ESP SUZUKI GRAND VITARA 1999 2.G Service User Guide

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VITARA
(A)
1
1. Make alignment marks
1. Steering wheel
Turn slowly till coil stops
Turn contact coil back about 2 and
a half turns
1. Align marks
3C1-6 AIR BAG STEERING WHEEL AND COLUMN
STEERING WHEEL
CAUTION:
Removal of the steering wheel allows the contact coil to turn
freely but do not turn the contact coil (on the combination
switch) more than allowable number of turns (about two and
a half turns from the center position clockwise or counter-
clockwise respectively), or coil will break.
REMOVAL
1) Remove driver air bag (inflator) module from steering wheel re-
ferring to ªDRIVER AIR BAG (INFLATOR) MODULEº earlier in
this section.
2) Remove steering shaft nut.
3) Make alignment marks on steering wheel and shaft for a guide
during reinstallation.
4) Remove steering wheel with special tool.
Special Tool
(A): 09944-36011
CAUTION:
Do not hammer the end of the shaft. Hammering it will
loosen the plastic shear pins which maintain the column
length and impair the collapsible design of the column.
CENTERING CONTACT COIL
1) Check that vehicle's wheels (front tires) are set at straight-ahead
position.
2) Check that ignition switch is at ªLOCKº position.
3) Turn contact coil counterclockwise slowly with a light force till
contact coil will not turn any further.
NOTE:
Contact coil can turn about 5 turns at maximum, that is, if
it is at the center position, can turn about two and a half
turns both clockwise and counterclockwise.
4) From the position where contact coil became unable to turn any
further (it stopped), turn it back clockwise about two and a half
rotations and align center mark with alignment mark.

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1
1. Lugs
2. Grooves
3. Alignment marks
2. Steering column upper cover
3. Steering column lower cover 1. Steering column
cover screw
(a)
1. Steering column hole cover
AIR BAG STEERING WHEEL AND COLUMN 3C1-7
INSTALLATION
1) Check that vehicle's front tires are at straight-ahead position and
contact coil is centered. Refer to ªCENTERING CONTACT
COILº in this section.
CAUTION:
These two conditions are prerequisite for installation of
steering wheel. If steering wheel has been installed with-
out these conditions, contact coil will break when steer-
ing wheel is turned.
2) Install steering wheel to steering shaft with 2 lugs on contact coil
fitted in two grooves in the back of steering wheel and also align-
ing marks on steering wheel and steering shaft.
3) Tighten steering shaft nut to specified torque.
Tightening Torque
(a): 33 N
.m (3.3 kg-m, 23.5 lb-ft)
4) Install driver air bag (inflator) module to steering wheel. Refer to
ªDRIVER AIR BAG (INFLATOR) MODULEº in this section.
CONTACT COIL AND COMBINATION SWITCH
ASSEMBLY
CAUTION:
Do not turn contact coil (on combination switch) more than
allowable number of turns (about two and a half turns from
the center position clockwise or counterclockwise respec-
tively), or coil will break.
REMOVAL
1) Remove steering wheel from steering column. Refer to
ªSTEERING WHEELº in this section.
2) Remove steering column hole cover.
3) Remove steering column cover screws (3 pieces).
4) Separate upper cover and lower cover, then remove them.
5) Disconnect all connectors for contact coil and combination
switch assembly.

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1. Boot
2. Boot band
1. Circlip1. Cage Wheel side
ªAº Fill grease 85g (3.0 oz)
4A2-6 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
ASSEMBLY
CAUTION:

To prevent any problem caused by washing solution, do
not wash joint boots. Degreasing of those parts with cloth
is allowed.

For M / T vehicle with H25 engine
To ensure full performance of joint as designed, be sure
to distinguish between two types of grease in repair set
and apply specified volume to respective joint. i.e. yellow
grease to wheel side joint and black one to differential
side.

Bend each boot band against forward rotation.

Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its du-
rability.
1) Fully apply joint grease to wheel side joint.
Use joint grease in the tube included in spare part.
2) Fit wheel side boot on shaft.
Fill up inside of boot with joint grease of about 90 gram.
Before fixing boot band, insert screwdriver into boot on joint side
and allow air to enter boot so that air pressure in boot becomes
the same as atmospheric pressure.
3) Fixing boot band.
4) Install boot onto drive shaft till its small diameter side fits to shaft
groove and fix there with boot band.
5) Install cage to shaft.
CAUTION:
Install cage directing smaller outside diameter side to
shaft end.
6) Install circlip by using snap ring plier.

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ªAº
1. Shaft bearing
1. Shaft oil seal
2. Right side
3. Left side
4A2-10 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
INSTALLATION
1) Clean drive shaft oil seal and then apply lithium grease.
ªAº: Grease 99000-25010
Check oil seal for breakage or deterioration.
Replace it as necessary.
2) Drive in drive shaft bearing with special tool (A) (on left hand
side).
Special Tool
(A): 09913-75520
3) Install circlip.
4) Drive in oil seal with special tools (B) and (C).
Special Tool
(B): 09951-16090
(C): 09924-74510
NOTE:
As depth to which oil seal should be driven into axle hous-
ing is different between the left and right, be sure to check
stamped marks on special tool (B) and drive each oil seal to
corresponding mark.
5) Install left drive shaft.
6) Install left side strut. Refer to steps 1) to 2) of item STRUT
DUMPER INSTALLATION in Section 3D.
7) Install drive shaft assembly.
Refer to DRIVE SHAFT INSTALLATION in this section.
8) Fill specified differential gear oil into differential case to specified
level.

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VITARA
1. Parking brake lever
2. Brake cable
3. Self locking nut
5-12 BRAKES
PARKING BRAKE CHECK AND
ADJUSTMENT
CHECK
Hold center of parking brake lever grip and pull it up with 20 kg
(40 lbs) force.
With parking brake lever pulled up as shown, count ratchet
notches.
There should be 5 to 7 notches.
Also, check if both right and left rear wheels are locked firmly.
To count number of notches easily, listen to click sounds that ratchet
makes while pulling parking brake lever without pressing its button.
One click sound corresponds to one notch.
If number of notches is out of specification, adjust cable by referring
to adjustment procedure described on the following as to obtain
specified parking brake stroke.
NOTE:
Check tooth tip of each notch for damage or wear. If any dam-
age or wear is found, replace parking brake lever.
ADJUSTMENT
NOTE:
Make sure for following conditions before cable adjustment.

No air is trapped in brake system.

Brake pedal travel is proper.

Brake pedal has been depressed a few times with about
30 kg (66 lbs) load.

Parking brake lever has been pulled up a few times with
about 20 kg (44 lbs) force.

Rear brake shoes are not worn beyond limit, and self adjust-
ing mechanism operates properly.

To slacken parking brake cable, loosen self locking nut as far
as end of bolt. Then depress brake pedal a few times with
about 30 kg (66 lbs) load.
After confirming that above 6 conditions are all satisfied, adjust
parking brake lever stroke by loosening or tightening locking nut.
NOTE:
Check brake drum for dragging after adjustment.
Parking brake stroke: 5 to 7 notches
(When lever is pulled up at 20 kg (44 lbs).)

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3. LSPV stay
1. Master cylinder
2. Disconnect brake pipe1. LSPV lever
2. LSPV spring
3, ªAº 2
1
2(a)
ªaº
ªbº
5-14 BRAKES
3) Depress brake pedal gradually till fluid pressure of front brake
becomes as specified below and check corresponding pressure
of rear brake then. It should be within specification given below.
Front brake
Rear brake
8,000 kPa
80 kg / cm2
3 Door
6,000 ± 7,300 kPa
60 ± 73 kg / cm2
853 ± 1,038 psi80 kg / cm2
1,138 psi5 Door
4,500 ± 7,300 kPa
45 ± 73 kg / cm2
640 ± 1,038 psi
As done above, apply 100 kg / cm2 pressure to front brake and
check that rear brake pressure then is within specification as giv-
en below.
Front brake
Rear brake
10,000 kPa
100 kg / cm2
3 Door
6,500 ± 8,000 kPa
65 ± 80 kg / cm2
924 ± 1,138 psi100 kg / cm2
1,422 psi5 Door
5,000 ± 8,000 kPa
50 ± 80 kg / cm2
711 ± 1,138 psi
4) If rear brake pressure is not within specification, adjust it by
changing stay ªAº position as follows.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

If rear brake pressure is higher than specification, move stay
ªAº to direction ªaº and if it is lower, to direction ªbº.

Repeat steps 3) and 4) until rear brake pressure is within spec-
ification.

After adjustment, be sure to torque bolt to specification.
5) Disconnect brake pipe (connecting between master cylinder
secondary side and 4-way joint) from master cylinder.
Tighten plug (special tool) to master cylinder.
Depress brake pedal. If rear brake pressure is 95 ± 100 kg / cm
2
when front brake pressure is 100 kg / cm2, it means that front fail-
safe system functions properly.
Front brake
Rear brake
10000 kPa
100 kg / cm2
1422 psi
9500 ± 10000 kPa
95 ± 100 kg / cm2
1350 ± 1422 psi
Special Tool
(A): 09956-02210

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VITARA
5A-18 BRAKES PIPE / HOSE / MASTER CYLINDER
1. LSPV spring bolt
2. LSPV bolt
3. Brake pipe flare nut
4. Air bleeding plug
1. LSPV lever
2. Stopper bolt (if equipped)
3. Coil spring ªAº: Don't turn(a)
2) Torque each bolt and nut to specification as indicated respec-
tively in figure.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
(b): 16 N
.m (1.6 kg-m, 11.5 lb-ft) (brake flare nut)
(c): 7.5 N
.m (0.75 kg-m, 9.0 lb-ft) (bleeder plug)
3) Upon completion of installation, fill reservoir tank with specified
fluid and bleed air from brake system.
NOTE:
Make sure to bleed air from LSPV bleeder without failure.
4) After bleeding air, check that LSPV is installed properly, referring
to following INSPECTION & ADJUSTMENT.
INSPECTION & ADJUSTMENT
Confirm the following before inspection and adjustment.

Fuel tank is filled with fuel fully.

Vehicle is equipped with spare tire, tools, jack and jack handle.

Vehicle is free from any other load.
With vehicle in above conditions;
1) Place it on level floor.
2) Push up (for 5 door model) or push down (for 3 door model)
LSPV lever with finger till it stops and measure length ªLº of coil
spring as it is pulled.
3) Spring length ªLº should be the value specified below.
Spring length (between spring end and spring bolt)
ªLº: 103 mm (4.06 in.) (5 door model). . . . .
ªLº: 157 mm (6.18 in.) (3 door model). . . . .
4) If it isn't, adjust it to specification by changing stay positions as
shown in figure. After adjustment, tighten bolt to specified
torque.
For details, refer to left figure.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
NOTE:
Check to make sure that LSPV body and brake pipe joints
are free from fluid leakage. Replace defective parts, if any.

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AUTOMATIC TRANSMISSION (4 A / T) 7B1-41
C51-1
-18C51-1
-17C51-1
-16C51-1
-15C51-1
-28C51-1
-27 G16/
J20
H25
C51-1-4 C51-1-3 C51-1-13 C51-1-12 C51-1-20 C51-1-19
Terminal
Select
lever
position
TROUBLESHOOTING (DTC P0705)
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
2Check Transmission Range Switch (Sensor) Circuit for
Operation.
When using SUZUKI scan tool:
1) Connect SUZUKI scan tool to DLC with ignition
switch OFF.
2) Turn ignition switch ON and check transmission
range signal (P, R, N, D, 2 or L) on display
when shifting select lever to each range.
Is applicable range indicated?
When not using SUZUKI scan tool:
1) Turn ignition switch ON.
2) Check voltage at terminals C51-1-15, C51-1-16,
C51-1-17, C51-1-18, C51-1-27 and C51-1-28 for
G16/J20 (C51-1-4, C51-1-3, C51-1-13, C51-1-12,
C51-1-20 and C51-1-19 for H25) respectively with
select lever shifted to each range.
Taking terminal C51-1-28 for G16/J20 (C51-1-20 for
H25) as an example, is battery voltage indicated
only when select lever is shifted to ª2º range and
0 V for other ranges as shown in figure?
Check voltage at other terminals likewise, referring
to figure.
Are check results satisfactory?Intermittent trouble.
Check for intermittent
referring to ªIntermit-
tent and Poor
Connectionº in
section 0A.Go to Step 3.
3Check Select Cable for Adjustment referring to ªSelect
Cable Adjustmentº in this section.
Is it adjusted correctly?Go to Step 4.Adjust.
4Check Transmission Range Switch for Installation
Position.
1) Shift select lever to ªNº range.
2) Check that ªNº reference line on switch and center
line on shaft are aligned.
Are they aligned?Go to Step 5.Adjust.
5Check Transmission Range Switch (Sensor) referring
to ªTransmission Range Switchº in this section.
Are check results satisfactory?ªYº, ªOr / Gº, ªRº,
ªOr / Blº, ªY / Gº,
ªG / Orº or ªG / Blº
circuit open or short.
If wires and
connections are OK,
substitute a known-
good PCM and
recheck.Replace TR switch.
Fig. for Step 2.

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VITARA
LH steering vehicle shown
X-X:Horizontal center line of headlight bulbs
A-A:Vertical center line of left headlight bulb
B-B:Vertical center line of right headlight bulb1. Screen
2. For right / left adjustment
3. For up / down adjustment
(for vehicle without leveling system)
4. For up / down adjustment
(for vehicle with leveling system)
5. Headlight leveling actuatorHOT
SPOT LH. HEADLIGHT RH. HEADLIGHT
LIGHTING SYSTEM 8B-7
BULB REPLACEMENT
WARNING:
Don't touch when the bulb is hot.
1) Disconnect negative cable at battery.
2) Disconnect harness from bulb.
3) Remove socket cover and bulb.
4) Replace bulb and install in reverse removal procedure.
HEADLIGHT AIMING WITH SCREEN
NOTE:

Unless otherwise obligated by local regulations, adjust
headlight aiming according to following procedure.

After replacing headlight, be sure to perform its aiming.

When inspecting and adjusting headlight with leveling sys-
tem, make sure to set the leveling switch to ª0º position with
IG switch ON.
Before adjustment, make sure the following.
a) Place vehicle on a flat surface in front of blank wall as below
ahead of headlight surface.
Clearance ªaº: 10 m (32.8 ft)
b) Adjust air pressure of all tires to a specified value respectively.
c) Bounce vehicle body up and down by hand to stabilize suspen-
sion.
d) Carry out one driver aboard.
Driver's weight: 75 kg (165 lb)
Adjustment
1) Check to see if hot spot (high intensity zone) of each main (low)
beam axis falls as illustrated.
Clearance ªHº: Approx. 130 mm (5.15 in.)
2) If headlight aiming is not set properly, align it to specification by
adjusting aiming screw and aiming gear.

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VITARA
Type B Type A
Type C
1. Washer tank
8D-10 WINDOWS, MIRRORS, SECURITY AND LOCKS
2) Testing automatic stop action.
a) Connect 12 V battery (+) terminal to terminal ªAº of wiper mo-
tor (1) and (±) terminal to Black lead wire (2) (Type A, B) or
terminal ªEº (Type C), and let the motor turn.
b) Disconnect terminal ªAº from battery, and let the motor stop.
c) Connect terminal ªAº and ªDº with a jumper wire (3), and con-
nect terminal ªCº to battery (+) terminal. Observe the motor
turns once again then stops at a given position.
d) Repeat a) thru c) several times and inspect if the motor stops
at the given position every time.
Washer Pump
Connect battery (+) and (±) terminals to pump (+) and (±) terminals
respectively to check pumping rate.
Check for both front (3) and rear (2) (if equipped) washer pump.
Pumping Rate:
Front and Rear (if equipped) more than 1.0 l / min.
(2.1 US pt. / min.,
1.76 lmp pt. / min.).