service lamp SUZUKI GRAND VITARA 1998 2.G Service Owner's Guide

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GRAND
VITARA
BODY SERVICE 9-75
1. Canvas top
2. Rear topbow
3. Side body garnish
4. Luggage mat end garnish
5. Assistant grip
6. Sunshade assembly
7. Sunshade hook
8. Front topbow lock
9. Canvas top snap
10. Front seat belt
11. Front pillar trim
12. Rear side inner lower trim
13. Rear side inner upper trim
14. Room light connector
15. Room light harness clamp
16. Roof trim
17. Left-front seat belt
ROOF TRIM (2 DOOR MODEL)
REMOVAL
1) Remove canvas top.
2) Remove rear topbow.
3) Remove side body garnishes.
4) Remove luggage mat end garnish.
5) Remove assistant grips.
6) Remove sunshade assemblies.
7) Remove sunshade hooks.
8) Remove front topbow locks.
9) Remove canvas top snaps.
10) Remove front seat belts.
11) Remove front pillar trims.
12) Remove rear side inner lower trims.
13) Remove rear side inner upper trims.
14) Disconnect room light connector and remove room light har-
ness clamp.
15) Remove roof trim.
CAUTION:
Be very careful not to separate roof trim consists of 4
components when removing. If disassemble it, it could
not be assembled to original unit.

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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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VITARA
10B-2 AIR BAG SYSTEM
Code 46 - Passenger pretensioner
initiator circuit resistance low 10B-46. . . . . . .
Code 43 - Driver pretensioner initiator
circuit short to ground 10B-48. . . . . . . . . . . . .
Code 47 - Passenger pretensioner
initiator circuit short to ground 10B-48. . . . . .
Code 44 - Driver pretensioner initiator
circuit short to power circuit 10B-50. . . . . . . .
Code 48 - Passenger pretensioner
initiator circuit short to power circuit 10B-50.
Code 51 - Frontal crash detected
(System activation command is
outputted) 10B-52. . . . . . . . . . . . . . . . . . . . . . .
Code 61 -ªAIR BAGº warning lamp
circuit failure 10B-53. . . . . . . . . . . . . . . . . . . . .
Code 71 - Internal SDM fault 10B-54. . . . . . . .
ON-VEHICLE SERVICE10B-55 . . . . . . . . . . . . . . .
Service Precautions 10B-55. . . . . . . . . . . . . . . . .
Service and diagnosis 10B-55. . . . . . . . . . . . . .
Disabling air bag system 10B-56. . . . . . . . . . . .
Enabling air bag system 10B-56. . . . . . . . . . . .
Handling and storage 10B-57. . . . . . . . . . . . . .
Disposal 10B-62. . . . . . . . . . . . . . . . . . . . . . . . . .
Repairs and Inspections Required
after an Accident 10B-63. . . . . . . . . . . . . . . . . . .
Accident with deployment
- component replacement 10B-63. . . . . . . . . . Accident with or without deployment
- component inspections 10B-64. . . . . . . . . . .
Driver Air Bag (Inflator) Module 10B-66. . . . . . . .
Contact Coil and Combination Switch
Assembly 10B-66. . . . . . . . . . . . . . . . . . . . . . . . .
Seat Belt Pretensioner 10B-66. . . . . . . . . . . . . . .
ªAIR BAGº Warning Lamp 10B-66. . . . . . . . . . . .
SDM 10B-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Passenger Air Bag (Inflator) Module 10B-69. . .
AIR BAG (INFLATOR) MODULES
DISPOSAL10B-71 . . . . . . . . . . . . . . . . . . . . . . . . . .
Deployment Outside Vehicle 10B-71. . . . . . . . . .
Deployment Inside Vehicle 10B-78. . . . . . . . . . . .
SEAT BELT PRETENSIONERS
DISPOSAL10B-83 . . . . . . . . . . . . . . . . . . . . . . . . . .
Activation Outside Vehicle 10B-83. . . . . . . . . . . .
Activation Inside Vehicle 10B-89. . . . . . . . . . . . . .
DEPLOYED AIR BAG (INFLATOR)
MODULES DISPOSAL10B-93 . . . . . . . . . . . . .
ACTIVATED SEAT BELT PRETENSIONERS
DISPOSAL10B-94 . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS10B-95 . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS10B-95 . . . . . . . . . . . . . . . . . . . .

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VITARA
10B-12 AIR BAG SYSTEM
1. Data link connector (DLC)
2. DLC cable adapter
3. DLC cable
-1. ªAIR BAGº
warning lamp
-2. ªAIR BAGº fuse box
-3. ªAIR BAGº
monitor coupler
3-1. Diagnostic switch
terminal
-4. Air bag harness
(covered yellow tube)
EXAMPLE: When driver air bag initiator circuit resistance high (Code No.21) is set
Malfunction indicator lamp
(ªAIR BAGº warning lamp)
Turn ON
Turn OFF
Time (sec.) Code No. 21 Code No. 21 Code No. 21 1
DIAGNOSTIC TROUBLE CODE (DTC) CHECK
[Using SUZUKI scan tool]
1) Turn ignition switch OFF.
2) After setting cartridge to Tech 1, connect it to data link connector
(DLC) located on underside of instrument panel at driver's seat
side.
Special Tool
(A): 09931-76011 (Tech 1)
(B): Mass storage cartridge
(C): 09931-76030
3) Turn ignition switch ON.
4) Read DTC according to instructions displayed on Tech 1 and
print it or write it down. Refer to Tech 1 operator's manual for fur-
ther details.
5) After completing the check, turn ignition switch OFF and discon-
nect Tech 1 from data link connector (DLC).
[Not using SUZUKI scan tool]
1) Check that malfunction indicator lamp (ªAIR BAGº warning
lamp) comes ON when ignition switch is turned ON.
If it does not come ªONº, proceed to ªTable Bº on p.10B-18.
2) Using service wire, ground diagnosis switch terminal in monitor
coupler.
3) Read DTC from flashing pattern of malfunction indicator lamp
(ªAIR BAGº warning lamp). (Refer to ªDiagnostic Trouble Code
Tableº on p.10B-14 and 10B-15.)
4) After completing the check, turn ignition switch OFF and discon-
nect service wire from ªAIR BAGº monitor coupler.

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VITARA
1. Data link connector
2. DLC cable adapter
3. DLC cable
1sec. 1sec.About 10 seconds
Open
Short-1. ªAIR BAGº warning lamp
-2. ªAIR BAGº fuse box
-3. ªAIR BAGº monitor coupler
3-1. Diagnostic switch terminal
-4. Air bag harness (covered yellow tube)1
AIR BAG SYSTEM 10B-13
DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE
[Using SUZUKI scan tool]
1) Turn ignition switch OFF.
2) Connect Tech 1 to data link connector (DLC) in the same manner
as when making this connection for DTC check.
Special Tool
(A): 09931-76011 (Tech 1)
(B): Mass storage cartridge
(C): 09931-76030
3) Turn ignition switch ON.
4) Erase DTC according to instructions displayed on Tech 1.
Refer to Tech 1 operator's manual for further details.
5) After completing the check, turn ignition switch OFF and discon-
nect Tech 1 from data link connector (DLC).
6) Perform ªDiagnosis Trouble Code (DTC) Checkº and confirm
that normal DTC (NO CODES) is displayed and not malfunction
DTC.
NOTE:
If DTC 51 or DTC 71 is stored in SDM, it is not possible to
clear DTC.
[Not using SUZUKI scan tool]
1) Turn ignition switch ON and wait about 6 seconds or more.
2) Using service wire, repeat shorting and opening between diag-
nosis switch terminal and ground terminal on ªAIR BAGº monitor
coupler 5 times at about 1 second intervals.
3) Perform ªDiagnosis Trouble Code (DTC) Checkº and confirm
that normal DTC (DTC 12) is displayed and not malfunction
DTC.
NOTE:
If DTC 51 or DTC 71 is stored in SDM, it is not possible to
clear DTC.

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GRAND
VITARA
1. From main fuse
2. Ignition switch
3. ªIG
.COIL METERº fuse in J/B
4. ªAIR BAGº warning lamp in combination meter7. Connection detection pin
8. SDM
8-1. ªAIR BAGº warning lamp driver circuit -5. ªAIR BAGº fuse in ªAIR BAGº fuse box
-6. ªAIR BAGº monitor coupler
6-1. Diagnosis switch terminal : Air bag harness
6±1 6
10B-20 AIR BAG SYSTEM
TABLE C ± ªAIR BAGº WARNING LAMP FLASHES (Page 1 of 2)
CAUTION:

When measurements are requested in this chart use specified digital multimeter with correct terminal
adapter from special tool (Connector test adapter kit).

When a check for proper connection is requested refer to ªIntermittent and Poor Connectionsº in this
section.

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.
STEPACTIONYESNO
11) Check ªAIR BAGº monitor coupler.
2) Is it connected diagnosis switch terminal and
ground terminal in ªAIR BAGº monitor coupler
by service wire?Remove service wire.Go to step 2.
21) With ignition switch OFF, disconnect SDM.
2) Measure resistance between ªA8º terminal of
SDM connector and body ground.
3) Is resistance 1 k
or more?Substitute a known-good
SDM and recheck.Repair short from ªVº
wire circuit to ground.

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GRAND
VITARA
AIR BAG SYSTEM 10B-55
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
SERVICE AND DIAGNOSIS
WARNING/CAUTION labels are attached on each part of air bag system components (SDM, air bag (inflator) mod-
ules and seat belt pretensioners). Be sure to follow the instructions.
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 or any other air bag system components. Modifications
can adversely affect air bag system performance and lead to injury.

Failure to follow procedures could result in possible air bag system activation, personal injury or un-
needed air bag system repairs.

Many of service procedures require disconnection of ªAIR BAGº fuse and air bag (inflator) modules (driver and
passenger) 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 chart requests
it, as this will set a diagnostic trouble code.

The ªAir Bag Diagnostic System Checkº must be the starting point of any air bag diagnostics. The ªAir Bag Diag-
nostic System Checkº will verify proper ªAIR BAGº warning lamp operation and will lead you to the correct chart
to diagnose any air bag malfunctions. Bypassing these procedures may result in extended diagnostic time, incor-
rect 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 activa-
tion.

When servicing, if shocks may be applied (eg., dropped from a height of 90 cm (3 ft) or more) to air bag system
component parts, remove those parts beforehand.

When using electric welding, be sure to disconnect air bag (inflator) module and seat belt pretensioner connec-
tors (driver and passenger) 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 proce-
dures listed in the following pages to temporarily disable the air bag system. Refer to appropriate ser-
vice manual procedures. Failure to follow procedures could result in possible air bag system activa-
tion, personal injury or unneeded air bag system repairs.