2005 SUZUKI GRAND VITARA Service Workshop Manual

YH4
GRAND
VITARA
SEAT BELT 10A-5
(a)
(a)(a)
(a)
(b)
1. Upper anchor
2. Lower anchor
3. Retractor assembly
4. Buckle
INSTALLATION
Install in reverse order of removal, noting the following.

Seat belt anchor bolts should have an unified fine thread (7 / 16-20 UNF). Under no circumstances should any
different sized or metric screw threads be used.

Be sure to tighten seat belt anchor bolts to specified torque.
Tightening torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)
(b): 5.5 N
.m (0.55 kg-m, 4.0 lb-ft)

YH4
GRAND
VITARA
10A-6 SEAT BELT
1. Upper anchor
2. Lower anchor
3. Retractor assembly
4. Buckle: If equipped* *
REAR SEAT BELT
WARNING:
Be sure to read ªService Precautionsº before starting to work and observe every precaution during
work.
REMOVAL
Refer to the figure below to remove rear seat belts.
INSPECTION
Check the rear seat belt in the same way as when inspecting front seat belt. (Refer to page 10A-4.)
INSTALLATION
Install the rear seat belt observing the same precautions as when installing front seat belt. (Refer to page 10A-5.)
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Upper and lower anchor bolt353.525.5
Retractor assembly bolt353.525.5
Retractor assembly screw5.50.554.0
Buckle bolt353.525.5

YH4
GRAND
VITARA
10B
AIR BAG SYSTEM 10B-1
GENERAL DESCRIPTION10B- 3 . . . . . . . . . . . . .
System Components and Wiring
Location View and Connectors 10B- 4. . . . . . .
System Wiring Diagram 10B- 5. . . . . . . . . . . . . .
DIAGNOSIS10B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Codes 10B- 6. . . . . . . . . . . .
Use of Special Tools 10B- 6. . . . . . . . . . . . . . . . .
Intermittent and Poor Connections 10B- 8. . . . .
Air Bag Diagnostic System Check 10B-10. . . . .
Air bag diagnostic system check
flow table 10B-11. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic trouble code (DTC) check 10B-12.
Diagnostic trouble code (DTC)
clearance 10B-13. . . . . . . . . . . . . . . . . . . . . . .
Diagnostic trouble code table 10B-14. . . . . . . .
Table A - ªAIR BAGº warning lamp
comes ªONº steady 10B-16. . . . . . . . . . . . . . .
Table B - ªAIR BAGº warning lamp
does not come ªONº 10B-18. . . . . . . . . . . . . .
Table C - ªAIR BAGº warning lamp
flashes 10B-20. . . . . . . . . . . . . . . . . . . . . . . . . .
Table D - SDM cannot communicate
through the serial data circuit 10B-22. . . . . . . Code 15 - Passenger air bag initiator
circuit resistance high 10B-24. . . . . . . . . . . . .
Code 16 - Passenger air bag initiator
circuit resistance low 10B-26. . . . . . . . . . . . . .
Code 18 - Passenger air bag initiator
circuit short to ground 10B-28. . . . . . . . . . . . .
Code 19 - Passenger air bag initiator
circuit short to power circuit 10B-30. . . . . . . .
Code 21 - Driver air bag initiator
circuit resistance high 10B-32. . . . . . . . . . . . .
Code 22 - Driver air bag initiator
circuit resistance low 10B-34. . . . . . . . . . . . . .
Code 24 - Driver air bag initiator
circuit short to ground 10B-36. . . . . . . . . . . . .
Code 25 - Driver air bag initiator
circuit short to power circuit 10B-38. . . . . . . .
Code 31 - Power source voltage high 10B-40
Code 32 - Power source voltage low 10B-42.
Code 41 - Driver pretensioner initiator
circuit resistance high 10B-44. . . . . . . . . . . . .
Code 45 - Passenger pretensioner
initiator circuit resistance high 10B-44. . . . . .
Code 42 - Driver pretensioner initiator
circuit resistance low 10B-46. . . . . . . . . . . . . .
SECTION 10B
AIR BAG SYSTEM
WARNING:

Service on or 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 this section before performing service on or around the air bag system components or
wiring. Failure to follow WARNINGS could result in unintended activation of the system or could ren-
der 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 condi-
tions are not followed, parts or system damage could result.
CONTENTS

YH4
GRAND
VITARA
10B-2 AIR BAG SYSTEM
Code 46 - Passenger pretensioner
initiator circuit resistance low 10B-46. . . . . . .
Code 43 - Driver pretensioner initiator
circuit short to ground 10B-48. . . . . . . . . . . . .
Code 47 - Passenger pretensioner
initiator circuit short to ground 10B-48. . . . . .
Code 44 - Driver pretensioner initiator
circuit short to power circuit 10B-50. . . . . . . .
Code 48 - Passenger pretensioner
initiator circuit short to power circuit 10B-50.
Code 51 - Frontal crash detected
(System activation command is
outputted) 10B-52. . . . . . . . . . . . . . . . . . . . . . .
Code 61 -ªAIR BAGº warning lamp
circuit failure 10B-53. . . . . . . . . . . . . . . . . . . . .
Code 71 - Internal SDM fault 10B-54. . . . . . . .
ON-VEHICLE SERVICE10B-55 . . . . . . . . . . . . . . .
Service Precautions 10B-55. . . . . . . . . . . . . . . . .
Service and diagnosis 10B-55. . . . . . . . . . . . . .
Disabling air bag system 10B-56. . . . . . . . . . . .
Enabling air bag system 10B-56. . . . . . . . . . . .
Handling and storage 10B-57. . . . . . . . . . . . . .
Disposal 10B-62. . . . . . . . . . . . . . . . . . . . . . . . . .
Repairs and Inspections Required
after an Accident 10B-63. . . . . . . . . . . . . . . . . . .
Accident with deployment
- component replacement 10B-63. . . . . . . . . . Accident with or without deployment
- component inspections 10B-64. . . . . . . . . . .
Driver Air Bag (Inflator) Module 10B-66. . . . . . . .
Contact Coil and Combination Switch
Assembly 10B-66. . . . . . . . . . . . . . . . . . . . . . . . .
Seat Belt Pretensioner 10B-66. . . . . . . . . . . . . . .
ªAIR BAGº Warning Lamp 10B-66. . . . . . . . . . . .
SDM 10B-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Passenger Air Bag (Inflator) Module 10B-69. . .
AIR BAG (INFLATOR) MODULES
DISPOSAL10B-71 . . . . . . . . . . . . . . . . . . . . . . . . . .
Deployment Outside Vehicle 10B-71. . . . . . . . . .
Deployment Inside Vehicle 10B-78. . . . . . . . . . . .
SEAT BELT PRETENSIONERS
DISPOSAL10B-83 . . . . . . . . . . . . . . . . . . . . . . . . . .
Activation Outside Vehicle 10B-83. . . . . . . . . . . .
Activation Inside Vehicle 10B-89. . . . . . . . . . . . . .
DEPLOYED AIR BAG (INFLATOR)
MODULES DISPOSAL10B-93 . . . . . . . . . . . . .
ACTIVATED SEAT BELT PRETENSIONERS
DISPOSAL10B-94 . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS10B-95 . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS10B-95 . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
12
3
3
1. Driver side air bag
2. Passenger side air bag
3. Seat belt pretensioner
(if equipped)
1-1. SDM
1-1. Sensor
1-2. Voltage converter1-3. Safing sensor
1-4. Micro-controller
1-5. Energy reserve circuit1-6. Ignition driver circuit
1-2. Power source
3. Driver air bag 4. Passenger air bag
5. Seat belt pretensioner (if equipped)
6. Squib circuit
AIR BAG SYSTEM 10B-3
GENERAL DESCRIPTION
With the air bag system which includes air bags for both the driver's
and passenger's sides as well as the seat belt pretensioners (if
equipped), the sag of the seat belt is taken up, the driver air bag (in-
flator) module is deployed from the center of the steering column
and the passenger air bag (inflator) module from the top of the
instrument panel in front of the front passenger seat in occurrence
of a front collision with an impact larger than a certain set value to
supplement protection offered by the driver and front passenger
seat belts.
The air bag system is designed to activate only in severe frontal col-
lisions. It is not designed to activate in rear impacts, side impacts,
rollovers, or minor frontal collisions, since it would offer no protec-
tion in those types of accidents.

YH4
GRAND
VITARA
10B-4 AIR BAG SYSTEM
1. Air bag harness
2. ªAIR BAGº fuse box
3. ªAIR BAGº monitor coupler
4. DLC
5. Contact coil assembly
6. Driver air bag (inflator) module
7. Passenger air bag (inflator) module
8. SDM
9. Seat belt pretensioner
(retractor assembly) (if equipped)
10. Pretensioner harness (if equipped)
11. Ground for air bag systemCONNECTOR ªAº
CONNECTOR ªCº, ªDº
CONNECTOR ªBº
CONNECTOR ªEº
CONNECTOR ªHº
CONNECTOR ªFº
CONNECTOR ªGº
SYSTEM COMPONENTS AND WIRING LOCATION VIEW AND CONNECTORS

YH4
GRAND
VITARA
WIRE HARNESS COLOR
B : Black
B/W : Black/White
Bl : Blue
Bl/B : Blue/Black
Bl/R : Blue/Red
Br : BrownG : Green
Gr : Gray
G/R : Green/Red
Lg : Lightgreen
P : Pink
V : VioletY : Yellow
Y / G : Yellow/Green
Y/R : Yellow/Red
W : White
W/B : White/Black
1. From main fuse
2. Ignition switch
3. ªIG
.COIL METERº fuse in J/B
4. ªAIR BAGº warning lamp in combination meter
5. ªAIR BAGº fuse in ªAIR BAGº fuse box
6. Connection detection pin
7. To ECM (or PCM), ICM (if equipped) and ABS
controller (if equipped)
8. To data link connector (DLC)
9. ªAIR BAGº monitor coupler
10. SDM
11. Contact coil assembly
12. Driver air bag (inflator) module
13. Driver seat belt pretensioner (if equipped)
14. Passenger air bag (inflator) module
15. Passenger seat belt pretensioner (if equipped)
16. Pretensioner harness (if equipped)
17. Ground for air bag system
TERMINAL
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A13 A11
A12
A14
A15
A16
Passenger air bag (inflator) moduleLow
High
CIRCUIT
Data link connector (DLC)
Low
High
Low
High
Low
High ªAIR BAGº warning lamp
Driver air bag (inflator) module
Diagnosis switch
±±±±±±±±±
Ground
Passenger pretensioner
Driver pretensioner
Ignition switch (power source)±±±±±±±±±
±±±±±±±±±
CONNECTOR ªAº (SDM connector) TERMINAL ARRANGEMENT OF SDM
(VIEWED FROM HARNESS SIDE)
L1
L2Connection detection pin
: Shorting bar
: Air bag harness
ªAº
ªHº : Connector
AIR BAG SYSTEM 10B-5
SYSTEM WIRING DIAGRAM

YH4
GRAND
VITARA
(A)(A)
(A)
10B-6 AIR BAG SYSTEM
DIAGNOSIS
WARNING:
To avoid deployment when troubleshooting the air bag system, do not use electrical test equipment
such as a battery powered or AC powered voltmeter, ohmmeter, etc., or any type of electrical equipment
other than that specified in this manual. Do not use a non-powered probe type tester.
Instructions in this manual must be followed carefully, otherwise personal injury may result.
DIAGNOSTIC TROUBLE CODES
The ªAir Bag Diagnostic System Checkº must always be the starting point of any air bag system diagnosis. The
ªAir Bag Diagnostic System Checkº checks for proper ªAIR BAGº warning lamp operation and checks for air bag
diagnostic trouble codes using the Tech-1 (scan tool) or on-board diagnosis function.

Current diagnostic trouble code ± Malfunction that are presently being detected.

History diagnostic trouble code ± All malfunction detected since the last time the history memory was cleared.
USE OF SPECIAL TOOLS
WARNING:
To avoid deployment when troubleshooting the air bag system, do not use electrical test equipment
such as a battery powered or AC powered voltmeter, ohmmeter, etc., or any type of electrical equipment
other than that specified in this manual. Do not use a non-powered probe type tester.
Instructions in this manual must be followed carefully, otherwise personal injury may result.
You should be familiar with the tools listed under ªSpecial Toolsº in this section. You should be able to measure
voltage and resistance. You should be familiar with proper use of a scan tool such as the Tech-1 Diagnostic Com-
puter, Driver/Passenger Load Tool, Connector Test Adapter Kit and the Digital Multimeter.
Special Tool (Connector Test Adapter Kit)
(A): 09932-76010
This must be used whenever a diagnostic procedure requests
checking or probing a terminal.
Using the appropriate adapter in the special tool will ensure that no
damage to the terminal will occur from the multimeter probe, such
as spreading or bending.
The adapter will also give an idea of whether contact tension is suffi-
cient, helping to find an open or intermittent open due to poor termi-
nal contact.