engine oil SUZUKI GRAND VITARA 1999 2.G Owners Manual

Table of Contents
GENERAL INFORMATION TRANSMISSION, CLUTCH AND
DIFFERENTIAL0A7A1
General Information0A
0B7B1
Maintenance and Lubrication0B
Manual Transmission7A1
7C1
HEATING AND AIR CONDITIONING
Automatic Transmission7B1
1A7D
Heater and Ventilation1A
Clutch7C1
1B7E
Air Conditioning1B
Transfer7D7F
STEERING, SUSPENSION, WHEELS
AND TIRESDifferential (Front)7E
3
Differential (Rear)7F
3A8
Steering, Suspension, Wheels and Tires3 ELECTRICAL SYSTEM3B18A
Front End Alignment3A
Electrical System8
3C18B
Power Steering (P/S) System3B1
Wiring Diagram8A3D8C
Air Bag Steering Wheel and Column3C1
Lightening System8B3E8D
Front Suspension3D
Instrumentation / Driver Information8C
3F8E
Rear Suspension3E
Windows, Mirrors, Security and Lock8D
8G
Wheels and Tires3F
Cruise Control System8E
4A2
DRIVE SHAFT AND PROPELLER SHAFT
Immobilizer control system (if equipped)8G4B9
Front Drive Shaft / Shaft Bearing,
Oil Seal4A2BODY SERVICE
Body Service9
510
Propeller Shaft4B RESTRAINT SYSTEM
5A10A
BRAKE SYSTEM
Restraint System10
5B10B
Brakes5
Seat Belt10A
5C
Brake Pipe / Hose / Master Cylinder5A
Air Bag System10B
5E2
Front Brake5B
Parking and Rear Brake5C
6-1
Antilock Brake System (ABS)5E2
6A2
ENGINE
6B
General Information and
Diagnosis (H27 Engine)6-1
6C
6E2
Engine Mechanical (H27 Engine)6A2
6F2
Engine Cooling6B
6G
Engine Fuel6C
6H
Engine and Emission Control System
(SFI For H27 Engine)6E2
6K
Ignition System (H27 Engines)6F2
Cranking System6G
Charging System6H
Exhaust System6K
NOTE:
For the screen toned Sections in the above table, refer to the same section of the Related Manuals
mentioned in FOREWORD of this manual.

0A-8 GENERAL INFORMATION
Warning, Caution and Information Labels
The figure below shows main labels among others that are attached to vehicle component parts.
When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels.
If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary.
1. Passenger seat belt label (if equipped) 5. Blank 9. Jacking instruction label
2. Radiator cap label 6. Air bag label on sun visor 10. Transfer label (if equipped)
3. Air bag label 7. Air bag label on sun visor (Back side)
Air bag label and utility vehicle label on sun visor (Face side)11. Armrest label on strap
4. Engine cooling fan label 8. Jacking instructions 12. Seat label (if equipped)
1. Air bag label on driver air bag (inflator) module 5. Air bag label on wire harness
2. Air bag label on combination switch and contact coil assembly 6. Air bag label on SDM
3. Air bag label on steering column cover 7. Pretensioner label on seat belt pretensioner
4. Air bag label on passenger air bag (inflator) module
3
7
7
56
4

MAINTENANCE AND LUBRICATION 0B-1
0B
SECTION 0B
MAINTENANCE AND LUBRICATION
CONTENTS
Maintenance Schedule .................................. 0B-2
Maintenance Schedule under Normal
Driving Conditions ........................................ 0B-2
Maintenance Recommended under Severe
Driving Conditions ........................................ 0B-4Maintenance Service ..................................... 0B-5
Engine and Emission Control....................... 0B-5
Drive belt inspection and replacement ..... 0B-5
Engine oil and filter replacement .............. 0B-6

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
 Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
 Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in FOREWORD of this manual.

0B-2 MAINTENANCE AND LUBRICATION
Maintenance Schedule
Maintenance Schedule under Normal Driving Conditions
NOTE:
 This interval should be judged by odometer reading or months, whichever comes first.
 This table includes service 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.
IntervalKm (× 1,000) 15 30 45 60 75 90
Miles (× 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
ENGINE
1-1. Drive belt V-rib belt (Flat type)––I––R
1-4. Engine oil and oil filter R R R R R R
1-5. Engine coolant––R––R
1-6. Exhaust system–I–I–I
IGNITION SYSTEM
2-1. Spark plugs When
unleaded
fuel is usedVehicle without
HO2SNickel plug –R–R–R
Iridium plug–––R––
Vehicle with
HO2SNickel plug ––R––R
Iridium plug Replace every 105,000 km or
63,000 miles
When leaded fuel is used, refer to “MAINTENANCE RECOMMENDED UNDER
SERVER DRIVING CONDITIONS” in this section.
FUEL SYSTEM
3-1. Air cleaner filter I I R I I R
3-2. Fuel lines and connections–I–I–I
3-3. Fuel filter Replace 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 valve Vehicle without HO2S––I––I
Vehicle with HO2S–––––I
4-3. Fuel evaporative emission con-
trol systemVehicle without HO2S–I–I–I
Vehicle with HO2S–––––I
NOTE:
 “R”: Replace or change
 “I”: Inspect and correct, replace or lubricate if necessary
 For Sweden, item 2-1, 4-2 and 4-3 should be performed by odometer reading only.
 For Item 2-1. Nickel spark plugs, replace every 50,000 km if the local law requires.
 Nickel spark plug: BKR6E-11 or K20PR-U11
 Iridium spark plug: IFR5J11 or SK16PR11

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 cold weather
B: Driving on rough and/or muddy roads F: Leaded fuel use
C: Driving on dusty roads G: – – – – – –
– –
D: Driving in extremely cold weather
and/or salted roadsH: Trailer towing (if admitted)
Severe
Condition CodeMaintenanceMaintenance
OperationMaintenance Interval
– B CD – – –ITEM 1-1
Drive belt (V-rib belt)IEvery 15,000 km
(9,000 miles) or 12 months
REvery 45,000 km
(27,000 miles) or 36 months
A – CDEF – 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
– – C – – – – – ITEM 3-1
Air cleaner filter *1IEvery 2,500 km
(1,5000 miles)
REvery 30,000 km
(18,000 miles) or 24 months
ABC–EF–HITEM 2-1
Spark plugsNickel plug REvery 10,000 km
(6,000 miles) or 8 months
Iridium plug REvery 30,000 km
(18,000 miles) or 24 months
– B – D E – – HITEM 6-9
Propeller shafts and drive shafts IEvery 15,000 km
(9,000 miles) or 12 months
– B – – E – – HITEM 6-10, 6-12, 6-13
Manual transmission,
transfer and differential oilREvery 30,000 km
(18,000 miles) or 24 months
– B – – E – – HITEM 6-11
Automatic transmission fluid REvery 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
(if equipped)IEvery 15,000 km
(9,000 miles) or 12 months
REvery 45,000 km
(27,000 miles) or 36 months
NOTE:
“I”: Inspect and correct, replace or lubricate if necessary
”R”: Replace or change
”T”: 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.

0B-6 MAINTENANCE AND LUBRICATION
POWER STEERING PUMP AND/OR A/C COMPRESSOR
DRIVE BELTS (IF EQUIPPED) INSPECTION
1) Disconnect negative (–) cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanli-
ness. If any defect exists, replace.
Check belt for tension.
If belt tension is out of above specification, adjust it referring
to Section 1B or 3B1.
Power steering pump and/or A/C compressor
drive belt tension
“a” : 4 - 7 mm (0.16 - 0.28 in.) deflection under
100 N (10 kg, 22 lb) pressure
3) Connect negative (–) cable to battery.
POWER STEERING PUMP AND/OR A/C COMPRESSOR
DRIVE BELTS (IF EQUIPPED) REPLACEMENT
Replace belt referring to Section 1B or 3B1 for replacement pro-
cedure of belt.
ITEM 1-4
Engine oil and filter replacement
Before draining engine oil, check engine for oil leakage. If any evi-
dence of leakage is found, make sure to correct defective part
before proceeding to the following work.
[A]: H27 engine with P/S system
[B]: H27 engine with P/S and A/C system
1. Crankshaft pulley
2. P/S pump pulley
3. A/C compressor pulley (if equipped)
4. Tension pulley
5. Tension pulley bolts
WARNING:
 New and used engine oil can be hazardous.
Be sure to read “WARNING” in General Precaution in
Section 0A and observe what in written there.
 Step 1) - 7) outlined below must be performed with
ENGINE NOT RUNNING. For step 8), be sure to have
adequate ventilation while engine is running.

MAINTENANCE AND LUBRICATION 0B-7
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
Engine oil drain plug (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
3) Loosen oil filter by using oil filter wrench (special tool).
Special tool
(A) : 09915-47310
4) Screw new filter on oil filter stand by hand until the filter O-
ring 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.
Tightening torque
(For reference)
Oil filter (b) : 14 N·m (1.4 kg-m, 10.5 lb-ft)
NOTE:
Before fitting new oil filter, be sure to oil its O-ring. Use
engine oil for this purpose.
CAUTION:
To tighten oil filter properly, it is important to accurately
identify the position at which filter O-ring first contacts
the mounting surface.
1. Oil filter
2. Oil filter wrench

0B-8 MAINTENANCE AND LUBRICATION
6) Replenish oil until oil level is brought to FULL level mark on
dipstick. (oil pan and oil filter capacity). The filler inlet is at
the top of the cylinder head cover.
It is recommended to use engine oil of SE, SF, SG, SH or SJ
grade.
NOTE:
Select the appropriate oil viscosity according to the proper
engine oil viscosity chart [A].
Engine oil specification :
7) Check oil filter and drain plug for oil leakage.
8) Start engine and run it for 3 minutes. Stop it and wait 5 min-
utes before checking oil level. Add oil, as necessary, to bring
oil level to FULL level mark on dipstick.
[A]: Proper engine oil viscosity chart
H27 engine
Oil pan capacity liters (US/lmp pt.) About 5.0 (10.6/8.8)
Oil filter capacity liters (US/lmp pt.) About 0.5 (1.1/0.9)
Others liters (US/lmp pt.) About 0.7 (1.5/1.2)
Total liters (US/lmp pt.) About 6.2 (13.1/10.9)
NOTE:
Engine oil capacity is specified. However, note that the
amount of oil required when actually changing oil may
somewhat differ from the data in the table depending on
various conditions (temperature, viscosity, etc.)
1. Full level mark (hole)
2. Low level mark (hole)

1B-12 AIR CONDITIONING (OPTIONAL)
Performance diagnosis table
HIGH PRESSURE GAUGE
LOW PRESSURE GAUGE
THERMOMETER AT CENTER DUCT
Condition Possible Cause Correction
Pressure high
(“A” area of high side
graph)Refrigerant overcharged Recharge.
Expansion valve frozen or clogged Check expansion valve.
Clogged refrigerant passage of high side Clean or replace.
Condenser cooling fan malfunction (Insufficient cooling
of condenser)Check condenser cooling fan.
Dirty or bent condenser fins (Insufficient cooling of con-
denser)Clean or repair.
Compressor malfunction (Insufficient oil etc.) Check compressor.
Engine overheat Check engine cooling system.
Pressure low
(“B” area of high side
graph)Insufficient refrigerant (Insufficient charge or leakage) Check for leakage, repair if necessary
and recharge.
Expansion valve malfunction (valve opens too wide) Check expansion valve.
Compressor malfunction (Insufficient compression) Check compressor.
Condition Possible Cause Correction
Pressure high
(“C” area of low side
graph)Expansion valve malfunction (valve opens too wide) Check expansion valve.
Compressor malfunction (Insufficient compression) Check compressor.
Pressure low
(“D” area of low side
graph)Insufficient refrigerant (Insufficient charge or leakage) Check for leakage, repair if necessary
and recharge.
Expansion valve malfunction (valve opens too narrow) Check expansion valve.
Clogged refrigerant passage (crashed pipe) Repair or replace.
Condition Possible Cause Correction
Outlet air temperature at
center duct is high
(Crossing point is in area
“E”)Insufficient or excessive charge of refrigerant Check refrigerant pressure.
Dirty or bent A/C evaporator fins Clean or repair.
Air leakage from cooling (heater) unit or air duct Repair or replace.
Malfunctioning, switch over function of damper in cool-
ing (heater) unitRepair or replace.
Compressor malfunction Check compressor.
Outlet air temperature at
center duct is low
(Crossing point is in area
“F”)Insufficient air volume from center duct (Heater blower
malfunction)Check blower motor and fan.
Compressor malfunction Check compressor.
NOTE:
If ambient temperature is within 30 - 35 °C (85 - 95 °F), it is possible to do using “DETAIL DIAGNOSIS
TABLE” in this section for detail diagnosis.

AIR CONDITIONING (OPTIONAL) 1B-13
Detail diagnosis table (at ambient temperature within 30 - 35 °C (85 - 95 °F))
Condition Possible Cause Correction
MANIFOLD
GAUGEMPa
(kg/cm
2)
(psi)Detail
Lo Hi
0.23 - 0.35
(2.3 - 3.5)
(33 - 50)1.4 - 1.75
(14 - 17.5)
(200 - 249)Normal condition––
Negative
pressure0.5 - 0.6
(5 - 6)
(71.2 - 85.3)The low pressure side
reads a negative pressure,
and the high pressure side
reads an extremely low
pressure.
Presence of frost around
tubing to and from receiver/
dryer and expansion valve.Dust particles or water drop-
lets are either stuck or frozen
inside expansion valve, pre-
venting the refrigerant from
flowing.Clean expansion valve.
Replace it if it cannot be
cleaned.
Replace condenser/dryer.
Evacuate the A/C system and
recharge with fresh refriger-
ant.
Normal :
0.23 - 0.35
(2.3 - 3.5)
(33 - 50)
↑ ↓
↑ ↓↑ ↓ ↑ ↓
Abnormal :
Negative
pressureNormal :
1.4 - 1.75
(14 - 17.5)
(200 - 249)
↑ ↓
↑ ↓↑ ↓ ↑ ↓
Abnormal :
0.7 - 1.0
(7 - 10)
(100 - 142)During A/C operation, the
low pressure side some-
times indicates negative
pressure, and sometimes
normal pressure. Also high
pressure side reading fluc-
tuates between the abnor-
mal and normal pressure.Expansion valve is frozen due
to moisture in the system, and
temporarily shuts off the
refrigeration cycle.Replace expansion valve.
Replace condenser/dryer.
Evacuate A/C system and
recharge with fresh refriger-
ant.
0.05 - 0.15
(0.5 - 1.5)
(4.2 - 21.3)0.7 - 1.0
(7 - 10)
(100 - 142)Both low and high pressure
sides indicate low readings.
Continuous air bubbles are
visible through sight glass.
Output air is slightly cold.Insufficient refrigerant in sys-
tem. (Refrigerant leaking)Using a gas leak detector,
check for leaks and repair as
necessary.
Recharge refrigerant to a
specified amount.
If the pressure reading is
almost 0 when the manifold
gauges are attached, check
for any leaks, repair them,
and evacuate the system.
0.4 - 0.6
(4 - 6)
(56.9 - 85.3)Pressure on low pressure
side is high.
Pressure on high pressure
side is low.
Both pressure becoming
equal right after A/C is
turned OFF.Internal leak in compressor Inspect compressor and
repair or replace as neces-
sary.
0.35 - 0.45
(3.5 - 4.5)
(50 - 64)2.0 - 2.5
(20 - 25)
(285 - 355)High pressure reading on
both low and high pressure
sides.
Air bubbles are not visible
even when engine rpm is
lowered.Overcharged A/C system.
Faulty condenser cooling
operation.
Faulty condenser fan opera-
tion.Adjust refrigerant to specified
amount.
Clean condenser.
Inspect and repair condenser
fan.
High pressure reading on
both low and high pressure
sides.
Low pressure side tubing is
not cold when touched.
Air bubbles are visible
through sight glass.Presence of air in A/C sys-
tem. (Improperly evacuated)Replace condenser dryer.
Inspect quantity of compres-
sor oil and presence of con-
taminants in oil.
Evacuate system and
recharge with fresh refriger-
ant.
0.45 - 0.55
(4.5 - 5.5)
(64 - 78)High pressure reading on
both low and high pressure
sides.
Large amount of frost or
dew on the low pressure
side tubing.Faulty expansion valve.
Refrigerant flow is not regu-
lated properly.Replace expansion valve.