Wiring system SUZUKI GRAND VITARA 1998 2.G Service Workshop Manual

YH4
GRAND
vol.1
0A
0B
1A
1B
3
3A
3B1
3C
3C1
3D
3E
3F
4A2
4B
5
6
7A5A
5B
5C
5E1
6A1
6A2
6A4
6B
6C
6E1
6E2
6F1
6F2
6G
6G1
6H
6K
7A1
7B1
7C1
7D
7E
7F
8
8B
8C
8D
8G
9
10
10A
8A
10B
6-1ENGINE
General Information and
Diagnosis (G16 / J20)
General Information and
Diagnosis (H25)
Engine Mechanical (G16)
Engine Mechanical (H25)
Engine Mechanical (J20)
Engine Cooling
Engine Fuel
Engine and Emission Control
System (SFI for G16 / J20)
Engine and Emission Control
System (SFI for H25)
Ignition System (G16)
Ignition System (J20 / H25)
Cranking System
(Reduction Type)
Cranking System
(No-Reduction Type)
Charging System
Exhaust System
TRANSMISSION, CLUTCH
AND DIFFERENTIAL
Manual Transmission (Type 1)
Manual Transmission (Type 2)
Automatic Transmission
Clutch (Hydraulic Type)
Transfer
Differential (Front)
Differential (Rear)
BODY ELECTRICAL SYSTEM
Wiring Diagram
Lighting System
Instrumentation / Driver
Information
Windows, Mirrors, Security
and Lock
Immobilizer Control System
BODY SERVICE
RESTRAINT SYSTEM
Seat Belt
Air Bag System GENERAL INFORMATION
General Information
Maintenance and Lubrication
TABLE OF CONTENTS TABLE OF CONTENTS SECTIONSECTION
0B
HEATING AND AIR
CONDITIONING
Heater and Ventilation
Air Conditioning
STEERING, SUSPENSION,
WHEELS AND TIRES
Front End Alignment
Power Steering (P / S) System
Steering Wheel and Column
(Not Equipped with Air Bag)
Air Bag Steering Wheel
and Column
Front Suspension
Rear Suspension
Wheel and Tires
1A
3A 0A
1B
3B1
3C
3C1
3D
3E
3F36A16
6A2
6A4
6B
6C
6E1
6E2
6F1
DRIVE SHAFT / PROP. SHAFT
Front Drive Shaft / Shaft
Bearing, Oil Seal
Propeller Shaft
BRAKES
Brake Pipe / Hose / Master
Cylinder
Front Brakes
Parking and Rear Brakes
Antilock Brake System
4A2
4B
5
5A
5B
5C
5E1
6F2
6G
6G1
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8
8A
8B
8C
8D
8G
9
10
10A
10B
6-1
NOTE:
The screen toned Sections 6 ± 6K are included in Volume 2 and Section 8A is in Wiring
Diagram Manual.

YH4
GRAND
VITARA
0A-16 GENERAL INFORMATION

Poor terminal-to-wire connection.
Check each wire harness in problem circuits for poor connection
by shaking it by hand lightly. If any abnormal condition is found,
repair or replace.

Wire insulation which is rubbed through, causing an intermittent
short as the bare area touches other wiring or parts of the vehicle.

Wiring broken inside the insulation. This condition could cause
continuity check to show a good circuit, but if only 1 or 2 strands
of a multi-strand-type wire are intact, resistance could be far too
high.
If any abnormality is found, repair or replace.
PRECAUTION FOR INSTALLING MOBILE
COMMUNICATION EQUIPMENT
When installing mobile communication equipment such as CB (Citi-
zens-Band)-radio or cellular-telephone, be sure to observe the fol-
lowing precautions.
Failure to follow cautions may adversely affect electronic control
system.

Keep the antenna as far away as possible from the vehicle's elec-
tronic control unit.

Keep the antenna feeder more than 20 cm (7.9 in.) away from
electronic control unit and its wire harnesses.

Do not run the antenna feeder parallel with other wire harnesses.

Confirm that the antenna and feeder are correctly adjusted.

YH4
GRAND
VITARA
0B
MAINTENANCE AND LUBRICATION 0B-1
SECTION 0B
MAINTENANCE AND LUBRICATION
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CONTENTS
MAINTENANCE SCHEDULE0B - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Schedule Under Normal Driving Conditions 0B - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Recommended Under Severe Driving Conditions 0B - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SERVICE0B - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine0B - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System0B - 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System0B - 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emission Control System0B - 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis and Body0B - 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Inspection0B - 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECOMMENDED FLUIDS AND LUBRICANTS0B - 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
1A
HEATER AND VENTILATION 1A-1
SECTION 1A
HEATER AND VENTILATION
WARNING:
For vehicles equipped with Supplement Restraint (Air Bag) System

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either or these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
The link mechanism of the heater varies depending on the specifications.
CONTENTS
GENERAL DESCRIPTION1A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body Ventilation1A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS1A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table1A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Circuit1A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE1A- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Unit1A- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor1A- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Relay1A- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Resistor1A- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Mode Control Switch1A-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Mode Control Actuator1A-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Control Lever Assembly 1A-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Control Cables1A-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Unit1A-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Duct1A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
HEATER AND VENTILATION 1A-3
BODY VENTILATION
The body ventilation system of this vehicle has a fresh air intake located at the cowl top panel. When fresh air intake
control lever is at FRESH AIR position, ventilating air is drawn into the interior from the cowl center garnish and
drawn out from the ventilator outlet provided at each side body outer panel (both right and left side).
DIAGNOSIS
DIAGNOSIS TABLE
TroublePossible causeRemedy
Heater blower won't
work even when its
switch is ON.Blower fuse blown
Blower resistor faulty
Blower motor faulty
Wiring or grounding faultyReplace fuse to check for short.
Check resistor.
Replace motor.
Repair as necessary.
Incorrect temperature
output.Control cables broken or binding
Air damper broken
Air ducts clogged
Heater radiator leaking or clogged
Heater hoses leaking or cloggedCheck cables.
Repair damper.
Repair air ducts.
Replace radiator.
Replace hoses.
When mode control
switch is changed,
air outlet port is not
changed.Mode control switch faulty
Mode actuator faulty
Fuse blown
Wiring or grounding faulty
Air damper broken
Air ducts cloggedCheck and replace as necessary.
Check and replace as necessary.
Replace fuse to check for short.
Repair as necessary.
Repair damper.
Repair air ducts.

YH4
GRAND
VITARA
1. Blower motor switch connector
1
1A-14 HEATER AND VENTILATION
HEATER CONTROL LEVER ASSEMBLY
REMOVAL
1) Disconnect negative (±) cable at battery.
2) If equipped with air bag system, disable air bag system.
Refer to DISABLING AIR BAG SYSTEM in Section 10B.
3) Remove mode control switch. Refer to item HEATER MODE
CONTROL SWITCH in this section.
INSPECTION
Check heater blower motor switch for each terminal-to-terminal
continuity. For the detail refer to WIRING CIRCUIT earlier in this
section.
EFLMLMHH
LOW
M1
M2
HIGH

YH4
GRAND
VITARA
1A-18 HEATER AND VENTILATION
11) Remove heater core pipe clamps (1) and grommet (2).
12) Pull out heater core (1) from unit (2).
INSTALLATION
1) Install heater unit by reversing removal procedure, noting the
following items.

When installing each part, be careful not to catch any cable or
wiring harness.

When installing steering column assembly, refer to STEER-
ING COLUMN INSTALLATION in Section 3C or 3C1.
2) Install control cables. (Refer to HEATER CONTROL CABLES in
this section.)
3) Fill engine coolant to radiator.
4) Enable air bag system, if equipped. Refer to ENABLING AIR
BAG SYSTEM in Section 10B.
5) Evacuate and charge system. Refer to items EVACUATING
SYSTEM and PROCEDURE OF CHARGING in Section 1B.

YH4
GRAND
VITARA
1B
AIR CONDITIONING (OPTIONAL) 1B-1
GENERAL DESCRIPTION1B- 3 . . . . . . . . . . . . . .
Identification of Refrigerating System 1B- 3. . . .
Refrigerant Flow of Air Conditioning
System 1B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Components and Location 1B- 5. . . . . . .
DIAGNOSIS1B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 1B- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis of Abnormal Noise 1B- 8. . . . . . . . . .
Quickly Checking of Refrigerant Charge
(If Equipped with Sight Glass) 1B-10. . . . . . . . .
Compression System Diagnosis 1B-11. . . . . . . .
Performance Diagnosis 1B-12. . . . . . . . . . . . . . .
Wiring Circuit 1B-16. . . . . . . . . . . . . . . . . . . . . . . .
Inspection of A / C Controller and Its
Circuits 1B-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . REFRIGERANT RECOVERY,
EVACUATION AND CHARGING1B-23 . . . . . . . .
Operation Procedure for Charging A / C
with Refrigerant 1B-23. . . . . . . . . . . . . . . . . . . . .
Recovery 1B-24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evacuating 1B-25. . . . . . . . . . . . . . . . . . . . . . . . . .
Charging 1B-26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Manifold Gauge Set 1B-29. . . . . . . . .
Leak-Testing Refrigerant System 1B-29. . . . . . .
Liquid Leak Detectors 1B-29. . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE1B-30 . . . . . . . . . . . . . . . .
Precaution 1B-30. . . . . . . . . . . . . . . . . . . . . . . . . . .
A / C Condenser Assembly 1B-33. . . . . . . . . . . . .
Condenser Cooling Fan Assembly 1B-35. . . . . .
SECTION 1B
AIR CONDITIONING (OPTIONAL)
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CAUTION:
The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a).
None of refrigerant, compressor oil and component parts is interchangeable between two types of A / C:
one using refrigerant CFC-12 (R-12) and the other using refrigerant HFC-134a (R-134a).
Be sure to check which refrigerant is used before any service work including inspection and mainte-
nance. For identification between these two types, refer to the description in page 1B-2.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A / C installed in the vehicle being serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.
For basic servicing method of the air conditioning system that is not described in this section, refer to AIR CONDI-
TIONING BASIC MANUAL (99520-02130).
CONTENTS

YH4
GRAND
VITARA
1B-6 AIR CONDITIONING (OPTIONAL)
DIAGNOSIS
GENERAL
ConditionPossible CauseCorrection
Cool air won't come out
(A / C system won't
operative)
No refrigerant

Fuse blown

A / C switch faulty

Blower motor switch faulty

A / C thermistor faulty

Dual pressure switch faulty

Wiring or grounding faulty

A / C ON permission signal in ECM
faulty

A / C controller and its circuit faultyRecover, evacuation and charging.
Check ªIG METERº fuse, ªREAR DEFGº
fuse, and ªA / C FUSEº and check for
short circuit to ground.
Check A / C switch.
Check blower motor switch.
Check A / C evaporator thermistor.
Check dual pressure switch.
Repair as necessary.
Check ON permission signal.
Check A / C controller and its circuit.
Cool air won't come out
(A / C compressor won't
operative)
Magnet clutch faulty

Compressor relay faulty

Compressor thermal switch faulty
(if equipped)

Drive belt loose or broken

Compressor faulty

A / C ON permission signal in ECM
faulty

A / C controller faultyCheck magnet clutch.
Check compressor thermal switch.
Check compressor relay.
Adjust or replace drive belt.
Check compressor.
Check ON permission signal.
Check A / C controller.
Cool air won't come out
(A / C condenser cooling
fan motor won't
operative)
Condenser cooling fan relay faulty

Wiring or grounding faulty

ªA / C condenser cooling fan relayº
signal in ECM faulty

Condenser cooling fan motor faultyCheck condenser cooling fan relay.
Repair as necessary.
Check A / C condenser cooling fan relay
signal.
Check condenser cooling fan motor.
Cool air won't come out
(Blower motor won't
operative)
Fuse blown

Blower motor relay faulty

Blower motor resistor faulty

Blower motor switch faulty

Wiring or grounding faulty

Blower motor faultyCheck ªHEATER FUSEº, ªREAR DEFGº
fuse and check for short circuit to
ground.
Check blower motor relay.
Check blower motor resistor.
Check blower motor switch.
Repair as necessary.
Check blower motor.
Cool air won't come out
or insufficient cooling
(A / C system normal
operative)
Insufficient or excessive charge of
refrigerant

Refrigerant leak in system

Condenser clogged

A / C evaporator clogged or frosted

A / C thermistor faulty

A / C controller faulty

Expansion valve faulty

Drive belt slipping

Magnetic clutch faultyCheck charge of refrigerant.
Check system for leaks.
Check condenser.
Check A / C evaporator.
Check A / C thermistor.
Check A / C controller.
Check expansion valve.
Check or replace drive belt.
Check magnetic clutch.

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-7
ConditionPossible CauseCorrection
Cool air does not come
out or insufficient
cooling (A / C system
normal operative)
Compressor faulty

Air in A / C system

Air leaking from cooling unit or air
duct

Heater and ventilation system faulty

Blower motor faulty

Excessive compressor oil existing in
A / C systemCheck compressor.
Replace condenser dryer, and
evacuation and charging.
Repair as necessary.
Check blower unit.
Check heater control lever assembly.
Check heater assembly.
Check blower motor.
Pull out compressor oil in A / C system
circuit, and replace compressor.
Cool air does not comes
out only intermittently
Wiring connection faulty

Expansion valve faulty

Excessive moisture in A / C system

A / C controller faulty

Magnetic clutch faulty

Excessive charge of refrigerantRepair as necessary.
Check expansion valve.
Replace condenser dryer, and
evacuation and charging.
Check A / C controller.
Check magnetic clutch.
Check charge of refrigerant.
Cool air comes out only
at high speeds
Condenser clogged

Insufficient charge of refrigerant

Air in A / C system

Drive belt slipping

Compressor faultyCheck condenser.
Check charge of refrigerant.
Replace condenser dryer, and
evacuation and charging.
Adjust or replace drive belt.
Check compressor.
Cool air does not comes
out only at high speeds
Excessive charge of refrigerant

A / C evaporator frostedCheck charge refrigerant.
Check A / C evaporator.
Check A / C thermistor.
Insufficient velocity of
cooled air
A / C evaporator clogged or frosted

Air leaking from cooling unit or air
duct

Blower motor faulty

Wiring or grounding faultyCheck A / C evaporator.
Repair as necessary.
Check blower motor.
Repair as necessary.