Cover SUZUKI GRAND VITARA 2000 2.G Service Manual PDF

YH4
GRAND
VITARA
CLUTCH 7C1-3
DIAGNOSIS
ConditionPossible CauseCorrection
Slipping
Improper 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 clutch
Improper 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 vibration
Glazed (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 clutch
Worn 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 clutch
Clutch 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.

YH4
GRAND
VITARA
7C1-10 CLUTCH
(B)1
12
(A)
1. Input shaft bearing
2. Flywheel
3. Clutch disc
4. Clutch cover
5. Bolt
6. Release bearing
7. Clutch release fork
8. Boot
9. Clip
10. Clutch release fork support
1. Bolt
2. Clutch cover
1. Input shaft bearing
UNIT REPAIR
CLUTCH COVER, CLUTCH DISC AND FLYWHEEL
DISMOUNTING / REMOUNTING
Refer to SECTION 7A ªDismounting / Remounting of Trans Unitº.
REMOVAL
1) Hold flywheel stationary with special tool (A) and remove clutch
cover bolts, clutch cover and clutch disc.
Special Tool
(A): 09924-17810
2) Pull out input shaft bearing by using special tool (B) and wrench.
Special Tool
(B): 09917-58010 (G16 engine)
(B): 09923-73210 (J20 and H25 engines)
3) Remove release bearing and release fork.

YH4
GRAND
VITARA
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.

YH4
GRAND
VITARA
7C1-12 CLUTCH
(C)
1
ªAº, (a)1
2
1. Flywheel
2. Bolt
1. Clutch cover
INSTALLATION
NOTE:
Before assembling, make sure that flywheel surface and pres-
sure plate surface have been cleaned and dried thoroughly.
1) Install flywheel to crankshaft and tighten bolts to which sealant
is applied to specification.
Special Tool
(A): 09924-17810
ªAº: Sealant 99000-31110
Tightening Torque
(a): 78 N
.m (7.8 kg-m, 56.5 lb-ft) (G16 engine)
(a): 70 N
.m (7.0 kg-m, 50.5 lb-ft) (J20 and H25 engines)
2) Using special tool (B), install input shaft bearing to flywheel.
Special Tool
(B): 09925-98210
3) Aligning clutch disc to flywheel center by using special tool (C),
install clutch cover and bolts. Then tighten bolts to specification.
NOTE:

While tightening clutch cover bolts, compress clutch disc
with special tool (C) by hand so that disc centered.

Tighten cover bolts little by little evenly in diagonal order.
Special Tools
(A): 09924-17810
(C): 09923-36330 (G16 engine)
(C): 09923-36320 (J20 and H25 engines)
Tightening Torque
(b): 23 N
.m (2.3 kg-m, 16.5 lb-ft)

YH4
GRAND
VITARA
7C1-14 CLUTCH
09917-58010 (G16 engine)
09923-73210
(J20 and H25 engines)
Bearing remover09923-36330 (G16 engine)
09923-36320
(J20 and H25 engines)
Clutch center guide09924-17810
Flywheel holder09925-98210
Input shaft bearing installer
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN.mkg-mlb-ft
Flare nut161.611.5
Master cylinder nut131.39.5
Lock nut101.07.5
Flywheel boltsG16 engine787.856.5Flywheel boltsJ20 and H25 engines707.050.5
Clutch cover bolts232.316.5
Operating cylinder bolt505.036.5
Clutch hose union bolt232.316.5
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium grease
SUZUKI SUPER GREASE A
(99000-25010)
Clutch master cylinder clevis pin.

Release fork.

Push rod tip of operating cylinder.
SUZUKI SUPER GREASE I
(99000-25210)Input shaft spline front end.
Clutch fluid
(Brake fluid)DOT3 or SAE J1703

Clutch reservoir.

Clutch master cylinder.

Clutch operating cylinder.
SealantSUZUKI BOND No.1215
(99000-31110)Flywheel bolts
SPECIAL TOOLS

YH4
GRAND
VITARA
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

YH4
GRAND
VITARA
8B-4 LIGHTING SYSTEM
DIAGNOSIS
NOTE:
Fuse name (ª º) in the table below is shown on the fuse box cover (Hard Top Model) or the junction box
(Canvas Top Model).
HEADLIGHTS
TroublePossible causeCorrection
Only one light does not
light
Bulb blown

Headlight L or R fuse blown

Socket, wiring or grounding faultyReplace bulb
Replace fuse to check for short
Repair
Headlights do not light
Headlight L and R fuses blown

Lighting and dimmer switch faulty

Defective light relay

Wiring or grounding faultyReplace fuses to check for short
Replace switches
Replace light relay
Repair
Only one beam (ªHiº or
ªLoº) does not light
Bulb blown

Lighting or dimmer switch faultyReplace bulb
Replace switch
HEADLIGHTS WITH LEVELING SYSTEM (IF EQUIPPED)
TroublePossible causeCorrection
Both headlights do not
move
ªTURN / BACKº fuse blown (Hard Top Model)
ªTRNº fuse blown (Canvas Top Model)

Leveling switch faulty

Supply voltage too lowReplace fuse to check for short
Replace switch
Recharge or replace battery
One of headlights (either
Right or Left) does not
move
Socket, wiring or grounding faulty

Actuator faulty

Vehicle body around headlight deformed

Headlight ass'y itself deformedRepair
Replace actuator
Repair body
Replace headlight ass'y
TURN SIGNAL AND HAZARD WARNING LIGHTS
TroublePossible causeCorrection
Flash rate high or one side
only flashes
Incorrect bulb

One of light bulbs burnt out

Turn signal / hazard warning relay faulty

Open circuit or high resistance existing
Replace bulb
Replace
Replace relay
Repair
Oen circuit or high resistance existing
between turn signal / hazard warning
switch and lights on one side

Wiring or grounding faulty
Re air
Repair
No flashing
ªTURN / BACKº and / or ªHAZARDº fuse(s)
blown (Hard Top Model)
ªTRNº and / or ªHAZº fuse(s) blown
(Canvas Top Model)

Open circuit or high resistance existing
between battery and switch

Turn signal / hazard relay faulty

Combination switch or hazard switch faulty

Wiring or grounding faultyReplace fuse(s) to check for
short
Check bulb and check circuit
Replace relay
Replace switch
Repair
Flash rate low
Supply voltage too low

Turn signal / hazard relay faultyCheck charging system
Replace relay

YH4
GRAND
VITARA
LH steering vehicle shown
X-X:Horizontal center line of headlight bulbs
A-A:Vertical center line of left headlight bulb
B-B:Vertical center line of right headlight bulb1. Screen
2. For right / left adjustment
3. For up / down adjustment
(for vehicle without leveling system)
4. For up / down adjustment
(for vehicle with leveling system)
5. Headlight leveling actuatorHOT
SPOT LH. HEADLIGHT RH. HEADLIGHT
LIGHTING SYSTEM 8B-7
BULB REPLACEMENT
WARNING:
Don't touch when the bulb is hot.
1) Disconnect negative cable at battery.
2) Disconnect harness from bulb.
3) Remove socket cover and bulb.
4) Replace bulb and install in reverse removal procedure.
HEADLIGHT AIMING WITH SCREEN
NOTE:

Unless otherwise obligated by local regulations, adjust
headlight aiming according to following procedure.

After replacing headlight, be sure to perform its aiming.

When inspecting and adjusting headlight with leveling sys-
tem, make sure to set the leveling switch to ª0º position with
IG switch ON.
Before adjustment, make sure the following.
a) Place vehicle on a flat surface in front of blank wall as below
ahead of headlight surface.
Clearance ªaº: 10 m (32.8 ft)
b) Adjust air pressure of all tires to a specified value respectively.
c) Bounce vehicle body up and down by hand to stabilize suspen-
sion.
d) Carry out one driver aboard.
Driver's weight: 75 kg (165 lb)
Adjustment
1) Check to see if hot spot (high intensity zone) of each main (low)
beam axis falls as illustrated.
Clearance ªHº: Approx. 130 mm (5.15 in.)
2) If headlight aiming is not set properly, align it to specification by
adjusting aiming screw and aiming gear.

YH4
GRAND
VITARA
8C-4 INSTRUMENTATION / DRIVER INFORMATION
DIAGNOSIS
NOTE:
Fuse name (ª º) in the table below is shown on the fuse box cover (Hard Top Model) or the junction box
(Canvas Top Model).
SPEEDOMETER AND VSS
TroublePossible CauseCorrection
Speedometer shows no
operation
ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)

VSS faulty

Printed plate in combination meter
faulty

Speedometer faulty

Wiring or grounding faultyReplace fuse to check for short
Replace VSS
Replace printed plate
Replace speedometer
Repair
FUEL METER / FUEL GAUGE UNIT
TroublePossible CauseCorrection
Fuel meter shows no
operation
ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)

Fuel gauge unit faulty

Printed plate in combination meter
faulty

Fuel meter faulty

Wiring or grounding faultyReplace fuse to check for short
Replace fuel gauge unit
Replace printed plate
Replace fuel meter
Repair
ENGINE COOLANT TEMP. (ECT) METER AND SENSOR
TroublePossible CauseCorrection
Engine coolant temp.
meter shows no operation
ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)

ECT meter faulty

Printed plate in combination meter
faulty

ECT sensor faulty

Wiring or grounding faultyReplace fuse to check for short
Replace ECT meter
Replace printed plate
Replace ECT sensor
Repair
OIL PRESSURE LIGHT
TroublePossible CauseCorrection
Oil pressure warning light
does not light up
Bulb in combination meter blown

ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)

Printed plate in combination meter
faulty

Oil pressure switch faulty

Wiring or grounding faultyReplace bulb
Replace fuse to check for short
Replace printed plate
Replace oil pressure switch
Repair

YH4
GRAND
VITARA
INSTRUMENTATION / DRIVER INFORMATION 8C-7
1. Steering column hole cover
COMBINATION METER
REMOVAL
1) Disconnect negative cable at battery.
2) If the vehicle is equipped with air bag system, disable air bag
system. Refer to DISABLING AIR BAG SYSTEM in Section
10B of this manual.
3) Remove column hole cover.
4) Remove instrument cluster panel.
5) Remove screws fastening combination meter.
6) Disconnect couplers from combination meter.
7) Remove combination meter from instrument panel.
INSTALLATION
Reverse removal procedure for installation, noting the following.

If the vehicle is equipped with air bag system, be sure to enable
air bag system after installation. Refer to ENABLING AIR BAG
SYSTEM in Section 10B of this manual for details.