steering SUZUKI GRAND VITARA 1999 2.G Owners Manual

Important
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
WARNING, CAUTION
and NOTE
have special meanings. Pay special attention to the messages highlighted by
these signal words.
WARNING:
Indicates a potential hazard that could result in death or injury.
CAUTION:
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
WARNING:
This service manual is intended for authorized Suzuki dealers and qualified service mechanics only.
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the driver
and passengers.
WARNING:
For vehicles equipped with a 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.
 If the air bag system and another vehicle system both need repair, Suzuki recommends that the air
bag system be repaired first, to help avoid unintended air bag system activation.
 Do not modify the steering wheel, instrument panel or any other air bag system component (on or
around air bag system components or wiring). Modifications can adversely affect air bag system
performance and lead to injury.
 If the vehicle will be exposed to temperatures over 93°C (200°F) (for example, during a paint baking
process), remove the air bag system components (air bag (inflator) modules, forward sensor(s),
SDM and/or seat belt pretensioners) beforehand to avoid component damage or unintended activa-
tion.

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-2 GENERAL INFORMATION
Precautions
Precaution for Vehicles Equipped with A Sup-
plemental Restraint
(Air Bag) System
Diagnosis
 When troubleshooting air bag system, be sure to follow
“DIAGNOSIS” in SECTION 10B. Bypassing these proce-
dures may result in extended diagnostic time, incorrect
diagnosis, and incorrect parts replacement.
 Never use electrical test equipment other than that
specified in this manual. WARNING:
 The configuration of air bag system parts are as shown
in the figure. When it is necessary to service (remove,
reinstall and inspect) these parts, be sure to follow
procedures described in SECTION 10B. Failure to fol-
low proper procedures could result in possible air bag
system activation, personal injury, damage to parts or
air bag system being unable to activate when neces-
sary.
 If the air bag system and another vehicle system both
need repair, SUZUKI recommends that the air bag sys-
tem be repaired first, to help avoid unintended air bag
system activation.
 Do not modify the steering wheel, dashboard, or any
other air bag system components. Modifications can
adversely affect air bag system performance and lead
to injury.
 If the vehicle will be exposed to temperatures over
93°C (200°F) (for example, during a paint baking pro-
cess), remove the air bag system components before-
hand to avoid component damage or unintended air
bag system activation.
1. Air bag wire harness 5. Contact coil
2. Passenger air bag (inflator) module 6. Driver air bag (inflator) module
3. SDM 7. Forward sensors
4. Seat belt pretensioners
15
2 6
7
5
3
44 7
1
WARNING:
Never attempt to measure the resistance of the air bag
(inflator) modules (driver and passenger) and seat belt
pretensioners (driver and passenger). It is very danger-
ous as the electric current from the tester may deploy the
air bag or activate the pretensioners.

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-3
IntervalKm (× 1,000) 153045607590
Miles (× 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
CHASSIS AND BODY
6-1. Clutch (pedal and fluid level)–I–I–I
6-2.Brake discs and pads (thickness, wear, damage) IIIIII
Brake drums and shoes (wear, damage)–I–I–I
6-3. Brake hoses and pipes (leakage, damage, clamp)–I–I–I
6-4. Brake fluid–R–R–R
6-5. Brake lever and cable (damage, stroke, operation) Inspect at first 15,000 km (9,000 miles)
only
6-6.Tires (wear, damage, rotation) IIIIII
6-7.Wheel discs (damage) IIIIII
6-8. Suspension system (tighteness, damage, rattle, breakage)–I–I–I
6-9. Propeller shafts and drive shafts––I––I
6-10. Manual transmission oil (leakage, level) (I: 1st 15,000 km only) I–R––R
6-11. Automatic transmission Fluid level –I–I–I
Fluid change Replace every 165,000 km (99,000
miles)
Fluid hose–––R––
6-12. Transfer oil (leakage, level) I–I–I–
6-13. Differential oil (leakage, level) (R: 1st 15,000 km only) R or I–I–I–
6-14. Steering system (tighteness, damage, breakage, rattle)–I–I–I
6-15.Power steering (if equipped) IIIIII
6-16. All latches, hinges and locks–I–I–I
6-17. Air conditioning filter (if equipped)–IR–IR
NOTE:
 “R”: Replace or change
 “I”: Inspect and correct, replace or lubricate if necessary

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.

AIR CONDITIONING (OPTIONAL) 1B-5
[A] : Dual A/C LH steering model 4. Condenser 11. Low pressure charge valve
[B] : Dual A/C RH steering model 5. Sight glass 12. Floor liquid pipe
[C] : Single A/C LH steering model 6. Refrigerant (dual) pressure sensor 13. Floor suction pipe
[D] : Single A/C RH steering model 7. Discharge pipe 14. Rear A/C unit
1. Front cooling unit 8. Liquid pipe 15. Rear A/C duct No.1
2. Heater unit 9. Suction pipe 16. Rear A/C duct No.2
3. Compressor 10. High pressure charge valve
[A]
[B]
[C][D]
10
7
9 3 4 6 5 1181
213
12 16
1514
1 2
13
12 16
1514
7
10
5
6
4
38
9 11
1 2
7
10
5
6
4
38
9 11
10
7
9 3 4 6 5 1181
2

POWER STEERING (P/S) SYSTEM 3B1-1
3B1
SECTION 3B1
POWER STEERING (P/S) SYSTEM
CONTENTS
General Description ......................................3B1-2
Power Steering (P/S) Pump ........................ 3B1-2
Diagnosis .......................................................3B1-2
Power Steering Pump Drive Belt ................. 3B1-2
Belt inspection ......................................... 3B1-2Belt tension check ................................... 3B1-2
Belt tension adjustment ........................... 3B1-2
Hydraulic Pressure in P/S Circuit ................ 3B1-3
Hydraulic pressure check ........................ 3B1-3 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 Man-
ual mentioned in the FOREWORD of this manual.
Some parts in the Power Steering Gear Box cannot be disassembled or adjusted. For detailed infor-
mation, refer to the description of “POWER STEERING GEAR BOX ASSEMBLY”.
All steering gear fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with
one of the same part number or with an equivalent part if replacement becomes necessary. Do not
use a replacement part of lesser quality or substitute design. Torque values must be used as speci-
fied during reassembly to assure proper retention of these parts.

3B1-2 POWER STEERING (P/S) SYSTEM
General Description
Power Steering (P/S) Pump
Power steering (P/S) pump specification :
The specification of this power steering pump is the same as the specification of the same section in the service
manual mentioned in this manual except for data of relieved pressure shown below.
Relieved pressure :
7850 kPa (78.5 kg/cm
2, 1116 psi)
Diagnosis
Power Steering Pump Drive Belt
Belt inspection
Check P/S pump drive belt (1) is free from any damage and prop-
erly fitted in pulley groove.
Belt tension check
Check belt tension by measuring how much it deflects when
pushed at arrow point (2) between pulleys with about 10 kg (22
lb) force.
Deflection of P/S belt :
4 – 7 mm (0.16 – 0.28 in.)
Belt tension adjustment
1) To adjust P/S pump drive belt (1) tension, loosen tension
pulley bolts (3) and turn tension pulley (4) using hexagon
wrench.
2) Adjust belt tension to above specification.
Then tighten tension pulley bolts (3) to specified torque.
Tightening torque
Tension pulley bolts (a) : 25 N·m (2.5 kg-m, 18.5 lb-ft)
5. P/S pump pulley
6. A/C compressor pulley (if equipped)
7. Crankshaft pulley
[A] : With A/C
[B] : Without A/C

POWER STEERING (P/S) SYSTEM 3B1-3
Hydraulic Pressure in P/S Circuit
Hydraulic pressure check
1) After cleaning joint of high pressure hose and P/S pump
thoroughly, disconnect hose from pump and install special
tool (oil pressure gauge, attachment and hose).
Special tool
(A) : 09915-77410
(B) : 09915-77420
2) Check each connection for fluid leakage and bleed air.
Refer to “AIR BLEEDING PROCEDURE” in this section.
3) With engine idling, turn steering wheel and warm up engine
till temperature of fluid in P/S fluid reservoir rises to 50 –
60°C (122 – 140°F).
4) Check back pressure by measuring hydraulic pressure with
engine idling and hands off steering wheel.
When back pressure is higher than specified values, check
control valve and piping for clogging.
Back pressure :
Lower than 1000 kPa (10 kg/cm
2, 142 psi) CAUTION:
Take care not to cause damage to A/C condenser during
service operation, if equipped.
1. P/S fluid reservoir
2. Attachment
3. Gasket
4. Union bolt
5. High pressure side
6. Low pressure side
1. P/S fluid reservoir 4. P/S gear box
2. Gauge valve (open) 5. High pressure side
3. P/S pump 6. Low pressure side