Light SUZUKI GRAND VITARA 1999 2.G Service Manual

7E-4 DIFFERENTIAL (FRONT)
Flow table
Step Action Yes No
1 Turn ON ignition switch (but engine at stop) and
check malfunction indicator lamp.
Does lamp light up?Go to step 2. A trouble has occurred
at some place. Repair
it referring to
MALFUNCTION INDI-
CATOR LAMP
(“CHECK ENGINE”
LAMP) CHECK in
DIAGNOSIS of Sec-
tion 6.
2 Check 4WD switch circuit.
Turn ignition switch ON and check that voltage
between terminal C51-3-7 and terminal C51-3-17
(ground) is as follows.
 When transfer shift lever is in N or 2H : 10 – 14 V
 When transfer shift lever is in 4L or 4H : 0 – 1 V
Is the check result satisfactory?Go to step 3. Check 4WD switch
(refer to Section 7A),
“BLK/ORN” and “BLK”
circuits of 4WD switch.
If OK, substitute a
known-good ECM
(PCM) and recheck.
3 Check power supply.
1) Turn ignition switch ON.
2) Check voltage between C51-1-9 and C51-3-17
(ground). The check results should be as follows.
 When transfer shift lever is in N or 2H : 0 – 1 V
 When transfer shift lever is in 4L or 4H : 10 – 14 V
Is the check result satisfactory?Go to step 4. Check “RED” circuit. If
it is OK, substitute a
known-good ECM
(PCM) and recheck.
4 Check air pump assembly circuit.
1) Check for proper connection to air pump assem-
bly at all terminals.
2) Turn ignition switch ON.
3) Check voltage between C51-3-18 and C51-3-17
(ground). The check result should be as follows.
 When transfer shift lever is in 2H or N : 0 – 1 V
 When transfer shift lever is in 4L or 4H (more than
4 seconds after shifted to 4L or 4H) : 10 – 14 V
Is the check result satisfactory?Go to step 5. Check air pump
assembly referring to
“ON-VEHICLE SER-
VICE”, and then
“PNK” circuit.
If OK, substitute a
known-good ECM
(PCM) and recheck.
5 Check 4WD indicator lamp circuit.
1) Turn ignition switch ON.
2) Check voltage between E61-19 and C51-3-17
(ground). The check result should be as follows.
 When transfer shift lever is in 2H or N : 10 – 14 V
 When transfer shift lever is in 4L or 4H : 0 – 1 V
Is the check result satisfactory?4WD control system is
in good condition.Check “ORN/BLK” cir-
cuit (including indica-
tor lamp and
combination meter).
If OK, substitute a
known-good ECM
(PCM) and recheck.

DIFFERENTIAL (REAR) 7F-15
3) Set dial gauge to mounting dummy and make 0 (zero)
adjustment on surface plate.
Special tool
(A) : 09900-20606
(B): 09926-78320
4) Place zero-adjusted mounting dummy and dial gauge set on
pinion mounting dummy and take measurement between
zero position and extended dial gauge measuring tip.
Special tool
(A) : 09900-20606
(B) : 09926-78311
(D) : 09922-76570
(F) : 09926-78311-002
5) Obtain adjusting shim thickness by using measured value by
dial gauge in previous step. NOTE:
When setting dial gauge to mounting dummy, tighten
screw lightly. Be careful not to overtighten it, which will
cause damage to dial gauge.
With dial gauge set, turn dummy back and force by
hand a couple of times and attain accurate 0 (zero)
adjustment.
It is desirable that short pointer indicates beyond 2 mm
when long one is at 0 (zero).
1. Surface plate
2. Screw
NOTE:
Repeat turning back and force of dummy and measure
distance as far as top surface of pinion dummy accu-
rately.
When dial gauge measuring tip extends from 0 (zero)
position, pointer turns counterclockwise.
Measured value may exceed 1 mm. Therefore, it is also
necessary to know reading of short pointer.
Neces-
sary shim
thickness
“e”=Dial gauge
measured
value “c”

7F-18 DIFFERENTIAL (REAR)
Assembling Unit
1) Place bearing outer races on their respective bearings.
Used left and right outer races are not interchangeable.
2) Install case assembly in carrier.
3) Install side bearing adjusters on their respective carrier,
making sure adjuster are threaded properly.
4) Align match marks (1) on cap and carrier. Screw in 2 side
bearing cap bolts 2 or 3 turns and press down bearing cap
by hand.
5) Tighten cap bolts (provisional torque).
Tightening torque
Bearing cap bolt (Provisional torque) (a) :
15 N·m (1.5 kg-m, 11.0 lb-ft)
6) Tighten both bearing adjusters (2) so as to obtain specified
gear backlash and at the same time, obtain preload of side
bearing.
Standard backlash
: 0.13 – 0.18 mm (0.005 – 0.007 in.)
Special tool
(A) : 09930-40120
(B) : 09930-40113
(C) : 09900-20701
NOTE:
If bearing cap does not fit tightly on carrier, side bearing
adjuster is not threaded properly. Reinstall adjuster.
NOTE:
Be sure to apply measuring tip of dial gauge at right
angles to convex side of tooth.
As a practical measure the following would be recom-
mended to obtain specified backlash and side bearing
preload at the same time.
–Obtain specified backlash by turning both adjusters
inward lightly.
–Tighten both adjusters further by one notch at a
time.
Measure at least 4 points on drive bevel gear periph-
ery.
1. Bearing cap bolt

BODY ELECTRICAL SYSTEM 8-1
6F1
6F2
6G
6H
6K
7A
8
6K
7C1
7D
7E
7F
8A
8D
8E
9
10
10A
10B
SECTION 8
BODY ELECTRICAL SYSTEM
Wiring System
(Harnesses, Connectors, Fuses, Relay, Switches, Grounds, System Circuit Diagram) .......... Section 8A
Lighting System .............................................................................................................................. Section 8B
Instrumententation and Driver Information .................................................................................. Section 8C
Windows, Mirrors, Security and Locks ......................................................................................... Section 8D
Immobilizer Control System............................................................................................................Section 8F
CONTENTS
General Description .......................................... 8-3

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
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” 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
“LOCK” 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:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in FOREWORD of this manual.

8-2 BODY ELECTRICAL SYSTEM
General Description
WIRE COLOR SYMBOLS
There are two kinds of colored wire used in this vehicle. One is
single-colored wire and the other is dual-colored (striped) wire.
The single-colored wire uses only one color symbol (i.e. “GRN”).
The dual-colored wire uses two color symbols (i.e. “GRN/YEL”).
The first symbol represents the base color of the wire (“GRN” in
the figure) and the second symbol represents the color of the
stripe (“YEL” in the figure). Symbol Wire Color Symbol Wire Color
B BLK Black O, Or ORN Orange
Bl BLU Blue R RED Red
Br BRN Brown W WHT White
GGRN Green Y YEL Yellow
Gr GRY Gray P PNK Pink
Lbl LT BLU Light blue V PPL Violet
Lg LT GRN Light green

INSTRUMENTATION/DRIVER INFORMATION 8C-1
8C
SECTION 8C
INSTRUMENTATION/DRIVER INFORMATION
CONTENTS
General Description ........................................8C-2
Combination Meter ........................................8C-2
On-vehicle Service ..........................................8C-4
Fuel Meter/Fuel Gauge Unit ..........................8C-4
Fuel level sensor (sender gauge) ..............8C-4
Engine Coolant Temperature (ECT) Meter
and Sensor ....................................................8C-5Engine coolant temperature sensor .......... 8C-5
Oil Pressure Light ......................................... 8C-5
Oil pressure switch .................................... 8C-5
Brake Warning Light ..................................... 8C-5
Brake fluid level switch .............................. 8C-5

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
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” 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
“LOCK” 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:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in the FOREWORD of this manual.

8C-2 INSTRUMENTATION/DRIVER INFORMATION
General Description
Combination Meter
1. Tachometer 8. Multifunction indicator light 15. Charge warning light
2. Speedometer 9. Turn signal pilot light (RH) 16. Brake fluid level, parking brake and EBD warning light
3. Fuel level meter 10. AIR BAG warning light 17. POWER indicator light (A/T vehicle only)
4. Engine coolant temperature meter 11. O/D OFF light (A/T vehicle only) 18. CRUISE indicator light
5. Turn signal pilot light (LH) 12. Fasten seat belt light (if equipped) 19. Immobilizer warning light (if equipped)
6. 4WD indicator 13. High beam light 20. Shift position indicator (A/T vehicle, if equipped)
7. ABS warning light 14. Engine oil pressure warning light

INSTRUMENTATION/DRIVER INFORMATION 8C-5
Engine Coolant Temperature (ECT) Meter and
Sensor
Engine coolant temperature sensor
REMOVAL AND INSTALLATION
Refer to “ECT SENSOR” in Section 6E2.
Oil Pressure Light
Oil pressure switch
REMOVAL AND INSTALLATION
Refer to “OIL PRESSURE CHECK” in Section 6A2.
Brake Warning Light
Brake fluid level switch
INSPECTION
Use an ohmmeter to check switch for continuity.
If found defective, replace switch (reservoir).
Brake fluid level switch specification
OFF position (float up) : No continuity
ON position (float down) : Continuity

CRUISE CONTROL SYSTEM 8E-3
Cruise Control System
The cruise control system is a device which maintains a preset vehicle speed while driving at a high speed, e.g.,
on a highway. It allows the driver to drive his vehicle at a constant speed of 40 km/h (25 mile/h) or higher without
depressing the accelerator pedal (constant cruising). The system also has such functions as to change the vehi-
cle speed without operating the accelerator pedal (but using SET COAST and ACCEL RESUME switches), can-
cel cruise control (CANCEL switch) and resume the speed in memory automatically after cruise control is
cancelled (ACCEL RESUME switch). The system mainly consists of a vehicle speed sensor, an actuator
assembly incorporated with control module, cruise main switch, SET COAST switch, ACCEL RESUME switch
and CANCEL switch, etc.
Cruise control system circuit
Refer to Section 8A.
1. Cruise main switch 6. PCM / ECM
1-1 Cruise main switch indicator lamp 7. Stop lamp switch (with brake pedal position switch)
2.“CRUISE” Indicator light 8. Clutch pedal position switch (M/T vehicle)
3. SET COAST/ACCEL RESUME/CANCEL switch 9. Automatic transmission
4. Vehicle speed sensor 10. Transmission range switch (Park/Neutral position switch) (A/T vehicle)
5. Cruise control actuator assembly (with control module)

8E-4 CRUISE CONTROL SYSTEM
Components and functions
Component Function
Cruise control actuator
assembly with control mod-
uleCruise control module:
Executes centralized control by means of a microcomputer over all functions
including setting a constant speed, resuming it, setting coast, limiting minimum
speed and cancelling cruise control.
Cruise control actuator (stepping motor & clutch) :
Actuates accelerator pedal through cruise cable and arm according to a signal
from cruise control module to control vehicle speed.
Cruise main switch This switch has a momentary contact type button to turn the cruise control
system ON and OFF.
SET COAST switch When this switch is rotated (ON) and then released (OFF) while vehicle is run-
ning at a speed 40 km/h (25 mile/h) or higher, vehicle speed at that OFF
moment is stored in memory and it is maintained (constant cruising).
Rotating this switch (ON) continuously during constant cruising keeps slowing
down vehicle speed as long as it is ON. When it is released (OFF), vehicle
speed at that moment is stored in memory and vehicle starts constant cruising.
ACCEL RESUME switch When this switch is rotated (ON) during constant cruising, vehicle speed keeps
increasing as long as it is ON. When it is released (OFF), vehicle speed at that
moment is stored in memory and vehicle starts constant cruising. If vehicle
speed is higher than 40 km/h (25 mile/h) after cruise control is cancelled, turn-
ing this switch ON momentarily will resume the speed at which vehicle was run-
ning before cancellation.
CANCEL switch When this switch is pressed (ON), cruise control (accelerator pedal control) is
cancelled.
Vehicle speed sensor (VSS) The vehicle speed sensor (VSS) is mounted on the transfer or transmission.
The VSS converts vehicle speed into pulse signal and send it to the cruise con-
trol module.
Stop lamp switch The stop lamp switch has 2 contact points. One contact point closes when the
brake pedal is depressed to light the stop lamp and provides a voltage signal to
the cruise control module. This signal, when inputted cancels cruise control
(sets the accelerator pedal free).
The other contact point (brake pedal position switch) opens when the brake
pedal is depressed, to shut off the power to the magnetic clutch in the actuator,
thereby cancelling cruise control (setting the accelerator pedal free).
This switch is installed to cancel cruise control (constant cruising) without fail.
Clutch pedal position switch
(M/T vehicle only)When the clutch pedal is depressed, the clutch pedal position switch closes and
provides a ground signal to cruise control module.
The cruise control module cancels cruise control (accelerator pedal control)
when this signal is inputted.
Transmission range switch
(Park/Neutral position switch)
(A/T vehicle only)When the selector lever is places in either “P” or “N” position, the transmission
range switch closes and provides a ground signal to cruise control module. The
cruise control module cancels cruise control (accelerator pedal control) when
this signal is inputted.
PCM – Throttle opening sig-
nal (4 A/T vehicle only)Throttle opening signal is inputted from PCM.
From this signal, the cruise control module detects the throttle opening and
uses it as one of the factors to output the overdrive and TCC OFF command sig-
nal to PCM.