sensor SUZUKI GRAND VITARA 2001 2.G Owners Manual

Important
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
WARNING, CAUTION
and NOTE
have special meanings. Pay special attention to the messages highlighted by
these signal words.
WARNING:
Indicates a potential hazard that could result in death or injury.
CAUTION:
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
WARNING:
This service manual is intended for authorized Suzuki dealers and qualified service mechanics only.
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the driver
and passengers.
WARNING:
For vehicles equipped with a 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.
 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, instrument panel or any other air bag system component (on or
around air bag system components or wiring). Modifications can adversely affect air bag system
performance and lead to injury.
 If the vehicle will be exposed to temperatures over 93°C (200°F) (for example, during a paint baking
process), remove the air bag system components (air bag (inflator) modules, forward sensor(s),
SDM and/or seat belt pretensioners) beforehand to avoid component damage or unintended activa-
tion.

0A-2 GENERAL INFORMATION
Precautions
Precaution for Vehicles Equipped with A Sup-
plemental Restraint
(Air Bag) System
Diagnosis
 When troubleshooting air bag system, be sure to follow
“DIAGNOSIS” in SECTION 10B. Bypassing these proce-
dures may result in extended diagnostic time, incorrect
diagnosis, and incorrect parts replacement.
 Never use electrical test equipment other than that
specified in this manual. WARNING:
 The configuration of air bag system parts are as shown
in the figure. When it is necessary to service (remove,
reinstall and inspect) these parts, be sure to follow
procedures described in SECTION 10B. Failure to fol-
low proper procedures could result in possible air bag
system activation, personal injury, damage to parts or
air bag system being unable to activate when neces-
sary.
 If the air bag system and another vehicle system both
need repair, SUZUKI recommends that the air bag sys-
tem 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
93°C (200°F) (for example, during a paint baking pro-
cess), remove the air bag system components before-
hand to avoid component damage or unintended air
bag system activation.
1. Air bag wire harness 5. Contact coil
2. Passenger air bag (inflator) module 6. Driver air bag (inflator) module
3. SDM 7. Forward sensors
4. Seat belt pretensioners
15
2 6
7
5
3
44 7
1
WARNING:
Never attempt to measure the resistance of the air bag
(inflator) modules (driver and passenger) and seat belt
pretensioners (driver and passenger). It is very danger-
ous as the electric current from the tester may deploy the
air bag or activate the pretensioners.

GENERAL INFORMATION 0A-5
CAUTION:
 Even when the accident was light enough not to cause air bags to activate, be sure to inspect sys-
tem parts and other related parts according to instructions under “REPAIR AND INSPECTION
REQUIRED AFTER AN ACCIDENT” in SECTION 10B.
 When servicing parts other than air bag system, if shocks may be applied to air bag system compo-
nent parts, remove those parts beforehand.
 When handling the air bag (inflator) modules (driver and passenger), forward sensors 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 disassembly 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 pas-
senger), wipe off immediately with a dry cloth.
 Air bag wire harness can be identified easily as it is covered with a yellow protection tube. Be very
careful when handling it.
 When an open in air bag wire harness, damaged wire harness, connector or terminal is found,
replace wire harness, connectors and terminals as an assembly.
 Do not apply power to the air bag system unless all components 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 disable air bag system referring to “DIS-
ABLING AIR BAG SYSTEM” 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 fol-
low the instructions.
 After vehicle is completely repaired, perform “AIR BAG DIAGNOSTIC SYSTEM CHECK” in SEC-
TION 10B.

AIR CONDITIONING (OPTIONAL) 1B-5
[A] : Dual A/C LH steering model 4. Condenser 11. Low pressure charge valve
[B] : Dual A/C RH steering model 5. Sight glass 12. Floor liquid pipe
[C] : Single A/C LH steering model 6. Refrigerant (dual) pressure sensor 13. Floor suction pipe
[D] : Single A/C RH steering model 7. Discharge pipe 14. Rear A/C unit
1. Front cooling unit 8. Liquid pipe 15. Rear A/C duct No.1
2. Heater unit 9. Suction pipe 16. Rear A/C duct No.2
3. Compressor 10. High pressure charge valve
[A]
[B]
[C][D]
10
7
9 3 4 6 5 1181
213
12 16
1514
1 2
13
12 16
1514
7
10
5
6
4
38
9 11
1 2
7
10
5
6
4
38
9 11
10
7
9 3 4 6 5 1181
2

1B-6 AIR CONDITIONING (OPTIONAL)
Diagnosis
General
Main A/C system (front A/C system)
Condition Possible Cause Correction
Cool air does not
come out (A/C system
does not operative)No refrigerant Perform recover, evacuation and
charging.
Fuse blown Check “IG METER”, “REAR DEFG”
and “A/C” fuses, and check for
short circuit to ground.
A/C switch faulty Check A/C switch.
Blower motor switch faulty Check blower motor switch.
A/C evaporator temperature sensor (A/C evap-
orator thermistor) faultyCheck A/C evaporator tempera-
ture sensor (A/C evaporator ther-
mistor).
Refrigerant (dual) pressure switch faulty Check refrigerant (dual) pressure
switch.
Wiring or grounding faulty Repair as necessary.
A/C ON permission signal in ECM faulty Check A/C ON permission signal.
A/C controller and its circuit faulty Check A/C controller and its circuit.
Cool air does not
come out (A/C com-
pressor does not
operative (won’t rota-
tive))Magnet clutch faulty Check magnet clutch.
Compressor relay faulty Check compressor thermal switch.
Compressor relay faulty Check compressor relay.
Drive belt loose or broken Adjust or replace drive belt.
Compressor faulty Check compressor.
A/C ON permission signal in ECM faulty Check A/C ON permission signal.
A/C controller faulty Check A/C controller.
Cool air does not
come out (A/C con-
denser cooling fan
motor does not opera-
tive)Condenser cooling fan motor relay faulty Check condenser cooling fan motor
relay.
Wiring or grounding faulty Repair as necessary.
A/C condenser fan motor relay signal in ECM
faultyCheck A/C condenser cooling fan
motor relay signal.
Condenser cooling fan motor faulty Check condenser cooling fan
motor.
Cool air does not
come out (Blower
motor does not opera-
tive)Fuse blown Check “FRONT BLOW” and
“REAR DEFG” fuses, and check for
short circuit to ground.
Blower motor relay faulty Check blower motor relay.
Blower motor resistor faulty Check blower motor resistor.
Blower motor switch faulty Check blower motor switch.
Wiring or grounding faulty Repair as necessary.
Blower motor faulty Check blower motor.

AIR CONDITIONING (OPTIONAL) 1B-7
Cool air does not
come out or insuffi-
cient cooling (A/C sys-
tem normal operative)Insufficient or excessive charge of refrigerant Check charge of refrigerant.
Refrigerant leak in system Check system for leaks.
Condenser clogged Check condenser.
A/C evaporator clogged or frosted Check A/C evaporator.
A/C evaporator temperature sensor (A/C evap-
orator thermistor) faultyCheck A/C evaporator tempera-
ture sensor (A/C evaporator ther-
mistor).
A/C controller faulty Check A/C controller.
Expansion valve faulty Check expansion valve.
Drive belt slipping Check or replace drive belt.
Magnetic clutch faulty Check magnetic clutch.
Cool air does not
come out or insuffi-
cient cooling (A/C sys-
tem normal operative)Compressor faulty Check compressor.
Air in A/C system Replace condenser dryer, and then
perform evacuation and charging.
Air leaking from cooling unit or air duct Repair as necessary.
Heater and ventilation system faulty Check air inlet box assembly.
Check heater control lever assem-
bly.
Check heater assembly.
Blower motor faulty Check blower motor.
Excessive compressor oil existing in A/C sys-
temPull out compressor oil in A/C sys-
tem circuit, and replace compres-
sor.
Cool air does not
comes out only inter-
mittentlyWiring connection faulty Repair as necessary.
Expansion valve faulty Check expansion valve.
Excessive moisture in A/C system Replace condenser dryer, and then
perform evacuation and charging.
A/C controller faulty Check A/C controller.
Magnetic clutch faulty Check magnetic clutch.
Excessive charge of refrigerant Check charge of refrigerant.
Cool air comes out
only at high speedsCondenser clogged Check condenser.
Insufficient charge of refrigerant Check charge of refrigerant.
Air in A/C system Replace condenser dryer, and then
perform evacuation and charging.
Drive belt slipping Adjust or replace drive belt.
Compressor faulty Check compressor.
Cool air does not
comes out only at high
speedsExcessive charge of refrigerant Check charge refrigerant.
A/C evaporator frosted Check A/C evaporator.
Check A/C thermistor.
Insufficient velocity of
cooled airA/C evaporator clogged or frosted Check A/C evaporator.
Air leaking from cooling unit or air duct Repair as necessary.
Blower motor faulty Check blower motor.
Wiring or grounding faulty Repair as necessary. Condition Possible Cause Correction

1B-14 AIR CONDITIONING (OPTIONAL)
Wiring Circuit
ACG
LT GRN
PNK
PNK
BLKORN
BLK
YEL/GRNRED/BLKBLK/WHT
BLU/WHTPNK/BLK
PNK/GRN
RED/BLK
WHT/RED
YEL/GRN
YEL/BLU
A/C
RED/BLU
RED/BLU
RED/BLKBLK
BLU/ORN
BLU/WHT
BLU/WHT
PNK
PNK/BLU
BLK
PNK/WHT
YEL/BLK
GRY/WHT
GRN/BLK
BLK/WHT
RED/BLK
YEL/GRN
BLK
BLK
BLK
YEL/BLK
YEL/GRN
YEL/GRNBLU/GRN
BLU/YELBLUBLU/BLK
BLU/BLK
17
21
22 18
16
15
19
2026 25 24 23
14
12
29
3
4
7
33 30
31
32
28
27
1213
10
11
35 349
856
A
1. Front blower motor main relay 10. Compressor relay 19. Battery 28. Solenoid valve relay
2. Front blower motor 11. Compressor 20. Generator 29. Rear blower motor relay
3. Front blower motor resistor 12. Condenser cooling fan motor
relay21. Ignition main fuse 60 A 30. Rear blower motor resistor
4. Front blower motor switch 13. Condenser cooling fan motor 22. Heater/A/C main fuse 60 A 31. Rear blower motor
5. A/C controller 14. Fuse box 23.“IG METER” fuse 20 A 32. Rear blower motor switch
6. ECM (PCM) 15.“A/C” fuse 25 A 24.“REAR DEFG” fuse 25 A 33. Rear A/C main switch
7. Heater mode control switch 16. Ignition switch 25.“REAR BLOW” fuse 20A 34. Rear A/C evaporator temperature con-
troller
8. Dual (refrigerant) pressure switch 17. Main fuse box 26.“FRONT BLOW” fuse 30A 35. Rear A/C evaporator temperature sensor
9. A/C evaporator thermistor
(A/C evaporator temperature sensor)18. Battery main fuse 100 A 27. Solenoid valve [A] : Rear A/C wiring circuit (if equipped)

1B-16 AIR CONDITIONING (OPTIONAL)
SYSTEM CIRCUIT
Terminal arrangement of A/C controller
Terminal arrangement of ECM
A: To “FRONT BLOW” fuse 1. Front blower motor relay 6. Dual (refrigerant) pressure switch 11. Condenser cooling fan motor
B: To “REAR DEFG” fuse 2. Front blower motor 7. A/C thermistor (evaporator temperature sensor) 12. A/C controller
C: To “IG METER” fuse 3. Front blower motor resistor 8. Compressor relay 13. ECM
D: To “A/C” fuse 4. Front blower motor switch 9. Compressor
5. A/C switch 10. Condenser cooling fan motor relay
5V
12V12V
12V5V
12V
5V
AC-A-1
AC-A-7
AC-A-4
AC-B-2
AC-B-1
AC-A-16AC-A-9
AC-A-2 AC-A-13
E61-8
E61-17
E61-22
A
DBBC
1
2
3
4
7 865
1011912
13
12 12
3
45 6 7 8 9 101112131415 16 AC-B
AC-A
87
22 23
34
3565
16 17
25
262
1
8 9
20
212
1
8 9
21
22 1 2 3 4 5 6
9
24 25 26 27 28 29 30 31 32 3310 11
12 13 14 15 16 17 18 19 20 211 2 3 4
7 8 9
10 11 12 13 14 15
18 19 20 21 22 23 243 4 5 6 7
10 11 12 13 14 15 16 17 18 19
22 23 24 25 26
27 283 4 5 6 7
10 11 12 13 14 15 16 19 18 2017
23
24 25 26 27 29 28 30 E61 C51-3 C51-1 C51-2

AIR CONDITIONING (OPTIONAL) 1B-17
A/C CONTROLLER VOLTAGE VALUES TABLE
Terminal Wire CircuitMeasurement
groundNormal value Condition
AC-A-1BLK/
WHTController main
power supplyGround to
engine (Fig B)10 – 14 VIgnition switch ON with engine
stopped
AC-A-2BLK/
YELController main
groundGround to body
(Fig A)–0.4 – 0 V Engine running
AC-A-4 ORNRefrigerant
(dual) pressure
switch inputGround to
engine (Fig B)0 – 1 VRefrigerant pressure within 225
kpa (2.3 kg/cm
2, 32.7 psi) to
2548 kpa (26 kg/cm
2, 370 psi)
with engine running
10 – 14 VRefrigerant pressure below 196
kpa (2.0 kg/cm
2, 28 psi) or above
3140 kpa (32 kg/cm
2, 455 psi)
with engine running
AC-A-7GRN/
BLKA/C switch and/
or defroster
switch inputGround to
engine (Fig B)8 – 14 VBlower fan motor switch or A/C or
defroster switch OFF with engine
running
0 – 1.5 VBlower fan motor switch and A/C
or defroster switch ON with
engine running
AC-A-9GRY/
WHTSignal input from
ECM (A/C ON
permission sig-
nal)Ground to
engine (Fig B)10 – 14 V Approve of A/C ON
0 – 1 V A/C ON forbid
AC-A-13YEL/
BLKSignal output to
ECM (A/C ON
request signal)Ground to
engine (Fig B)0 – 1.5 VBlower fan motor switch and A/C
or defroster switch ON with
engine running at A/C evaporator
temperature sensor temperature
input more than approx. 2.5 °C
(less than 2.5 V (5840 Ω)) and
refrigerant pressure switch is ON
10 – 14 VExcept the above-mentioned with
engine running
AC-A-16 PNKCompressor
magnet clutch
relay outputGround to
engine (Fig B)0 – 1 VBlower fan motor switch and A/C
or defroster switch ON with
engine running at A/C evaporator
temperature sensor temperature
input more than approx. 2.5 °C
(less than 2.5 V (5840 Ω)), refrig-
erant pressure switch ON and
signal input from ECM ON
10 – 14 VExcept the above-mentioned with
engine running
AC-B-1BLU/
YELSensor groundGround to body
(Fig A)–0.4 – 0 V Engine running

1B-18 AIR CONDITIONING (OPTIONAL)
Terminal Wire CircuitMeasurement
groundNormal value Condition
AC-B-2WHT/
BLKA/C evaporator
temperature
sensor (A/C
evaporator ther-
mistor) inputGround to
engine (Fig B)1.8 V
(3520 Ω)A/C evaporator temperature sen-
sor temperature at approx. 15 °C
(59 °F) with engine running
2.51 V
(5.855 Ω)A/C evaporator temperature sen-
sor temperature at approx. 4.5 °C
(34 °F) with engine running
If the temperature is less than
approx. 4.5 °C, in this case com-
pressor and condenser fan
should be stop (come back at
more than approx. 6.1 °C (less
than 5403 Ω, 2.4 V))
E61-8GRY/
WHTSignal output to
A/C controller
(A/C ON permis-
sion signal)Ground to
engine (Fig C)10 – 14 VRequired A/C ON (terminal AC-
A13) at engine running with nor-
mal condition (refer to “INSPEC-
TION OF ECM AND ITS
CIRCUIT” in Section 6E)
0 – 1 VExcept the above-mentioned with
engine running
In this case compressor should
be stop
E61-17YEL/
BLKSignal input from
A/C controller
(A/C ON request
signal)Ground to
engine (Fig C)0 – 1.5 V Require A/C ON
10 – 14 V Turn off the A/C
E61-22YEL/
BLUCondenser cool-
ing fan motor
relay outputGround to
engine (Fig C)0 – 1 VBlower fan motor switch and A/C
or defroster switch ON with
engine running at A/C evaporator
temperature sensor temperature
input more than approx. 2.5 °C
(less than 2.5 V (5840 Ω)), refrig-
erant pressure switch ON and
signal input from ECM ON
Engine coolant temperature sen-
sor more than 113 °C (236 °F)
with engine running
10 – 14 VExcept the above-mentioned with
engine running