ABS SUZUKI GRAND VITARA 1999 2.G Service Workshop Manual

YH4
GRAND
VITARA
BODY SERVICE 9-25
a. Front bumper
b. 1st mounting
c. Suspension frame
d. Front strut
e. Suspension arm
f. 2nd mounting
g. ù20 zig hole
h. Zig hole
i. 3rd mounting
j. Lower rod
k. Upper rod
l. Lateral rod
m. Rear shock absorber
n. 4th mounting
o. Fuel tank
p. Fuel tank
q. Lower roda ± g : 1315 mm (51.77 in.)
a ± g' : 1534 mm (60.39 in.)
b ± g : 1243 mm (48.94 in.)
b ± g' : 1518 mm (59.76 in.)
c ± g : 1377 mm (54.21 in.)
c ± g' : 1105 mm (43.50 in.)
d ± g' : 1319 mm (51.93 in.)
d ± f : 874 mm (34.41 in.)
e ± g : 525 mm (20.67 in.)
e ± g' : 857 mm (33.74 in.)
f ± g' : 927 mm (36.50 in.)
h ± i : 178 mm (7.01 in.)
h ± j : 133 mm (5.24 in.)
h ± k : 325 mm (12.80 in.)
h ± l : 674 mm (26.54 in.)h ± m : 803 mm (31.61 in.)
h ± n : 1161 mm (45.71 in.)
h ± o : 1184 mm (46.61 in.)
h ± p : 1190 mm (46.85 in.)
i ± q : 999 mm (39.33 in.)
j ± q : 997 mm (39.25 in.)
k ± q : 824 mm (32.44 in.)
l ± q : 1130 mm (44.49 in.)
m ± q : 1258 mm (49.53 in.)
n ± q : 1483 mm (58.39 in.)
o ± q : 1349 mm (53.11 in.)
p ± q : 1334 mm (52.52 in.)
For 4 door model
g' ± q : 1275 mm (50.20 in.)
g ± q : 1534 mm (60.39 in.)
For 2 door model
g' ± q : 995 mm (39.17 in.)
g ± q : 1310 mm (51.57 in.)
UNDER BODY DIMENSIONS

YH4
GRAND
VITARA
9-36 BODY SERVICE
Sealer is applied to the specific joints of a vehicle dur-
ing production. The sealer is intended to prevent dust
from entering the vehicle and serves also as an anti-
corrosion barrier. The sealer is applied to the door and
hood hem areas and between panels. Correct and re-
seal the originally sealed joints if damaged. Reseal
the attaching joints of a new replacement panel and
reseal the hem area of a replacement door or hood.
Use a quality sealer to seal the flanged joints, overlap
joints and seams. The sealer must have flexible char-
acteristics and paintability after it's applied to repair
areas.
For the sealer to fill open joints, use caulking material.
Select a sealer in conformance with the place and
purpose of a specific use. Observe the manufactur-
er's label-stand instructions when using the sealer.
In many cases, repaired places require color painting.
When this is required, follow the ordinary techniques
specified for the finish preparation, color painting and
undercoating build-up.
Rust proof wax, a penetrative compound, is applied
to the metal-to-metal surfaces (door and side sill in-
sides) where it is difficult to use ordinary undercoating
material for coating. Therefore, when selecting the
rust proof wax, it may be the penetrative type.
During the undercoating (vinyl coating) application,
care should be taken that sealer is not applied to the
engine-related parts and shock absorber mounting or
rotating parts. Following the under coating, make
sure that body drain holes are kept open.
he sequence of the application steps of the anti-corro-
sion materials are as follows:
1) Clean and prepare the metal surface.
2) Apply primer.
3) Apply sealer (all joints sealed originally).
4) Apply color in areas where color is required such
as hem flanges, exposed joints and under body
components.
5) Apply anticorrosion compound (penetrative wax).
6) Apply undercoating (rust proof material).
PAINT AND COATINGS
ANTI-CORROSION TREATMENT
WARNING:
Standard shop practices, particularly eye
protection, should be followed during the per-
formance of the below-itemized operations to
avoid personal injury.
As rust proof treatment, steel sheets are given corro-
sion resistance on the interior and / or exterior.
These corrosion resistance steel sheet materials are
called one of two-side galvanized steel sheets.
It is for the sake of rust protection that these materials
are selected and given a variety of treatments as de-
scribed blow.
1) Steel sheets are treated with cathodic electroprim-
er which is excellent in corrosion resistance.
2) Rust proof wax coatings are applied to door and
side sill insides where moisture is liable to stay.
3) Vinyl coating is applied to body underside and
wheel housing inside.
4) Sealer is applied to door hem, engine compart-
ment steel sheet-to-steel sheet joint, and the like
portions to prevent water penetration and resulting
in rust occurrence.
In panel replacement or collision damage repair, leav-
ing the relevant area untreated as it is in any operation
which does disturb the above-mentioned rust proof
treatment will cause corrosion to that area. Therefore,
it is the essential function of any repair operation to
correctly recoat the related surfaces of the relevant
area.
All the metal panels are coated with metal condition-
ers and primer coating during vehicle production. Fol-
lowing the repair and / or replacement parts installa-
tion, every accessible bare metal surface should be
cleaned and coated with rust proof primer. Perform
this operation prior to the application of sealer and
rust proof wax coating.

YH4
GRAND
VITARA
When the welding or heating operation causes the
original galvanization or other anticorrosive materials
to be burnt, the interior and under-body panel sur-
faces must be cleaned.
Removal of residues of the burning should be carried
out carefully when the relevant place has boxtype
construction or has shape which limits the access to
the interior surfaces. In general, the following method
can be used satisfactorily for the removal of those res-
idues.Scrape the accessible places. If a standard putty knife
or scraper does not fit to the elevant place, consider
to use a more flexible scraper to a place narrowly en-
closed by sheet metals.
A jet of compressed air can remove most residues,
and is effective to limited areas.
However, this type of operation absolutely requires
eye protection.
BODY SERVICE 9-37
The metal service replacement parts (or assemblies)
are coated with electro-deposition primer.
For the proper adhesion of a paint, the following finish
process (refinish steps) becomes necessary.
1) Use wax or grease-removing solvent to clean the
part.
2) Use a wet or dry sand-paper (No. 400) to polish the
panel lightly. Do not polish it forcibly to produce any
scratch. Clean the part again.
3) If factory-applied primer coating is cut through to
the bare metal, apply metal conditioner to the bare
metal exposed to open air. As for method of use of
the metal conditioner, follow directions on the con-
tainer.
4) Apply primer-surfacer to the part completely dry
before starting sand-paper polishing. As for drying
time, follow directions advised on the primer-sur-
facer container.
5) Use a wet or dry sand-paper (No. 400) and water
to polish the panel lightly.
6) Wash the part again.
7) Apply color, coating to the part.
8) Different paints demand different drying methods.
Hence, follow directions advised on the pertinent
paint container.9) When lacquer coating (quick-drying paint coat-
ing) is applied, dry coated surface and polish it
with compound.
In the case of the melamine or acrylic coating,
compound polishing can be omitted after drying.
10) If the case of lacquer coating, wax should not be
applied to coated surface until the surface has
dried completely (for approx. two months).
Before replacing exterior parts or assemblies, check
paint conditions of all the covered or hidden interior
surfaces. If any rust scale is found at these places,
proceed as follows:
1) Use a proper wire brush, adhesive or liquid rust re-
moving agent to remove rust. As for the method of
use, follow directions advised for respecitve mate-
rials.
2) If necessary, wash parts with detergent, rinse, and
dry them.
3) Before installing exterior body parts, apply anticor-
rosive compound to all cleaner surfaces of exterior
body parts. Also, apply anticorrosive compound to
inner surfaces of exterior body parts to be
installed.
METAL REPLACEMENT PARTS FINISHING

YH4
GRAND
VITARA
9-58 BODY SERVICE
PLASTIC PARTS FINISHING
Paintable plastic parts are ABS plastic parts.
Painting
Rigid or hard ABS plastic needs no primer coating.
General acrylic lacquers can be painted properly over hard ABS
plastic in terms of adherence.
1) Use cleaning solvent for paint finish to wash each part.
2) Apply conventional acrylic color lacquer to part surface.
3) Follow lacquer directions for required drying time. (Proper dry-
ing temperature range is 60 to 70
C).
Reference
Plastic parts employ not only ABS (Acrylonitrile Butadiene Styrene)
plastic but also polypropylene, vinyl, or the like plastic. Burning test
method to identify ABS plastic is described below.
1) Use a sharp blade to cut off a plastic sliver from the part at its
hidden backside.
2) Hold sliver with pincers and set it on fire.
3) Carefully observe condition of the burning plastic.
4) ABS plastic must raise readily distinguishable back smoke while
burning with its residue suspended in air temporarily.
5) Polypropylene must raise no readily distinguishable smoke
while burning.

YH4
GRAND
VITARA
WIRE HARNESS COLOR
B : Black
B/W : Black/White
Bl : Blue
Bl/B : Blue/Black
Bl/R : Blue/Red
Br : BrownG : Green
Gr : Gray
G/R : Green/Red
Lg : Lightgreen
P : Pink
V : VioletY : Yellow
Y / G : Yellow/Green
Y/R : Yellow/Red
W : White
W/B : White/Black
1. From main fuse
2. Ignition switch
3. ªIG
.COIL METERº fuse in J/B
4. ªAIR BAGº warning lamp in combination meter
5. ªAIR BAGº fuse in ªAIR BAGº fuse box
6. Connection detection pin
7. To ECM (or PCM), ICM (if equipped) and ABS
controller (if equipped)
8. To data link connector (DLC)
9. ªAIR BAGº monitor coupler
10. SDM
11. Contact coil assembly
12. Driver air bag (inflator) module
13. Driver seat belt pretensioner (if equipped)
14. Passenger air bag (inflator) module
15. Passenger seat belt pretensioner (if equipped)
16. Pretensioner harness (if equipped)
17. Ground for air bag system
TERMINAL
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A13 A11
A12
A14
A15
A16
Passenger air bag (inflator) moduleLow
High
CIRCUIT
Data link connector (DLC)
Low
High
Low
High
Low
High ªAIR BAGº warning lamp
Driver air bag (inflator) module
Diagnosis switch
±±±±±±±±±
Ground
Passenger pretensioner
Driver pretensioner
Ignition switch (power source)±±±±±±±±±
±±±±±±±±±
CONNECTOR ªAº (SDM connector) TERMINAL ARRANGEMENT OF SDM
(VIEWED FROM HARNESS SIDE)
L1
L2Connection detection pin
: Shorting bar
: Air bag harness
ªAº
ªHº : Connector
AIR BAG SYSTEM 10B-5
SYSTEM WIRING DIAGRAM

YH4
GRAND
VITARA
1. DLC
2. Scan tool1. ªW/Bº wire terminal
AIR BAG SYSTEM 10B-23
TABLE D ± SDM CANNOT COMMUNICATE THROUGH THE SERIAL DATA CIRCUIT
(Page 2 of 2)
STEPACTIONYESNO
21) Check if communication is possible by
trying communication with other
controller (ECM (or PCM), ICM or ABS
controller).
2) Is it possible to communicate with other
controller?Go to step 3.Repair open in common
section of serial data circuit
(ªW/Bº wire circuit) used by
all controllers or short to
ground or power circuit
which has occurred some-
where in serial data circuit
(ªW/Bº wire circuit).
31) With ignition switch OFF, disconnect
SDM and ªLamp, DLC and Monitor
Coupler Groundº (ªEº) connector.
2) Check proper connection at ªW/Bº wire
terminal for DLC in ªEº connector.
3) If OK, then check resistance between
ªW/Bº wire terminal in ªEº connector and
ªA4º terminal of SDM connector.
4) Is resistance 1
or less?Substitute a known-good
SDM and recheck.Repair high resistance or
open in ªW/Bº wire circuit
(in air bag harness).
Fig. for STEP 1 Fig. for STEP 3
Special Tool
(A): 09932-76010
NOTE:
Upon completion of inspection and repair work, perform following items.
1) Reconnect all air bag system components, ensure all components are properly mounted.
2) Repeat ªAir Bag Diagnostic System Check Flow Tableº, referring to p.10B-11 to confirm that the trouble
has been corrected.