Head SUZUKI GRAND VITARA 2000 2.G Service Owner's Manual
[x] Cancel search | Manufacturer: SUZUKI, Model Year: 2000, Model line: GRAND VITARA, Model: SUZUKI GRAND VITARA 2000 2.GPages: 801, PDF Size: 12.15 MB
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3C1-14 AIR BAG STEERING WHEEL AND COLUMN
1. Steering column
2. Steering lock 1
2
1. Center punch (with sharp point)
2. Steering lock mounting bolt
1. Steering column
2. Steering shaft
STEERING LOCK ASSEMBLY (IGNITION
SWITCH)
REMOVAL
1) Remove steering column. Refer to ªSTEERING COLUMNº in
this section.
2) Using center punch as shown, loosen and remove steering lock
mounting bolts.
NOTE:
Use care not to damage aluminum part of steering lock
body with center punch.
3) Turn ignition key to ªACCº or ªONº position and remove steering
lock assembly from steering column.
INSTALLATION
1) Position oblong hole of steering shaft in the center of hole in col-
umn.
2) Turn ignition key to ªACCº or ªONº position and install steering
lock assembly onto column.
3) Now turn ignition key to ªLOCKº position and pull it out.
4) Align hub on lock with oblong hole of steering shaft and rotate
shaft to assure that steering shaft is locked.
5) Tighten new bolts until head of each bolt is broken off.
6) Turn ignition key to ªACCº or ªONº position and check to be sure
that steering shaft rotates smoothly. Also check for lock opera-
tion.
7) Install steering column. Refer to ªSTEERING COLUMNº in this
section.
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AIR BAG STEERING WHEEL AND COLUMN 3C1-15
1. Steering column assembly
2. Steering shaft joint
1. Steering column assembly
2. Steering shaft joint
3. Steering lower shaft assembly
4. Bolt (column side)
5. Bolt (lower shaft assembly side)
1. Steering lower shaft assembly
2. Steering lower shaft assembly
lower joint bolt
3. Steering shaft joint
STEERING LOWER SHAFT ASSEMBLY
CAUTION:
Never turn steering wheel while steering lower shaft assem-
bly is removed.
Should it have been turned and contact coil (on combina-
tion switch) have got out of its centered position, it needs
to be centered again. Also, turning steering wheel more
than about two and a half turns will break contact coil.
REMOVAL
1) Turn steering wheel so that vehicle's front tires are at straight-
ahead position.
2) Turn ignition switch to ªLOCKº position and remove key.
3) After removing bolt on column side of shaft joint and loosening
bolt on its lower shaft assembly side, move shaft joint to lower
shaft assembly side (in arrow direction in figure).
4) Remove lower shaft assembly lower joint bolt and then remove
lower shaft assembly.
5) Remove shaft joint bolt (lower shaft assembly side) from shaft
joint and then remove shaft joint from lower shaft assembly.
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2
1
1. Steering shaft joint
2. Bolt (Steering column assembly side)
3. Bolt (Steering lower shaft assembly side)1. Steering shaft joint
2. Steering lower shaft assembly
1. Steering lower shaft
assembly
2. Steering lower shaft
assembly lower joint
3. Steering lower shaft
assembly lower joint bolt
4. Steering shaft joint
5. Mark
6. Slit
1. Steering column assembly
2. Steering shaft joint
3C1-16 AIR BAG STEERING WHEEL AND COLUMN
INSTALLATION
1) Be sure that front wheels and steering wheel are in straight
ahead position.
2) Align flat part ªAº of lower shaft assembly with bolt hole ªBº of
shaft joint as shown. Then insert shaft joint into lower shaft as-
sembly.
3) Install shaft joint bolt (lower shaft assembly side) to shaft joint.
Then tighten it by hand.
4) Insert pinion shaft into lower shaft assembly lower joint with slit
of lower joint, marks on pinion shaft and gear case aligned.
And then install lower shaft assembly lower joint bolt to lower
shaft assembly lower joint. Tighten it to specified torque.
Tightening Torque
(a): 25 N
.m (2.5 kg-m, 18.0 lb-ft)
5) Install steering shaft joint to steering shaft.
NOTE:
Be sue that front wheels and steering wheel are in straight-
ahead position.
6) Install shaft joint bolt (column side) to shaft joint. Tighten shaft
joint bolt (column side) to specified torque first and then shaft
joint bolt (shaft lower assembly side) to specified torque.
Tightening Torque
(b): 25 N
.m (2.5 kg-m, 18.0 lb-ft)
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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.)
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ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-35
FORWARD
1. Front wheel speed
sensor connector
2. Headlight assembly
1. Front wheel speed sensor
2. Bolt
REMOVAL
1) Disconnect negative cable at battery.
2) Hoist vehicle and remove wheel.
3) Disconnect front wheel speed sensor connector.
4) Remove harness clamp bolts and remove front wheel speed
sensor from knuckle.
CAUTION:
Do not pull wire harness when removing front wheel
speed sensor.
Do not cause damage to surface of front wheel speed
sensor and do not allow dust, etc. to enter its installa-
tion hole.
SENSOR INSPECTION
Check sensor for damage.
Check sensor for resistance.
Resistance between terminals: 1.2 ± 1.6 k at 20C (68F)
Resistance between terminal and sensor body: 1 M or more
If any faulty is found, replace.
SENSOR ROTOR INSPECTION
Check rotor for being missing, damaged or deformed.
Turn drive shaft and check if rotor rotation is free from eccentricity
and looseness.
Check that no foreign material is attached.
If any faulty is found, repair or replace. Refer to WHEEL HUB RE-
MOVAL and INSTALLATION in Section 3D.
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1. Transmission
2. Breather clamp
3. Breather hose
4. Wiring harness clamp
5. Intake manifold
MANUAL TRANSMISSION (TYPE 1) 7A-9
DISMOUNTING OF TRANS. UNIT
IN CABIN
Remove transmission shift control lever (refer to page 7A-4) and
transfer shift control lever knob.
IN ENGINE ROOM
1) Disconnect negative (±) cable of battery.
2) Remove breather hose from clamp at the rear end of cylinder
head.
3) Remove starting motor fixing bolts and nut and then remove
starter.
4) Remove transmission fastening bolts.
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CLUTCH 7C1-3
DIAGNOSIS
ConditionPossible CauseCorrection
SlippingImproper clutch pedal free travel.
Worn or oily clutch disc facing.
Warped disc, pressure plate or flywheel
surface.
Weakened diaphragm spring.
Master cylinder piston or seal cup not returning.Bleed air or replace master
cylinder.
Replace disc.
Replace disc, clutch cover or
flywheel.
Replace clutch cover.
Repair master cylinder.
Dragging clutchImproper clutch pedal free travel.
Weakened diaphragm spring, or worn spring tip.
Rusted input shaft splines.
Damaged or worn splines of transmission
input shaft.
Excessively wobbly clutch disc.
Clutch facings broken or dirty with oil.
Fluid leakage.Bleed air or replace master
cylinder.
Replace clutch cover.
Lubricate.
Replace input shaft.
Replace disc.
Replace disc.
Repair or replace.
Clutch vibrationGlazed (glass-like) clutch facings.
Clutch facings dirty with oil.
Release bearing slides unsmoothly on input
shaft bearing retainer.
Wobbly clutch disc, or poor facing contact.
Weakened torsion springs in clutch disc.
Clutch disc rivets loose.
Distorted pressure plate or flywheel surface.
Weakened or loosened engine mounting
bolt or nut.Repair or replace disc.
Replace disc.
Lubricate or replace input
shaft bearing retainer.
Replace disc.
Replace disc.
Replace disc.
Replace clutch cover or flywheel.
Retighten or replace mounting.
Noisy clutchWorn or broken release bearing.
Input shaft front bearing worn down.
Excessive rattle of clutch disc hub.
Cracked clutch disc.
Pressure plate and diaphragm spring rattling.Replace release bearing.
Replace input shaft bearing.
Replace disc.
Replace disc.
Replace clutch cover.
Grabbing clutchClutch disc facings soaked with oil.
Clutch disc facings excessively worn.
Rivet heads showing out of facing.
Weakened torsion springs.Replace disc.
Replace disc.
Replace disc.
Replace disc.
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CLUTCH 7C1-11
INSPECTION
Input Shaft Bearing and Release Bearing
Check bearing for smooth rotation and replace it if abnormality is
found.
Clutch Disc
Measure depth of rivet head depression, i.e. distance between rivet
head and facing surface. If depression is found to have reached
service limit at any of holes, replace disc assembly.
Rivet head depth
Standard: 1.6 mm (0.06 in.)
Service limit: 0.5 mm (0.02 in.)
Clutch Cover
1) Check diaphragm spring for abnormal wear or damage.
2) Inspect pressure plate for wear or heat spots.
3) If abnormality is found, replace it as assembly. Do not disas-
semble it into diaphragm and pressure plate.
Flywheel
Check surface contacting clutch disc for abnormal wear or heat
spots. Replace or repair as required.
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8B
LIGHTING SYSTEM 8B-1
SECTION 8B
LIGHTING SYSTEM
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).
CONTENTS
GENERAL DESCRIPTION8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions in Servicing8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols and Marks8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Color Symbols8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joint Connector8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Box and Relay8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Diagram8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight with Leveling System (If Equipped) 8B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS8B- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights8B- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights with Leveling System (If Equipped) 8B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal and Hazard Warning Lights 8B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance, Tail and License Plate Lights 8B- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back-up Lights8B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lights8B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Fog Light (If Equipped)8B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interior Lights8B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE8B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights8B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights with Leveling System (If Equipped) 8B- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal and Hazard Warning Lights 8B- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Fog Light (If Equipped)8B-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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6
5
1. Headlight assembly
2. Halogen bulb
3. Socket cover
4. Turn signal light bulb
5. Position light bulb
6. Turn signal light bulb socket
7. Position light bulb socket
8B-2 LIGHTING SYSTEM
GENERAL DESCRIPTION
CAUTIONS IN SERVICING
Refer to Section 8.
SYMBOLS AND MARKS
Refer to Section 8.
WIRING COLOR SYMBOLS
Refer to Section 8.
ABBREVIATIONS
Refer to Section 8.
JOINT CONNECTOR
Refer to Section 8.
FUSE BOX AND RELAY
Refer to Section 8.
POWER SUPPLY DIAGRAM
Refer to Section 8.
HEADLIGHTS