light SUZUKI GRAND VITARA 1987 Service Repair Manual

STANDARD TIGHTENING TORQUE
Each fastener should be tightened to the torque specified in each section of this manual. If no description
or specification is provided, refer to the following tightening torque chart for the applicable torque for
each fastener. When a fastener of greater strength than the original one is used, however, use the torque
specified for the original fastener.
NOTE:
l For the flanged bolt and nut, add 10% to the tightening torque given in the below chart
l The below chart is applicable only where the fastened parts are made of steel or light alloy.
0-13

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. During acceleration
2. During deceleration
3. Diaphragm
Movement of EGR valve diaphragm
14. ECM AND ASSOCIATED SENSORS
INSPECTION
1) Start engine and warm it up to normal operat-
ing temperature.
For Canadian specification vehicle, turn on
check switch.
2) Run engine at 1500 - 2000 r/min (t-pm).
In this state, make sure that “CHECK EON-
GINE” light flashes.
Flashing of light proves that ECM and associ-
ated sensors are in good condition.
If the light does not flash, check them and
replace or adjust as necessary. Refer to
SECTION 5 for checking procedure.
A
CHECKENGINE
“CHECK ENGINE” ligh t
3)Turn off “CHECK ENGINE” light cancel or
check switch on steering holder bracket.
4) Stop engine.
15. WIRING HARNESS AND CONNECTIONS
INSPECTION
1) Visually inspect all wires located in engine
compartment for evidence of breakage.
Inspect the condition of the insulation
(cracks). All clips and clamps should have
solid connections to wires.
2) Replace any wires in a deteriorated or other-
wise defective condition.
16. SPARK PLUGS REPLACEMENT
1) Disconnect high-tension cords from‘ spark
plugs. Make sure to pull only on spark plug
caps.
2) Using a spark plug wrench, loosen and remove
plugs.
0.7 - 0.8 mm(0.028 - 0.032 in.)
1-12

1. Mixture adjusting screw pin
2. Rod
Mixture adjusting screw pin
10) With engine running at idle speed, adjust idle
mixture adjusting screw slowly in small incre-
ment allowing time for duty to stabilize after
turning screw to obtain duty of 10 - 50.
If duty is too low, back screw out; if too
high, screw it in. After obtaining duty of
10- 50, recheck idle speed, and adjust if
necessary.
NOTE:
If adjustment can’t be made because duty meter
indicator does not deflect, check feed baCk
system according to the checking procedure of
system described in section of Emission Control
System.
3) Reinstall carburetor following normal service
procedures.
Connect emission control system hoses and
lead wires. Make specified play on accelerator
cable and refill cooling system.
11) After adjustment, install seal rubber to duty
check coupler and drive in idle mixture
adjusting screw pin.
4) Place transaxle gear shift lever in “Neutral”,
set parking brake and block drive wheels.
5) Start engine, and warm it up to normal
operating temperature, stop engine.
6) Be sure to check the following before idle
mixutre adjustment.
l Fuel level is within round mark at the
center of level gauge.
l Valve lash is checked and adjusted accord-
ing to the maintenance schedule.
l Air cleaner has been properly installed
and is in good condition.
l All accessories (wipers, heater, lights etc)
are out of service.
29. CARBURETOR INSPECTION
Check each carburetor mounting nut for tight-
ness.
If it is found loose, tighten it securely.
Also, check where the carburetor and intake
manifold are mated and other parts of the
carburetor body for leakage. Be sure to correct
the cause for leakage, if any.
l Ignition timing is within specification.
l Choke valve opens fully.
l Idle-up actuator does not operate.
7) Check and adjust idle speed to specification
if necessary.
8) 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.
9) Run engine at 1,500 - 2,000 r/min for 30
seconds and bring it to idle speed.
1-16

Condition
Excessive pedal travel
(Pedal stroke too
large)
Possible cause
1. Partial brake system failure
2. Insufficient fluid in master
cylinder reservoirs
Correction
Check diagonal brake systems and
repair as necessary
Fill reservoirs with approved brake
fluid. Check for leaks and air in
brake systems. Check warning light.
Bleed system if necessary.
3. Air in system (Pedal soft/spongy)Bleed system
4. Rear brake system not adjustedAdjust rear brakes (Repair auto
(malfunctioning auto adjustingadjusting mechanism)
mechanism)
5. Bent brake shoesReplace brake shoes
6. Worn rear brake shoesReplace brake shoes.
Dragging brakes (A
very light drag is pre-
sent in all disc brakes
immediately after
pedal is released)
1. Master cylinder pistons not
returning correctly
2. Clogged return port in master
cylinder
3. Restricted brake tubes or hoses
4. Incorrect parking brake
adjustment
5. Weakened or broken return
springs in the brake
Repair master cylinder
Clean
Check for soft hoses or damaged tubes
and replace with new hoses and/or
new double-walled steel brake tubing
Check and adjust to correct specifica-
tions
Replace
6. Sluggish parking-brake cables or
linkage
Repair or replace
7. Wheel cylinder or caliper piston
sticking
Repair as necessary
Pedal pulsation1. Damaged or loose wheel bearingsReplace wheel bearings
(Pedal pulsates when2. Excessive disc lateral runout Check per instructions. If not within
depressed for braking)specifications, replace or machine the
disc.
3. Parallelism not within specifica-Check per instructions. If not within
tionsspecifications, replace or machine the
disc.
4. Rear drums out of roundCheck runout.
Braking noise1. Glazed shoe linings, or foreignRepair or replace shoe lining
matters stuck to linings
2. Worn or distorted shoe liningsReplace shoe lining (or pad)
3. Loose front wheel bearingsReplace wheel bearings
4. Distorted backing plates or looseReplace or retighten securing bolts
mounting bolts
2-13

Condition
Starter will not run
at all, or runs but
runs too slow to
crank with full
force
Starter does not
stop running.
2-11. ALTERNATOR
Condition
Battery quickly
becomes over-
discharged.
Charge light does not
light with ignition ON
and engine off
Alternator noise
Possible cause
Magnet switch trouble
1. Lead wire socket loose in place
2. Burnt contact plate, or poor contacting
action
3. Open-circuit in pull-in coil
4. Open-circuit in holding coil
Starter proper trouble
1. Brushes seating poorly or worn down
2. Burnt commutator
3. Open-circuit in armature winding
4. Worn-down starter.
1. Fused contact points of magnet-switch
contact plate
2. Short-circuit between turns of magnet-
switch coil (layer short-circuit)
3. Failure of returning action in ignition
switch
Possible cause
1. Loose or broken “V” belt
2. Battery cables loose, corroded or worn
3. Low level of battery electrolyte
4. Defective battery cell plates
5. Insufficient contact in battery terminal
connection.
6. Excessive electrical load
7. IC regulator or alternator faulty
8. Defective idle up system
1. Fuse blown
2. Light burned out
3. Loose wiring connection
4. IC regulator faulty
1. Worn, loose or otherwise defective bearings
Correction
Retighten
Replace, or repair
Replace
Replace
Repair or replace
Repair or replace
Replace
Replace
Repair or replace
Replace
Replace
Correction
Adjust or replace
Repair or replcae
Replace
Replace the battery
Clean and retighten
Check charging system
Replace
Repair or replace
Check fuse
Replace light
Tighten loose connection!
Replace
i
Replace
2-17

3-3. ENGINE REMOVAL
1) Disconnect negative (-) and positive (+)
cords from battery terminals.
‘)From starter motor terminals, disconnect
black/yellow lead wire and positive (+)
battery cord.
Disconnect coupler and white lead wire
from alternator terminals.
Disconnect lead wires from water tempera-
ture gauge and thermal switch. The gauge
and switch are on intake manifold.
Disconnect earth lead wire from intake
manifold.
5) Disconnect couplers of carburetor fuel cut
solenoid valve, vent solenoid valve and
mixture control solenoid valve, and dis-
connect couplers from TWSVS and VSV.
6) Remove warm air hose.
) Disconnect breather hose from air cleaner
case.
,) Remove air intake case from carburetor
body and air inlet hose.
1) Disconnect accelerator cable from carbure-
tor.
10) Disconnect vacuum hoses of TCAC and
canister from intake manifold.
11) Remove fuel tank filler cap to release fuel
vapor pressure in fuel tank. After releasing,
reinstall it. Disconnect fuel feed and return
hoses from fuel pump.
12) Disconnect lead wire from oil pressure unit
terminal and oxygen sensor lead wire at the
coupler.
13) Disconnect lead wires of back-up light
switch and fifth switch at their couplers.
14) Disconnect distributor lead wire at the
coupler.
15) Pull off high-tension cord from ignition coil.
16) Loosen radiator drain plug to drain cooling
water,
17) Disconnect water hoses from thermostat
cap and water inlet pipe. After removing
cooling fan & clutch and fan shroud, remove
radiator.
Fig. 3-3- 1
Fig. 3-3-2
16) Disconnect heater hoses from heater unit
outlet pipe and intake manifold.
Fig. 3-3-3
3)
4)
3-6

Engine Coolant
This subject is covered in SECTION 6 ENGINE
COOLING SYSTEM.
Exhaust Line and Muffler
Inspect each exhaust line connection for tight-
ness, and examine muffler and other parts for
evidence of breakage and leakage of gases.
Repair or replace defective parts, if any.
Compression Pressure Measurement
Check compression pressure on all four cylinders
as follows:
1) Warm up engine.
2) Stop engine after warming up.
3) Remove all spark plugs and disconnect
high tension cord from ignition coil.
4) Install compression gauge (special tool) into
spark plug hole.
5) Disengage clutch (to lighten starting load on
engine), and depress accelerator pedal all
the way to make throttle full-open.
6) Crank engine with fully charged battery, and
read the highest pressure on compression
gauge.
Standard
Limit
Max. difference
between any two
cylinders
Compression pressure
14.0 kg/cm2 (199.0 psi)
400 r/min
12.0 kg/cm2 (170.0 psi)
400 r/min
1 .O kg/cm2 (14.2 psi),
400 r/min
3
7) Carry out steps 4) through 6) on each cylin-
der to obtain four readings.
NOTE:
Compression pressure value is measured by using
compression gauge (Special tool 09915-64510).
Oil Pump Discharge Pressure Measurement
NOTE:
Prior to checking oil pressure, check the follow-
ing.
l Oil level in oil pan.
If level is low, add oil up to Full level hole on
oil level gauge.
0 Oil quality.
If oil is discolored, or deteriorated, change oil.
For particular oil to be used, refer to table on
p l-8 of SECTION 1.
l Oil leak.
If leak is found, repair it
1. Compression gauge (Special tool 09915-64510)
Fig. 3-8-7 Installing compression gauge
3-55

Fig. 4- l- 13 When coolant temp. rises
[Unloader system1
If accelerator pedal is depressed for acceleration
while the opening of the choke valve is small,
the throttle lever pulls down the unloader lever
and the choke valve opens up temporarily for
smooth acceleration.
1. Unloader lever
2. Choke valve
Fig. 4-1-14 Unloader system
Idle Up System
This system operates at idling and compensates
the idle speed;
1) When any one of following electric loads is
operating.
l Small light, tail light, side marker light &
license light
l Rear defogger (if equipped)
l Heater fan
2) When car is at a high altitude (higher than
1,220 m (4,000 ft) and HAC is ON).
3) When temperature in engine room is cold
(below 7°C (44°F) and thermal switch is
ON).
4) When engine speed after engine start is lower
than 1,500 r/min.
The ECM sends an electric signal to the Three
Way Solenoid Valve (TWSV). Receiving the
signal, the TWSV opens its inner valve and
transmits the manifold vacuum to the idle-up
diaphragm. As the diaphragm moves down by
the vacuum, the rod move down and push the
throttle lever to open the throttle valve a little
for the idle-up state.
In this way, the idle-up system helps to stabilize
the idle speed even when electric loads operate.
When electric loads stop operating, the TWSV
closes. Then the idle-up diaphragm as well as
rod moves back up, thus the idle-up state is
released.
I
5 1.
2.
3.
4.5.
8.
7.
8.
Idle-up actuatorAdjusting screw
Diaphragm
Rod
Throttle lever
Throttle valve
Twsv
To intake manifold
Fig. 4- I- 15 Idle-up system operation
4-11

Float Adjustment
l)The fuel level in float chamber should be
within round mark at the center of level
gauge.
1. Level gauge
2. Round mark3. Fuel level
Fig. 4- l-42 Fuel level
2) If the fuel level is not found within the round
mark, check the float level and adjust it as
follows:
a) Remove the air horn, and invert it.
b) Measure the distance between the float and
the gasketed surface of air horn. The
measured distance is float level, and it
should be the specification.
If the float level is out of specification,
adjust it by bending the tongue up or
down.
NOTE:
l This measurement should be made without a
gasket on the air horn.
l Check float height with float weight applied
to needle valve.
l As a gauge for checking float level, use
something whose thickness measurement is
the same as specified level measurement
(such as a drill or M8 bolt) after confirming
thickness with vernier calipers.
Float level8mm
specification(0.31 in.)
.
Fig. 4- l-43 Float level
1. Air horn
2. Float
3. Float level
4. Tongue
Idle Up Adjustment
1) Warm up engine to normal operating tempe-
rature.
2)Check to be sure that engine idle speed is
specification.
3) Check to ensure that idle-up actuator rod
moves down (indicating that idle-up is at
work) when small light, tail light, license
light and side marker light are turned “ON”.
1. Idle-up actuator
2. Idle-up actuator rod
3. Choke piston
4. Idle up adjustingsorew
Fig. 4- l-44 Idle-up adjusting screw
4-20