Oli SUZUKI GRAND VITARA 2000 2.G Service Owner's Guide

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3. Compressor and condenser cooling fan fuse
1B-48 AIR CONDITIONING (OPTIONAL)
A / C COMPRESSOR RELAY AND A / C
CONDENSER COOLING FAN RELAY
INSPECTION
1) Disconnect negative (±) cable at battery.
2) Remove condenser cooling fan motor relay (2) and / or compres-
sor relay (1) from vehicle.
3) Check that there is no continuity between terminal ªcº and ªdº.
If there is continuity, replace relay.
4) Connect battery positive (+) terminal to terminal ªbº of relay.
Connect battery negative (±) terminal ªaº of relay.
Check continuity between terminal ªcº and ªdº.
If there is no continuity when relay is connected to the battery,
replace relay.

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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).

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1. Boot
2. Snap ring
1. Circlip
2 Snap ring plier
3. Cage
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-5
DISASSEMBLY
1) Remove boot band of differential side joint.
2) Slide boot toward the center of shaft and remove snap ring from
outer race, then take shaft out of outer race.
3) Remove circlip and then cage.
4) Remove inside and outside boots from shaft.
CAUTION:

Do not disassemble wheel side joint (outboard joint). If
any malcondition is found in joint, replace it as assem-
bly.

Do not disassemble ball joint of differential side joint.
If any malcondition is found in ball joint, replace differ-
ential side joint assembly.
INSPECTION

Check boots for breakage or deterioration. Replace them as nec-
essary.

Check circlip, snap ring and boot bands for breakage or deforma-
tion. Replace as necessary.
CLEANING

Wash disassembled parts (except boots) in degreaser. After
washing, dry parts completely by blowing air.

Clean boots with cloth. DO NOT wash boots in degreaser, such
as gasoline or kerosene, etc.
Washing in degreaser causes deterioration of boot.

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5A-12 BRAKES PIPE / HOSE / MASTER CYLINDER
Vehicle not equipped with ABSVehicle equipped with ABS
1. Rod
2. Circlip
INSPECTION
Inspect all disassembled parts for wear or damage, and replace
parts if necessary.
NOTE:

Wash disassembled parts with brake fluid.

Do not reuse piston cups.
Inspect master cylinder bore for scoring or corrosion. It is best to re-
place corroded cylinder.
Corrosion can be identified as pits or excessive roughness.
NOTE:
Polishing bore or master cylinder with cast aluminum body
with anything abrasive is prohibited, as damage to cylinder
bore may occur.
Rinse cylinder in clean brake fluid. Shake excess rinsing fluid from
cylinder. Do not use a cloth to dry cylinder, as lint from cloth cannot
be kept from cylinder bore surfaces.
ASSEMBLY
NOTE:

See NOTE at the beginning of this section.

Before assembling, wash each part in fluid recommended to
use for that vehicle.
1) Install secondary piston assembly into cylinder.
2) Install primary piston assembly in cylinder.
3) Depress, and install circlip.
4) Install piston stopper bolt with pistons pushed in all the way and
tighten it to specified torque (For vehicle without ABS).
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)

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1. Caliper
2. Caliper pin bolts
3. Disc
1. Caliper
2. Wire hook
3. Pad
FRONT BRAKE 5B-3
DIAGNOSIS
Refer to Section 5 (BRAKES).
CHECK AND ADJUSTMENT
Refer to Section 5 (BRAKES).
ON-VEHICLE SERVICE
FRONT DISC BRAKE PAD
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove caliper pin bolts.
3) Remove E-ring from strut and then remove caliper from caliper
carrier.
NOTE:
Hang removed caliper with a wire hook or the like so as to
prevent brake hose from bending and twisting excessively
or being pulled. Don't operate brake pedal with pads re-
moved.
4) Remove pads.
INSPECTION
Brake Pad
Check pad lining for wear. When wear exceeds limit, replace with
new one.
CAUTION:
Never polish pad lining with sandpaper. If lining is polished
with sandpaper, hard particles of sandpaper will be depos-
ited in lining and may damage disc. When pad lining re-
quires correction, replace it with a new one.
Pad thickness (lining + rim) ªaº
Standard: 15.0 mm (0.590 in.) For SUMITOMO ELECTRIC. . .
brake calliper
15.5 mm (0.610 in.) For TOKICO brake caliper. . .
Service limit: 7.0 mm (0.275 in.) For SUMITOMO ELECTRIC. .
brake caliper
7.5 mm (0.295 in.) For TOKICO brake caliper. .
NOTE:
When pads are removed, visually inspect caliper for brake
fluid leak. Correct leaky point, if any.

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5B-4 FRONT BRAKE
1. Wheel nut
2. Washer
(or spacer)
ªAº: Apply grease
Brake Disc
Before this inspection, brake pads must be removed.
Check disc surface for scratches in wearing parts. Scratches on
disc surface noticed at the time of specified inspection or replace-
ment are normal and disc is not defective unless they are serious.
But when there are deep scratches or scratches all over disc sur-
face, replace it. When only one side is scratched, polish and correct
that side.
Disc thickness ªaº
Standard: 22 mm (0.866 in.) For SUMITOMO ELECTRIC. . . . .
brake caliper
17 mm (0.670 in.) For TOKICO brake caliper. . . . .
Service limit: 20 mm (0.787 in.) For SUMITOMO ELECTRIC. .
brake caliper
15 mm (0.590 in.) For TOKICO brake caliper. .
Use wheel nuts and suitable plain washers to hold the disc securely
against the hub, then mount a dial indicator as shown and measure
the runout at 25 mm (0.98 in.) from the outer edge of the disc.
Limit on disc deflection: 0.15 mm (0.006 in.)
NOTE:
Check front wheel bearing for looseness before measure-
ment.
Cylinder Slide Guide Pin / Pin Bolt
Check guide pin for smooth movement as shown.
If it is found faulty, correct or replace. Apply rubber grease to guide
pin outer surface. Rubber grease should be the on whose viscosity
is less affected by such low temperature a ±40
C (±40
F).
Dust Boot
Check boot for breakage, crack and damage. If defective, replace.

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1. Pawl lever
2. Adjuster
3. Brake shoes
5C-8 PARKING AND REAR BRAKE
Cracked, Scored, or Grooved Drum
A cracked, drum is unsafe for further service and must be replaced.
Do not attempt to weld a cracked drum.
Smooth up any slight scores. Heavy or extensive scoring will cause
excessive brake lining wear and it will probably be necessary to re-
surface drum braking surface.
If brake linings are slightly worn and drum is grooved, drum should
be polished with fine emery cloth but should no be turned.
NOTE:
When drum is removed, visually inspect wheel cylinder for
brake fluid leakage. Correct leaky point, if any.
Brake Shoe
Where lining is worn out beyond service limit, replace shoe.
Thickness ªaº
Standard: 6.5 mm (0.24 in.)
Service limit: 3.0 mm (0.12 in.)
If one of brake linings is to service limit, all linings must be replaced
at the same time.
CAUTION:
Never polish lining with sandpaper. If lining is polished with
sandpaper, hard particles of sandpaper will be deposited in
lining and may damage drum. When it is required to correct
lining, replace it with a new one.
INSTALLATION
NOTE:
See NOTE at the beginning of the section.
1) Before installing brake drum, check outer diameter of brake
shoes. If it is not within value as specified below, adjust it to spec-
ification by turning adjuster.
Outer diameter of brake shoes
ªaº: 219.4 ± 219.7 mm (8.638 ± 8.650 in.)

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7B1-4 AUTOMATIC TRANSMISSION (4 A / T)
ItemSpecifications
Torque
conver-
terType
Stall torque ratio3-element, 1-step, 2-phase type (with TCC (lock-up)
mechanism)
2.4 (G16 engine) 2.0 (J20 engine) 1.9 (H25 engine)
Oil
pumpType
Drive systemTrochoid type oil pump
Engine driven
TypeForward 4-step, reverse 1-step planetary gear type
Shift position
ªPº range Gear in neutral, output shaft fixed,engine start
ªRº range Reverse
ªNº range Gear in neutral, engine start
ªDº range Forward 1st
2nd
3rd
4th (O / D)
(O / D ON) automatic gear change
ªDº range Forward 1st
2nd
3rd
(O / D OFF) automatic gear change
ª2º range (Normal mode) Forward 1st
2nd  3rd automatic gear
change
(Power mode) Forward 2nd  3rd automatic gear
change and fixed at 2nd gear
ªLº range Forward 1st  2nd  3rd reduction, and fixed at 1st gear
GearEngine typeG16 engineJ20 / H25 engines
change
device1st (low gear)2.8262.826device2nd (second gear)1.4931.493
Gear3rd (top gear)1.0001.000Gear
ratio4th (overdrive
4th gear)0.7300.689
Reverse (reverse
Reverse gear)2.7032.703
Control elements
Wet type multi-disc clutch 3 sets. . . . . . . . . .
Wet type multi-disc brake 4 sets. . . . . . . . . .
One-way clutch 3 sets. . . . . . . . . . . . . . . . . . .
TransferHi: 1.000 Lo: 1.816 (4WD model only)
Final gear reduction
ratio (Differential)5.125 (G16 engine) 4.875 (J20 / H25 engines)
Lubrica-
tionLubrication systemForce feed system by oil pump
CoolingCooling systemRadiator assisted cooling (water-cooled)
Fluid usedAn equivalent of DEXRON
III

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AUTOMATIC TRANSMISSION (4 A / T) 7B1-31
Brake pedal Released Depressed
Voltage 0 VBattery
voltage
DIAGNOSTIC FLOW TABLE A-1 (NO TCC LOCK-UP OCCURS)
SYSTEM DESCRIPTION
PCM turns TCC solenoid OFF under any of the following conditions.

Brake pedal switch: ON

4WD LOW switch: ON

Cruise control module: TCC OFF command signal is output (if equipped).

ECT: ECT < 30C (86F)
TROUBLESHOOTING
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 person, a driver and tester, on a level road.
STEPACTIONYESNO
1Was ªAUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLEº performed?Go to Step 2.Go to ªAUTOMATIC
TRANSMISSION
DIAGNOSTIC FLOW
TABLEº.
2ECT check:
(1) Warm up engine to normal operating
temperature.
(2) Check ECT using scan tool.
Is ECT more than 30C (86F)?Go to Step 3.Faulty ECT sensor, its
circuit or engine cooling
system.
If OK, substitute a known-
good PCM and recheck.
3Perform running test under the following
conditions and check voltage between
C51-1-8 (G16 / J20 engines) or C51-1-2 (H25
engine) terminal of PCM coupler and ground.

Normal mode in ªDº range.

Transfer ª2Hº position.

Cruise control is not operated (if equipped).

Brake pedal released.

Drive vehicle with TCC ON condition
referring to ªTCC lock-up diagramº in
this section.
Is it battery voltage?Faulty TCC solenoid
valve, its circuit or
transmission.Go to Step 4.
4Is vehicle equipped with H25 engine?Go to Step 5.Go to Step 6.
5Brake switch signal inspection:
(1) With ignition switch ON, check voltage
between E61-31 terminal of PCM coupler
terminal and ground.
Is the result as specified?Go to Step 6.Faulty brake pedal switch
or its circuit.
If OK, substitute a known-
good PCM and recheck.

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AUTOMATIC TRANSMISSION (4 A / T) 7B1-33
O / D cut
switchOFF ON
VoltageBattery
voltage0 V
DIAGNOSTIC FLOW TABLE A-2 (NO GEAR SHIFT TO O / D)
SYSTEM DESCRIPTION
PCM does not shift to O / D gear under any of the following conditions.

O / D cut switch: ON

4WD LOW switch: ON

Cruise control module: O / D OFF command signal is output (if equipped).

ECT: ECT < 30C (86F)
TROUBLESHOOTING
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 person, a driver and tester, on a level road.
STEPACTIONYESNO
1Was ªAUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLEº performed?Go to Step 2.Go to ªAUTOMATIC
TRANSMISSION
DIAGNOSTIC FLOW
TABLEº.
2ECT check:
(1) Warm up engine to normal operating
temperature.
(2) Check ECT using scan tool.
Is ECT more than 30C (86F)?Go to Step 3.Faulty ECT sensor,
its circuit or engine
cooling system.
If OK, substitute a known-
good PCM and recheck.
3Perform running test under the following
conditions and check voltage between
C51-1-2 (G16 / J20 engines) or C51-1-6 (H25
engine) terminal of PCM coupler and ground,
C51-1-1 terminal of PCM coupler and ground.

O / D cut switch OFF (ªO / D OFFº lamp OFF).

Normal mode in ªDº range.

Transfer ª2Hº position.

Cruise control is not operated (if equipped).

Drive vehicle with 4th gear condition
referring to ªGear shift diagramº in this
section.
Is each voltage about 0 V?Faulty shift solenoid
valve, its circuit or
transmission.ªGº wire or ªG / Rº wire
shorted to power circuit.
If OK, go to Step 4.
4O / D cut switch signal inspection:
(1) With ignition switch ON, check voltage
between E61-33 (G16 / J20 engines) or
E61-14 (H25 engine) terminal of PCM
coupler and ground.
Is the result as specified?Go to Step 5.Faulty O / D cut switch or
its circuit.
If OK, substitute a known-
good PCM and recheck.