2004 SUZUKI GRAND VITARA Water

YH4
GRAND
VITARA
When the welding or heating operation causes the
original galvanization or other anticorrosive materials
to be burnt, the interior and under-body panel sur-
faces must be cleaned.
Removal of residues of the burning should be carried
out carefully when the relevant place has boxtype
construction or has shape which limits the access to
the interior surfaces. In general, the following method
can be used satisfactorily for the removal of those res-
idues.Scrape the accessible places. If a standard putty knife
or scraper does not fit to the elevant place, consider
to use a more flexible scraper to a place narrowly en-
closed by sheet metals.
A jet of compressed air can remove most residues,
and is effective to limited areas.
However, this type of operation absolutely requires
eye protection.
BODY SERVICE 9-37
The metal service replacement parts (or assemblies)
are coated with electro-deposition primer.
For the proper adhesion of a paint, the following finish
process (refinish steps) becomes necessary.
1) Use wax or grease-removing solvent to clean the
part.
2) Use a wet or dry sand-paper (No. 400) to polish the
panel lightly. Do not polish it forcibly to produce any
scratch. Clean the part again.
3) If factory-applied primer coating is cut through to
the bare metal, apply metal conditioner to the bare
metal exposed to open air. As for method of use of
the metal conditioner, follow directions on the con-
tainer.
4) Apply primer-surfacer to the part completely dry
before starting sand-paper polishing. As for drying
time, follow directions advised on the primer-sur-
facer container.
5) Use a wet or dry sand-paper (No. 400) and water
to polish the panel lightly.
6) Wash the part again.
7) Apply color, coating to the part.
8) Different paints demand different drying methods.
Hence, follow directions advised on the pertinent
paint container.9) When lacquer coating (quick-drying paint coat-
ing) is applied, dry coated surface and polish it
with compound.
In the case of the melamine or acrylic coating,
compound polishing can be omitted after drying.
10) If the case of lacquer coating, wax should not be
applied to coated surface until the surface has
dried completely (for approx. two months).
Before replacing exterior parts or assemblies, check
paint conditions of all the covered or hidden interior
surfaces. If any rust scale is found at these places,
proceed as follows:
1) Use a proper wire brush, adhesive or liquid rust re-
moving agent to remove rust. As for the method of
use, follow directions advised for respecitve mate-
rials.
2) If necessary, wash parts with detergent, rinse, and
dry them.
3) Before installing exterior body parts, apply anticor-
rosive compound to all cleaner surfaces of exterior
body parts. Also, apply anticorrosive compound to
inner surfaces of exterior body parts to be
installed.
METAL REPLACEMENT PARTS FINISHING

YH4
GRAND
VITARA
10A-2 SEAT BELT
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
WARNING:
If replacing seat belt is necessary, replace buckle and ELR (or webbing) together as a set. This is for
the reason of ensuring locking of tongue plate with buckle. If these parts are replaced individually, such
a locking condition may become unreliable. For this reason, SUZUKI will supply only the spare buckle
and ELR (or webbing) in a set part.
Before servicing or replacing seat belts, refer to following precautionary items.

Seat belts should be normal relative to strap retractor and buckle portions.

Keep sharp edges and damaging objects away from belts. Avoid bending or damaging any portion of belt buckle,
latch plate and ELR.

Do not bleach or dye belt webbing. (Use only mild soap and lukewarm water to clean it.)

When installing a seat belt anchor bolt, start bolt by hand to prevent cross-threading.

Use only the correct seat belt anchor bolts and screws and tighten to the correct torque value.

Do not attempt any repairs on retractor mechanisms or retractor covers. Replace defective assemblies with new
replacement parts.

Keep belts dry and clean at all times.

If there exist any parts in question, replace such parts.

Replace belts whose webbing is cut or otherwise damaged.

Do not put anything into trim panel opening which seat belt webbing passes through.

YH4
GRAND
VITARA
1. Yellow connector of passenger air bag (inflator) module
2. Steering support member
3. Air bag harness
AIR BAG SYSTEM 10B-57
3) Connect Yellow connector of passenger air bag (inflator) mod-
ule, and be sure to lock connector with lock lever.
ii) Connect connector.
ii) Lock connector with lock lever.
4) Install glove box.
5) Install ªAIR BAGº fuse to ªAIR BAGº fuse box.
6) Turn ignition switch to ON and verify that ªAIR BAGº warning
lamp flashes 6 times and then turns off.
If it does not operate as described, perform ªAir Bag Diagnostic
System Checkº in this section.
HANDLING AND STORAGE
SDM
WARNING:
Never power up air bag system when SDM is not rigidly at-
tached to the vehicle. Otherwise, personal injury may result.
CAUTION:
After detecting one time of such collision as to meet deploy-
ment conditions, the SDM must not be used.
Refer to ªDiagnosisº when checking the SDM.

Never attempt disassembly of SDM.

When storing SDM, select a place where neither high tempera-
ture nor high humidity is anticipated and oil, water and dust are
kept off.

If SDM was dropped from a height of 90 cm (3 ft) or more or if it
is found to be damaged or deformed, replace it with a new one.

If installation part of SDM was damaged, repair that part com-
pletely before reinstallation.

All SDM and mounting bracket fasteners must be carefully
torqued and the arrow must be pointed toward the front of the ve-
hicle to ensure proper operation of the air bag system.

YH4
GRAND
VITARA
ALWAYS CARRY AIR BAG (INFLATOR) MODULE
WITH TRIM COVER (AIR BAG OPENING) AWAY
FROM BODY.
10B-58 AIR BAG SYSTEM
LIVE (UNDEPLOYED) AIR BAG (INFLATOR) MODULES
Special care is necessary when handling and storing a live (unde-
ployed) air bag (inflator) modules.
The rapid gas generation produced during deployment of the air
bag could cause the air bag (inflator) module, or an object in front
of the air bag (inflator) module, to be thrown through the air in the
unlikely event of an accidental deployment.
WARNING:
Never attempt to measure the resistance of the air bag (in-
flator) modules (driver and passenger). It is very dangerous
as the electric current from the tester may deploy the air
bag.

Never attempt disassembly of the air bag (inflator) modules.

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 (undeployed)
air bag (inflator) module, be sure to deploy it before discarding it.

When grease, cleaning agent, oil, water, etc., got on the air bag
(inflator) modules (driver and passenger), wipe it off immediately
with a dry cloth.

If air bag (inflator) module was dropped from a height of 90 cm (3
ft) or more, it should be replaced with a new one as an assembly.
WARNING:

For handling and storage of a live air bag (inflator) module,
select a place where the ambient temperature below 65
C
(150
F), without high humidity and away from electric
noise.

When carrying a live air bag (inflator) module, make sure
the bag opening is pointed away from you. In case of an
accidental deployment, the bag will then deploy with mini-
mal chance of injury. Never carry the air bag (inflator)
module by the wires or connector on the underside of the
module.
Otherwise, personal injury may result.

YH4
GRAND
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 65
C
(150
F), 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.

YH4
GRAND
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.

YH4
GRAND
VITARA
AIR BAG SYSTEM 10B-73
1. Driver air bag (inflator) module
2. Trim cover must face up
3. 185 cm (6 ft) of clearance
1. Trim cover must face up
2. 185 cm (6 ft) of clearance
3. Mounting attachment
4. Bag opening side
5. M8 bolt and nut
6. Hold-down bolt and nut
(B)
6) [In case of Driver Air Bag (Inflator) Module]
ii) Clear a space on the ground about 185 cm (6 ft) in diameter
where the driver air bag (inflator) module is to be deployed.
A paved, outdoor location where there is no activity is pre-
ferred. If an outdoor location is not available, a space on the
shop floor where there is no activity and sufficient ventilation
is recommended.
Ensure no loose or flammable objects are within the deploy-
ment area.
ii) Place the driver air bag (inflator) module, with its vinyl trim
cover facing up, on the ground in the space just cleared.
[In case of Passenger Air Bag (Inflator) Module]
iii) Clear a space on the ground about 185 cm (6 ft) in diameter
where the fixture (special tool) with attached air bag (inflator)
module is to be placed for deployment. A paved outdoor loca-
tion where there is no activity is preferred. If an outdoor loca-
tion is not available, a space on the shop floor where there is
no activity and sufficient ventilation is recommended. Ensure
that no loose or flammable objects are within the deployment
area.
iii) Place special tool (passenger air bag (inflator) module de-
ployment fixture) on the ground in the space cleared in step
i), if it has not already been placed there.
Special Tool
(B): 09932-75040
iii) Fill plastic reservoir in fixture (special tool) with water or sand.
This is necessary to provide sufficient stabilization of the fix-
ture during deployment.
iv) Securely attach the passenger air bag (inflator) module in the
fixture (special tool) using mounting attachment, hold-down
bolts and nuts and M8 bolts and nuts.
CAUTION:
Be sure to use the following bolt and nut for fixing pas-
senger air bag (inflator) module to mounting attach-
ment. Size: M8, Strength: 7T
Passenger air bag (inflator) module must be mounted so that
the bag will deploy upward. Securely tighten all fastener prior
to deployment.

YH4
GRAND
VITARA
AIR BAG SYSTEM 10B-75
1. Connect one banana plug to positive terminal of
power source (12V vehicle battery) and then the
other to negative terminal to immediately deploy.
2. Short to two deployment harness leads.
WARNING:

After deployment, the metal surfaces of the air bag (in-
flator) module will be very hot. Do not touch the metal
areas of the air bag (inflator) module for about 30 min-
utes after deployment.

Do not place the deployed air bag (inflator) module
near any flammable objects.

Do not apply water, oil, etc. to deployed air bag (infla-
tor) module.

If the deployed air bag (inflator) module must be
moved before it is cool, wear gloves and handle it by
using nonmetal material such as the air bag and vinyl
trim.
Failure to follow procedures may result in fire or per-
sonal injury.
13) Separate the two banana plugs on the deployment harness.
14) Connect the deployment harness to the power source (12V ve-
hicle battery) to immediately deploy the driver or passenger air
bag.
15) Disconnect the deployment harness from power source (12V
vehicle battery) and short the two deployment harness leads
together by fully seating one banana plug into the other.
16) In the unlikely event that the driver or passenger air bag (infla-
tor) module did not deploy after following these procedures,
proceed immediately with Steps 21) through 24). If the air bag
(inflator) module did deploy, proceed with Steps 17) through
20).