2006 SUZUKI SX4 PPL

Downloaded from www.Manualslib.com manuals search engine 8-ii Table of Contents
DTC B1062 / B1066: Side-Air Bag Circuit Low
Resistance ...................................................... 8B-59
DTC B1063 / B1067: Side-Air Bag Circuit
Shorted to Ground .......................................... 8B-61
DTC B1064 / B1068: Side-Air Bag Circuit
Shorted to Power Supply ................................ 8B-64
DTC B1071: Driver Forward Impact-Sensor
Communication Data Inconsistent .................. 8B-66
DTC B1072: Driver Forward Impact-Sensor
Communication Data Invalid ........................... 8B-66
DTC B1073: Driver Forward Impact-Sensor
Circuit Shorted to Ground ............................... 8B-67
DTC B1074: Driver Forward Impact-Sensor
Circuit Open .................................................... 8B-68
DTC B1081 / B1091: Side Impact-Sensor No
Response ........................................................ 8B-70
DTC B1082 / B1092: Side Impact-Sensor
Communication DATA Invalid ......................... 8B-70
DTC B1083 / B1093: Side Impact-Sensor
Circuit Shorted to Ground ............................... 8B-71
DTC B1084 / B1094: Side Impact-Sensor
Circuit Open .................................................... 8B-73
DTC B1085 / B1095: Side Impact-Sensor
Communication DATA Inconsistent ................ 8B-74
DTC B1361 / B1365: Curtain-Air Bag Circuit
High Resistance .............................................. 8B-75
DTC B1362 / B1366: Curtain-Air Bag Circuit
Low Resistance ............................................... 8B-79
DTC B1363 / B1367: Curtain-Air Bag Circuit
Shorted to Ground .......................................... 8B-81
DTC B1364 / B1368: Curtain-Air Bag Circuit
Shorted to Power Supply ................................ 8B-83
SDM Power Supply and Ground Circuit
Check .............................................................. 8B-85
Contact Coil Cable and Its Circuit Check .......... 8B-87
Inspection of Intermittent and Poor
Connections .................................................... 8B-89Repair and Inspection Required after
Accident .......................................................... 8B-90
Repair Instructions ............................................8B-93
Disabling Air Bag System.................................. 8B-93
Enabling Air Bag System .................................. 8B-93
SDM Removal and Installation .......................... 8B-94
SDM Inspection ................................................. 8B-95
Driver Air Bag (Inflator) Module Removal and
Installation ....................................................... 8B-95
Driver Air Bag (Inflator) Module Inspection ....... 8B-97
Passenger Air Bag (Inflator) Module Removal
and Installation ................................................ 8B-97
Passenger Air Bag (Inflator) Module
Inspection ........................................................ 8B-99
Side-Air Bag (Inflator) Module Removal and
Installation ....................................................... 8B-99
Side-Air Bag (Inflator) Inspection .................... 8B-101
Side Curtain-Air Bag (Inflator) Module
Removal and Installation ............................... 8B-102
Side Curtain-Air Bag (Inflator) Module
Inspection ...................................................... 8B-103
Forward Impact-Sensor Removal and
Installation ..................................................... 8B-103
Forward Impact-Sensor Inspection ................. 8B-104
Side Impact-Sensor Removal and Installation 8B-105
Side Impact-Sensor Inspection ....................... 8B-105
Passenger Air Bag (Inflator) Module Repair
Harness Installation....................................... 8B-106
Air Bag (Inflator) Module and Seat Belt
Pretensioner Disposal ................................... 8B-107
Deployed Air Bag (Inflator) Module and
Activated Seat Belt Pretensioner Disposal.... 8B-117
Specifications ...................................................8B-118
Tightening Torque Specifications .................... 8B-118
Special Tools and Equipment .........................8B-118
Use of Special Tools ....................................... 8B-118
Special Tool .................................................... 8B-120

Downloaded from www.Manualslib.com manuals search engine 8A-1 Seat Belts:
Restraint
Seat Belts
Precautions
Precautions on Service and Diagnosis of Seat BeltS6RW0D8100001
WARNING!
If replacing seat belt is necessary, replace buckle and seat belt together as a set. This is for the reason
of ensuring locking of tongue plate with buckle. If these parts are replaced individually, such a locking
condition may become unreliable. For this reason, SUZUKI will supply only the spare buckle and seat
belt assembly in a set part.

Before servicing or replacing seat belts, refer to the following precautionary items.
• Seat belts should be normal relative to strap retractor and buckle portions.
• Keep sharp edges and damaging objects away from belts.
• Avoid bending or damaging any portion of belt buckle or latch plate.
• Do not bleach or dye belt webbing. (Use only mild soap and lukewarm water to clean it.)
• When installing a seat belt anchor bolt, it should be tightened by hand at first to prevent cross-threading and then to
specified torque.
• Do not attempt any repairs on retractor mechanisms or retractor covers. Replace defective assemblies with new
replacement parts.
• Keep belts dry and clean at all times.
• If there exist any parts in question, replace such parts.
• Replace belts whose webbing is cut or otherwise damaged.
• Do not put anything into trim panel opening which seat belt webbing passes through.

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-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.
1
I2RH01820048-01
4
12
6
3
5
I5RW0A820006-02

Downloaded from www.Manualslib.com manuals search engine 8B-5 Air Bag System:
Precautions on Disposal of Air Bag and Seat
Belt Pretensioner
S6RW0D8200003
Do not dispose of the live (undeployed) air bag (inflator)
modules and the live (inactivated) seat belt
pretensioners.
When disposal is necessary, be sure to deploy / activate
the air bag and seat belt pretensioner according to
deployment / activation procedure described in “Air Bag
(Inflator) Module and Seat Belt Pretensioner Disposal”.
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 could
cause personal injury. Undeployed air bag
(inflator) module and inactivated seat belt
pretensioner must not be disposed of
through normal refuse channels.
The undeployed air bag (inflator) module and
inactivated seat belt pretensioner contain
substances that can cause severe illness or
personal injury if the sealed container is
damaged during disposal.

General Description
Air Bag System ConstructionS6RW0D8201001
There are two types of air bag system in this model
depending on vehicle specification.
One is 4-channel air bag system and other is 8-channel
air bag system.
4-channel air bag system consists of the following parts.
• Driver and passenger air bag (inflator) modules
• Driver and passenger seat belt pretensioners
• Forward impact-sensor
•SDM
8-channel air bag system consists of the following
component.
• Driver and passenger air bag (inflator) modules
• Driver and passenger seat belt pretensioners
• Driver and passenger side-air bag (inflator) modules
• Driver and passenger side curtain-air bag (inflator)
modules
• Forward impact-sensor
• Driver and passenger side impact-sensors
•SDM
With the air bag system which includes front air bags for
both the driver’s and passenger’s sides as well as the
seat belt pretensioners, the sag of the seat belt is taken
up (for seat belt with pretensioner), the driver air bag
(inflator) module is deployed from the center of the
steering column and the passenger air bag (inflator)
module from the top of the instrument panel in front of
the front passenger seat in occurrence of a front collision
with an impact larger than a certain set value to
supplement protection offered by the driver and front
passenger seat belts.
In addition, with the air bag system which includes side-
air bags and side curtain-air bags for both the driver’s
and passenger’s side (8-channel system).
Side-air bag (inflator) module is deployed from the side
of the seat back in occurrence of a sideward collision
with an impact larger than a certain set value.Side curtain-air bag (inflator) module is deployed from
the roof side in occurrence of a sideward collision with
an impact larger than a certain set value.
For details of air bag system input / output, refer to “Air
Bag System Input / Output Table”.
1. Driver air bag 4. Side-air bag
2. Passenger air bag 5. Side curtain-air bag
3. Seat belt pretensioner
I4RS0B820002-02

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-8
Schematic and Routing Diagram
Air Bag System Wiring Circuit DiagramS6RW0D8202001
BLK
YEL/GRN YEL/GRN
YEL/BLU YEL/BLU
WHT/RED
LT GRN/BLK
WHT/GRN
LT GRN
2223 15
29
21 19
20GRN/RED GRN/RED
GRN GRN
[A]
[B]“E40”, “E388”, “G04” “E388”, “L04” “L395”, “Q102” “Q134”, “S121” and “S172”
L04-4
L04-3
“L395” “Q132” “Q103”
L04-28 L04-46
L04-47
L04-45
L04-44 “L36”“G347” “S172” “L378” “G345”
“L35”ORN
18L04-50
L04-51 “E40”
“Q134” “Q105” “L385”
L04-12
L04-11
GRY/RED
GRY
BLK BLU
27
PNK/BLK ORN
PNK/BLK
BLU/RED
YEL/REDBLU/RED
YEL/RED
“L377” “G344” “G259”
24L04-5
L04-6
GRN/ORN
GRN/YEL
BLU/ORN
BLU/YEL
L04-9
L04-7
L04-8
25
26 “L283”
L04-10
“L285”
L04-20
L04-19“Q104” “Q133” “L384”
L04-13
L04-14BLK BLU BRN/WHT
BRN28
BLK/YEL
BRN/YELBLK/YEL
BRN/YEL30 “Q102”L04-21
L04-22
L04-2
L04-27
L04-37
“L04”
“L04”
“E388” “L372”
L04-32
32
31
G
33Y
X
34
: 12V : 30V : 30V : 5V
12V5V30V 30V
35RED 7
119
10“L313” “G272” “G271”
“G241”
“G273”
“G04”
YEL
1314
YEL/BLK
YEL/BLK
RED/BLK
12
12V
PPL/WHT
8
WHT/RED
WHT
WHT
GRN
12
3
3
5
4
6
BLK
“E324”
17+BB
[C]
16
[D]12V
PPL/WHTYEL11
16
I6RW0C820003-01

Downloaded from www.Manualslib.com manuals search engine 8B-13 Air Bag System:
Air Bag Diagnostic System Check FlowS6RW0D8204002
CAUTION!
• Be sure to perform “Air Bag Diagnostic System Check” before starting diagnosis according to each
flow.
• When measurement of resistance or voltage is required in the flow, use a tester along with a correct
terminal adapter from special tool (Connector test adapter kit).
• When a check for proper connection is required, refer to “Inspection of Intermittent and Poor
Connections”.
• If an open circuit in the air bag wire harness damaged, connector or terminal is found, replace the
wire harness, connectors and terminals as an assembly.

Step Action Yes No
1Battery voltage check.
1) Measure battery voltage.
Is it 10 – 14 V?Go to Step 2. Proceed to “Battery
Inspection in Section
1J”.
2“AIR BAG” warning light check (6 times flushing check).
1) Turn ON ignition switch, and then check that “AIR BAG”
warning light flushes.
Does “AIR BAG” warning light flash 6 times?Go to Step 3. Go to Step 4.
3“AIR BAG” warning light check (turning off check).
1) In the state of Step 2. check that “AIR BAG” warning light
turn OFF after flashing 6 times.
Does “AIR BAG” warning light turn OFF?Go to Step 5. Go to Step 6.
4“AIR BAG” warning light circuit check
Does “AIR BAG” warning light come ON steady?Go to checking flow of
““AIR BAG” Warning
Light Comes ON
Steady”. After carrying
out it flow, proceed to
St ep 6 .Go to checking flow of
““AIR BAG” Warning
Light Does Not Come
ON”. After carrying out it
flow, proceed to Step 6.
5DTC check
1) Check DTC using SUZUKI scan tool referring to “DTC
Check”.
Is “NO CODES” displayed on SUZUKI scan tool?Air bag system is in
good condition.Check intermittent
troubles referring to
“Inspection of
Intermittent and Poor
Connections”.
If intermittent troubles
are OK, check and
repair applicable DTC
flow and then repeat
this flow.
6DTC check
1) Check DTC using SUZUKI scan tool, referring to “DTC
Check”.
Is “NO CODES” displayed on SUZUKI scan tool?Substitute a known-
good SDM and recheck.Check and repair
applicable DTC flow,
and then repeat this
flow.