parking brake SUZUKI GRAND VITARA 2004 2.G Service Workshop Manual

YH4
GRAND
vol.1
0A
0B
1A
1B
3
3A
3B1
3C
3C1
3D
3E
3F
4A2
4B
5
6
7A5A
5B
5C
5E1
6A1
6A2
6A4
6B
6C
6E1
6E2
6F1
6F2
6G
6G1
6H
6K
7A1
7B1
7C1
7D
7E
7F
8
8B
8C
8D
8G
9
10
10A
8A
10B
6-1ENGINE
General Information and
Diagnosis (G16 / J20)
General Information and
Diagnosis (H25)
Engine Mechanical (G16)
Engine Mechanical (H25)
Engine Mechanical (J20)
Engine Cooling
Engine Fuel
Engine and Emission Control
System (SFI for G16 / J20)
Engine and Emission Control
System (SFI for H25)
Ignition System (G16)
Ignition System (J20 / H25)
Cranking System
(Reduction Type)
Cranking System
(No-Reduction Type)
Charging System
Exhaust System
TRANSMISSION, CLUTCH
AND DIFFERENTIAL
Manual Transmission (Type 1)
Manual Transmission (Type 2)
Automatic Transmission
Clutch (Hydraulic Type)
Transfer
Differential (Front)
Differential (Rear)
BODY ELECTRICAL SYSTEM
Wiring Diagram
Lighting System
Instrumentation / Driver
Information
Windows, Mirrors, Security
and Lock
Immobilizer Control System
BODY SERVICE
RESTRAINT SYSTEM
Seat Belt
Air Bag System GENERAL INFORMATION
General Information
Maintenance and Lubrication
TABLE OF CONTENTS TABLE OF CONTENTS SECTIONSECTION
0B
HEATING AND AIR
CONDITIONING
Heater and Ventilation
Air Conditioning
STEERING, SUSPENSION,
WHEELS AND TIRES
Front End Alignment
Power Steering (P / S) System
Steering Wheel and Column
(Not Equipped with Air Bag)
Air Bag Steering Wheel
and Column
Front Suspension
Rear Suspension
Wheel and Tires
1A
3A 0A
1B
3B1
3C
3C1
3D
3E
3F36A16
6A2
6A4
6B
6C
6E1
6E2
6F1
DRIVE SHAFT / PROP. SHAFT
Front Drive Shaft / Shaft
Bearing, Oil Seal
Propeller Shaft
BRAKES
Brake Pipe / Hose / Master
Cylinder
Front Brakes
Parking and Rear Brakes
Antilock Brake System
4A2
4B
5
5A
5B
5C
5E1
6F2
6G
6G1
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8
8A
8B
8C
8D
8G
9
10
10A
10B
6-1
NOTE:
The screen toned Sections 6 ± 6K are included in Volume 2 and Section 8A is in Wiring
Diagram Manual.

YH4
GRAND
VITARA
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.

YH4
GRAND
VITARA
ªaº: Parking brake lever
stroke:
5 ± 7 notches
(With 20 kg or 44 lbs
of pull pressure)
ªaº
0B-16 MAINTENANCE AND LUBRICATION
ITEM 6-3
Brake Hoses and Pipes Inspection
Check brake hoses and pipes for proper hookup, leaks, cracks,
chafing and other damage.
Replace any of these parts as necessary.
CAUTION:
After replacing any brake pipe or hose, be sure to carry out
air purge operation.
ITEM 6-4
Brake Fluid Change
Change brake fluid as follows.
Drain existing fluid from brake system completely, fill system with
specified fluid and carry out air purge operation.
For air purging procedure, refer to Section 5.
ITEM 6-5
Parking Brake Lever and Cable Inspection
Parking brake lever
1) Check tooth tip of each notch for damage or wear. If any damage
or wear is found, replace parking lever.
2) Check parking brake lever for proper operation and stroke, and
adjust it if necessary.
For checking and adjusting procedures, refer to Parking Brake
Inspection and Adjustment in Section 5.
Parking brake cable
Inspect brake cable for damage and smooth movement.
Replace cable if it is in deteriorated condition.

YH4
GRAND
VITARA
0B-24 MAINTENANCE AND LUBRICATION
FINAL INSPECTION
Seats
Check that seat slides smoothly and locks securely at
any position. Also check that reclining mechanism of
front seat back allows it to be locked at any angle.
Seat Belt
Inspect belt system including webbing, buckles, latch
plates, retractors and anchors for damage or wear.
If ªREPLACE BELTº label on front seat belt is visible,
replace belt.
Check that seat belt is securely locked.
Battery Electrolyte Level Check
Check that the electrolyte level of all battery cells is
between the upper and lower level lines on the case.
If battery is equipped with built-in indicator, check bat-
tery condition by the indicator.
Accelerator Pedal Operation
Check that pedal operates smoothly without getting
caught or interfered by and other part.
Engine Start
Check engine start for readiness.
On automatic transmission vehicles, try to start the
engine in each select lever position. The starting mo-
tor should crank only in ªPº (Park) or ªNº (Neutral).
On manual transmission vehicles, place the shift le-
ver in ªNeutral,º depress clutch pedal fully and try to
start.
Exhaust System Check
Check for leakage, cracks or loose supports.
Clutch (For Manual transmission)
Check for the following:

Clutch is completely released when depressing
clutch pedal.

No slipping clutch occurs when releasing pedal and
accelerating.

Clutch itself is free from any abnormal condition.
Gearshift or Select Lever (Transmission)
Check gear shift or select lever for smooth shifting to
all positions and for good performance of transmis-
sion in any position.
With automatic transmission equipped vehicle, also
check that shift indicator indicates properly according
to which position select lever is shifted to.
With automatic transmission equipped vehicle, make
sure that vehicle is at complete stop when shifting se-
lect lever to ªPº range position and release all brakes.
Brake
[Foot brake]
Check the following:

that brake pedal has proper travel,

that brake works properly,

that it is free from noise,

that braking force is applied equally on all wheels,

and that brake do not drag.
[Parking brake]
Check that lever has proper travel.
WARNING:
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property damage.
Be prepared to apply regular brake quickly
even if vehicle should start to move.
Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and
brake lever is pulled all the way.
WARNING:
When carrying out road tests, select a safe
place where no man or no running vehicle is
seen so as to prevent any accident.
WARNING:
Before performing the following check, be
sure to have enough room around the vehicle.
Then, firmly apply both the parking brake and
the regular brakes. Do not use the accelerator
pedal. If the engine starts, be ready to turn off
the ignition promptly. Take these precautions
because the vehicle could move without warn-
ing and possibly cause personal injury or
property damage.

YH4
GRAND
VITARA
3B1-12 POWER STEERING (P / S) SYSTEM
TIE-ROD END BOOT CHECK
Check boot for crack and damage and if any, replace it with a new
one.
AIR BLEEDING PROCEDURE
1) Hoist the front end of vehicle and apply safety stands.
2) Fill P / S fluid reservoir with fluid up to specified level.
NOTE:
Before starting engine, place transmission gear shift lever
in ªNeutralº (shift selector lever to ªPº range for A / T mod-
el), and set parking brake.
3) After running engine at idling speed for 3 to 5 seconds, stop it
and add fluid to satisfy specification.
4) With engine stopped, turn steering wheel to the right and left as
far as it stops, repeat it a few times and fill fluid to specified level.
5) With engine running at idling speed, repeat stop-to-stop turn of
steering wheel till all foams in P / S fluid reservoir are gone.
NOTE:
Make sure to bleed air completely. If air remains in fluid, P / S
pump may make humming noise or steering wheel may feel
heavy.
6) Finally check to make sure that fluid is filled to specified level.

YH4
GRAND
VITARA
1. Parking brake
cable hanger
2. Cross member
3. Clamp
4. Chassis frame1. Rear axle housing
2. Floor jack
1. Shock absorber
2. Lower bolt
1. Clamp
2. Upper rod
3E-6 REAR SUSPENSION
COIL SPRING
REMOVAL
1) Hoist vehicle and remove rear wheel.
2) Support rear axle housing by using floor jack.
3) Disconnect parking brake cable hanger from chassis frame and
clamp from cross member.
4) Remove shock absorber lower mounting bolt.
5) Remove wheel speed sensor clamps from upper rod and axle
housing, if equipped with ABS.
For right side, remove E-ring for fixing brake pipe from cross
member and disconnect breather hose from axle housing.
6) Lower rear axle housing gradually as far down as where coil
spring can be removed.
7) Remove coil spring.

YH4
GRAND
VITARA
1. Rear axle housing
2. Spring seat
3. Coil spring
4. Stepped part
1. Body center
2. Body outside
1. Body center
2. Body outside 1. Parking brake
cable hanger
2. Cross member
3. Clamp
4. Chassis frame
REAR SUSPENSION 3E-7
INSTALLATION
1) Install coil spring on spring seat of axle housing and then raise
axle housing.
NOTE:
When seating coil spring, mate spring end with stepped
part of rear axle spring seat as shown.
2) Install shock absorber lower bolt. For its proper installing direc-
tion, refer to figure.
Nut should not be tightened.
3) Install wheel speed sensor clamp (if equipped) and E-ring, and
connect breather hose to axle housing.
4) Connect cable hanger to chassis frame and clamp to cross
member. Remove floor jack from axle housing.
5) Install wheel and tighten wheel nuts to specified torque.
Tightening Torque
(a): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
6) Lower hoist and tighten absorber lower nut to specified torque.
Tightening Torque
(b): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
NOTE:
For tightening of lower nut, refer to NOTE given under
SHOCK ABSORBER INSTALLATION in this section.

YH4
GRAND
VITARA
1. Bearing retainer
2. Parking brake shoe
lever
3. Clearance1. Wheel speed sensor
1
L
REAR SUSPENSION 3E-11
4) Remove wheel speed sensor from rear axle housing (if
equipped with ABS).
CAUTION:

Do not pull wire harness or twist more than necessary
when removing rear wheel speed sensor.

Do not cause damage to surface of rear wheel speed
sensor or pole piece and do not allow dust, etc. to enter
its installation hole.
5) Check to ensure that there is clearance between rear wheel
bearing retainer and parking brake shoe lever. If no clearance
is found, loosen cable locking nut further to obtain clearance.
6) Using special tools (B) & (C) indicated below, draw out axle
shaft.
NOTE:
Use care not to pull brake back plate along with shaft.
CAUTION:
Pull out axle shaft using care so that upper and lower
brake struts and parking cable are not caught.
Special Tool
(C): 09943-35512
(B): 09942-15510
7) Rear axle shaft that was drawn out.
Shaft length ªLº:
Left side: 711.5 mm (28.0 in.)
Right side: 757.5 mm (29.8 in.)
8) If equipped with ABS, in order to remove sensor rotor from re-
tainer ring, grind with a grinder one part of the sensor rotor as
illustrated till it becomes thin.

YH4
GRAND
VITARA
1. Brake pipe flare nut
2. Brake pipe
3. Brake back plate
1. Bearing retainer
2. Parking brake shoe
lever
3. Clearance1. Nut 1. Wheel speed sensor
2. Wheel speed sensor coupler
3. Wheel speed sensor harness clamp
4. Wheel speed sensor harness
3E-16 REAR SUSPENSION
REAR AXLE HOUSING
REMOVAL
1) Drain differential gear oil.
Carry out steps 2) to 7) and 15) to 18) on both right and left
wheels.
Note that left wheel and its related parts are used in illustrations
in this section.
2) Remove rear brake drum. (Refer to steps 1) to 5) of BRAKE
DRUM REMOVAL.)
3) Disconnect brake pipe from wheel cylinder. With right side wheel
cylinder, disconnect 2 brake pipes.
4) For vehicle with ABS, disconnect wheel speed sensor coupler
and remove wheel speed sensor with its harness.
5) Remove rear wheel bearing retainer nuts from rear axle hous-
ing.
6) Check to ensure that there is clearance between rear wheel
bearing retainer and parking brake shoe lever. If no clearance
is found, loosen cable locking nut further to obtain clearance.

YH4
GRAND
VITARA
3E-22 REAR SUSPENSION
23) Install wheel and tighten wheel nuts to specified torque.
Tightening Torque
(h): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
24) Upon completion of all jobs, depress brake pedal with about 30
kg (66 lbs) load three to ten times so as to obtain proper drum-
to-shoe clearance.
Adjust parking brake cable (for adjustment, see SECTION 5C
of this manual.)
25) Tighten parking brake lever cover screws.
26) Lower hoist.
27) Tighten right and left lower / upper rod nuts lateral rod mount
bolt and shock absorber nuts to specified torque.
NOTE:
When tightening these nuts, be sure that vehicle is off
hoist and in non loaded condition.
Tightening Torque
(i): 90 N
.m (9.0 kg-m, 65.0 lb-ft)
(j): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
28) Check to ensure that brake drum is free from dragging and
proper braking is obtained.
29) Perform brake test (foot brake and parking brake).
30) Check each installed part for oil leakage.