2005 SUZUKI GRAND VITARA Service Workshop Manual

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GRAND
VITARA
AIR BAG SYSTEM 10B-71
AIR BAG (INFLATOR) MODULES DISPOSAL
WARNING:
Failure to follow proper air bag (inflator) module disposal procedures can result in air bag deployment
which may cause personal injury. Undeployed air bag (inflator) module must not be disposed of
through normal refuse channels.
The undeployed air bag (inflator) module contain substances that can cause severe illness or personal
injury if the sealed container is damaged during disposal.
Do not dispose of the live (undeployed) air bag (inflator) modules.
The method employed depends upon the final disposition of the particular vehicle, as noted in ªDeployment Out-
side Vehicleº and ªDeployment Inside Vehicleº in this section.
Deployment Outside Vehicle disposing of the air bag (inflator) module(s) only (i.e., the vehicle itself will be. . . . . .
used again).
Deployment Inside Vehicle scrapping the entire vehicle including the air bag (inflator) module(s).. . . . . . . .
DEPLOYMENT OUTSIDE VEHICLE
Use this procedure when the vehicle itself is used again (only the air bag (inflator) module(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 deployment, 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 air bag (inflater) module beforehand.

Never connect deployment harness to any power source before connecting deployment harness to
the air bag (inflator) module. Deployment harness shall remain shorted and not be connected to a
power source until the air bag is to be deployed.

Since a large amount of smoke is produced when air bag is deployed, select a well-ventilated area.

The air bag (inflator) module will immediately deploy the air bag when a power source is connected
to it. Wear safety glasses throughout this entire deployment and disposal procedure.

Wear suitable ear protection when deploying air bag. Also, advise those who are in the area close to
deployment site to wear suitable ear protection.

Do not deploy driver and passenger air bag (inflator) modules at the same time.
The following procedure requires use of special tool(s) (deployment harness and passenger air bag (inflator) mod-
ule deployment fixture). Do not attempt procedure without it (them).

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GRAND
VITARA
1. Shorted
1. Slit on workbench
2. Workbench vise
3. Lower mounting bracket
ALWAYS CARRY AIR BAG (INFLATOR) MODULE
WITH TRIM COVER (AIR BAG OPENING) AWAY
FROM BODY.
ALWAYS PLACE AIR BAG (INFLATOR) MODULE
ON WORKBENCH WITH TRIM COVER (AIR BAG
OPENING) UP, AWAY FROM LOOSE OBJECTS.
10B-72 AIR BAG SYSTEM
1) Turn ignition switch to ªLOCKº, remove key and put on safety
glasses.
2) Check that there is no open, short or damage in special tool (de-
ployment harness). If any faulty is found, do not use it and be
sure to use new deployment harness.
Special Tool
(A): 09932-75030
3) Short the two deployment harness leads together by fully seat-
ing one banana plug into the other.
WARNING:
Deployment harness shall remain shorted and not be
connected to a power source until the air bag is to be
deployed.
Special Tool
(A): 09932-75030
4) Remove driver or passenger air bag (inflator) module from ve-
hicle, referring to SECTION 3C1 or 10B.
WARNING:

Always carry live air bag (inflator) module with trim cov-
er away from you.

When storing a live air bag (inflator) module or when
leaving a live air bag (inflator) module unattended on a
bench or other surface, always face the bag and trim
cover up and away from the surface. As the live passen-
ger 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.
This is necessary so that a free space is provided to al-
low the air bag to expand in the unlikely event of acci-
dental deployment.
Failure to follow procedures may result in personal inju-
ry.
5) Temporarily place driver or passenger air bag (inflator) module
on the workbench or the vise according to above WARNING.

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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.

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VITARA
4
31
2
2
4
31
For driver air bag (inflator) module
For passenger air bag (inflator) module
1. Stretch deployment harness to full length 10 m (33 ft).
2. Connect connectors.
3. Power source (12V vehicle battery).
4. Short the two deployment harness leads.
10B-74 AIR BAG SYSTEM
7) Stretch the deployment harness from the driver or passenger
air bag (inflator) module to its full length 10 m (33 ft).
8) Place a power source near the shorted end of the deployment
harness. Recommended application: 12 Volts minimum, 2
amps minimum. A vehicle battery is suggested.
9) Verify that the area around the driver or passenger air bag (in-
flator) module is clear of all people and loose or flammable ob-
jects.
10) [In case of Driver Air Bag (Inflater) Module]
Verify that the driver air bag (inflator) module is resting with its
vinyl trim cover facing up.
[In case of Passenger Air Bag (Inflator) Module]
Verify that the passenger air bag (inflator) module is firmly and
properly secured in passenger air bag (inflator) module deploy-
ment fixture (special tool).
11) Connect the driver or passenger air bag (inflator) module to the
deployment harness connector and lock connector with lock le-
ver.
12) Notify all people in the immediate area that you intend to deploy
the air bag (inflator) module.
NOTE:

When the air bag deploys, the rapid gas expansion will
create a substantial report. Wear suitable ear protection.
Notify all people in the immediate area that you intend to
deploy the air bag (inflator) module and suitable ear
protection should be worn.

When the air bag deploys, the driver air bag (inflator)
module may jump about 30 cm (1 ft) vertically. This is a
normal reaction of the driver air bag (inflator) module to
the force of the rapid gas expansion inside the air bag.

After the 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 lu-
bricate the bag as it inflates) and byproducts of the
chemical reaction.

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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).

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GRAND
VITARA
1
2
1. Deployed driver air bag (inflator) module
2. Gloves
For driver air bag (inflator) module
10B-76 AIR BAG SYSTEM
17) Put on a pair of shop gloves to protect your hands from possible
irritation and heat when handling the deployed air bag (inflator)
module.
NOTE:
As a precaution, gloves and safety glasses are recom-
mended to prevent any possible irritation of the skin or
eyes.
18) Disconnect the deployment harness from the air bag (inflator)
module as soon after deployment as possible. This will prevent
damage to the deployment harness due to possible contact
with the hot air bag (inflator) module canister. The deployment
harness are designed to be reused. They should, however, be
inspected for damage after each deployment and replaced if
necessary.
19) Dispose of the deployed air bag (inflator) module through nor-
mal refuse channels after it has cooled for at least 30 minutes
and tightly seal the air bag (inflator) module in a strong vinyl
bag. (Refer to ªDeployed Air Bag (Inflator) Modules Disposalº
in detail.)
20) Wash your hands with mild soap and water afterward.
NOTE:
The remaining steps are to be followed in the unlikely event
that the air bag (inflator) module did not deploy after following
these procedures.
21) Ensure that the deployment harness has been disconnected
from the power source and that its two banana plugs have been
shorted together by fully seating one banana plug into the oth-
er.
22) Disconnect the deployment harness from the air bag (inflator)
module.

YH4
GRAND
VITARA
AIR BAG SYSTEM 10B-77
1. Slit on workbench
2. Workbench vise
3. Lower mounting bracket
ALWAYS CARRY AIR BAG (INFLATOR) MODULE
WITH TRIM COVER (AIR BAG OPENING) AWAY
FROM BODY.
ALWAYS PLACE AIR BAG (INFLATOR) MODULE
ON WORKBENCH WITH TRIM COVER (AIR BAG
OPENING) UP, AWAY FROM LOOSE OBJECTS.WARNING:

Always carry a live air bag (inflator) module with trim
cover away from you.

When storing a live air bag (inflator) module or when
leaving a live air bag (inflator) module unattended on
a bench or other surface, always face the bag and trim
cover up and away from the surface. As the live pas-
senger air bag (inflator) module must be placed with
its bag (trim cover) facing up, place it or the work-
bench with a slit or use the workbench vise to hold it
securely at its lower mounting bracket.

This is necessary so that a free space is provided to
allow the air bag to expand in the unlikely event of ac-
cidental deployment.
Failure to follow procedures may result in personal inju-
ry.
23) Temporarily store the air bag (inflator) module with its vinyl trim
cover facing up, away from the surface upon which it rests. Re-
fer to ªService Precautionsº in this section for details.
24) Contact your local distributor for further assistance.

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GRAND
VITARA
10B-78 AIR BAG SYSTEM
DEPLOYMENT INSIDE VEHICLE
Use this procedure when scrapping the entire vehicle including the driver and passenger air bag (inflator) modules.
CAUTION:
When vehicle itself will be used again, deploy the air bag outside vehicle according to ªDeployment
Outside Vehicleº, for deploying it inside will cause the instrument panel, glove box and their vicinity
to be deformed.
Failure to observe this CAUTION may require unneeded vehicle inspection and repair.
WARNING:
Following precautions must be observed for this work. Failure to observe any of them may result in
personal injury.

To avoid an accidental deployment, 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 for the air bag (inflator) module beforehand.

Never connect deployment harness to any power source before connecting deployment harness to
the air bag (inflator) module. Deployment harness shall remain shorted and not be connected to a
power source until the air bag is to be deployed.

The air bag (inflator) module will immediately deploy the air bag when a power source is connected
to it. Wear safety glasses throughout this entire deployment and disposal procedure.

Wear suitable ear protection when deploying air bag. Also, advise those who are in the area close to
deployment site to wear suitable ear protection.

Do not deploy driver and passenger air bag (inflator) modules at the same time.
1) Turn ignition switch to ªLOCKº, remove key and put on safety
glasses.
2) Remove all loose objects from front seats and instrument panel.
3) [For driver air bag (inflator) module]
Disconnect contact coil connector (yellow connector) located
near the base of the steering column.
ii) Release locking of lock lever.
ii) After unlocked, disconnect to connector.
[For passenger air bag (inflator) module]
Remove glove box from instrument panel and disconnect pas-
senger air bag (inflator) module connector (yellow connector).
ii) Release locking of lock lever.
ii) After unlocked, disconnect to connector.