2004 Suzuki Vitara 4WD, AutomaticFACTORY OEM SERVICE PROCEDURE

Main Relay Inspection

  1. Disconnect negative cable at battery.
  2. Remove main relay (1) from relay box (2).
    Fig 1: Removing Main Relay From Relay Box
    G02256654Courtesy of SUZUKI OF AMERICA CORP.
  3. Check for resistance between each two terminal. If check results are as specified, proceed to next operation check. If not, replace main relay.

    Main relay resistance

    Between "A" and "B": (infinity)Β 

    Between "C" and "D": 79-95 ohm at 20 Β°C (68 Β°F)Β 

    Fig 2: Checking Main Relay Resistance
    G02256655Courtesy of SUZUKI OF AMERICA CORP.
  4. Check for resistance between terminals "A" and "B" when battery is connected to terminals "C" and "D".

    If check result is not specified, replace main relay.

    Main relay resistance with turned on

    Less than 1 ohmΒ 

    Fig 3: Checking Main Relay Resistance With Turned On
    G02256656Courtesy of SUZUKI OF AMERICA CORP.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.

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