Adjust SUZUKI GRAND VITARA 2003 2.G Service Workshop Manual

YH4
GRAND
VITARA
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.

YH4
GRAND
VITARA
1. Crankshaft pulley
2. Water pump pulley
3. 100 N, 10 kg or 22 lb
G16
H25
MAINTENANCE AND LUBRICATION 0B-5
MAINTENANCE SERVICE
ENGINE
ITEM 1-1
Drive Belt Inspection and Replacement
WARNING:
All inspection and replacement are to be performed with
ENGINE NOT RUNNING.
Water pump and generator drive belt (G16 and H25 engines)
Inspection
1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
If any defect exists, replace.
Check belt for tension.
Water pump and generator belt tension
ªaº: 6 ± 8 mm (0.24 ± 0.32 in.) deflection for G16, 9 ± 11 mm
(0.35 ± 0.43 in.) deflection for H25 under 100 N, 10 kg or
22 lb pressure
NOTE:
When replacing belt with a new one, adjust belt tension to
5 ± 6 mm (0.20 ± 0.24 in.) for G16, 7 ± 9 mm (0.28 ± 0.35 in.)
for H25.
3) If belt is too tight or too loose, adjust it to specification by adjust-
ing alternator position.
4) Tighten alternator adjusting bolt and pivot bolts.
5) Connect negative cable to battery.
Replacement
Replace belt. Refer to Section 6B for replacement procedure of
pump belt.

YH4
GRAND
VITARA
J20
J20
1. 100 N, 10 kg or 22 lb
2. Fan pulley3. Crankshaft pulley
4. Adjusting and pivot bolt
0B-6 MAINTENANCE AND LUBRICATION
Water pump, generator, power steering and / or A / C
compressor (if equipped) drive belt (J20 engine)
Inspection
1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
If any of above conditions are found, replace.
Also, check belt for tension.
Tension indicator ªBº should be the right of indicator ªAº as
shown in figure. If indicator ªBº is found to the left of indicator ªAº,
replace generator belt.
Replacement
Replace belt referring to Section 6H for replacement procedure of
generator drive belt.
Engine cooling fan drive belt (J20 engine)
Inspection
1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
If any defect exists, replace. Check belt for tension.
Cooling fan belt tension
ªaº: 5 ± 7 mm (0.20 ± 0.27 in.) deflection under 100 N, 10 kg
or 22 lb pressure.
NOTE:
When replacing belt with a new one, adjust belt deflection
to 4 ± 5 mm (0.16 ± 0.19 in.).
3) If the belt is too tight or too loose, adjust it to specification by ad-
justing cooling fan pulley position.
4) Tighten adjusting bolt and pivot bolt.
5) Connect negative cable at battery.
Replacement
Replace belt referring to Section 6B for replacement procedure of
cooling fan drive belt.

YH4
GRAND
VITARA
G16 with P / S
G16 with P / S and A / C
H25 with P / S
H25 with P / S and A / C
1. Crankshaft pulley
2. P / S pump pulley
3. A / C compressor pulley
(if equipped)4. Tension pulley
5. Tension pulley bolts
MAINTENANCE AND LUBRICATION 0B-7
Power steering pump and / or A / C compressor drive belts (if
equipped) for G16 and H25 engines.
Inspection
1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
If any defect exists, replace.
Check belt for tension.
Power steering pump and / or A / C compressor drive belt
tension.
ªaº: 6 ± 9 mm (0.24 ± 0.35 in.) deflection under 100 N, 10 kg
or 22 lb pressure.
ªbº: 4 ± 7 mm (0.16 ± 0.28 in.) deflection under 100 N, 10 kg
or 22 lb pressure.
If belt tension is out of above specification, adjust it referring to
Section 1B or 3B1.
3) Connect negative cable to battery.
Replacement
Replace belt referring to Section 1B or 3B1 for replacement proce-
dure of belt.

YH4
GRAND
VITARA
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)

YH4
GRAND
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.

YH4
GRAND
VITARA
ªaº: Parking brake lever
stroke:
5 ± 7 notches
(With 20 kg or 44 lbs
of pull pressure)
ªaº
0B-16 MAINTENANCE AND LUBRICATION
ITEM 6-3
Brake Hoses and Pipes Inspection
Check brake hoses and pipes for proper hookup, leaks, cracks,
chafing and other damage.
Replace any of these parts as necessary.
CAUTION:
After replacing any brake pipe or hose, be sure to carry out
air purge operation.
ITEM 6-4
Brake Fluid Change
Change brake fluid as follows.
Drain existing fluid from brake system completely, fill system with
specified fluid and carry out air purge operation.
For air purging procedure, refer to Section 5.
ITEM 6-5
Parking Brake Lever and Cable Inspection
Parking brake lever
1) Check tooth tip of each notch for damage or wear. If any damage
or wear is found, replace parking lever.
2) Check parking brake lever for proper operation and stroke, and
adjust it if necessary.
For checking and adjusting procedures, refer to Parking Brake
Inspection and Adjustment in Section 5.
Parking brake cable
Inspect brake cable for damage and smooth movement.
Replace cable if it is in deteriorated condition.

YH4
GRAND
VITARA
1. Wear indicator
MAINTENANCE AND LUBRICATION 0B-17
ITEM 6-6
Tire Inspection and Rotation
1) Check tires for uneven or excessive wear, or damage.
If defective, replace.
Refer to Section 3 for details.
2) Check inflating pressure of each tire and adjust pressure to
specification as necessary.
Refer to Section 3F for details.
NOTE:

Tire inflation pressure should be checked when tires are
cool.

Specified tire inflation pressure should be found on tire
placard or in owner's manual which came with the vehicle.
3) Rotate tires.
For details, refer to Section 3F.
ITEM 6-7
Wheel Discs Inspection
Inspect each wheel disc for dents, distortion and cracks. A disc in
badly damaged condition must be replaced.
Wheel Bearing Inspection
1) Check front wheel bearing for wear, damage, abnormal noise or
rattles. For details, refer to Section 3D.
2) Check rear wheel bearing for wear, damage, abnormal noise or
rattles. For details, refer to Section 3E.

YH4
GRAND
VITARA
1. ªUPPERº or ªLOWERº mark
MAINTENANCE AND LUBRICATION 0B-23
3) Visually check pump drive belt for cracks and wear.
4) Check belt for tension, referring to item 1-1.
If necessary, have belt adjusted or replaced.
ITEM 6-16
All Hinges, Latches and Locks Inspection
Doors
Check that each door of front, rear and back doors opens and
closes smoothly and locks securely when closed.
If any malfunction is found, lubricate hinge and latch or repair door
lock system.
Engine hood
Check that secondary latch operates properly (check that second-
ary latch keeps hood from opening all the way even when pulling
hood release handle inside vehicle.). Also check that hood opens
and closes smoothly and properly and hood locks securely when
closed.
If any malfunction is found, lubricate hinge and latch, or repair hood
lock system.
ITEM 6-17
Air Conditioning Filter (if equipped)
Inspection
1) Remove air conditioning filter from cooling unit referring to Sec-
tion 1B.
2) Check filter for dirt. Replace excessively dirty filter.
3) Blow off dust by compressed air from air outlet side of filter.
4) Install filter to cooling unit referring to Section 1B.
Replacement
Replace air conditioning filter with new one referring to Section 1B.

YH4
GRAND
VITARA
1A-12 HEATER AND VENTILATION
1. Temperature control lever
2. Fresh air control lever
1. Fresh air control cable 1. Heater unit
2. Control cable1
2
INSTALLATION
1) Install in reverse order of removal procedure.
2) Adjust cables as follows.
(1) Move control lever fully in arrow direction.
(2) Push heater lever fully in arrow direction and fix cable with
clamp in position as shown in left figure.
(3) Push blower lever fully in arrow direction and fix cable with
clamp in position as shown in left figure.
NOTE:
After installing control cables, be sure that control levers
move smoothly and stop at proper position.
3) If equipped with air bag, enable air bag system. Refer to ªENAB-
LING AIR BAG SYSTEMº in Section 10B.
HEATER MODE CONTROL ACTUATOR
REMOVAL
1) Disconnect negative (±) cable at battery.
2) If equipped with air bag system, disable air bag system.
Refer to DISABLING AIR BAG SYSTEM in Section 10B.
3) Remove column hole cover.