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

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VITARA
5B-4 FRONT BRAKE
1. Wheel nut
2. Washer
(or spacer)
ªAº: Apply grease
Brake Disc
Before this inspection, brake pads must be removed.
Check disc surface for scratches in wearing parts. Scratches on
disc surface noticed at the time of specified inspection or replace-
ment are normal and disc is not defective unless they are serious.
But when there are deep scratches or scratches all over disc sur-
face, replace it. When only one side is scratched, polish and correct
that side.
Disc thickness ªaº
Standard: 22 mm (0.866 in.) For SUMITOMO ELECTRIC. . . . .
brake caliper
17 mm (0.670 in.) For TOKICO brake caliper. . . . .
Service limit: 20 mm (0.787 in.) For SUMITOMO ELECTRIC. .
brake caliper
15 mm (0.590 in.) For TOKICO brake caliper. .
Use wheel nuts and suitable plain washers to hold the disc securely
against the hub, then mount a dial indicator as shown and measure
the runout at 25 mm (0.98 in.) from the outer edge of the disc.
Limit on disc deflection: 0.15 mm (0.006 in.)
NOTE:
Check front wheel bearing for looseness before measure-
ment.
Cylinder Slide Guide Pin / Pin Bolt
Check guide pin for smooth movement as shown.
If it is found faulty, correct or replace. Apply rubber grease to guide
pin outer surface. Rubber grease should be the on whose viscosity
is less affected by such low temperature a ±40
C (±40
F).
Dust Boot
Check boot for breakage, crack and damage. If defective, replace.

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1. Clips
2. Pads
3. Disc
4. Caliper carrier
5. Sensor
6. Shim
1. Caliper pin bolts
ELECTRIC brake
caliper
FRONT BRAKE 5B-5
INSTALLATION
NOTE:
See NOTE at the beginning of this section.
1) Install pad clips and pads.
NOTE:
Install pad with sensor to body center side of caliper.
2) Install caliper and torque caliper pin bolts to specification.
Tightening Torque
(a), (b): 27 N
.m (2.7 kg-m, 20.0 lb-ft) For TOKICO brake. .
caliper
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft) For SUMITOMO. . . . . .
(b): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
NOTE:
Make sure that boots are fit into groove securely.
3) Torque front wheel nuts to specification.
Tightening Torque
(b): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
4) Upon completion of installation, perform brake test.

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FRONT BRAKE 5B-7
2) Remove piston seal using a thin blade like a thickness gauge,
etc.
CAUTION:
Be careful not to damage inside (bore side) of cylinder.
INSPECTION
Cylinder Boot
Check boots for breakage, crack and damage. If defective, replace.
Piston Seal
Excessive or uneven wear of pad lining may indicate unsmooth re-
turn of the piston. In such a case, replace rubber seal.
ASSEMBLY
Reassemble front brake in reverse order of disassembly, noting the
following points.
CAUTION:

Wash each part cleanly before installation in the same
fluid as the one used in master cylinder reservoir.

Never use other fluid or thinner.

Before installing piston and piston seal to cylinder, apply
fluid to them.

After reassembling brake lines, bleed air from them.
Piston Seal
Piston seal is used to seal piston and cylinder and to adjust clear-
ance between pad and disc. Replace with a new one at every over-
haul. Fit piston seal into groove in cylinder taking care not to twist
it.

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1. Boot
2. Piston
5B-8 FRONT BRAKE
Piston and Boot
1) Before inserting piston into cylinder, install boot onto piston as
shown.
2) Fit boot as it is in above figure into boot groove in cylinder with
fingers.
Check to make sure that boot is fitted into boot groove in cylinder
completely in its circumference.
3) Insert piston into cylinder by hand and fit boot in boot groove in
piston.
4) To confirm that boot is fitted in its groove in cylinder properly, pull
piston out of cylinder a little but do not take it all out.
5) Insert piston into cylinder by hand.
6) Install anti noise shim, if equipped.

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1. Caliper pin bolts
1. Flexible hose bolt
FRONT BRAKE 5B-9
Caliper
Before installing caliper (cylinder body) to carrier, check to ensure
that guide pin (pin bolt) inserted in each caliper carrier hole can be
moved smoothly in thrust direction.
NOTE:
Where temperature gets as low as ±30
C in cold weather, use
rubber grease whose viscosity varies very little even at ±40
C
(±40
F).
INSTALLATION
1) Install caliper to caliper carrier.
2) Torque caliper pin bolts to specifications.
Tightening Torque
(a), (b): 27 N
.m (2.7 kg-m, 20.0 lb-ft) For TOKICO brake. .
caliper
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft) For SUMITOMO. . . . .
(b): 85 N.m (8.5 kg-m, 61.5 lb-ft) ELECTRIC brake
85 N.m (8.5 kg-m, 61.5 lb-ft)caliper
NOTE:
Make sure that boots are fit into groove securely.
3) Install brake flexible hose as shown and torque hose mounting
bolt to specification.
Tightening Torque
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
4) Torque wheel nuts to specification.
Tightening Torque
(c): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
5) After completing installation, fill reservoir with brake fluid and
bleed brake system. Perform brake test and check each
installed part for oil leakage.

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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)

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1. Bolt
2. Console box
bracket
3. Boot cover
1. Boot No. 3
2. Boot cover
3. Boot No. 2
4. Control lever
5. Lever case
6. Control case cover
7. Boot No. 1
1. Transmission control
lever locating bolt
2. Transfer control lever
locating bolt
7A-4 MANUAL TRANSMISSION (TYPE 1)
SHIFT CONTROL LEVERS
REMOVAL
1) Remove 4 screws at the front and rear and 2 clips at the center
then take off front and rear center console boxes.
NOTE:
To remove clip, push in its center pin first.
2) Remove console box bracket by removing bolts and lift up boot
cover and boot No. 2.
3) Remove boot clamp and then remove boot No. 1 from transmis-
sion shift lever case.
4) With gear shift control case cover pushed down with fingers, turn
it to counter clockwise and take out shift control lever.
5) Take out transfer shift control lever in similar manner as de-
scribed above.
INSPECTION AND INSTALLATION
1) Check shift control lever lower portion and control lever locating
sheet for excessive wear, and boot for damage. Correct or re-
place if necessary.
2) Apply grease to pivot portions and seat, then install shift control
lever.
ªAº: Grease 99000-25010
3) Perform above steps also for transfer shift control lever.
4) If control lever locating bolts (a) are replaced or retightened,
torque them as specified below.
Replacing of control lever locating bolts requires thread lock ce-
ment.
ªBº: Cement 99000-32020
Tightening Torque
(a): 17 N
.m (1.7 kg-m, 12.5 lb-ft)

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1. Boot No. 1
2. Boot clamp
3. Boot cover
4. Boot No. 2
1. Transfer boot No. 1
2. Boot clamp
1. Console box
bracket
2. Boot cover
3. Boot No. 3
MANUAL TRANSMISSION (TYPE 1) 7A-5
5) Install transmission boot No. 1 from inside of cabin and clamp
it with a new clamp securely.
6) Install transfer boot No. 1 securely on lift and clamp it by using
a new clamp.
7) Tighten transmission boot No. 2 with boot cover and console box
bracket.
Tightening Torque
(a): 6 N
.m (0.6 kg-m, 4.0 lb-ft)
8) Install console box.
NOTE:
Be sure that flare end of transmission boot No. 3 is engaged
with console box.

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7A-6 MANUAL TRANSMISSION (TYPE 1)
3, (a)
1. Coupler
2. Clamp3. 4WD switch
4. Boot No. 2
1. Back up light switch
2. 4WD switch
1. Back up light switch coupler
2. Front propeller shaft
SWITCHES
TRANSFER 4WD SWITCH
1) Remove console box and lift transmission control lever boots
No. 2 and No. 3. (Refer to page 7A-4.)
2) Remove transfer control lever boot No. 2, unclamp wiring on
transfer case to free it and pull off coupler.
3) Replace switch and connect as it was.
Tightening Torque
(a): 20 N
.m (2.0 kg-m, 14.5 lb-ft)
4) Turn ON ignition switch, shift transfer shift control lever to 4WD
position and check that indicator lights. Turn OFF switch after
checking.
NOTE:

When removing and reinstalling switch, use care not to let
dust enter transfer box inside.

Make sure to reset clamp for wiring which is located
where invisible directly.

It is recommended to work on transfer shift control lever
boot No. 1 from underside of vehicle on lift.

Identify this switch by its leg part which is different for that
of back up light switch.
BACK UP LIGHT SWITCH
WARNING:
Refrain from work while exhaust center pipe is hot.
REMOVAL AND INSTALLATION
NOTE:
When replacing switch, use care not to let dust enter transmis-
sion through switch hole.
1) Lift up vehicle.
2) Remove coupler(s) for switch wiring.

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1. Match mark
7A-12 MANUAL TRANSMISSION (TYPE 1)
REMOUNTING OF TRANS. UNIT
For remounting, reverse dismounting procedure.
Use specified torques as given below.
Tightening Torque
(a): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

For tightening torque of transmission stiffener bolt, refer to
ªENGINE MECHANICALº section.

Set each clamp for wiring, hose and cable securely.

Set clamp for shift control lever boots securely.

After installing clutch operating cylinder, check clutch pedal free
travel. Refer to SECTION 7C1 ªCLUTCHº.

Fill gear oil to transmission and transfer as specified.

Connect battery and check function of engine, clutch and trans.

When installing propeller shaft, align the match marks.