torque SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

YH4
GRAND
VITARA
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YH4
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VITARA
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.

YH4
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VITARA
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.

YH4
GRAND
VITARA
L
LH : Left Hand
LSPV : Load Sensing Proportioning
Valve
M
MAF Sensor : Mass Air Flow Sensor
(Air Flow Sensor, AFS, Air
Flow Meter, AFM)
MAP Sensor : Manifold Absolute Pressure
Sensor (Pressure Sensor, PS)
Max : Maximum
MFI : Multiport Fuel Injection
(Multipoint Fuel Injection)
Min : Minimum
MIL : Malfunction Indicator Lamp
(ªCHECK ENGINEº Light)
M / T : Manual Transmission
N
NOx : Nitrogen Oxides
O
OBD : On-Board Diagnostic System
(Self-Diagnosis Function)
O / D : Overdrive
OHC : Over Head Camshaft
P
PNP : Park / Neutral Position
P / S : Power Steering
PSP Switch : Power Steering Pressure
Switch (P / S Pressure Switch)
PCM : Powertrain Control Module
PCV : Positive Crankcase Ventilation
R
RH : Right Hand
S
SAE : Society of Automotive
Engineers
SDM : Sensing and Diagnostic
Module (Air bag controller,
Air bag control module)
SFI : Sequential Multiport Fuel
Injection
SOHC : Single Over Head Camshaft
T
TBI : Throttle Body Fuel Injection
(Single-Point Fuel Injection,
SPI)
TCC : Torque Converter Clutch
TCM : Transmission Control Module
(A / T Controller, A / T Control
Module)
TP Sensor : Throttle Position Sensor
TVV : Thermal Vacuum Valve
(Thermal Vacuum Switching
Valve, TVSV, Bimetal Vacuum
Switching Valve, BVSV)
TWC : Three Way Catalytic
Converter (Three Way
Catalyst)
2WD : 2 Wheel Drive
V
VIN : Vehicle Identification
Number
VSS : Vehicle Speed Sensor
W
WU-OC : Warm Up Oxidation
Catalytic Converter
WU-TWC : Warm Up Three Way
Catalytic Converter
0A-22 GENERAL INFORMATION

YH4
GRAND
VITARA
0A-24 GENERAL INFORMATION
Self-lock
nut
STANDARD TIGHTENING TORQUE
Each fastener should be tightened to the torque specified in each section of this manual. If no description or specifi-
cation is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When
a fastener of greater strength than the original one is used, however, use the torque specified for the original fasten-
er.
NOTE:

For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening torque
given in the chart below.

The chart below is applicable only where the fastened parts are made of steel or light alloy.
Tightening torque chart
Thread Diameter (Nominal Diameter)
(mm)
45681012141618
Strength
45681012141618
A equivalent of 4T strength
fastenerN.m1.53.05.513294565105160
kg-m0.150.300.551.32.94.56.510.516
lb-ft1.02.54.09.521.032.547.076.0116.0
A equivalent of 6.8 strength
fastener without flan
geN.m2.44.78.4204280125193280g
kg-m0.240.470.842.04.28.012.519.328
lb-ft2.03.56.014.530.558.090.5139.5202.5
A equivalent of 6.8 strength
fastener with flan
geN.m2.44.98.8214484133203298g
kg-m0.240.490.882.14.48.413.320.329.8
lb-ft2.03.56.515.532.061.096.5147.0215.5
A equivalent of 7T strength
fastenerN.m2.34.510235085135210240
kg-m0.230.451.02.35.08.513.52124
lb-ft2.03.57.517.036.561.598.0152.0174.0
A equivalent of 8.8 strength
fastener without flan
geN.m3.16.3112756105168258373g
kg-m0.310.631.12.75.610.516.825.837.3
lb-ft2.54.58.019.540.576.0121.5187.0270.0
A equivalent of 8.8 strength
fastener with flan
geN.m3.26.512295911 3175270395g
kg-m0.320.651.22.95.911.317.52739.5
lb-ft2.55.09.021.043.082.0126.5195.5286.0

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VITARA
0B-4 MAINTENANCE AND LUBRICATION
MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS
If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is
recommended that applicable maintenance operation be performed at the particular interval as given in the chart
below.
Severe condition code
A ± Repeated short trips E ± Repeated short trips in extremely
B ± Driving on rough and / or muddy roads cold weather
C ± Driving on dusty roads F ± Leaded fuel use
D ± Driving in extremely cold weather G ± ± ± ± ± ± ± ± ±
and / or salted roads H ± Trailer towing (if admitted)
Severe
Condition Code
MaintenanceMaintenance
OperationMaintenance Interval
BCDITEM 1-1IEvery 15,000 km
(9,000 miles) or 12 months
± B C D ± ± ± ±Drive belt (V-rib belt)REvery 45,000 km
(27,000 miles) or 36 months
A ± C D E F ± HITEM 1-4
Engine oil and oil filterREvery 5,000 km
(3,000 miles) or 4 months
± B ± ± ± ± ± ±ITEM 1-6
Exhaust pipe mountingsIEvery 15,000 km
(9,000 miles) or 12 months
CITEM 3-1IEvery 2,500 km
(1,500 miles)
± ± C ± ± ± ± ±Air cleaner filter*1REvery 30,000 km
(18,000 miles) or 24 months
ABC EF HITEM 2-1Nickel plugREvery 10,000 km
(6,000 miles) or 8 months
A B C ± E F ± HSpark plugsIridium plugREvery 30,000 km
(18,000 miles) or 24 months
± B ± D E ± ± HITEM 6-9
Propeller shafts and drive shaftsIEvery 15,000 km
(9,000 miles) or 12 months
± B ± ± E ± ± H
ITEM 6-10, 6-12, 6-13
Manual transmission,
transfer and differential oil
REvery 30,000 km
(18,000 miles) or 24 months
± B ± ± E ± ± HITEM 6-11
Automatic transmission fluidREvery 30,000 km
(18,000 miles) or 24 months
± B ± ± ± ± ± ±ITEM 6-8
Suspension bolts and nutsTEvery 15,000 km
(9,000 miles) or 12 months
± B C D ± ± ± HITEM 6-7
Wheel bearingIEvery 15,000 km
(9,000 miles) or 12 months
CD
ITEM 6-17
Air conditioning filter*2
IEvery 15,000 km
(9,000 miles) or 12 months
± ± C D ± ± ± ±Air conditioning filter 2
(if equipped)REvery 45,000 km
(27,000 miles) or 36 months
NOTES:
ªIº : Inspect and correct, replace or lubricate if necessary
ªRº : Replace or change
ªTº : Tighten to the specified torque
*1 : Inspect or replace more frequently if necessary.
*2 : Clean or replace more frequently if the air from the air conditioning decreases.

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0B-8 MAINTENANCE AND LUBRICATION
ITEM 1-2
Camshaft Timing Belt Replacement (G16 engine only)
Replace timing belt referring to Section 6A1.
ITEM 1-3
Valve Lash Inspection (G16 engine only)
1) Remove cylinder head cover.
2) Inspect intake and exhaust valve lash and adjust as necessary.
Refer to Section 6A1 for valve lash inspection and adjustment
procedure.
Valve
lash
(ªº)
When cold
(Coolant tempera-
ture is 15 ± 25
C
or 59 ± 77
F)When hot
(Coolant tempera-
ture is 60 ± 68
C
or 140 ± 154
F)
(gap ªaº)
specifica-
tion
Intake0.13 ± 0.17 mm
(0.005 ± 0.007 in.)0.17 ± 0.21 mm
(0.007 ± 0.008 in.)
tion
Exhaust0.23 ± 0.27 mm
(0.009 ± 0.011 in.)0.28 ± 0.32 mm
(0.011 ± 0.013 in.)
3) Install cylinder head cover and tighten bolts to specification.
ITEM 1-4
Engine Oil and Filter Change
WARNING:
New and used engine oil can be hazardous.
Be sure to read ªWARNINGº in General Precaution in Sec-
tion 0A and observe what in written there.
Before draining engine oil, check engine for oil leakage. If any evi-
dence of leakage is found, make sure to correct defective part be-
fore proceeding to the following work.
1) Drain engine oil by removing drain plug.
2) After draining oil, wipe drain plug clean. Reinstall drain plug, and
tighten it securely as specified below.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)

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2
1. Oil filter
2. Oil filter wrench
MAINTENANCE AND LUBRICATION 0B-9
3) Loosen oil filter by using oil filter wrench (special tool).
Special Tool
(A): 09915-47310 (H25 engine)
09915-47330 (G16 and J20 engines)
NOTE:
Before fitting new oil filter, be sure to oil its O-ring. Use engine
oil for this purpose.
4) Screw new filter on oil filter stand by hand until the filter O-ring
contacts the mounting surface.
CAUTION:
To tighten oil filter properly, it is important to accurately
identify the position at which at filter O-ring first contacts
the mounting surface.
5) Tighten the filter 3 / 4 turn from the point of contact with the
mounting surface using an oil filter wrench.
Tightening Torque (Reference)
(b): 14 N
.m (1.4 kg-m, 10.5 lb-ft)
6) Replenish oil until oil level is brought to FULL level mark on dip-
stick. (oil pan and oil filter capacity). The filler inlet is at the top
of the cylinder head cover.
It is recommended to use engine oil of SG, SH or SJ grade.
NOTE:
For temperature between ±20
C (±4
F) and 30
C (86
F), it
is highly recommended to use SAE 10W ± 30 oil.
G16 EngineJ20 EngineH25 Engine
Oil pan capacityAbout 4.0 liters
(10.6 / 8.8 US / Imp pt.)About 5.0 liters
(10.6 / 8.8 US / Imp pt.)

Oil filter capacityAbout 0.2 liters
(0.4 / 0.3 US / Imp pt.)
About 0.5 liters
(1.1 / 0.9 US / Imp pt.)
OthersAbout 0.3 liters
(0.6 / 0.5 US / Imp pt.)About 0.4 liters
(1.1 / 0.9 US / Imp pt.)About 0.7 liters
(1.5 / 1.2 US / Imp pt.)
TotalAbout 4.5 liters
(9.5 / 7.9 US / Imp pt.)About 5.6 liters
(11.8 / 9.8 US / Imp pt.)About 6.2 liters
(13.1 / 10.9 US / Imp pt.)

YH4
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VITARA
1
1. Clutch pedal free travel
MAINTENANCE AND LUBRICATION 0B-15
CHASSIS AND BODY
ITEM 6-1
Clutch
Pedal inspection
Check clutch pedal for height and free travel referring to Section
7C1. Adjust or correct if necessary.
Fluid inspection
1) Check around master cylinder and reservoir for fluid leakage.
If found leaky, correct.
2) Check fluid level.
If fluid level is lower than the minimum level of reservoir, refilling
is necessary. Fill reservoir with specified brake fluid indicated on
clutch reservoir cap.
For the details, refer to On-vehicle service in Section 7C1.
CAUTION:
Since clutch system of this vehicle is factory-filled with
glycol-base brake fluid, do not use or mix different type
of fluid when refilling system; otherwise serious damage
will occur. Do not use old or used brake fluid, or one taken
from unsealed container.
ITEM 6-2
Brake Discs, Pads, Brake Drums and Shoes Inspection
[Brake discs and pads]
1) Remove wheel and caliper but don't disconnect brake hose from
caliper.
2) Check front disc brake pads and discs for excessive wear, dam-
age and deflection. Replace parts as necessary. For details, re-
fer to Section 5B.
Be sure to torque caliper pin bolts to specification.
[Brake drums and shoes]
1) Remove wheel and brake drum.
2) Check rear brake drums and brake linings for excessive wear
and damage, while wheels and drums are removed. At the same
time, check wheel cylinders for leaks. Replace these parts as
necessary.
For details, refer to Section 5C.

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0B-18 MAINTENANCE AND LUBRICATION
ITEM 6-8
Suspension System Inspection
Check suspension bolts and nuts for tightness and retighten them
as necessary.
Repair or replace defective parts, if any.
NOTE:
For details of check points, refer to tables of Tightening Torque
Specification in Section 3D and 3E.
Front
1) Check stabilizer bar for damage or deformation.
2) Check bushing for damage, wear or deterioration.
3) Inspect strut for damage, deformation, oil leakage and opera-
tion. If strut is found faulty, replace it as an assembly unit, be-
cause it can not be disassembled.
Refer to strut check Section 3D for operation check.
4) Inspect strut boot for damage or crack.
5) Inspect for cracks or deformation in spring seat.
6) Inspect for deterioration of bump stopper.
7) Inspect strut mount for wear, cracks or deformation.
8) Check ball joint stud dust seal (boot) for leaks, detachment,
tear or other damage. Check suspension arm bushing for dam-
age, wear or deterioration.
Rear
9) Check shock absorber for damage, deformation, oil leakage
and operation.
10) Check bushings for wear and damage.