panel SUZUKI GRAND VITARA 2000 2.G Service User Guide

YH4
GRAND
VITARA
1. Steering column
2. Mounting bolt
3. Steering column lower seal
4. Dash panel
1. Steering column lower seal
In engine room
In cabin
1. Shift (key) interlock cable
2. Screw
3C1-12 AIR BAG STEERING WHEEL AND COLUMN
4) Check steering column lower seal for breakage or deformation.
If found defective, replace.
5) Check steering shaft joints and shaft for any damages such as
crack, breakage, malfunction or excessive play.
If anything is found faulty, replace as steering lower shaft assem-
bly or steering column assembly.
6) Check steering shaft for smooth rotation.
If found defective, replace as column assembly.
7) Check steering shaft and column for bend, cracks or deforma-
tion.
If found defective, replace as column assembly.
INSTALLATION
CAUTION:
After tightening steering column mounting bolts, steering
shaft joint bolts should be tightened.
1) Be sure that front wheels and steering wheel are in straight-
ahead position.
2) If equipped with shift (key) interlock cable, install shift (key) inter-
lock cable to ignition switch.
Tightening Torque
(a): 2.2 N
.m (0.22 kg-m, 1.6 lb-ft)
3) Install steering column assembly to dash panel and upper
bracket so that boss of steering column lower seal and all around
it project out of hole in dash panel into engine room. Tighten
steering column lower bolts (4 pieces) first and then upper bolts
(2 pieces) to specified torque.
Tightening Torque
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

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VITARA
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.

YH4
GRAND
VITARA
1. Stop light switch
BRAKES 5-9
BRAKE PEDAL FREE HEIGHT CHECK
Remove foot rest and displace carpet and dash silencer(s) so as to
measure brake pedal free height between pedal face and asphalt
sheet installed on dash panel.
Brake pedal free height ªaº from asphalt sheet:
208 ± 218 mm (8.19 ± 8.58 in.)
If the measurement is not within the specification, check the posi-
tion of booster push rod clevis and / or stop light switch according
to the instruction shown in this section.
The free height varies depending on installation position of booster
push rod clevis and stop light switch.
BRAKE LIGHT SWITCH ADJUSTMENT
Adjustment should be made as follows when installing switch. Pull
up brake pedal toward you and while holding it there, adjust switch
position so that clearance between end of thread and brake pedal
return cushion (shown as ªbº in figure).
Then tighten lock nut to specified torque.
Clearance ªbº: 1.5 ± 2.0 mm (0.06 ± 0.08 in.)
Tightening Torque
(b): 7.5 N
.m (0.75 kg-m, 5.5 lb-ft)
EXCESSIVE PEDAL TRAVEL CHECK
1) Remove foot rest and displace carpet and dash silencer(s).
2) Start engine.
3) Depress brake pedal a few times.
4) With brake pedal depressed with approximately 30 kg (66 lbs)
load, measure pedal to asphalt sheet clearance ªcº.
Clearance ªcº: over 115 mm (4.53 in.)
5) If clearance ªcº is less than specification, the most possible
cause is either rear brake shoes are worn out beyond limit or air
is in lines.
Should clearance ªcº remain less than specification even after
replacement of brake shoes and bleeding of system, other pos-
sible but infrequent cause is malfunction of rear brake shoe ad-
justers or booster push rod length out of adjustment.

YH4
GRAND
VITARA
5A-16 BRAKES PIPE / HOSE / MASTER CYLINDER
1. Clevis
2. Nut
1. Steering column 4. Clevis pin
2. Push rod clevis 5. Clip
3. Brake pedal arm 6. NutBOOSTER PUSH ROD CLEVIS ADJUSTMENT
Install push rod clevis so that measurement ªaº is obtained and
torque nut to specification.
Tightening Torque
(a): 25 N
.m (2.5 kg-m, 18.0 lb-ft)
Length
ªaº: 109.5 ± 110.5 mm (4.31 ± 4.35 in.)
INSTALLATION
NOTE:

See NOTE at the beginning of this section.

Check length of push rod clevis. (Refer to BOOSTER PUSH
ROD CLEVIS ADJUSTMENT.)

Before installing master cylinder, adjust booster piston rod.
(Refer to CLEARANCE BETWEEN BOOSTER PISTON ROD
AND MASTER CYLINDER PISTON ADJUSTMENT of this sec-
tion.)

Apply silicone grease to master cylinder piston.
1) Install booster to dash panel as shown. Then connect booster
push rod clevis to pedal arm with clevis pin and clip.
2) Tighten booster attaching nuts to the specified torque.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
3) Connect brake vacuum hose to brake booster.
4) For vehicle equipped with ABS, connect brake pipes to ABS hy-
draulic unit. If ABS hydraulic unit bracket bolts removed, tighten
flare nuts to specification after installing master cylinder.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 12.0 lb-ft)
5) Install master cylinder, referring to MASTER CYLINDER AS-
SEMBLY INSTALLATION in this section.

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VITARA
1. Malfunction indicator lamp (MIL)
2. Scan tool
3. DLC
7B1-18 AUTOMATIC TRANSMISSION (4 A / T)
[For Vehicle without Monitor Connector]
ON-BOARD DIAGNOSTIC SYSTEM
For automatic transmission control system, PCM (ECM) has follow-
ing functions. Refer to Section 6 / 6-1 for details.

When the ignition switch is turned ON with the engine at a stop,
malfunction indicator lamp (MIL) turns ON to check the bulb of the
MIL.

When PCM detects a malfunction in A / T control system (and / or
a malfunction which gives an adverse effect to vehicle emission)
while the engine is running, it makes the malfunction indicator
lamp in the meter cluster of the instrument panel turn ON and
stores the malfunction area in its memory. (If it detects that contin-
uously 3 driving cycles are normal after detecting a malfunction,
however, it makes MIL turn OFF although DTC stored in its
memory will remain.)

It is possible to communicate through DLC by using not only SU-
ZUKI scan tool (Tech-1) but also generic scan tool. (Diagnostic in-
formation can be accessed by using a scan tool.)
2 Driving Cycle Detection Logic
Refer to section 6 / 6-1 for details.
Pending DTC
Refer to section 6 / 6-1 for details.
Freeze Frame Data
Refer to section 6 / 6-1 for details.

YH4
GRAND
VITARA
1. Wood block
2. Dash panel
t: 45 mm / 1.8 in.
H: 200 mm / 8 in.
W: 100 ± 150 mm / 4 ± 6 in.
1. Transmission jack
2. Engine rear mounting member
3. Gear shift lever case
4. Bolt
TRANSFER 7D-5
TRANSFER ASSEMBLY
Dismounting and remounting of transfer and transmission together
as a unit is described in Section 7A for Manual Transmission or 7B1
for Automatic Transmission, but it is also possible to dismount and
remount transfer assembly by itself as described below.
DISMOUNTING
IN ENGINE ROOM
1) Disconnect negative (±) cable from battery.
2) Remove distributor assembly (if equipped).
3) Place wood block between engine and dash panel so that it
serves as stopper when engine, transmission and transfer unit
hangs down as rear mounting member is removed.
CAUTION:
Make sure to use wood block to prevent contact which
may occur between dash panel and CMP sensor case
(G16), CMP sensor (J20) or intake manifold (H25), and fan
and shroud.
IN CABIN
1) Remove console box.
2) Remove shift lever of transmission and transfer.
ON LIFT
1) Drain transfer oil.
2) Remove rear propeller shaft.
3) Remove front propeller shaft.
4) Disconnect exhaust center pipe.
5) Disconnect speed sensor coupler.
6) Place transmission jack and remove mounting member.
7) Lower transmission jack gradually and check to ensure that
wood block serves as stopper between engine and dash panel.
8) Remove bolts for gear shift lever case.
9) Pull off breather hose.

YH4
GRAND
VITARA
1. Meter cluster
2. Hazard switch
Terminal
Wire ColorSwitch Position
LH steering vehicle shown
LIGHTING SYSTEM 8B-9
TURN SIGNAL AND HAZARD WARNING
LIGHTS
TURN SIGNAL SWITCH (IN COMBINATION SWITCH)
INSPECTION
1) Disconnect negative cable at battery.
2) Disconnect combination switch lead wire coupler.
3) Check for continuity between terminals at each switch position
shown below. If check result is not as specified, replace switch.
TLTBTR
G/RGG/Y
L
N
R
REMOVAL AND INSTALLATION
Refer to Section 3C COMBINATION SWITCH for vehicle without air
bag system and Section 3C1 CONTACT COIL AND COMBINA-
TION SWITCH ASSEMBLY for vehicle with air bag system.
HAZARD SWITCH
REMOVAL
1) Remove meter cluster.
2) Pull hazard switch out of instrument panel.
3) Disconnect coupler from hazard switch.
4) Remove hazard switch.
INSTALLATION
Reverse removal procedure.
INSPECTION
Check for continuity between terminals at each switch position
shown below. If check result is not as specified, replace siwtch.

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VITARA
INSTRUMENTATION / DRIVER INFORMATION 8C-7
1. Steering column hole cover
COMBINATION METER
REMOVAL
1) Disconnect negative cable at battery.
2) If the vehicle is equipped with air bag system, disable air bag
system. Refer to DISABLING AIR BAG SYSTEM in Section
10B of this manual.
3) Remove column hole cover.
4) Remove instrument cluster panel.
5) Remove screws fastening combination meter.
6) Disconnect couplers from combination meter.
7) Remove combination meter from instrument panel.
INSTALLATION
Reverse removal procedure for installation, noting the following.

If the vehicle is equipped with air bag system, be sure to enable
air bag system after installation. Refer to ENABLING AIR BAG
SYSTEM in Section 10B of this manual for details.

YH4
GRAND
VITARA
Terminal
Operation
If mirror heater is not equipped
If mirror heater is equipped
8D-30 WINDOWS, MIRRORS, SECURITY AND LOCKS
POWER DOOR MIRROR CONTROL SYSTEM
INSPECTION
MIRROR SWITCH
1) Remove mirror switch from instrument panel.
2) Check for continuity between terminals at each switch position
as shown below.
If check result is not as specified, replace mirror switch.
DOOR MIRROR ACTUATOR
1) Remove garnish from door.
2) Disconnect door mirror coupler.
3) Check that door mirror operates properly when battery voltage
is applied to connector terminals.
Connect battery positive and negative terminal to the door mirror
terminal shown below and check operation.
If it does not operate as specified in table below, replace door
mirror assembly.
VBlYVBlY
Up

Down

Left

Right

NOTE:
When installing door mirror to door, be careful not to pinch
harness between door and door mirror.

YH4
GRAND
VITARA
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-31
DOOR MIRROR HEATER (IF EQUIPPED)
INSPECTION
MIRROR HEATER SWITCH
1) Remove mirror heater switch from instrument panel.
2) Check for continuity between terminals at each switch position
as shown below. If check result is not as specified, replace
switch.
MIRROR HEATER (IF EQUIPPED)
1) Remove garnish from door.
2) Disconnect door mirror coupler.
3) Check for continuity between terminals ªaº and ºbº.
If not continuity, replace outside mirror.