ten SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

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vol.1
0A
0B
1A
1B
3
3A
3B1
3C
3C1
3D
3E
3F
4A2
4B
5
6
7A5A
5B
5C
5E1
6A1
6A2
6A4
6B
6C
6E1
6E2
6F1
6F2
6G
6G1
6H
6K
7A1
7B1
7C1
7D
7E
7F
8
8B
8C
8D
8G
9
10
10A
8A
10B
6-1ENGINE
General Information and
Diagnosis (G16 / J20)
General Information and
Diagnosis (H25)
Engine Mechanical (G16)
Engine Mechanical (H25)
Engine Mechanical (J20)
Engine Cooling
Engine Fuel
Engine and Emission Control
System (SFI for G16 / J20)
Engine and Emission Control
System (SFI for H25)
Ignition System (G16)
Ignition System (J20 / H25)
Cranking System
(Reduction Type)
Cranking System
(No-Reduction Type)
Charging System
Exhaust System
TRANSMISSION, CLUTCH
AND DIFFERENTIAL
Manual Transmission (Type 1)
Manual Transmission (Type 2)
Automatic Transmission
Clutch (Hydraulic Type)
Transfer
Differential (Front)
Differential (Rear)
BODY ELECTRICAL SYSTEM
Wiring Diagram
Lighting System
Instrumentation / Driver
Information
Windows, Mirrors, Security
and Lock
Immobilizer Control System
BODY SERVICE
RESTRAINT SYSTEM
Seat Belt
Air Bag System GENERAL INFORMATION
General Information
Maintenance and Lubrication
TABLE OF CONTENTS TABLE OF CONTENTS SECTIONSECTION
0B
HEATING AND AIR
CONDITIONING
Heater and Ventilation
Air Conditioning
STEERING, SUSPENSION,
WHEELS AND TIRES
Front End Alignment
Power Steering (P / S) System
Steering Wheel and Column
(Not Equipped with Air Bag)
Air Bag Steering Wheel
and Column
Front Suspension
Rear Suspension
Wheel and Tires
1A
3A 0A
1B
3B1
3C
3C1
3D
3E
3F36A16
6A2
6A4
6B
6C
6E1
6E2
6F1
DRIVE SHAFT / PROP. SHAFT
Front Drive Shaft / Shaft
Bearing, Oil Seal
Propeller Shaft
BRAKES
Brake Pipe / Hose / Master
Cylinder
Front Brakes
Parking and Rear Brakes
Antilock Brake System
4A2
4B
5
5A
5B
5C
5E1
6F2
6G
6G1
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8
8A
8B
8C
8D
8G
9
10
10A
10B
6-1
NOTE:
The screen toned Sections 6 ± 6K are included in Volume 2 and Section 8A is in Wiring
Diagram Manual.

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0A
GENERAL INFORMATION 0A-1
SECTION 0A
GENERAL INFORMATION
CONTENTS
HOW TO USE THIS MANUAL0A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS0A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Vehicle Equipped with a Supplemental Restraint (Air Bag) System 0A- 3. . . . . . . . . . . . . . . .
Diagnosis0A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing and Handling0A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Precautions0A- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Catalytic Converter 0A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Electrical Circuit Service 0A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Circuit Inspection Procedure 0A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermittent and Poor Connection 0A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precaution for Installing Mobile Communication Equipment 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDENTIFICATION INFORMATION0A-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body Number0A-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Identification Number0A-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Identification Number 0A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING, CAUTION AND INFORMATION LABELS0A-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE LIFTING POINTS0A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABBREVIATIONS MAY BE USED IN THIS MANUAL0A-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
METRIC INFORMATION0A-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric Fasteners0A-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fasteners Strength Identification 0A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tightening Torque0A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6) Install oil pump. Refer to ªOil pumpº.
7) Install flywheel (for M/T vehicle) or drive plate (for A/T vehicle).
Using special tool, lock flywheel or drive plate, and tighten
flywheel or drive plate bolts to specified torque.
Special Tool
(A): 09924-17810
Tightening Torque
(c): 78 N
.m (7.8 kg-m, 56.0 lb-ft)1. Flywheel bolts or drive plate bolts for A/T vehicle1, (c)
0A-2 GENERAL INFORMATION
HOW TO USE THIS MANUAL
1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL
on the third page of this manual, whereby you can easily find the
section that offers the information you need. Also, there is a
CONTENTS on the first page of EACH SECTION, where the
main items in that section are listed.
2) Each section of this manual has its own pagination. It is indicated
at the top of each page along with the Section name.
3) The SPECIAL TOOL usage and TORQUE SPECIFICATION are
given as shown in figure below.
4) A number of abbreviations are used in the text.
For their full explanations, refer to ªABBREVIATIONS MAY BE
USED IN THIS MANUALº of this section.
5) The SI, metric and foot-pound systems are used as units in this
manual.
6) DIAGNOSIS are included in each section as necessary.
7) At the end of each section, there are descriptions of SPECIAL
TOOLS, REQUIRED SERVICE MATERIALS and TIGHT-
ENING TORQUE SPECIFICATIONS that should be used for the
servicing work described in that section.

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1. Air bag wire harness
2. Passenger air bag
(inflator) module
3. SDM
4. DLC5. Contact coil
6. Driver air bag (inflator)
module
7. Seat belt pretensioner
(if equipped)
GENERAL INFORMATION 0A-3
PRECAUTIONS
PRECAUTION FOR VEHICLES EQUIPPED
WITH A SUPPLEMENTAL RESTRAINT
(AIR BAG) SYSTEM
WARNING:

The configuration of air bag system parts are as shown in
the figure. When it is necessary to service (remove, rein-
stall and inspect) these parts, be sure to follow proce-
dures described in SECTION 10B. Failure to follow proper
procedures could result in possible air bag system activa-
tion, personal injury, damage to parts or air bag system
being unable to activate when necessary.

If the air bag system and another vehicle system both
need repair, SUZUKI recommends that the air bag system
be repaired first, to help avoid unintended air bag system
activation.

Do not modify the steering wheel, dashboard, or any other
air bag system components. Modifications can adversely
affect air bag system performance and lead to injury.

If the vehicle will be exposed to temperatures over 93
C
(200
F) (for example, during a paint baking process), re-
move the air bag system components beforehand to avoid
component damage or unintended air bag system activa-
tion.
DIAGNOSIS

When troubleshooting air bag system, be sure to follow
ªDIAGNOSISº in SECTION 10B. Bypassing these proce-
dures may result in extended diagnostic time, incorrect diag-
nosis, and incorrect parts replacement.

Never use electrical test equipment other than that specified
in this manual.
WARNING:
Never attempt to measure the resistance of the air bag (in-
flator) modules (driver and passenger) and seat belt preten-
tioners (driver and passenger). It is very dangerous as the
electric current from the tester may deploy the air bag or ac-
tivate the pretensioner.

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1. Exhaust hole
1 1
NG
GENERAL INFORMATION 0A-5
WARNING:
SDM

During service procedures, be very careful when handling
a Sensing and Diagnostic Module (SDM). Never strike or
jar the SDM.
Never power up the air bag system when the SDM is not
rigidly attached to the vehicle. All SDM and mounting
bracket fasteners must be carefully torqued and the arrow
must be pointing toward the front of the vehicle to ensure
proper operation of the air bag system.
The SDM could be activated when powered while not rigid-
ly attached to the vehicle which could cause deployment
and result in personal injury.
WARNING:
Driver and Passenger Seat Belt Pretensioners

For handling and storage of a live seat belt pretensioner,
select a place where the ambient temperature below 65
C
(150
F), without high humidity and away from electric
noise.

Never carry seat belt pretensioner by wire or connector of
pretensioner. When placing a live seat belt pretensioner
on the workbench or some place like that, be sure not to
lay it with its exhaust hole provided side facing down. It is
also prohibited to put something on its face with an ex-
haust hole or to put a seat belt pretensioner on top of
another. Otherwise, personal injury may result.

Never dispose of live (inactivated) seat belt pretensioners
(driver and passenger). If disposal is necessary, be sure
to activate them according to activation procedures de-
scribed in SECTION 10B before disposal.

The seat belt pretensioner immediately after activation is
very hot. Wait for at least half an hour to cool it off before
proceeding the work.

With many service procedures, gloves and safety glasses
should be worn to prevent any possible irritation of the
skin or eyes.

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0A-6 GENERAL INFORMATION
CAUTION:

Even when the accident was light enough not to cause air
bags to activate, be sure to inspect system parts and other
related parts according to instructions under ªRepair and
Inspection Required after an Accidentº in SECTION 10B.

When servicing parts other than air bag system, if shocks
may be applied to air bag system component parts, re-
move those parts beforehand.

When handling the air bag (inflator) modules (driver and
passenger), seat belt pretensioners (driver and passen-
ger) or SDM, be careful not to drop it or apply an impact to
it. If an excessive impact was applied (e.g., dropped from
a height of 91.4 cm (3 feet) or more), never attempt disas-
sembly or repair but replace it with a new one.

When grease, cleaning agent, oil, water, etc. has got onto
air bag (inflator) modules (driver and passenger) or seat
belt pretensioners (drive and passenger), wipe off im-
mediately with a dry cloth.

Air bag wire harness can be identified easily as it is cov-
ered with a yellow protection tube. Be very careful when
handling it.

When an open in air bag wire harness, damaged wire har-
ness, connector or terminal is found, replace wire har-
ness, connectors and terminals as an assembly.

Do not apply power to the air bag system unless all com-
ponents are connected or a diagnostic chart requests it,
as this will set a diagnostic trouble code.

Never use air bag system component parts from another
vehicle.

When using electric welding, be sure to temporarily dis-
able air bag system referring to ªDisabling Air Bag Sys-
temº described in ªService Precautionsº under ªOn-Ve-
hicle Serviceº in SECTION 10B.

Never expose air bag system component parts directly to
hot air (drying or baking the vehicle after painting) or
flames.

WARNING / CAUTION labels are attached on each part of
air bag system components. Be sure to follow the instruc-
tions.

After vehicle is completely repaired, perform ªAir Bag
Diagnostic System Checkº described in ªDiagnosisº in
SECTION 10B.

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0A-12 GENERAL INFORMATION
1. Check for loose connectionSensor
ECM
Check contact tension by
Inserting and removing just for
once
1. Looseness of crimping
2. Open
3. Thin wire (Single strand of wire)
ELECTRICAL CIRCUIT INSPECTION
PROCEDURE
While there are various electrical circuit inspection methods, de-
scribed here is a general method to check its open and short circuit
by using an ohmmeter and a voltmeter.
OPEN CIRCUIT CHECK
Possible causes for the open circuit are as follows. As the cause is
in the connector or terminal in many cases, they need to be checked
particularly carefully.

Loose connection of connector

Poor contact of terminal (due to dirt, corrosion or rust on it, poor
contact tension, entry of foreign object etc.)

Wire harness being open
When checking system circuits including an electronic control unit
such as ECM, TCM, ABS control module, etc., it is important to per-
form careful check, starting with items which are easier to check.
1) Disconnect negative cable from battery.
2) Check each connector at both ends of the circuit being checked
for loose connection. Also check lock condition of connector if
equipped with connector lock.
3) Using a test male terminal, check both terminals of the circuit be-
ing checked for contact tension of its female terminal.
Check each terminal visually for poor contact (possibly caused
by dirt, corrosion, rust entry of foreign object, etc.).
At the same time, check to make sure that each terminal is
locked in the connector fully.
4) Using continuity check or voltage check procedure described in
the following page, check the wire harness for open circuit and
poor connection with its terminals. Locate abnormality, if any.

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1. Check contact tension by inserting and removing
just once.
2. Check each terminal for bend and proper alignment.
GENERAL INFORMATION 0A-15
INTERMITTENT AND POOR CONNECTION
Most intermittent are caused by faulty electrical connections or wir-
ing, although a sticking relay or solenoid can occasionally be at
fault. When checking it for proper connection, perform careful
check of suspect circuits for:

Poor mating of connector halves, or terminals not fully seated in
the connector body (backed out).

Dirt or corrosion on the terminals. The terminals must be clean
and free of any foreign material which could impede proper termi-
nal contact.
However, cleaning the terminal with a sand paper or the like is
prohibited.

Damaged connector body, exposing the terminals to moisture
and dirt, as well as not maintaining proper terminal orientation
with the component or mating connector.

Improperly formed or damaged terminals.
Check each connector terminal in problem circuits carefully to en-
sure good contact tension by using the corresponding mating ter-
minal.
If contact tension is not enough, reform it to increase contact ten-
sion or replace.

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0A-16 GENERAL INFORMATION

Poor terminal-to-wire connection.
Check each wire harness in problem circuits for poor connection
by shaking it by hand lightly. If any abnormal condition is found,
repair or replace.

Wire insulation which is rubbed through, causing an intermittent
short as the bare area touches other wiring or parts of the vehicle.

Wiring broken inside the insulation. This condition could cause
continuity check to show a good circuit, but if only 1 or 2 strands
of a multi-strand-type wire are intact, resistance could be far too
high.
If any abnormality is found, repair or replace.
PRECAUTION FOR INSTALLING MOBILE
COMMUNICATION EQUIPMENT
When installing mobile communication equipment such as CB (Citi-
zens-Band)-radio or cellular-telephone, be sure to observe the fol-
lowing precautions.
Failure to follow cautions may adversely affect electronic control
system.

Keep the antenna as far away as possible from the vehicle's elec-
tronic control unit.

Keep the antenna feeder more than 20 cm (7.9 in.) away from
electronic control unit and its wire harnesses.

Do not run the antenna feeder parallel with other wire harnesses.

Confirm that the antenna and feeder are correctly adjusted.

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METRIC BOLTS±IDENTIFICATION CLASS NUMBERS
OR MARKS CORRESPOND TO BOLT
STRENGTH±INCREASING NUMBERS REPRESENT
INCREASING STRENGTH.NUT STRENGTH
IDENTIFICATION
GENERAL INFORMATION 0A-23
METRIC INFORMATION
METRIC FASTENERS
Most of the fasteners used for this vehicle are metric fasteners.
When replacing any fasteners, it is most important that replacement
fasteners be the correct diameter, thread pitch and strength.
FASTENER STRENGTH IDENTIFICATION
Most commonly used metric fastener strength property classes are
4T, 6.8, 7T, 8.8 and radial line with the class identification embossed
on the head of each bolt. Some metric nuts will be marked with
punch, 6 or 8 mark strength identification on the nut face. Figure
shows the different strength markings.
When replacing metric fasteners, be careful to use bolts and nuts
of the same strength or greater than the original fasteners (the
same number marking or higher). It is likewise important to select
replacement fasteners of the correct diameter and thread pitch.
Correct replacement bolts and nuts are available through the parts
division.