cylinder SUZUKI GRAND VITARA 2000 2.G Service Manual PDF

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
ªAº
1. Reservoir cap
2. Cylinder
3. Piston assembly
4. Push rod
5. Piston stopper
6. Circlip
7. Boot
8. Lock nut
9. Clevis
1. Clutch operating cylinder
2. Hose
3. E-ring
7C1-8 CLUTCH
4) Tighten lock nut to specified torque.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
5) For installation of master cylinder to vehicle, refer to INSTALLA-
TION described previously.
CLUTCH OPERATING CYLINDER
REMOVAL
NOTE:
Do not allow fluid to get on painted surfaces.
1) Clean around reservoir cap and take out fluid with syringe or
such.
2) Disconnect fluid hose from operating cylinder.
3) Remove operating cylinder attaching bolts and operating cylin-
der.
INSTALLATION
1) For air bleeding of master cylinder alone, it must be removed
from vehicle.
For procedures of removal and installation of master cylinder as-
sembly and air bleeding, refer to CLUTCH MASTER CYLINDER
section.
2) Apply small amount of grease to rod tip.
ªAº: Grease 99000-25010
NOTE:
Don't allow any grease to be on boot.
3) Install clutch operating cylinder and torque attaching bolts to
specification.
4) Connect clutch fluid hose and torque union bolt to specification.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
(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
G16
J20
H25
1. Oil pressure switch
INSTRUMENTATION / DRIVER INFORMATION 8C-11
INSPECTION
1) Warm up ECT sensor (1) observing resistance between sensor
terminal (2) and sensor unit (1). Resistance should be de-
creased with increase of its temperature.
2) Check resistance between sensor terminal (2) and sensor unit
(1) shown below. If check result is not as specified, replace sen-
sor.
Temperature
Resistance
50
C (122
F)136 ± 216

OIL PRESSURE LIGHT
OIL PRESSURE SWITCH
REMOVAL AND INSTALLATION
Refer to OIL PRESSURE CHECK in Section 6A1 (for G16), Section
6A2 (for H25), and Section 6A4 (for J20) of this manual for details.
INSPECTION
1) Disconnect oil pressure switch (1) lead wire.
2) Check for continuity between oil pressure switch terminal (2)
and cylinder block (3) as shown.
During Engine Running
No continuity
At Engine StopContinuity
If check result is not as specified, replace oil pressure switch (1).

YH4
GRAND
VITARA
Terminal
Key
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-21
6) Connect negative cable at battery.
7) Check that the voltage and resistance between following termi-
nals are specifications.
Terminals
ConditionSpecification
E02-7 and
groundAnytime10 ± 14 V
E02-14 and
groundAnytimecontinuity
E02-8 and
When driver side door key
switch is OFF positionNo continuity
groundWhen driver side door key
switch is LOCK positionContinuity
E02-9 and
When driver side door key
switch is OFF positionNo continuity
groundWhen driver side door key
switch is UNLOCK positionContinuity
If check result is not satisfactory, repair circuit and recheck.
If check result is satisfactory, replace controller.
KEY CYLINDER SWITCH (DRIVER SIDE)
Check for continuity between terminals according to the key action
shown below.
321
LOCK
OFF
UNLOCK

YH4
GRAND
VITARA
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-27
POWER DOOR LOCK SWITCH
INSPECTION
Refer to POWER DOOR LOCK SWITCH INSPECTION of POWER
DOOR LOCK SYSTEM (IF KEYLESS ENTRY IS NOT EQUIPPED)
in this section.
KEY CYLINDER SWITCH (DRIVER SIDE)
INSPECTION
Refer to KEY CYLINDER SWITCH (DRIVER SIDE) INSPECTION
of POWER DOOR LOCK SYSTEM (IF KEYLESS ENTRY IS NOT
EQUIPPED) in this section.
POWER DOOR LOCK ACTUATOR
INSPECTION
Refer to POWER DOOR LOCK ACTUATOR INSPECTION of
POWER DOOR LOCK SYSTEM (IF KEYLESS ENTRY IS NOT
EQUIPPED) in this section.

YH4
GRAND
VITARA
BODY SERVICE 9-19
1. Back door panel assy
2. Back door window glass
3. Back door hinge
4. Back door / Rear gate balancer unit
1. Back door hinge
2. Back door
3. Body
BACK DOOR / REAR GATE ASSEMBLY
REMOVAL
1) Remove back door trim, and door / rear gate sealing cover, refer
to steps 1) to 4) of BACK DOOR LOCK ASSEMBLY in this sec-
tion.
2) Remove wire harness connector inside the back door / rear gate.
3) Remove back door / rear gate balancer (first at its door-side and
next at its body-side), as shown.
WARNING:
Handling of Back Door / Rear Gate Balancer (Damper)

Do not disassemble balancer because its cylinder is
filled with gas.

The gas itself is harmless but it may issue out of the
hole together with chips generated by the drill.
Therefore, be sure to wear goggle.

When discarding removed back door / rear gate balanc-
er (damper), use a 2 to 3 mm (0.08 to 0.12 in.) drill to
make a hole as shown.

Handle balancer carefully. Do not scar or scratch ex-
posed surface of its piston rod, and never allow any
paint or oil to stick to its surface.

Do not turn piston rod with balancer fully extended.
5) Remove back door / rear gate hinge bolts and back door / rear
gate.

YH4
GRAND
VITARA
BODY SERVICE 9-63
KEY CODING
KEY USAGE AND IDENTIFICATION
Key is used for ignition and door lock cylinder. Keys are cut on both
edges to make them reversible.
Key identification is obtained from five character key code stamped
on key code tag. Using this key code, key code cutting combination
can be determined from a code list (available to owners of key cut-
ting equipment from suppliers).
If key codes are not available from records or tags, key code can
be obtained from the right hand door lock cylinder (if lock has not
been replaced). Lock cylinders supplied by the factory as service
parts are unmarked.
If original key is available, key code cutting combination can be de-
termined by laying key.
IGNITION SWITCH LOCK CYLINDER
Removal / Installation
See Section 3C1, ªAIR BAG STEERING WHEEL AND COLUMNº.
ELECTRICAL DIAGNOSIS
For ignition switch electrical troubleshooting, see Section 8, ªBODY
ELECTRICAL SYSTEMº.