sec 8 SUZUKI GRAND VITARA 2004 2.G Service User Guide

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

YH4
GRAND
VITARA
0B
MAINTENANCE AND LUBRICATION 0B-1
SECTION 0B
MAINTENANCE AND LUBRICATION
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CONTENTS
MAINTENANCE SCHEDULE0B - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Schedule Under Normal Driving Conditions 0B - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Recommended Under Severe Driving Conditions 0B - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SERVICE0B - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine0B - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System0B - 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System0B - 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emission Control System0B - 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis and Body0B - 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Inspection0B - 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECOMMENDED FLUIDS AND LUBRICANTS0B - 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. 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.

YH4
GRAND
VITARA
0B-12 MAINTENANCE AND LUBRICATION
IGNITION SYSTEM
ITEM 2-1
Spark Plugs Replacement
Replace spark plugs with new ones referring to Section 6F1 or 6F2.
FUEL SYSTEM
ITEM 3-1
Air Cleaner Filter
Inspection
1) Remove air cleaner case clamps.
2) Take cleaner filter out of air cleaner case.
3) Check air cleaner filter for dirt. Replace excessively dirty filter.
4) Blow off dust by compressed air from air outlet side of filter.
5) Install air cleaner filter into case.
6) Install air cleaner case cap and clamp it securely.
Replacement
Replace air cleaner filter with new one according to above steps 1),
2) and 5), 6).
ITEM 3-2
Fuel Lines and Connections Inspection
1) Visually inspect fuel lines and connections for evidence of fuel
leakage, hose cracking and damage. Make sure all clamps are
secure.
Repair leaky joints, if any.
Replace hoses that are suspected of being cracked.

YH4
GRAND
VITARA
MAINTENANCE AND LUBRICATION 0B-13
ITEM 3-3
Fuel Filter Replacement
WARNING:
This work must be performed in a well ventilated area and
away from any open flames (such as gas hot water heaters).
Fuel filter is located at the front part of fuel tank, inside the right-
hand side of chassis.
Replace fuel filter with new one periodically, referring to Section 6C
for proper procedure.
ITEM 3-4
Fuel Tank Inspection
Check fuel tank for damage, cracks, fuel leakage, corrosion and
tank bolts looseness.
If a problem is found, repair or replace.

YH4
GRAND
VITARA
[A]
[B]
[A]: Type 1
[B]: Type 2
0B-14 MAINTENANCE AND LUBRICATION
EMISSION CONTROL SYSTEM
ITEM 4-1
Crankcase Ventilation Hoses and Connections Inspection
(Vehicle not equipped with oxygen sensor)
Refer to the following item 4-2, PCV valve inspection.
ITEM 4-2
PCV (Positive Crankcase Ventilation) Valve Inspection
Check crankcase ventilation hose and PCV hose for leaks, cracks
or clog, and PCV valve for stick or clog. Refer to On-vehicle service
of Section 6E1 / 6E2 for PCV valve checking procedure.
ITEM 4-3
Evaporative Emission Control System Inspection
1) Visually inspect hoses for cracks, damage, or excessive bends.
Inspect all clamps for damage and proper position.
2) Check EVAP canister for operation and clog, referring to Section
6E1 / 6E2.
If a malfunction is found, repair or replace.