service SUZUKI GRAND VITARA 2000 2.G Service Workshop Manual

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GRAND
VITARA
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-9
Fig. 1 for Step 1 Fig. 2 for Step 1 Fig. 3 for Step 2
1. Monitor coupler
2. Service wire
A: Diagnosis switch terminal
B: Ground terminal
Fig. 4 for Step 3
ªCHECK ENGINEº light
0.5
ON
OFF
TIME (sec.)
DIAGNOSTIC FLOW TABLE

STEPACTIONYESNO
11) Make sure that diagnosis switch
terminal in monitor coupler is not
grounded by service wire. See Fig. 1.
2) Check malfunction indicator lamp
while ignition switch is ON (but without
starting engine). See Fig. 2.
Dose malfunction indicator lamp flash?Go to Step 3.
If malfunction indicator lamp
remains ON, go to Step 2.

If malfunction indicator lamp
remains OFF, go to
ªMALFUNCTION INDICATOR
LAMP CHECKº in Section 6.
21) Using service wire, ground diagnosis
switch terminal in monitor coupler.
See Fig. 3.
Dose malfunction indicator lamp flash?Immobilizer control
system is in good
condition.Go to ªMALFUNCTION
INDICATOR LAMP CHECKº in
Section 6.
3Dose malfunction indicator lamp flash as
Fig. 4?Go to Step 4.Go to ªMALFUNCTION
INDICATOR LAMP CHECKº in
Section 6.
41) Check DTC stored in immobilizer
control module referring to
ªDIAGNOSTIC TROUBLE CODE
CHECK (IMMOBILIZER CONTROL
MODULE)º in this section.
Is there any DTC(s)?Go to flow table for
DTC No.Go to Step 5.
51) Check DTC stored in ECM/PCM
referring to ªDIAGNOSTIC TROUBLE
CODE CHECK (ECM / PCM)º in this
section.
Is there any DTC(s)?Go to flow table for
DTC No.Substitute a known-good ECM/
PCM and recheck.
NOTE:
After replacing with a known-
good ECM/PCM, register
ECM / Immobilizer Control
Module code in ECM/PCM by
performing procedure described
in ªProcedure after ECM/PCM
Replacementº section.

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VITARA
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-11
1. Immobilizer diagnostic coupler
EXAMPLE :
COIL ANTENNA FAILURE (CODE NO.13)
Voltmeter indicator

NORMAL (No code)
Voltmeter indicatorTIME (sec.)
TIME (sec.) CODE No. 13CODE No. 13CODE No. 13
High
Low
High
Low
1. Monitor coupler
2. Service wire
A: Diagnosis switch
terminal
B: Ground terminal
DIAGNOSTIC TROUBLE CODE (DTC) CHECK
(IMMOBILIZER CONTROL MODULE)
1) Using analog type voltmeter, connect positive probe to diagnos-
tic output terminal and negative probe to ground of immobilizer
diagnostic coupler with ignition switch turned ON.
2) Read deflection of voltmeter indicator which represents DTC as
shown in example below and write it down. For details of DTC,
refer to Immobilizer Control Module side in ªDiagnostic Trouble
Code Tableº.
If voltmeter indicator dose not deflect, go to ªDiagnostic Flow
Table Aº.
NOTE:
If abnormality or malfunction lies in two or more areas, volt-
meter indicates applicable codes three times each.
DIAGNOSTIC TROUBLE CODE (DTC) CHECK (ECM/PCM)
[Not using SUZUKI scan tool] (Vehicle equipped with
monitor coupler)
1) Using service wire, ground diagnostic switch terminal in monitor
coupler.
2) Read DTC from flashing pattern of malfunction indicator lamp as
shown in example below and write it down. For details of DTC,
refer to ECM / PCM side in ªDiagnostic Trouble Code Tableº.
If lamp remains ON, go to ªMalfunction Indicator Lamp Checkº
in Section 6.
NOTE:
If abnormality or malfunction lies in two or more areas, mal-
function indicator lamp indicates applicable codes three
times each.
And flashing of these codes is repeated as long as diagno-
sis terminal is grounded and ignition switch is held at ON
position.

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8G-12 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED)
EXAMPLE: When serial data link wire is defective (Code No.83)
ON
OFFMalfunction
indicator lamp
Code No.83 Code No.83 Code No.83
Time (sec.)
1. Data link connector (DLC)
3) After completing the check, turn ignition switch OFF and discon-
nect service wire from monitor coupler.
[Using SUZUKI scan tool]
1) Turn ignition switch OFF.
2) After setting cartridge to Suzuki scan tool, connect it to data link
connector (DLC) located on underside of instrument panel at
driver's seat side.
Special Tool
(A): 09931-76011 (Suzuki scan tool)
(B): Mass storage cartridge
(C): 09931-76030 (16 / 12 pin DLC adapter)
3) Turn ignition switch ON.
4) Read DTC according to instructions displayed on Suzuki scan
tool and print it or write it down. Refer to Suzuki scan tool opera-
tor's manual for further details.
NOTE:

When reading DTC stored in ECM / PCM using Suzuki scan
tool, select ªECMº from the applications menu and ªSU-
ZUKI modeº from the communication mode menu dis-
played on Suzuki scan tool.

If ECM / PCM detects a trouble in both electric fuel injec-
tion system and immobilizer control system, Suzuki scan
tool indicates trouble codes of both systems using Suzu-
ki mode of ECM application.
If communication between Suzuki scan tool and ECM / PCM is
not possible, check if Suzuki scan tool is communicable by con-
necting it to ECM / PCM in another vehicle. If communication is
possible in this case, Suzuki scan tool is in good condition. Then
check data link connector and serial data line (circuit) in the ve-
hicle with which communication was not possible.
5) After completing the check, turn ignition switch OFF and discon-
nect Suzuki scan tool from data link connector (DLC).

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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.

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8G-26 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED)
ON-VEHICLE SERVICE
PRECAUTIONS IN HANDLING IMMOBILIZER
CONTROL SYSTEM

Do not turn ON ignition switch with ignition key for immobilizer
control system put together with another one or placed quite close
to another one. Or the system may detect abnormal condition and
prevent engine from starting.

Do not turn ON ignition switch by using ignition key with any type
of metal wound around its grip or in contact with it. Or the system
may detect abnormal condition and prevent engine from starting.

Do not leave ignition key where high temperature is anticipated.
High temperature will cause transponder in ignition key to be ab-
normal or damaged.

Do not turn ON ignition switch with a radio antenna placed near
coil antenna or its harness to Immobilizer Control Module. Or the
system may detect abnormal condition and prevent engine from
starting.

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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

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6. Door trim
7. Door hinge
8. Door open stop
9. Door sealing cover
10. Window regulator handle (if equipped) 1. Door glass
2. Weatherstrip
3. Opening weatherstrip
4. Window regulator
5. Glass run
9-2 BODY SERVICE
GLASS, WINDOWS AND MIRROR
FRONT DOOR GLASS

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VITARA
1. Screws 1. Door outside weatherstrip
2. Screw1. Door inside pull handle bracket
BODY SERVICE 9-3
REMOVAL
1) Remove inside handle bezel.
2) Remove door mirror bezel (if equipped).
3) Remove inside lock knob and door inside pull handle case fitting
screw.
3-1) Remove window regulator handle (if equipped).
To remove regulator handle, pull off snap ring by using a cloth
as shown below.
4) Remove door trim.
With inside handle bezel tilted as shown in figure, turn door trim
90
counterclockwise to remove it.
And disconnect power window switch lead wire at coupler (if
equipped).
5) Remove door inside pull handle bracket.
6) Remove door sealing cover.
7) Remove door outside weatherstrip.
Lower window all the way down. Then, use a tape-wrapped putty
knife (or screwdriver) to pry off weatherstrip.
CAUTION:
Use a tape-wrapped putty knife (or screwdriver) to pry off
weatherstrip. Use of an unwrapped tool will cause dam-
age to painting.
8) Remove glass attaching screws.
9) Take out door glass.

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1. Screws
1. Bolts
1. Door sealing cover
2. Adhesive1, (a)
9-4 BODY SERVICE
INSTALLATION
Reverse removal procedure to install door glass noting following
points:

Tighten glass attaching screws to specified torque. Tighten front
screw first, then rear screw.
Tightening Torque
(a): 2.5 N
.m (0.25 kg-m, 1.8 lb-ft)

When window becomes hard to raise and lower, adjust screws to
correct tilted glass as shown in figure.

Adjust equalizer of window regulator so that measurement A and
B are equal.

Secure door sealing cover with adhesive.

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1. Window regulator lubrication point 1. Regulator mounting bolts
2. Regulator motor mounting nuts
3. Hole
BODY SERVICE 9-5
FRONT DOOR WINDOW REGULATOR
REMOVAL
1) Remove door glass, referring to steps 1) to 9) of FRONT DOOR
GLASS REMOVAL in this section.
2) Disconnect power window motor lead wire at coupler and loosen
clamp.
3) Loosen regulator mounting bolts, nuts and take out regulator
through hole as shown in left figure.
INSPECTION
1) Check regulator sliding and rotating parts for greasing.
2) Check rollers for wear and damage.
3) Check wire for damage.
INSTALLATION
Reverse removal procedure to install window regulator noting the
following point.

Tighten bolts and nuts according to the order (a, b, c / 1, 2, 3, 4)
shown in left figure.

When installing glass, check that the top part of the glass contacts
the glass run evenly and that the glass moves up and down
smoothly.
If the glass is tilted with respect to the glass run, make a fine ad-
justment with the screws.

Install door window regulator handle (if equipped) so that it has
an angle as shown in figure when glass is fully closed.