Lock SUZUKI GRAND VITARA 2004 2.G Service Workshop Manual

YH4
GRAND
VITARA
10A-2 SEAT BELT
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
WARNING:
If replacing seat belt is necessary, replace buckle and ELR (or webbing) 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 ELR (or webbing) in a set part.
Before servicing or replacing seat belts, refer to 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,
latch plate and ELR.

Do not bleach or dye belt webbing. (Use only mild soap and lukewarm water to clean it.)

When installing a seat belt anchor bolt, start bolt by hand to prevent cross-threading.

Use only the correct seat belt anchor bolts and screws and tighten to the correct torque value.

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.

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VITARA
1. Buckle tongue
2. Buckle catch
10A-4 SEAT BELT
INSPECTION
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.

Fully extend the seat belt to make sure there are no twists or tears
in it.
Retractor assembly
Let the seat belt retract fully to confirm its easy retraction.

The retractor assembly should lock webbing when pulled quickly.

The retractor assembly should lock webbing even when tilted
(approx. 15) toward the fore and aft or right and left directions.
Anchor bolt

Inspect all seat belt anchor bolts to verify that they are secure.

All anchor bolts should be secure and torqued to specification.
Belt latch

Belt latch should be secure when latched.

Inspect the seat belt buckle, ensuring that it locks and unlocks
easily.

After buckling the seat belt, tug sharply on the belt, checking that
the buckle remains locked.
Warning system
Check driver side seat belt strap switch for continuity by using ohm-
meter.
Without inserted buckle tongue to buckle catch:
Terminal ªAº and ªBº: Continuity
With inserted buckle tongue to buckle catch:
Terminal ªAº and ªBº: No continuity (

)
As to seat belts with ALR (other than driver side seat belt), check
them as follows in addition to above check.

With vehicle at stop, pull seat belt all the way out, let it retract a
little and try to pull it. It should not be pulled out, that is, it should
be locked where retracted.

Let seat belt retract to its original state. Next, pull it half way out,
let it retract a little and try to pull it again. It should be pulled out
smoothly, that is it should not be locked at this time.

YH4
GRAND
VITARA
10B
AIR BAG SYSTEM 10B-1
GENERAL DESCRIPTION10B- 3 . . . . . . . . . . . . .
System Components and Wiring
Location View and Connectors 10B- 4. . . . . . .
System Wiring Diagram 10B- 5. . . . . . . . . . . . . .
DIAGNOSIS10B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Codes 10B- 6. . . . . . . . . . . .
Use of Special Tools 10B- 6. . . . . . . . . . . . . . . . .
Intermittent and Poor Connections 10B- 8. . . . .
Air Bag Diagnostic System Check 10B-10. . . . .
Air bag diagnostic system check
flow table 10B-11. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic trouble code (DTC) check 10B-12.
Diagnostic trouble code (DTC)
clearance 10B-13. . . . . . . . . . . . . . . . . . . . . . .
Diagnostic trouble code table 10B-14. . . . . . . .
Table A - ªAIR BAGº warning lamp
comes ªONº steady 10B-16. . . . . . . . . . . . . . .
Table B - ªAIR BAGº warning lamp
does not come ªONº 10B-18. . . . . . . . . . . . . .
Table C - ªAIR BAGº warning lamp
flashes 10B-20. . . . . . . . . . . . . . . . . . . . . . . . . .
Table D - SDM cannot communicate
through the serial data circuit 10B-22. . . . . . . Code 15 - Passenger air bag initiator
circuit resistance high 10B-24. . . . . . . . . . . . .
Code 16 - Passenger air bag initiator
circuit resistance low 10B-26. . . . . . . . . . . . . .
Code 18 - Passenger air bag initiator
circuit short to ground 10B-28. . . . . . . . . . . . .
Code 19 - Passenger air bag initiator
circuit short to power circuit 10B-30. . . . . . . .
Code 21 - Driver air bag initiator
circuit resistance high 10B-32. . . . . . . . . . . . .
Code 22 - Driver air bag initiator
circuit resistance low 10B-34. . . . . . . . . . . . . .
Code 24 - Driver air bag initiator
circuit short to ground 10B-36. . . . . . . . . . . . .
Code 25 - Driver air bag initiator
circuit short to power circuit 10B-38. . . . . . . .
Code 31 - Power source voltage high 10B-40
Code 32 - Power source voltage low 10B-42.
Code 41 - Driver pretensioner initiator
circuit resistance high 10B-44. . . . . . . . . . . . .
Code 45 - Passenger pretensioner
initiator circuit resistance high 10B-44. . . . . .
Code 42 - Driver pretensioner initiator
circuit resistance low 10B-46. . . . . . . . . . . . . .
SECTION 10B
AIR BAG SYSTEM
WARNING:

Service on or around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Please observe all WARNINGS and ªService Precautionsº under ªOn-Vehicle
Serviceº in this section before performing service on or around the air bag system components or
wiring. Failure to follow WARNINGS could result in unintended activation of the system or could ren-
der the system inoperative. Either of these two conditions may result in severe injury.

The procedures in this section must be followed in the order listed to disable the air bag system tem-
porarily and prevent false diagnostic trouble codes from setting. Failure to follow procedures could
result in possible activation of the air bag system, personal injury or otherwise unneeded air bag sys-
tem repairs.
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were re-
moved. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may
be used. Fasteners that are not reused, and those requiring thread-locking compound, will be called
out. The correct torque value must be used when installing fasteners that require it. If the above condi-
tions are not followed, parts or system damage could result.
CONTENTS

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GRAND
VITARA
1. Air bag harness
2. ªAIR BAGº monitor coupler
3. Yellow connector of contact coil and combination
switch assembly
4. Yellow connector of passenger air bag (inflator) module
5. Steering support member
1. Air bag harness
2. ªAIR BAGº monitor coupler
3. Yellow connector of contact coil and combination
switch assembly
10B-56 AIR BAG SYSTEM
DISABLING AIR BAG SYSTEM
1) Turn steering wheel so that vehicle's wheels (front tires) and
pointing straight ahead.
2) Turn ignition switch to ªLOCKº position and remove key.
3) Remove ªAIR BAGº fuse from ªAIR BAGº fuse box.
4) Disconnect Yellow connector of contact coil and combination
switch assembly.
ii) Release locking of lock lever.
ii) After unlocked, disconnect to connector.
5) Pull out glove box while pushing its stopper from both right and
left sides and disconnect Yellow connector of passenger air bag
(inflator) module.
ii) Release locking of lock lever.
ii) After unlocked, disconnect to connector.
NOTE:
With ªAIR BAGº fuse removed and ignition switch ON, ªAIR
BAGº warning lamp will be ON.
This is normal operation and does not indicate an air bag
system malfunction.
ENABLING AIR BAG SYSTEM
1) Turn ignition switch to ªLOCKº and remove key.
2) Connect Yellow connector of contact coil and combination
switch assembly, and be sure to lock connector with lock lever.
ii) Connect connector.
ii) Lock connector with lock lever.

YH4
GRAND
VITARA
1. Yellow connector of passenger air bag (inflator) module
2. Steering support member
3. Air bag harness
AIR BAG SYSTEM 10B-57
3) Connect Yellow connector of passenger air bag (inflator) mod-
ule, and be sure to lock connector with lock lever.
ii) Connect connector.
ii) Lock connector with lock lever.
4) Install glove box.
5) Install ªAIR BAGº fuse to ªAIR BAGº fuse box.
6) Turn ignition switch to ON and verify that ªAIR BAGº warning
lamp flashes 6 times and then turns off.
If it does not operate as described, perform ªAir Bag Diagnostic
System Checkº in this section.
HANDLING AND STORAGE
SDM
WARNING:
Never power up air bag system when SDM is not rigidly at-
tached to the vehicle. Otherwise, personal injury may result.
CAUTION:
After detecting one time of such collision as to meet deploy-
ment conditions, the SDM must not be used.
Refer to ªDiagnosisº when checking the SDM.

Never attempt disassembly of SDM.

When storing SDM, select a place where neither high tempera-
ture nor high humidity is anticipated and oil, water and dust are
kept off.

If SDM was dropped from a height of 90 cm (3 ft) or more or if it
is found to be damaged or deformed, replace it with a new one.

If installation part of SDM was damaged, repair that part com-
pletely before reinstallation.

All SDM and mounting bracket fasteners must be carefully
torqued and the arrow must be pointed toward the front of the ve-
hicle to ensure proper operation of the air bag system.

YH4
GRAND
VITARA
1. SDM
2. SDM connector
3. SDM plate
4. SDM cover
1. Air bag wire harness
2. Ground
3. SDM case ground
AIR BAG SYSTEM 10B-65

Passenger air bag (inflator) module
± Check for dents, cracks, damage or fitness.
± Check trim cover for cracks or deformities.
± Check harness and connector for damage or tightness.
If any faulty condition is found in above checks, replace.

SDM and SDM plate
± Check for external damage such as deformation, scratch,
crack, peeled paint, etc.
± Check whether SDM can installed properly due to a cause in it-
self. (There is a gap between SDM and SDM plate, or it cannot
be fixed securely.)
± Check whether connector or lead wire of SDM has a scorching,
melting or damage.
± Check whether connector can be connected securely or locked.
± Check SDM connector and terminals for tightness.
± Check SDM sets a diagnostic trouble code and the diagnostic
table leads to a malfunctioning SDM.
If any faulty condition is found in above checks, replace.

Air bag wire harness and connections
± Check for damages, deformities or poor connections.
(Refer to ªIntermittent And Poor Connectionsº in this section.)
± Check wire harness clamps for tightness.
If any faulty condition is found, correct or replace.

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GRAND
VITARA
1. SDM
2. SDM bolt
3. SDM cover
4. SDM connector1. Front center console box
2. Center garnish panel
3. Ashtray
4. Radio hole cover
5. Clock assembly
AIR BAG SYSTEM 10B-67
SDM
WARNING:
During service procedures, be very careful when handling
a Sensing and Diagnostic Module (SDM).
Be sure to read ªService Precautionsº in this section before
starting to work and observe every precaution during work.
Neglecting them may result in personal injury or inactiva-
tion of the air bag system when necessary.
REMOVAL
1) Disconnect negative cable at battery.
2) Disable air bag system. Refer to ªDisabling Air Bag Systemº ear-
lier in this section.
3) Remove rear and front center console box by removing screw
and clips.
4) Remove center garnish panel.
5) Remove ashtray and tuner assembly, clock assembly, tuner
pocket, radio hole cover, etc.
6) Disconnect SDM connector from SDM.
7) Remove SDM (with SDM plate) as an assembly from vehicle.
NOTE:
Do not separate SDM and SDM plate.
INSPECTION
CAUTION:

Do not connect a tester whatever type it may be.

Never repair or disassemble SDM.

If SDM was dropped from a height of 90 cm (3 ft) or more,
it should be replaced.

Check SDM and SDM plate for dents, cracks or deformation.

Check SDM connector for damage, cracks or lock mechanism.

Check SDM terminal for bent, corrosion or rust.
If any faulty condition is found in above checks, replace.

YH4
GRAND
VITARA
1. SDM
2. SDM bolt
3. SDM cover
4. SDM connector
5. Arrow
1. Front center console box
2. Center garnish panel
3. Ashtray
4. Radio hole cover
5. Clock assembly
10B-68 AIR BAG SYSTEM
INSTALLATION
1) Check that none of following faulty conditions exists.

Bend, scratch, deformity in vehicle body mounted on SDM

Foreign matter or rust on mating surface of vehicle body
mounted on SDM
2) Install SDM (with SDM plate) to vehicle.
CAUTION:
Ensure that arrow on the SDM is pointing toward the front
of the vehicle.
3) Tighten SDM bolts to specified torque.
Tightening Torque
(a): 6.0 N´m (0.6 kg-m, 4.5 lb-ft)
4) Connect SDM connector to SDM securely.
5) Install tuner assembly, clock assembly, tuner pocket, radio hole
cover, etc. and ashtray.
6) Install center garnish panel.
7) Install front and rear center console box.
8) Connect negative cable to battery.
9) Enable air bag system. Refer to ªEnabling Air Bag Systemº earli-
er in this section.

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GRAND
VITARA
1. Shorted
1. Slit on workbench
2. Workbench vise
3. Lower mounting bracket
ALWAYS CARRY AIR BAG (INFLATOR) MODULE
WITH TRIM COVER (AIR BAG OPENING) AWAY
FROM BODY.
ALWAYS PLACE AIR BAG (INFLATOR) MODULE
ON WORKBENCH WITH TRIM COVER (AIR BAG
OPENING) UP, AWAY FROM LOOSE OBJECTS.
10B-72 AIR BAG SYSTEM
1) Turn ignition switch to ªLOCKº, remove key and put on safety
glasses.
2) Check that there is no open, short or damage in special tool (de-
ployment harness). If any faulty is found, do not use it and be
sure to use new deployment harness.
Special Tool
(A): 09932-75030
3) Short the two deployment harness leads together by fully seat-
ing one banana plug into the other.
WARNING:
Deployment harness shall remain shorted and not be
connected to a power source until the air bag is to be
deployed.
Special Tool
(A): 09932-75030
4) Remove driver or passenger air bag (inflator) module from ve-
hicle, referring to SECTION 3C1 or 10B.
WARNING:

Always carry live air bag (inflator) module with trim cov-
er away from you.

When storing a live air bag (inflator) module or when
leaving a live air bag (inflator) module unattended on a
bench or other surface, always face the bag and trim
cover up and away from the surface. As the live passen-
ger air bag (inflator) module must be placed with its bag
(trim cover) facing up, place it on the workbench with
a slit or use the workbench vise to hold it securely at its
lower mounting bracket.
This is necessary so that a free space is provided to al-
low the air bag to expand in the unlikely event of acci-
dental deployment.
Failure to follow procedures may result in personal inju-
ry.
5) Temporarily place driver or passenger air bag (inflator) module
on the workbench or the vise according to above WARNING.

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GRAND
VITARA
4
31
2
2
4
31
For driver air bag (inflator) module
For passenger air bag (inflator) module
1. Stretch deployment harness to full length 10 m (33 ft).
2. Connect connectors.
3. Power source (12V vehicle battery).
4. Short the two deployment harness leads.
10B-74 AIR BAG SYSTEM
7) Stretch the deployment harness from the driver or passenger
air bag (inflator) module to its full length 10 m (33 ft).
8) 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.
9) Verify that the area around the driver or passenger air bag (in-
flator) module is clear of all people and loose or flammable ob-
jects.
10) [In case of Driver Air Bag (Inflater) Module]
Verify that the driver air bag (inflator) module is resting with its
vinyl trim cover facing up.
[In case of Passenger Air Bag (Inflator) Module]
Verify that the passenger air bag (inflator) module is firmly and
properly secured in passenger air bag (inflator) module deploy-
ment fixture (special tool).
11) Connect the driver or passenger air bag (inflator) module to the
deployment harness connector and lock connector with lock le-
ver.
12) Notify all people in the immediate area that you intend to deploy
the air bag (inflator) module.
NOTE:

When the air bag deploys, the rapid gas expansion will
create a substantial report. Wear suitable ear protection.
Notify all people in the immediate area that you intend to
deploy the air bag (inflator) module and suitable ear
protection should be worn.

When the air bag deploys, the driver air bag (inflator)
module may jump about 30 cm (1 ft) vertically. This is a
normal reaction of the driver air bag (inflator) module to
the force of the rapid gas expansion inside the air bag.

After the 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 lu-
bricate the bag as it inflates) and byproducts of the
chemical reaction.