2000 SUZUKI GRAND VITARA air bag system

YH4
GRAND
VITARA
3C1
AIR BAG STEERING WHEEL AND COLUMN 3C1-1
GENERAL DESCRIPTION3C1- 2 . . . . . . . . . . . . .
DIAGNOSIS3C1- 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair Required after
Accident 3C1- 3. . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE3C1- 3 . . . . . . . . . . . . . . .
Service Precautions 3C1- 3. . . . . . . . . . . . . . . . .
Diagnosis and Servicing 3C1- 3. . . . . . . . . . . .
Disabling Air Bag System 3C1- 3. . . . . . . . . . .
Enabling Air Bag System 3C1- 3. . . . . . . . . . .
Handling and Storage 3C1- 3. . . . . . . . . . . . . .
Disposal 3C1- 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Driver Air Bag (Inflator) Module 3C1- 4. . . . . . . .
Steering Wheel 3C1- 6. . . . . . . . . . . . . . . . . . . . . . Centering Contact Coil 3C1- 6. . . . . . . . . . . . .
Contact Coil and Combination Switch
Assembly 3C1- 7. . . . . . . . . . . . . . . . . . . . . . . . .
Steering Column 3C1- 9. . . . . . . . . . . . . . . . . . . .
Steering Lock Assembly (Ignition
Switch) 3C1-14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Lower Shaft Assembly 3C1-15. . . . . . .
Checking Steering Column for Accident
Damage 3C1-17. . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustable Steering Column Release
Lever 3C1-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS3C1-18 . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL3C1-18 . . . . . . . . . . . . . . . . . . . . . .
SECTION 3C1
AIR BAG STEERING WHEEL AND COLUMN
WARNING:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Please observe all WARNINGS and ªService Precautionsº under ªOn-Vehicle
Serviceº in air bag system section before performing service on or around the air bag system compo-
nents 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.

The procedures in this section must be followed in the order listed to disable the air bag system tem-
porarily and prevent false diagnostic trouble codes from setting. Failure to follow procedures could
result in possible activation of the air bag system, personal injury or otherwise unneeded air bag sys-
tem repairs.
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were re-
moved. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may
be used. Fasteners that are not reused, and those requiring thread-locking compound, will be called
out. The correct torque value must be used when installing fasteners that require it. If the above proce-
dures are not followed, parts or system damage could result.
CONTENTS

YH4
GRAND
VITARA
14
15
1. Driver air bag (inflator) module
2. Steering wheel
3. Steering wheel nut
4. Contact coil and combination switch assembly
5. Steering column upper cover
6. Steering column lower cover
7. Steering column assembly
8. Steering lock assembly
9. Steering column hole cover
10. Steering shaft joint
11. Steering lower shaft assembly
12. Adjustable steering column release lever
(if equipped)
13. Steering column lower seal
14. With adjustable steering column release lever type
15. Without adjustable steering column release lever type
3C1-2 AIR BAG STEERING WHEEL AND COLUMN
GENERAL DESCRIPTION
This double tube type steering column has the following three important features in addition to the steering function:

The column is energy absorbing, designed to compress in a front-end collision.

The ignition switch and lock are mounted conveniently on this column.

With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehicle.
To insure the energy absorbing action, it is important that only the specified screws, bolts, and nuts be used as
designated and that they are tightened to the specified torque. When the column assembly is removed from the
vehicle, special care must be taken in handling it. Use of a steering wheel puller other than the one recommended
in this manual or a sharp blow on the end of the steering shaft, leaning on the assembly, or dropping the assembly
could shear the plastic shear pins which maintain column length and position.
The driver air bag (inflator) module is one of the supplemental restraint (air bag) system components and is
mounted to the center of the steering wheel. During certain frontal crashes, the air bag system supplements the
restraint of the driver's and passenger's seat belts by deploying the air bags. The air bag (inflator) module should
be handled with care to prevent accidental deployment. When servicing, be sure to observe all WARNINGS in this
section. Refer to ªSERVICE PRECAUTIONSº in Section 10B.

YH4
GRAND
VITARA
AIR BAG STEERING WHEEL AND COLUMN 3C1-3
DIAGNOSIS
For diagnosis of the steering wheel and steering column, refer to
Section 3. For diagnosis of the air bag system, refer to Section 10B.
INSPECTION AND REPAIR REQUIRED AFTER
ACCIDENT
After an accident, whether the air bag has been deployed or not, be
sure to perform checks, inspections and repairs described under
ªCHECKING STEERING COLUMN FOR ACCIDENT DAMAGEº in
this section as well as ªREPAIRS AND INSPECTIONS REQUIRED
AFTER ACCIDENTº in Section 10B.
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
For service precautions, refer to ªSERVICE PRECAUTIONSº un-
der ªON-VEHICLE SERVICEº in Section 10B.
DIAGNOSIS AND SERVICING
For diagnosis and servicing, refer to ªDIAGNOSIS AND SERVIC-
INGº under ªSERVICE PRECAUTIONSº in Section 10B.
DISABLING AIR BAG SYSTEM
For disabling air bag system, refer to ªDISABLING AIR BAG SYS-
TEMº under ªSERVICE PRECAUTIONSº in Section 10B.
ENABLING AIR BAG SYSTEM
For enabling air bag system, refer to ªENABLING AIR BAG SYS-
TEMº under ªSERVICE PRECAUTIONSº in Section 10B.
HANDLING AND STORAGE
For handling and storage, refer to ªHANDLING AND STORAGEº
under ªSERVICE PRECAUTIONSº in Section 10B.
DISPOSAL
For disposal, refer to ªDISPOSALº under ªSERVICE PRECAU-
TIONSº in Section 10B.

YH4
GRAND
VITARA
1 11
1. Mounting bolt
1. Driver air bag (inflator) module connector
2. Horn connector
3. Driver air bag (inflator) module
4. Steering wheel
3C1-4 AIR BAG STEERING WHEEL AND COLUMN
DRIVE AIR BAG (INFLATOR) MODULE
WARNING:
When handling an air bag (inflator) module, be sure to read
ªSERVICE PRECAUTIONSº under ªON-VEHICLE SERVICEº
in Section 10B and observe each instruction. Failure to fol-
low them could cause a damage to the air bag (inflator) mod-
ule or result in personal injury.
REMOVAL
1) Disconnect negative battery cable at battery terminal.
2) Disable air bag system. Refer to ªDISABLING AIR BAG SYS-
TEMº under ªSERVICE PRECAUTIONSº in Section 10B.
3) Loosen 2 bolts mounting driver air bag (inflator) module till it
turns freely, pull them out and fix them to bolt clamps.
4) Remove air bag (inflator) module from steering wheel.
5) Remove driver air bag (inflator) module (yellow) connector and
horn connector from steering wheel.
6) Disconnect driver air bag (inflator) module (yellow) connector of
driver air bag (inflator) module and horn connector as shown in
the figure.
ii) Release locking of lever.
ii) After unlocked, disconnect connector.
WARNING:
Special care is necessary when handling and storing a
live (undeployed) air bag (inflator) module. Observe
ªSERVICE PRECAUTIONSº under ªON-VEHICLE SER-
VICEº in Section 10B. Otherwise, personal injury may re-
sult.

YH4
GRAND
VITARA
6, (a)
1. Trim cover (pad surface)
2. Inflator case
3. Wire harness
1. Driver air bag (inflator) module connector
2. Horn connector
3. Driver air bag (inflator) module
4. Steering wheel
5. Mounting bolt (left side)
6. Mounting bolt (right side)
AIR BAG STEERING WHEEL AND COLUMN 3C1-5
INSPECTION
WARNING:
Never disassemble air bag (inflator) module or measure its
resistance. Otherwise, personal injury may result.
CAUTION:
If air bag (inflator) module was dropped from a height of
90 cm (3 ft) or more, it should be replaced.
Check air bag (inflator) module visually and if any of the following
is found, replace it with a new one.

Air bag being deployed.

Trim cover (pad surface) being cracked.

Wire harness or connector being damaged.

Air bag (inflator) module being damaged or having been exposed
to strong impact (dropped).
INSTALLATION
1) Connect horn connector securely.
2) Connect yellow connector of driver air bag (inflator) module con-
nector as shown in the figure securely.
ii) Connect connector.
ii) Lock connector with lock lever.
3) Install horn connector and driver air bag (inflator) module con-
nector.
4) Install driver air bag (inflator) module to steering wheel, taking
care so that no part of wire harness is caught between them.
5) Make sure that clearance between module and steering wheel
is uniform all the way.
6) Tighten driver air bag (inflator) module mounting bolt (left side)
to specified torque first and then driver air bag (inflator) module
mounting bolt (right side) to specified torque.
Tightening Torque
(a): 9 N
.m (0.9 kg-m, 6.5 lb-ft)
7) Connect negative battery cable.
8) Enable air bag system. Refer to ªENABLING AIR BAG SYS-
TEMº under ªSERVICE PRECAUTIONSº in Section 10B.

YH4
GRAND
VITARA
1. Steering column assembly
2. Steering shaft joint
3. Marks
1. Steering column assembly
2. Steering shaft joint
3. Steering lower shaft assembly
4. Bolt (column side)
5. Bolt (lower shaft assembly side)1. Steering column hole cover
1
3C1-10 AIR BAG STEERING WHEEL AND COLUMN
REMOVAL
WARNING:
Never rest a steering column assembly on the steering
wheel with air bag (inflator) module face down and column
vertical. Otherwise personal injury may result.
1) Disconnect negative battery cable at battery terminal.
2) Disable air bag system. Refer to ªDISABLING AIR BAG SYS-
TEMº under ªSERVICE PRECAUTIONSº in Section 10B.
3) Remove steering wheel and contact coil and combination switch
assembly, if necessary. Refer to ªSTEERING WHEELº and
ªCONTACT COIL AND COMBINATION SWITCH ASSEMBLYº
in this section.
Perform the following procedure if not removing steering wheel
and/or combination switch.
ii) Turn steering wheel so that vehicle's front tires are at straight-
ahead position.
ii) Turn ignition switch to ªLOCKº position and remove key.
4) Remove steering column hole cover.
5) Disconnect all connectors for the following parts.

Contact coil and combination switch

Ignition switch
6) Make alignment marks on shaft joint and shaft (column side) for
a guide during reinstallation.
7) After removing bolt on column side of shaft joint and loosening
bolt on its lower shaft assembly side, move shaft joint to lower
shaft assembly side (in arrow direction in the figure).

YH4
GRAND
VITARA
1. Steering shaft joint
2. Steering shaft (column side)
3. Marks
1. Steering shaft joint
2. Bolt (column side)
3. Bolt (lower shaft assembly side)
1. Steering column hole cover
1
AIR BAG STEERING WHEEL AND COLUMN 3C1-13
4) Install steering shaft joint to steering shaft by matching it to
marks made before removal.
5) Install shaft joint bolt (column side) to steering shaft joint. Tighten
shaft joint bolt (column side) to specified torque first and then
shaft joint bolt (lower shaft assembly side) to specified torque.
Tightening Torque
(c): 25 N
.m (2.5 kg-m, 18.0 lb-ft)
6) If contact coil and combination switch assembly is removed,
install it, referring to ªCONTACT COIL AND COMBINATION
SWITCH ASSEMBLYº in this section.
7) Connect all connectors that have been removed in removal.
8) Install steering column hole cover.
9) If steering wheel is removed, install it by referring to ªSTEER-
ING WHEELº in this section.
10) Connect negative battery cable.
11) After installing steering column assembly, be sure to enable air
bag system by referring to ªENABLING AIR BAG SYSTEMº un-
der ªSERVICE PRECAUTIONSº in Section 10B.

YH4
GRAND
VITARA
5
BRAKES 5-1
GENERAL DESCRIPTION5- 2 . . . . . . . . . . . . . .
DIAGNOSIS5- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Road Testing Brakes 5- 3. . . . . . . . . . . . . . . . . .
Brake Fluid Leaks 5- 3. . . . . . . . . . . . . . . . . . . .
Substandard or Contaminated
Brake Fluid 5- 3. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table 5- 4. . . . . . . . . . . . . . . . . . . . . .
CHECK AND ADJUSTMENT5- 7 . . . . . . . . . . . .
Bleeding Brakes 5- 7. . . . . . . . . . . . . . . . . . . . . .
Brake Pedal Free Height Check 5- 9. . . . . . . .
Brake Light Switch Adjustment 5- 9. . . . . . . . .
Excessive Pedal Travel Check 5- 9. . . . . . . . .
Brake Pedal Play Check 5-10. . . . . . . . . . . . . . .
Brake Fluid Level Check 5-10. . . . . . . . . . . . . . . Brake Hose and Pipe Check 5-10. . . . . . . . . . .
Master Cylinder Check 5-10. . . . . . . . . . . . . . . .
Brake Disc Check 5-11. . . . . . . . . . . . . . . . . . . .
Brake Pad Check 5-11. . . . . . . . . . . . . . . . . . . . .
Brake Shoe Check 5-11. . . . . . . . . . . . . . . . . . . .
Parking Brake Check and
Adjustment 5-12. . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Brake Hydraulic System 5-13. . . . . . .
Fluid Pressure Test 5-13. . . . . . . . . . . . . . . . . . .
Booster Operation Check 5-15. . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS5-17 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIAL5-17 . . . . . . . .
SPECIAL TOOLS5-18 . . . . . . . . . . . . . . . . . . . . . .
SECTION 5
BRAKES
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).
NOTE:

When inspecting and servicing vehicle equipped with ABS, be sure to refer to section 5E or 5E1 first.

All brake fasteners are important attaching parts in that they could affect the performance of vital parts
and systems, and / or could result in major repair expense. They must be replaced with one of same part
number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to as-
sure proper retention of all parts. There is to be no welding as it may result in extensive damage and
weakening of the metal.
DIAGNOSIS5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PIPE / HOSE / MASTER CYLINDER5A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE5B-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING AND REAR BRAKE5C-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS