check oil SUZUKI GRAND VITARA 1987 Service Manual PDF

19-5. BRAKE BOOSTERDISASSEMBLY
REMOVAL
1) Take out fluid from master cylinder with a
syringe or such.
2) Disconnect 2 brake pipes from master cylinder
and remove master cylinder from booster.
3) Disconnect vacuum hose from booster.
4) Disconnect push rod clevis from brake pedal
arm.
5) Remove attaching nuts and then booster as
shown.
Vacuum hose
2.Booster3. Push rod clevis
4.Dash panel5.Attaching nuts6.Master cylinder
7.Gasket
8. Split pin
9. Master cylinder pin
10. Gasket11 Attaching nuts
Fig. 19-65
49
-@P
Iii
1. Vacuum check valve
2. Grommet3. Booster No. 1 body4. Piston rod
5. Reaction disc6. Booster piston return
spring7. Valve stopper key8. Booster piston9. Booster air valve assembly10. Pressure plate
Fig. 19-66
11.Diaphragm12.Booster No. 2body
13.No. 2 body oilseal14. Air cleaner separator15. Air cleaner element
16.Body bootNut
18.Bracket
19. Push rod clevis
1) Remove piston rod from booster.
2) Remove push rod clevis and nut.
Fig. 19-67
19-30
1.
17.

ASSEMBLY
NOTE:
See NOTE at the beginning of this section.
Be sure to use silicon grease wherever appli-
cation of grease is instructed during assembly.
Use of oil and grease for installation of check
valve and its grommet is strictly prohibited.
1) Apply grease to oil seal outer surface and oil
seal lip as shown.
Press-fit oil seal to booster No. 2 body by
using special tool (B) and (C).
Apply grease here
1. Hammer2. No. 2 body3. Oil seal
(6) : Oil seal remover& installer No. 1(09951’38210)
Oil seal remover
Fig. 19-80
2) Install booster air valve assembly to booster
piston. Before installation, apply grease as
shown.
Sliding surface against piston(sealed surface)
Fig. 19-81
3) Compress air valve assembly and insert valve
stopper key.
NOTE:
Be sure that valve assembly is in piston “A”
as indicated in figure. (Don’t force installation.)
Push
n
1. Air valve assembly2. Valve stopper key3. Booster piston
Fig. 19-82
4) Install diaphragm to pressure plate by hand.
NOTE:
Check to be sure that diaphragm is seated
securely in pressure plate groove for diaphragm
by turning diaphragm.
Groove2. Diaphragm
3. Booster piston4. Pressure plate
Apply grease to entire mating surfacesof pistonand diaphragm
Fig. 19-83
5) Install reaction disc to booster piston after
greasing its entire face.
6) Install booster piston to booster No. 2 body.
Fig. 19-84
Special tool
(09917-682101
19-35
1.

19-8. MAINTENANCE SERVICE
ROAD TESTING BRAKES
Brakes should be tested on dry, clean, smooth
and reasonably level roadway which is not
crowned. Road test brakes by making brake
applications with both light and heavy pedal
forces at various speeds to determine if the car
stops evenly and effectively.
Also drive car to see if it leads to one side or the
other without brake application. If it does,
check tire pressure, front end alignment and
front suspension attachments for looseness.
See diagnosis chart for other causes.
BRAKE FLUID LEAKS
Check master cylinder fluid levels. While a slight
drop in reservoir level does result from normal
lining wear, an abnormally low level indicates a
leak in the system.In such a case, check the
entire brake system for leakage. If even a slight
evidence of leakage is noted, the cause should be
corrected or defective parts should be replaced.
BRAKE FLUID LEVEL INSPECTION
Be sure to use particular brake fluid either as
marked on reservoir cap of that car or recom-
mended in owner’s manual which comes along
with that car.
Use of any other fluid is strictly prohibited.
Fluid level should be between MIN and MAX
lines marked on reservoir.
When warning light lights sometimes during
driving, replenish fluid to MAX line.
When fluid decreases quickly, inspect brake
system for leakage. Correct leaky points and
then refill to specified level.
FILL RESERVOIR
CAUTION:
Do not use shock absorber fluid or any
other fluid which contains mineral oil. Do
not use a container which has been used for
mineral oil or a container which is wet
from water. Mineral oil will cause swelling
and distortion of rubber parts in the hy-
draulic brake system and water will mix
with brake fluid, lowering the fluid boiling
point. Keep all fluid containers capped to
prevent contamination.
Fluid to fill reservoir which is indicated on
reservoir cap of the car with embossed letters or
in owner’s manual supplied with the car.
Add fluid up to MAX line.
Fig. 19-8-2
Fig. 19-8-1
19-42

Door Lock Stricker
After reinstalling the door lock striker or door
lock which was once removed, adjust dimension
“C” in Fig. 20-3-3 to 1.0 mm (0.04 in) by mov-
ing the striker up and down.
Door lock armopen position
Fig. 20-3-3
To position the door lock striker correctly in
the front and rear direction, adjust dimension
“D” to 5.5 mm (0.22 in) as shown in Fig. 20-3-4
by increasing or decreasing spacers fitted in “E”
position behind the striker.
After adjustment, check the difference in level
between the door and body and adjust when
there is a difference by moving the door lock
striker to right or left.
CAUTION:
Do not adjust the door lock.
t---l
31.0-320mm
Door inner panel(1.22 - 1 26 in)
Striker fitting
/ surface
’ Spacer fitting
position “E”
Handling of Back Door Balancer.
WARNING:
l Handle the balancer carefully. Do not
scar or scratch the exposed surface of
its piston rod, and never allow any paint
or oil to stick to the surface.
l Do not disassemble the balancer because
its cylinder is filled with high pressure
Qas.
l Do not put it into the fire.
l Do not store it where it gets hot.
l When discarding the removed back door
balancer, envelop it, as illustrated, with
a vinyl bag. Then, use a 2 to 3 mm (0.08
to 0.12 in) drill to make a hole, as shown,
from above through the bag into the
balancer and let gas out.
It-10 mm (0.4 in)
Fig. 20-3-5
5.5 mm
(0.22 in)Fig. 20-3-4
20-12

Wire color
G/R . . .Green/RedOr . Orange
0 . . . . .BlackBI/B . Blue/Black
0rlB . . .Brown/Blackw . White
Y/B . . .Yellow/BlackY/R . Yellow/Red
B/W . .Black/WhiteG/Y . .Green/Yellow
W/R .White/RedY/W . . Yellow/White
RIB .Red/BlackR/Y . Red/Yellow
G. . .GreenR/G . . .Red/Green
1.
2.
3.
4.
5.
6.7.
8.
9.
10.
50,000 mile, 80,000 mile and11. 4WD light
100,000 mile sensor switch12. Noise’suppressor
Turn signal pilot light (Lb13. Turn signal pilot light (RI
Cancel switch14. Beam pilot light
Seat belt warning light15. Fuel level meter
Brake oil level warning light16. Temp. meter
and parking brake light17. Illumination light
Charge light”18. Tachometer
Engine oil pressure light19. Seat belt warning buzzer
“CHECK ENGINE" light 20. Combination meter
Diode21. Check switch
Seat belt relay
[Combination meter without tachometer][Combination meter with tachometer]
4. TEMP. meter5. Meter print plate
6. Bulb
7. Socket
Combination meter
Fig. 21-1
8. Tachometer
REMOVAL AND INSTALLATION
1. Disconnect battery negative cable.
2. Remove instrument lower panel.
3. Lower steering column.
4. Remove combination meter cover.
5. Disconnect speedometer cable and wire
harness coupler.
7. To install combination meter, reverse above
removal procedure.
6. Remove combination meter.
Fig. 21-2
2. Speedometer3. Fuel Meter
21-3

INSPECTION21-8. OIL PRESSURE LAMP
[Brake fluid level switch]
Use ohmmeter to check switch for resistance
and continuity.
If found defective, replace switch.
The oil pressure lamp circuit consists of the oil
pressure switch installed to the cylinder block
and the lamp (warning lamp) inside the combi-
nation meter.
The oil pressure switch so operates that it is
switched OFF when oil pressure is produced by
the started engine and then fed to switch.
Fig. 21-23W/R : White/Red
6 : Black
RI0 : RedlBlack
1. Battery
2. Main switch
3. Fuse4. Oil pressure lamp
6. Oil pressure switch
B/El : Black/Blue
B/W : Black/White
Y/0 : Yellow/Black
W/Y : White/Yellow
Fig. 21-24
INSPECTION
[Oil pressure switch]
Use a ohmmeter to check the switch continuity.
During engine
Running
No continuity
obtained (- 52 1
IAt Engine StopContinuity obtained
(052)
1. To wiring harness
2. Cylinder block
Fig. 21-2521-14

DEFOGGER WIRE
NOTE:
When cleaning the rear window glass, use a
dry cloth to wipe it along the wire direction.
When cleaning the glass, do not use detergent
or abrassive-containing glass cleaner.
When measuring wire voltage, use a tester
with the negative probe wrapped with a tin
foil which should be held down on the wire
by finger pressure.
1. Heat wire2. Tin foil
3. Tester probe
Fig. 21-33 NOTE:
1) Checking wire damage
a) Turn the main switch ON.
b) Turn the defogger switch ON.
c) Use a voltmeter to check the voltage at the
center of each heat wire, as illustrated.
At center
Good
Broken wire
B.roken wire
1. Voltmeter
Fig. 21-34
If the obtained voltage is lOV, the wire must be
damaged between its center and positive end. If
the voltage is zero, the wire must be damaged
between its center and earth.
2) Checking wire for damaged place
a) Set the voltmeter positive (+) lead to the
heat wire positive terminal end.
b) Set the voltmeter negative (-) lead with a
foil strip to the heat wire positive terminal
end to then move it along the wire to the
negative terminal end.
c) The place which causes the voltmeter to
fluctuate from zero to several volts is a
damaged place.
Several volts -_(( (
Fig. 21-35
If the heat wire is free from damage, the volt-
meter should point 12V at the heat wire positive
terminal end with its indication gradually
decreased toward zero to thus equal 0V at the
other terminal (earth) end.
REPAIR
[Defogger circuit]
1) Use white gasoline for cleaning.
2) Apply a masking tape at both the upper and
lower sides of a heat wire to be. repaired.
1. Mas
2. Wood spatula
3. Broken wire4. Repair agent
Fig. 21-36
3) Apply commercially-available repair agent
with a fine-tip brush.
4) Two to three minutes later, remove the
masking tapes previously applied.
5) Leave the repaired heat wire as it is for at
least 24 hours before operating the defogger
again.
21-17

21-15. WIRING HARNESS ROUTING
When reinstalling wire harness, be careful for the following.
l When doing wiring harness related work, make always sure to disconnect battery negative cable from
battery.
l Clamp wire harness securely at prescribed positions.
l Try to route wire harness so as to avoid contact with other parts as much as possible. Use special care
not to let it contact sharp edges of body or other parts.
0 Connect connectors securely.
Engine Room Wiring
1.Wire harness No. 2
2.Battery3. To starter, alternator, head light, small light, horn and etc.
4. To license light, stop/tail light, 4WD switch
5.Earth
6.To wiring harness No.17. To head light, small light, etc.
8.To distributor
9. To ignition coil
10. To back up light switch
11. To fifth switch
12.To TWSV
13.Duty check coupler
14. Thermal engine room switch
15. HAC
16.Ignition coil
17.Brake fluidreservoir
Fig. 27-37
21-19

Fig. 21-39
Instrument Panel Wiring
1.Wire harness No.2
2. Side marker light3.Head light
4.Earth
5.Washer motor
6. To oil pressure gauge
7. To combination light
16
1.Wire harness No. 1
2.To wire~harness No.2
3.To wire harness No.2
4. To fuse box5.Horn relay
6. To combination switch7.To clutch switch
8.Tostop lampswitch15.Doorwarning buzzer
9. To heater blower motor16. Check relay
10.Toradio17.To wipermotor
Il. To heater fan switch18.To illumination lamp
12. To cigar light19. To optional meter
13.Toradio20.Toclock
14.ToECM21.Tometer
Fig. 21-40
21-21