warning SUZUKI GRAND VITARA 2000 2.G Service Owners Manual

YH4
GRAND
VITARA
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-7
POWER DOOR LOCK AND KEYLESS ENTRY SYSTEM (IF KEYLESS ENTRY IS
EQUIPPED)
TroublePossible causeCorrection

All power doors are not
locked / unlocked by
both driver side door key
switch and power door
lock switch. But all
power doors are locked /
unlocked by keyless
entry transmitter

All power doors are not
locked / unlocked by
driver side door key
switch, power door lock
switch and keyless entry
transmitter

When power doors are
locked / unlocked by
keyless entry
transmitter, hazard
warning lights do not
flash
ªDOOR LOCKº fuse blown

Power door lock and keyless entry system
faultyReplace fuse to check for short
Refer to SYSTEM INSPECTION
of POWER DOOR LOCK AND
KEYLESS ENTRY SYSTEM
(IF KEYLESS ENTRY IS
EQUIPPED) in this section
All power doors are not
locked / unlocked by only
power door lock switch
Power door lock switch faulty

Wiring or grounding faultyReplace switch
Repair
All power doors are not
locked / unlocked by only
driver side door key
switch
Driver side door key switch faulty

Wiring or grounding faultyReplace switch
Repair
All power doors are not
locked / unlocked by only
keyless entry transmitter
Code registration error

Transmitter battery dead

Transmitter faulty

Power door lock and keyless entry system
faultyRegister code
Replace battery
Replace transmitter
Refer to SYSTEM INSPECTION
of POWER DOOR LOCK AND
KEYLESS ENTRY SYSTEM
(IF KEYLESS ENTRY IS
EQUIPPED) in this section
Although any door is
opened within 30 seconds
after power door(s)
unlocked by keyless entry
transmitter, all power
doors are locked again
automatically
Door switch faulty

Wiring harness connected to door switch
brakesReplace switch
Repair
Only one power door is not
locked / unlocked
Wiring or coupler faulty

Actuator (door lock motor) faultyRepair
Replace actuator
Operation distance of
keyless entry is unstable
Transmitter battery dead

Transmitter faultyReplace battery
Replace transmitter

YH4
GRAND
VITARA
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-23
POWER DOOR LOCK AND KEYLESS ENTRY SYSTEM (IF KEYLESS ENTRY IS
EQUIPPED)
SYSTEM INSPECTION
STEPACTIONYESNO
1Check power door lock operation referring to its
INSPECTION in this section.
Is this operation OK?Go to Step 2.Go to Step 3.
2Check keyless entry operation referring to its
INSPECTION in this section.
Is this operation OK?Go to Step 4.Go to Step 6.
3Check keyless entry operation referring to its
INSPECTION in this section.
Is this operation OK?Go to Step 5.Go to Step 7.
4Check hazard warning lights operation referring to
its INSPECTION in this section.
Is this operation OK?This system is OK.Go to Step 10.
5Check door lock key and power door lock switch
circuit referring to its INSPECTION in this section.
Is this circuit OK?Replace controller and
recheck.
And go to Step 4.Repair circuit referring
to WIRING DIAGRAM
MANUAL and recheck.
And go to Step 4.
6Check ignition switch and door switch circuit
referring to its INSPECTION in this section.
Is this circuit OK?Replace controller and
recheck.
And go to Step 4.Repair circuit referring
to WIRING DIAGRAM
MANUAL and recheck.
And go to Step 4.
7Check power door lock actuator circuit referring to
its INSPECTION in this section.
Is this circuit OK?Go to Step 8.Repair circuit referring
to WIRING DIAGRAM
MANUAL and recheck.
If OK, go to Step 4.
If not OK, go to next
Step 8.
8Check power supply and grounding circuit
referring to its INSPECTION in this section.
Is this circuit OK?Go to Step 9.Repair circuit referring
to WIRING DIAGRAM
MANUAL and recheck.
If OK, go to Step 4.
If not OK, go to next
Step 9.
91) Check door lock key and power door lock
switch circuit referring to its INSPECTION in
this section.
2) Check ignition switch and door switch circuit
referring to its INSPECTION in this section.
Are these circuits OK?Replace controller and
recheck.
And go to Step 4.Repair circuit referring
to WIRING DIAGRAM
MANUAL and recheck.
And go to Step 4.

YH4
GRAND
VITARA
8D-24 WINDOWS, MIRRORS, SECURITY AND LOCKS
STEPACTIONYESNO
10Check that hazard warning lights flash with hazard
switch ON.
Is check result OK?Go to Step 11.Refer to ªTurn Signal
and Hazard Warning
Lightsº in DIAGNOSIS
and repair.
And go to Step 4.
11Check door knob switch and turn signal relay
circuit referring to its INSPECTION in this section.
Is this circuit OK?Replace controller and
recheck.Repair circuit referring
to WIRING DIAGRAM
MANUAL and recheck.
POWER DOOR LOCK OPERATION
INSPECTION
1) With the driver side door key turned LOCK, check all power
doors are locked.
2) With the driver side door key turned UNLOCK, check only the
driver side power door is unlocked.
Turn the driver side door key to UNLOCK again within 5 se-
conds, check all power doors are unlocked.
If check result of Step 1) and Step 2) is satisfactory, this operation
is OK.
KEYLESS ENTRY OPERATION
INSPECTION
1) With the IG switch OFF and all doors closed, push LOCK button
on transmitter. Check all power doors are locked.
2) Push UNLOCK button on transmitter. Check only driver side
power door is unlocked.
3) Push UNLOCK button on transmitter again within 5 seconds.
Check all power doors are unlocked.
But if any door is not opened within 30 seconds after power
door(s) unlocked, all power doors are locked again automatical-
ly.
If check result of Step 1) to Step 3) is satisfactory, this operation is
OK.
HAZARD WARNING LIGHTS OPERATION
INSPECTION
1) Check that hazard warning lights flash one time when power
doors are locked by pushing LOCK button on transmitter.
2) Check that hazard warning lights flash two times when power
door(s) is (are) unlocked by pushing UNLOCK button on trans-
mitter.
If check result of Step 1) and Step 2) is satisfactory, this operation
is OK.

YH4
GRAND
VITARA
8G
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-1
GENERAL DESCRIPTION8G- 2 . . . . . . . . . . . . . .
Ignition Key 8G- 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Coil Antenna 8G- 3. . . . . . . . . . . . . . . . . . . . . . . . .
Immobilizer Control Module 8G- 4. . . . . . . . . . . .
ECM/PCM 8G- 4. . . . . . . . . . . . . . . . . . . . . . . . . . .
On-Board Diagnostic System
(Self-Diagnosis Function) 8G- 4. . . . . . . . . . . . .
DIAGNOSIS8G- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions in Diagnosing Troubles 8G- 6. . . . .
Diagnostic Flow Table with monitor coupler> 8G- 9. . . . . . . . . . . . . . . .
Diagnostic Flow Table equipped with monitor coupler> 8G-10. . . . . . .
Diagnostic Trouble Code Check
(Immobilizer Control Module) 8G-11. . . . . . . .
Diagnostic Trouble Code Check
(ECM / PCM) 8G-11. . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code Table 8G-13. . . . . . . . .
TABLE A DTC is not Output
from Diagnostic Output Terminal 8G-14. . . . . . .
TABLE B Immobilizer Indicator Lamp
Check (Immobilizer Indicator Lamp
does not Light at Ignition Switch ON) 8G-15. . .
TABLE C Immobilizer Indicator Lamp
Check (Immobilizer Indicator Lamp
Remains on after Engine Starts) 8G-16. . . . . . .
DTC11 Transponder Code Not Matched8G-17 . .
DTC31 Transponder Code Not
Registered 8G-17. . . . . . . . . . . . . . . . . . . . . . . . .
DTC12 Fault in Immobilizer
Control Module 8G-17. . . . . . . . . . . . . . . . . . . . . .
DTC13 No Transponder Code Transmitted
or Coil Antenna Opened/Shorted 8G-18. . . . . . DTC21 ECM/Immobilizer Control Module
Code Not Matched (Immobilizer Control
Module Side) 8G-20. . . . . . . . . . . . . . . . . . . . . . .
DTC81 (P1623) ECM/Immobilizer
Control Module Code Not Matched
(ECM/PCM Side) 8G-20. . . . . . . . . . . . . . . . . . . .
DTC84 (P1620) ECM/Immobilizer Control
Module Code Not Registered 8G-20. . . . . . . . .
DTC22 Ignition Switch Circuit Open/Short8G-21 . .
DTC23 No ECM/Immobilizer Control
Module Code Transmitted from ECM/
PCM or DLC Circuit Opened/Shorted8G-22 . . . .
DTC83 (P1621) No ECM/Immobilizer
Control Module Code Transmitted from
Immobilizer Control Module or DLC
Circuit Opened/Shorted 8G-22. . . . . . . . . . . . . .
DTC82 (P1622) Fault in ECM/PCM 8G-23. . . . .
Inspection of ECM/PCM, Immobilizer
Control Module and Its Circuit 8G-24. . . . . . . . .
Voltage Check 8G-24. . . . . . . . . . . . . . . . . . . . .
Resistance Check 8G-25. . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE8G-26 . . . . . . . . . . . . . . . .
Precautions in Handling Immobilizer
Control System 8G-26. . . . . . . . . . . . . . . . . . . . .
Immobilizer Control Module 8G-27. . . . . . . . . . . .
Coil Antenna 8G-27. . . . . . . . . . . . . . . . . . . . . . . . .
HOW TO REGISTER IGNITION KEY8G-28 . . . . .
PROCEDURE AFTER IMMOBILIZER
CONTROL MODULE REPLACEMENT8G-29 . .
PROCEDURE AFTER ECM/PCM
REPLACEMENT8G-30 . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS8G-30 . . . . . . . . . . . . . . . . . . . . . .
SECTION 8G
IMMOBILIZER CONTROL SYSTEM
(IF EQUIPPED)
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

YH4
GRAND
VITARA
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-15
1. Main fuse
2. Main relay
3. ECM/PCM
4. Immobilizer indicator lamp
(Vehicle not equipped with
monitor coupler) For G16 / J20 engine For H25 engine
G16 / J20 Engine
H25 Engine
TABLE B IMMOBILIZER INDICATOR LAMP CHECK
(IMMOBILIZER INDICATOR LAMP DOSE NOT LIGHT AT IGNITION
SWITCH ON)
STEPACTIONYESNO
11) Turn ignition switch ON.
Do other indicator / warning lights in
combination meter come ON?Go to Step 2.ªIGº fuse blown, main fuse blown,
ignition switch malfunction,
ªB / Wº circuit between ªIGº fuse
and combination meter or poor
coupler connection at
combination meter.
21) Turn ignition switch OFF and
disconnect connectors from ECM /
PCM.
2) Check for proper connection to ECM /
PCM at terminal E61-5 for G16 / J20
engine or E61-23 for H25 engine.
3) If OK, then using service wire, ground
terminal E61-5 for G16 / J20 engine or
E61-23 for H25 engine in connector
disconnected.
Does immobilizer indicator lamp turn on
at ignition switch ON?Substitute a known-
good ECM / PCM and
recheck.Bulb burned out or ª(b)º wire
circuit open.

YH4
GRAND
VITARA
9
BODY SERVICE 9-1
GLASS, WINDOWS AND MIRRORS9- 2 . . . . .
Front Door Glass 9- 2. . . . . . . . . . . . . . . . . . . . .
Front Door Window Regulator 9- 5. . . . . . . . . .
Windshield 9- 6. . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Door Glass 9-12. . . . . . . . . . . . . . . . . . . . .
Rear Door Window Regulator 9-14. . . . . . . . . .
Quarter Window 9-15. . . . . . . . . . . . . . . . . . . . . .
Back Door Glass 9-16. . . . . . . . . . . . . . . . . . . . .
BODY STRUCTURE9-17 . . . . . . . . . . . . . . . . . . .
Front Door Assembly 9-17. . . . . . . . . . . . . . . . .
Rear Door Assembly 9-18. . . . . . . . . . . . . . . . . .
Back Door / Rear Gate Assembly 9-19. . . . . . . .
Hood 9-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Fender 9-22. . . . . . . . . . . . . . . . . . . . . . . . .
Front Bumper 9-23. . . . . . . . . . . . . . . . . . . . . . . .
Rear Bumper 9-24. . . . . . . . . . . . . . . . . . . . . . . .
Under Body Dimensions 9-25. . . . . . . . . . . . . . .
Body Dimensions 9-26. . . . . . . . . . . . . . . . . . . . .
INSTRUMENTATION AND DRIVER
INFORMATION9-33 . . . . . . . . . . . . . . . . . . . . . . .
Instrument Panel 9-33. . . . . . . . . . . . . . . . . . . . .
SEAT9-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Seat 9-34. . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Seat 9-35. . . . . . . . . . . . . . . . . . . . . . . . . . .
PAINT AND COATINGS9-36 . . . . . . . . . . . . . . . .
Anti-Corrosion Treatment 9-36. . . . . . . . . . . . . .
Metal Replacement Parts Finishing 9-37. . . . .
Plastic Parts Finishing 9-58. . . . . . . . . . . . . . . . .
SECURITY AND LOCKS9-59 . . . . . . . . . . . . . . . .
Front Door Lock Assembly 9-59. . . . . . . . . . . . .
Rear Door Lock Assembly 9-61. . . . . . . . . . . . .
Back Door / Rear Gate Lock Assembly 9-62. . .
Key Coding 9-63. . . . . . . . . . . . . . . . . . . . . . . . . .
SUNROOF / CONVERTIBLE TOP9-64 . . . . . . . . .
Sliding Roof (if equipped) 9-64. . . . . . . . . . . . . .
Canvas Top And Topbow Frames 9-71. . . . . . .
EXTERIOR AND INTERIOR TRIM9-72 . . . . . . .
Floor Carpet 9-72. . . . . . . . . . . . . . . . . . . . . . . . .
Head lining 9-73. . . . . . . . . . . . . . . . . . . . . . . . . .
Roof Trim (2 Door Model) 9-75. . . . . . . . . . . . . .
Side Moldings (if equipped) 9-77. . . . . . . . . . . .
Splash Guard (if equipped) 9-78. . . . . . . . . . . .
Roof Rail (if equipped) 9-79. . . . . . . . . . . . . . . .
Roof Molding 9-79. . . . . . . . . . . . . . . . . . . . . . . .
Luggage Under Box 9-80. . . . . . . . . . . . . . . . . .
SECTION 9
BODY SERVICE
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).

When body servicing, if shock may be applied to air bag system component parts, remove those parts
beforehand. (Refer to Section 10B.)
NOTE:
Fasteners are important attaching parts in that they could affect the performance of vital components and
systems, and / or could result in major repair expense. They must be replaced with one of the same part
number of with an equivalent part if replacement becomes necessary.
Do not use a replacement part of lesser quality or substitute a design. Torque values must be used as spe-
cified during reassembly to assure proper retention of these parts.
CONTENTS

YH4
GRAND
VITARA
BODY SERVICE 9-19
1. Back door panel assy
2. Back door window glass
3. Back door hinge
4. Back door / Rear gate balancer unit
1. Back door hinge
2. Back door
3. Body
BACK DOOR / REAR GATE ASSEMBLY
REMOVAL
1) Remove back door trim, and door / rear gate sealing cover, refer
to steps 1) to 4) of BACK DOOR LOCK ASSEMBLY in this sec-
tion.
2) Remove wire harness connector inside the back door / rear gate.
3) Remove back door / rear gate balancer (first at its door-side and
next at its body-side), as shown.
WARNING:
Handling of Back Door / Rear Gate Balancer (Damper)

Do not disassemble balancer because its cylinder is
filled with gas.

The gas itself is harmless but it may issue out of the
hole together with chips generated by the drill.
Therefore, be sure to wear goggle.

When discarding removed back door / rear gate balanc-
er (damper), use a 2 to 3 mm (0.08 to 0.12 in.) drill to
make a hole as shown.

Handle balancer carefully. Do not scar or scratch ex-
posed surface of its piston rod, and never allow any
paint or oil to stick to its surface.

Do not turn piston rod with balancer fully extended.
5) Remove back door / rear gate hinge bolts and back door / rear
gate.

YH4
GRAND
VITARA
1. (a)
1. (a)
1
11
Tightening Torque
(a): 23 N.m (2.3 kg-m, 17.0 lb-ft)
1. Bolt
BODY SERVICE 9-33
INSTRUMENTATION AND DRIVER INFORMATION
INSTRUMENT PANEL
WARNING:
See WARNING at the beginning of this section.
REMOVAL
1) Disconnect negative cable at battery.
2) Disable air bag system. Refer to ªDisabling Air Bag Systemº in
Section 10B.
3) Remove console box.
4) Remove glove box and column hole cover.
5) Disconnect wires and cables from heater unit and blower motor
assembly.
6) Remove steering column assembly. Refer to Section 3C1.
7) Disconnect speedometer connector and remove speedometer
assembly. If equipped with air bag, disconnect wire coupler at
SDM and air bag ground terminal for air bag.
8) Remove engine hood opener.
9) Disconnect couplers which need to be disconnected for removal
for instrument panel.
10) Remove instrument panel mounting screws.
11) Remove instrument panel mounting bolt.
12) Remove instrument panel.
CAUTION:
For vehicle with Air Bag, instrument panel could not be re-
moved with SDM coupler connected and ground terminal
installed.
Use care not to damage Air Bag harness.
INSTALLATION
1) Install instrument panel 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 ªAIR BAG
STEERING COLUMN INSTALLATIONº in Section 3C1.
2) Adjust control cables. (Refer to Section 1A ªHEATER CON-
TROL CABLESº.)
3) Enable air bag system. Refer to ªEnabling Air Bag Systemº in
Section 10B.

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
9-80 BODY SERVICE
1. Bolt
2. Member
LUGGAGE UNDER BOX
WARNING:
Do not remove member in the center of luggage under box.
If member had to be removed temporarily for repair or for some oth-
er reason, be sure to reinstall it by using specified new bolts until
head of bolt is broken off.