stop start SUZUKI GRAND VITARA 2002 2.G Service Owner's Manual

YH4
GRAND
VITARA
1. Dipstick (G16 / J20)
2. Dipstick (H25)
AUTOMATIC TRANSMISSION (4 A / T) 7B1-59
ON-VEHICLE SERVICE
MAINTENANCE SERVICE
FLUID LEVEL
LEVEL CHECK AT NORMAL OPERATING TEMPERATURE
1) Stop vehicle and place it level.
2) Apply parking brake and place chocks against wheels.
3) With selector at P position, start engine.
4) Warm up engine till fluid temperature reaches normal operating
temperature (70 ± 80C / 158 ± 176F). As a guide to check fluid
temperature, warm up engine till engine coolant temperature
meter indicated around 1 unit above ªCº point.
5) Keep engine idling and shift selector slowly to L and back to P
position.
6) With engine idling, pull out dipstick, wipe it off with a clean cloth
and put it back into place.
7) Pull out dipstick again and check fluid level indicated on it. Fluid
level should be between FULL HOT and LOW HOT. If it is below
LOW HOT, add an equivalent of DEXRON-III up to FULL HOT.
Fluid specification
An equivalent of DEXRON-III
NOTE:

DO NOT RACE ENGINE while checking fluid level, even af-
ter the engine start.

DO NOT OVERFILL. Overfilling can causes foaming and
loss of fluid through breather. Then slippage and trans-
mission failure can result.

Bringing the level from LOW HOT to FULL HOT requires
0.3 liters (0.64/0.53 US/lmp.pt).

If vehicle was driven under high load such as pulling a
trailer, fluid level should be checked about half an hour af-
ter it is stopped.

YH4
GRAND
VITARA
7E-10 DIFFERENTIAL (FRONT)
1. Plugged hose
2. Adjusting screw
3. Pipe (to air pump assembly)
4. Hose (to differential carrier)
5. Differential housing
4 5
INSPECTION
4WD Control System
1) Install special tool to air hose connecting between air pump as-
sembly and differential (actuator) as shown in figure. Tighten ad-
justing screw of special tool as far as it stops. Close air check
side opening by using fuel hose as blind plug.
Special Tool
(A): 09918-18110
(B): 09367-04002
NOTE:
Use care not to bend any part of hose.
2) Turn ON ignition switch and shift transfer lever from 2H to 4H
range.
3) Check that motor starts running (a sound can be heard) within
1 second and it stops when gauge of special tool indicates speci-
fied pressure value.
Check also for air leakage.
Pressure specification:
30.0 ± 45.0 kPa (0.30 ± 0.45 kg / cm
2, 4.25 ± 6.40 psi)
4) Check that pressure value indicated on gauge of special tool
drops as soon as transfer lever is shifted to 2H position.
5) Start motor by shifting transfer lever to 4H position again. Loos-
en adjusting screw to lower pressure value on gauge. Motor
should start to run again and stop in about 4 seconds.
6) With the adjusting screw of special tool loosened, shift transfer
shift lever to N or 2H position and then 4L or 4H position.
Pump motor should stop about 10 seconds after motor starts to
run.

YH4
GRAND
VITARA
7E-12 DIFFERENTIAL (FRONT)
1. Pump assembly
Air Pump Assembly
Removal / Installation
1) Disconnect air hoses and coupler from air pump assembly.
2) Remove pump assembly by removing bolts.
3) Reverse removal procedure for installation.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
Inspection
1) Install special tool, voltmeter and battery to pump assembly as
shown in figure.
2) Tighten adjusting screw of special tool as far as it stops and
close its air check side opening by using fuel hose as blind plug.
Special Tool
(A): 09918-18110
3) Check that motor starts to run (a sound can be heard) when bat-
tery is connected and it stops when specified pressure is ob-
tained.
Check also for air leakage.
Specified pressure: 30.0 ± 45.0 kPa
(0.30 ± 0.45 kg / cm
2, 4.25 ± 6.40 psi)
4) Check that value indicated on voltmeter is within specification
shown below.
When motor is running: 0 ± 1 V
When motor has stopped running: 10 ± 14 V
CAUTION:
Do not run motor more than 10 seconds continuously to
prevent motor breakage.

YH4
GRAND
VITARA
1. Coil antenna
2. Ignition key
3. Immobilizer control module
4. Data link connector (DLC)
5. Immobilizer diagnostic coupler Ignition key
Transponder
code
Immobilizer
Control
ModuleECM/
PCM
8G-2 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED)
GENERAL DESCRIPTION
The immobilizer control system designed to prevent vehicle burglar consists of following components.

Engine control module (ECM) / Powertrain control module (PCM)

Immobilizer control module

Ignition key (with built-in transponder)

Coil antenna
Operation of this system is as follows.
(1) Each ignition key has its own code (Transponder code) stored in memory. When the ignition switch is turned
ON, Immobilizer Control Module tries to read the Transponder code through the coil antenna installed to the
steering lock assembly.
(2) Immobilizer Control Module compares the Transponder code read in (1) and that registered in Immobilizer Con-
trol Module and checks if they match.
(3) When it is confirmed that two Transponder codes match each other as described above, Immobilizer Control
Module and ECM / PCM check if ECM/Immobilizer Control Module codes registered in them respectively match.
(4) Only when it is confirmed that ECM/Immobilizer Control Module codes match, the engine starts running. If
Transponder codes in Step (2) or ECM/Immobilizer Control Module codes in Step (3) do not match, ECM / PCM
will stop operation of the injector and ignition of spark plug.

YH4
GRAND
VITARA
1. Windshield glass
2. Fastener No. 1
3. Windshield molding4. Stopper
5. Fastener No. 2
9-6 BODY SERVICE
WINDSHIELD
The front windshield is installed by using a special type of adhesive (that is, one component urethane adhesive
used with primer). For the Windshield replacement, it is important to use an adhesive which provides sufficient
adhesion strength and the follow the proper procedure.
CAUTION:

Described in this section is the glass replacement by using 3 types of primers and 1 type of adhesive
made by YOKOHAMA (one component urethane adhesive to be used with primer in combination).
When using primer and adhesive made by other manufacturers, be sure to refer to handling instruc-
tions supplied with them. Negligence in following such procedure or misuse of the adhesive in any
way hinders its inherent adhesive property. Therefore, before the work, make sure to read carefully
the instruction and description given by the maker of the adhesive to be used and be sure to follow
the procedure and observe each precaution throughout the work.

Should coated surface be scratched or otherwise damaged, be sure to repair damaged part, or corro-
sion may start from there.
Use an adhesive of above mentioned type which has following property.
Shearing strength: 40 kg / cm
2 (569 lb / in2) or more
Adhesive materials and tools required for removal and installation.

One component urethane adhesive and primers used in combination (for one sheet of windshield).
Adhesive (470 g (15.7 oz.))
Primer for glass (30 g (1.0 oz.))
Primer for body (30 g (1.0 oz.))
Primer for molding (30 g (1.0 oz.))

Eyeleteer

Piano string

Windshield knife

Brush for primer application (2 pcs.)

Knife

Rubber sucker grip

Sealant gun (for filling adhesive)

Putty spatula (for correcting adhered parts)

YH4
GRAND
VITARA
1. Passenger air bag (inflator) module
2. Instrument panel
3. Glove box
1. Glove box
2. Push
3. Pull
AIR BAG SYSTEM 10B-69
PASSENGER AIR BAG (INFLATOR) MODULE
WARNING:

Never attempt to disassemble or repair the passenger air bag (inflator) module. If any abnormality is
found, be sure to replace it with new one as an assembly.

Be sure to read ªService Precautionsº in this section before starting to work and observe every pre-
caution during work. Neglecting them may result in personal injury or undeployment of the air bag
when necessary.
REMOVAL
1) Disconnect negative battery cable at battery.
2) Disable air bag system. Refer to ªDisabling Air Bag Systemº ear-
lier in this section.
3) Open glove box, then while pressing glove box stopper, pull out
glove box from instrument panel.
4) Remove glove box from instrument panel.
5) Remove passenger air bag (inflator) module attaching bolts and
screws, and passenger air bag (inflator) module from vehicle.
WARNING:

When carrying a live air bag (inflator) module, make
sure the bag opening is pointed away from you.
Never carry air bag (inflator) module by wires or con-
nector on the side of the module. In case of an acciden-
tal deployment, the bag will then deploy with minimal
chance of injury.

As the live passenger air bag (inflator) module must be
kept with its bag (trim cover) facing up while being
stored or left standing, place it on the workbench with
a slit or use the workbench vise to hold it securely at its
lower mounting bracket. This is necessary so that a
free space is provided to allow the air bag to expand in
the unlikely event of accidental deployment.

Observe ªService Precautionsº earlier in this section
for handling and storing it.
Otherwise personal injury may result.