warning SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

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GRAND
VITARA
1. Air bag harness
2. Seat belt pretensioner harness
For driver side
AIR BAG SYSTEM 10B-89
ACTIVATION INSIDE VEHICLE
Use this procedure when scrapping the entire vehicle including the seat belt pretensioners.
CAUTION:
When vehicle itself will be used again, activate pretensioner outside vehicle according to ªActivation
Outside Vehicleº, for activating it inside will cause the center pillar inner garnish and their vicinity to
be deformed.
Failure to observe this CAUTION may require unneeded vehicle inspection and repair.
WARNING:
Following precautions must be observed for this work. Failure to observe any of them may result in
personal injury.

To avoid an accidental activation, this work should be performed by no more than one person.

The procedure should be followed strictly as described here.

Be sure to read ªService Precautionsº for the seat belt pretensioner beforehand.

Never connect deployment harness to any power source before connecting deployment harness to
the seat belt pretensioner. Deployment harness shall remain shorted and not be connected to a power
source until the pretensioner is to be activated.

The seat belt pretensioner will immediately activate the pretensioner when a power source is con-
nected to it. Wear safety glasses throughout this entire activation and disposal procedure.

Wear suitable ear protection when activating pretensioner. Also, advise those who are in the area
close to activation site to wear suitable ear protection.

Do not activate driver and passenger seat belt pretensioners at the same time.
1) Turn ignition switch to ªLOCKº, remove key and put on safety
glasses.
2) Remove all loose objects from front seats and instrument panel.
3) Remove both side (driver and passenger side) front pillar lower
trims and disconnect seat belt pretensioner harnesses from air
bag harness.
4) Confirm that each seat belt pretensioner is securely mounted.

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1. Shorted
Driver side for left hand steering vehicle
Driver side for right hand steering vehicle
1. Stretch deployment harness
to its full length 10 m (33 ft).
2. Drop cloth, blanket or similar item.
10B-90 AIR BAG SYSTEM
5) Check that there is no open/short or damage in special tool (de-
ployment harness). If any faulty condition is found, do not use
it and be sure to use new deployment harness.
Special Tool
(A): 09932-75030
6) Short the two deployment harness leads together by fully seat-
ing one banana plug into the other.
WARNING:
Deployment wires shall remain shorted and not be con-
nected to a power source until the pretensioner is to be
activated.
Special Tool
(A): 09932-75030
7) Connect the deployment harness connector to the seat belt
pretensioner harness and lock the connector with lock lever.
Special Tool
(A): 09932-75030
8) Route deployment harness out the vehicle.
9) Verify that the inside of the vehicle and the area surrounding
the vehicle are clear of all people and loose or flammable ob-
jects.
10) Stretch the deployment harness to its full length 10 m (33 ft).
11) Place a power source near the shorted end of the deployment
harness. Recommended application: 12 Volts minimum, 2
amps minimum. A vehicle battery is suggested.
12) Completely cover windshield area and front door window
openings with a drop cloth, blanket to similar item. This reduces
the possibility of injury due to possible fragmentation of the ve-
hicle's glass or interior.
13) Notify all people in the immediate area that you intend to acti-
vate the seat belt pretensioner.

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1. Stretch it to full length 10m (33 ft).
2. Power source (12V vehicle battery)
3. Connect one banana plug to positive terminal of power
source (12V vehicle battery) and then the other to
negative terminal to immediately activate.
4. Short harness leads after activation.
5. Drop cloth, blanket or similar them.
AIR BAG SYSTEM 10B-91
NOTE:
When the pretensioner activates, the rapid gas expansion
will create a substantial report. Wear suitable ear protec-
tion. Notify all people in the immediate area that you intend
to activate the seat belt pretensioner and suitable ear
protection should be worn.
WARNING:
Safety precautions must be observed when handling an
activated seat belt pretensioner.

After activation, the metal surfaces of the seat belt
pretensioner will be very hot. Do not touch the metal
areas of the seat belt pretensioner for about 30 min-
utes after activation.

Do not apply water, oil, etc. to activated seat belt pre-
tensioner.

If the activated seat belt pretensioner must be moved
before it is cool, wear gloves and handle by using non-
metal material.
Failure to follow procedures may result in fire or per-
sonal injury.
14) Separate the two banana plugs on the deployment harness.
15) Connect the deployment harness to the power source (12 V ve-
hicle battery) to immediately activate the pretensioner.
16) Disconnect the deployment harness from the power source (12
V vehicle battery) and short the two deployment harness leads
together by fully seating one banana plug into the other.

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1. Exhaust hole
1 1
NG
10B-92 AIR BAG SYSTEM
17) Put on a pair of shop gloves to protect your hands from possible
irritation and heat when handling the activated seat belt preten-
sioner.
NOTE:
As a precaution, gloves and safety glasses are recom-
mended to prevent any possible irritation of the skin or
eyes.
18) Disconnect the deployment harness from the seat belt preten-
sioner as soon after activation as possible. This will prevent
damage to the deployment harness due to possible contact
with the hot seat belt pretensioner canister. The deployment
harness are designed to be reused. They should, however, be
inspected for damage after each activation and replaced if nec-
essary.
19) Carefully remove drop cloth from vehicle and clean off any frag-
ments or discard drop cloth entirely.
20) Repeat steps 2) through 19) to activate seat belt pretensioner
which has not been activated, if any.
21) In the unlikely event that either or both of the seat belt preten-
sioners proceed immediately with steps 23) through 25). If the
seat belt pretensioner did activate, proceed with step 22).
22) With pretensioners activated the vehicle may be scrapped in
the same manner as a non-air bag system equipped vehicle.
23) Remove the inactivated seat belt pretensioner(s) from the ve-
hicle. Refer to SECTION 10A.
WARNING:

For handling and storage of a live seat belt pretension-
er, select a place where the ambient temperature be-
low 65
C (150
F), without high humidity and away
from electric noise.

Never carry the seat belt pretensioner by the wires or
connector on the underside of the pretensioner.

When placing a live seat belt pretensioner on the
workbench or some place like that, be sure not to lay
it with its exhaust hole provided side facing down. It
is also prohibited to put something on its face with an
exhaust hole or to put a seat belt pretensioner on top
of another.
Otherwise, personal injury may result.

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AIR BAG SYSTEM 10B-93
24) Temporarily store the seat belt pretensioner. At that time, be
sure NOT to face its exhaust hole provided side down. It must
face up. Refer to ªService Precautionsº in this section for de-
tails.
25) Contact your local distributor for further assistance.
DEPLOYED AIR BAG (INFLATOR)
MODULES DISPOSAL
WARNING:
Failure to follow proper air bag (inflator) module disposal
procedures can result in air bag deployment which may
cause personal injury. Undeployed air bag (inflator) module
must not be disposed of through normal refuse channels.
The undeployed air bag (inflator) module contains sub-
stances that can cause severe illness or personal injury if
the sealed container is damaged during disposal.
Deployed air bag (inflator) modules (driver/passenger) can be dis-
posed of through normal refuse channels just like any other parts.
For their disposal, however, following points should be noted.

The air bag (inflator) module immediately after deployment is very
hot. Wait for 30 minutes to cool it off before handling it.

Never apply water, oil, etc. to deployed air bag (inflator) module
to cool it off and be careful so that water, oil etc. does not get on
the deployed air bag (inflator) module.

After the air bag (inflator) module has been deployed, the surface
of the air bag may contain a powdery residue. This powder con-
sists primarily of cornstarch (used to lubricate the bag as it in-
flates) and byproducts of the chemical reaction. As with many ser-
vice procedures, you should wear gloves and safety glasses.

When disposing of the deployed air bag (inflator) module, be sure
to seal it in a vinyl bag.

When air bag (inflator) module(s) have been deployed inside the
vehicle which is going to be scrapped, leave them as installed to
the vehicle.

Be sure to wash your hands with mild soap and water after han-
dling it.

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10B-94 AIR BAG SYSTEM
ACTIVATED SEAT BELT
PRETENSIONERS DISPOSAL
WARNING:
Failure to follow proper seat belt pretensioner (retractor as-
sembly)
disposal procedures can result in pretensioner ac-
tivation which may cause personal injury. Inactivated seat
belt pretensioner must not be disposed of through normal
refuse channels.
The inactivated seat belt pretensioner contains substances
that can cause severe illness or personal injury if the sealed
container is damaged during disposal.
Activated seat belt pretensioners (driver/passenger) can be dis-
posed of through normal refuse channels just like any other parts.
For their disposal, however, following points should be noted.

The seat belt pretensioner immediately after activation is very
hot. Wait for 30 minutes to cool it off before handling it.

Never apply water, oil, etc. to activated seat belt pretensioner to
cool it off and be careful so that water, oil etc. does not get on the
activated seat belt pretensioner.

With many service procedures, gloves and safety glasses should
be worn to prevent any possible irritation of the skin or eyes.

When disposing of the activated seat belt pretensioner alone, be
sure to seal it in a vinyl bag.

When seat belt pretensioners have been activated inside the ve-
hicle which is going to be scrapped, leave them as installed to the
vehicle.

Be sure to wash your hands with mild soap and water after han-
dling it.

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GRAND
VITARA
AIR BAG SYSTEM 10B-95
09931-76011
Suzuki scan tool (tech 1A) kit1. Storage case
2. Operator's manual
3. Tech 1A
4. DLC cable
5. Test lead/probe
6. Power source cable
7. DLC cable adapter
8. Self-test adapter Mass storage cartridge for air bag system
09931-76030
16/14 pin DLC cable09932-75010
Air bag driver/passenger
load tool09932-76010
Connector test adapter kit09932-75030
Air bag deployment harness
09932-75040
Passenger air bag (inflator)
module deployment fixtureDigital multimeter for
which the maximum test
current is 10 mA or less
at the minimum range of
resistance measurement.
WARNING:
Be sure to use the specified
digital multimeter.
Otherwise, air bag deploy-
ment or personal injury may
result.
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
SDM bolt60.64.5
Passenger air bag (inflator) modulescrew5.50.554.0Passenger air bag (inflator) modulebolt232.316.5
Driver air bag (inflator) module boltRefer to SECTION 3C1.
Seat belt pretensioner (retractor assembly) boltRefer to SECTION 10A.
SPECIAL TOOLS