figure.

5) Connect each connector securely till click is heard.
5. Driver air bag (inflator) module 7. Floor harness
6. Passenger air bag (inflator) module 8. Vinyl tape
1I4RS0A820082-01
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Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-113
Air Bag (Inflator) Module and Seat Belt
Pretensioner Disposal
S7RS0B8206018
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. Do not dispose of live
(undeployed) air bag (inflator) modules and
seat belt pretensioners. Because undeployed
air bag (inflator) module / inactivated seat
belt pretensioner must not be disposed of
through normal refuse channels. Undeployed
air bag (inflator) module and inactivated seat
belt pretensioner contain substances that
can cause severe illness or personal injury if
sealed container is damaged during disposal.

Air bag (inflator) module / seat belt pretensioner can be
deployed / activated inside or outside of vehicle.
Deployment / Activation method used depends upon
final disposition of vehicle. Review the following
instructions in order to deter mine which will work best in
a given situation.
Deployment / Activation Ou tside of Vehicle: When you
intend to return the vehicle to service, deploy the air bag
(inflator) module(s) and/or activate seat belt
pretensioner(s) outside of the vehicle.
Deployment / Activation Insi de of Vehicle: When the
vehicle will be destroyed, or salvaged for component
parts, deploy the air bag module(s) and/or activate seat
belt pretensioner(s) installed on vehicle.
WARNING!
The following precautions must be observed
for this work. Failure to observe any of them
may result in personal injury.
• Procedure should be followed strictly as described here.
• Be sure to read “Precautions on Service and Diagnosis of Air Bag System”
beforehand.
• To avoid accidental deployment / activation, this work should be performed
by no more than one person.
• Since smoke is produced when air bag (inflator) module is deployed and
pretensioner is activated, select well-
ventilated area.
• Air bag (inflator) module and seat belt pretensioner will immediately deploy /
activate when 12 volts vehicle battery is
connected to it. Wear safety glasses
throughout this entire deployment /
activation and disposal procedure.
• Wear suitable ear protection when deploying air bag (inflator) module /
activating seat belt pretensioner. Also,
advise those who are in area close to
deployment / activation site to wear
suitable ear protection.
• Do not deploy / activate two or more air bag system components (air bag (inflator)
modules and seat belt pretensioners) at
the same time.
• Never connect deployment harness to any 12 volts vehicle battery before connecting
deployment harness to air bag (inflator)
module and seat belt pretensioner.
Deployment harness sh all remain shorted
and not be connected to 12 volts vehicle
battery till you are ready to deploy air bag
(inflator) module or activate seat belt
pretensioner.

Downloaded from www.Manualslib.com manuals search engine 8B-114 Air Bag System:
Deployment / Activation Outside of Vehicle
When you intend to return the vehicle to service, deploy
the air bag (inflator) module(s) or activate seat belt
pretensioner(s) outside of the vehicle.1) Turn ignition switch to LOCK position and remove key.
2) Wear safety glasses during this deployment / activation procedure.
3) Check that there is no open, short or damage in special tools (deployment harness (A) and adapter
cable (B)). If any faulty is found, do not use it and be
sure to use new special tool.
Special tool
(A): 09932-75031
(B): 09932–76510
4) Short two deployment harness leads (1) 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 till you are ready to deploy air bag
module or activate seat belt pretensioner.

5) Remove air bag (inflator) module(s) or seat belt pretensioner(s) from vehicle referring to “Driver Air
Bag (Inflator) Module Re moval and Installation”,
“Passenger Air Bag (Inflator) Module Removal and
Installation”or “Front Seat Belt Removal and
Installation in Section 8A”.
WARNING!
• For handing and storage of live air bag (inflator) module, select place where
ambient temperature below 65 °C (150 °F),
without high humidity and away from
electric noise.
• Always carry live air bag (inflator) module with trim cover away from you.
• When storing live air bag (inflator) module or when leaving live air bag (inflator)
module unattended on bench or other
surface, always face trim cover up and
away from surface. As the live passenger
air bag (inflator) module must be placed
with its bag (trim cover) facing up, place it
on the workbench with a slit (1) or use the
workbench vise (2) to hold it securely at its
lower mounting bracket (3). It is also
prohibited to place anything on top of the
trim cover and stack air bag (inflator)
modules. This is necessary so that free
space is provided to allow air bag (inflator)
module to expand in the unlikely event of
accidental deployment.
Failure to follow procedures may result in
personal injury.

I4RS0A820084-01

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-117
• For side curtain-air bag (inflator) modulea. Cut off bag (1) of side curtain-air bag (inflator) module.
b. Tie side curtain-air bag inflator (1) to tire (3) with wire harness (2) 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)
CAUTION!
Make sure that wire harness is tight. It is very
dangerous if looseness in wire harness
results in side curtain-air bag inflator flying
off due to shock from inflator deploying.

NOTE
Wind wire harness (2) around at least 3 times.

c. Clear space (5) on ground about 185 cm (6 ft) in diameter where side curtain-air bag
(inflator) module (1) is set for deployment.
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.
d. Pile tire with side curtain-air bag (inflator) module on tire (4). • 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.
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10 cm (3.9 in.)
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