Temperature SUZUKI GRAND VITARA 1999 2.G Service Owner's Guide

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1. Paint
3F-4 WHEELS AND TIRES
Higher than Recommended Pressure Can Cause:
1. Hard ride
2. Tire bruising or carcass damage
3. Rapid tread wear at center of tire
Unequal Pressure on Same Axle Can Cause:
1. Uneven braking
2. Steering lead
3. Reduced handling
4. Swerve on acceleration
Valve caps should be kept on valves to keep dust and
water out.Lower than Recommended Pressure Can Cause:
1. Tire squeal on turns
2. Hard steering
3. Rapid and uneven wear on the edges of the tread
4. Tire rim bruises and rupture
5. Tire cord breakage
6. High tire temperatures
7. Reduced handling
8. High fuel consumption
MAINTENANCE AND MINOR ADJUSTMENTS
WHEEL AND TIRE
Wheel repairs that use welding, heating, or peening are not approved. All damaged wheels should be replaced.
STUDS
If a broken stud is found, see Section 3E (rear) or Section 3D (front) for Note and Replacement procedure.
MATCHED TIRES AND WHEELS
(For vehicle equipped with steel wheels)
Tires and wheels are matchmounted at the assembly plant.
This means that the radially stiffest part of the tire, or ªhigh spotº, is
matched to the smallest radius or ªlow spotº of the wheel.
This is done to provide the smoothest possible ride.
The ªhigh spotº of the tire is originally marked by paint dot on the
outboard sidewall. This paint dot will eventually wash off the tire.
The ªlow spotº of the wheel is originally marked by paint dot on the
wheel rim-flange. Properly assembled, the wheel rims' paint dot
should be aligned with the tires' paint dot as shown in left figure.
Whenever a tire is dismounted from its wheel, it should be re-
mounted so that the tire and wheel are matched. If the tire's paint
dot cannot be located, a line should be scribed on the tire and wheel
before dismounting to assure that it is remounted in the same posi-
tion.
INFLATION OF TIRES
The pressure recommended for any model is carefully calculated to give a satisfactory ride, stability, steering, tread
wear, tire life and resistance to bruises.
Tire pressure, with tires cold, (after vehicle has set for three hours or more, or driven less than one mile) should
be checked monthly or before any extended trip. Set to the specifications on the tire placard located on the side
of instrument panel.
It is normal for tire pressure increase when the tires become hot during driving. Do not bleed or reduce tire pressure
after driving. Bleeding reduces the ªCold Inflation Pressureº.

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5B-4 FRONT BRAKE
1. Wheel nut
2. Washer
(or spacer)
ªAº: Apply grease
Brake Disc
Before this inspection, brake pads must be removed.
Check disc surface for scratches in wearing parts. Scratches on
disc surface noticed at the time of specified inspection or replace-
ment are normal and disc is not defective unless they are serious.
But when there are deep scratches or scratches all over disc sur-
face, replace it. When only one side is scratched, polish and correct
that side.
Disc thickness ªaº
Standard: 22 mm (0.866 in.) For SUMITOMO ELECTRIC. . . . .
brake caliper
17 mm (0.670 in.) For TOKICO brake caliper. . . . .
Service limit: 20 mm (0.787 in.) For SUMITOMO ELECTRIC. .
brake caliper
15 mm (0.590 in.) For TOKICO brake caliper. .
Use wheel nuts and suitable plain washers to hold the disc securely
against the hub, then mount a dial indicator as shown and measure
the runout at 25 mm (0.98 in.) from the outer edge of the disc.
Limit on disc deflection: 0.15 mm (0.006 in.)
NOTE:
Check front wheel bearing for looseness before measure-
ment.
Cylinder Slide Guide Pin / Pin Bolt
Check guide pin for smooth movement as shown.
If it is found faulty, correct or replace. Apply rubber grease to guide
pin outer surface. Rubber grease should be the on whose viscosity
is less affected by such low temperature a ±40
C (±40
F).
Dust Boot
Check boot for breakage, crack and damage. If defective, replace.

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1. Caliper pin bolts
1. Flexible hose bolt
FRONT BRAKE 5B-9
Caliper
Before installing caliper (cylinder body) to carrier, check to ensure
that guide pin (pin bolt) inserted in each caliper carrier hole can be
moved smoothly in thrust direction.
NOTE:
Where temperature gets as low as ±30
C in cold weather, use
rubber grease whose viscosity varies very little even at ±40
C
(±40
F).
INSTALLATION
1) Install caliper to caliper carrier.
2) Torque caliper pin bolts to specifications.
Tightening Torque
(a), (b): 27 N
.m (2.7 kg-m, 20.0 lb-ft) For TOKICO brake. .
caliper
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft) For SUMITOMO. . . . .
(b): 85 N.m (8.5 kg-m, 61.5 lb-ft) ELECTRIC brake
85 N.m (8.5 kg-m, 61.5 lb-ft)caliper
NOTE:
Make sure that boots are fit into groove securely.
3) Install brake flexible hose as shown and torque hose mounting
bolt to specification.
Tightening Torque
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
4) Torque wheel nuts to specification.
Tightening Torque
(c): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
5) After completing installation, fill reservoir with brake fluid and
bleed brake system. Perform brake test and check each
installed part for oil leakage.

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ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-9
1-1. CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a questionnaire form as shown below will facilitate collecting information to the
point required for proper analysis and diagnosis.
CUSTOMER QUESTIONNAIRE (EXAMPLE)
Customer's name:Model:VIN:
Date of issue:Date Reg.Date of problem:Mileage:
Problem Symptoms

ªABSº warning light abnormal: fails to turn on/fails to go off /
flashes

Abnormal noise while vehicle is running: from motor, from valve,
other__________________

Wheel is locked at braking:

Pump motor does not stop (running):

Braking does not work:

Other:
Frequency of occurrence
Continuous/Intermittent ( times a day, a month) /
other______________
Conditions for Occurrence
of Problem

Vehicle at stop & ignition switch ON:

When starting: at initial start only / at every start / Other______________

Vehicle speed: while accelerating / while decelerating / at stop /
while turning / while running at constant speed /
other________________

Road surface condition: Paved road / rough road / snow-covered
road / other_________________

Chain equipment:
Environmental Condition
Weather: fair / cloudy / rain / snow / other___________________

Temperature: F (C)
Diagnostic Trouble Code

First check: Normal code/malfunction code ( )

Second check after
test drive: Normal code / malfunction code ( )

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Viscosity chart
SAE
Temperature
1. Drain plug
2. Oil level / filler plug
MANUAL TRANSMISSION (TYPE 2) 7A1-3
ON-VEHICLE SERVICE
GEAR OIL
INSPECTION AND CHANGE
1) Before changing or inspecting oil, be sure to stop engine and lift
vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage ex-
ists, correct or repair it.
3) Drain old oil and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
NOTE:

It is highly recommended to use SAE 75W-90 gear oil.

Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage and
status of breather hoses.

If water or rust is mixed in drained oil, be sure to check
breather hose and boot of transmission and transfer.
Gear Oil Specification
Oil grade: API GL-4
Viscosity: SAE 75W-85, 75W-90 or 80W-90
Oil Capacity:
Transmission 2.6 liters (5.5 / 4.6 US / Imp. pt)
Transfer 1.7 liters (3.6 / 3.0 US / Imp. pt)
4) Torque drain plug and level / filler plug as specified below after
applying sealant to thread of plug (c).
CAUTION:
Transmission oil must not be poured through gear shift
control lever part.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 38 N´m (3.8 kg-m, 27.5 lb-ft)
(b): 23 N´m (2.3 kg-m, 17.0 lb-ft)

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AUTOMATIC TRANSMISSION (4 A / T) 7B1-23
User name: Model: VIN:
Date of issue: Date of Reg: Date of problem: Mileage:
PROBLEM SYMPTOMS
Engine does not start
Vehicle does not move
(forward, rearward)
No lock-up (TCC clutch operation)
Shift point too high or too low
Excessive gear change shockEngine stops
Transmission does not shift
(1st, 2nd, 3rd, 4th, Rev) gear
Automatic shift does not occur
Transmission slipping in
(1st, 2nd, 3rd, 4th, Rev) gear
Other:
VEHICLE/ ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS
Environmental Condition
Weather
Temperature
Frequency
RoadFair/Cloudy/Rain/Snow/Always/Other ( )
Hot/Warm/Cool/Cold/(
C
F)/Always
Always/Sometimes/( times/ day, month)/Only Once
Urban/Suburb/Highway/Mountainous (uphill/downhill)/Paved road/Gravel/
Other( )
Vehicle Condition
Engine
Brake
O/D cut switch
P/N change switch
(P,R,N,D,2,L) range/(
) range
Cold/Warming up phase/Warmed up
At stop/During driving (constant speed/accelerating/decelerating/
right hand corner/left hand corner)/Other ( )/Speed ( km/h mile/h)
Speed( r/min)/Throttle opening(idle/about %/full)
Apply/Not apply
ON/OFF
Power/Normal
Malfunction indicator lamp condition
Always ON Sometimes ON Always OFF Good condition
Diagnostic trouble
codeFirst check : No codeMalfunction code( )
Second check : No code Malfunction code( )
Transmission range
Transmission temp.
Vehicle
CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE)
NOTE:
The above form is a standard sample. It should be modified according to conditions characteristic of each
market.

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AUTOMATIC TRANSMISSION (4 A / T) 7B1-31
Brake pedal Released Depressed
Voltage 0 VBattery
voltage
DIAGNOSTIC FLOW TABLE A-1 (NO TCC LOCK-UP OCCURS)
SYSTEM DESCRIPTION
PCM turns TCC solenoid OFF under any of the following conditions.

Brake pedal switch: ON

4WD LOW switch: ON

Cruise control module: TCC OFF command signal is output (if equipped).

ECT: ECT < 30C (86F)
TROUBLESHOOTING
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 person, a driver and tester, on a level road.
STEPACTIONYESNO
1Was ªAUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLEº performed?Go to Step 2.Go to ªAUTOMATIC
TRANSMISSION
DIAGNOSTIC FLOW
TABLEº.
2ECT check:
(1) Warm up engine to normal operating
temperature.
(2) Check ECT using scan tool.
Is ECT more than 30C (86F)?Go to Step 3.Faulty ECT sensor, its
circuit or engine cooling
system.
If OK, substitute a known-
good PCM and recheck.
3Perform running test under the following
conditions and check voltage between
C51-1-8 (G16 / J20 engines) or C51-1-2 (H25
engine) terminal of PCM coupler and ground.

Normal mode in ªDº range.

Transfer ª2Hº position.

Cruise control is not operated (if equipped).

Brake pedal released.

Drive vehicle with TCC ON condition
referring to ªTCC lock-up diagramº in
this section.
Is it battery voltage?Faulty TCC solenoid
valve, its circuit or
transmission.Go to Step 4.
4Is vehicle equipped with H25 engine?Go to Step 5.Go to Step 6.
5Brake switch signal inspection:
(1) With ignition switch ON, check voltage
between E61-31 terminal of PCM coupler
terminal and ground.
Is the result as specified?Go to Step 6.Faulty brake pedal switch
or its circuit.
If OK, substitute a known-
good PCM and recheck.

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AUTOMATIC TRANSMISSION (4 A / T) 7B1-33
O / D cut
switchOFF ON
VoltageBattery
voltage0 V
DIAGNOSTIC FLOW TABLE A-2 (NO GEAR SHIFT TO O / D)
SYSTEM DESCRIPTION
PCM does not shift to O / D gear under any of the following conditions.

O / D cut switch: ON

4WD LOW switch: ON

Cruise control module: O / D OFF command signal is output (if equipped).

ECT: ECT < 30C (86F)
TROUBLESHOOTING
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 person, a driver and tester, on a level road.
STEPACTIONYESNO
1Was ªAUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLEº performed?Go to Step 2.Go to ªAUTOMATIC
TRANSMISSION
DIAGNOSTIC FLOW
TABLEº.
2ECT check:
(1) Warm up engine to normal operating
temperature.
(2) Check ECT using scan tool.
Is ECT more than 30C (86F)?Go to Step 3.Faulty ECT sensor,
its circuit or engine
cooling system.
If OK, substitute a known-
good PCM and recheck.
3Perform running test under the following
conditions and check voltage between
C51-1-2 (G16 / J20 engines) or C51-1-6 (H25
engine) terminal of PCM coupler and ground,
C51-1-1 terminal of PCM coupler and ground.

O / D cut switch OFF (ªO / D OFFº lamp OFF).

Normal mode in ªDº range.

Transfer ª2Hº position.

Cruise control is not operated (if equipped).

Drive vehicle with 4th gear condition
referring to ªGear shift diagramº in this
section.
Is each voltage about 0 V?Faulty shift solenoid
valve, its circuit or
transmission.ªGº wire or ªG / Rº wire
shorted to power circuit.
If OK, go to Step 4.
4O / D cut switch signal inspection:
(1) With ignition switch ON, check voltage
between E61-33 (G16 / J20 engines) or
E61-14 (H25 engine) terminal of PCM
coupler and ground.
Is the result as specified?Go to Step 5.Faulty O / D cut switch or
its circuit.
If OK, substitute a known-
good PCM and recheck.

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7B1-46 AUTOMATIC TRANSMISSION (4 A / T)
DTC P0741 TCC (LOCK-UP) SOLENOID VALVE PERFORMANCE OR STUCK OFF
DTC DETECTING CONDITION AND TROUBLE AREA
DTC DETECTING CONDITIONTROUBLE AREA
While running in 2nd or 4th gear, D range, TCC control
of PCM does not agree with actual operation of trans-
mission TCC even though solenoid valve is electrically
in good condition.
(2 driving cycles detection logic)
TCC (lock-up) solenoid valve stuck

TCC control valve stuck

Valve body fluid passage clogged

TCC faulty
DTC CONFIRMATION PROCEDURE
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 persons, a driver and a tester, on a level road.
1) Connect scan tool to DLC with ignition switch OFF.
2) Clear DTC, pending DTC and freeze frame data in PCM memory by using scan tool and check fuel level meter
indication is 1/4 or more.
3) Start engine, warm it up to normal operating temperature and shift transfer lever to ª2Hº or ª4Hº range.
4) Increase vehicle speed with D range, and check that gear position changes from 1st to 2nd and keep driving
about 20 mph, 30 km/h in 2nd of ªDº range for 10 seconds. (Throttle valve should be not at idle position and
the opening should be kept constant in this step.)
5) Keep driving about 50 mph, 80 km/h in 4th of ªDº range for 10 seconds.
6) Release accelerator pedal, decrease vehicle speed and stop vehicle.
7) Check pending DTC and DTC by using scan tool.
TROUBLESHOOTING
STEPACTIONYESNO
1Was ªA / T DIAG. FLOW TABLEº performed?Go to Step 2.Go to ªA / T DIAG.
FLOW TABLEº.
2TCC solenoid valve operation check:
1) Check TCC solenoid valve operation referring to
ªSolenoid Valves Operation Checkº in this section.
Is it in good condition?Go to Step 3.Faulty TCC solenoid
valve.
3Valve body check:
1) Check valve body referring to ªUnit Repairº in this
section.
Is it in good condition?Faulty torque
converter.Faulty valve body.

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G16/J20 Engines H25 Engine
G16/J20 Engines
H25 Engine
1. PCM
2. Shift solenoid-A
3. Shift solenoid-B
4. TCC solenoid
AUTOMATIC TRANSMISSION (4 A / T) 7B1-47
DTC P0743 (DTC NO.65 / 66) TCC (LOCK-UP) SOLENOID ELECTRICAL
WIRING DIAGRAM
DTC DETECTING CONDITION AND TROUBLE AREA
DTC DETECTING CONDITIONTROUBLE AREA
Voltage at terminal C51-1-8 for G16 / J20 (C51-1-2 for
H25) of PCM is high while TCC solenoid OFF is com-
manded or low while TCC solenoid ON is comman-
ded.
TCC (lock-up) solenoid valve

TCC (lock-up) solenoid valve circuit

PCM
DTC CONFIRMATION PROCEDURE
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and be very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 persons, a driver and a tester, on a level road.
1) Connect scan tool to DLC with ignition switch OFF, if available.
2) Clear DTC.
3) Start engine, warm it up to normal operating temperature and shift transfer lever to ª2Hº or ª4Hº range.
4) Shift selector lever in D range and keep it there for 10 seconds.
5) Increase vehicle speed to about 80 km / h (50 mph) in 4th gear and in D range.
6) Keep driving at above speed for 20 seconds.
7) Release accelerator pedal, decrease vehicle speed and stop vehicle.
8) Check DTC and / or pending DTC.