2004 SUZUKI GRAND VITARA Rear light

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-15
1. Battery
2. Main fuses
3. Ignition switch
4. Circuit fuses
5. ABS hydraulic unit / control module
5-1. Terminal arrangement for ABS hydraulic unit /
control module assembly
5-2. ABS fail-safe relay (Solenoid valve relay)
5-3. ABS pump motor relay
5-4. Pump motor
5-5. Solenoid valves
6. ªABSº warning lamp
7. Right-rear wheel speed sensor
8. Left-rear wheel speed sensor
9. Right-front wheel speed sensor
10. Left-front wheel speed sensor
11. Data link connector
12. Diagnosis connector
13. Stop lamp
14. Stop lamp switch
15. PCM (ECM+TCM) or ECM
16. G sensor (For 4WD model only)
17. 4WD switch (For 4WD model only)
18. 4WD indicator lamp (For 4WD model only)
19. 4WD controller (If equipped)
20. EBD warning lamp (Brake warning lamp)
21. Combination meter
22. Parking brake switch
23. Brake fluid lever switch
24. Warning lamp driver moduleWire colorB : Black
B / Bl : Black / Blue
B / O : Black / Orange
B / W : Black / White
Bl : Blue
Bl /B : Blue / Black
Bl / O : Blue / Orange
Br : Brown
G : Green
G / B : Green / Black
G / W : Green / White
Lg : Lightgreen
Lg / B : Lightgreen / Black
O / B : Orange / Black
O / G : Orange / Green
O / W : Orange / White
P : Pink
P / B : Pink / Black
V / G : Violet / Green
W / BI : White / Blue
W / G : White / Green
W / Y : White / Yellow
Y : Yellow
Y / B : Yellow / Black
SYSTEM CIRCUIT
TERMINALCIRCUIT
A1Right-rear wheel speed sensor (+)
A2Right-front wheel speed sensor (±)
A3Right-front wheel speed sensor (+)
A4G sensor ground (For 4WD model only)
A5ÐÐÐ
A6ÐÐÐ
A7Idle up signal
A8Diagnosis switch terminal
A9Stop lamp switch
A10Ground (For ABS control module)
A11ABS fail-safe relay
A12Right-rear wheel speed sensor (±)
A13Left-front wheel speed sensor (±)
A14G sensor signal (For 4WD model only)
A15ÐÐÐ
A16ÐÐÐ
A17ªABSº warning lamp
A18Left-rear wheel speed sensor (+)
A19Left-rear wheel speed sensor (±)
A20Left-front wheel speed sensor (+)
A21ÐÐÐ
A22Data link connector
A23ÐÐÐ
A244WD switch (For 4WD model only)
A25Ignition switch
A26ªEBDº warning lamp
A27ABS pump motor relay
A28Ground (For ABS pump motor)

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GRAND
VITARA
1. Match mark
1. Flange bolt
2. Front propeller shaft
1. Transmission jack
2. Engine rear mounting member
7A-10 MANUAL TRANSMISSION (TYPE 1)
ON LIFT
1) Drain oil from transmission and transfer.
2) Give match marks on joint flange and propeller shaft as shown
in figure. (front and rear)
3) Remove flange bolts of rear propeller shaft universal joint and
pull out propeller shaft.
4) Remove flange bolts of front propeller shaft universal joint and
pull out propeller shaft.
5) Remove clutch operating cylinder from transmission. It is not
necessary to disconnect clutch hose from operating cylinder.
NOTE:

It is not necessary to drain transmission oil when dis-
mounting transmission and transfer for clutch mainte-
nance only.

Work without draining transfer oil is possible if front pro-
peller shaft is dismounted together with transmission and
transfer.
6) Remove clutch housing lower plate.
7) Disconnect couplers from 4WD switch, back up light switch and
speed sensor assembly and release their harness from clamps.
Remove nuts from joint with engine.
8) Apply transmission jack and remove engine rear mounting
member taking off its bolts.
9) After removing mounting member, move rearward transmission
and transfer assemblies placed on jack and then lower them.

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GRAND
VITARA
7A-14 MANUAL TRANSMISSION (TYPE 1)
09951-16060
Oil seal installer
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN.mkg-mlb-ft
Oil filler / level and drain plugs232.317.0
Control lever boot cover bolts60.64.0
4WD switch202.014.5
Back up light switch (Type 1)202.014.5
Back up light switch (Type 2)454.532.5
Control lever locating bolts171.712.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts and nut505.036.5
Exhaust center pipe to manifold nuts505.036.5
Muffler to exhaust center pipe bolts505.036.5
Universal joint flange bolts505.036.5
Select return spring bolts232.317.0
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)
Shift control lever.

Select return springs, bolts and guides.
Thread lock cementTHREAD LOCK CEMENT
SUPER 1333B (99000-32020)
Shift control lever locating bolts.
SealantSUZUKI BOND No. 1215
(99000-31110)
Oil Drain and filler / level plugs.
SPECIAL TOOL

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VITARA
MANUAL TRANSMISSION (TYPE 2) 7A1-5
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN´mkg-mlb-ft
Transfer oil filler / level and drain plugs232.317.0
Transmission oil filler / level and drain plugs383.827.5
Control lever boot cover bolts60.64.0
4WD switch202.014.5
Back-up light switch454.532.5
Control lever locating bolts171.712.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts505.036.5
Muffler to exhaust No. 2 pipe nuts505.036.5
Universal joint flange bolts505.036.5
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)
Shift control lever
Thread lock cement
THREAD LOCK CEMENT
SUPER 1333B
(99000-32020)

Shift control lever locating bolts
SealantSUZUKI BOND No. 1215
(99000-31110)
Oil drain and filler / level plugs

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GRAND
VITARA
8B
LIGHTING SYSTEM 8B-1
SECTION 8B
LIGHTING 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).
CONTENTS
GENERAL DESCRIPTION8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions in Servicing8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols and Marks8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Color Symbols8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joint Connector8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Box and Relay8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Diagram8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight with Leveling System (If Equipped) 8B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS8B- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights8B- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights with Leveling System (If Equipped) 8B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal and Hazard Warning Lights 8B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance, Tail and License Plate Lights 8B- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back-up Lights8B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lights8B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Fog Light (If Equipped)8B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interior Lights8B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE8B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights8B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights with Leveling System (If Equipped) 8B- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal and Hazard Warning Lights 8B- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Fog Light (If Equipped)8B-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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GRAND
VITARA
LIGHTING SYSTEM 8B-5
CLEARANCE, TAIL AND LICENCE PLATE LIGHTS
TroublePossible causeCorrection
All lights do not light
ªTAILº fuse blown

Lighting switch faulty

Wiring or grounding faultyReplace fuse to check for short
Replace switch
Repair
Some lights do not light
up
Bulb(s) blown

Wiring or grounding faultyReplace bulb(s)
Repair
BACK-UP LIGHTS
TroublePossible causeCorrection
Back-up lights do not
light
ªTURN / BACKº fuse blown (Hard Top Model)
ªTRNº fuse blown (Canvas Top Model)

Bulb blown

 
  
 switch faulty

Wiring or grounding faultyReplace fuse to check for short
Replace bulb
Replace switch
Repair
Back-up lights remains
ON
Back-up light switch or shift switch faulty

Wiring or grounding faultyReplace switch
Repair
BRAKE LIGHTS
TroublePossible causeCorrection
Brake lights do not light
up
ªSTOP / HORNº fuse blown (Hard Top
Model)
ªSTPº fuse blown (Canvas Top Model)

Bulb(s) blown

Brake light switch faulty

Wiring or grounding faultyReplace fuse to check for short
Replace bulb(s)
Adjust or replace switch
Repair
Brake lights stay on
Brake light switch faultyAdjust or replace switch
Only one light does not
light
Bulb blown

Wiring or grounding faultyReplace bulb
Repair
REAR FOG LIGHT (IF EQUIPPED)
TroublePossible causeCorrection
Rear fog light does not
come on
ªFOGº fuse blown

Rear fog light switch faulty

Lighting switch faulty

Wiring or grounding faulty

Bulb blownReplace fuse to check for short
Replace fog light switch
Replace switch
Repair
Replace bulb
INTERIOR LIGHTS
TroublePossible causeCorrection
Interior light (s) does (do)
not light up
Bulb(s) blown

ªDOMEº fuse blown (Hard Top Model)
ªDOMº fuse blown (Canvas Top Model)

Wiring or grounding faulty

Door switch faulty

Interior light switch faultyReplace bulb(s)
Replace fuse to check for short
Repair
Replace switch
Replace light assy
Front spot lights do not
light up
Bulb(s) blown

Wiring or grounding faulty

Spot light switch faultyReplace bulb(s)
Repair
Replace light assy

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GRAND
VITARA
LIGHTING SYSTEM 8B-11
REAR FOG LIGHT (IF EQUIPPED)
REAR FOG LIGHT SWITCH
INSPECTION
Check for continuity between terminals at each switch position
shown below. Hold the switch button (ON or OFF) pushed in during
checking switch.
NOTE:
Rear fog light lights up only when headlights (low or high
beams) or front fog lights (if equipped) are ON.
Rear fog lights turns OFF automatically when headlights or
front lights are turned OFF.

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GRAND
VITARA
INSTRUMENTATION / DRIVER INFORMATION 8C-9
1. Exhaust pipe
FUEL METER / FUEL GAUGE UNIT
FUEL METER
INSPECTION
1) Remove rear bumper facing.
2) Detach grommet (3) from vehicle.
3) Disconnect coupler (2) of fuel pump and gauge.
4) Turning switch ON, and check that fuel meter indicates E.
5) Turn ignition switch OFF.
6) Ground Bl / W lead through a 3.4 W test bulb (4) as illustrated.
7) Turn ignition switch ON and check that bulb light up and pointer
(5) moves to F side.
8) If fuel meter shows no operation, repair or replace defective
parts.
FUEL SENDER GAUGE
INSPECTION
1) Remove fuel pump assembly (1) referring to FUEL PUMP RE-
MOVAL in Section 6C.
2) Check resistance between terminals (A) and (B) under each
float position.
Float Position
FuelResistance (
)56
model66
modelMeterResistance (
)
ªaº88.3 mm
(3.48 in.)51.7 mm
(2.04 in.)F6 ± 8
ªbº157.2 mm
(6.20 in.)139.6 mm
(5.50 in.)1/229.5 ± 35.5
ªcº254.9 mm
(10.0 in.)254.9 mm
(10.0 in.)E94 ± 96
If measured valve is out of specification, replace fuel sender gauge.