on vehicle service SUZUKI GRAND VITARA 2004 2.G Service Workshop Manual

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RELATED MANUAL
MANUAL NAMEMANUAL NO.APPLICABILITY
SQ416 / SQ420 / SQ625
Unit Repair Manual99501-65D01-xxxTransmission, Transfer and Differentials
(Front and Rear) of SQ series.
SQ416 / SQ420 / SQ625
Wiring Diagram Manual99512-65D10-015Applicable model mentioned in FOREWORD
of this manual.
SQ416 / SQ420 / SQ625
Service Manual99500-65D00-xxxVehicles before the vehicle identification number
mentioned in FOREWORD of this manual.
SQ416 / SQ420 / SQ625
Wiring Diagram Manual99512-65D01-015

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0A
GENERAL INFORMATION 0A-1
SECTION 0A
GENERAL INFORMATION
CONTENTS
HOW TO USE THIS MANUAL0A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS0A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Vehicle Equipped with a Supplemental Restraint (Air Bag) System 0A- 3. . . . . . . . . . . . . . . .
Diagnosis0A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing and Handling0A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Precautions0A- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Catalytic Converter 0A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Electrical Circuit Service 0A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Circuit Inspection Procedure 0A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermittent and Poor Connection 0A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precaution for Installing Mobile Communication Equipment 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDENTIFICATION INFORMATION0A-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body Number0A-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Identification Number0A-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Identification Number 0A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING, CAUTION AND INFORMATION LABELS0A-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE LIFTING POINTS0A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABBREVIATIONS MAY BE USED IN THIS MANUAL0A-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
METRIC INFORMATION0A-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric Fasteners0A-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fasteners Strength Identification 0A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tightening Torque0A-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6) Install oil pump. Refer to ªOil pumpº.
7) Install flywheel (for M/T vehicle) or drive plate (for A/T vehicle).
Using special tool, lock flywheel or drive plate, and tighten
flywheel or drive plate bolts to specified torque.
Special Tool
(A): 09924-17810
Tightening Torque
(c): 78 N
.m (7.8 kg-m, 56.0 lb-ft)1. Flywheel bolts or drive plate bolts for A/T vehicle1, (c)
0A-2 GENERAL INFORMATION
HOW TO USE THIS MANUAL
1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL
on the third page of this manual, whereby you can easily find the
section that offers the information you need. Also, there is a
CONTENTS on the first page of EACH SECTION, where the
main items in that section are listed.
2) Each section of this manual has its own pagination. It is indicated
at the top of each page along with the Section name.
3) The SPECIAL TOOL usage and TORQUE SPECIFICATION are
given as shown in figure below.
4) A number of abbreviations are used in the text.
For their full explanations, refer to ªABBREVIATIONS MAY BE
USED IN THIS MANUALº of this section.
5) The SI, metric and foot-pound systems are used as units in this
manual.
6) DIAGNOSIS are included in each section as necessary.
7) At the end of each section, there are descriptions of SPECIAL
TOOLS, REQUIRED SERVICE MATERIALS and TIGHT-
ENING TORQUE SPECIFICATIONS that should be used for the
servicing work described in that section.

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1. Air bag wire harness
2. Passenger air bag
(inflator) module
3. SDM
4. DLC5. Contact coil
6. Driver air bag (inflator)
module
7. Seat belt pretensioner
(if equipped)
GENERAL INFORMATION 0A-3
PRECAUTIONS
PRECAUTION FOR VEHICLES EQUIPPED
WITH A SUPPLEMENTAL RESTRAINT
(AIR BAG) SYSTEM
WARNING:

The configuration of air bag system parts are as shown in
the figure. When it is necessary to service (remove, rein-
stall and inspect) these parts, be sure to follow proce-
dures described in SECTION 10B. Failure to follow proper
procedures could result in possible air bag system activa-
tion, personal injury, damage to parts or air bag system
being unable to activate when necessary.

If the air bag system and another vehicle system both
need repair, SUZUKI recommends that the air bag system
be repaired first, to help avoid unintended air bag system
activation.

Do not modify the steering wheel, dashboard, or any other
air bag system components. Modifications can adversely
affect air bag system performance and lead to injury.

If the vehicle will be exposed to temperatures over 93
C
(200
F) (for example, during a paint baking process), re-
move the air bag system components beforehand to avoid
component damage or unintended air bag system activa-
tion.
DIAGNOSIS

When troubleshooting air bag system, be sure to follow
ªDIAGNOSISº in SECTION 10B. Bypassing these proce-
dures may result in extended diagnostic time, incorrect diag-
nosis, and incorrect parts replacement.

Never use electrical test equipment other than that specified
in this manual.
WARNING:
Never attempt to measure the resistance of the air bag (in-
flator) modules (driver and passenger) and seat belt preten-
tioners (driver and passenger). It is very dangerous as the
electric current from the tester may deploy the air bag or ac-
tivate the pretensioner.

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1. Exhaust hole
1 1
NG
GENERAL INFORMATION 0A-5
WARNING:
SDM

During service procedures, be very careful when handling
a Sensing and Diagnostic Module (SDM). Never strike or
jar the SDM.
Never power up the air bag system when the SDM is not
rigidly attached to the vehicle. All SDM and mounting
bracket fasteners must be carefully torqued and the arrow
must be pointing toward the front of the vehicle to ensure
proper operation of the air bag system.
The SDM could be activated when powered while not rigid-
ly attached to the vehicle which could cause deployment
and result in personal injury.
WARNING:
Driver and Passenger Seat Belt Pretensioners

For handling and storage of a live seat belt pretensioner,
select a place where the ambient temperature below 65
C
(150
F), without high humidity and away from electric
noise.

Never carry seat belt pretensioner by wire or connector of
pretensioner. When placing a live seat belt pretensioner
on the workbench or some place like that, be sure not to
lay it with its exhaust hole provided side facing down. It is
also prohibited to put something on its face with an ex-
haust hole or to put a seat belt pretensioner on top of
another. Otherwise, personal injury may result.

Never dispose of live (inactivated) seat belt pretensioners
(driver and passenger). If disposal is necessary, be sure
to activate them according to activation procedures de-
scribed in SECTION 10B before disposal.

The seat belt pretensioner immediately after activation is
very hot. Wait for at least half an hour to cool it off before
proceeding the work.

With many service procedures, gloves and safety glasses
should be worn to prevent any possible irritation of the
skin or eyes.

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0A-6 GENERAL INFORMATION
CAUTION:

Even when the accident was light enough not to cause air
bags to activate, be sure to inspect system parts and other
related parts according to instructions under ªRepair and
Inspection Required after an Accidentº in SECTION 10B.

When servicing parts other than air bag system, if shocks
may be applied to air bag system component parts, re-
move those parts beforehand.

When handling the air bag (inflator) modules (driver and
passenger), seat belt pretensioners (driver and passen-
ger) or SDM, be careful not to drop it or apply an impact to
it. If an excessive impact was applied (e.g., dropped from
a height of 91.4 cm (3 feet) or more), never attempt disas-
sembly or repair but replace it with a new one.

When grease, cleaning agent, oil, water, etc. has got onto
air bag (inflator) modules (driver and passenger) or seat
belt pretensioners (drive and passenger), wipe off im-
mediately with a dry cloth.

Air bag wire harness can be identified easily as it is cov-
ered with a yellow protection tube. Be very careful when
handling it.

When an open in air bag wire harness, damaged wire har-
ness, connector or terminal is found, replace wire har-
ness, connectors and terminals as an assembly.

Do not apply power to the air bag system unless all com-
ponents are connected or a diagnostic chart requests it,
as this will set a diagnostic trouble code.

Never use air bag system component parts from another
vehicle.

When using electric welding, be sure to temporarily dis-
able air bag system referring to ªDisabling Air Bag Sys-
temº described in ªService Precautionsº under ªOn-Ve-
hicle Serviceº in SECTION 10B.

Never expose air bag system component parts directly to
hot air (drying or baking the vehicle after painting) or
flames.

WARNING / CAUTION labels are attached on each part of
air bag system components. Be sure to follow the instruc-
tions.

After vehicle is completely repaired, perform ªAir Bag
Diagnostic System Checkº described in ªDiagnosisº in
SECTION 10B.

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GENERAL INFORMATION 0A-7
GENERAL PRECAUTIONS
The WARNING and CAUTION below describe some general precautions that you should observe when servicing
a vehicle. These general precautions apply to many of the service procedures described in this manual, and they
will not necessarily be repeated with each procedure to which they apply.
WARNING:

Whenever raising a vehicle for service, be sure to follow the instructions under ªVEHICLE LIFTING
POINTSº on SECTION 0A.

When it is necessary to do service work with the engine running, make sure that the parking brake
is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for automatic
transmission vehicles). Keep hands, hair, clothing, tools, etc. away from the fan and belts when the
engine is running.

When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.

Do not perform service work in areas where combustible materials can come in contact with a hot
exhaust system. When working with toxic or flammable materials (such as gasoline and refrigerant),
make sure that the area you work in is well-ventilated.

To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail-
pipe, muffler, etc.

New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or
used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory animals.
Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a
long-sleeve shirt and moisture-proof gloves (such as dishwashing gloves) when changing engine oil.
If engine oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags
if wet with oil, recycle or properly dispose of used oil and filters.

Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly
during driving, obstructing your view and resulting in an accident.
CAUTION:

Before starting any service work, cover fenders, seats and
any other parts that are likely to get scratched or stained dur-
ing servicing. Also, be aware that what you wear (e.g, but-
tons) may cause damage to the vehicle's finish.

When performing service to electrical parts that does not re-
quire use of battery power, disconnect the negative cable of
the battery.

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When using frame contact hoist:
1. Front lifting point
2. Rear lifting point
3. Front
GENERAL INFORMATION 0A-19
VEHICLE LIFTING POINTS
WARNING

When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up the
vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by trying to
move vehicle body in both ways. Work can be started only after this confirmation.

Before applying hoist to underbody, always take vehicle balance throughout service into consider-
ation. Vehicle balance on hoist may change depending of what part to be removed.

Make absolutely sure to lock hoist after vehicle is hoisted up.

Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe,
fuel pipe, bracket or any other part.

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1. Front differential housing
2. Rear axle
housing
When using floor jack:
Front
Rear
1. Safety stands
0A-20 GENERAL INFORMATION
In raising front or rear vehicle end off the floor by jacking, be sure
to put the jack against the center portion of the front suspension
frame or rear axle housing.
WARNING:

Never apply jack against suspension parts (i.e., stabilizer,
etc.) or vehicle floor, or it may get deformed.

If the vehicle to be jacked up only at the front or rear end,
be sure to block the wheels on ground in order to ensure
safety.
After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on the
vehicle raised on jack alone.
To perform service with either front or rear vehicle end jacked up,
be sure to place safety stands under chassis frame so that body is
securely supported. And then check to ensure that chassis frame
does not slide on safety stands and the vehicle is held stable for
safety's sake.

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .