light SUZUKI GRAND VITARA 1998 2.G Service Workshop Manual
[x] Cancel search | Manufacturer: SUZUKI, Model Year: 1998, Model line: GRAND VITARA, Model: SUZUKI GRAND VITARA 1998 2.GPages: 801, PDF Size: 12.15 MB
Page 3 of 801
YH4
GRAND
vol.1
0A
0B
1A
1B
3
3A
3B1
3C
3C1
3D
3E
3F
4A2
4B
5
6
7A5A
5B
5C
5E1
6A1
6A2
6A4
6B
6C
6E1
6E2
6F1
6F2
6G
6G1
6H
6K
7A1
7B1
7C1
7D
7E
7F
8
8B
8C
8D
8G
9
10
10A
8A
10B
6-1ENGINE
General Information and
Diagnosis (G16 / J20)
General Information and
Diagnosis (H25)
Engine Mechanical (G16)
Engine Mechanical (H25)
Engine Mechanical (J20)
Engine Cooling
Engine Fuel
Engine and Emission Control
System (SFI for G16 / J20)
Engine and Emission Control
System (SFI for H25)
Ignition System (G16)
Ignition System (J20 / H25)
Cranking System
(Reduction Type)
Cranking System
(No-Reduction Type)
Charging System
Exhaust System
TRANSMISSION, CLUTCH
AND DIFFERENTIAL
Manual Transmission (Type 1)
Manual Transmission (Type 2)
Automatic Transmission
Clutch (Hydraulic Type)
Transfer
Differential (Front)
Differential (Rear)
BODY ELECTRICAL SYSTEM
Wiring Diagram
Lighting System
Instrumentation / Driver
Information
Windows, Mirrors, Security
and Lock
Immobilizer Control System
BODY SERVICE
RESTRAINT SYSTEM
Seat Belt
Air Bag System GENERAL INFORMATION
General Information
Maintenance and Lubrication
TABLE OF CONTENTS TABLE OF CONTENTS SECTIONSECTION
0B
HEATING AND AIR
CONDITIONING
Heater and Ventilation
Air Conditioning
STEERING, SUSPENSION,
WHEELS AND TIRES
Front End Alignment
Power Steering (P / S) System
Steering Wheel and Column
(Not Equipped with Air Bag)
Air Bag Steering Wheel
and Column
Front Suspension
Rear Suspension
Wheel and Tires
1A
3A 0A
1B
3B1
3C
3C1
3D
3E
3F36A16
6A2
6A4
6B
6C
6E1
6E2
6F1
DRIVE SHAFT / PROP. SHAFT
Front Drive Shaft / Shaft
Bearing, Oil Seal
Propeller Shaft
BRAKES
Brake Pipe / Hose / Master
Cylinder
Front Brakes
Parking and Rear Brakes
Antilock Brake System
4A2
4B
5
5A
5B
5C
5E1
6F2
6G
6G1
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8
8A
8B
8C
8D
8G
9
10
10A
10B
6-1
NOTE:
The screen toned Sections 6 ± 6K are included in Volume 2 and Section 8A is in Wiring
Diagram Manual.
Page 9 of 801
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0A-6 GENERAL INFORMATION
CAUTION:
Even when the accident was light enough not to cause air
bags to activate, be sure to inspect system parts and other
related parts according to instructions under ªRepair and
Inspection Required after an Accidentº in SECTION 10B.
When servicing parts other than air bag system, if shocks
may be applied to air bag system component parts, re-
move those parts beforehand.
When handling the air bag (inflator) modules (driver and
passenger), seat belt pretensioners (driver and passen-
ger) or SDM, be careful not to drop it or apply an impact to
it. If an excessive impact was applied (e.g., dropped from
a height of 91.4 cm (3 feet) or more), never attempt disas-
sembly or repair but replace it with a new one.
When grease, cleaning agent, oil, water, etc. has got onto
air bag (inflator) modules (driver and passenger) or seat
belt pretensioners (drive and passenger), wipe off im-
mediately with a dry cloth.
Air bag wire harness can be identified easily as it is cov-
ered with a yellow protection tube. Be very careful when
handling it.
When an open in air bag wire harness, damaged wire har-
ness, connector or terminal is found, replace wire har-
ness, connectors and terminals as an assembly.
Do not apply power to the air bag system unless all com-
ponents are connected or a diagnostic chart requests it,
as this will set a diagnostic trouble code.
Never use air bag system component parts from another
vehicle.
When using electric welding, be sure to temporarily dis-
able air bag system referring to ªDisabling Air Bag Sys-
temº described in ªService Precautionsº under ªOn-Ve-
hicle Serviceº in SECTION 10B.
Never expose air bag system component parts directly to
hot air (drying or baking the vehicle after painting) or
flames.
WARNING / CAUTION labels are attached on each part of
air bag system components. Be sure to follow the instruc-
tions.
After vehicle is completely repaired, perform ªAir Bag
Diagnostic System Checkº described in ªDiagnosisº in
SECTION 10B.
Page 19 of 801
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0A-16 GENERAL INFORMATION
Poor terminal-to-wire connection.
Check each wire harness in problem circuits for poor connection
by shaking it by hand lightly. If any abnormal condition is found,
repair or replace.
Wire insulation which is rubbed through, causing an intermittent
short as the bare area touches other wiring or parts of the vehicle.
Wiring broken inside the insulation. This condition could cause
continuity check to show a good circuit, but if only 1 or 2 strands
of a multi-strand-type wire are intact, resistance could be far too
high.
If any abnormality is found, repair or replace.
PRECAUTION FOR INSTALLING MOBILE
COMMUNICATION EQUIPMENT
When installing mobile communication equipment such as CB (Citi-
zens-Band)-radio or cellular-telephone, be sure to observe the fol-
lowing precautions.
Failure to follow cautions may adversely affect electronic control
system.
Keep the antenna as far away as possible from the vehicle's elec-
tronic control unit.
Keep the antenna feeder more than 20 cm (7.9 in.) away from
electronic control unit and its wire harnesses.
Do not run the antenna feeder parallel with other wire harnesses.
Confirm that the antenna and feeder are correctly adjusted.
Page 24 of 801
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GENERAL INFORMATION 0A-21
A
ABS : Anti-lock Brake System
ATDC : After Top Dead Center
API : American Petroleum Institute
ATF : Automatic Transmission Fluid
ALR : Automatic Locking Retractor
AC : Alternating Current
A / T : Automatic Transmission
A / C : Air Conditioning
ABDC : After Bottom Dead Center
A / F : Air Fuel Mixture Ratio
A-ELR : Automatic-Emergency
Locking Retractor
B
B+ : Battery Positive Voltage
BTDC : Before Top Dead Center
BBDC : Before Bottom Dead Center
C
CKT : Circuit
CMP Sensor : Camshaft Position Sensor
(Crank Angle Sensor, CAS)
CO : Carbon Monoxide
CPP Switch : Clutch Pedal Position Switch
(Clutch Switch, Clutch Start
Switch)
CPU : Central Processing Unit
CRS : Child Restraint System
D
DC : Direct Current
DLC : Data Link Connector
(Assembly Line Diag. Link,
ALDL, Serial Data Link, SDL)
DOHC : Double Over Head Camshaft
DOJ : Double Offset Joint
DRL : Daytime Running Light
DTC : Diagnostic Trouble Code
(Diagnostic Code)
E
EBCM : Electronic Brake Control
Module, ABS Control
Module
EBD : Electric Brake force Distribution
ECM : Engine Control Module
ECT Sensor : Engine Coolant Temperature
Sensor (Water Temp.
Sensor, WTS)
EGR : Exhaust Gas Recirculation
EGRT Sensor : EGR Temperature Sensor
(Recirculated Exhaust Gas
Temp. Sensor, REGTS)
EFE Heater : Early Fuel Evaporation
Heater (Positive Temperature
Coefficient, PTC Heater)
ELR : Emergency Locking Retractor
EPS : Electronic Power Steering
EVAP : Evaporative Emission
EVAP Canister : Evaporative Emission
Canister (Charcoal Canister)
F
4WD : 4 Wheel Drive
G
GEN : Generator
GND : Ground
H
HC : Hydrocarbons
HO2S : Heated Oxygen Sensor
I
IAC Valve : Idle Air Control Valve (Idle
Speed Control Solenoid
Valve, ISC Solenoid Valve)
IAT Sensor : Intake Air Temperature
Sensor (Air temperature
Sensor, ATS)
ICM : Immobilizer Control Module
IG : Ignition
ISC Actuator : Idle Speed Control Actuator
(Motor)
ABBREVIATIONS MAY BE USED IN THIS MANUAL
Page 25 of 801
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L
LH : Left Hand
LSPV : Load Sensing Proportioning
Valve
M
MAF Sensor : Mass Air Flow Sensor
(Air Flow Sensor, AFS, Air
Flow Meter, AFM)
MAP Sensor : Manifold Absolute Pressure
Sensor (Pressure Sensor, PS)
Max : Maximum
MFI : Multiport Fuel Injection
(Multipoint Fuel Injection)
Min : Minimum
MIL : Malfunction Indicator Lamp
(ªCHECK ENGINEº Light)
M / T : Manual Transmission
N
NOx : Nitrogen Oxides
O
OBD : On-Board Diagnostic System
(Self-Diagnosis Function)
O / D : Overdrive
OHC : Over Head Camshaft
P
PNP : Park / Neutral Position
P / S : Power Steering
PSP Switch : Power Steering Pressure
Switch (P / S Pressure Switch)
PCM : Powertrain Control Module
PCV : Positive Crankcase Ventilation
R
RH : Right Hand
S
SAE : Society of Automotive
Engineers
SDM : Sensing and Diagnostic
Module (Air bag controller,
Air bag control module)
SFI : Sequential Multiport Fuel
Injection
SOHC : Single Over Head Camshaft
T
TBI : Throttle Body Fuel Injection
(Single-Point Fuel Injection,
SPI)
TCC : Torque Converter Clutch
TCM : Transmission Control Module
(A / T Controller, A / T Control
Module)
TP Sensor : Throttle Position Sensor
TVV : Thermal Vacuum Valve
(Thermal Vacuum Switching
Valve, TVSV, Bimetal Vacuum
Switching Valve, BVSV)
TWC : Three Way Catalytic
Converter (Three Way
Catalyst)
2WD : 2 Wheel Drive
V
VIN : Vehicle Identification
Number
VSS : Vehicle Speed Sensor
W
WU-OC : Warm Up Oxidation
Catalytic Converter
WU-TWC : Warm Up Three Way
Catalytic Converter
0A-22 GENERAL INFORMATION
Page 27 of 801
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0A-24 GENERAL INFORMATION
Self-lock
nut
STANDARD TIGHTENING TORQUE
Each fastener should be tightened to the torque specified in each section of this manual. If no description or specifi-
cation 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 fasten-
er.
NOTE:
For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening torque
given in the chart below.
The chart below is applicable only where the fastened parts are made of steel or light alloy.
Tightening torque chart
Thread Diameter (Nominal Diameter)
(mm)
45681012141618
Strength
45681012141618
A equivalent of 4T strength
fastenerN.m1.53.05.513294565105160
kg-m0.150.300.551.32.94.56.510.516
lb-ft1.02.54.09.521.032.547.076.0116.0
A equivalent of 6.8 strength
fastener without flan
geN.m2.44.78.4204280125193280g
kg-m0.240.470.842.04.28.012.519.328
lb-ft2.03.56.014.530.558.090.5139.5202.5
A equivalent of 6.8 strength
fastener with flan
geN.m2.44.98.8214484133203298g
kg-m0.240.490.882.14.48.413.320.329.8
lb-ft2.03.56.515.532.061.096.5147.0215.5
A equivalent of 7T strength
fastenerN.m2.34.510235085135210240
kg-m0.230.451.02.35.08.513.52124
lb-ft2.03.57.517.036.561.598.0152.0174.0
A equivalent of 8.8 strength
fastener without flan
geN.m3.16.3112756105168258373g
kg-m0.310.631.12.75.610.516.825.837.3
lb-ft2.54.58.019.540.576.0121.5187.0270.0
A equivalent of 8.8 strength
fastener with flan
geN.m3.26.512295911 3175270395g
kg-m0.320.651.22.95.911.317.52739.5
lb-ft2.55.09.021.043.082.0126.5195.5286.0
Page 52 of 801
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MAINTENANCE AND LUBRICATION 0B-25
Steering
Check to ensure that steering wheel is free from in-
stability, or abnormally heavy feeling.
Check that the vehicle does not wander or pull to
one side.
Engine
Check that engine responds readily at all speeds.
Check that engine is free from abnormal noise and
abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting sys-
tem are free from abnormal noise and abnormal
vibration or any other abnormal condition.
Meters and Gauge
Check that speedometer, odometer, fuel meter, tem-
perature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set fan switch lever to ªHIº position for this check.
RECOMMENDED FLUIDS AND LUBRICANTS
Engine oilSG, SH or SJ (Refer to engine oil viscosity chart in item 1-4)
Engine coolant (Ethylene glycol
base coolant)ªAntifreeze / Anticorrosion coolantº
Brake fluidDOT 3
Manual transmission oilRefer to Section 7A or 7A1Transfer oilRefer to Section 7A or 7A1.
Differential oil (front & rear)Refer to Section 7E or 7F.
Automatic transmission fluid and
Power steering fluidRefer to Section 3B1 or 7B1.
Door hingesEngine oil or water resistance chassis greaseHood latch assemblyEngine oil or water resistance chassis grease
Key lock cylinderSpray lubricant
Page 56 of 801
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1A-4 HEATER AND VENTILATION
FOR LH VEHICLE
FOR RH VEHICLE
1. From ignition switch 1
2. From ignition switch 2
3. From blower fuse
4. Head light relay
5. To A / C controller6. Blower motor relay
7. Blower motor switch
8. Blower resistor
9. Blower motor
10. To ECM11. To illumination controller
(if equipped) or body ground
12. Mode control actuator
13. Mode control switch
14. From main fuse15. TAIL fuse 15 A
16. IG METER fuse 20 A
17. HEATER fuse 30 A
18. REAR DEFG fuse 15 A
19. Drive circuit
WIRING CIRCUIT
Page 63 of 801
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HEATER AND VENTILATION 1A-11
1
1. Mode control switch coupler
7) Disconnect heater blower motor switch connector (1).
8) Remove mode control switch with heater control lever assem-
bly from the removed hole in mentioned step (5).
9) Pull off heater control lever knob.
10) Remove heater mode control switch (2) with heater control
panel (3) from heater control lever assembly (1).
11) Remove heater control panel from mode control switch.
INSPECTION
Mode Control Switch
Check if continuity exists between each pair of terminals listed be-
low when mode control button is pressed.
Mode
Mode control switch terminals
VENTF ± M
BI-LEVELF ± N
HEATF ± E
DEF / HEATF ± B
DEFF ± C
With battery voltage (+) connected to terminal ªIº and (±) to termi-
nal ªFº, press each mode control button and check if indicator
lamp (3) lights.
With battery voltage (+) connected to terminal ªAº and (±) to termi-
nal ªHº, check if illumination lamp lights.
Page 80 of 801
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AIR CONDITIONING (OPTIONAL) 1B-9
ABNORMAL NOISE FROM CRANKSHAFT PULLEY
ConditionPossible CauseCorrection
A large rattling noise is heard at
idle or sudden acceleration.Loosen pulley mounting bolt.
Worn or broken bearings.Retighten bolt.
Replace bearings.
ABNORMAL NOISE FROM TENSION PULLEY
ConditionPossible CauseCorrection
Clattering noise is heard from
pulley.
Pulley cranks upon contact.Worn or damaged bearings.
Cracked or loose bracket.Replace bearings.
Replace or retighten bracket.
ABNORMAL NOISE FROM EVAPORATOR
ConditionPossible CauseCorrection
Whistling sound is heard from
evaporator.Depending on the combination of
the interior / exterior
temperatures, engine rpm and
refrigerant pressure, the
refrigerant flowing out of the
expansion valve may, under
certain conditions, make a
whistling sound.At times, slightly decreasing
refrigerant volume may stop this
noise.
Inspect expansion valve and
replace if faulty.
ABNORMAL NOISE FROM BLOWER MOTOR
ConditionPossible CauseCorrection
Blower motor emits a chirping
sound in proportion to its speed of
rotation.
Fluttering noise or large droning
noise is heard from blower motor.Worn or damaged motor brushes
or commutator.
Leaves or other debris
introduced from fresh air inlet to
blower motor.Repair or replace blower motor.
Remove debris and make sure
that the screen at fresh air inlet is
intact.