2006 SUZUKI SX4 Air bag

Downloaded from www.Manualslib.com manuals search engine 6B-7 Steering Wheel and Column:
Removal
WARNING!
Never rest a steering column assembly on
the steering wheel with the air bag (inflator)
module face down and column vertical.
Otherwise, personal injury may result.

1) Disconnect negative (–) cable at battery.
2) Disable air bag system. Refer to “Disabling Air Bag
System in Section 8B”.
3) Remove steering wheel and contact coil cable
assembly referring to “Steering Wheel Removal and
Installation” and “Contact Coil Cable Assembly
Removal and Installation”.
4) (Immobilizer model)
Remove immobilizer control module from steering
column, referring to “ICM Removal and Installation in
Section 10C”.
5) Detach lighting switch and wiper switch from steering
column.
6) Remove lower shaft upper joint bolt (1).
7) Remove steering column mounting nuts (1), and
then remove steering column from vehicle.
NOTE
Do not move tilt lever until mounting bolts
and nuts are tightened to specified torque.

Installation
CAUTION!
After tightening steering column mounting
nuts, shaft joint bolts should be tightened.
Wrong tightening order could cause a
damage to shaft joint.

1) Be sure that front wheels are in straight.
2) Install steering column assembly to lower and upper
brackets. Tighten steering column mounting nuts
No.2 (1) first and then steering column mounting
nuts No.1 (2) to specifications as given below.
Tightening torque
Steering column mounting nut No.1 (a): 14 N·m (
1.4 kgf-m, 10.5 lb-ft)
Steering column mounting nut No.2 (b): 14 N·m (
1.4 kgf-m, 10.5 lb-ft)
NOTE
• When installing, make sure that clearance
“a” between bolt (3) and bracket (4) should
be 0 (zero).
• After installing tilt steering column, make
sure that steering column moves upwards
and downwards smoothly and stops when
tilt lever is fixed.

1
I5RW0A620005-01
1
1
I4RS0A620017-01
2, (a)
1, (b)
1, (b) 2, (a)
4
3“a” “a”
I5RW0A620006-02

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-8
3) Align flat part “a” of steering lower shaft (1) with bolt
hole “b” of shaft joint (2) of column as shown. Then
insert lower shaft into shaft joint of steering column.
4) Tighten lower shaft upper joint bolt (3) to specified
torque.
CAUTION!
After tightening column nuts, tighten steering
shaft upper joint bolt. Otherwise, shaft joint
bearing is damaged.

Tightening torque
Steering lower shaft assembly upper joint bolt
(a): 25 N·m (2.5 kgf-m, 18.5 lb-ft)
5) Install lighting switch and wiper switch to steering
column.
6) (Immobilizer model)
Install immobilizer control module from steering
column, referring to “ICM Removal and Installation in
Section 10C”.
7) Install contact coil cable assembly and steering
wheel referring to “Contact Coil Cable Assembly
Removal and Installation” and “Steering Wheel
Removal and Installation”.
8) Connect negative (–) cable to battery.
9) Enable air bag system referring to “Enabling Air Bag
System in Section 8B”.
Steering Column InspectionS6RW0D6206009
Check steering column for damage and operation
referring to “Checking Steering Column for Accident
Damage”.
Ignition Switch Cylinder Assembly Removal
and Installation (Non- Keyless Start Model)
S6RW0D6206010
Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air
Bag System in Section 8B”.
3) Remove steering column upper and lower covers.
4) (Immobilizer model)
Remove immobilizer control module referring to
“ICM Removal and Installation in Section 10C”.
5) Remove ignition switch cylinder assembly as follows.
a) Turn ignition key to “ACC” position.
b) Insert 2 mm (0.078 in.) rod (2) through hole (3)
and push ignition switch cylinder lock.
c) Detach ignition switch cylinder assembly (1) from
steering lock assembly (4).
Installation
1) Install ignition switch cylinder assembly as follows.
a) Turn ignition key to “ACC” position.
b) In this state, push ignition switch cylinder
assembly into steering lock assembly till it clicks.
2) (Immobilizer model)
Install immobilizer control module referring to “ICM
Removal and Installation in Section 10C”.
3) Install upper and lower cover and screws.
4) Connect negative (–) cable to battery.
5) Enabling air bag system referring to “Enabling Air
Bag System in Section 8B”.
6) (Immobilizer model)
If ignition switch cylinder assembly (that is ignition
key) has replaced, register ignition key transponder
code to ECM referring to “Registration of the Ignition
Key in Section 10C”.
1 2
“a”“b”
3, (a)
I5RW0A620007-01
2
3
1
4
I5JB0A620025-01

Downloaded from www.Manualslib.com manuals search engine 6C-34 Power Assisted Steering System:
Steering Wheel Play CheckS6RW0D6304021
• Check steering wheel for looseness or rattle by
moving it in its shaft direction and lateral direction.
If found defective, repair or replace.
• Check steering wheel for play, holding vehicle in
straight forward condition on the ground with engine
stopped.
If steering wheel play is not within specification,
inspect as follows and replace if found defective.
– Tie-rod end ball stud for wear (Ball stud should
move when more than 0.2 N⋅m (2 kg-cm, 0.44 lb-ft)
torque is applied.)
– Lower ball joint for wear
– Steering shaft joint for wear
– Steering pinion or rack gear for wear or breakage
– Each part for looseness
Steering wheel play
“a”
: 0 – 30 mm (0 – 1.18 in.)
Steering Force CheckS6RW0D6304022
1) Place vehicle on level road and set steering wheel at
straight-ahead position.
2) Check if tire inflation pressure is as specified
referring to the tire placard.
3) Remove driver air bag (inflator) module referring to
“Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
4) Start engine.
5) With engine idling, measure steering force by turning
torque wrench.
Steering force
: Less than 6.4 N⋅m (0.64 kgf-m, 4.6 lb-ft)
6) Install driver air bag (inflator) module referring to
“Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
I3RM0A630021-01
I3RM0A630022-01

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-37
3) Inspect for proper toe referring to “Front Wheel
Alignment Inspection and Adjustment in Section 2B”.
4) After confirming proper toe, tighten tie-rod end lock
nut to specified torque.
Tightening torque
Tie-rod end lock nut (a): 45 N·m (4.5 kgf-m, 32.5
lb-ft)
5) Tighten wheel bolts to specified torque and lower
hoist.
Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
Tie-Rod End InspectionS6RW0D6306004
• Inspect for play in ball joint.
• Inspect for play in rack end ball joint.
In either case, if found defective, replace.
Steering Shaft Joint On-Vehicle InspectionS6RW0D6306005
Check shaft joint for wear, breakage and any other
damage and replace if any defect exists.
Steering Gear Case Assembly Removal and
Installation
S6RW0D6306006
Removal
CAUTION!
Be sure to set front wheels (tires) in straight
direction and remove ignition key from key
cylinder before performing the following
steps, otherwise, contact coil of air bag
system may get damaged.

1) Remove steering joint cover.
2) Make alignment marks (1) on pinion shaft (2) and
joint of steering lower shaft (3) for a guide during
reinstallation.
3) Loosen joint bolt (steering column side) (4) and
remove joint bolt (pinion shaft side) (5) and
disconnect steering lower shaft (3) from pinion shaft
(2).
4) Disconnect torque sensor connector and P/S motor
connector from steering gear case.
5) Remove front suspension frame referring to “Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation in Section 2B”, and then
remove steering gear case.
Installation
1) Install grommet (1) as shown in figure.
I3RM0A630030-01
I4RS0A630043-01
I4RS0B630012-01
2. Protrusion
5
2
1
5
34
3
I4RS0B630013-01
1
2
1
2
I5RW0A630018-02

Downloaded from www.Manualslib.com manuals search engine 7-1 Precautions:
HVAC
Precautions
Precautions
Precautions on HVACS6RW0D7000001
Air Bag Warning
Refer to “Air Bag Warning in Section 00”.
A/C System Caution
Refer to “A/C System Caution in Section 7B” or “A/C System Caution in Section 7B”.
Precautions on Servicing A/C System
Refer to “Precautions on Servicing A/C System in Section 7B” or “Precautions on Servicing A/C System in Section
7B”.
Precaution in Diagnosing Trouble (Automatic Type)
Refer to “Precautions in Diagnosing Trouble in Section 7B”.

Downloaded from www.Manualslib.com manuals search engine 7A-6 Heater and Ventilation:
Blower Motor Relay InspectionS6RW0D7106007
1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air
Bag System in Section 8B”.
3) Remove junction block assembly (2).
4) Disconnect blower motor relay (1) from junction
block assembly (2).
5) Check that there is no continuity between terminal
“C” and “D”. If there is continuity, replace relay.
6) Connect battery positive (+) terminal to terminal “B”
of relay. Connect battery negative (–) terminal “A” of
relay.
Check continuity between terminal “C” and “D”.
If there is no continuity when relay is connected to
the battery, replace relay.
HVAC Control Unit ComponentsS6RW0D7106008
“D” “B”“A”“C”
1
2
I4RS0B710008-01
1. Heater control body assembly 4. Bulb 7. Air intake selector 10. Rear defogger switch
2. Air flow selector 5. Temperature control cable 8. Temperature selector
3. Blower speed selector 6. Air flow control cable 9. A/C switch (if equipped)
7
10
9
2
3 8
45
61
I5RW0A710005-01

Downloaded from www.Manualslib.com manuals search engine 7B-24 Air Conditioning System: Manual Type
5) Move condenser assembly from the vehicle in the
arrow direction in the order of 1, 2 and 3 as shown,
and it can be removed.
Installation
Reverse the removal procedure to install condenser
noting the following instructions.
• Replenish specified amount of compressor oil to
compressor suction side referring to “Replenishing
Compressor Oil” in “Operation Procedure for
Refrigerant Charge”.
• Evacuate and charge the A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
Desiccant Removal and InstallationS6RW0D7216006
Removal
1) Remove condenser assembly referring to
“Condenser Assembly Removal and Installation”.
2) Remove circlip (4) using special tool.
Special tool
: 09900–06107
3) Remove the cap (1) from the receiver / dryer tank
(2).
4) Remove desiccant (3).Installation
Reverse the removal procedure noting the following
instructions.
• Replenish specified amount of compressor oil to
compressor suction side referring to “Operation
Procedure for Refrigerant Charge”.
• Do not remove desiccant from the plastic bag until just
before inserting it into the receiver.
• Apply compressor oil to O-ring (1).
• Be sure to install circlip (2) with its flat face (3)
directed to cap.
• Install condenser assembly referring to “Condenser
Assembly Removal and Installation”.
• Evacuate and charge the A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
“1”
“2”
“3”
I5RW0A721021-02
3
2
1
4
I5RW0A721022-01
: Do not reuse
1
2
3
I5RW0A721052-01

Downloaded from www.Manualslib.com manuals search engine 7B-38 Air Conditioning System: Automatic Type
Automatic Type
Precautions
A/C System CautionS6RW0D7220001
Refer to “A/C System Caution”.
Precautions in Diagnosing TroubleS6RW0D7220002
• Do not disconnect couplers from HVAC control module, battery cable from battery, HVAC control module ground
wire harness from body or main fuse before confirming diagnostic information (diagnostic trouble code) stored in
HVAC control module memory.
• Diagnostic information (diagnostic trouble code) stored in HVAC control module can be checked by display of HVAC
control module. Also, it can be checked by using SUZUKI scan tool. Before checking diagnostic information
(diagnostic trouble code), read this manual and operator's manual for SUZUKI scan tool to know how to read
diagnostic information (diagnostic trouble code).
• When trouble is diagnosed using diagnostic information (diagnostic trouble code) on display of HVAC control
module, keep in your mind that each diagnostic information (diagnostic trouble code) has priority, and only
diagnostic information (diagnostic trouble code) which has the highest priority is indicated. Therefore, after
troubleshooting the malfunction, make sure if there exists any other diagnostic information (diagnostic trouble
code).
• Be sure to read “Air Bag Warning in Section 00” before inspection.
Precautions on Servicing A/C SystemS6RW0D7220003
Refer to “Precautions on Servicing A/C System”.