electrical SUZUKI GRAND VITARA 2003 2.G Service Owner's Manual

YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-5
DIAGNOSIS
DIAGNOSIS TABLE
Differential Assembly
ConditionPossible CauseCorrection
Gear noise
Deteriorated or water mixed lubricant

Inadequate or insufficient lubricant

Maladjusted backlash between bevel
pinion and gear

Improper tooth contact in the mesh between
bevel pinion and gear

Loose bevel gear securing bolts

Damaged side gear(s) or side pinion(s)Repair and replenish
Repair and replenish
Adjust
Adjust or replace
Replace or retighten
Replace
Bearing noise
(Constant noise) Deteriorated or water
mixed lubricant

(Constant noise) Inadequate or insufficient
lubricant

(Noise while coasting) Damaged bearing(s)
of bevel pinion

(Noise while turning) Damaged diff. side
bearing(s) or axle bearing(s)Repair and replenish
Repair and replenish
Replace
Replace
Oil leakage
Worn or damaged oil seal

Excessive oil

Loose differential carrier boltsReplace
Adjust oil level
Replace or retighten
2WD / 4WD
switching error
Defective actuator

Abnormality in 4WD control systemReplace
Inspect referring to ª4WD
CONTROL SYSTEM DIAG-
NOSTIC FLOW TABLEº.
4WD Control System Diagnostic Flow Table
Before performing the trouble diagnosis, check that the transfer and front differential are in good condition and
there is no air leakage from air hoses and the actuator. Refer to ªON-VEHICLE SERVICEº in this section for air
leakage.
[NOTES ON SYSTEM CIRCUIT INSPECTION]

Be sure to read ªPrecautions for Electrical Circuit Serviceº in Section 0A before circuit inspection and observe
what is written there.

For system circuit, refer to the figure of ªGENERAL DESCRIPTIONº in this section.

For terminal arrangement, refer to ª4WD Control Circuit Inspectionº in this section.

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8
BODY ELECTRICAL SYSTEM 8-1
SECTION 8
BODY ELECTRICAL SYSTEM
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).
WIRING SYSTEM
(Harnesses, Connectors, Fuses, Relay, Switches, Grounds, System Circuit Diagram)Section 8A . . . . . . .
LIGHTING SYSTEMSection 8B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENTATION AND DRIVER INFORMATIONSection 8C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDOWS, MIRRORS, SECURITY AND LOCKSSection 8D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMMOBILIZER CONTROL SYSTEMSection 8F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS
GENERAL DESCRIPTION8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions in Servicing8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols and Marks8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Color Symbols8-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joint Connector8-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Box and Relay8-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Diagram8-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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8-2 BODY ELECTRICAL SYSTEM
GENERAL DESCRIPTION
The body electrical components of this vehicle are designed to operate on 12 Volts power supplied by the battery.
The electrical system utilizes negative ground polarity.
CAUTIONS IN SERVICING
When performing works related to electric systems, observe follow-
ing cautions for the purpose of protection of electrical parts and pre-
vention of a fire from occurrence.

When removing the battery from the vehicle or disconnecting the
cable from the battery terminals for inspection or service works
on the electric systems, always confirm first that the ignition
switch and all the other switches have been turned OFF. Other-
wise, the semi-conductor part may be damaged.

When disconnecting cables from the battery, be sure to discon-
nect the one from the negative (±) terminal first and then the other
from the positive (+) terminal.

Reverse the above order when connecting the cables to the bat-
tery terminals.

When disconnecting connectors, never pull the wiring harnesses.
Unlock the connector lock first and then pull them apart by holding
connectors themselves.

When connecting connectors, also hold connectors and put them
together until they lock securely (a click is heard).

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BODY ELECTRICAL SYSTEM 8-3

When installing the wiring harness, fix it with clamps so that no
slack is left.

When installing vehicle parts, be careful so that the wiring har-
ness is not interfered with or caught by any other part.

To avoid damage to the harness, protect its part which may con-
tact against a part forming a sharp angle by winding tape or the
like around it.

When replacing a fuse, make sure to use a fuse of the specified
capacity. Use of a fuse with a larger capacity will cause a damage
to the electrical parts and a fire.

Always be careful not to handle electrical parts (computer, relay,
etc.) in a rough manner or drop them.

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8-4 BODY ELECTRICAL SYSTEM

When performing a work that produces a heat exceeding 80C
in the vicinity of the electrical parts, remove the heat sensitive
electrical part(s) beforehand.

Use care not to expose connectors and electrical parts to water
which will be a cause of a trouble.

When using a tester for checking continuity or measuring voltage,
be sure to insert the tester probe from the wire harness side.
SYMBOLS AND MARKS
Refer to Section 8A.
ABBREVIATIONS
Refer to Section 8A.

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VITARA
Symbol
G : Green
G / Y : Green / Yellow G (Base Color)
G (Base Color)
Y (Stripe Color)G/Y
BODY ELECTRICAL SYSTEM 8-5
WIRE COLOR SYMBOLS
The wire color is abbreviated to the first (or first two) alphabet(s) of
each color.
There are two kinds of colored wire used in this vehicle. One is
single-colored wire and the other is dual-colored (striped) wire.
The single-colored wire uses only one color symbol (i.e. ªGº).
The dual-colored wire uses two color symbols (i.e. ªG / Yº). The first
symbol represents the base color of the wire (ªGº in the figure) and
the second symbol represents the color of the stripe (ªYº in the fig-
ure).
JOINT CONNECTOR (J / C)

Wiring of this vehicle employs joint connector (J / C) which divide
one wire into several different wires or combine several different
wires into one wire.

The joint connector is as shown in the figure.
FUSE BOX AND RELAY
Refer to Section 8A.

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8-6 BODY ELECTRICAL SYSTEM
POWER SUPPLY DIAGRAM
Refer to Section 8A.

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8G-8 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED)
[NOTES ON SYSTEM CIRCUIT INSPECTION]
Refer to ªPrecautions for Electrical Circuit Serviceº and ªIntermit-
tents and Poor Connectionº in Section 0A.
[Precaution after replacing ECM / PCM or Immobilizer Control Mod-
ule]

When ECM / PCM was replaced, including when replaced be-
cause rechecking by using a known-good ECM / PCM was neces-
sary during trouble diagnosis, the ECM/Immobilizer Control Mod-
ule code must be registered in ECM / PCM and Immobilizer
Control Module by performing procedure described in ªProce-
dure after ECM / PCM Replacementº on p. 8G-27. If it is not regis-
tered, the engine would not start and accurate trouble diagnosis
would not be assured.

When Immobilizer Control Module was replaced, including when
replaced because rechecking by using a known-good Immobiliz-
er Control Module was necessary during trouble diagnosis, the
Transponder code and ECM/Immobilizer Control Module code
must be registered in Immobilizer Control Module and ECM/Im-
mobilizer Control Module code in ECM / PCM by performing pro-
cedure described in ªProcedure after Immobilizer Control Module
Replacementº on p. 8G-26. If they are not registered, the engine
would not start and accurate trouble diagnosis would not be as-
sured.

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BODY SERVICE 9-63
KEY CODING
KEY USAGE AND IDENTIFICATION
Key is used for ignition and door lock cylinder. Keys are cut on both
edges to make them reversible.
Key identification is obtained from five character key code stamped
on key code tag. Using this key code, key code cutting combination
can be determined from a code list (available to owners of key cut-
ting equipment from suppliers).
If key codes are not available from records or tags, key code can
be obtained from the right hand door lock cylinder (if lock has not
been replaced). Lock cylinders supplied by the factory as service
parts are unmarked.
If original key is available, key code cutting combination can be de-
termined by laying key.
IGNITION SWITCH LOCK CYLINDER
Removal / Installation
See Section 3C1, ªAIR BAG STEERING WHEEL AND COLUMNº.
ELECTRICAL DIAGNOSIS
For ignition switch electrical troubleshooting, see Section 8, ªBODY
ELECTRICAL SYSTEMº.

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(A)(A)
(A)
10B-6 AIR BAG SYSTEM
DIAGNOSIS
WARNING:
To avoid deployment when troubleshooting the air bag system, do not use electrical test equipment
such as a battery powered or AC powered voltmeter, ohmmeter, etc., or any type of electrical equipment
other than that specified in this manual. Do not use a non-powered probe type tester.
Instructions in this manual must be followed carefully, otherwise personal injury may result.
DIAGNOSTIC TROUBLE CODES
The ªAir Bag Diagnostic System Checkº must always be the starting point of any air bag system diagnosis. The
ªAir Bag Diagnostic System Checkº checks for proper ªAIR BAGº warning lamp operation and checks for air bag
diagnostic trouble codes using the Tech-1 (scan tool) or on-board diagnosis function.

Current diagnostic trouble code ± Malfunction that are presently being detected.

History diagnostic trouble code ± All malfunction detected since the last time the history memory was cleared.
USE OF SPECIAL TOOLS
WARNING:
To avoid deployment when troubleshooting the air bag system, do not use electrical test equipment
such as a battery powered or AC powered voltmeter, ohmmeter, etc., or any type of electrical equipment
other than that specified in this manual. Do not use a non-powered probe type tester.
Instructions in this manual must be followed carefully, otherwise personal injury may result.
You should be familiar with the tools listed under ªSpecial Toolsº in this section. You should be able to measure
voltage and resistance. You should be familiar with proper use of a scan tool such as the Tech-1 Diagnostic Com-
puter, Driver/Passenger Load Tool, Connector Test Adapter Kit and the Digital Multimeter.
Special Tool (Connector Test Adapter Kit)
(A): 09932-76010
This must be used whenever a diagnostic procedure requests
checking or probing a terminal.
Using the appropriate adapter in the special tool will ensure that no
damage to the terminal will occur from the multimeter probe, such
as spreading or bending.
The adapter will also give an idea of whether contact tension is suffi-
cient, helping to find an open or intermittent open due to poor termi-
nal contact.