Water SUZUKI GRAND VITARA 2004 2.G Service Owner's Manual

YH4
GRAND
VITARA
1. Paint
3F-4 WHEELS AND TIRES
Higher than Recommended Pressure Can Cause:
1. Hard ride
2. Tire bruising or carcass damage
3. Rapid tread wear at center of tire
Unequal Pressure on Same Axle Can Cause:
1. Uneven braking
2. Steering lead
3. Reduced handling
4. Swerve on acceleration
Valve caps should be kept on valves to keep dust and
water out.Lower than Recommended Pressure Can Cause:
1. Tire squeal on turns
2. Hard steering
3. Rapid and uneven wear on the edges of the tread
4. Tire rim bruises and rupture
5. Tire cord breakage
6. High tire temperatures
7. Reduced handling
8. High fuel consumption
MAINTENANCE AND MINOR ADJUSTMENTS
WHEEL AND TIRE
Wheel repairs that use welding, heating, or peening are not approved. All damaged wheels should be replaced.
STUDS
If a broken stud is found, see Section 3E (rear) or Section 3D (front) for Note and Replacement procedure.
MATCHED TIRES AND WHEELS
(For vehicle equipped with steel wheels)
Tires and wheels are matchmounted at the assembly plant.
This means that the radially stiffest part of the tire, or ªhigh spotº, is
matched to the smallest radius or ªlow spotº of the wheel.
This is done to provide the smoothest possible ride.
The ªhigh spotº of the tire is originally marked by paint dot on the
outboard sidewall. This paint dot will eventually wash off the tire.
The ªlow spotº of the wheel is originally marked by paint dot on the
wheel rim-flange. Properly assembled, the wheel rims' paint dot
should be aligned with the tires' paint dot as shown in left figure.
Whenever a tire is dismounted from its wheel, it should be re-
mounted so that the tire and wheel are matched. If the tire's paint
dot cannot be located, a line should be scribed on the tire and wheel
before dismounting to assure that it is remounted in the same posi-
tion.
INFLATION OF TIRES
The pressure recommended for any model is carefully calculated to give a satisfactory ride, stability, steering, tread
wear, tire life and resistance to bruises.
Tire pressure, with tires cold, (after vehicle has set for three hours or more, or driven less than one mile) should
be checked monthly or before any extended trip. Set to the specifications on the tire placard located on the side
of instrument panel.
It is normal for tire pressure increase when the tires become hot during driving. Do not bleed or reduce tire pressure
after driving. Bleeding reduces the ªCold Inflation Pressureº.

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GRAND
VITARA
BRAKES 5-3
SUBSTANDARD OR
CONTAMINATED BRAKE FLUID
Improper brake fluid, mineral oil or water in the fluid
may cause the brake fluid to boil or the rubber compo-
nents in the hydraulic system to deteriorate.
If primary piston cups are swollen, then rubber parts
have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston cups on the
drum brake wheels.
If deterioration of rubber is evident, disassemble all
hydraulic parts and wash with alcohol. Dry these parts
with compressed air before assembly to keep alcohol
out of the system. Replace all rubber parts in the sys-
tem, including hoses. Also, when working on the
brake mechanisms, check for fluid on the linings. If ex-
cessive fluid is found, replace the linings.
If master cylinder piston seals are satisfactory, check
for leakage or excessive heat conditions. If condition
is not found, drain fluid, flush with brake fluid, refill and
bleed system.
The system must be flushed if there is any doubt as
to the grade of fluid in the system or if fluid has been
used which contained parts that have been subjected
to contaminated fluid.
DIAGNOSIS
ROAD TESTING BRAKES
Brakes should be tested on dry, clean, smooth and
reasonably level roadway which is not crowned. Road
test brakes by making brake applications with both
light and heavy pedal forces at various speeds to de-
termine if the vehicle stops evenly and effectively.
Also drive vehicle to see if it leads to one side or the
other without brake application. If it does, check the
tire pressure, front end alignment and front suspen-
sion attachments for looseness. See diagnosis chart
for other causes.
BRAKE FLUID LEAKS
Check the master cylinder fluid levels. While a slight
drop in reservoir level does result from normal lining
wear, an abnormally low level indicates a leak in the
system. In such a case, check the entire brake system
for leakage. If even a slight evidence of leakage is
noted, the cause should be corrected or defective
parts should be replaced.
If fluid level is lower than the minimum level of reser-
voir, refilling is necessary. Fill reservoir with specified
brake fluid.
Brake fluid: Refer to reservoir tank cap.
CAUTION:
Since brake system of this vehicle is factory-
filled with brake fluid indicated on reservoir
tank cap, do not use or mix different type of
fluid when refilling; otherwise serious damage
will occur.
Do not use old or used brake fluid, or any fluid
from a unsealed container.

YH4
GRAND
VITARA
5-4 BRAKES
DIAGNOSIS TABLE
ConditionPossible CauseCorrection
Not enough brak-
ing force
Brake oil leakage from brake lines.

Brake disc or pads stained with oil.

Overheated brakes.

Poor contact of shoes on brake drum.

Brake shoes linings stained with oil or wet
with water.

Badly worn brake shoe linings.

Defective wheel cylinders.

Malfunctioning caliper assembly.

Air in system.

Maladjusted sensor spring length of LSPV.

Broken sensor spring of LSPV.

Defective collar of LSPV.

Malfunctioning ABS (Antilock brake system),
if equipped.Locate leaking point and repair.
Clean or replace.
Determine cause and repair.
Repair for proper contact.
Replace.
Replace.
Repair or replace.
Repair or replace.
Bleed system.
Check or adjust.
Replace.
Replace.
Check system and replace as
necessary.
Brake pull
(Brakes not work-
ing in unison)
Pad or shoe linings are wet with water or
stained with oil in some brakes.

Drum-to-shoe clearance out of adjustment in
some brakes.
(Malfunctioning auto adjusting mechanism)

Drum is out of round in some brakes.

Wheel tires are inflated unequally.

Malfunctioning wheel cylinders.

Disturbed front end alignment.

Unmatched tires on same axle.

Restricted brake pipes or hoses.

Malfunctioning caliper assembly.

Loose suspension parts.

Loose calipers.Replace.
Check for inoperative auto adjusting
mechanism.
Replace.
Inflate equally.
Repair or replace.
Adjust as prescribed.
Tires with approximately the same
amount of tread should be used on the
same axle.
Check for soft hoses and damaged
lines.
Replace with new hoses and new
brake pipes.
Check for stuck or sluggish pistons
and proper lubrication of caliper slide
bush.
Caliper should slide.
Check all suspension mountings.
Check and torque bolts to specifica-
tions.
Noise (High pitched
squeak without
brake applied)
Front lining worn out.Replace linings.
Rear brake locked
prematurely
Maladjusted sensor spring length of LSPV.

Malfunction LSPV assembly.Check or adjust.
Replace assembly.
Brake locked
(For vehicles
equipped with
ABS)
Malfunctioning ABS, if equipped.Check system and replace as
necessary.

YH4
GRAND
VITARA
5-10 BRAKES
BRAKE PEDAL PLAY CHECK
Pedal play should be within specification. If out of specification,
check brake light switch for proper installation position and adjust
if necessary.
Also check pedal shaft bolt and master cylinder pin installation for
looseness and replace if defective.
Pedal play ªdº: 1 ± 8 mm (0.04 ± 0.32 in.)
BRAKE FLUID LEVEL CHECK
Be sure to use particular brake fluid either as indicated on reservoir
cap of that vehicle or recommended in owner's manual which
comes along with that vehicle.
Use of any other fluid is strictly prohibited.
Fluid level should be between MIN and MAX lines marked on reser-
voir.
When warning light lights sometimes during driving, replenish fluid
to MAX line.
When fluid decreases quickly, inspect brake system for leakage.
Correct leaky points and then refill to specified level.
CAUTION:
Do not use shock absorber fluid or any other fluid which
contains mineral oil. Do not use a container which has been
used for mineral oil or a container which is wet from water.
Mineral oil will cause swelling and distortion of rubber parts
in hydraulic brake system and water mixed into brake fluid
will lower fluid boiling point. Keep all fluid containers
capped to prevent contamination.
BRAKE HOSE AND PIPE CHECK
The brake hose assembly should be checked for road hazard dam-
age, for cracks and chafing of the outer cover, for leaks and blisters.
A light and mirror may be needed for an adequate inspection. If any
of the above conditions are observed on the brake hose, it is neces-
sary to replace it.
Inspect the pipe for damage, cracks, dents and corrosion. If any de-
fect is found, replace it.
MASTER CYLINDER CHECK
Check for a cracked master cylinder casting or brake fluid around
the master cylinder. Leaks are indicated only if there is at least a
drop of fluid. A damp condition is not abnormal.

YH4
GRAND
VITARA
PARKING AND REAR BRAKE 5C-17
09943-35512
Brake drum remover
(Front wheel hub remover)09942-15510
Sliding hammer
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Wheel cylinder bleeder plug7.50.755.5
Parking brake lever bolt232.317.0
Wheel cylinder bolt (For non sealed type)8.50.856.5
Wheel cylinder bolt (For gasket sealed type)111.112.0
Brake pipe flare nut161.612.0
Brake back plate nut232.317.0
Wheel nut10010.072.5
REQUIRED SERVICE MATERIALS
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Brake fluid
Indicated on reservoir
cap or described in owner's
manual of vehicle
To fill master cylinder reservoir.

To clean and apply to inner parts of master
cylinder caliper and wheel cylinder when
they are disassembled.
Water tight
sealantSEALING COMPOUND 366E
99000-31090
To apply to mating surfaces of brake back
plate and rear wheel cylinder.
SealantSUZUKI BOND NO. 1215
99000-31110

To apply to mating surfaces of brake back
plate and rear axle housing.

To apply mating surfaces of brake back
plate and rear wheel bearing retainer.
SPECIAL TOOLS

YH4
GRAND
VITARA
Viscosity chart
SAE
1. Reverse idle gear shaft bolt
(DO NOT LOOSEN IT)
MANUAL TRANSMISSION (TYPE 1) 7A-3
ON-VEHICLE SERVICE
GEAR OIL
INSPECTION AND CHANGE
1) Before changing or inspecting oil, be sure to stop engine and lift
vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage ex-
ists, correct or repair it.
3) Drain old oil and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
NOTE:

It is highly recommended to use SAE 75W-90 gear oil.

Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage and
status of breather hoses.

If water or rust is mixed in drained oil, be sure to check
breather hose and boot of transmission and transfer.
Gear Oil Specification
Oil grade: API GL-4
Viscosity: SAE 75W-85, 75W-90 or 80W-90
Oil Capacity:
Transmission 1.5 liters (3.2 / 2.6 US / Imp. pt)
Transfer 1.7 liters (3.6 / 3.0 US / Imp. pt)
4) Torque drain plug and level / filler plug as specified below after
applying sealant to its thread.
CAUTION:

Transmission oil must not be poured through gear shift
control lever part.

Do not loosen or remove reverse idle gear shaft bolt.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

YH4
GRAND
VITARA
Viscosity chart
SAE
Temperature
1. Drain plug
2. Oil level / filler plug
MANUAL TRANSMISSION (TYPE 2) 7A1-3
ON-VEHICLE SERVICE
GEAR OIL
INSPECTION AND CHANGE
1) Before changing or inspecting oil, be sure to stop engine and lift
vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage ex-
ists, correct or repair it.
3) Drain old oil and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
NOTE:

It is highly recommended to use SAE 75W-90 gear oil.

Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage and
status of breather hoses.

If water or rust is mixed in drained oil, be sure to check
breather hose and boot of transmission and transfer.
Gear Oil Specification
Oil grade: API GL-4
Viscosity: SAE 75W-85, 75W-90 or 80W-90
Oil Capacity:
Transmission 2.6 liters (5.5 / 4.6 US / Imp. pt)
Transfer 1.7 liters (3.6 / 3.0 US / Imp. pt)
4) Torque drain plug and level / filler plug as specified below after
applying sealant to thread of plug (c).
CAUTION:
Transmission oil must not be poured through gear shift
control lever part.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 38 N´m (3.8 kg-m, 27.5 lb-ft)
(b): 23 N´m (2.3 kg-m, 17.0 lb-ft)

YH4
GRAND
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. Master cylinder
1. Attaching bolt
2. Attaching nut
3. Clevis pin
ªAº
7C1-6 CLUTCH
INSTALLATION
1) To bleed air from master cylinder itself, tilt it as shown in figure
and add fluid into it.
NOTE:
After bleeding air from master cylinder, plug pipe hole in it
to prevent fluid from spilling out of it till pipe is connected.
2) Install master cylinder assembly and new gasket to body, attach-
ing bolt, nuts and push rod clevis pin.
NOTE:
Do not reuse gasket.
3) Torque attaching bolt and nut to specification.
4) Connect fluid pipe and torque flare nut to specification.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
(b): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
5) Apply grease to clevis pin and install it.
ªAº: Grease 99000-25010
6) Fill reservoir with specified brake fluid and check fluid leakage.
7) After installation, bleed air from system and check clutch pedal
free travel. Refer to BRAKE section for air bleeding procedure.
FLUID INSPECTION
Fluid level should be always between MIN and MAX lines on reser-
voir. If fluid decreases quickly, check for leakage, repair leaky point,
if any, and add fluid up to MAX level.
NOTE:

Brake fluid damages painted surface badly. Should it get on
painted surface, remove it immediately and clean surface
thoroughly.

Do not use shock absorber fluid or any other fluid which con-
tains mineral oil. Do not use container which has been used
for mineral oil or which is wet from water. Mineral oil will
cause swelling and distortion of rubber parts in hydraulic
clutch system and water will mix with brake fluid, lowering
fluid boiling point. Keep all fluid containers capped to pre-
vent contamination.

Make sure not to use fluid whose container cap was first
opened more than a year ago.

YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-5
DIAGNOSIS
DIAGNOSIS TABLE
Differential Assembly
ConditionPossible CauseCorrection
Gear noise
Deteriorated or water mixed lubricant

Inadequate or insufficient lubricant

Maladjusted backlash between bevel
pinion and gear

Improper tooth contact in the mesh between
bevel pinion and gear

Loose bevel gear securing bolts

Damaged side gear(s) or side pinion(s)Repair and replenish
Repair and replenish
Adjust
Adjust or replace
Replace or retighten
Replace
Bearing noise
(Constant noise) Deteriorated or water
mixed lubricant

(Constant noise) Inadequate or insufficient
lubricant

(Noise while coasting) Damaged bearing(s)
of bevel pinion

(Noise while turning) Damaged diff. side
bearing(s) or axle bearing(s)Repair and replenish
Repair and replenish
Replace
Replace
Oil leakage
Worn or damaged oil seal

Excessive oil

Loose differential carrier boltsReplace
Adjust oil level
Replace or retighten
2WD / 4WD
switching error
Defective actuator

Abnormality in 4WD control systemReplace
Inspect referring to ª4WD
CONTROL SYSTEM DIAG-
NOSTIC FLOW TABLEº.
4WD Control System Diagnostic Flow Table
Before performing the trouble diagnosis, check that the transfer and front differential are in good condition and
there is no air leakage from air hoses and the actuator. Refer to ªON-VEHICLE SERVICEº in this section for air
leakage.
[NOTES ON SYSTEM CIRCUIT INSPECTION]

Be sure to read ªPrecautions for Electrical Circuit Serviceº in Section 0A before circuit inspection and observe
what is written there.

For system circuit, refer to the figure of ªGENERAL DESCRIPTIONº in this section.

For terminal arrangement, refer to ª4WD Control Circuit Inspectionº in this section.