2006 SUZUKI SX4 height

Downloaded from www.Manualslib.com manuals search engine 4A-7 Brake Control System and Diagnosis:
Repair Instructions
Brake Pedal ComponentsS6RW0D4106018
CAUTION!
If equipped Brake Pedal Foot Protection
System, never disassemble brake pedal
assembly. Disassemble will spoil its original
function. If faulty condition is found, replace
it with new one.

Brake Pedal Free Height InspectionS6RW0D4106001
1) Check brake pedal free height. If it is not within
specification, check and adjust following item 2) and
6).
Brake pedal free height “a” from carpet
111 – 131 mm (4.4 – 5.1 in.)
2) Check measurement between booster mounting
surface and center of clevis pin hole. When booster
push rod clevis has been reinstalled, it is important
that the measurement is adjusted (refer to “Brake
Booster Inspection”).
3) Check brake light switch position. Adjust it if it is out
of specification.
4) Check pedal for dent.
5) Check brake booster for installation.6) Check brake booster push rod for length.
Brake Pedal Play InspectionS6RW0D4106002
Pedal play should be within the following specification. If
out of specification, check brake light switch for proper
installation position and adjust if necessary.
Also check pedal shaft bolt and booster clevis pin
installation for looseness and replace if defective.
Brake pedal play
“a”
: 1 – 8 mm (0.04 – 0.31 in.)
Excessive Pedal Travel InspectionS6RW0D4106003
1) Start engine.
2) Depress brake pedal a few times.
3) With brake pedal depressed with approximately 300
N (30 kg, 66 lbs) load, measure brake pedal to wall
(dash panel silencer) clearance “a”. If clearance is
out of specification, possible causes are as follows.
If clearance “a” is less than specification, the most
possible cause is that air is in lines or brake fluid
leakage.
Should clearance “a” remain less than specification
even after bleeding of system, other possible but
infrequent cause is malfunction of booster push rod
length out of adjustment.
• Bleed brake system. Refer to “Air Bleeding of
Brake System”.
Brake pedal arm to wall clearance
“a”
When pedal is depressed at 300 N (30 kg, 66 lbs)
: Over 40 mm (1.57 in.)
[A]: A/T model : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
1. Brake pedal : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft)
2. Brake pedal bracket
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“a”I3RH0A410010-01
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Downloaded from www.Manualslib.com manuals search engine 4A-15 Brake Control System and Diagnosis:
2) Hold brake pedal depressed for 30 seconds. If pedal
height does not change, condition is good. But it isn’t
if pedal rises.
Brake Booster Removal and InstallationS6RW0D4106015
Removal
1) Remove master cylinder assembly from booster
referring to “Master Cylinder Removal and
Installation”.
2) Disconnect vacuum hose from booster referring to
“Master Cylinder and Brake Booster Components”.
3) Remove front brake pipe (from master cylinder
primary and secondary to ABS hydraulic unit pipe)
referring to “Front Brake Hose / Pipe Removal and
Installation”.
4) Remove clip (1) and then remove push rod clevis pin
(2).
5) Loosen booster mounting nuts (3) and then remove
booster.Installation
1) Install booster to dash panel. Then connect push rod
clevis pin (2) and clip (1).
2) Tighten booster mounting nuts (3) to specified
torque.
Tightening torque
Booster mounting nut (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft)
3) Connect vacuum hose to booster referring to
“Master Cylinder and Brake Booster Components”.
4) Install front brake pipe (from master cylinder primary
and secondary to ABS hydraulic unit pipe) referring
to “Front Brake Hose / Pipe Removal and
Installation”.
5) Install master cylinder assembly to booster referring
to “Master Cylinder Removal and Installation”.
6) Fill reservoir with specified fluid.
7) Bleed air from brake system referring to “Air
Bleeding of Brake System” and at the same time
bleed air from clutch system referring to “Air
Bleeding of Clutch System in Section 5C” (M/T
model).
8) Check pedal height and play referring to “Brake
Pedal Free Height Inspection” and “Brake Pedal
Play Inspection”.
9) Check each installed part for fluid leakage and
perform brake test.
Brake Booster InspectionS6RW0D4106016
• Check brake booster for damage and operation.
• Check boot for damage and deterioration.
• Check for push clevis rod distance.
If any malfunction is found, replace brake booster.
H: Hold
T: 30 seconds
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3 1 2
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Downloaded from www.Manualslib.com manuals search engine Seat Belts: 8A-6
Front Seat Belt InspectionS6RW0D8106003
WARNING!
• Never attempt to disassemble or repair the
seat belt pretensioner (retractor). 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 Seat Belt”, before
starting to work and observe every
precaution during work. Neglecting them
may result in personal injury or
unactivation of the seat belt pretensioner
when necessary.
• Never measure resistance of pretensioner
or disassemble it. Otherwise, personal
injury may result.

CAUTION!
If seat belt pretensioner (retractor) was
dropped from a height of 30 cm (1 ft) or more,
it should be replaced.

Seat belts and attaching parts can affect the vital
components and systems of a vehicle.
Therefore, they should be inspected carefully and
replaced with genuine parts only.
Seat Belt
• The seat belt webbing or strap should be free from
damage.
Retractor (with Seat Belt Pretensioner)
1) Let the seat belt retract fully to confirm its easy
retraction.
• The retractor should lock webbing when pulled
quickly.
• The front seat belt retractor (1) should pass the
inspection and should lock webbing even when
tilted (approx. 15°) toward the fore and aft or right
and left directions.2) Check retractor (1) with seat belt pretensioner
appearance visually for following symptoms and if
any one of them is applicable, replace it with a new
one as an assembly.
• Pretensioner has activated.
• There is a crack in seat belt pretensioner
(retractor).
• Seat belt pretensioner (retractor) is damaged or a
strong impact (e.g., dropping) was applied to it.
Anchor Bolt
• Anchor bolts should be torqued to specification.
Belt Latch
• It should be secure when latched.
Seat Belt Buckle Switch
Check driver side seat belt switch and passenger side
seat belt switch for continuity by using ohmmeter.
Seat belt switch specification
Without inserted buckle tongue to buckle catch:
Terminal “A” and “B”: Continuity
With inserted buckle tongue to buckle catch:
Terminal “A” and “B”: No continuityI2RH01810004-01
1. Buckle tongue
2. Buckle catch
I2RH01810005-01
I4RS0B810001-01

Downloaded from www.Manualslib.com manuals search engine 8B-1 Air Bag System:
Restraint
Air Bag System
Precautions
Precautions on Service and Diagnosis of Air
Bag System
S6RW0D8200004
WARNING!
• If the air bag system and another vehicle
system both need repair, SUZUKI
recommends that the air bag system be
repaired first, to help avoid unintended air
bag system activation.
• Do not modify the steering wheel,
dashboard, both front seat or any other on
or around air bag system components.
Modifications can adversely affect air bag
system performance and lead to injury.
• Be sure to follow the procedures described
in this section. Failure to follow
procedures could result in possible air bag
system activation, personal injury or
unneeded air bag system repairs.

• WARNING / CAUTION labels are attached on each
part of air bag system components (SDM, air bag
(inflator) modules and seat belt pretensioners). Be
sure to follow the instructions.
• Many of service procedures require disconnection of
“A/B” fuse and air bag (inflator) module(s) (driver
module, passenger module, side modules and curtain
modules) from initiator circuit to avoid an accidental
deployment.
• Do not apply power to the air bag system unless all
components are connected or a diagnostic flow
requests it, as this will set a DTC.
• The “Air Bag Diagnostic System Check” must be the
starting point of any air bag diagnostics. The “Air Bag
Diagnostic System Check” will verify proper “AIR
BAG” warning light operation and will lead you to the
correct flow to diagnose any air bag malfunctions.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacements.
• Never use air bag component parts from another
vehicle.
• If the vehicle will be exposed to temperatures over 93
°C (200 °F) (for example, during a paint baking
process), remove the air bag system components
beforehand to avoid component damage or
unintended system activation.• When handling the air bag (inflator) modules (driver
module, passenger module, side modules and curtain
modules), seat belt pretensioners (driver module and
passenger module), SDM, forward impact-sensor or
side impact-sensor be careful not to drop it or apply
an impact to it. If an excessive impact was applied
(e.g., SDM, forward impact-sensor are dropped, air
bag (inflator) module is dropped from a height of 90
cm (3 ft) or more, seat belt pretensioner (retractor
assembly) is dropped from a height of 30 cm (1 ft) or
more), never attempt disassembly or repair but
replace it with a new one.
• When using electric welding, be sure to disconnect air
bag (inflator) module connectors (driver module,
passenger module, side modules and curtain
modules) and seat belt pretensioner connectors
(driver module and passenger module) respectively.
• When applying paint around the air bag system
related parts, use care so that the harness or
connector will not be exposed to the paint mist.
• Never expose air bag system component parts
directly to hot air (drying or baking the vehicle after
painting) or flames.
WARNING!
When performing service on or around air
bag system components or air bag wiring,
follow the procedures listed in “Disabling Air
Bag System” to temporarily disable the air
bag system.
Failure to follow procedures could result in
possible air bag system activation, personal
injury or unneeded air bag system repairs.

Precautions on Handling and Storage of Air Bag
System Components
S6RW0D8200002
SDM
WARNING!
Never power up air bag system when SDM is
not rigidly attached to the vehicle. Otherwise,
personal injury may result.

CAUTION!
After detecting one time of such collision as
to meet deployment conditions, SDM must
not be used. Refer to “Air Bag Diagnostic
System Check” when checking SDM.

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-2
• Never attempt disassembly of SDM.
• When storing SDM, select a place where neither high
temperature nor high humidity is anticipated and oil,
water and dust are kept off.
• If SDM has been dropped, replace it with a new one.
• If SDM installation part of floor was damaged, repair
that part completely before reinstallation.
• All SDM and mounting bracket fasteners must be
carefully torqued and the arrow must be pointed
toward the front of the vehicle to ensure proper
operation of the air bag system.
Live (Undeployed) Air Bag (Inflator) Modules
Special care is necessary when handling and storing a
live (undeployed) air bag (inflator) modules.
The rapid gas generation produced during deployment
of the air bag could cause the air bag (inflator) module,
or an object in front of the air bag (inflator) module, to be
thrown through the air in the unlikely event of an
accidental deployment.
WARNING!
Never attempt to measure the resistance of
the air bag (inflator) modules (driver module,
passenger module and side modules and
curtain modules). It is very dangerous as the
electric current from the tester may deploy
the air bag.

• Never attempt disassembly of the air bag (inflator)
modules.
• If any abnormality is found, be sure to replace it with
new one as an assembly.
• When an abnormality is noted as existing in the live
(undeployed) air bag (inflator) module, be sure to
deploy it before discarding it.
• When grease, cleaning agent, oil, water, etc., got on
the air bag (inflator) modules (driver and passenger),
wipe it off immediately with a dry cloth.
• If air bag (inflator) module was dropped from a height
of 90 cm (3 ft) or more, it should be replaced with a
new one as an assembly.
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Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-4
• Never attempt to disassemble the seat belt
pretensioners (retractor assembly).
• If any abnormality is found, be sure to replace it with
new one as an assembly.
• When an abnormality is noted as existing in the live
(inactivated) seat belt pretensioner, be sure to activate
it before discarding it.
• When grease, cleaning agent oil, water, etc., got on
the seat belt pretensioners (retractor assembly), wipe
it off immediately with a dry cloth.
• If seat belt pretensioner was dropped from a height of
30 cm (1 ft) or more, it should be replaced with a new
one as an assembly.
WARNING!
• For handling and storage of a live seat belt
pretensioner, select a place where the
ambient temperature below 65 °C (150 °F),
without high humidity and away from
electric noise.
• Never carry the seat belt pretensioner by
webbing.
• When placing a live seat belt pretensioner
on the workbench or other surface, be sure
not to lay it with its exhaust hole (1)
provided side facing down. It is also
prohibited to put something on its face
with an exhaust hole (1) or to put a seat
belt pretensioner on top of another.
Otherwise, personal injury may result.

Deployed Air Bag (Inflator) Module and Activated
Seat Belt Pretensioner
WARNING!
• The air bag (inflator) module and seat belt
pretensioner immediately after
deployment/activation is very hot. Wait for
at least 30 minutes to cool it off before
proceeding the work.
• Do not apply water, oil, etc. to deployed air
bag (inflator) module and to activate seat
belt pretensioner.
• After an air bag (inflator) module has been
deployed, the surface of the air bag may
contain a powdery residue. This powder
consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by-
products of the chemical reaction. As with
many service procedures, gloves and
safety glasses should be worn.
• Wash your hands with mild soap and water
after completing the work.

Refer to the procedure described under “Deployed Air
Bag (Inflator) Module and Activated Seat Belt
Pretensioner Disposal” for disposal.
Air Bag Wire Harness and Connector
Air bag wire harness is included in main harness (1),
instrument panel harness (4), floor harness (3), seat
harness (5) and curtain air bag harness (6). Air bag wire
harness can be identified easily as the part of connector
side wire harness is covered with a yellow protection
tube. Be very careful when handling it.
• When an open in air bag wire harness, damaged wire
harness, connector or terminal is found, replace wire
harness, connectors and terminals as an assembly.
• When installing it, be careful so that the air bag wire
harness is not caught or does not interfere with other
parts.
• Make sure air bag system grounding point (2) is clean
and ground is securely fastened for optimum metal-to-
metal contact. Poor grounding can cause intermittent
problems that are difficult to diagnose.
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Downloaded from www.Manualslib.com manuals search engine 8B-97 Air Bag System:
Driver Air Bag (Inflator) Module InspectionS6RW0D8206006
WARNING!
Never disassemble air bag (inflator) module
or measure its resistance. Otherwise,
personal injury may result.

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 visually and if any of the
following is found, replace it with a new one.
• Air bag being deployed
• Trim cover (pad surface) (1) being cracked
• Inflator case (2) being damaged or having been
exposed to strong impact (dropped)
• Bend or deformity of air bag (inflator) module bracket.
Passenger Air Bag (Inflator) Module Removal
and Installation
S6RW0D8206007
WARNING!
• 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.

Removal
1) Disable air bag system. Refer to “Disabling Air Bag
System”.
2) Remove center ventilation louver with garnish
referring to “Center Ventilation Louver Removal and
Installation in Section 7A”.
3) Pull out glove box while pushing its stopper from
both right and left sides.
4) Remove passenger air bag (inflator) module
attaching bolts (1) and its facing cover bolt (6).
5) Hold up passenger air bag (inflator) module with its
facing cover (5) without extending wire harness (2)
to avoid air bag connector damage and to
disconnect passenger air bag (inflator) module
connector (3) as shown in figure.
a) Unlock lock button (4).
b) With lock button unlocked, disconnect connector.
6) Remove passenger air bag (inflator) module with its
facing cover (5) from instrument panel.
1
2
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“A”
5
“A”“A”
3
4a)
b)
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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.
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(a)7 6
8
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