ECU SUZUKI GRAND VITARA 1987 Service Repair Manual

O-2. STANDARD SHOP PRACTICES
1. Protect painted surfaces of the body, and
avoid staining or tearing seats. When working
on fenders and seats, be sure to cover them
up with sheets.
2. Disconnect negative terminal connection of
the battery when working on any electrical
part or component. This is necessary for
avoiding electrical shocks and short-circuit-
ing, and is very simple to accomplish: merely
loosen wing nut on negative terminal and
separate cable from terminal post.
3. In raising front or rear car end off the floor
by jacking, be sure to put the jack against
differential portion of axle housing.
NOTE:
Don’t get on the car, get under it or service it in
this state.
Fig. O-3 Front Side
4. To perform service with either front or rear
car end jacked up, be sure to place safety
stands under chassis frame so that body is
securely supported. Refer to below figures
for where to place safety stands. And then
check to ensure that chassis frame does not
slide on safety stands and the car is held
stable for safety’s sake.
WARNING:
Place chocks against both right and left
wheels on the ground from both front and
rear.
Fig. O-5 Front Side
&
Fig. O-6 Rear Side
Fig. 0.4 Rear Side
0-2

O-3. SPECIAL TOOLS
Special tools assure three things: 1) improved workmanship; 2) speedy execution of jobs for which they
are meant; and 3) protection of parts and components against damage. Here are the special tools pres-
cribed for this Model:
0-5

1-2. ENGINE AND EMISSION CONTROL
1. WATER PUMP BELT INSPECTION
AND REPLACEMENT
[INSPECTION]
1) Disconnect negative battery lead at battery.
2) Inspect belt for cracks, cuts, deformation,
wear and cleanliness. If any defect, replace.
Check belt for tension. The belt is in’ proper
tension if it deflects 6 to 9 mm (0.24 - 0.35
in.) under thumb pressure (about 10 kg or
22 lb.)..
Belt tension6 - 9 mm (0.24 - 0.35 in.)
specificationas deflection
pulley
3) If the belt is too tight or too loose, adjust it
to specification by adjusting alternator
position.
4) Tighten alternator adjusting bolt and pivot
bolts.
5) Connect negative battery lead to battery.
[REPLACEMENT]
1) Disconnect negative battery lead at battery.
2) Loosen alternator adjusting bolt and pivot
bolts.
3) Replace water pump belt.
4) Adjust belt tension to specification and
tighten alternator adjusting bolt and pivot
bolts.
5) Connect negative battery lead to battery.
2. CAMSHAFT TIMING BELT INSPECTION
1) Disconnect negative battery lead at battery.
2) Loosen fan drive belt, and remove 4 bolts
securing radiator shroud panel and 4 nuts
securing engine cooling fan & clutch. Then
remove radiator shroud and cooling fan &
clutch at the same time.
3) Remove water pump belt and pump pulley.
4) Remove crankshaft pulley by removing 4
pulley bolts. The crankshaft timing belt
pulley bolt at the center need not be loosen-
ed.2 1
‘31. Key
2. Crankshaft pulley
3. Pulley bolt
1-5

NOTE:
Steps 1) - 6) outlined above must be performed
with ENGINE NOT RUNNING. For step 7),
be sure to have adequate ventilation while
engine is running
It is recommended to use engine oil of SE or
SF class.
NOTE:For temperatures below
32”F(O”C), it is highly
recommended to use SAE 5W-30 oil.
Proper Engine Oil Viscosity Chart
12OW-50
lSW-40.15w-501
Ilow-4O.lOW-50
Ilow-30I
5w-30I“C-3 0 -2
0 -1
0 0 102
0
30 4
0
OF-2 2 -
4 14
32506886104
Temperatur e
Engine Oil Viscosity Chart
Engine oil capacity
Oil pan capacity 3.5 liters (7.4/6.2
US/Imp pt.)I
Total 4.0 liters(8.4/7.0 US/Imp pt.)I
8) Check oil filter and drain plug for oil leakage.
5. COOLING SYSTEM HOSES AND
CONNECTIONS INSPECTION
1) Visually inspect cooling system hoses for any
evidence of leakage and cracks. Examine them
for damage, and check connection clamps
for tightness.
2) Replace all hoses which show evidence of
leakage, cracks or other damage. Replace all
clamps which cannot maintain proper tight-
ness.
6. ENGINE COOLANT CHANGE
WARNING:
To help avoid danger of being burned, do
not remove radiator cap while engine and
radiator are still hot. Scalding fluid and
steam can be blown out under pressure if
the cap is taken off too soon.
1) Remove radiator cap when engine is cool.
2) Loosen radiator drain plug @
to drain
coolant.
3) Remove reservoir tank 0, which is on the
side of radiator, and drain.
4) Tighten plug
@ securely. Also reinstall reser-
voir tank.
1-8

4. ENGINE OIL AND FILTER CHANGEBefore draining engine oil, check engine for oil
leakage. If any evidence of leakage is found,
make sure to correct defective part before
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.
Tightening torque N-m kg-mlb-ft
for oil drain plug30-40 3.0-4.0 22.0-28.
5
3) Loosen oil filter by using oil filter wrench
“A” (special tool 09915-47310).
4) Screw new filter on oil filter stand by hand
until the filter “0” ring contacts the mounting
surface.
ICAUTION:
To tighten the oil filter properly, it is important to accurately identify the
1-position at which the filter “0” ring first
contacts the mounting surface.
5)Tighten the filter 3/4 turn from the point of
contact with the mounting surface using an
oil filter wrench
@.
filter tightening
12-16N.m
1.2
-1.6kg.m
8.5-l l.lilb-ft
6) Replenish oil until oil level is brought to
FULL level mark on dipstick. (about 3.7liters or 7.8/6.5

US/Imp pt.). The filler
inlet is atop the cylinder head cover.
7) Start engine and run it for three minutes.
Stop engine and wait another three minutes
before checking oil level. Add oil, as necessary,
to bring oil level to FULL level mark on dip
stick.
NOTE:
Before fitting new oil filter, be sure to oil its
“0” ring. Use engine oil for this purpose.
v
Full level mark (hole)
1-7

8. PCV VALVE REPLACEMENT
1) Disconnect crankcase ventilation hose from
PCV valve.
2) Remove PCV valve from intake manifold.
3) Wind sealing tape on thread of the new valve
and install it securely.
Tightenlng torque
for PCV valve
15-25 N.m
1.5-2.5 kg-m,
11 .O-18.0 lb-ft
4) Install hose and clamp it securely.
9. OXYGEN SENSOR REPLACEMENT
[Canadian specification vehicle]
When the odometer indicates 50,000 and 100,000
miles, replace oxygen sensor as follows.
CAUTION:
To avoid the danger of being burned, do
not touch the exhaust system when the
system is hot. This work should be perform-
ed when the system is cool.
1) Disconnect battery negative cable from
battery and disconnect oxygen sensor wire at
the coupler.
1. Oxygen sensor
2. Exhaust manifold
3. Coupler
2) Remove oxygen sensor from exhaust mani-
fold.
3) Install new gasket and oxygen sensor, and
tighten it to specification.
-Tightening45torque55 N-m
4.5-foroxygensensor5.5 kg-m
33.0-39.5 lb-ft
4) Connect oxygen sensor- wire at the coupler
securely and clamp its wire.
5) Connect negative cable to battery.
6) Start engine and check for gas leak.
For Canadian specification vehicle, turn on
check switch.
7) Run engine at 1,500 - 2,000 r/min for 30
sec. after warming up engine. Check to be
sure that “CHECK ENGINE” light flashes,
and turn off “CHECK ENGINE” light cancel/
check switch on steering column holder
bracket.
1. Cancel switch (U.S.A.)Check switch (Canada)
2. instrument panel
3. Steering columnholder bracket
4. Steering wheel
10. CATALYTIC CONVERTER INSPECTION
1) All accessories (wipers, heater, lights, etc.) are
out of service.
2) Warm up engine to normal operating tem-
perature.
3) Connect CO tester to mufler tail pipe.
4) With the engine warmed up, keep the engine
speed at 1,500 to 2,000 r/min. (t-pm). If the
CO concentration is 0.4% or less in this state,
the catalytic converter is in good condition.
If it exceeds the specification, refer to DIA-
GNOSIS (p. 5-15).
1-10

1. CHARCOAL CANISTER REPLACEMENT
WARNING:
The following cautions should be always
observed.
l Disconnect negative cable at battery.
l DO NOT smoke and place “NO SMOK-
ING” signs near work area.
l Be sure to have COZ fire extinguisher
handy.
l Wear safety glasses.
l To release the fuel vapor pressure in
fuel tank, remove the fuel tank cap and
then reinstall it.
1) Disconnect 3 hoses from canister.
2) Remove canister from car body.
3) Install new canister.
4) Connect 3 hoses to canister securely.
5) Clamp them securely.
//valve
To fuel tank
12. EMISSION-RELATED HOSES AND
TUBES INSPECTION
Check each vacuum hose and tube for secure
connection. Also, check that it is free from any
bend or damage.
Correct faulty condition, if any.
13. EXHAUST GAS RECIRCULATION (EGR)
SYSTEM INSPECTION
NOTE:
l Before checking, confirm that altitude is not
higher than 1,220 m (4,088 ftt) (atmospheric
pressure is below 680mmHg) and gear shift
lever is at neutral position.
o When performing this check at higher than
1,220 m (4,000 ft) altitude, be sure to dis-
connect HAC coupler.
.
1) Run engine when it is cool (coolant tempe-
rature is below 55°C (131°F)) and check
that EGR valve diaphragm is not operating in
this state, by touching diaphragm with
finger.
WARNING:
If EGR valve is hot, it may be necessary to
wear gloves to avoid burning finger.
1. EGR valve
22. Diaphragm
Checking EGR valve diaphragm
2) Warm up engine to normal operating tempe-
rature and race it after warming up. Then
check to be sure that diaphragm moves
toward @ in below figure during acceleration
and toward @ during deceleration.
l- 11

NOTE:
When replacing plugs, make sure to use new
plugs of specified heat range and size.
PLUG SPECIFICATION
~1
3) Install new spark plugs. Tighten plugs to
specification.
4) Connect high tension cords to spark plugs.
DO NOT push cords for connection. Push
boots.
17. DISTRIBUTOR CAP AND ROTOR
INSPECTION
1) Inspect distributor cap and rubber caps for
cracks.
2) Inspect center electrode and terminals for
wear.\‘(
3) Inspect rotor for cracks, and its electrode
for wear.
4) Check to see that there are no excessive
closes in ventilation plug hole.
5) Repair or replace as necessary any compo-
nent which is found to be in malcondition as
described above.
18. IGNITION WIRING REPLACEMENT
1) Disconnect high tension cords from spark
plugs, ignition coil and distributor.
2) Connect new high tension cords as shown
and clamp them securely. DO NOT push
cords for connection. Push boots.
19. IGNITION~TIMING INSPECTION
Check to make sure that ignition timing is set
properly. If out of specification, adjust it.
Refer to p. 8-9 for inspection and adjustment
procedure.
20. DISTRIBUTOR ADVANCER INSPECTION
Check advancer for proper operation. Refer to
p. 8-9 for checking procedure.
Check vacuum hose for pinhole, crack or break.
Correct or replace if necessary.
NOTE:
Dust and stains found within distributor can be
cleaned by using a dry, soft cloth.
1-13

21. FUEL TANK CAP GASKET INSPECTION
AND REPLACEMENT
Visually inspect gasket of fuel tank cap. If it is
damaged or deteriorated, replace it with new
one.
22. AIR CLEANER ELEMENT
REPLACEMENT
1) Remove air cleaner cap.
2) Take cleaner element @ out of air cleaner
case.
3) Install new cleaner element @ into cleaner
case.
4) Install air cleaner cap securely.
23. THERMOSTATICALLY CONTROLLED
AIR CLEANER SYSTEM INSPECTION
Check thermostatically controlled air cleaner
system for proper operation. Refer to p. 5-19
for checking procedure.
24. CARBURETOR CHOKE SYSTEM
LUBRICATION AND INSPECTION
1) Remove air intake case, and lubricate rotating
paItS.
2) Check choke for proper operation.
Refer to p. 4-22 for checking procedure.
25. FUEL FILTER REPLACEMENT
This work must be performed in a well
1) Disconnect negative cable from battery.
2) Remove fuel tank cap to release fuel vapor
pressure in fuel tank. After releasing, reinstall
the cap.
3) Disconnect inlet and outlet hoses from fuel
filter located at the front part of fuel tank,
inside the right-hand side of chassis.
4) Remove fuel filter with clamp.
5) Install new filter with clamp, and connect
inlet and outlet hoses to fuel filter.
NOTE:
The top connection is for the outlet hose, the
lower one for the inlet hose.
6) Connect negative cable to battery.
7) After installation, start engine and check it
for leaks.
26. FUEL LINES AND CONNECTIONS
INSPECTION AND REPLACEMENT
[INSPECTION]
Visually inspect fuel lines and connections for
evidence of fuel leakage, hose cracking, and
damage. Make sure all clamps are secure.
Repair leaky joints, if any.
Replace hoses that are suspected of being
cracked.
[REPLACEMENT]
WARNING:
The following cautions should be always
observed.
l Disconnect negative cable at battery.
l DO NOT smoke and place “NO SMOK-
ING” signs near work area.
l Be sure to have CO2 fire extinguisher
handy.
0 Wear safety glasses.
l To release the fuel vapor pressure in fuel
tank, remove the fuel tank cap and
then reinstall it.
1-14

1) Replace fuel hoses (pipe to fuel pump, pipe to
fuel filter and breather hose) in fuel feed and
return lines with new ones.
2) Remove fuel tank.
3) Replace return hose (tank to return pipe)
with new one.
4) Clamp hoses securely.
5) Install fuel tank referring to p. 4-35.
6) After installation, start engine and check it
for leaks.
27. IDLE SPEED INSPECTION
NOTE:
Before starting engine, place transmission gear
shift lever in “Neutral”, and set parking brake
and block drive wheels.
1) Warm up engine to normal operating tempe-
rature.
2) Check to ensure that idle speed is within
750 - 850 r/min (rpm).
3) If idle speed is not within specified range,
adjust idle speed. Refer to MAINTENANCE
SERVICE (p. 4-26) for procedures to check
and adjust idle speed.
28. IDLE MIXTURE INSPECTION
1) Warm up engine to normal operating tem-
perature.
2) Remove seal rubber of duty check coupler
and connect positive terminal of duty meter
to “Blue/Red” wire and negative terminal to
“Black/Green” wire.
1
1. Duty check coupler
2. Air intake case
3) Set tachometer.
4) Run engine at 1,500 - 2,000 r/min for 30
seconds and bring it to idle speed.
5) Check duty at specified idle speed. If it is out
of specification,adjust it to specification
according to following adjustment procedure.
Specified Duty10-50
at 750 - 850 r/min.I
After inspection, install seal rubber to duty
check coupler.
Idle mixture adjustment procedure is as follows:
1) Remove carburetor from intake manifold
following normal service procedure to gain
access to mixture adjusting screw pin covering
mixture adjusting screw.
2) Drive out mixture adjusting screw pin using
about 4.5 mm (0.18 in) thick iron rod as
shown below.
1-15