SUZUKI GRAND VITARA 1987 Service Repair Manual

FOREWORD
This manual contains procedures for diagnosis, maintenance adjustments, \
service operations,
replacement of components (Service) and for disassembly and assembly o\
f major compo-
nents.
The contents are classified into sections each of which is given a secti\
on number as indicated
in the Table of Contents on next page. And on the first page of each ind\
ividual section is an
index of that section.
This manual should be kept in a handy place for ready reference of the s\
ervice work. Strict
observance of the so specified items will enable one to obtain the full \
performance of the
vehicle.
When replacing parts or servicing by disassembling, it is recommended to\
use SUZUKI
genuine parts, tools and service materials (lubricants, sealants, etc.)\
as specified in each
description.
All information, illustrations and specifications contained in this lite\
rature are based on the
latest product information available at the time of publication approval\
. The right is reserved
to make changes at any time without notice. And used as the main subject\
of description is
the vehicle of standard specifications among others. Therefore, note tha\
t illustrations and
photos may differ from the vehicle being actually serviced.
IMPORTANT:
It is important to note that, during any vehicle maintenance procedures,\
replacement
fasteners must have the same measurements as those removed.
Mismatched or incorrect fasteners can result in vehicle damage or malfun\
ction, or possible
personal injury.
Therefore, fasteners removed from the vehicle should be saved for re-use\
whenever possible.
Where the fasteners are not satisfactory for reuse, care should be taken\
to select a replace-
ment that matches the original.
Additional information concerning this subject will be found in the sect\
ion 0 (METRIC
INFORMATION).
This service manual is applicable to vehicles of and after the following\
body number.
Effective body No.:
J4235001

SUZUKI MOTOR
TECHNICAL DEPARTMENT
AUTOMOBILE SERVICE DIVISION
0 COPYRIGHT SUZUKI MOTOR CO., LTD. 1987
CO LTD
JS3JC51C J4235001
JS3JC51V J4150001
JS4JC51C J4235001
JS4JC51V 54150001

TABLE OF CONTENTS
GENERAL, SPECIAL TOOLS AND SERVICE MATERIALS
PERIODIC MAINTENANCE SERVICE
TROUBLE SHOOTING
ENGINE
FUEL SYSTEM (CARBURETOR, AIR CLEANER FUEL PUMP AND FUEL FILTER)
EMISSION CONTROL SYSTEM
ENGINE COOLING SYSTEM
CAR HEATER
IGNITION SYSTEM
CRANKING SYSTEM
CHARGING SYSTEM
CLUTCH
GEAR SHIFTING CONTROL
TRANSMISSION
TRANSFER GEAR BOX
PROPELLER SHAFTS
DIFFERENTIAL
SUSPENSION
STEERING SYSTEM
BRAKES
BODY SERVICE
,i BODY ELECTRICAL EQUIPMENT
SERVICE DATA
0
1
2
5
6
7
8
9
10
1111
12
13
14
15
16
17
18
19
20
21
22
4
3
SECTION

SECTION 0
GENERAL, SPECIAL TOOLS AND
SERVICE MATERIALS
CONTENTS
0-1. IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-1
0-2. STANDARD SHOP PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-2
0-3.SPECIAL TOOLS.. . . . . . . . . . . . 1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0-4.REQUIRED SERVICE MATERIALS . . . . . . . . . . . . . . . . . . . . . s . . . . . O-9
METRIC INFORMATION . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . O-12
O-l. IDENTIFICATION NUMBER
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is on the instrument panel left side.
Refer to below figure for detailed VIN cord information and its location.
5 1 C G 4 100001
Sequential Number
Assembly Plant
Model Year
(“G” = 1986, “H” = 1987, “J” = 1988)
Check Digit
Body Type
Design Sequence
Engine Type
Series, Chassis and
Restraint System Type
Car Line
World Manufacturer Identifier
Fig. O-l
ENGINE IDENTIFICATION NUMBER
The engine number is punched on the rear portion
of the left-hand skirt part of cylinder block.
Exhaust manifold
Fig. O-2 Location of Engine No.
O-l
JS4 J C
0-5.
O- 5
0

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

5. Fig. O-7 and O-8 show how to lift the car by
using a hoist.
WARNING:
l When using frame contact hoist, apply
hoist as shown below (right and left at
the same position), Lift up the car till 4
tires are a little off the ground and make
sure that the car will not fall off by try-
ing to move car body in both ways. Work
can be started only after this confirma-
tion.
l Before applying hoist to underbody,
always take car balance throughout serv-
ice into consideration. Car balance on
hoist may change depending of what
part to be removed.
lFor suspention parts removal, follow pre-
vious steps 3 and 4.
l Make absolutely sure to lock hoist after
car is hoisted up.
When using frame contact hoist:
6. Orderliness is a key to successful overhauling.
Trays, pans and shelves are needed to set
aside disassembled parts in groups or sets
in order to avoid confusion and misplace-
ment. This is particularly important for
engine overhauling.
7. Have on hand liquid packing-SUZUKI
BOND No. 1215 (99000-31110) - for
ready use. This packing dope is an essential
item to assure leak-free (water and oil) work-
manship.
8. Each bolt must be put back to where it was
taken from or for which it is intended. Do
not depend on your hunch in tightening
bolts for which tightening torque values are
specified: be sure to use torque wrenches on
those bolts.
9. It is advisable to discard and scrap gaskets
and “0” rings removed in disassembly. Use
new ones in reassembly, and try not to
econimize gaskets and “0” rings.
10. Use of genuine SUZUKI parts is imperative.
Use of imitation parts is a big gamble on
safetyand performance. Use genuine
SUZUKI parts and live up to the trust your
customer places on you.
11. Special tools save time and ensure good
workmanship: They are available from
SUZUKI. Use them where their use is
specified. Moreover, your own safety is
assured by the use of special tools in many
of the disassembly and reassembly steps.
Fig. O-7 Front Support Location
Fig. O-8 Rear Support Location
0-3

12. Refer to the contents of this MANUAL as
often as practical, and do each job properly
as prescribed.
NOTE:
Engine cylinders are identified by numbers.
See Fig. O-9. Counting from the front end, the
cylinders are referred to as No. 1, No. 2, No. 3
and No. 4 cylinders.
Fig. O-9 Engine Cylinder Numbers
0-4

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

0-9

0-6

0-7