Suzuki sq-416-420-625 User manual

SUZUKI
────────────
SQ 416-420-625
────────────
M.Y 1998 - 2005
SERVICE MANUAL
VOLUME 1
- CHASSIS SECTIONS
- ELECTRICAL
- BODY SECTIONS

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RELATED MANUAL
MANUAL NAME MANUAL NO. APPLICABILITY
SQ416/SQ420/SQ625
Unit Repair Manual 99501-65D01-xxx Transmission, Transfer and Differentials (Front and Rear) of SQ series.
SQ416/SQ420/SQ625
Wiring Diagram Manual 99512-65D10-015 Applicable model mentioned in FOREWORD of this manual.
SQ416/SQ420/SQ625
Service Manual 99500-65D00-xxx Vehicles before the vehicle identification number
mentioned in FOREWORD of this manual.
SQ416/SQ420/SQ625
Wiring Diagram Manual 99512-65D01-015

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0A
0B
1A
1B
3
3A
3B1
3C
3C1
3D
3E
3F
4A2
4B
5
6
7A5A
5B
5C
5E1
6A1
6A2
6A4
6B
6C
6E1
6E2
6F1
6F2
6G
6G1
6H
6K
7A1
7B1
7C1
7D
7E
7F
8
8B
8C
8D
8G
9
10
10A
8A
10B
6-1
ENGINE
General Information and
Diagnosis (G16/J20)
General Information and
Diagnosis (H25)
Engine Mechanical (G16)
Engine Mechanical (H25)
Engine Mechanical (J20)
Engine Cooling
Engine Fuel
Engine and Emission Control
System (SFI for G16/J20)
Engine and Emission Control
System (SFI for H25)
Ignition System (G16)
Ignition System (J20/H25)
Cranking System
(Reduction Type)
Cranking System
(No-Reduction Type)
Charging System
Exhaust System
TRANSMISSION, CLUTCH
AND DIFFERENTIAL
Manual Transmission (Type 1)
Manual Transmission (Type 2)
Automatic Transmission
Clutch (Hydraulic Type)
Transfer
Differential (Front)
Differential (Rear)
BODY ELECTRICAL SYSTEM
Wiring Diagram
Lighting System
Instrumentation/Driver
Information
Windows, Mirrors, Security
and Lock
Immobilizer Control System
BODY SERVICE
RESTRAINT SYSTEM
Seat Belt
Air Bag System
GENERAL INFORMATION
General Information
Maintenance and Lubrication
TABLE OF CONTENTS TABLE OF CONTENTS SECTIONSECTION
0B
HEATING AND AIR
CONDITIONING
Heater and Ventilation
Air Conditioning
STEERING, SUSPENSION,
WHEELS AND TIRES
Front End Alignment
Power Steering (P/S) System
Steering Wheel and Column
(Not Equipped with Air Bag)
Air Bag Steering Wheel
and Column
Front Suspension
Rear Suspension
Wheel and Tires
1A
3A
0A
1B
3B1
3C
3C1
3D
3E
3F
3
6A1
6
6A2
6A4
6B
6C
6E1
6E2
6F1
DRIVE SHAFT/PROP. SHAFT
Front Drive Shaft/Shaft
Bearing, Oil Seal
Propeller Shaft
BRAKES
Brake Pipe/Hose/Master
Cylinder
Front Brakes
Parking and Rear Brakes
Antilock Brake System
4A2
4B
5
5A
5B
5C
5E1
6F2
6G
6G1
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8
8A
8B
8C
8D
8G
9
10
10A
10B
6-1
NOTE:
The screen toned Sections 6 – 6K are included in Volume 2 and Section 8A is in Wiring
Diagram Manual.

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0A
GENERAL INFORMATION 0A-1
SECTION 0A
GENERAL INFORMATION
CONTENTS
HOW TO USE THIS MANUAL 0A- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS 0A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Vehicle Equipped with a Supplemental Restraint (Air Bag) System 0A- 3. . . . . . . . . . . . . . . .
Diagnosis 0A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing and Handling 0A- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Precautions 0A- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Catalytic Converter 0A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Electrical Circuit Service 0A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Circuit Inspection Procedure 0A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermittent and Poor Connection 0A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precaution for Installing Mobile Communication Equipment 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDENTIFICATION INFORMATION 0A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body Number 0A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Identification Number 0A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Identification Number 0A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING, CAUTION AND INFORMATION LABELS 0A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE LIFTING POINTS 0A-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABBREVIATIONS MAY BE USED IN THIS MANUAL 0A-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
METRIC INFORMATION 0A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric Fasteners 0A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fasteners Strength Identification 0A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tightening Torque 0A-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6) Install oil pump. Refer to “Oil pump”.
7) Install flywheel (for M/T vehicle) or drive plate (for A/T vehicle).
Using special tool, lock flywheel or drive plate, and tighten
flywheel or drive plate bolts to specified torque.
Special Tool
(A): 09924-17810
Tightening Torque
(c): 78 N.m (7.8 kg-m, 56.0 lb-ft)
1. Flywheel bolts or drive plate bolts for A/T vehicle
1, (c)
0A-2 GENERAL INFORMATION
HOW TO USE THIS MANUAL
1) ThereisaTABLEOFCONTENTSFORTHEWHOLEMANUAL
onthethirdpageofthismanual,wherebyyoucaneasily find the
section that offers the information you need. Also, there is a
CONTENTS on the first page of EACH SECTION, where the
main items in that section are listed.
2) Eachsectionofthismanualhasitsownpagination.Itisindicated
at the top of each page along with the Section name.
3) TheSPECIALTOOLusageandTORQUESPECIFICATIONare
given as shown in figure below.
4) A number of abbreviations are used in the text.
For their full explanations, refer to “ABBREVIATIONS MAY BE
USED IN THIS MANUAL” of this section.
5) The SI, metric and foot-pound systems are used as units in this
manual.
6) DIAGNOSIS are included in each section as necessary.
7) At the end of each section, there are descriptions of SPECIAL
TOOLS, REQUIRED SERVICE MATERIALS and TIGHT-
ENINGTORQUESPECIFICATIONSthatshouldbeusedforthe
servicing work described in that section.

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1. Air bag wire harness
2. Passenger air bag
(inflator) module
3. SDM
4. DLC
5. Contact coil
6. Driver air bag (inflator)
module
7. Seat belt pretensioner
(if equipped)
GENERAL INFORMATION 0A-3
PRECAUTIONS
PRECAUTION FOR VEHICLES EQUIPPED
WITH A SUPPLEMENTAL RESTRAINT
(AIR BAG) SYSTEM
WARNING:
The configuration of air bag system parts are as shown in
the figure. When it is necessary to service (remove, rein-
stall and inspect) these parts, be sure to follow proce-
dures described in SECTION 10B. Failure to follow proper
procedurescouldresultinpossibleairbagsystemactiva-
tion, 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.
Donotmodifythesteeringwheel,dashboard,oranyother
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), re-
movetheairbagsystemcomponentsbeforehandtoavoid
component damage or unintended air bag system activa-
tion.
DIAGNOSIS
When troubleshooting air bag system, be sure to follow
“DIAGNOSIS” in SECTION 10B. Bypassing these proce-
duresmayresultinextendeddiagnostictime,incorrectdiag-
nosis, and incorrect parts replacement.
Neveruseelectrical test equipment other than that specified
in this manual.
WARNING:
Never attempt to measure the resistance of the air bag (in-
flator)modules (driver andpassenger)andseat beltpreten-
tioners (driver and passenger). It is very dangerous as the
electriccurrent from thetestermaydeploythe air bagorac-
tivate the pretensioner.

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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.
1. Slit on workbench
2. Workbench vise
3. Lower mounting bracket
0A-4 GENERAL INFORMATION
SERVICING AND HANDLING
WARNING:
Many of service procedures require disconnection of “AIR
BAG” fuse and all air bag (inflator) module(s) from initiator
circuit to avoid an accidental deployment.
Driver and Passenger Air Bag (Inflator) Modules
Forhandlingandstorageofaliveairbag(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
accidentaldeployment,thebagwillthendeploywithmini-
mal 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. As the live passenger air bag (inflator)
modulemust be placed withits bag (trim cover) facing up,
placeitontheworkbenchwithaslitor 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 accidental de-
ployment. Otherwise, personal injury may result.
Never dispose of live (undeployed) air bag (inflator) mod-
ules (driver and passenger). If disposal is necessary, be
suretodeploythemaccordingtodeploymentprocedures
described in SECTION 10B before disposal.
The air bag (inflator) module immediately after deploy-
ment 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
surfaceoftheairbagmaycontainapowderyresidue.This
powder consists primarily of cornstarch (used to lubri-
catethebagasitinflates)andby-productsofthechemical
reaction. As with many service procedures, gloves and
safety glasses should be worn.

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1. Exhaust hole
1
1NG
GENERAL INFORMATION 0A-5
WARNING:
SDM
Duringserviceprocedures,beverycarefulwhenhandling
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
bracketfastenersmustbecarefullytorquedandthearrow
must be pointing toward the front of the vehicle to ensure
proper operation of the air bag system.
TheSDMcouldbeactivatedwhenpoweredwhilenotrigid-
ly 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.
Nevercarry seat beltpretensioner bywireor 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 provided side facing down. It is
also prohibited to put something on its face with an ex-
haust hole or to put a seat belt pretensioner on top of
another. Otherwise, personal injury may result.
Neverdisposeoflive(inactivated)seatbeltpretensioners
(driver and passenger). If disposal is necessary, be sure
to activate them according to activation procedures de-
scribed in SECTION 10B 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.
Withmany service procedures,gloves and safety glasses
should be worn to prevent any possible irritation of the
skin or eyes.

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0A-6 GENERAL INFORMATION
CAUTION:
Even when the accident was light enough not to cause air
bagstoactivate,besuretoinspectsystempartsandother
related parts according to instructions under “Repair and
Inspection Required after an Accident” in SECTION 10B.
When servicing parts other than air bag system, if shocks
may be applied to air bag system component parts, re-
move those parts beforehand.
When handling the air bag (inflator) modules (driver and
passenger), seat belt pretensioners (driver and passen-
ger) 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 disas-
sembly or repair but replace it with a new one.
When grease, cleaning agent, oil, water, etc. has got onto
air bag (inflator) modules (driver and passenger) or seat
belt pretensioners (drive and passenger), wipe off im-
mediately with a dry cloth.
Air bag wire harness can be identified easily as it is cov-
ered with a yellow protection tube. Be very careful when
handling it.
When an open in air bag wire harness, damaged wire har-
ness, connector or terminal is found, replace wire har-
ness, connectors and terminals as an assembly.
Do not apply power to the air bag system unless all com-
ponents are connected or a diagnostic chart requests it,
as this will set a diagnostic trouble code.
Never use air bag system component parts from another
vehicle.
When using electric welding, be sure to temporarily dis-
able air bag system referring to “Disabling Air Bag Sys-
tem” described in “Service Precautions” under “On-Ve-
hicle Service” in SECTION 10B.
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
airbagsystem components. Be sure to follow theinstruc-
tions.
After vehicle is completely repaired, perform “Air Bag
Diagnostic System Check” described in “Diagnosis” in
SECTION 10B.

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GENERAL INFORMATION 0A-7
GENERAL PRECAUTIONS
TheWARNINGand CAUTIONbelow describesomegeneral precautionsthat youshouldobserve whenservicing
a vehicle. These general precautions apply to many of the service procedures described in this manual,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” on SECTION 0A.
When it is necessary to do service work with the engine running, make sure that the parking brake
issetfullyandthetransmissionisinNeutral(formanualtransmissionvehicles)orPark(forautomatic
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.
Continuouscontactwithusedengineoilhasbeenfoundtocause[skin]cancerinlaboratoryanimals.
Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a
long-sleeveshirtandmoisture-proofgloves(suchasdishwashinggloves)whenchangingengineoil.
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.
CAUTION:
Before starting any service work, cover fenders, seats and
anyotherpartsthatarelikelytogetscratchedorstaineddur-
ing servicing. Also, be aware that what you wear (e.g, but-
tons) may cause damage to the vehicle’s finish.
When performing service to electrical parts that does not re-
quire use of battery power, disconnect the negative cable of
the battery.

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“A”
0A-8 GENERAL INFORMATION
When removing the battery, be sure to disconnect the nega-
tive cable first and then the positive cable. When reconnect-
ing the battery, connect the positive cable first and then the
negative cable, and replace the terminal cover.
When removing parts that are to be reused, be sure to keep
themarrangedinanorderlymannersothattheymayberein-
stalled in the proper order and position.
Wheneveryouuse oil seals, gaskets, packing, O-rings, lock-
ing washers, split pins, self-locking nuts, and certain other
parts as specified, be sure to use new ones. Also, before
installing new gaskets, packing, etc., be sure to remove any
residual material from the mating surfaces.
Make sure that all parts used in reassembly are perfectly
clean.
When use of a certain type of lubricant, bond or sealant is
specified, be sure to use the specified type.
“A”: Sealant 99000-31150
Be sure to use special tools when instructed.
Special Tool
(A):09917-98221
(B):09916-58210

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GENERAL INFORMATION 0A-9
When disconnecting vacuum hoses, attach a tag describing
thecorrect installationpositionssothatthehosescan bere-
installed correctly.
After servicing fuel, oil, coolant, vacuum, exhaust or brake
systems, check all lines related to the system for leaks.
Forvehiclesequippedwithfuelinjectionsystems,neverdis-
connect the fuel line between the fuel pump and injector
without first releasing the fuel pressure, or fuel can be
sprayed out under pressure.
PRECAUTIONSFORCATALYTICCONVERTER
For vehicles equipped with a catalytic converter, use only un-
leaded gasoline and be careful not to let a large amount of un-
burned gasoline enter the converter or it can be damaged.
– Conduct a spark jump test only when necessary, make it as
short as possible, and do not open the throttle.
– Conduct engine compression checks within the shortest
possible time.
– Avoid situations which can result in engine misfire (e.g.
starting the engine when the fuel tank is nearly empty).

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1. Coupler
2. Probe
1. Coupler
2. Probe
3. Where male
terminal fits
0A-10 GENERAL INFORMATION
PRECAUTIONS FOR ELECTRICAL CIRCUIT
SERVICE
When disconnecting and connecting coupler, make sure to
turn ignition switch OFF, or electronic parts may get dam-
aged.
Becarefulnottotouchtheelectricalterminalsofpartswhich
use microcomputers (e.g. electronic control unit like as
ECM, PCM, P/S controller, etc.). The static electricity from
your body can damage these parts.
Neverconnectanytester(voltmeter,ohmmeter,orwhatever)
to electronic control unit when its coupler is disconnected.
Attempt to do it may cause damage to it.
Never connect an ohmmeter to electronic control unit with
its coupler connected to it. Attempt to do it may cause dam-
age to electronic control unit and sensors.
Be sure to use a specified voltmeter/ohmmeter. Otherwise,
accuratemeasurementsmay not be obtained or personal in-
jury may result.
When taking measurements at electrical connectors using a
tester probe, be sure to insert the probe from the wire har-
ness side (backside) of the connector.
When connecting meter probe from terminal side of coupler
because it can’t be connected from harness side, use extra
care not to bend male terminal of coupler of force its female
terminal open for connection.
In case of such coupler as shown connect probe as shown
to avoid opening female terminal.
Never connect probe where male terminal is supposed to fit.

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GENERAL INFORMATION 0A-11
When checking connection of terminals, check its male half
for bend and female half for excessive opening and both for
locking (looseness), corrosion, dust, etc.
Before measuring voltage at each terminal, check to make
surethatbattery voltage is 11V or higher.Suchterminal volt-
age check at low battery voltage will lead to erroneous diag-
nosis.

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0A-12 GENERAL INFORMATION
1. Check for loose connection
Sensor ECM
Check contact tension by
Inserting and removing just for
once
1. Looseness of crimping
2. Open
3. Thin wire (Single strand of wire)
ELECTRICAL CIRCUIT INSPECTION
PROCEDURE
While there are various electrical circuit inspection methods, de-
scribedhere isa generalmethodto checkitsopen andshort circuit
by using an ohmmeter and a voltmeter.
OPEN CIRCUIT CHECK
Possible causes for the open circuit are as follows. As the cause is
intheconnectororterminalinmanycases,theyneedtobechecked
particularly carefully.
Loose connection of connector
Poor contact of terminal (due to dirt, corrosion or rust on it, poor
contact tension, entry of foreign object etc.)
Wire harness being open
When checking system circuits including an electronic control unit
suchasECM,TCM,ABScontrolmodule,etc.,itisimportanttoper-
form careful check, starting with items which are easier to check.
1) Disconnect negative cable from battery.
2) Check each connector at both ends of the circuit being checked
for loose connection. Also check lock condition of connector if
equipped with connector lock.
3) Usingatestmaleterminal,checkbothterminalsofthecircuitbe-
ing checked for contact tension of its female terminal.
Check each terminal visually for poor contact (possibly caused
by dirt, corrosion, rust entry of foreign object, etc.).
At the same time, check to make sure that each terminal is
locked in the connector fully.
4) Using continuity check or voltage check procedure described in
the following page, check the wire harness for open circuit and
poor connection with its terminals. Locate abnormality, if any.

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GENERAL INFORMATION 0A-13
2V voltage drop
Continuity Check
1) Measure resistance between connector terminals at both ends
ofthe circuitbeingchecked (betweenA-1 andC-1in thefigure).
Ifnocontinuityisindicated (infinityor over limit),that meansthat
the circuit is open between terminals A-1 and C-1.
2) Disconnect the connector included in the circuit (connector-B in
the figure) and measure resistance between terminals A-1 and
B-1.
If no continuity is indicated, that means that the circuit is open
between terminals A-1 and B-1. If continuity is indicated, there
is an open circuit between terminals B-1 and C-1 or an ab-
normality in connector-B.
Voltage Check
Ifvoltageissuppliedtothecircuitbeingchecked,voltagecheckcan
be used as circuit check.
1) With all connectors connected and voltage applied to the circuit
being checked, measure voltage between each terminal and
body ground.
If measurements were taken as shown in the figure at the left
andresultswereas listedbelow,itmeans thatthecircuitisopen
between terminals B-1 and A-1.
Voltage Between:
C-1 and body ground: Approx. 5V
B-1 and body ground: Approx. 5V
A-1 and body ground: 0V
Also, if measured values were as listed below, it means that
there is a resistance (abnormality) of such level that corre-
sponds to the voltage drop in the circuit between terminals A-1
and B-1.
Voltage Between:
C-1 and body ground: Approx. 5V
B-1 and body ground: Approx. 5V
A-1 and body ground: Approx. 3V

YH4
GRAND
VITARA
0A-14 GENERAL INFORMATION
To other
parts
Other parts
To other
parts
SHORT CIRCUIT CHECK (Wire harness to ground)
1) Disconnect negative cable from battery.
2) Disconnectconnectorsatbothendsofthecircuittobechecked.
NOTE:
If the circuit to be checked is connected to other parts, dis-
connect all connectors of those parts.
Otherwise, diagnosis will be misled.
3) Measure resistance between terminal at one end of circuit (A-1
terminal in figure) and body ground. If continuity is indicated, it
meansthatthereisashorttogroundbetweenterminalsA-1and
C-1 of the circuit.
4) Disconnect the connector included in circuit (connector B) and
measure resistance between A-1 and body ground.
Ifcontinuityisindicated,itmeansthatthecircuitisshortedtothe
ground between terminals A-1 and B-1.

YH4
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VITARA
1. Check contact tension by inserting and removing
just once.
2. Check each terminal for bend and proper alignment.
GENERAL INFORMATION 0A-15
INTERMITTENT AND POOR CONNECTION
Mostintermittentare causedbyfaultyelectrical connectionsorwir-
ing, although a sticking relay or solenoid can occasionally be at
fault. When checking it for proper connection, perform careful
check of suspect circuits for:
Poor mating of connector halves, or terminals not fully seated in
the connector body (backed out).
Dirt or corrosion on the terminals. The terminals must be clean
andfreeofanyforeignmaterialwhichcouldimpedepropertermi-
nal contact.
However, cleaning the terminal with a sand paper or the like is
prohibited.
Damaged connector body, exposing the terminals to moisture
and dirt, as well as not maintaining proper terminal orientation
with the component or mating connector.
Improperly formed or damaged terminals.
Checkeachconnectorterminalinproblemcircuitscarefullytoen-
suregoodcontacttensionbyusingthecorrespondingmatingter-
minal.
Ifcontact tension is not enough,reform itto increasecontact ten-
sion or replace.

YH4
GRAND
VITARA
0A-16 GENERAL INFORMATION
Poor terminal-to-wire connection.
Check each wire harness in problem circuits for poor connection
by shaking it by hand lightly. If any abnormal condition is found,
repair or replace.
Wire insulation which is rubbed through, causing an intermittent
shortasthebareareatouchesotherwiringorpartsofthevehicle.
Wiring broken inside the insulation. This condition could cause
continuity check to show a good circuit, but if only 1 or 2 strands
of a multi-strand-type wire are intact, resistance could be far too
high.
If any abnormality is found, repair or replace.
PRECAUTION FOR INSTALLING MOBILE
COMMUNICATION EQUIPMENT
WheninstallingmobilecommunicationequipmentsuchasCB(Citi-
zens-Band)-radio or cellular-telephone, be sure to observe the fol-
lowing precautions.
Failure to follow cautions may adversely affect electronic control
system.
Keeptheantennaasfarawayaspossiblefromthevehicle’selec-
tronic control unit.
Keep the antenna feeder more than 20 cm (7.9 in.) away from
electronic control unit and its wire harnesses.
Donot runtheantenna feederparallelwith otherwireharnesses.
Confirm that the antenna and feeder are correctly adjusted.

YH4
GRAND
VITARA
G16 engine
J20 engine
H25 engine
M/T (Type1)
4-speed A/T
M/T (Type2)
GENERAL INFORMATION 0A-17
IDENTIFICATION INFORMATION
BODY NUMBER
The vehicle body number is on the left side of instrument panel and
punchedonthechassisinsidethetirehousingonthe right frontside.
It is possible to identify the country of origin (the production plant)
of the vehicle by the first three digits of the body number as shown
below.
JSAxxx Japan (Iwata) produced. . . . . . . . . . .
2S2xxx Canada (CAMI) produced. . . . . . . . . . .
ENGINE IDENTIFICATION NUMBER
The number is punched on the cylinder block.
TRANSMISSION IDENTIFICATION NUMBER
The number is located on the transmission case.