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

YH4
GRAND
VITARA
1. Reservoir
2. Pin
1. Reservoir
2. Cap
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-9
INSTALLATION
NOTE:
See NOTE at the beginning of this section.
1) When using new grommets, lubricate them with the same fluid
as the one to fill reservoir with. Then press-fit grommets to mas-
ter cylinder. Grommets must be seated in place.
2) Install reservoir and drive in reservoir pin.
NOTE:
Drive in reservoir pin till both of its ends at the right and left
or reservoir becomes the same length.
3) Connect reservoir lead wire.
4) Fill reservoir with specified fluid.
5) Upon completion of installation, check for fluid leakage.

YH4
GRAND
VITARA
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-15
1. Booster piston rod
2. Master cylinder piston
1. Master cylinder
2. Piston
3. Pin head
1. Booster body
2. Piston rod
1. Booster piston rod
2. Master cylinder piston
CLEARANCE BETWEEN BOOSTER PISTON ROD AND
MASTER CYLINDER PISTON ADJUSTMENT
The length of booster piston rod is adjusted to provide specified
clearance ªaº between piston rod end and master cylinder piston.

Before measuring clearance, push piston rod several times so as
to make sure reaction disc is in place.

Keep inside of booster at atmospheric pressure for measure-
ment.
1) Set special tool (A) on master cylinder and push pin until con-
tacts piston.
Special Tool
(A): 09950-96010
2) Turn special tool upside down and place it on booster. Adjust
booster piston rod length until rod end contacts pin head.
Special Tool
(A): 09950-96010
Clearance ªbº: 0 mm (0 in.)
NOTE:
Take measurement with booster set vertically and rod at the
center.
3) Adjust clearance by turning adjusting screw of piston rod.
Special Tool
(F): 09952-16010
Reference
When adjusted as above, its negative pressure is applied to boost-
er with engine at idle, piston to piston rod clearance ªaº should be-
come below.
Clearance ªaº: 0.25 ± 0.5 mm (0.010 ± 0.020 in.)

YH4
GRAND
VITARA
5A-16 BRAKES PIPE / HOSE / MASTER CYLINDER
1. Clevis
2. Nut
1. Steering column 4. Clevis pin
2. Push rod clevis 5. Clip
3. Brake pedal arm 6. NutBOOSTER PUSH ROD CLEVIS ADJUSTMENT
Install push rod clevis so that measurement ªaº is obtained and
torque nut to specification.
Tightening Torque
(a): 25 N
.m (2.5 kg-m, 18.0 lb-ft)
Length
ªaº: 109.5 ± 110.5 mm (4.31 ± 4.35 in.)
INSTALLATION
NOTE:

See NOTE at the beginning of this section.

Check length of push rod clevis. (Refer to BOOSTER PUSH
ROD CLEVIS ADJUSTMENT.)

Before installing master cylinder, adjust booster piston rod.
(Refer to CLEARANCE BETWEEN BOOSTER PISTON ROD
AND MASTER CYLINDER PISTON ADJUSTMENT of this sec-
tion.)

Apply silicone grease to master cylinder piston.
1) Install booster to dash panel as shown. Then connect booster
push rod clevis to pedal arm with clevis pin and clip.
2) Tighten booster attaching nuts to the specified torque.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
3) Connect brake vacuum hose to brake booster.
4) For vehicle equipped with ABS, connect brake pipes to ABS hy-
draulic unit. If ABS hydraulic unit bracket bolts removed, tighten
flare nuts to specification after installing master cylinder.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 12.0 lb-ft)
5) Install master cylinder, referring to MASTER CYLINDER AS-
SEMBLY INSTALLATION in this section.

YH4
GRAND
VITARA
5A-18 BRAKES PIPE / HOSE / MASTER CYLINDER
1. LSPV spring bolt
2. LSPV bolt
3. Brake pipe flare nut
4. Air bleeding plug
1. LSPV lever
2. Stopper bolt (if equipped)
3. Coil spring ªAº: Don't turn(a)
2) Torque each bolt and nut to specification as indicated respec-
tively in figure.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
(b): 16 N
.m (1.6 kg-m, 11.5 lb-ft) (brake flare nut)
(c): 7.5 N
.m (0.75 kg-m, 9.0 lb-ft) (bleeder plug)
3) Upon completion of installation, fill reservoir tank with specified
fluid and bleed air from brake system.
NOTE:
Make sure to bleed air from LSPV bleeder without failure.
4) After bleeding air, check that LSPV is installed properly, referring
to following INSPECTION & ADJUSTMENT.
INSPECTION & ADJUSTMENT
Confirm the following before inspection and adjustment.

Fuel tank is filled with fuel fully.

Vehicle is equipped with spare tire, tools, jack and jack handle.

Vehicle is free from any other load.
With vehicle in above conditions;
1) Place it on level floor.
2) Push up (for 5 door model) or push down (for 3 door model)
LSPV lever with finger till it stops and measure length ªLº of coil
spring as it is pulled.
3) Spring length ªLº should be the value specified below.
Spring length (between spring end and spring bolt)
ªLº: 103 mm (4.06 in.) (5 door model). . . . .
ªLº: 157 mm (6.18 in.) (3 door model). . . . .
4) If it isn't, adjust it to specification by changing stay positions as
shown in figure. After adjustment, tighten bolt to specified
torque.
For details, refer to left figure.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
NOTE:
Check to make sure that LSPV body and brake pipe joints
are free from fluid leakage. Replace defective parts, if any.

YH4
GRAND
VITARA
7E-14 DIFFERENTIAL (FRONT)
1. Mounting bracket R
2. Mounting bracket L
1. Bolt and nut
2. Differential carrier
3. Cross member
4. Bolt
5. Differential rear mounting assembly
7) Position each bush to bracket as shown.
Length ªaº: 3.0 mm (0.12 in.)
8) Use following torque for reinstallation.
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)
REAR MOUNTING
(For front differential carrier)
1) Lift up vehicle and remove mounting assembly by removing 2
bolts and nuts from differential carrier side and 2 bolts from cross
member side.
2) Check mounting rubber for damage or deterioration and replace
as necessary.
3) Use following torque for reinstallation.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

YH4
GRAND
VITARA
10B-64 AIR BAG SYSTEM
ACCIDENT WITH OR WITHOUT DEPLOYMENT ± COM-
PONENT INSPECTIONS
Certain air bag and restraint system components must be in-
spected after any crash, whether the air bag deployed or not.
Those components are:

Steering column and shaft joints
± Check for length, damage and bend according to ªChecking
Steering Column for Accident Damageº in SECTION 3C1.

Steering column bracket and capsules
± Check for damage and bent.
If any faulty condition is found in above checks, replace faulty
part.

Steering wheel and driver air bag (inflator) module
± Check for damage or air bag (inflator) module fitness.
± Check trim cover (pad surface) for cracks.
± Check wire harness and connector for damage or tightness.
If any faulty condition is found in above checks, replace faulty
part.

Contact coil and combination switch assembly
± Check wire harness and connectors for damage or tightness.
± Check contact coil case for damage.
If any faulty condition is found in above checks, replace.

Instrument panel member and reinforcement
± Check for any distortion, bending, cracking or other damage.
If any faulty condition is found in above checks, replace.

YH4
GRAND
VITARA
4
31
2
2
4
31
For driver air bag (inflator) module
For passenger air bag (inflator) module
1. Stretch deployment harness to full length 10 m (33 ft).
2. Connect connectors.
3. Power source (12V vehicle battery).
4. Short the two deployment harness leads.
10B-74 AIR BAG SYSTEM
7) Stretch the deployment harness from the driver or passenger
air bag (inflator) module to its full length 10 m (33 ft).
8) Place a power source near the shorted end of the deployment
harness. Recommended application: 12 Volts minimum, 2
amps minimum. A vehicle battery is suggested.
9) Verify that the area around the driver or passenger air bag (in-
flator) module is clear of all people and loose or flammable ob-
jects.
10) [In case of Driver Air Bag (Inflater) Module]
Verify that the driver air bag (inflator) module is resting with its
vinyl trim cover facing up.
[In case of Passenger Air Bag (Inflator) Module]
Verify that the passenger air bag (inflator) module is firmly and
properly secured in passenger air bag (inflator) module deploy-
ment fixture (special tool).
11) Connect the driver or passenger air bag (inflator) module to the
deployment harness connector and lock connector with lock le-
ver.
12) Notify all people in the immediate area that you intend to deploy
the air bag (inflator) module.
NOTE:

When the air bag deploys, the rapid gas expansion will
create a substantial report. Wear suitable ear protection.
Notify all people in the immediate area that you intend to
deploy the air bag (inflator) module and suitable ear
protection should be worn.

When the air bag deploys, the driver air bag (inflator)
module may jump about 30 cm (1 ft) vertically. This is a
normal reaction of the driver air bag (inflator) module to
the force of the rapid gas expansion inside the air bag.

After the air bag (inflator) module has been deployed, the
surface of the air bag may contain a powdery residue.
This powder consists primarily of cornstarch (used to lu-
bricate the bag as it inflates) and byproducts of the
chemical reaction.

YH4
GRAND
VITARA
Driver side for left hand steering vehicle
Driver side for right hand steering vehicle
1. Stretch deployment harness to its full length
10 m (33 ft).
2. Drop cloth, blanket or similar item2
10B-80 AIR BAG SYSTEM
8) Route deployment harness out the vehicle.
9) Verify that the inside of the vehicle and the area surrounding
the vehicle are clear of all people and loose or flammable ob-
jects.
10) Stretch the deployment harness to its full length 10 m (33 ft).
11) Place a power source near the shorted end of the deployment
harness. Recommended application: 12 Volts minimum, 2
amps minimum. A vehicle battery is suggested.
12) Completely cover windshield area and front door window
openings with a drop cloth, blanket to similar item. This reduces
the possibility of injury due to possible fragmentation of the ve-
hicle's glass or interior.
13) Notify all people in the immediate area that you intend to deploy
the air bag (inflator) module.
NOTE:

When the air bag deploys, the rapid gas expansion will
create a substantial report. Wear suitable ear protection.
Notify all people in the immediate area that you intend to
deploy the air bag (inflator) module and suitable ear
protection should be worn.

After the air bag (inflator) module has been deployed, the
surface of the air bag may contain a powdery residue.
This powder consists primarily of cornstarch (used to lu-
bricate the bag as it inflates) and byproducts of the
chemical reaction.
WARNING:
Safety precautions must be observed when handling a
deployed air bag (inflator) module.

After deployment, the metal surfaces of the air bag (infla-
tor) module will be very hot. Do not touch the metal areas
of the air bag (inflator) module for about 30 minutes after
deployment.

Do not apply water, oil, etc. to deployed air bag (inflator)
module.

If the deployed air bag (inflator) module must be moved
before it is cool, wear gloves and handle by the air bag or
vinyl trim.
Failure to follow procedures may result in fire or personal
injury.

YH4
GRAND
VITARA
1. Stretch it to full length 10m (33 ft).
2. Power source (12V vehicle battery)
3. Connect one banana plug to positive terminal of power
source (12V vehicle battery) and then the other to
negative terminal to immediately deploy.
4. Short harness leads after deployment.
5. Drop cloth, blanket or similar them
5
AIR BAG SYSTEM 10B-81
14) Separate the two banana plugs on the deployment harness.
15) Connect the deployment harness to the power source (12 V ve-
hicle battery) to immediately deploy the driver or passenger air
bag.
16) Disconnect the deployment harness from the power source (12
V vehicle battery) and short the two deployment harness leads
together by fully seating one banana plug into the other.
17) Put on a pair of shop gloves to protect your hands from possible
irritation and heat when handling the deployed air bag (inflator)
module.
NOTE:
As a precaution, gloves and safety glasses are recom-
mended to prevent any possible irritation of the skin or
eyes.
18) Disconnect the deployment harness from the air bag (inflator)
module as soon after deployment as possible. This will prevent
damage to the deployment harness due to possible contact
with the hot air bag (inflator) module canister. The deployment
harness are designed to be reused. They should, however, be
inspected for damage after each deployment and replaced if
necessary.
19) Carefully remove drop cloth from vehicle and clean off any frag-
ments or discard drop cloth entirely.
20) Repeat Steps 2) through 19) to deploy driver or passenger air
bag (inflator) module which has not been deployed, if any.

YH4
GRAND
VITARA
1. Seat belt pretensioner (retractor assembly)
2. Webbing
3. 185 cm (6 ft) of clearance
4. Exhaust hole
1. Stretch deployment harness to full length 10 m (33 ft).
2. Connect connectors.
3. Power source (12V vehicle battery)
4. Short the two deployment harness leads.
5. Seat belt pretensioner harness
4
AIR BAG SYSTEM 10B-85
6) Pull out the webbing fully as shown at the left and cut it at the
root of the pretensioner (retractor assembly) as shown in the
figure.
WARNING:
As the drum of the retractor assembly turns very quick-
ly as soon as the webbing is cut, fix the retractor assem-
bly with a vise on the workbench and keep your hands
and fingers away from it when cutting the webbing.
7) Clear a space on the ground about 185 cm (6 ft) in diameter
where the seat belt pretensioner is to be activated. A paved,
outdoor location where there is no activity is preferred. If an out-
door location is not available, a space on the shop floor where
there is no activity and sufficient ventilation is recommended.
Ensure no loose or flammable objects are within the activation
area.
8) Place the seat belt pretensioner as shown in the figure on the
ground in the space just cleared.
9) Stretch the deployment harness from the seat belt pretension-
er to its full length 10 m (33 ft).
10) Place a power source near the shorted end of the deployment
harness. Recommended application: 12 Volts minimum, 2
amps minimum. A vehicle battery is suggested.
11) Verify that the area around the seat belt pretensioner is clear
of all people and loose or flammable objects.
12) Verify that the seat belt pretensioner is placed as shown in the
figure on the ground in the space just cleared.
13) Connect the seat belt pretensioner harness to the deployment
harness connector and lock the connector with lock lever.
Special Tool
(A): 09932-75030