2006 SUZUKI SX4 engine mount

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)
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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
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1. Seat belt 2. Retractor assembly
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Downloaded from www.Manualslib.com manuals search engine 8B-95 Air Bag System:
Installation
1) Check that none of the following faulty conditions
exists.
• Bend, scratch, deformity in vehicle body where
SDM is mounted.
• Foreign matter or rust on mating surface of vehicle
body where SDM is mounted.
2) Install SDM (2) to vehicle.
CAUTION!
Ensure that arrow on the SDM is pointing
toward the front of the vehicle.

3) Tighten SDM bolts (1) to specified torque.
Tightening torque
SDM bolt (a): 9 N·m (0.9 kgf-m, 6.5 lb-ft)
4) Connect SDM connector (2) to SDM (3) securely.
5) Install G sensor bracket (1) to floor panel.6) Install G sensor referring to “G Sensor Removal and
Installation (4WD Model) in Section 4E”.
7) Install console box upper cover.
8) Enable air bag system referring to “Enabling Air Bag
System”.
9) Connect negative (–) cable at battery.
SDM InspectionS6RW0D8206004
WARNING!
During service procedures, be very careful
when handling a Sensing and Diagnostic
Module (SDM).
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 inactivation of the air bag system
when necessary.

CAUTION!
• Do not connect a tester whatever type it
may be.
• Never repair or disassemble SDM.
• If SDM has been dropped, it should be
replaced.

If any faulty condition is found in the following checks,
replace.
• Check SDM and SDM plate for dents, cracks or
deformation.
• Check SDM connector for damage, cracks or lock
mechanism.
• Check SDM terminal for bend, corrosion or rust.
Driver Air Bag (Inflator) Module Removal and
Installation
S6RW0D8206005
WARNING!
When handling an air bag (inflator) module,
be sure to read “Precautions on Handling
and Storage of Air Bag System Components”
and observe each instruction. Failure to
follow them could cause a damage to the air
bag (inflator) module or result in personal
injury.

A: Forward
2. SDM
23 A1, (a)
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Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-96
Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system. Refer to “Disabling Air Bag
System”.
3) Loosen driver air bag (inflator) module mounting
bolts (1) till it turns freely, pull them out and fix them
to bolt clamps.
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) (if equipped) 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 (if equipped).
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 that 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 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)
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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
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I7RW01821035-01
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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.
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1I7RW01822149-01
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4I7RW01822150-01

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-110
• For side-air bag (inflator) module
a. Remove sleeve (1) and sleeve lock nut (2), if
equipped.
b. Clear space (3) on ground about 185 cm (6 ft)
in diameter where side-air bag (inflator)
module for deployment. Paved, outdoor
location where there is no activity is preferred.
If outdoor location is not available, space on
shop floor where there is no activity and
provide sufficient ventilation. Ensure no loose
or flammable objects are within deployment
area.
c. Place deployment fixture (A) on ground.
Special tool
(A): 09932–75041
d. Fill plastic reservoir in deployment fixture (A)
with water or sand. This is necessary to
provide sufficient stabilization of fixture during
deployment.
e. Attach side-air bag (inflator) module (1) in
deployment fixture using mounting
attachment, sleeve lock nut and washer (2).
NOTE
Make sure that deploying direction faces as
shown in the figure against mounting
attachment.

• For side curtain-air bag (inflator) module
a. 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).
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