torque SUZUKI GRAND VITARA 2005 2.G Service User Guide

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GRAND
VITARA
MAINTENANCE AND LUBRICATION 0B-19
11) Check coil spring, upper rod, lower rod and lateral rod for de-
formation and damage.
12) Check upper rod, lower rod and lateral rod bushings and bump
stopper for wear, damage and deterioration.
13) Check other suspension parts for damage, loose or missing
parts; also for parts showing signs of wear or lack of lubrication.
Replace any parts found defective in steps 1) to 13).
ITEM 6-9
Propeller Shafts and Drive Shafts Inspection
1) Check universal joint and spline of propeller shaft for rattle. If
rattle is found, replace defective part with a new one.
2) Check propeller shaft (front & rear) flange yoke bolts for tight-
ness, and retighten them as necessary.
Refer to Section 4B for tightening torque.
3) Check drive axle boots (wheel side and differential side) for
leaks, detachment, tear or other damage.
Replace boot as necessary.

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GRAND
VITARA
1. Drain plug (Apply sealant)
2. Reverse idle gear shaft bolt (DO NOT LOOSEN IT)
3. Filler / level plug (Apply sealant)
1. Drain plug
2. Filler / level plug
Type 1
Type 2
1. Level gauge
2. FULL HOT mark
3. LOW HOT mark
4. FULL COLD mark
5. LOW COLD mark
0B-20 MAINTENANCE AND LUBRICATION
ITEM 6-10
Manual Transmission Oil Inspection and Change
Inspection
1) Inspect transmission case for evidence of oil leakage.
Repair leaky point if any.
2) Make sure that vehicle is placed level for oil level check.
3) Remove level plug of transmission.
4) Check oil level.
Oil level can be checked roughly by means of level plug hole.
That is, if oil flows out of level plug hole or if oil level is found up
to hole when level plug is removed, oil is properly filled.
If oil is found insufficient, pour specified amount of specified oil.
5) Tighten level plug to specified torque.
Refer to Section 7A or 7A1 for installation and tightening torque.
Change
Change transmission oil with new specified oil referring to Section
7A or 7A1.
ITEM 6-11
Automatic Transmission Fluid Inspection and Change
Inspection
1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Check fluid level.
For fluid level checking procedure, refer to On-vehicle service in
Section 7B1 and be sure to perform it under specified conditions.
If fluid level is low, replenish specified fluid.

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GRAND
VITARA
1. Drain plug
Transfer
Front differential
Rear differential
1
21
2
MAINTENANCE AND LUBRICATION 0B-21
Change
1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Change fluid. For its procedure, refer to On-vehicle service in
Section 7B1.
Fluid cooler hose change
Replace inlet and outlet hoses of cooler hose and their clamps.
For replacement procedure, refer to On-vehicle service in Section
7B1.
ITEM 6-12 and 6-13
Transfer and Differential Oil Inspection and Change
Inspection
1) Check transfer case and differential for evidence of oil leakage.
Repair leaky point if any.
2) Make sure that vehicle is placed level for oil level check.
3) Remove level plug of transfer or differentials (front and rear) and
check oil level.
Oil level can be checked roughly by means of level plug hole.
That is, if oil flows out of level plug hole or if oil level is found up
to hole when level plug is removed, oil is properly filled.
If oil is found insufficient, pour specified amount of specified oil
referring to Section 7D, 7B or 7F.
4) Tighten level plug to specified torque.
Refer to Section 7D, 7E or 7F for tightening torque.
Change
Change transfer oil or differentials oil with new specified oil referring
to Section 7D, 7E and 7F respectively.

YH4
GRAND
VITARA
The figure shows right-hand steering vehicle
The figure shows right-hand steering vehicle
0B-22 MAINTENANCE AND LUBRICATION
ITEM 6-14
Steering System Inspection
1) Check steering wheel for play and rattle, holding vehicle in
straight forward condition on the ground.
Steering wheel play ªaº: 0 ± 30 mm (0 ± 1.2 in.)
2) Check universal joints of steering shaft for rattle and damage. If
rattle or damage is found, replace defective part with a new one.
3) Check steering linkage for looseness and damage. Repair or re-
place defective part, if any.
4) Check bolts and nuts for tightness and retighten them as neces-
sary. Repair or replace defective parts, if any.
Refer to table of Tightening Torque Specification in Section 3B
(or 3B1) and 3C (or 3C1) for particular check points.
5) Check boots of steering linkage for damage (leaks, detachment,
tear, dent, etc.). If damage is found, replace it with new one.
If any dent is found on steering rack boots, correct it to original
shape by turning steering wheel to the right or left as far as it
stops and holding it for a few seconds.
6) Check wheel alignment.
NOTE:
For details of wheel alignment, refer to Wheel Alignment in
Section 3A.
ITEM 6-15
Power Steering (P / S) System Inspection (if equipped)
1) Visually check power steering system for fluid leakage and hose
for damage and deterioration.
Repair or replace defective parts, if any.
2) With engine stopped, check fluid level indicated on fluid tank,
which should be between MAX and MIN marks. If it is lower than
MIN, fill fluid up to MAX mark.
NOTE:

Be sure to use an equivalent of DEXRON

-II or DEX-
RON

-III for P / S fluid.

Fluid level should be checked when fluid is cool.

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GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-31

Tighten flared nuts to specified torque.
Tightening Torque (Flared Nut Used for)
8 mm pipe: 13 N
.m (1.3 kg-m, 9.5 lb-ft)
14.5 mm pipe: 23 N
.m (2.3 kg-m, 16.6 lb-ft)
16 mm pipe: 33 N
.m (3.3 kg-m, 23.8 lb-ft)

Route drain hose so that drained water does not make any contact to vehicle components.
HANDLING REFRIGERANT HFC-134a (R-134a)

When handling refrigerant, always wear goggles to protect your eyes.

Avoid you direct contact to liquid refrigerant.

Do not heat refrigerant container higher than 40C (104F).

Do not discharge refrigerant into atmosphere.

Do not allow liquid refrigerant to touch bright metals. Refrigerant combined with moisture is corrosive and will
tarnish surfaces of bright metals including chrome.

After recovering refrigerant from system, the amount of compressor oil removed must be measured and the same
amount added to the system.
REFRIGERANT RECOVERY
When discharging refrigerant out of A / C system, always recover it by using refrigerant recovery and recycling
equipment. Discharging refrigerant HFC-134a (R-134a) into atmosphere would cause adverse effect to environ-
ments.
NOTE:
When handling recovery and recycling equipment, be sure to follow the instruction manual for the equip-
ment.
REFRIGERANT CHARGE
Charge a proper amount of refrigerant to A / C system according to charging procedure described in recovery, evac-
uation and charging.
CAUTION:
Do not perform an additional refrigerant charging to A / C system. This cause it to overcharge.

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VITARA
12
2. Condenser dryer section
1B-36 AIR CONDITIONING (OPTIONAL)
CONDENSER DRYER (RECEIVER / DRYER)
REMOVAL
1) Remove A / C condenser assembly (1) from vehicle (Refer to
ªA / C CONDENSER ASSEMBLY REMOVALº in this section.).
2) Remove the condenser dryer cap from condenser.
3) Remove the filter (1) from the condenser (2).
4) Remove the dryer (1) using a plier (2).
INSTALLATION
Reverse removal sequence to install condenser dryer, according to
instruction manual with supply parts.
NOTE:

When replacing condenser dryer, add 40 cc of refrigerating
oil the same as compressor oil.

Do not remove the dryer from the plastic bag until just before
inserting it into the receiver.

Install the condenser dryer (1) with its double-layer portion
facing the bottom of the receiver.

If condenser dryer cap installing is bolt type, tighten speci-
fied torque for its bolt.
Tightening Torque:
Cap: 12.5 N
.m (1.25 kg-m, 9 lb-ft)

YH4
GRAND
VITARA
Pressure ABCD SWITCH
ON
(Continuity)
OFF
(No continuity)
AIR CONDITIONING (OPTIONAL) 1B-47
DUAL PRESSURE SWITCH
INSPECTION
1) Check dual pressure switch (1) on liquid pipe for continuity at
normal temperature (approx. 25
C (77
F)) when A / C system
has a proper charge of refrigerant and when A / C system (com-
pressor) is under operation. In each of these cases, switch
should show proper continuity.
2) Using a manifold gauge set, check switch for operation at speci-
fied pressure as shown, refer to ªPERFORMANCE DIAGNO-
SISº in this section.
Switch ON : above ªCº and below ªDº
Switch OFF : below ªAº or above ªBº
ªAº: Approx. 200 kPa (2.0 kg / cm
2)
ªBº: Approx. 3200 kPa (32 kg / cm
2)
ªCº: Approx. 230 kPa (2.3 kg / cm
2)
ªDº: Approx. 2800 kPa (28 kg / cm
2)
Tightening torque:
Dual pressure switch: 10 N
.m (1.0 kg-m, 7.5 lb-ft)

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-51
G16 engine
J20 engine
H25 engine
3. Compressor pulley
4. Crankshaft pulley
INSTALLATION
FOR IWATA PRODUCTION VEHICLE
1) Pour new compressor oil. The amount must be the same with
the amount measured in REMOVAL.
NOTE:
Compressor assembly supplied from factory is filled up
with following amount of oil.
Amount of oil in compressor: 120 cm
3 (120 cc, 7.5 in3)
2)For G16 engine:
Install compressor assembly temporarily to bracket, then install
compressor drive belt (2).
For J20 and H25 engines:
Install compressor assembly to its bracket.
Tighten bolts (a) first, then (b).
Tightening Torque
(a), (b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
3) Connect suction and discharge hoses to compressor assembly.
4)For G16 engine:
Tension compressor drive belt (2) by tightening compressor as-
sembly mounting bolts. Refer to Section 3B1 for drive belt ten-
sion.
Tighten bolt (a) first, then (b).
Tightening Torque
(a), (b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
For J20 engine:
Install generator belt (1). Refer to Section 6H for details.
For H25 engine:
Install compressor drive belt (2). Refer to Section 3B1 for instal-
lation and belt tension.
5) Connect thermal protector lead wire.
6) Evacuate and charge system according to previously described
procedure.
CAUTION:
Be sure to use HFC-134a (R-134a) compressor oil.

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GRAND
VITARA
1B-52 AIR CONDITIONING (OPTIONAL)
G16 engine
J20 engine
3. Compressor pulley
4. Crankshaft pulley
FOR CAMI PRODUCTION VEHICLE
1) Pour new compressor oil. The amount must be the same with
the amount measured in REMOVAL.
NOTE:
Compressor assembly supplied from factory is filled up
with the following amount of oil.
Amount of oil in compressor: 120 cm
3 (120 cc, 7.5 in3)
2)For G16 engine:
Install compressor assembly temporarily to bracket, then install
compressor drive belt (2).
For J20 engine:
Install compressor assembly to its bracket.
Tighten bolts (a).
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
3) Connect suction and discharge hoses to compressor assembly.
4)For G16 engine:
Tension compressor drive belt (2) by tightening compressor as-
sembly mounting bolts. Refer to Section 3B1 for drive belt ten-
sion.
Tighten bolt (a) first, then (b).
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
For J20 engine:
Install generator belt (1). Refer to Section 6H for details.
5) Connect thermal protector lead wire.
6) Evacuate and charge system according to previously described
procedure.
CAUTION:
Be sure to use HFC-134a (R-134a) compressor oil.

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GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-55
1. Armature plate
4) Clutch pulley (1).
(1) Set clutch pulley squarely over clutch pulley installation boss.
(2) Place special tool (D) onto clutch pulley bearing.
Ensure that edge rests only on inner race of bearing.
(3) Install snap ring.
Special Tool
(D): 09991-06010
CAUTION:
Be careful not to scratch bearing seal.
5) Adjust clearance, between clutch plate (1) and clutch pulley by
putting shim on compressor shaft.
Standard clearance ªaº: 0.3 ± 0.5 mm (0.012 ± 0.02 in.)
6) Tighten new clutch plate bolt as specified below.
Tightening Torque
(a): 14 N
.m (1.4 kg-m, 10.5 lb-ft)
Special Tool
(A): 09991-06020