Suzuki Grand Vitara JB416 / JB420. Manual - part 1

00-1 Precautions: 

Precautions

Precautions

Precautions

Precautions for Vehicles Equipped with a 
Supplemental Restraint (Air Bag) System

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WARNING

!

 

• The configuration of air bag system parts 

are as shown in the figure. When it is 
necessary to service (remove, reinstall and 
inspect) these parts, be sure to follow 
procedures described in “Precautions on 
Service and Diagnosis of Air Bag System 
in Section 8B”. Failure to follow proper 
procedures could result in possible air bag 
system activation, personal injury, damage 
to parts or air bag system being unable to 
activate when necessary.

• If the air bag system and another vehicle 

system both need repair, SUZUKI 
recommends that the air bag system be 
repaired first, to help avoid unintended air 
bag system activation.

• Do not modify the steering wheel, 

dashboard, or any other air bag system 
components.
Modifications can adversely affect air bag 
system performance and lead to injury.

• If the vehicle will be exposed to 

temperatures over 93 

°C (200 °F) (for 

example, during a paint baking process), 
remove the air bag system components 
beforehand to avoid component damage 
or unintended air bag system activation.

 

1. Passenger air bag (inflator) 

module

9. Ground for air bag system

2. Driver air bag (inflator) module

10. SDM

3. Contact coil assembly

11. Side-sensor (if equipped)

4. Air bag harness in main harness

12. Seat belt pretensioner

5. Forward-sensor

13. Side curtain-air bag (inflator) 

module (if equipped)

6. “A/B” fuse in junction block 

assembly

14. Air bag harness in instrument 

panel harness

7. Air bag harness in floor harness

15. “AIR BAG” monitor coupler (if 

equipped)

8. Side-air bag (inflator) module (if 

equipped)

16. Passenger air bag harness

5

4

6

5

15

3

2

14

16

1

8

910

11

8

13

7

11

12

12

7

13

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Precautions: 00-2

Diagnosis
• When troubleshooting air bag system, be sure to 

follow “Air Bag Diagnostic System Check in Section 
8B”. Bypassing these procedures may result in 
extended diagnostic time, incorrect diagnosis, and 
incorrect parts replacement.

• Never use electrical test equipment other than that 

specified.

WARNING

!

 

Never attempt to measure the resistance of 
the air bag (inflator) modules (driver, 
passenger, side and curtain) and seat belt 
pretensioners (driver and passenger). It is 
very dangerous as the electric current from 
the tester may deploy the air bag or activate 
the pretensioners.

 

Servicing and Handling

WARNING

!

 

Many of service procedures require 
disconnection of “A/B” fuse and all air bag 
(inflator) module(s) from system circuit to 
avoid an accidental deployment.
Driver, Passenger, Side and Curtain Air Bag 
(Inflator) Modules
• 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 minimal chance of injury. 
Never carry the air bag (inflator) module by 
the wires or connector on the underside of 
the module. When placing a live air bag 
(inflator) module on a bench or other 
surface, always face the bag up, away from 
the surface. This is necessary so that a 
free space is provided to allow the air bag 
to expand in the unlikely event of 
accidental deployment. Otherwise, 
personal injury may result.

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[A]: Always carry air bag (inflator) module with trim cover (air bag opening) 

away from body.

[B]: Always place air bag (inflator) module on workbench with trim cover (air 

bag opening) up, away from loose objects.

[A]

[B]

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00-3 Precautions: 

• Never dispose of live (undeployed) air bag 

(inflator) modules (driver, passenger, side 
and curtain). If disposal is necessary, be 
sure to deploy them according to 
deployment procedures described in “Air 
Bag (Inflator) Module and Seat Belt 
Pretensioner Disposal in Section 8B”. 

• The air bag (inflator) module immediately 

after deployment is very hot. Wait for at 
least half an hour to cool it off before 
proceeding the work.

• 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 
lubricate the bag as it inflates) and by-
products of the chemical reaction. As with 
many service procedures, gloves and 
safety glasses should be worn.

 

WARNING

!

 

SDM
• During service procedures, be very careful 

when handling a Sensing and Diagnostic 
Module (SDM).

• Never strike or jar the SDM.
• Never power up the air bag system when 

the SDM is not rigidly attached to the 
vehicle. All SDM and mounting bracket 
fasteners must be carefully torqued and 
the arrow must be pointing toward the 
front of the vehicle to ensure proper 
operation of the air bag system.
The SDM could be activated when powered 
while not rigidly attached to the vehicle 
which could cause deployment and result 
in personal injury.

 

WARNING

!

 

Driver and Passenger Seat Belt 
Pretensioners
• 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 seat belt pretensioner by wire 

or connector of pretensioner. When 
placing a live seat belt pretensioner on the 
workbench or some place like that, be sure 
not to lay it with its exhaust hole (1) 
provided side facing down. It is also 
prohibited 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.

• Never dispose of live (inactivated) seat belt 

pretensioners (drive and passenger). If 
disposal is necessary, be sure to activate 
them according to activation procedures 
described in “Air Bag (Inflator) Module and 
Seat Belt Pretensioner Disposal in Section 
8B” before disposal.

• The seat belt pretensioner immediately 

after activation is very hot. Wait for at least 
half an hour to cool it off before 
proceeding the work.

• With many service procedures, gloves and 

safety glasses should be worn to prevent 
any possible irritation of the skin or eyes.

 

1

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Precautions: 00-4

CAUTION

!

 

• Even when the accident was light enough 

not to cause air bags to activate, be sure to 
inspect system parts and other related 
parts according to instructions under 
“Repair and Inspection Required after 
Accident in Section 8B”.

• When servicing parts other than air bag 

system, if shocks may be applied to air bag 
system component parts, remove those 
parts beforehand.

• When handling the air bag (inflator) 

modules (driver, passenger, side and 
curtain), forward sensors, side sensors or 
SDM, be careful not to drop it or apply an 
impact to it. If an excessive impact was 
applied (e.g., dropped from a height of 91.4 
cm (3 feet) or more), never attempt 
disassembly or repair but replace it with a 
new one.

• When grease, cleaning agent, oil, water, 

etc. has got onto air bag (inflator) modules 
(driver, passenger, side and curtain), wipe 
off immediately with a dry cloth.

• Air bag wire harness is included in main 

harness, instrument panel harness, floor 
harness and seat harness. Air bag wire 
harness can be identified easily as the part 
of connector side wire harness is covered 
with a yellow protection tube and it has 
yellow connectors. Be very careful when 
handling it.

• When an open in air bag wire harness, 

damaged wire harness, connector or 
terminal is found, replace wire harness, 
connectors and terminals as an assembly.

• Do not apply power to the air bag system 

unless all components are connected or a 
diagnostic flow requests it, as this will set 
a DTC.

• Never use air bag system component parts 

from another vehicle.

• When using electric welding, be sure to 

temporarily disable air bag system 
referring to “Disabling Air Bag System in 
Section 8B”.

• Never expose air bag system component 

parts directly to hot air (drying or baking 
the vehicle after painting) or flames.

• WARNING / CAUTION labels are attached 

on each part of air bag system 
components. Be sure to follow the 
instructions.

• After vehicle is completely repaired, 

perform “Air Bag Diagnostic System 
Check in Section 8B”.

 

General Precautions

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The WARNING and CAUTION describe some general 
precautions that you should observe when servicing a 
vehicle. These general precautions apply to many of the 
service procedures, and they will not necessarily be 
repeated with each procedure to which they apply.

WARNING

!

 

• Whenever raising a vehicle for service, be 

sure to follow the instructions under 
“Vehicle Lifting Points in Section 0A”.

• When it is necessary to do service work 

with the engine running, make sure that 
the parking brake is set fully and the 
transmission is in Neutral (for manual 
transmission vehicles) or Park (for 
automatic transmission vehicles), Keep 
hands, hair, clothing, tools, etc. away from 
the fan and belts when the engine is 
running.

• When it is necessary to run the engine 

indoors, make sure that the exhaust gas is 
forced outdoors.

• Do not perform service work in areas 

where combustible materials can come in 
contact with a hot exhaust system. When 
working with toxic or flammable materials 
(such as gasoline and refrigerant), make 
sure that the area you work in is well-
ventilated.

• To avoid getting burned, keep away from 

hot metal parts such as the radiator, 
exhaust manifold, tail pipe, muffler, etc.

• New and used engine oil can be 

hazardous. Children and pets may be 
harmed by swallowing new or used oil. 
Keep new and used oil and used engine oil 
filters away from children and pets.
Continuous contact with used engine oil 
has been found to cause [skin] cancer in 
laboratory animals. Brief contact with used 
oil may irritate skin. To minimize your 
exposure to used engine oil, wear a long-
sleeve shirt and moisture-proof gloves 
(such as dish washing gloves) when 
changing engine oil. If engine oil contacts 
your skin, wash thoroughly with soap and 
water. Launder any clothing or rags if wet 
with oil, recycle or properly dispose of 
used oil and filters.

• Make sure the bonnet is fully closed and 

latched before driving. If it is not, it can fly 
up unexpectedly during driving, 
obstructing your view and resulting in an 
accident.