radiator SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

YH4
GRAND
VITARA
GENERAL INFORMATION 0A-7
GENERAL PRECAUTIONS
The WARNING and CAUTION below describe some general precautions that you should observe when servicing
a vehicle. These general precautions apply to many of the service procedures described in this manual, and they
will not necessarily be repeated with each procedure to which they apply.
WARNING:

Whenever raising a vehicle for service, be sure to follow the instructions under ªVEHICLE LIFTING
POINTSº on SECTION 0A.

When it is necessary to do service work with the engine running, make sure that the parking brake
is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for automatic
transmission vehicles). Keep hands, hair, clothing, tools, etc. away from the fan and belts when the
engine is running.

When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.

Do not perform service work in areas where combustible materials can come in contact with a hot
exhaust system. When working with toxic or flammable materials (such as gasoline and refrigerant),
make sure that the area you work in is well-ventilated.

To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail-
pipe, muffler, etc.

New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or
used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory animals.
Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a
long-sleeve shirt and moisture-proof gloves (such as dishwashing gloves) when changing engine oil.
If engine oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags
if wet with oil, recycle or properly dispose of used oil and filters.

Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly
during driving, obstructing your view and resulting in an accident.
CAUTION:

Before starting any service work, cover fenders, seats and
any other parts that are likely to get scratched or stained dur-
ing servicing. Also, be aware that what you wear (e.g, but-
tons) may cause damage to the vehicle's finish.

When performing service to electrical parts that does not re-
quire use of battery power, disconnect the negative cable of
the battery.

YH4
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VITARA
NOTE:
Air bag CAUTION / WARNING labels are attached on
the vehicle equipped with air bag system only.
Engine cooling
fan label
Radiator cap
labelAir bag labelEmission control label
(Australia only)
Air bag label
on sun visor
Transfer label
0A-18 GENERAL INFORMATION
WARNING, CAUTION AND INFORMATION LABELS
The figure below shows main labels among others that are attached to vehicle component parts.
When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels.
If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.

YH4
GRAND
VITARA
1. Full level mark (hole)
2. Low level mark (hole)
0B-10 MAINTENANCE AND LUBRICATION
NOTE:
Engine oil capacity is specified. However, note that the
amount of oil required when actually changing oil may
somewhat differ from the data in the table depending on
various conditions (temperature, viscosity, etc.).
7) Check oil filter and drain plug for oil leakage.
8) Start engine and run it for three minutes. Stop it and wait five min-
utes before checking oil level. Add oil, as necessary, to bring oil
level to FULL level mark on dipstick.
NOTE:
Step 1) ± 7) outlined above must be performed with ENGINE
NOT RUNNING. For step 8), be sure to have adequate ven-
tilation while engine is running.
ITEM 1-5
Engine Coolant Change
WARNING:
To help avoid danger of being burned, do not remove radia-
tor cap while engine and radiator are still hot. Scalding fluid
and steam can be blown out under pressure if cap is taken
off too soon.
1) Remove radiator cap when engine is cool.
2) Loosen radiator drain plug to drain coolant.
3) Remove reservoir, which is on the side of radiator, and drain.
4) Tighten plug securely. Also reinstall reservoir.
5) Fill radiator with specified amount of coolant, and run engine for
2 or 3 minutes at idle. This drives out any air which may still be
trapped within cooling system. STOP ENGINE. Add coolant as
necessary until coolant level reaches the filler throat of radiator.
Reinstall radiator cap.

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GRAND
VITARA
HEATER AND VENTILATION 1A-3
BODY VENTILATION
The body ventilation system of this vehicle has a fresh air intake located at the cowl top panel. When fresh air intake
control lever is at FRESH AIR position, ventilating air is drawn into the interior from the cowl center garnish and
drawn out from the ventilator outlet provided at each side body outer panel (both right and left side).
DIAGNOSIS
DIAGNOSIS TABLE
TroublePossible causeRemedy
Heater blower won't
work even when its
switch is ON.Blower fuse blown
Blower resistor faulty
Blower motor faulty
Wiring or grounding faultyReplace fuse to check for short.
Check resistor.
Replace motor.
Repair as necessary.
Incorrect temperature
output.Control cables broken or binding
Air damper broken
Air ducts clogged
Heater radiator leaking or clogged
Heater hoses leaking or cloggedCheck cables.
Repair damper.
Repair air ducts.
Replace radiator.
Replace hoses.
When mode control
switch is changed,
air outlet port is not
changed.Mode control switch faulty
Mode actuator faulty
Fuse blown
Wiring or grounding faulty
Air damper broken
Air ducts cloggedCheck and replace as necessary.
Check and replace as necessary.
Replace fuse to check for short.
Repair as necessary.
Repair damper.
Repair air ducts.

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VITARA
1A-18 HEATER AND VENTILATION
11) Remove heater core pipe clamps (1) and grommet (2).
12) Pull out heater core (1) from unit (2).
INSTALLATION
1) Install heater unit by reversing removal procedure, noting the
following items.

When installing each part, be careful not to catch any cable or
wiring harness.

When installing steering column assembly, refer to STEER-
ING COLUMN INSTALLATION in Section 3C or 3C1.
2) Install control cables. (Refer to HEATER CONTROL CABLES in
this section.)
3) Fill engine coolant to radiator.
4) Enable air bag system, if equipped. Refer to ENABLING AIR
BAG SYSTEM in Section 10B.
5) Evacuate and charge system. Refer to items EVACUATING
SYSTEM and PROCEDURE OF CHARGING in Section 1B.

YH4
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VITARA
For CAMI production vehicle
For IWATA production vehicle
1B-12 AIR CONDITIONING (OPTIONAL)
PERFORMANCE DIAGNOSIS
1) Confirm that vehicle and environmental conditions are as fol-
lows.

Vehicle is not exposed to direct sun.

Ambient temperature is within 15C ± 35C (59F ± 95F).
2) Make sure that high pressure valve (1) and low pressure valve
(2) of manifold gauge are firmly closed.
3) Connect high pressure charging hose (3) to high pressure ser-
vice valve (5) on vehicle, and connect low pressure charging
hose (4) to low pressure service valve (6) on vehicle.
4) Bleed the air in charging hoses (3), (4) by loosening their respec-
tive nuts on manifold gauge, utilizing the refrigerant pressure.
When a hiss is heard, immediately tighten nut.
CAUTION:
Do not interchange high and low pressure charging
hoses by mistake.
5) Warm up engine to normal operating temperature (engine cool-
ant temperature at 80 ± 90C (176 ± 194F)) and keep it at spe-
cified idle speed. (Radiator cooling fan should not be working
when checking pressure and temperature.)
6) Turn A / C switch ON, and set blower switch at ªHIº (4th position),
temperature control knob at ªCOOLº, air outlet control knob at
ªFACEº, fresh / circulation control knob at ªCIRCULATIONº.
(Confirm that A / C compressor and condenser fan are working.)
7) Keep all windows, doors and engine food open.
Ambient temperature
15 ± 35C (59F ± 95F)
Engine rpmKeep to 1,500 rpm.
Blower motor switchMax. (4th position)
Temperature controlMax. cool
Air outlet controlFace
Vehicle doorsAll open
Air inlet door positionRecirculation
8) With about 20 mm (0.8 in.) of dry bulb thermometer (1) inserted
into center duct air outlet and another one set near evaporator
air inlet, read temperature indicated on each thermometer.

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VITARA
3
1B-34 AIR CONDITIONING (OPTIONAL)
5) Disconnect coupler from dual pressure switch (1).
6) Disconnect condenser outlet pipe (3).
7) Disconnect condenser cooling fan motor coupler (2).
8) Remove condenser with fan.
NOTE:
Be careful not to damage fins of condenser and radiator.
9) Remove A / C condenser cooling fan assembly from condenser.
INSTALLATION
Reverse removal sequence to install condenser, noting following
point.
1) When replacing condenser, add 20 to 30 cc of refrigerating oil
from compressor suction-side.
2) Evacuate and charge system according to previously-described
procedure.

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VITARA
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

YH4
GRAND
VITARA
1. Radiator
2. Inlet hose (Outlet from oil cooler)
3. Outlet hose (Inlet to coil cooler)
4. Converter housing
5. Outlet hose
6. Inlet hose
1. A / T throttle cable
2. Adjusting nut
3. Lock nut
1. A / T throttle cable
2. Adjusting nut
3. Lock nut
G16 / J20
H25
1. A / T throttle cable
2. Stopper
3. Inner cable
4. A / T assemblyR100 mm
(3.94 in.)
AUTOMATIC TRANSMISSION (4 A / T) 7B1-61
OIL COOLER HOSES
When replacing them, be sure to note the followings.

to replace clamps at the same time.

to insert hose as far as its limit mark.

to clamp hose securely.
A / T THROTTLE CABLE
ADJUSTMENT
1) Pull inner cable by force of 2 N (0.2 kg, 0.45 lb) or less to be no
slack of inner cable with A / T throttle cable curved as shown in
the figure.
2) Fix stopper to inner cable with clearance ªcº.
Clearance ªcº : 0.8 ± 1.5 mm (0.03 ± 0.06 in.)
3)For G16 / J20 engines
a) Check clearance ªcº. If it is out of specifications, adjust it by
turning cable adjusting nut.
Clearance ªcº : 0.8 ± 1.5 mm (0.03 ± 0.06 in.)
b) Tighten lock nut securely.
For H25 engine
a) Warm up engine and transmission to normal operating tem-
perature.
b) Make sure that accelerator cable is adjusted as specified.
c) With throttle valve closed, check clearance ªcº which should
be within the following specification.
Clearance ªcº : 0.8 ± 1.5 mm (0.03 ± 0.06 in.)
If it is out of specification, adjust it by turning cable adjusting nut.