2002 SUZUKI GRAND VITARA belt
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YH4
GRAND
VITARA
AIR BAG SYSTEM 10B-55
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
SERVICE AND DIAGNOSIS
WARNING/CAUTION labels are attached on each part of air bag system components (SDM, air bag (inflator) mod-
ules and seat belt pretensioners). Be sure to follow the instructions.
WARNING:
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, dashboard or any other air bag system components. Modifications
can adversely affect air bag system performance and lead to injury.
Failure to follow procedures could result in possible air bag system activation, personal injury or un-
needed air bag system repairs.
Many of service procedures require disconnection of ªAIR BAGº fuse and air bag (inflator) modules (driver and
passenger) from initiator circuit to avoid an accidental deployment.
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.
The ªAir Bag Diagnostic System Checkº must be the starting point of any air bag diagnostics. The ªAir Bag Diag-
nostic System Checkº will verify proper ªAIR BAGº warning lamp operation and will lead you to the correct chart
to diagnose any air bag malfunctions. Bypassing these procedures may result in extended diagnostic time, incor-
rect diagnosis, and incorrect parts replacements.
Never use air bag component parts from another vehicle.
If the vehicle will be exposed to temperatures over 93C (200F) (for example, during a paint baking process),
remove the air bag system components beforehand to avoid component damage or unintended system activa-
tion.
When servicing, if shocks may be applied (eg., dropped from a height of 90 cm (3 ft) or more) to air bag system
component parts, remove those parts beforehand.
When using electric welding, be sure to disconnect air bag (inflator) module and seat belt pretensioner connec-
tors (driver and passenger) respectively.
When applying paint around the air bag system related parts, use care so that the harness or connector will not
be exposed to the paint mist.
Never expose air bag system component parts directly to hot air (drying or baking the vehicle after painting) or
flames.
WARNING:
When performing service on or around air bag system components or air bag wiring, follow the proce-
dures listed in the following pages to temporarily disable the air bag system. Refer to appropriate ser-
vice manual procedures. Failure to follow procedures could result in possible air bag system activa-
tion, personal injury or unneeded air bag system repairs.
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ALWAYS PLACE AIR BAG (INFLATOR) MODULE
ON WORKBENCH WITH TRIM COVER (AIR BAG
OPENING) UP, AWAY FROM LOOSE OBJECTS.
1. Slit on workbench
2. Workbench vise
3. Lower mounting bracket
2-1. Webbing
2-2. Retractor assembly
2-1. Seat belt pretensioner
2-2. Seat belt pretensioner harness
2-2
AIR BAG SYSTEM 10B-59
WARNING:
When placing a live air bag (inflator) module on bench or
other surface, always face the bag up, away from the sur-
face. As the live passenger air bag (inflator) module must be
placed with its bag (trim cover) facing up, place it on the
workbench with a slit or use the workbench vise to hold it
securely at its lower mounting bracket.
It is also prohibited to place anything on top of the trim cov-
er and stack air bag (inflator) modules.
This is necessary so that a free space is provided to allow
the air bag to expand in the unlikely event of accidental de-
ployment.
Otherwise, personal injury may result.
LIVE (INACTIVATED) SEAT BELT PRETENSIONERS
Special care is necessary when handling and storing a live (inacti-
vated) seat belt pretensioners.
Also, when the seat belt pretensioners activate, gas is generated
and the seat belt is retracted into the retractor quickly.
Note, therefore, that if they activate accidentally, the seat belt pre-
tensioners and other object(s) around them may be thrown through
the air.
WARNING:
Never attempt to measure the resistance of the seat belt pre-
tensioners. It is very dangerous as the electric current from
the tester may activate pretensioner.
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VITARA
1. Exhaust hole
1 1
NG
10B-60 AIR BAG SYSTEM
Never attempt to disassemble the seat belt pretensioners (retrac-
tor assembly).
If any abnormality is found, be sure to replace it with new one as
an assembly.
When an abnormality is noted as existing in the live (inactivated)
seat belt pretensioner, be sure to activate it before discarding it.
When grease, cleaning agent oil, water, etc., got on the seat belt
pretensioners (retractor assembly), wipe it off immediately with a
dry cloth.
If seat belt pretensioner was dropped from a height of 30 cm (1
ft) or more, it should be replaced with a new one as an assembly.
WARNING:
For handling and storage of a live seat belt pretensioner,
select a place where the ambient temperature below 65C
(150F), without high humidity and away from electric
noise.
Never carry the seat belt pretensioner by the wires or con-
nector on the underside of the pretensioner.
When placing a live seat belt pretensioner on the work-
bench or some place like that, be sure not to lay it with its
exhaust hole provided side facing down. It is also prohib-
ited to put something on its face with an exhaust hole or
to put a seat belt pretensioner on top of another.
Otherwise, personal injury may result.
Page 767 of 801
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VITARA
AIR BAG SYSTEM 10B-61
DEPLOYED AIR BAG (INFLATOR) MODULES
WARNING:
The air bag (inflator) module immediately after deploy-
ment is very hot. Wait for at least 30 minutes to cool it off
before proceeding the work.
Do not apply water, oil, etc. to deployed air bag (inflator)
module.
After an air bag (inflator) module has been deployed, the
surface of the air bag may contain a powdery residue. This
powder consists primarily of cornstarch (used to lubri-
cate the bag as it inflates) and byproducts of the chemical
reaction. As with many service procedures, gloves and
safety glasses should be worn.
Wash your hands with mild soap and water after complet-
ing the work.
Refer to the procedure described under ªDeployed Air Bag (Inflator)
Modules Disposalº in this section.
ACTIVATED SEAT BELT PRETENSIONERS
WARNING:
The seat belt pretensioner immediately after activation is
very hot. Wait for at least 30 minutes to cool it off before
proceeding the work.
Do not apply water, oil, etc. to activated seat belt preten-
sioner.
With many service procedures, gloves and safety glasses
should be worn to prevent any possible irritation of the
skin or eyes.
Wash your hands with mild soap and water after complet-
ing the work.
Refer to the procedure described under ªActivated Seat Belt Pre-
tensioners Disposalº in this section.
Page 768 of 801
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VITARA
10B-62 AIR BAG SYSTEM
1. Air bag wire harness
2. Ground
3. SDM case ground
AIR BAG WIRE HARNESS AND CONNECTORS
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.
When installing it, be careful so that the air bag wire harness is not
caught or does not interfere with other parts.
Make sure all air bag system grounding points are clean and
grounds are securely fastened for optimum metal-to-metal con-
tact. Poor grounding can cause intermittent problems that are dif-
ficult to diagnose.
DISPOSAL
Do not dispose of the live (undeployed) air bag (inflator) modules
and the live (inactivated) seat belt pretensioners. When disposal is
necessary, be sure to deploy the air bag according to deployment
procedure described under ªAir Bag (Inflator) Modules Disposalº
and to activate the pretensioner according to activation procedure
described under ªSeat Belt Pretensioners Disposalº.
WARNING:
Failure to follow proper air bag (inflator) module and seat
belt pretensioner disposal procedures can result in air bag
deployment and pretensioner activation which could cause
personal injury. Undeployed air bag (inflator) module and
inactivated seat belt pretensioner must not be disposed of
through normal refuse channels.
The undeployed air bag (inflator) module and inactivated
seat belt pretensioner contain substances that can cause
severe illness or personal injury if the sealed container is
damaged during disposal.
Page 769 of 801
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AIR BAG SYSTEM 10B-63
REPAIRS AND INSPECTIONS REQUIRED AFTER AN ACCIDENT
CAUTION:
All air bag system components, including the electrical harness (component mounting points), must
be inspected after an accident. If any components are damaged or bent, they must be replaced even
if air bag system activation did not occur.
Never use air bag system parts from another vehicle.
Do not attempt to service the parts below. Service of these parts is by replacement only.
± Driver/Passenger air bag (inflator) module
± Driver/Passenger seat belt pretensioner
± SDM
± Contact coil and combination switch assembly
± Air bag wire harness
Proper operation of the sensors and air bag system requires that any repairs to the vehicle structure
return it to its original production configuration.
CAUTION:
After detecting one time of such collision as to meet deployment conditions, the SDM must not be used.
Refer to ªDiagnosisº when checking the SDM.
ACCIDENT WITH DEPLOYMENT ± COMPONENT
REPLACEMENT
Certain air bag system components must be replaced. Those com-
ponents are:
Driver and passenger air bag (inflator) modules
± Replace with new one.
Driver and passenger seat belt pretensioners
± Replace with new one as an assembly.
SDM after detecting such collision as to meet deployment condi-
tions
± Replace with new one.
Page 772 of 801
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2-2
2-1. Webbing
2-2. Retractor assembly
2-1. Seat belt pretensioner
2-2. Seat belt pretensioner harness
10B-66 AIR BAG SYSTEM
Seat belt pretensioner
± Check for dents, cracks, damage or fitness.
± Check harness and connector for damage or tightness.
If any faulty condition is found in above checks, replace.
Seat belts and mounting points
± Refer to SECTION 10A.
ªAIR BAGº warning lamp (air bag system)
± After vehicle is completely repaired, perform ªAir Bag Diagnos-
tic System Checkº under ªDiagnosisº in this section.
DRIVER AIR BAG (INFLATOR) MODULE
Refer to SECTION 3C1 for removal, inspection and installation.
CONTACT COIL AND COMBINATION SWITCH
ASSEMBLY
Refer to SECTION 3C1 for removal, inspection and installation.
SEAT BELT PRETENSIONER
Refer to SECTION 10A for removal, inspection and installation.
ªAIR BAGº WARNING LAMP
Refer to SECTION 8C for removal and installation of combination
meter.
Page 789 of 801
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VITARA
AIR BAG SYSTEM 10B-83
SEAT BELT PRETENSIONERS DISPOSAL
WARNING:
Failure to follow proper seat belt pretensioner (retractor assembly) disposal procedures can result in
pretensioner activation which may cause personal injury. Inactivated seat belt pretensioner must not
be disposed of through normal refuse channels.
The inactivated seat belt pretensioner contain substances that can cause severe illness or personal
injury if the sealed container is damaged during disposal.
Do not dispose of the live (inactivated) seat belt pretensioners.
The method employed depends upon the final disposition of the particular vehicle, as noted in ªActivation Outside
Vehicleº and ªActivation Inside Vehicleº in this section.
Activation Outside Vehicle disposing of the seat belt pretension(s) only (i.e., the vehicle itself will be used. . . . . . . .
again).
Activation Inside Vehicle scrapping the entire vehicle including the seat belt pretensioners.. . . . . . . . . .
ACTIVATION OUTSIDE VEHICLE
Use this procedure when the vehicle itself is used again (only the seat belt pretensioner(s) are disposed of).
WARNING:
Following precautions must be observed for this work. Failure to observe any of them may result in
personal injury.
To avoid an accidental activation, this work should be performed by no more than one person.
The procedure should be followed strictly as described here.
Be sure to read ªService Precautionsº in this section for the seat belt pretensioner beforehand.
Never connect deployment harness to any power source before connecting deployment harness to
the seat belt pretensioner. Deployment harness shall remain shorted and not be connected to a power
source until the pretensioner is to be activated.
The seat belt pretensioner will immediately activate the pretensioner when a power source is con-
nected to it. Wear safety glasses throughout this entire activation and disposal procedure.
Wear suitable ear protection when activating pretensioner. Also, advise those who are in the area
close to activation site to wear suitable ear protection.
Do not activate driver and passenger seat belt pretensioners at the same time.
The following procedure requires use of special tools (deployment harness). Do not attempt procedure without it.