exhaust SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

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vol.1
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
6-1ENGINE
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
3F36A16
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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1. Exhaust hole
1 1
NG
GENERAL INFORMATION 0A-5
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 rigid-
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.

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 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.

Never dispose of live (inactivated) seat belt pretensioners
(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.

With many service procedures, gloves and safety glasses
should be worn to prevent any possible irritation of the
skin or eyes.

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GENERAL INFORMATION 0A-7
GENERAL PRECAUTIONS
The WARNING and CAUTION below describe some general precautions that you should observe when servicing
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 ªVEHICLE LIFTING
POINTSº on 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 dishwashing 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.
CAUTION:

Before starting any service work, cover fenders, seats and
any other parts that are likely to get scratched or stained dur-
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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GENERAL INFORMATION 0A-9

When disconnecting vacuum hoses, attach a tag describing
the correct installation positions so that the hoses can be re-
installed correctly.

After servicing fuel, oil, coolant, vacuum, exhaust or brake
systems, check all lines related to the system for leaks.

For vehicles equipped with fuel injection systems, never dis-
connect the fuel line between the fuel pump and injector
without first releasing the fuel pressure, or fuel can be
sprayed out under pressure.
PRECAUTIONS FOR CATALYTIC CONVERTER
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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GENERAL INFORMATION 0A-21
A
ABS : Anti-lock Brake System
ATDC : After Top Dead Center
API : American Petroleum Institute
ATF : Automatic Transmission Fluid
ALR : Automatic Locking Retractor
AC : Alternating Current
A / T : Automatic Transmission
A / C : Air Conditioning
ABDC : After Bottom Dead Center
A / F : Air Fuel Mixture Ratio
A-ELR : Automatic-Emergency
Locking Retractor
B
B+ : Battery Positive Voltage
BTDC : Before Top Dead Center
BBDC : Before Bottom Dead Center
C
CKT : Circuit
CMP Sensor : Camshaft Position Sensor
(Crank Angle Sensor, CAS)
CO : Carbon Monoxide
CPP Switch : Clutch Pedal Position Switch
(Clutch Switch, Clutch Start
Switch)
CPU : Central Processing Unit
CRS : Child Restraint System
D
DC : Direct Current
DLC : Data Link Connector
(Assembly Line Diag. Link,
ALDL, Serial Data Link, SDL)
DOHC : Double Over Head Camshaft
DOJ : Double Offset Joint
DRL : Daytime Running Light
DTC : Diagnostic Trouble Code
(Diagnostic Code)
E
EBCM : Electronic Brake Control
Module, ABS Control
Module
EBD : Electric Brake force Distribution
ECM : Engine Control Module
ECT Sensor : Engine Coolant Temperature
Sensor (Water Temp.
Sensor, WTS)
EGR : Exhaust Gas Recirculation
EGRT Sensor : EGR Temperature Sensor
(Recirculated Exhaust Gas
Temp. Sensor, REGTS)
EFE Heater : Early Fuel Evaporation
Heater (Positive Temperature
Coefficient, PTC Heater)
ELR : Emergency Locking Retractor
EPS : Electronic Power Steering
EVAP : Evaporative Emission
EVAP Canister : Evaporative Emission
Canister (Charcoal Canister)
F
4WD : 4 Wheel Drive
G
GEN : Generator
GND : Ground
H
HC : Hydrocarbons
HO2S : Heated Oxygen Sensor
I
IAC Valve : Idle Air Control Valve (Idle
Speed Control Solenoid
Valve, ISC Solenoid Valve)
IAT Sensor : Intake Air Temperature
Sensor (Air temperature
Sensor, ATS)
ICM : Immobilizer Control Module
IG : Ignition
ISC Actuator : Idle Speed Control Actuator
(Motor)
ABBREVIATIONS MAY BE USED IN THIS MANUAL

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0B-2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE UNDER NORMAL DRIVING CONDITIONS
Interval:
This interval should be judged by
This table includes services as scheduled up to 90,000 km
(54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry
out the same services at the same intervals respectively.
This interval should be judged by
odometer reading or months,Km (x 1,000)153045607590g
whichever comes first.Miles (x 1,000)91827364554
Months122436486072
ENGINE
1-1. Drive beltV-beltIRIRIR
V-rib belt (Flat type)±±I±±R
1-2. Camshaft timing belt (G16 engine only)Replace every 100,000 km or
60,000 miles
1-3. Valve lash (clearance)G16 engine only±I±I±I
1-4. Engine oil and
oil filterJ20 / H25 engines
G16 engine with HO2S (SG, SH, SJ)RRRRRR
G16 engine with HO2S (SE, SF),
G16 engine without HO2SReplace every 10,000 km (6,000 miles)
or 8 months
1-5. Engine coolant±±R±±R
1-6. Exhaust system±I±I±I
IGNITION SYSTEM
2-1. Spark plugs
Wh
Vehicle without
HO2S
Nickel plug±R±R±R
When
unleaded
HO2SIridium plug±±±R±±unleaded
fuel isVehicle with
HO2S
Nickel plug±±R±±Rfuel is
usedHO2SIridium plugReplace every 105,000 km or 63,000
miles
When leaded fuel is used, refer to ªSevere Driving Conditionº schedule
FUEL SYSTEM
3-1. Air cleaner filterIIRIIR
3-2. Fuel lines and connections±I±I±I
3-3. Fuel filterReplace every 105,000 km or 63,000
miles
3-4. Fuel tank±±I±±I
EMISSION CONTROL SYSTEM
4-1. Crankcase ventilation hoses and connections
(Vehicle without HO2S)±±I±±I
4-2. PCV valveVehicle without HO2S±±I±±I
Vehicle with HO2S±±±±±I
4-3. Fuel evaporative emission
tl t
Vehicle without HO2S±I±I±I
control systemVehicle with HO2S±±±±±I
NOTES:

ªRº : Replace or change

ªIº : Inspect and correct, replace or lubricate if necessary

For Item 1-2. Camshaft timing belt: This belt may be replaced every 90,000 km (54,000 miles) according
to customer's maintenance convenience.

For Sweden, item 2-1, 4-2 and 4-3 should be performed by odometer reading only.

For Item 2-1. Spark plugs, replace every 50,000 km if the local law requires.

Nickel spark plug: BKR6E-11 or K20PR-U11

Iridium spark plug: IFR6E11 or SK20PR-A11 for G16 engine, IFR5J11 or SK16PR11 for J20 / H25 engines

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0B-4 MAINTENANCE AND LUBRICATION
MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS
If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is
recommended that applicable maintenance operation be performed at the particular interval as given in the chart
below.
Severe condition code
A ± Repeated short trips E ± Repeated short trips in extremely
B ± Driving on rough and / or muddy roads cold weather
C ± Driving on dusty roads F ± Leaded fuel use
D ± Driving in extremely cold weather G ± ± ± ± ± ± ± ± ±
and / or salted roads H ± Trailer towing (if admitted)
Severe
Condition Code
MaintenanceMaintenance
OperationMaintenance Interval
BCDITEM 1-1IEvery 15,000 km
(9,000 miles) or 12 months
± B C D ± ± ± ±Drive belt (V-rib belt)REvery 45,000 km
(27,000 miles) or 36 months
A ± C D E F ± HITEM 1-4
Engine oil and oil filterREvery 5,000 km
(3,000 miles) or 4 months
± B ± ± ± ± ± ±ITEM 1-6
Exhaust pipe mountingsIEvery 15,000 km
(9,000 miles) or 12 months
CITEM 3-1IEvery 2,500 km
(1,500 miles)
± ± C ± ± ± ± ±Air cleaner filter*1REvery 30,000 km
(18,000 miles) or 24 months
ABC EF HITEM 2-1Nickel plugREvery 10,000 km
(6,000 miles) or 8 months
A B C ± E F ± HSpark plugsIridium plugREvery 30,000 km
(18,000 miles) or 24 months
± B ± D E ± ± HITEM 6-9
Propeller shafts and drive shaftsIEvery 15,000 km
(9,000 miles) or 12 months
± B ± ± E ± ± H
ITEM 6-10, 6-12, 6-13
Manual transmission,
transfer and differential oil
REvery 30,000 km
(18,000 miles) or 24 months
± B ± ± E ± ± HITEM 6-11
Automatic transmission fluidREvery 30,000 km
(18,000 miles) or 24 months
± B ± ± ± ± ± ±ITEM 6-8
Suspension bolts and nutsTEvery 15,000 km
(9,000 miles) or 12 months
± B C D ± ± ± HITEM 6-7
Wheel bearingIEvery 15,000 km
(9,000 miles) or 12 months
CD
ITEM 6-17
Air conditioning filter*2
IEvery 15,000 km
(9,000 miles) or 12 months
± ± C D ± ± ± ±Air conditioning filter 2
(if equipped)REvery 45,000 km
(27,000 miles) or 36 months
NOTES:
ªIº : Inspect and correct, replace or lubricate if necessary
ªRº : Replace or change
ªTº : Tighten to the specified torque
*1 : Inspect or replace more frequently if necessary.
*2 : Clean or replace more frequently if the air from the air conditioning decreases.

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0B-8 MAINTENANCE AND LUBRICATION
ITEM 1-2
Camshaft Timing Belt Replacement (G16 engine only)
Replace timing belt referring to Section 6A1.
ITEM 1-3
Valve Lash Inspection (G16 engine only)
1) Remove cylinder head cover.
2) Inspect intake and exhaust valve lash and adjust as necessary.
Refer to Section 6A1 for valve lash inspection and adjustment
procedure.
Valve
lash
(ªº)
When cold
(Coolant tempera-
ture is 15 ± 25
C
or 59 ± 77
F)When hot
(Coolant tempera-
ture is 60 ± 68
C
or 140 ± 154
F)
(gap ªaº)
specifica-
tion
Intake0.13 ± 0.17 mm
(0.005 ± 0.007 in.)0.17 ± 0.21 mm
(0.007 ± 0.008 in.)
tion
Exhaust0.23 ± 0.27 mm
(0.009 ± 0.011 in.)0.28 ± 0.32 mm
(0.011 ± 0.013 in.)
3) Install cylinder head cover and tighten bolts to specification.
ITEM 1-4
Engine Oil and Filter Change
WARNING:
New and used engine oil can be hazardous.
Be sure to read ªWARNINGº in General Precaution in Sec-
tion 0A and observe what in written there.
Before draining engine oil, check engine for oil leakage. If any evi-
dence of leakage is found, make sure to correct defective part be-
fore proceeding to the following work.
1) Drain engine oil by removing drain plug.
2) After draining oil, wipe drain plug clean. Reinstall drain plug, and
tighten it securely as specified below.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)

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MAINTENANCE AND LUBRICATION 0B-11
1. Reservoir
2. FULL level mark
3. LOW level mark
4. Arrow mark
5. Reservoir cap
546) Add coolant to reservoir so that its level aligns with Full mark.
Then, reinstall cap aligning arrow marks on reservoir and cap.
NOTE:
When installing reservoir cap, align arrow marks on reser-
voir and cap.
CAUTION:
When changing engine coolant, use mixture of 50% wa-
ter and 50% ANTIFREEZE / ANTICORROSION COOLANT
for the market where ambient temperature falls lower
than ±16C (3F) in winter, and mixture of 70% water and
30% ANTIFREEZE / ANTICORROSION COOLANT for the
market where ambient temperature doesn't fall lower
than ±16C (3F).
Even in a market where no freezing temperature is antici-
pated, mixture of 70% water and 30% ANTIFREEZE / AN-
TICORROSION COOLANT should be used for the pur-
pose of corrosion protection and lubrication.
ITEM 1-6
Exhaust System Inspection
WARING:
To avoid danger of being burned, do not touch exhaust sys-
tem when it is still hot. Any service on exhaust system
should be performed when it is cool.
When carrying out periodic maintenance, or the vehicle is raised for
other service, check exhaust system as follows:

Check rubber mountings for damage, deterioration, and out of
position.

Check exhaust system for leakage, loose connections, dents and
damages.
If bolts or nuts are loose, tighten them to specification.

Check nearby body areas for damaged, missing, or misposi-
tioned parts, open seams, holes, loose connections or other de-
fects which could permit exhaust fumes to seep into the vehicle.

Make sure that exhaust system components have enough clear-
ance from the underbody to avoid overheating and possible dam-
age to the floor carpet.

Any defects should be fixed at once.

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0B-24 MAINTENANCE AND LUBRICATION
FINAL INSPECTION
Seats
Check that seat slides smoothly and locks securely at
any position. Also check that reclining mechanism of
front seat back allows it to be locked at any angle.
Seat Belt
Inspect belt system including webbing, buckles, latch
plates, retractors and anchors for damage or wear.
If ªREPLACE BELTº label on front seat belt is visible,
replace belt.
Check that seat belt is securely locked.
Battery Electrolyte Level Check
Check that the electrolyte level of all battery cells is
between the upper and lower level lines on the case.
If battery is equipped with built-in indicator, check bat-
tery condition by the indicator.
Accelerator Pedal Operation
Check that pedal operates smoothly without getting
caught or interfered by and other part.
Engine Start
Check engine start for readiness.
On automatic transmission vehicles, try to start the
engine in each select lever position. The starting mo-
tor should crank only in ªPº (Park) or ªNº (Neutral).
On manual transmission vehicles, place the shift le-
ver in ªNeutral,º depress clutch pedal fully and try to
start.
Exhaust System Check
Check for leakage, cracks or loose supports.
Clutch (For Manual transmission)
Check for the following:

Clutch is completely released when depressing
clutch pedal.

No slipping clutch occurs when releasing pedal and
accelerating.

Clutch itself is free from any abnormal condition.
Gearshift or Select Lever (Transmission)
Check gear shift or select lever for smooth shifting to
all positions and for good performance of transmis-
sion in any position.
With automatic transmission equipped vehicle, also
check that shift indicator indicates properly according
to which position select lever is shifted to.
With automatic transmission equipped vehicle, make
sure that vehicle is at complete stop when shifting se-
lect lever to ªPº range position and release all brakes.
Brake
[Foot brake]
Check the following:

that brake pedal has proper travel,

that brake works properly,

that it is free from noise,

that braking force is applied equally on all wheels,

and that brake do not drag.
[Parking brake]
Check that lever has proper travel.
WARNING:
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property damage.
Be prepared to apply regular brake quickly
even if vehicle should start to move.
Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and
brake lever is pulled all the way.
WARNING:
When carrying out road tests, select a safe
place where no man or no running vehicle is
seen so as to prevent any accident.
WARNING:
Before performing the following check, be
sure to have enough room around the vehicle.
Then, firmly apply both the parking brake and
the regular brakes. Do not use the accelerator
pedal. If the engine starts, be ready to turn off
the ignition promptly. Take these precautions
because the vehicle could move without warn-
ing and possibly cause personal injury or
property damage.