7f Oil SUZUKI GRAND VITARA 2004 2.G Service Workshop Manual

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VITARA
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-27
1
1. Immobilizer Control Module
1. Steering column lower cover
1. Coil antenna
IMMOBILIZER CONTROL MODULE
Removal
1) Disconnect negative (±) cable at battery.
2) Remove steering column hole cover.
3) Disconnect coupler at Immobilizer Control Module.
4) Remove Immobilizer Control Module.
Installation
Reverse removal procedure for installation.
NOTE:
After replacing Immobilizer Control Module, be sure to register
Transponder code and ECM/Immobilizer Control Module code
in Immobilizer Control Module and ECM/Immobilizer Control
Module code in ECM / PCM by performing procedure described
in ªProcedure after Immobilizer Control Module Replacementº
section.
COIL ANTENNA
Removal
1) Disconnect negative (±) cable at battery.
2) Remove steering column upper and lower cover by removing 3
screws.
3) Remove steering column hole cover.
4) Remove coil antenna.
Installation
For installation, reverse removal procedure.

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1. Knife
2. Adhesive
3. Body
1. Adhesive
2. Primer coated surface
9-8 BODY SERVICE
11) Using knife, smoothen adhesive remaining on body side so
that it is 1 to 2 mm thick all around.
NOTE:
Before using knife, clean it with alcohol or the like to re-
move oil from it.
12) When reusing windshield, remove the adhesive from it, using
care not to damage primer coated surface.

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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.

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9-60 BODY SERVICE
1. Door latch
2. Door latch striker
3. Shaft
1. Door latch striker
2. Body
3. Door4. Front side
5. Shim
INSTALLATION
To install front door lock, reverse removal procedure, noting follow-
ing.

Door latch striker.
Move door latch striker up or down so its center aligns with the
center of groove ªAº on the door, as shown.
NOTE:
Striker should be moved vertically and placed level. Do not
adjust door lock.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)

Move door latch striker sideways to adjust door surface flush with
body surface, as shown.
In order to correctly obtain door latch striker position in the fore-
and-aft direction, increase or decrease number of shims inserted
between body and striker to adjust it.
Dimension ªaº: 10.9 ± 12.9 mm (0.43 ± 0.5 in.)
ªbº: 3.4 ± 5.4 mm (0.13 ± 0.21 in.)
NOTE:
Apply oil or grease to striker joints periodically.

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10B-2 AIR BAG SYSTEM
Code 46 - Passenger pretensioner
initiator circuit resistance low 10B-46. . . . . . .
Code 43 - Driver pretensioner initiator
circuit short to ground 10B-48. . . . . . . . . . . . .
Code 47 - Passenger pretensioner
initiator circuit short to ground 10B-48. . . . . .
Code 44 - Driver pretensioner initiator
circuit short to power circuit 10B-50. . . . . . . .
Code 48 - Passenger pretensioner
initiator circuit short to power circuit 10B-50.
Code 51 - Frontal crash detected
(System activation command is
outputted) 10B-52. . . . . . . . . . . . . . . . . . . . . . .
Code 61 -ªAIR BAGº warning lamp
circuit failure 10B-53. . . . . . . . . . . . . . . . . . . . .
Code 71 - Internal SDM fault 10B-54. . . . . . . .
ON-VEHICLE SERVICE10B-55 . . . . . . . . . . . . . . .
Service Precautions 10B-55. . . . . . . . . . . . . . . . .
Service and diagnosis 10B-55. . . . . . . . . . . . . .
Disabling air bag system 10B-56. . . . . . . . . . . .
Enabling air bag system 10B-56. . . . . . . . . . . .
Handling and storage 10B-57. . . . . . . . . . . . . .
Disposal 10B-62. . . . . . . . . . . . . . . . . . . . . . . . . .
Repairs and Inspections Required
after an Accident 10B-63. . . . . . . . . . . . . . . . . . .
Accident with deployment
- component replacement 10B-63. . . . . . . . . . Accident with or without deployment
- component inspections 10B-64. . . . . . . . . . .
Driver Air Bag (Inflator) Module 10B-66. . . . . . . .
Contact Coil and Combination Switch
Assembly 10B-66. . . . . . . . . . . . . . . . . . . . . . . . .
Seat Belt Pretensioner 10B-66. . . . . . . . . . . . . . .
ªAIR BAGº Warning Lamp 10B-66. . . . . . . . . . . .
SDM 10B-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Passenger Air Bag (Inflator) Module 10B-69. . .
AIR BAG (INFLATOR) MODULES
DISPOSAL10B-71 . . . . . . . . . . . . . . . . . . . . . . . . . .
Deployment Outside Vehicle 10B-71. . . . . . . . . .
Deployment Inside Vehicle 10B-78. . . . . . . . . . . .
SEAT BELT PRETENSIONERS
DISPOSAL10B-83 . . . . . . . . . . . . . . . . . . . . . . . . . .
Activation Outside Vehicle 10B-83. . . . . . . . . . . .
Activation Inside Vehicle 10B-89. . . . . . . . . . . . . .
DEPLOYED AIR BAG (INFLATOR)
MODULES DISPOSAL10B-93 . . . . . . . . . . . . .
ACTIVATED SEAT BELT PRETENSIONERS
DISPOSAL10B-94 . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS10B-95 . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS10B-95 . . . . . . . . . . . . . . . . . . . .

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10B-4 AIR BAG SYSTEM
1. Air bag harness
2. ªAIR BAGº fuse box
3. ªAIR BAGº monitor coupler
4. DLC
5. Contact coil assembly
6. Driver air bag (inflator) module
7. Passenger air bag (inflator) module
8. SDM
9. Seat belt pretensioner
(retractor assembly) (if equipped)
10. Pretensioner harness (if equipped)
11. Ground for air bag systemCONNECTOR ªAº
CONNECTOR ªCº, ªDº
CONNECTOR ªBº
CONNECTOR ªEº
CONNECTOR ªHº
CONNECTOR ªFº
CONNECTOR ªGº
SYSTEM COMPONENTS AND WIRING LOCATION VIEW AND CONNECTORS

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WIRE HARNESS COLOR
B : Black
B/W : Black/White
Bl : Blue
Bl/B : Blue/Black
Bl/R : Blue/Red
Br : BrownG : Green
Gr : Gray
G/R : Green/Red
Lg : Lightgreen
P : Pink
V : VioletY : Yellow
Y / G : Yellow/Green
Y/R : Yellow/Red
W : White
W/B : White/Black
1. From main fuse
2. Ignition switch
3. ªIG
.COIL METERº fuse in J/B
4. ªAIR BAGº warning lamp in combination meter
5. ªAIR BAGº fuse in ªAIR BAGº fuse box
6. Connection detection pin
7. To ECM (or PCM), ICM (if equipped) and ABS
controller (if equipped)
8. To data link connector (DLC)
9. ªAIR BAGº monitor coupler
10. SDM
11. Contact coil assembly
12. Driver air bag (inflator) module
13. Driver seat belt pretensioner (if equipped)
14. Passenger air bag (inflator) module
15. Passenger seat belt pretensioner (if equipped)
16. Pretensioner harness (if equipped)
17. Ground for air bag system
TERMINAL
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A13 A11
A12
A14
A15
A16
Passenger air bag (inflator) moduleLow
High
CIRCUIT
Data link connector (DLC)
Low
High
Low
High
Low
High ªAIR BAGº warning lamp
Driver air bag (inflator) module
Diagnosis switch
±±±±±±±±±
Ground
Passenger pretensioner
Driver pretensioner
Ignition switch (power source)±±±±±±±±±
±±±±±±±±±
CONNECTOR ªAº (SDM connector) TERMINAL ARRANGEMENT OF SDM
(VIEWED FROM HARNESS SIDE)
L1
L2Connection detection pin
: Shorting bar
: Air bag harness
ªAº
ªHº : Connector
AIR BAG SYSTEM 10B-5
SYSTEM WIRING DIAGRAM

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AIR BAG SYSTEM 10B-7
Special Tool (Air Bag Driver/Passenger Load Tool)
(B): 09932-75010
This tool is used only when called for in this section. It is used as
a diagnostic aid and safety device to prevent inadvertent air bag (in-
flator) module deployment and seat belt pretensioner activation.
The load tool has three connectors attached to its case are electri-
cally functional and serve as resistive load substitutions.
No more than two connectors are used at any time.
One of connectors (ªAº: BASE OF COLUMN) is used to substitute
the load of the driver air bag (inflator) module and the contact coil
assembly when it is connected at the base of the column to the air
bag wire harness.
Another connector (ªBº: STEERING WHEEL) is used to substitute
the load of followings.

Driver air bag (inflator) module when it is connected at the top of
the column to the contact coil assembly.

Passenger air bag (inflator) module when it is connected to the
air bag harness connector for passenger air bag (inflator) module.

Driver and passenger seat belt pretensioner when it is connected
to air bag harness connector for driver and passenger seat belt
pretensioner.
The third connector (ªCº: PASSENGER INFLATOR) is not used.
By substituting the resistance of the load tool when called for, a de-
termination can be made as to whether an inflator circuit compo-
nent is causing system malfunction and which component is caus-
ing the malfunction.
The load tool should be used only when specifically called for in the
diagnostic procedures.

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7. SDM
7-1. ªAIR BAGº warning lamp driver circuit 4. ªAIR BAGº warning lamp in combination meter
5. ªAIR BAGº fuse in ªAIR BAGº fuse box
6. Connection detection pin 1. From main fuse
2. Ignition switch
3. ªIG
.COIL METERº fuse in J/B: Air bag harness
10B-16 AIR BAG SYSTEM
TABLE A ± ªAIR BAGº WARNING LAMP COMES ªONº STEADY (Page 1 of 2)
CAUTION:

When measurements are requested in this chart use specified digital multimeter with correct terminal
adapter from special tool (Connector test adapter kit).

When a check for proper connection is requested refer to ªIntermittent and Poor Connectionsº in this
section.

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.
STEPACTIONYESNO
11) Ignition switch OFF.
2) Remove and inspect ªAIR BAGº fuse.
3) Is fuse good?Go to step 2.ªBI/Rº wire short to ground.
After repair, replace
ªAIR BAGº fuse.
21) Disconnect SDM.
2) Check proper connection to SDM at
terminal ªA16º.
3) If OK then check voltage between ªA16º
terminal of SDM connector and body
ground with ignition switch ON.
4) Is it 8 V or more?Go to step 3.ªBI/Rº wire (between
ªAIR BAGº fuse and SDM
connector) open ªBI/Bº wire
(between ignition switch and
ªAIR BAGº fuse) open or short
to ground.
31) Disconnect 16p connector from
combination meter, referring to Section
8C.
2) Check resistance between ªA5º terminal
of SDM connector and body ground.
3) Is resistance 1 k
or more?Substitute a known-
good SDM and
recheck.ªBIº wire (between combina-
tion meter and SDM connec-
tor) short to ground.

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7. SDM
7-1. ªAIR BAGº warning lamp driver circuit 4. ªAIR BAGº warning lamp in combination meter
5. ªAIR BAGº fuse in ªAIR BAGº fuse box
6. Connection detection pin 1. From main fuse
2. Ignition switch
3. ªIG
.COIL METERº fuse in J/B: Air bag harness
10B-18 AIR BAG SYSTEM
TABLE B ± ªAIR BAGº WARNING LAMP DOES NOT COME ªONº (Page 1 of 2)
CAUTION:

When measurements are requested in this chart use specified digital multimeter with correct terminal
adapter from special tool (Connector test adapter kit).

When a check for proper connection is requested refer to ªIntermittent and Poor Connectionsº in this
section.

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.
STEPACTIONYESNO
11) Set parking brake.
2) Note combination meter as ignition switch
is turned ON.
3) Does the ªBRAKEº indicator (warning lamp)
come ON?Go to step 2.ªB/Wº wire, ªIG.COIL
METERº fuse or J/B
(between ignition
switch and combination
meter) open or short to
ground.
21) With ignition switch OFF, disconnect SDM.
2) Check electrical connection check
mechanism (connection detection pin).
3) Is it in good condition?Go to step 3.Repair electrical
connection check
mechanism.
31) Disconnect SDM.
2) Check proper connection to SDM at
terminal ªA5º.
3) If OK then check voltage from ªA5º terminal of
SDM connector to body ground with ignition
switch ON.
4) Is it 9 V or more?Substitute a known-good
SDM and recheck.Go to step 4 on the
next page.