Oli SUZUKI GRAND VITARA 2000 2.G Service Service Manual

YH4
GRAND
VITARA
1. Crankshaft
2. Flywheel
3. Clutch disc
4. Pressure plate
5. Clutch cover
6. Diaphragm spring
7. Release bearing
8. Input shaft bearing
9. Input shaft
10. Operating cylinder
11. Clutch housing
12. Release fork
7C1-2 CLUTCH
The clutch is a diaphragm-spring clutch of a dry single
disc type. The diaphragm spring is of a tapering-finger
type, which is a solid ring in the outer diameter part,
with a series of tapered fingers pointing inward.
The disc, carrying torsional coil springs, is positioned
on the transmission input shaft with an involute spline
fit.
The clutch cover is secured to the flywheel, and car-
ries the diaphragm spring in such a way that the pe-
ripheral edge part of the spring pushes on the pres-
sure plate against the flywheel (with the disc in be-
tween), when the clutch release bearing is held back.
This is the engaged condition of the clutch.Depressing the clutch pedal causes the release bear-
ing to advance and pushes on the tips of the tapered
fingers of the diaphragm spring. When this happens,
the diaphragm spring pulls the pressure plate away
from the flywheel, thereby interrupting the flow of
drive from flywheel through clutch disc to transmis-
sion input shaft.
GENERAL DESCRIPTION

YH4
GRAND
VITARA
3
4
1. Reservoir cap
2. Cylinder
3. Piston assembly
4. Push rod
5. Piston stopper
6. Circlip
7. Boot
8. Lock nut
9. Clevis
1. Circlip
2. Push rod
3. Piston
4. Cylinder
1. Circlip
2. Push rod
3. Piston stopper
CLUTCH 7C1-7
DISASSEMBLY AND ASSEMBLY CLUTCH
MASTER CYLINDER
DISASSEMBLY
1) Remove boot and then circlip with piston pushed in.
2) Remove push rod and blow compressed air gradually into hole
for pipe connection to remove piston assembly, using care to
prevent it from jumping out.
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 assembly and circlip.
Inspect cylinder bore for scoring or corrosion. It is best to replace
corroded cylinder. Corrosion can be identified as pits or excessive
roughness.
NOTE:
Polishing bore of cylinder with anything abrasive is prohib-
ited, 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 away from cylinder bore surfaces.
ASSEMBLY
NOTE:
Before installation, wash each part in specified brake fluid.
1) Apply brake fluid to inside of piston assembly and cylinder body.
2) Install piston assembly into cylinder.
3) With piston pushed down, install circlip as shown.
And install boot.

YH4
GRAND
VITARA
1. Masking tape
2. Wood spatula
3. Broken wire
4. Repair agent
Several volts
0 volt
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-17
2) Locating damage in wire
a. Touch voltmeter positive (+) lead to heat wire positive termi-
nal end.
b. Touch voltmeter negative (±) lead with a foil strip to heat wire
positive terminal end, then move it along wire to the negative
terminal end.
c. The place where voltmeter fluctuates from zero to several
volts is where there is damage.
NOTE:
If heat wire is free from damage, voltmeter should indicate
12 V at heat wire positive terminal end and its indication
should decrease gradually toward zero at the other terminal
(ground).
REPAIR
DEFOGGER CIRCUIT
1) Use white gasoline for cleaning.
2) Apply masking tape at both upper and lower sides of heat wire
to be repaired.
3) Apply commercially-available repair agent with a fine-tip brush.
4) Two to three minutes later, remove masking tapes previously
applied.
5) Leave repaired heat wire as it is for at least 24 hours before oper-
ating defogger again.

YH4
GRAND
VITARA
When the welding or heating operation causes the
original galvanization or other anticorrosive materials
to be burnt, the interior and under-body panel sur-
faces must be cleaned.
Removal of residues of the burning should be carried
out carefully when the relevant place has boxtype
construction or has shape which limits the access to
the interior surfaces. In general, the following method
can be used satisfactorily for the removal of those res-
idues.Scrape the accessible places. If a standard putty knife
or scraper does not fit to the elevant place, consider
to use a more flexible scraper to a place narrowly en-
closed by sheet metals.
A jet of compressed air can remove most residues,
and is effective to limited areas.
However, this type of operation absolutely requires
eye protection.
BODY SERVICE 9-37
The metal service replacement parts (or assemblies)
are coated with electro-deposition primer.
For the proper adhesion of a paint, the following finish
process (refinish steps) becomes necessary.
1) Use wax or grease-removing solvent to clean the
part.
2) Use a wet or dry sand-paper (No. 400) to polish the
panel lightly. Do not polish it forcibly to produce any
scratch. Clean the part again.
3) If factory-applied primer coating is cut through to
the bare metal, apply metal conditioner to the bare
metal exposed to open air. As for method of use of
the metal conditioner, follow directions on the con-
tainer.
4) Apply primer-surfacer to the part completely dry
before starting sand-paper polishing. As for drying
time, follow directions advised on the primer-sur-
facer container.
5) Use a wet or dry sand-paper (No. 400) and water
to polish the panel lightly.
6) Wash the part again.
7) Apply color, coating to the part.
8) Different paints demand different drying methods.
Hence, follow directions advised on the pertinent
paint container.9) When lacquer coating (quick-drying paint coat-
ing) is applied, dry coated surface and polish it
with compound.
In the case of the melamine or acrylic coating,
compound polishing can be omitted after drying.
10) If the case of lacquer coating, wax should not be
applied to coated surface until the surface has
dried completely (for approx. two months).
Before replacing exterior parts or assemblies, check
paint conditions of all the covered or hidden interior
surfaces. If any rust scale is found at these places,
proceed as follows:
1) Use a proper wire brush, adhesive or liquid rust re-
moving agent to remove rust. As for the method of
use, follow directions advised for respecitve mate-
rials.
2) If necessary, wash parts with detergent, rinse, and
dry them.
3) Before installing exterior body parts, apply anticor-
rosive compound to all cleaner surfaces of exterior
body parts. Also, apply anticorrosive compound to
inner surfaces of exterior body parts to be
installed.
METAL REPLACEMENT PARTS FINISHING