psi SUZUKI GRAND VITARA 2000 2.G Service User Guide

YH4
GRAND
VITARA
3F-2 WHEELS AND TIRES
The metric term for tire inflation pressure is the kilopascal (kPa).
Tire pressures will usually be printed in both kPa and psi on the Tire
Placard. Metric tire gauges are available from tool suppliers. The
chart, left table, converts commonly used inflation pressures from
kPa to psi.kPakgf / cm2psi
160
180
200
220
240
260
280
300
320
3401.6
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.423
26
29
32
35
38
41
44
47
50
Conversion:1 psi = 6.895 kPa
1 kgf / cm
2 = 98.066 kPa
WHEELS REPLACEMENT
Wheels must be replaced if they are bent, dented, have excessive
lateral or radial runout, leak air through welds, have elongated bolt
holes, if lug nuts won't stay tight, or if they are heavily rusted.
Wheels with greater runout than shown in left figure may cause ob-
jectional vibrations.
Wheels for replacement must be equivalent to the originally
equipped wheels in load capacity, diameter, rim width, off-set and
mounting configuration. A wheel of improper size or type may affect
wheel and bearing life, brake cooling, speedometer / odometer cal-
ibration, ground clearance to the body and chassis.
To measure the wheel runout, it is necessary to use accurate dial
indicator. The tire may be on or off the wheel. The wheel should be
installed to the wheel balancer of the like for proper measurement.
Take measurements of both lateral runout and radial runout at both
inside and outside of the rim flange. With dial indicator set in place
securely, turn the wheel one full revolution slowly and record every
reading of the indicator.
When the measured runout exceeds the specification and correc-
tion by the balancer adjustment is impossible, replace the wheel.
If the reading is affected by welding, paint or scratch, it should be
ignored.
Lateral runout limit ªaº: 1.20 mm (0.047 in.)
Radial runout limit ªbº: 1.20 mm (0.047 in.)
METRIC LUG NUTS AND WHEEL STUDS
All models use metric lug nuts and wheel studs (size M12 x 1.25).

YH4
GRAND
VITARA
WHEELS AND TIRES 3F-7
TIRE
MOUNTING AND DEMOUNTING
Use tire changing machine to mount or demount tires. Follow equip-
ment manufacturer's instructions. Do not use hand tools or tire
irons alone to change tires as they may damage tire beads or wheel
rim.
Rim bead seats should be cleaned with wire brush or coarse steel
wool to remove lubricants, old rubber and light rust. Before mount-
ing or demounting tire, bead area should be well lubricated with ap-
proved tire lubricant.
After mounting, inflate to 240 kPa (35psi) so that beads are com-
pletely seated. Then adjust pressure to specified shown an tire
placard.
WARNING:
Do not stand over tire when inflating. Bead may break when
bead snaps over rim's safety hump and cause serious per-
sonal injury.
Do not exceed 240 kPa (35 psi) pressure when inflating. If
240 kPa (35 psi) pressure will not seat beads, deflate, re-lu-
bricate and reinflate. Over inflation may cause bead to break
and cause serious personal injury.
Install valve core and inflate to proper pressure.
TIRE REPAIR
There are many different materials and techniques on the market
to repair tires. As not all of these work on all types of tires, tire
manufacturers have published detailed instructions on how and
when to repair tires. These instructions can be obtained from the
tire manufacturer.

YH4
GRAND
VITARA
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

YH4
GRAND
VITARA
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-15
1. Booster piston rod
2. Master cylinder piston
1. Master cylinder
2. Piston
3. Pin head
1. Booster body
2. Piston rod
1. Booster piston rod
2. Master cylinder piston
CLEARANCE BETWEEN BOOSTER PISTON ROD AND
MASTER CYLINDER PISTON ADJUSTMENT
The length of booster piston rod is adjusted to provide specified
clearance ªaº between piston rod end and master cylinder piston.

Before measuring clearance, push piston rod several times so as
to make sure reaction disc is in place.

Keep inside of booster at atmospheric pressure for measure-
ment.
1) Set special tool (A) on master cylinder and push pin until con-
tacts piston.
Special Tool
(A): 09950-96010
2) Turn special tool upside down and place it on booster. Adjust
booster piston rod length until rod end contacts pin head.
Special Tool
(A): 09950-96010
Clearance ªbº: 0 mm (0 in.)
NOTE:
Take measurement with booster set vertically and rod at the
center.
3) Adjust clearance by turning adjusting screw of piston rod.
Special Tool
(F): 09952-16010
Reference
When adjusted as above, its negative pressure is applied to boost-
er with engine at idle, piston to piston rod clearance ªaº should be-
come below.
Clearance ªaº: 0.25 ± 0.5 mm (0.010 ± 0.020 in.)

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-33
1. ABS hydraulic unit /
control module
assembly
2. Nut
1. To left-front
2. To right-front
3. To rear
4. From master cylinder4) Remove three nuts and take out ABS hydraulic unit / control
module assembly from bracket.
CAUTION:

Do not give an impact to hydraulic unit.

Use care not to allow dust to enter hydraulic unit.

Do not place hydraulic unit on its side or upside down.
Handling it in inappropriate way will affect its original
performance.
INSTALLATION
1) Install hydraulic unit by reversing removal procedure.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 12.0 lb-ft)
(b): 21 N
.m (2.1 kg-m, 15.5 lb-ft)
(c): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
2) Bleed air from brake system. Refer to ªBLEEDING BRAKESº in
Section 5.
3) Check each installed part for fluid leakage and perform hydraulic
unit operation check.

YH4
GRAND
VITARA
1. Fluid pressure check hole
2. Oil pan
1. Oil pan
2. Exhaust pipe
7B1-54 AUTOMATIC TRANSMISSION (4 A / T)
LINE PRESSURE TEST
Purpose of this test is to check operating conditions of each part by
measuring fluid pressure in fluid pressure line. Line pressure test
requires following conditions.

Automatic fluid is at normal operating temperature (70 to 80C /
158 ± 176F).

Fluid is filled to proper level (between FULL HOT and LOW HOT
on dipstick).
1) Apply parking brake securely and place checks against wheels.
2) Attach oil pressure gauge to fluid pressure check hole in trans-
mission case.
Special Tool
(A): 09925-37810
CAUTION:
After attaching oil pressure gauge, check that not fluid
leakage exists.
3) Depress foot brake fully, run engine at idle and stall and then
check fluid pressure in ªDº or ªRº range.
CAUTION:
Do not continue running engine at stall speed longer than
5 seconds.
G16 Engine
Engine runningLine pressuregg
modeªDº rangeªRº range
At idle speed3.9 ± 4.4 kg / cm2
55 ± 63 psi
5.1 ± 5.7 kg / cm2
73 ± 81 psi
At stall speed11.7 ± 13.2 kg / cm2
166 ± 188 psi
14.2 ± 16.7 kg / cm2
202 ± 237 psi
J20 Engine
Engine runningLine pressuregg
modeªDº rangeªRº range
At idle speed3.8 ± 4.3 kg / cm2
54 ± 61 psi
5.3 ± 5.9 kg / cm2
75 ± 84 psi
At stall speed9.7 ± 11.2 kg / cm2
138 ± 159 psi
12.9 ± 15.5 kg / cm2
183 ± 220 psi
H25 Engine
Engine runningLine pressuregg
modeªDº rangeªRº range
At idle speed3.9 ± 4.4 kg / cm2
55 ± 63 psi
6.6 ± 7.2 kg / cm2
94 ± 102 psi
At stall speed11.3 ± 12.7 kg / cm2
161 ± 181 psi
14.7 ± 22.7 kg / cm2
209 ± 323 psi

YH4
GRAND
VITARA
7E-10 DIFFERENTIAL (FRONT)
1. Plugged hose
2. Adjusting screw
3. Pipe (to air pump assembly)
4. Hose (to differential carrier)
5. Differential housing
4 5
INSPECTION
4WD Control System
1) Install special tool to air hose connecting between air pump as-
sembly and differential (actuator) as shown in figure. Tighten ad-
justing screw of special tool as far as it stops. Close air check
side opening by using fuel hose as blind plug.
Special Tool
(A): 09918-18110
(B): 09367-04002
NOTE:
Use care not to bend any part of hose.
2) Turn ON ignition switch and shift transfer lever from 2H to 4H
range.
3) Check that motor starts running (a sound can be heard) within
1 second and it stops when gauge of special tool indicates speci-
fied pressure value.
Check also for air leakage.
Pressure specification:
30.0 ± 45.0 kPa (0.30 ± 0.45 kg / cm
2, 4.25 ± 6.40 psi)
4) Check that pressure value indicated on gauge of special tool
drops as soon as transfer lever is shifted to 2H position.
5) Start motor by shifting transfer lever to 4H position again. Loos-
en adjusting screw to lower pressure value on gauge. Motor
should start to run again and stop in about 4 seconds.
6) With the adjusting screw of special tool loosened, shift transfer
shift lever to N or 2H position and then 4L or 4H position.
Pump motor should stop about 10 seconds after motor starts to
run.

YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-11
1. Differential housing
2. Adjusting screw
3. To air compressor
Actuator
1) Disconnect air hose from pump assembly and install special tool
to air hose as shown in figure. Loosen adjusting screw of special
tool.
Special Tool
(A): 09918-18110
2) Connect compressor air hose to special tool.
Blow air and turn adjusting screw to obtain specified pressure.
Specified pressure: 30.0 kPa (0.3 kg / cm
2, 4.25 psi)
CAUTION:
Do not apply a pressure exceeding 200 kPa (2.0 kg / cm
2,
28.4 psi) which may cause damage to diaphragm.
3) With the vehicle lifted so that both of the front wheels are off the
ground, turn one of the front wheels by hand and check the other
wheel, which should act as described below.

When the pressure from compressor is applied to actuator:
The other front wheel should turn in the direction opposite to
the wheel being turned by hand.

When the pressure from compressor is not applied to actuator:
The other front wheel should remain stationary while the wheel
pushed by hand is turning.
If the result is not satisfactory, inspect differential assembly. Re-
fer to ªINSPECTIONº of SECTION 7E in UNIT REPAIR MANU-
AL.

YH4
GRAND
VITARA
7E-12 DIFFERENTIAL (FRONT)
1. Pump assembly
Air Pump Assembly
Removal / Installation
1) Disconnect air hoses and coupler from air pump assembly.
2) Remove pump assembly by removing bolts.
3) Reverse removal procedure for installation.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
Inspection
1) Install special tool, voltmeter and battery to pump assembly as
shown in figure.
2) Tighten adjusting screw of special tool as far as it stops and
close its air check side opening by using fuel hose as blind plug.
Special Tool
(A): 09918-18110
3) Check that motor starts to run (a sound can be heard) when bat-
tery is connected and it stops when specified pressure is ob-
tained.
Check also for air leakage.
Specified pressure: 30.0 ± 45.0 kPa
(0.30 ± 0.45 kg / cm
2, 4.25 ± 6.40 psi)
4) Check that value indicated on voltmeter is within specification
shown below.
When motor is running: 0 ± 1 V
When motor has stopped running: 10 ± 14 V
CAUTION:
Do not run motor more than 10 seconds continuously to
prevent motor breakage.