specification SUZUKI GRAND VITARA 2000 2.G Service Workshop Manual

YH4
GRAND
VITARA
1. Differential to rear axle nut
(a)
(a)
DIFFERENTIAL (REAR) 7F-5
REMOUNTING
1) Clean mating surfaces of rear axle and differential assembly and
apply sealant (Suzuki bond 1215) to axle side evenly.
ªAº: Sealant 99000-31110
2) Install differential assembly to axle and fix it with nuts tightened
to specified torque.
Tightening Torque
(a): 55 N
.m (5.5 kg-m, 40.0 lb-ft)
3) Install propeller shaft to joint flange aligning match marks and
torque flange bolts to specification.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
4) Install right and left rear axle shafts and drums.
(Refer to rear axle installation of SECTION 3E and rear brake
drum installation of SECTION 5.)
5) Install wheels.
6) Fill hypoid gear oil as specified and tighten plug to specification.
Lower lift.
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in Foreword of this manual.

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7F-6 DIFFERENTIAL (REAR)
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN.mkg-mlb-ft
Differential oil filler / level plug505.036.5
Differential oil drain plug282.820.5
Propeller shaft flange bolts505.036.5
Differential carrier nuts555.540.0
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
SealantSUZUKI BOND NO. 1215
(99000-31110)

Rear differential oil drain plug

Mating surface of differential
housing

Mating surface of rear axle housing

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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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INSTRUMENTATION / DRIVER INFORMATION 8C-9
1. Exhaust pipe
FUEL METER / FUEL GAUGE UNIT
FUEL METER
INSPECTION
1) Remove rear bumper facing.
2) Detach grommet (3) from vehicle.
3) Disconnect coupler (2) of fuel pump and gauge.
4) Turning switch ON, and check that fuel meter indicates E.
5) Turn ignition switch OFF.
6) Ground Bl / W lead through a 3.4 W test bulb (4) as illustrated.
7) Turn ignition switch ON and check that bulb light up and pointer
(5) moves to F side.
8) If fuel meter shows no operation, repair or replace defective
parts.
FUEL SENDER GAUGE
INSPECTION
1) Remove fuel pump assembly (1) referring to FUEL PUMP RE-
MOVAL in Section 6C.
2) Check resistance between terminals (A) and (B) under each
float position.
Float Position
FuelResistance (
)56
model66
modelMeterResistance (
)
ªaº88.3 mm
(3.48 in.)51.7 mm
(2.04 in.)F6 ± 8
ªbº157.2 mm
(6.20 in.)139.6 mm
(5.50 in.)1/229.5 ± 35.5
ªcº254.9 mm
(10.0 in.)254.9 mm
(10.0 in.)E94 ± 96
If measured valve is out of specification, replace fuel sender gauge.

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Terminal
Key
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-21
6) Connect negative cable at battery.
7) Check that the voltage and resistance between following termi-
nals are specifications.
Terminals
ConditionSpecification
E02-7 and
groundAnytime10 ± 14 V
E02-14 and
groundAnytimecontinuity
E02-8 and
When driver side door key
switch is OFF positionNo continuity
groundWhen driver side door key
switch is LOCK positionContinuity
E02-9 and
When driver side door key
switch is OFF positionNo continuity
groundWhen driver side door key
switch is UNLOCK positionContinuity
If check result is not satisfactory, repair circuit and recheck.
If check result is satisfactory, replace controller.
KEY CYLINDER SWITCH (DRIVER SIDE)
Check for continuity between terminals according to the key action
shown below.
321
LOCK
OFF
UNLOCK

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WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-25
POWER DOOR LOCK ACTUATOR CIRCUIT
INSPECTION
1) Disconnect negative cable at battery.
2) Disconnect coupler of power door lock and keyless entry con-
troller.
3) Use a 12 V battery to connect its (+) terminal to terminal E02-1,
and its (±) terminal to terminal E02-2 and E02-3. Check all power
doors are locked.
If check result is satisfactory, this circuit is OK.
POWER SUPPLY AND GROUNDING CIRCUIT
INSPECTION
1) Disconnect negative cable at battery.
2) Disconnect coupler of power door lock and keyless entry con-
troller, and connect negative cable at battery.
3) Check that the voltage and resistance between following termi-
nals are specifications.
Terminals
ConditionSpecification
E02-7 and
groundAnytime10 ± 14 V
E02-14 and
groundAnytimeContinuity
If check result is satisfactory, this circuit is OK.
DOOR LOCK KEY AND POWER DOOR LOCK SWITCH
CIRCUIT
INSPECTION
1) Disconnect negative cable at battery.
2) Disconnect coupler of power door lock and keyless entry con-
troller.
3) Check for continuity between following terminals at each condi-
tion.
Terminals
ConditionSpecification
E02-8 and
When driver side door key
switch is OFF positionNo continuity
groundWhen driver side door key
switch is LOCK positionContinuity
E02-9 and
When driver side door key
switch is OFF positionNo continuity
groundWhen driver side door key
switch is UNLOCK positionContinuity
If check result is satisfactory, this circuit is OK.

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8D-26 WINDOWS, MIRRORS, SECURITY AND LOCKS
IGNITION SWITCH AND DOOR SWITCH CIRCUIT
INSPECTION
1) Disconnect negative cable at battery.
2) Disconnect coupler of power door lock and keyless entry con-
troller, and connect negative cable at battery.
3) Check that the voltage and resistance between following termi-
nals are specifications.
Terminals
ConditionSpecification
E02-4 and
When ignition switch is OFF
position0 V
groundWhen ignition switch is ON
position10 ± 14 V
E02 10 andWhen all doors are closedNo continuityE02-10 and
groundWhen any one door is
openedContinuity
If check result is satisfactory, this circuit is OK.
DOOR KNOB SWITCH AND TURN SIGNAL RELAY CIRCUIT
INSPECTION
1) Disconnect negative cable at battery.
2) Disconnect coupler of power door lock and keyless entry con-
troller, and connect negative cable at battery.
3) Check that the voltage and resistance between following termi-
nals are specifications.
Terminals
ConditionSpecification
E02-6 and
groundAnytime10 ± 14 V
E02-11 and
When driver side door lock
knob is pulled upContinuity
groundWhen driver side door lock
knob is pushed downNo continuity
If check result is satisfactory, this circuit is OK.

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VITARA
1. Seat cushion
2. Seat back
3. Reclining assy (RH side)
4. Reclining assy (LH side)
5. Seat adjuster (RH outside)
6. Seat adjuster (RH inside)
7. Seat adjuster (LH outside)
8. Seat adjuster (LH inside)
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)
(b): 23 N.m (2.3 kg-m, 17.0 lb-ft)
1. Cover
2. Coupler(b)
9-34 BODY SERVICE
SEAT
FRONT SEAT
REMOVAL
1) Disconnect lead wire(s) at coupler (if equipped). Remove four
mounting bolts fixing front seat to seat rail to remove front seat.
2) Disassemble and repair seat as necessary.
INSTALLATION
Reverse removal procedure to install front seat.
Torque to specifications, as shown.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)

YH4
GRAND
VITARA
1. Seat cushion
2. Seat back
3. Seat auto lock release handle
4. Seat hinge male
5. Hinge male cover
BODY SERVICE 9-35
REAR SEAT
REMOVAL
1) Remove four mounting bolt to remove seat cushion.
2) Remove four mounting bolts to remove seat back.
3) Disassemble and repair seat as necessary.
INSTALLATION
Reverse removal procedure to install rear seat.
Torque to specifications, as shown.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)

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VITARA
10A
SEAT BELT 10A-1
SECTION 10A
SEAT BELT
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 autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº 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
ªLOCKº 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).
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were re-
moved. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may
be used. Fasteners that are not reused, and those requiring thread-locking compound, will be called
out. The correct torque value must be used when installing fasteners that require it. If the above proce-
dures are not followed, parts or system damage could result.
CONTENTS
GENERAL DESCRIPTIONRefer to SECTION 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE10A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service precautions10A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front seat belt10A-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear seat belt10A-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS10A-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .