mirror SUZUKI GRAND VITARA 2003 2.G Service Workshop Manual
[x] Cancel search | Manufacturer: SUZUKI, Model Year: 2003, Model line: GRAND VITARA, Model: SUZUKI GRAND VITARA 2003 2.GPages: 801, PDF Size: 12.15 MB
Page 3 of 801
YH4
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vol.1
0A
0B
1A
1B
3
3A
3B1
3C
3C1
3D
3E
3F
4A2
4B
5
6
7A5A
5B
5C
5E1
6A1
6A2
6A4
6B
6C
6E1
6E2
6F1
6F2
6G
6G1
6H
6K
7A1
7B1
7C1
7D
7E
7F
8
8B
8C
8D
8G
9
10
10A
8A
10B
6-1ENGINE
General Information and
Diagnosis (G16 / J20)
General Information and
Diagnosis (H25)
Engine Mechanical (G16)
Engine Mechanical (H25)
Engine Mechanical (J20)
Engine Cooling
Engine Fuel
Engine and Emission Control
System (SFI for G16 / J20)
Engine and Emission Control
System (SFI for H25)
Ignition System (G16)
Ignition System (J20 / H25)
Cranking System
(Reduction Type)
Cranking System
(No-Reduction Type)
Charging System
Exhaust System
TRANSMISSION, CLUTCH
AND DIFFERENTIAL
Manual Transmission (Type 1)
Manual Transmission (Type 2)
Automatic Transmission
Clutch (Hydraulic Type)
Transfer
Differential (Front)
Differential (Rear)
BODY ELECTRICAL SYSTEM
Wiring Diagram
Lighting System
Instrumentation / Driver
Information
Windows, Mirrors, Security
and Lock
Immobilizer Control System
BODY SERVICE
RESTRAINT SYSTEM
Seat Belt
Air Bag System GENERAL INFORMATION
General Information
Maintenance and Lubrication
TABLE OF CONTENTS TABLE OF CONTENTS SECTIONSECTION
0B
HEATING AND AIR
CONDITIONING
Heater and Ventilation
Air Conditioning
STEERING, SUSPENSION,
WHEELS AND TIRES
Front End Alignment
Power Steering (P / S) System
Steering Wheel and Column
(Not Equipped with Air Bag)
Air Bag Steering Wheel
and Column
Front Suspension
Rear Suspension
Wheel and Tires
1A
3A 0A
1B
3B1
3C
3C1
3D
3E
3F36A16
6A2
6A4
6B
6C
6E1
6E2
6F1
DRIVE SHAFT / PROP. SHAFT
Front Drive Shaft / Shaft
Bearing, Oil Seal
Propeller Shaft
BRAKES
Brake Pipe / Hose / Master
Cylinder
Front Brakes
Parking and Rear Brakes
Antilock Brake System
4A2
4B
5
5A
5B
5C
5E1
6F2
6G
6G1
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8
8A
8B
8C
8D
8G
9
10
10A
10B
6-1
NOTE:
The screen toned Sections 6 ± 6K are included in Volume 2 and Section 8A is in Wiring
Diagram Manual.
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5-10 BRAKES
BRAKE PEDAL PLAY CHECK
Pedal play should be within specification. If out of specification,
check brake light switch for proper installation position and adjust
if necessary.
Also check pedal shaft bolt and master cylinder pin installation for
looseness and replace if defective.
Pedal play ªdº: 1 ± 8 mm (0.04 ± 0.32 in.)
BRAKE FLUID LEVEL CHECK
Be sure to use particular brake fluid either as indicated on reservoir
cap of that vehicle or recommended in owner's manual which
comes along with that vehicle.
Use of any other fluid is strictly prohibited.
Fluid level should be between MIN and MAX lines marked on reser-
voir.
When warning light lights sometimes during driving, replenish fluid
to MAX line.
When fluid decreases quickly, inspect brake system for leakage.
Correct leaky points and then refill to specified level.
CAUTION:
Do not use shock absorber fluid or any other fluid which
contains mineral oil. Do not use a container which has been
used for mineral oil or a container which is wet from water.
Mineral oil will cause swelling and distortion of rubber parts
in hydraulic brake system and water mixed into brake fluid
will lower fluid boiling point. Keep all fluid containers
capped to prevent contamination.
BRAKE HOSE AND PIPE CHECK
The brake hose assembly should be checked for road hazard dam-
age, for cracks and chafing of the outer cover, for leaks and blisters.
A light and mirror may be needed for an adequate inspection. If any
of the above conditions are observed on the brake hose, it is neces-
sary to replace it.
Inspect the pipe for damage, cracks, dents and corrosion. If any de-
fect is found, replace it.
MASTER CYLINDER CHECK
Check for a cracked master cylinder casting or brake fluid around
the master cylinder. Leaks are indicated only if there is at least a
drop of fluid. A damp condition is not abnormal.
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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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8D
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-1
GENERAL DESCRIPTION8D- 2 . . . . . . . . . . . . . .
Cautions in Servicing 8D- 2. . . . . . . . . . . . . . . . .
Symbols and Marks 8D- 2. . . . . . . . . . . . . . . . . . .
Wiring Color Symbols 8D- 2. . . . . . . . . . . . . . . . .
Abbreviations 8D- 2. . . . . . . . . . . . . . . . . . . . . . . .
Joint Connector 8D- 2. . . . . . . . . . . . . . . . . . . . . .
Fuse Box and Relay 8D- 2. . . . . . . . . . . . . . . . . .
Power Supply Diagram 8D- 2. . . . . . . . . . . . . . . .
Windshield Wiper and Washer 8D- 2. . . . . . . . .
Front Wiper and Washer 8D- 2. . . . . . . . . . . . .
Rear Wiper and Washer (If Equipped) 8D- 3.
Power Door Lock and Keyless Entry
(If Equipped) System 8D- 4. . . . . . . . . . . . . . . .
DIAGNOSIS8D- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windshield Wiper and Washer 8D- 5. . . . . . . . .
Front Wiper and Washer 8D- 5. . . . . . . . . . . . .
Rear Wiper and Washer (If Equipped) 8D- 5.
Rear Window Defogger (If Equipped) 8D- 5. . .
Power Window Control System 8D- 5. . . . . . . . .
Power Door Lock System (If Keyless
Entry is not Equipped) 8D- 6. . . . . . . . . . . . . . . Power Door Lock and Keyless Entry
System (If Keyless Entry is Equipped) 8D- 7. .
Power Door Mirror Control System 8D- 8. . . . . .
Door Mirror Heater (If Equipped) 8D- 8. . . . . . . .
Power Sliding Roof (If Equipped) 8D- 8. . . . . . .
Front Seat Heater (If Equipped) 8D- 8. . . . . . . .
ON-VEHICLE SERVICE8D- 9 . . . . . . . . . . . . . . . .
Windshield Wiper and Washer 8D- 9. . . . . . . . .
Front Wiper and Washer 8D- 9. . . . . . . . . . . . .
Rear Wiper and Washer (If Equipped) 8D-13.
Rear Window Defogger (If Equipped) 8D-16. . .
Power Window Control System 8D-18. . . . . . . . .
Power Door Lock System (If Keyless
Entry is not Equipped) 8D-20. . . . . . . . . . . . . . .
Power Door Lock and Keyless Entry
System (If Keyless Entry is Equipped) 8D-23. .
Power Door Mirror Control System 8D-30. . . . . .
Door Mirror Heater (If Equipped) 8D-31. . . . . . . .
Power Sliding Roof (If Equipped) 8D-32. . . . . . .
Front Seat Heater (If Equipped) 8D-33. . . . . . . .
SECTION 8D
WINDOWS, MIRRORS, SECURITY AND LOCKS
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
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Front Wiper Assembly
Washer AssemblyFront Wiper Switch
8D-2 WINDOWS, MIRRORS, SECURITY AND LOCKS
GENERAL DESCRIPTION
CAUTIONS IN SERVICING
Refer to Section 8.
SYMBOLS AND MARKS
Refer to Section 8.
WIRING COLOR SYMBOLS
Refer to Section 8.
ABBREVIATIONS
Refer to Section 8.
JOINT CONNECTOR
Refer to Section 8.
FUSE BOX AND RELAY
Refer to Section 8.
POWER SUPPLY DIAGRAM
Refer to Section 8.
WINDSHIELD WIPER AND WASHER
FRONT WIPER AND WASHER
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Rear Wiper Switch
Rear Wiper Intermittent Relay Rear Wiper Assembly
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-3
REAR WIPER AND WASHER (IF EQUIPPED)
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8D-4 WINDOWS, MIRRORS, SECURITY AND LOCKS
LH steering vehicleRH steering vehicle
Type 1
Type 2
Power Door Lock Controller (Canvas Top Model)
Power Door Lock SwitchBack Door Actuator
(except Canvas Top
Model)
Rear Door Actuator
Front Door Actuator
Fuse box
Power Door Lock and Keyless Entry (if equipped)
Controller (Hard Top Model)Keyless Entry Transmitter
(If keyless entry is equipped)
The illustration shows LH steering vehicle.
And RH steering vehicle is symmetrical.
POWER DOOR LOCK AND KEYLESS ENTRY (IF EQUIPPED) SYSTEM
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WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-5
DIAGNOSIS
NOTE:
Fuse name (ª º) in the table below is shown on the fuse box cover (Hard Top Model) or the junction box
(Canvas Top Model).
WINDSHIELD WIPER AND WASHER
FRONT WIPER AND WASHER
REAR WIPER AND WASHER (IF EQUIPPED)
TroublePossible causeCorrection
Wiper malfunctionsªWIPER / WASHERº fuse blown (Hard Top
Model)
ªWIPº fuse blown (Canvas Top Model)
Wiper motor faulty
Wiper switch faulty
Wiring or grounding faultyReplace fuse to check for short
Replace motor
Replace switch
Repair
Washer malfunctionsWasher hose or nozzle clogged
ªWIPER / WASHERº fuse blown (Hard Top
Model)
ªWIPº fuse blown (Canvas Top Model)
Washer motor faulty
Washer switch faulty
Wiring faultyClean or repair clogged hose or
nozzle
Replace fuse to check for short
Replace motor
Replace switch
Repair
REAR WINDOW DEFOGGER (IF EQUIPPED)
TroublePossible causeCorrection
Defogger does not workªREAR DEFGº fuse blown
Defogger switch faulty
Defogger heat wire faulty
Wiring or grounding faultyReplace fuse to check for short
Replace switch
Repair heat wire
Repair
POWER WINDOW CONTROL SYSTEM
TroublePossible causeCorrection
All power windows do not
operateªPOWER WINDOWº fuse blown (Hard Top
Model)
ªP / Wº fuse blown (Canvas Top Model)
Ignition switch faulty
Wiring or grounding faultyReplace fuse to check for short
Replace switch
Repair
Only one power window
does not operatePower window switch (main or sub) faulty
Power window motor faulty
Window lock switch faulty
Wiring or grounding faultyReplace switch
Replace motor
Replace switch
Repair
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8D-6 WINDOWS, MIRRORS, SECURITY AND LOCKS
POWER DOOR LOCK SYSTEM (IF KEYLESS ENTRY IS NOT EQUIPPED)
TroublePossible causeCorrection
All power doors are not
locked / unlocked by both
driver side door key
switch and power door
lock switchªDOOR LOCKº fuse blown (Hard Top
Model)
ªD / Lº fuse blown (Canvas Top Model)
Power door controller faulty
Wiring or grounding faultyReplace fuse to check for short
Replace controller
Repair
All power doors are not
locked / unlocked by only
power door lock switchPower door lock switch faulty
Wiring or grounding faultyReplace switch
Repair
All power doors are not
locked / unlocked by only
driver side door key
switchDriver side door key switch faulty
Wiring or grounding faultyReplace switch
Repair
Only one power door is not
locked / unlockedWiring or coupler faulty
Actuator (door lock motor) faultyRepair
Replace actuator
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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
flashªDOOR 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 switchPower door lock switch faulty
Wiring or grounding faultyReplace switch
Repair
All power doors are not
locked / unlocked by only
driver side door key
switchDriver side door key switch faulty
Wiring or grounding faultyReplace switch
Repair
All power doors are not
locked / unlocked by only
keyless entry transmitterCode 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
automaticallyDoor switch faulty
Wiring harness connected to door switch
brakesReplace switch
Repair
Only one power door is not
locked / unlockedWiring or coupler faulty
Actuator (door lock motor) faultyRepair
Replace actuator
Operation distance of
keyless entry is unstableTransmitter battery dead
Transmitter faultyReplace battery
Replace transmitter