Wire harness SUZUKI GRAND VITARA 1999 2.G Service Workshop Manual
[x] Cancel search | Manufacturer: SUZUKI, Model Year: 1999, Model line: GRAND VITARA, Model: SUZUKI GRAND VITARA 1999 2.GPages: 801, PDF Size: 12.15 MB
Page 6 of 801
YH4
GRAND
VITARA
1. Air bag wire harness
2. Passenger air bag
(inflator) module
3. SDM
4. DLC5. Contact coil
6. Driver air bag (inflator)
module
7. Seat belt pretensioner
(if equipped)
GENERAL INFORMATION 0A-3
PRECAUTIONS
PRECAUTION FOR VEHICLES EQUIPPED
WITH A SUPPLEMENTAL RESTRAINT
(AIR BAG) SYSTEM
WARNING:
The configuration of air bag system parts are as shown in
the figure. When it is necessary to service (remove, rein-
stall and inspect) these parts, be sure to follow proce-
dures described in SECTION 10B. Failure to follow proper
procedures could result in possible air bag system activa-
tion, personal injury, damage to parts or air bag system
being unable to activate when necessary.
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.
If the vehicle will be exposed to temperatures over 93C
(200F) (for example, during a paint baking process), re-
move the air bag system components beforehand to avoid
component damage or unintended air bag system activa-
tion.
DIAGNOSIS
When troubleshooting air bag system, be sure to follow
ªDIAGNOSISº in SECTION 10B. Bypassing these proce-
dures may result in extended diagnostic time, incorrect diag-
nosis, and incorrect parts replacement.
Never use electrical test equipment other than that specified
in this manual.
WARNING:
Never attempt to measure the resistance of the air bag (in-
flator) modules (driver and passenger) and seat belt preten-
tioners (driver and passenger). It is very dangerous as the
electric current from the tester may deploy the air bag or ac-
tivate the pretensioner.
Page 9 of 801
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0A-6 GENERAL INFORMATION
CAUTION:
Even when the accident was light enough not to cause air
bags to activate, be sure to inspect system parts and other
related parts according to instructions under ªRepair and
Inspection Required after an Accidentº in SECTION 10B.
When servicing parts other than air bag system, if shocks
may be applied to air bag system component parts, re-
move those parts beforehand.
When handling the air bag (inflator) modules (driver and
passenger), seat belt pretensioners (driver and passen-
ger) or SDM, be careful not to drop it or apply an impact to
it. If an excessive impact was applied (e.g., dropped from
a height of 91.4 cm (3 feet) or more), never attempt disas-
sembly or repair but replace it with a new one.
When grease, cleaning agent, oil, water, etc. has got onto
air bag (inflator) modules (driver and passenger) or seat
belt pretensioners (drive and passenger), wipe off im-
mediately with a dry cloth.
Air bag wire harness can be identified easily as it is cov-
ered with a yellow protection tube. Be very careful when
handling it.
When an open in air bag wire harness, damaged wire har-
ness, connector or terminal is found, replace wire har-
ness, connectors and terminals as an assembly.
Do not apply power to the air bag system unless all com-
ponents are connected or a diagnostic chart requests it,
as this will set a diagnostic trouble code.
Never use air bag system component parts from another
vehicle.
When using electric welding, be sure to temporarily dis-
able air bag system referring to ªDisabling Air Bag Sys-
temº described in ªService Precautionsº under ªOn-Ve-
hicle Serviceº in SECTION 10B.
Never expose air bag system component parts directly to
hot air (drying or baking the vehicle after painting) or
flames.
WARNING / CAUTION labels are attached on each part of
air bag system components. Be sure to follow the instruc-
tions.
After vehicle is completely repaired, perform ªAir Bag
Diagnostic System Checkº described in ªDiagnosisº in
SECTION 10B.
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1. Coupler
2. Probe
1. Coupler
2. Probe
3. Where male
terminal fits
0A-10 GENERAL INFORMATION
PRECAUTIONS FOR ELECTRICAL CIRCUIT
SERVICE
When disconnecting and connecting coupler, make sure to
turn ignition switch OFF, or electronic parts may get dam-
aged.
Be careful not to touch the electrical terminals of parts which
use microcomputers (e.g. electronic control unit like as
ECM, PCM, P/S controller, etc.). The static electricity from
your body can damage these parts.
Never connect any tester (voltmeter, ohmmeter, or whatever)
to electronic control unit when its coupler is disconnected.
Attempt to do it may cause damage to it.
Never connect an ohmmeter to electronic control unit with
its coupler connected to it. Attempt to do it may cause dam-
age to electronic control unit and sensors.
Be sure to use a specified voltmeter / ohmmeter. Otherwise,
accurate measurements may not be obtained or personal in-
jury may result.
When taking measurements at electrical connectors using a
tester probe, be sure to insert the probe from the wire har-
ness side (backside) of the connector.
When connecting meter probe from terminal side of coupler
because it can't be connected from harness side, use extra
care not to bend male terminal of coupler of force its female
terminal open for connection.
In case of such coupler as shown connect probe as shown
to avoid opening female terminal.
Never connect probe where male terminal is supposed to fit.
Page 15 of 801
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0A-12 GENERAL INFORMATION
1. Check for loose connectionSensor
ECM
Check contact tension by
Inserting and removing just for
once
1. Looseness of crimping
2. Open
3. Thin wire (Single strand of wire)
ELECTRICAL CIRCUIT INSPECTION
PROCEDURE
While there are various electrical circuit inspection methods, de-
scribed here is a general method to check its open and short circuit
by using an ohmmeter and a voltmeter.
OPEN CIRCUIT CHECK
Possible causes for the open circuit are as follows. As the cause is
in the connector or terminal in many cases, they need to be checked
particularly carefully.
Loose connection of connector
Poor contact of terminal (due to dirt, corrosion or rust on it, poor
contact tension, entry of foreign object etc.)
Wire harness being open
When checking system circuits including an electronic control unit
such as ECM, TCM, ABS control module, etc., it is important to per-
form careful check, starting with items which are easier to check.
1) Disconnect negative cable from battery.
2) Check each connector at both ends of the circuit being checked
for loose connection. Also check lock condition of connector if
equipped with connector lock.
3) Using a test male terminal, check both terminals of the circuit be-
ing checked for contact tension of its female terminal.
Check each terminal visually for poor contact (possibly caused
by dirt, corrosion, rust entry of foreign object, etc.).
At the same time, check to make sure that each terminal is
locked in the connector fully.
4) Using continuity check or voltage check procedure described in
the following page, check the wire harness for open circuit and
poor connection with its terminals. Locate abnormality, if any.
Page 17 of 801
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0A-14 GENERAL INFORMATION
To other
parts
Other parts
To other
partsSHORT CIRCUIT CHECK (Wire harness to ground)
1) Disconnect negative cable from battery.
2) Disconnect connectors at both ends of the circuit to be checked.
NOTE:
If the circuit to be checked is connected to other parts, dis-
connect all connectors of those parts.
Otherwise, diagnosis will be misled.
3) Measure resistance between terminal at one end of circuit (A-1
terminal in figure) and body ground. If continuity is indicated, it
means that there is a short to ground between terminals A-1 and
C-1 of the circuit.
4) Disconnect the connector included in circuit (connector B) and
measure resistance between A-1 and body ground.
If continuity is indicated, it means that the circuit is shorted to the
ground between terminals A-1 and B-1.
Page 19 of 801
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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.
Page 59 of 801
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HEATER AND VENTILATION 1A-7
1. Fastening nuts
1. Air flow
BLOWER MOTOR
REMOVAL
1) Disconnect negative (±) cable at battery.
2) Disable air bag system, if equipped. Refer to DISABLING AIR
BAG SYSTEM in Section 10B.
3) Remove ECM with bracket from blower motor unit.
4) Disconnect harness clamps from dash panel.
5) Loosen three nuts fastening blower unit.
6) Disconnect blower motor lead wire at coupler (2).
7) Remove blower motor (3) from blower unit (1).
INSPECTION
Check continuity between terminal to terminal as shown in left fig-
ure.
If check results are continuity, proceed to next operation check.
If not, replace.
Connect battery to blower motor as shown, then check that the
blower motor operates smoothly and specified current.
Specified current: Max. 25 A at 12 V
INSTALLATION
1) Reverse removal procedure for installation.
2) Enable air bag system, if equipped. Refer to ENABLING AIR
BAG SYSTEM in Section 10B.
Page 174 of 801
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1. Combination switch
1. Steering column hole cover
: If equipped
2. Screw
1. Combination switch 2. Screw1. Steering column cover screw
2. Steering column lower cover
*
3. Steering column
upper cover
3C-4 STEERING WHEEL AND COLUMN
COMBINATION SWITCH
REMOVAL
1) Disconnect negative battery cable at battery terminal.
2) Remove steering wheel from steering column. Refer to
ªSTEERING WHEELº in this section.
3) Remove steering column hole cover.
4) Remove steering column cover screws (3 pieces).
5) Separate upper cover and lower cover, then remove them.
6) Disconnect all connectors for combination switch.
7) Remove combination switch from steering column.
INSPECTION
Check combination switch wire harness for any signs of scorching,
melting or other damage. If it is damaged, replace.
INSTALLATION
1) Install combination switch to steering column.
2) Connect all connectors that have been removed in removal.
Page 189 of 801
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6, (a)
1. Trim cover (pad surface)
2. Inflator case
3. Wire harness
1. Driver air bag (inflator) module connector
2. Horn connector
3. Driver air bag (inflator) module
4. Steering wheel
5. Mounting bolt (left side)
6. Mounting bolt (right side)
AIR BAG STEERING WHEEL AND COLUMN 3C1-5
INSPECTION
WARNING:
Never disassemble air bag (inflator) module or measure its
resistance. Otherwise, personal injury may result.
CAUTION:
If air bag (inflator) module was dropped from a height of
90 cm (3 ft) or more, it should be replaced.
Check air bag (inflator) module visually and if any of the following
is found, replace it with a new one.
Air bag being deployed.
Trim cover (pad surface) being cracked.
Wire harness or connector being damaged.
Air bag (inflator) module being damaged or having been exposed
to strong impact (dropped).
INSTALLATION
1) Connect horn connector securely.
2) Connect yellow connector of driver air bag (inflator) module con-
nector as shown in the figure securely.
ii) Connect connector.
ii) Lock connector with lock lever.
3) Install horn connector and driver air bag (inflator) module con-
nector.
4) Install driver air bag (inflator) module to steering wheel, taking
care so that no part of wire harness is caught between them.
5) Make sure that clearance between module and steering wheel
is uniform all the way.
6) Tighten driver air bag (inflator) module mounting bolt (left side)
to specified torque first and then driver air bag (inflator) module
mounting bolt (right side) to specified torque.
Tightening Torque
(a): 9 N
.m (0.9 kg-m, 6.5 lb-ft)
7) Connect negative battery cable.
8) Enable air bag system. Refer to ªENABLING AIR BAG SYS-
TEMº under ªSERVICE PRECAUTIONSº in Section 10B.
Page 192 of 801
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1
1. Contact coil and combination switch assembly
2. Screw
1. Contact coil and combination switch assembly
1. Seal (if equipped, remove lock pin after installing
contact coil and combination switch assembly.)
2. Lock pin (if equipped, remove lock pin after installing
contact coil and combination switch assembly.)
3C1-8 AIR BAG STEERING WHEEL AND COLUMN
6) Remove contact coil and combination switch assembly from
steering column.
INSPECTION
Check contact coil and combination switch wire harness for any
signs of scorching, melting or other damage. If it is damaged, re-
place.
INSTALLATION
1) Check to make sure that vehicle's front tires are set at straight-
ahead position and then ignition switch is at ªLOCKº position.
2) Install contact coil and combination switch assembly to steering
column.
NOTE:
New contact coil and combination switch assembly is sup-
plied with contact coil set and held at its center position
with a lock pin and seal. Remove this lock pin after installing
contact coil and combination switch assembly to steering
column.