brake fluid SUZUKI GRAND VITARA 2005 2.G Service Repair Manual
[x] Cancel search | Manufacturer: SUZUKI, Model Year: 2005, Model line: GRAND VITARA, Model: SUZUKI GRAND VITARA 2005 2.GPages: 801, PDF Size: 12.15 MB
Page 461 of 801
YH4
GRAND
VITARA
1. Dipstick (G16 / J20)
2. Dipstick (H25)
AUTOMATIC TRANSMISSION (4 A / T) 7B1-59
ON-VEHICLE SERVICE
MAINTENANCE SERVICE
FLUID LEVEL
LEVEL CHECK AT NORMAL OPERATING TEMPERATURE
1) Stop vehicle and place it level.
2) Apply parking brake and place chocks against wheels.
3) With selector at P position, start engine.
4) Warm up engine till fluid temperature reaches normal operating
temperature (70 ± 80C / 158 ± 176F). As a guide to check fluid
temperature, warm up engine till engine coolant temperature
meter indicated around 1 unit above ªCº point.
5) Keep engine idling and shift selector slowly to L and back to P
position.
6) With engine idling, pull out dipstick, wipe it off with a clean cloth
and put it back into place.
7) Pull out dipstick again and check fluid level indicated on it. Fluid
level should be between FULL HOT and LOW HOT. If it is below
LOW HOT, add an equivalent of DEXRON-III up to FULL HOT.
Fluid specification
An equivalent of DEXRON-III
NOTE:
DO NOT RACE ENGINE while checking fluid level, even af-
ter the engine start.
DO NOT OVERFILL. Overfilling can causes foaming and
loss of fluid through breather. Then slippage and trans-
mission failure can result.
Bringing the level from LOW HOT to FULL HOT requires
0.3 liters (0.64/0.53 US/lmp.pt).
If vehicle was driven under high load such as pulling a
trailer, fluid level should be checked about half an hour af-
ter it is stopped.
Page 485 of 801
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VITARA
1. Clutch pedal
2. Clevis lock nut
3. Push rod
1. Clutch master cylinder
2. Clutch pipe
3. Clutch hose
4. Clutch operating cylinder
1. Pipe
2. Hose
3. Spanner
4. Flare nut wrench2, (a)
7C1-4 CLUTCH
ON-VEHICLE SERVICE
CLUTCH PEDAL HEIGHT
Adjust clutch pedal height by loosening clevis lock nut and turning
push rod as shown.
Clutch pedal height is normal if clutch pedal is about
20 mm (0.79 in.) higher than brake pedal.
After adjusting, tighten lock nut to specified torque.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
CLUTCH PEDAL FREE TRAVEL
Depress clutch pedal, stop the moment clutch resistance is felt and
measure distance (clutch pedal free travel). Free travel should be
within following specification.
Pedal free travel ªaº: 15 ± 25 mm (0.6 ± 1.1 in.)
CLUTCH FLUID PIPE AND HOSE
REMOVAL
NOTE:
Do not allow fluid to get on painted surface.
1) Remove dust and dirt from each joint of hose and pipe to be dis-
connected and clean around reservoir cap.
2) Take out fluid with syringe or such.
3) Disconnect fluid pipe from hose.
NOTE:
To disconnect pipe from hose, separate them by using flare
nut wrench and spanner so as not to kink them.
Page 487 of 801
YH4
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VITARA
1. Master cylinder
1. Attaching bolt
2. Attaching nut
3. Clevis pin
ªAº
7C1-6 CLUTCH
INSTALLATION
1) To bleed air from master cylinder itself, tilt it as shown in figure
and add fluid into it.
NOTE:
After bleeding air from master cylinder, plug pipe hole in it
to prevent fluid from spilling out of it till pipe is connected.
2) Install master cylinder assembly and new gasket to body, attach-
ing bolt, nuts and push rod clevis pin.
NOTE:
Do not reuse gasket.
3) Torque attaching bolt and nut to specification.
4) Connect fluid pipe and torque flare nut to specification.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
(b): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
5) Apply grease to clevis pin and install it.
ªAº: Grease 99000-25010
6) Fill reservoir with specified brake fluid and check fluid leakage.
7) After installation, bleed air from system and check clutch pedal
free travel. Refer to BRAKE section for air bleeding procedure.
FLUID INSPECTION
Fluid level should be always between MIN and MAX lines on reser-
voir. If fluid decreases quickly, check for leakage, repair leaky point,
if any, and add fluid up to MAX level.
NOTE:
Brake fluid damages painted surface badly. Should it get on
painted surface, remove it immediately and clean surface
thoroughly.
Do not use shock absorber fluid or any other fluid which con-
tains mineral oil. Do not use container which has been used
for mineral oil or which is wet from water. Mineral oil will
cause swelling and distortion of rubber parts in hydraulic
clutch system and water will mix with brake fluid, lowering
fluid boiling point. Keep all fluid containers capped to pre-
vent contamination.
Make sure not to use fluid whose container cap was first
opened more than a year ago.
Page 488 of 801
YH4
GRAND
VITARA
3
4
1. Reservoir cap
2. Cylinder
3. Piston assembly
4. Push rod
5. Piston stopper
6. Circlip
7. Boot
8. Lock nut
9. Clevis
1. Circlip
2. Push rod
3. Piston
4. Cylinder
1. Circlip
2. Push rod
3. Piston stopper
CLUTCH 7C1-7
DISASSEMBLY AND ASSEMBLY CLUTCH
MASTER CYLINDER
DISASSEMBLY
1) Remove boot and then circlip with piston pushed in.
2) Remove push rod and blow compressed air gradually into hole
for pipe connection to remove piston assembly, using care to
prevent it from jumping out.
INSPECTION
Inspect all disassembled parts for wear or damage and replace
parts if necessary.
NOTE:
Wash disassembled parts with brake fluid.
Do not reuse piston assembly and circlip.
Inspect cylinder bore for scoring or corrosion. It is best to replace
corroded cylinder. Corrosion can be identified as pits or excessive
roughness.
NOTE:
Polishing bore of cylinder with anything abrasive is prohib-
ited, as damage to cylinder bore may occur.
Rinse cylinder in clean brake fluid. Shake excess rinsing fluid from
cylinder. Do not use a cloth to dry cylinder, as lint from cloth cannot
be kept away from cylinder bore surfaces.
ASSEMBLY
NOTE:
Before installation, wash each part in specified brake fluid.
1) Apply brake fluid to inside of piston assembly and cylinder body.
2) Install piston assembly into cylinder.
3) With piston pushed down, install circlip as shown.
And install boot.
Page 490 of 801
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CLUTCH 7C1-9
5) Fill reservoir with specified brake fluid and check for fluid leak-
age.
6) Bleed air from system and check clutch pedal free travel. Refer
to BRAKE section for air bleeding procedure.
Page 495 of 801
YH4
GRAND
VITARA
7C1-14 CLUTCH
09917-58010 (G16 engine)
09923-73210
(J20 and H25 engines)
Bearing remover09923-36330 (G16 engine)
09923-36320
(J20 and H25 engines)
Clutch center guide09924-17810
Flywheel holder09925-98210
Input shaft bearing installer
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN.mkg-mlb-ft
Flare nut161.611.5
Master cylinder nut131.39.5
Lock nut101.07.5
Flywheel boltsG16 engine787.856.5Flywheel boltsJ20 and H25 engines707.050.5
Clutch cover bolts232.316.5
Operating cylinder bolt505.036.5
Clutch hose union bolt232.316.5
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium grease
SUZUKI SUPER GREASE A
(99000-25010)Clutch master cylinder clevis pin.
Release fork.
Push rod tip of operating cylinder.
SUZUKI SUPER GREASE I
(99000-25210)Input shaft spline front end.
Clutch fluid
(Brake fluid)DOT3 or SAE J1703
Clutch reservoir.
Clutch master cylinder.
Clutch operating cylinder.
SealantSUZUKI BOND No.1215
(99000-31110)Flywheel bolts
SPECIAL TOOLS
Page 545 of 801
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1. To door switch (driver side) B / Bl
2. To transmission range switch G / Bl
(A / T vehicle only, if equipped) L
3. To transmission range switch G / O
(A / T vehicle only, if equipped) 2
4. To transmission range switch Y / G
(A / T vehicle only, if equipped) D
5. To transmission range switch O / Bl
(A / T vehicle only, if equipped) N
6. To transmission range switch O / G
(A / T vehicle only, if equipped) P
7. To transmission range switch R
(A / T vehicle only, if equipped) R
8. To ground B
9. To PCM (A / T vehicle only) W / B
10. To ECT sensor Y / W
11. To fuel level gauge Bl / W
12. To ground B / Y
13. To combination switch G / Y
NOTE:
Terminal arrangement of coupler viewed from harness side.
Coupler A Coupler B Coupler C
Coupler A Coupler B Coupler C
1. Blank ÐÐ
2. Blank ÐÐ
3. To ignition switch B / W
4. Blank ÐÐ
5. To ABS control module Bl / O
(if equipped)
6. To PCM (A / T vehicle only) Gr / Bl
7. To ABS control module Br
(if equipped)
8. To VSS Bl / Y
9. To combination switch G / R
10. To SDM (if equipped) Y / G or Bl
11. To main fuse W / Bl
12. To fuse box W
13. To combination switch R
14. To ECM (PCM for A / T vehicle) V
(if equipped)
15. To ECM (PCM for A / T vehicle) V / Y
16. To ECM (PCM for A / T vehicle) O / B
(if equipped)1. To ground B
2. To ECM (PCM for A / T vehicle) Br
3. To ignition switch (if equipped) V / R
4. To brake fluid level switch R / B
5. To parking brake switch V
6. To seat belt switch (if equipped) Gr / R
7. To generator W / R
8. To oil pressure switch Y / B
9. To combination switch R / Y
10. To ignition switch (if equipped) Bl / R or CHECK
or ENGINE
or ABSif equipped
if equippedif equipped
INSTRUMENTATION / DRIVER INFORMATION 8C-3
Page 547 of 801
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INSTRUMENTATION / DRIVER INFORMATION 8C-5
BRAKE AND PARKING BRAKE WARNING LIGHT
TroublePossible CauseCorrection
Brake warning light does
not light upBulb in combination meter blown
ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)
Printed plate in combination meter
faulty
Parking brake switch faulty
Brake fluid level switch faulty
Wiring or grounding faultyReplace bulb
Replace fuse to check for short
Replace printed plate
Replace parking brake switch
Replace brake fluid level switch
Repair
LIGHT REMAINDER WARNING BUZZER
TroublePossible CauseCorrection
Light remainder warning
buzzer shows no
soundingªTAILº fuse blown
Buzzer faulty
Wiring or grounding faulty
Driver side door switch faultyReplace fuse to check for short
Replace buzzer
Repair
Replace door switch
SEAT BELT WARNING LIGHT (IF EQUIPPED)
TroublePossible CauseCorrection
Seat belt warning light
does not light upBulb in combination meter blown
ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)
Seat belt switch faulty
Wiring or grounding faultyReplace bulb
Replace fuse to check for short
Replace seat belt switch
Repair
IGNITION KEY REMAINDER WARNING BUZZER (IF EQUIPPED)
TroublePossible CauseCorrection
Ignition key remainder
warning buzzer shows no
soundingªDOMEº fuse blown (Hard Top Model)
ªDOMº fuse blown (Canvas Top
Model)
Buzzer faulty
Wiring or grounding faulty
Driver side door switch faulty
Ignition key switch faultyReplace fuse to check for short
Replace buzzer
Repair
Replace door switch
Replace ignition key switch
CIGARETTE LIGHTER AND ACCESSORY SOCKET
TroublePossible CauseCorrection
Cigarette lighter /
accessory socket shows
no operationªCIGARº fuse blown (Hard Top Model)
ªCIGº fuse blown (Canvas Top Model)
Ignition switch faulty
Cigarette lighter / accessory socket
faulty
Wiring or grounding faultyReplace fuse to check for short
Replace ignition switch
Replace cigarette lighter / accessory
socket
Repair
Page 554 of 801
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VITARA
8C-12 INSTRUMENTATION / DRIVER INFORMATION
BRAKE AND PARKING BRAKE WARNING
LIGHT
BRAKE FLUID LEVEL SWITCH
INSPECTION
Check switch (1) for continuity.
If check result is not as specified, replace switch (reservoir).
OFF position (float up)
No continuity
ON position (float down)Continuity
PARKING BRAKE SWITCH
INSPECTION
Check switch (1) for continuity.
If check result is not as specified, replace switch.
OFF position
(parking brake lever released)
No continuity
ON position
(parking brake lever pulled up)Continuity
IGNITION KEY REMAINDER (IF EQUIPPED) /
LIGHT REMAINDER WARNING BUZZER
REMOVAL
1) Remove combination meter (1). Refer to COMBINATION ME-
TER in this section.
2) Remove buzzer unit (2) from combination meter.
INSTALLATION
Reverse removal procedure for installation.