2005 SUZUKI GRAND VITARA Service Workshop Manual

YH4
GRAND
VITARA
1. To door switch (driver side) B / Bl
2. To transmission range switch G / Bl
(A / T vehicle only, if equipped) L
3. To transmission range switch G / O
(A / T vehicle only, if equipped) 2
4. To transmission range switch Y / G
(A / T vehicle only, if equipped) D
5. To transmission range switch O / Bl
(A / T vehicle only, if equipped) N
6. To transmission range switch O / G
(A / T vehicle only, if equipped) P
7. To transmission range switch R
(A / T vehicle only, if equipped) R
8. To ground B
9. To PCM (A / T vehicle only) W / B
10. To ECT sensor Y / W
11. To fuel level gauge Bl / W
12. To ground B / Y
13. To combination switch G / Y
NOTE:
Terminal arrangement of coupler viewed from harness side.
Coupler A Coupler B Coupler C
Coupler A Coupler B Coupler C
1. Blank ÐÐ
2. Blank ÐÐ
3. To ignition switch B / W
4. Blank ÐÐ
5. To ABS control module Bl / O
(if equipped)
6. To PCM (A / T vehicle only) Gr / Bl
7. To ABS control module Br
(if equipped)
8. To VSS Bl / Y
9. To combination switch G / R
10. To SDM (if equipped) Y / G or Bl
11. To main fuse W / Bl
12. To fuse box W
13. To combination switch R
14. To ECM (PCM for A / T vehicle) V
(if equipped)
15. To ECM (PCM for A / T vehicle) V / Y
16. To ECM (PCM for A / T vehicle) O / B
(if equipped)1. To ground B
2. To ECM (PCM for A / T vehicle) Br
3. To ignition switch (if equipped) V / R
4. To brake fluid level switch R / B
5. To parking brake switch V
6. To seat belt switch (if equipped) Gr / R
7. To generator W / R
8. To oil pressure switch Y / B
9. To combination switch R / Y
10. To ignition switch (if equipped) Bl / R or CHECK
or ENGINE
or ABSif equipped
if equippedif equipped
INSTRUMENTATION / DRIVER INFORMATION 8C-3

YH4
GRAND
VITARA
8C-4 INSTRUMENTATION / DRIVER INFORMATION
DIAGNOSIS
NOTE:
Fuse name (ª º) in the table below is shown on the fuse box cover (Hard Top Model) or the junction box
(Canvas Top Model).
SPEEDOMETER AND VSS
TroublePossible CauseCorrection
Speedometer shows no
operation
ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)

VSS faulty

Printed plate in combination meter
faulty

Speedometer faulty

Wiring or grounding faultyReplace fuse to check for short
Replace VSS
Replace printed plate
Replace speedometer
Repair
FUEL METER / FUEL GAUGE UNIT
TroublePossible CauseCorrection
Fuel meter shows no
operation
ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)

Fuel gauge unit faulty

Printed plate in combination meter
faulty

Fuel meter faulty

Wiring or grounding faultyReplace fuse to check for short
Replace fuel gauge unit
Replace printed plate
Replace fuel meter
Repair
ENGINE COOLANT TEMP. (ECT) METER AND SENSOR
TroublePossible CauseCorrection
Engine coolant temp.
meter shows no operation
ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)

ECT meter faulty

Printed plate in combination meter
faulty

ECT sensor faulty

Wiring or grounding faultyReplace fuse to check for short
Replace ECT meter
Replace printed plate
Replace ECT sensor
Repair
OIL PRESSURE LIGHT
TroublePossible CauseCorrection
Oil pressure warning light
does not light up
Bulb in combination meter blown

ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)

Printed plate in combination meter
faulty

Oil pressure switch faulty

Wiring or grounding faultyReplace bulb
Replace fuse to check for short
Replace printed plate
Replace oil pressure switch
Repair

YH4
GRAND
VITARA
INSTRUMENTATION / DRIVER INFORMATION 8C-5
BRAKE AND PARKING BRAKE WARNING LIGHT
TroublePossible CauseCorrection
Brake warning light does
not light up
Bulb in combination meter blown

ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)

Printed plate in combination meter
faulty

Parking brake switch faulty

Brake fluid level switch faulty

Wiring or grounding faultyReplace bulb
Replace fuse to check for short
Replace printed plate
Replace parking brake switch
Replace brake fluid level switch
Repair
LIGHT REMAINDER WARNING BUZZER
TroublePossible CauseCorrection
Light remainder warning
buzzer shows no
sounding
ªTAILº fuse blown

Buzzer faulty

Wiring or grounding faulty

Driver side door switch faultyReplace fuse to check for short
Replace buzzer
Repair
Replace door switch
SEAT BELT WARNING LIGHT (IF EQUIPPED)
TroublePossible CauseCorrection
Seat belt warning light
does not light up
Bulb in combination meter blown

ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)

Seat belt switch faulty

Wiring or grounding faultyReplace bulb
Replace fuse to check for short
Replace seat belt switch
Repair
IGNITION KEY REMAINDER WARNING BUZZER (IF EQUIPPED)
TroublePossible CauseCorrection
Ignition key remainder
warning buzzer shows no
sounding
ªDOMEº fuse blown (Hard Top Model)
ªDOMº fuse blown (Canvas Top
Model)

Buzzer faulty

Wiring or grounding faulty

Driver side door switch faulty

Ignition key switch faultyReplace fuse to check for short
Replace buzzer
Repair
Replace door switch
Replace ignition key switch
CIGARETTE LIGHTER AND ACCESSORY SOCKET
TroublePossible CauseCorrection
Cigarette lighter /
accessory socket shows
no operation
ªCIGARº fuse blown (Hard Top Model)
ªCIGº fuse blown (Canvas Top Model)

Ignition switch faulty

Cigarette lighter / accessory socket
faulty

Wiring or grounding faultyReplace fuse to check for short
Replace ignition switch
Replace cigarette lighter / accessory
socket
Repair

YH4
GRAND
VITARA
8C-6 INSTRUMENTATION / DRIVER INFORMATION
KeyPosition
TerminalWire
color
Hard Top Model
Canvas Top Model
ON-VEHICLE SERVICE
IGNITION (MAIN) SWITCH
INSPECTION
1) Disconnect negative cable at battery.
2) Disable air bag system. Refer to DISABLING AIR BAG SYSTEM
in Section 10B of this manual.
3) Disconnect main switch lead wire coupler.
4) Check for continuity between terminals at each switch position
shown below. If check result is not as specified, replace ignition
(main) switch.
+B+ACCIG1-1IG1-2IG2STL1L2K1K2
W/YBlB/WB/WY/BB/YBBGG
OUTLOCKLOCK
ACC
IN
ON
START
REMOVAL
1) Disconnect negative cable at battery.
2) Disable air bag system. Refer to DISABLING AIR BAG SYSTEM
in Section 10B of this manual.
3) Remove steering column referring to Section 3C1 of this manu-
al. Then remove steering lock / ignition (main) switch from steer-
ing column.
INSTALLATION
1) Install steering lock / ignition (main) switch to steering column.
Install steering column assembly referring to Section 3C1 of this
manual.
2) Enable air bag system. Refer to ENABLING AIR BAG SYSTEM
in Section 10B of this manual.
NOTE:
When installing steering column, special care must be tak-
en for tightening sequence and its torque.

YH4
GRAND
VITARA
INSTRUMENTATION / DRIVER INFORMATION 8C-7
1. Steering column hole cover
COMBINATION METER
REMOVAL
1) Disconnect negative cable at battery.
2) If the vehicle is equipped with air bag system, disable air bag
system. Refer to DISABLING AIR BAG SYSTEM in Section
10B of this manual.
3) Remove column hole cover.
4) Remove instrument cluster panel.
5) Remove screws fastening combination meter.
6) Disconnect couplers from combination meter.
7) Remove combination meter from instrument panel.
INSTALLATION
Reverse removal procedure for installation, noting the following.

If the vehicle is equipped with air bag system, be sure to enable
air bag system after installation. Refer to ENABLING AIR BAG
SYSTEM in Section 10B of this manual for details.

YH4
GRAND
VITARA
8C-8 INSTRUMENTATION / DRIVER INFORMATION
SPEEDOMETER AND VSS
VEHICLE SPEED SENSOR (VSS)
REMOVAL
1) Hoist vehicle.
2) Disconnect coupler from VSS (1).
3) Remove VSS.
INSTALLATION
Reverse removal procedure for installation.
Tightening Torque
(a): 5.5 N
.m (0.55 kg-m, 4.0 lb-ft)

YH4
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.

YH4
GRAND
VITARA
8C-10 INSTRUMENTATION / DRIVER INFORMATION
G16
J20
H25
1. ECT sensor
1
ENGINE COOLANT TEMP. (ECT) METER AND
SENSOR
ENGINE COOLANT TEMPERATURE (ECT) METER
INSPECTION
1) Disconnect Y/W lead wire going to ECT sensor.
2) Turn ignition switch ON, and check that ECT meter indicates
COOL.
3) Turn ignition switch OFF.
4) Ground Y/W lead wire through a 3.4 W test bulb (1) as illustrated.
5) Turn ignition switch ON, and check that bulb light up and pointer
(2) moves to hot side.
6) If ECT meter shows no operation, repair or replace defective
parts.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
REMOVAL AND INSTALLATION
Refer to ECT SENSOR in ON-VEHICLE SERVICE in Section 6E1
(for G16 and J20) or Section 6E2 (for H25) of this manual for details.