System SUZUKI GRAND VITARA 2000 2.G Service Owner's Manual

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GRAND
VITARA
1
1. Clutch pedal free travel
MAINTENANCE AND LUBRICATION 0B-15
CHASSIS AND BODY
ITEM 6-1
Clutch
Pedal inspection
Check clutch pedal for height and free travel referring to Section
7C1. Adjust or correct if necessary.
Fluid inspection
1) Check around master cylinder and reservoir for fluid leakage.
If found leaky, correct.
2) Check fluid level.
If fluid level is lower than the minimum level of reservoir, refilling
is necessary. Fill reservoir with specified brake fluid indicated on
clutch reservoir cap.
For the details, refer to On-vehicle service in Section 7C1.
CAUTION:
Since clutch system of this vehicle is factory-filled with
glycol-base brake fluid, do not use or mix different type
of fluid when refilling system; otherwise serious damage
will occur. Do not use old or used brake fluid, or one taken
from unsealed container.
ITEM 6-2
Brake Discs, Pads, Brake Drums and Shoes Inspection
[Brake discs and pads]
1) Remove wheel and caliper but don't disconnect brake hose from
caliper.
2) Check front disc brake pads and discs for excessive wear, dam-
age and deflection. Replace parts as necessary. For details, re-
fer to Section 5B.
Be sure to torque caliper pin bolts to specification.
[Brake drums and shoes]
1) Remove wheel and brake drum.
2) Check rear brake drums and brake linings for excessive wear
and damage, while wheels and drums are removed. At the same
time, check wheel cylinders for leaks. Replace these parts as
necessary.
For details, refer to Section 5C.

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ªaº: Parking brake lever
stroke:
5 ± 7 notches
(With 20 kg or 44 lbs
of pull pressure)
ªaº
0B-16 MAINTENANCE AND LUBRICATION
ITEM 6-3
Brake Hoses and Pipes Inspection
Check brake hoses and pipes for proper hookup, leaks, cracks,
chafing and other damage.
Replace any of these parts as necessary.
CAUTION:
After replacing any brake pipe or hose, be sure to carry out
air purge operation.
ITEM 6-4
Brake Fluid Change
Change brake fluid as follows.
Drain existing fluid from brake system completely, fill system with
specified fluid and carry out air purge operation.
For air purging procedure, refer to Section 5.
ITEM 6-5
Parking Brake Lever and Cable Inspection
Parking brake lever
1) Check tooth tip of each notch for damage or wear. If any damage
or wear is found, replace parking lever.
2) Check parking brake lever for proper operation and stroke, and
adjust it if necessary.
For checking and adjusting procedures, refer to Parking Brake
Inspection and Adjustment in Section 5.
Parking brake cable
Inspect brake cable for damage and smooth movement.
Replace cable if it is in deteriorated condition.

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0B-18 MAINTENANCE AND LUBRICATION
ITEM 6-8
Suspension System Inspection
Check suspension bolts and nuts for tightness and retighten them
as necessary.
Repair or replace defective parts, if any.
NOTE:
For details of check points, refer to tables of Tightening Torque
Specification in Section 3D and 3E.
Front
1) Check stabilizer bar for damage or deformation.
2) Check bushing for damage, wear or deterioration.
3) Inspect strut for damage, deformation, oil leakage and opera-
tion. If strut is found faulty, replace it as an assembly unit, be-
cause it can not be disassembled.
Refer to strut check Section 3D for operation check.
4) Inspect strut boot for damage or crack.
5) Inspect for cracks or deformation in spring seat.
6) Inspect for deterioration of bump stopper.
7) Inspect strut mount for wear, cracks or deformation.
8) Check ball joint stud dust seal (boot) for leaks, detachment,
tear or other damage. Check suspension arm bushing for dam-
age, wear or deterioration.
Rear
9) Check shock absorber for damage, deformation, oil leakage
and operation.
10) Check bushings for wear and damage.

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The figure shows right-hand steering vehicle
The figure shows right-hand steering vehicle
0B-22 MAINTENANCE AND LUBRICATION
ITEM 6-14
Steering System Inspection
1) Check steering wheel for play and rattle, holding vehicle in
straight forward condition on the ground.
Steering wheel play ªaº: 0 ± 30 mm (0 ± 1.2 in.)
2) Check universal joints of steering shaft for rattle and damage. If
rattle or damage is found, replace defective part with a new one.
3) Check steering linkage for looseness and damage. Repair or re-
place defective part, if any.
4) Check bolts and nuts for tightness and retighten them as neces-
sary. Repair or replace defective parts, if any.
Refer to table of Tightening Torque Specification in Section 3B
(or 3B1) and 3C (or 3C1) for particular check points.
5) Check boots of steering linkage for damage (leaks, detachment,
tear, dent, etc.). If damage is found, replace it with new one.
If any dent is found on steering rack boots, correct it to original
shape by turning steering wheel to the right or left as far as it
stops and holding it for a few seconds.
6) Check wheel alignment.
NOTE:
For details of wheel alignment, refer to Wheel Alignment in
Section 3A.
ITEM 6-15
Power Steering (P / S) System Inspection (if equipped)
1) Visually check power steering system for fluid leakage and hose
for damage and deterioration.
Repair or replace defective parts, if any.
2) With engine stopped, check fluid level indicated on fluid tank,
which should be between MAX and MIN marks. If it is lower than
MIN, fill fluid up to MAX mark.
NOTE:

Be sure to use an equivalent of DEXRON

-II or DEX-
RON

-III for P / S fluid.

Fluid level should be checked when fluid is cool.

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1. ªUPPERº or ªLOWERº mark
MAINTENANCE AND LUBRICATION 0B-23
3) Visually check pump drive belt for cracks and wear.
4) Check belt for tension, referring to item 1-1.
If necessary, have belt adjusted or replaced.
ITEM 6-16
All Hinges, Latches and Locks Inspection
Doors
Check that each door of front, rear and back doors opens and
closes smoothly and locks securely when closed.
If any malfunction is found, lubricate hinge and latch or repair door
lock system.
Engine hood
Check that secondary latch operates properly (check that second-
ary latch keeps hood from opening all the way even when pulling
hood release handle inside vehicle.). Also check that hood opens
and closes smoothly and properly and hood locks securely when
closed.
If any malfunction is found, lubricate hinge and latch, or repair hood
lock system.
ITEM 6-17
Air Conditioning Filter (if equipped)
Inspection
1) Remove air conditioning filter from cooling unit referring to Sec-
tion 1B.
2) Check filter for dirt. Replace excessively dirty filter.
3) Blow off dust by compressed air from air outlet side of filter.
4) Install filter to cooling unit referring to Section 1B.
Replacement
Replace air conditioning filter with new one referring to Section 1B.

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0B-24 MAINTENANCE AND LUBRICATION
FINAL INSPECTION
Seats
Check that seat slides smoothly and locks securely at
any position. Also check that reclining mechanism of
front seat back allows it to be locked at any angle.
Seat Belt
Inspect belt system including webbing, buckles, latch
plates, retractors and anchors for damage or wear.
If ªREPLACE BELTº label on front seat belt is visible,
replace belt.
Check that seat belt is securely locked.
Battery Electrolyte Level Check
Check that the electrolyte level of all battery cells is
between the upper and lower level lines on the case.
If battery is equipped with built-in indicator, check bat-
tery condition by the indicator.
Accelerator Pedal Operation
Check that pedal operates smoothly without getting
caught or interfered by and other part.
Engine Start
Check engine start for readiness.
On automatic transmission vehicles, try to start the
engine in each select lever position. The starting mo-
tor should crank only in ªPº (Park) or ªNº (Neutral).
On manual transmission vehicles, place the shift le-
ver in ªNeutral,º depress clutch pedal fully and try to
start.
Exhaust System Check
Check for leakage, cracks or loose supports.
Clutch (For Manual transmission)
Check for the following:

Clutch is completely released when depressing
clutch pedal.

No slipping clutch occurs when releasing pedal and
accelerating.

Clutch itself is free from any abnormal condition.
Gearshift or Select Lever (Transmission)
Check gear shift or select lever for smooth shifting to
all positions and for good performance of transmis-
sion in any position.
With automatic transmission equipped vehicle, also
check that shift indicator indicates properly according
to which position select lever is shifted to.
With automatic transmission equipped vehicle, make
sure that vehicle is at complete stop when shifting se-
lect lever to ªPº range position and release all brakes.
Brake
[Foot brake]
Check the following:

that brake pedal has proper travel,

that brake works properly,

that it is free from noise,

that braking force is applied equally on all wheels,

and that brake do not drag.
[Parking brake]
Check that lever has proper travel.
WARNING:
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property damage.
Be prepared to apply regular brake quickly
even if vehicle should start to move.
Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and
brake lever is pulled all the way.
WARNING:
When carrying out road tests, select a safe
place where no man or no running vehicle is
seen so as to prevent any accident.
WARNING:
Before performing the following check, be
sure to have enough room around the vehicle.
Then, firmly apply both the parking brake and
the regular brakes. Do not use the accelerator
pedal. If the engine starts, be ready to turn off
the ignition promptly. Take these precautions
because the vehicle could move without warn-
ing and possibly cause personal injury or
property damage.

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MAINTENANCE AND LUBRICATION 0B-25
Steering

Check to ensure that steering wheel is free from in-
stability, or abnormally heavy feeling.

Check that the vehicle does not wander or pull to
one side.
Engine

Check that engine responds readily at all speeds.

Check that engine is free from abnormal noise and
abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting sys-
tem are free from abnormal noise and abnormal
vibration or any other abnormal condition.
Meters and Gauge
Check that speedometer, odometer, fuel meter, tem-
perature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set fan switch lever to ªHIº position for this check.
RECOMMENDED FLUIDS AND LUBRICANTS
Engine oilSG, SH or SJ (Refer to engine oil viscosity chart in item 1-4)
Engine coolant (Ethylene glycol
base coolant)ªAntifreeze / Anticorrosion coolantº
Brake fluidDOT 3
Manual transmission oilRefer to Section 7A or 7A1Transfer oilRefer to Section 7A or 7A1.
Differential oil (front & rear)Refer to Section 7E or 7F.
Automatic transmission fluid and
Power steering fluidRefer to Section 3B1 or 7B1.
Door hingesEngine oil or water resistance chassis greaseHood latch assemblyEngine oil or water resistance chassis grease
Key lock cylinderSpray lubricant

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1A
HEATER AND VENTILATION 1A-1
SECTION 1A
HEATER AND VENTILATION
WARNING:
For vehicles equipped with Supplement 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 or 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).
NOTE:
The link mechanism of the heater varies depending on the specifications.
CONTENTS
GENERAL DESCRIPTION1A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body Ventilation1A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS1A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table1A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Circuit1A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE1A- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Unit1A- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor1A- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Relay1A- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Resistor1A- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Mode Control Switch1A-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Mode Control Actuator1A-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Control Lever Assembly 1A-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Control Cables1A-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Unit1A-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Duct1A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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HEATER AND VENTILATION 1A-3
BODY VENTILATION
The body ventilation system of this vehicle has a fresh air intake located at the cowl top panel. When fresh air intake
control lever is at FRESH AIR position, ventilating air is drawn into the interior from the cowl center garnish and
drawn out from the ventilator outlet provided at each side body outer panel (both right and left side).
DIAGNOSIS
DIAGNOSIS TABLE
TroublePossible causeRemedy
Heater blower won't
work even when its
switch is ON.Blower fuse blown
Blower resistor faulty
Blower motor faulty
Wiring or grounding faultyReplace fuse to check for short.
Check resistor.
Replace motor.
Repair as necessary.
Incorrect temperature
output.Control cables broken or binding
Air damper broken
Air ducts clogged
Heater radiator leaking or clogged
Heater hoses leaking or cloggedCheck cables.
Repair damper.
Repair air ducts.
Replace radiator.
Replace hoses.
When mode control
switch is changed,
air outlet port is not
changed.Mode control switch faulty
Mode actuator faulty
Fuse blown
Wiring or grounding faulty
Air damper broken
Air ducts cloggedCheck and replace as necessary.
Check and replace as necessary.
Replace fuse to check for short.
Repair as necessary.
Repair damper.
Repair air ducts.

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HEATER AND VENTILATION 1A-5
1. Blower unit
2. Blower motor resistor
3. Blower motor relay
4. Blower fan
5. Blower motor
3. Cover
ON-VEHICLE SERVICE
BLOWER UNIT
REMOVAL
1) Disconnect negative (±) cable at battery.
2) Disable air bag system, if equipped. Refer to DISABLING AIR
BAG SYSTEM in Section 10B.
3) Remove passenger lower member (1).
4) Remove ECM (1) with bracket (2) from blower motor unit (4).
5) Disconnect blower motor (1), blower motor relay (2) and resistor
lead wires (3) at couplers.