clutch SUZUKI GRAND VITARA 2007 3.G Owners Manual

Downloaded from www.Manualslib.com manuals search engine Part No. 99011-66J21-03E
June, 2006
OWNER’S MANUAL
99011-66J21-03E GRAND VITARA
Printed in Japan
See page 1-1
12.5 mm
Keep With Vehicle At All Times.
Contains Important Information
On Safety, Operation & Maintenance.
SERVICE STATION INFORMATION
Fuel recommendation: Brake and clutch fluid:
Engine oil recommendation: Automatic transmission fluid:
Tire cold pressure:
For further details, see “Engine Oil and Filter” in the
“INSPECTION AND MAINTENANCE” section.DOT3
See the “Tire Information Label” located on the
driver’s door lock pillar.
2007Engine oil with “Starburst” symbol
Made from 100% recycled paper,
except for cover.
ENGLISH
Suzuki Red: PANTONE 485
Suzuki Blue: PANTONE 294
SUZUKI ATF 3317 or Mobil ATF 3309

Downloaded from www.Manualslib.com manuals search engine 8-6 VEHICLE LOADING AND TOWING
66J21-03E
60A186
WARNING
(Continued)
 Avoid “riding” the brakes. “Riding”
the brakes could cause the brakes
to overheat, resulting in reduced
braking efficiency. Use engine
braking as much as possible.
 Because of the added trailer
weight, your engine may overheat
on hot days when going up long or
steep hills. Pay attention to your
engine temperature gauge. If it indi-
cates overheating, pull off the road
and stop in a safe place. Refer to
the “If the Engine Overheats” in
“EMERGENCY SERVICE” section
for details on how to proceed.
WARNING
When parking your vehicle and con-
nected trailer, always use the follow-
ing procedure:
1) Apply the vehicle’s brakes firmly.
2) Have another person place wheel
chocks under the wheels of the
vehicle and the trailer while you
are holding the brakes.
3) Slowly release the brakes until the
wheel chocks absorb the load.
4) Fully engage the parking brake.
5) Manual Transmission – Shift into
Reverse or first gear and turn off
the engine.
Automatic Transmission – Shift
into Park and turn off the engine.
6) If you have a 4-wheel drive vehi-
cle, make sure the transfer switch
is not in “N” (Neutral).
(Continued)
WARNING
(Continued)
When starting out after parking:
1) Push in the clutch (if equipped)
and start the engine.
2) Depress the brake pedal, shift into
gear, release the parking brake
and slowly pull away from the
chocks.
3) Stop, apply the brakes firmly and
hold the brakes while you have
another person remove the
chocks.
Trailer Towing: 5, 11, 13

Downloaded from www.Manualslib.com manuals search engine 8-8 VEHICLE LOADING AND TOWING
66J21-03E
Before towing
64J147
Vehicles equipped with a transfer switch
may be towed from the front with all four
wheels on the ground. Be sure to use
proper towing equipment designed for rec-
reational towing and make sure that towing
speed does not exceed 90 km/h (55 mph).To tow a vehicle equipped with a trans-
fer switch with all four wheels on the
ground:
1) Turn the ignition key to the “ON” posi-
tion.
2) Place the transmission in “N” (Neutral)
and depress the brake pedal and the
clutch pedal fully (if equipped).
3) Use the transfer switch to shift into neu-
tral.
64J218
NOTE:
First, push in and turn the switch to the
mark (1) at the left of the “N” position, and
hold the switch in this position for 5 sec-
onds until the “N” indicator blinks, then turn
the switch to the “N” position.
When you turn the transfer switch to the
“N” position, “N” indicator will come on with
the buzzer sound.
4) Make sure the “N” light on the instru-
ment cluster comes on.
5) Shift the manual transmission lever into
2nd gear or the automatic transmission
lever into “P” (Park).
6) Turn the ignition key to the “ACC” posi-
tion to unlock the steering wheel.
WARNING
When you tow your vehicle, follow
the instructions below to avoid acci-
dents and damage to your vehicle. In
addition, be sure to observe govern-
ment and local requirements regard-
ing vehicle lighting and trailer hitches
or tow bars.
WARNING
A safety chain should always be used
when you tow your vehicle.
CAUTION
Do not tow your vehicle with either
front wheels or rear wheels directly
on the ground (and the transmission
in neutral). If you do, the transmis-
sion will be damaged fatally.
(1)
Towing Your Vehicle (recreational towing): 13

Downloaded from www.Manualslib.com manuals search engine 8-9 VEHICLE LOADING AND TOWING
66J21-03E
7) Release the parking brake.
Stop towing the vehicle every 300 km (200
miles). Start the engine. With the manual
transmission lever in 2nd gear (or the auto-
matic transmission lever in “D”) and the
transfer switch in neutral, rev the engine for
about one minute with the clutch engaged
(if equipped), to circulate oil in the transfer
case.
64J148
TOWING METHOD AFOUR WHEELS ON THE GROUND
Towing Your Vehicle (recreational towing): 13

Downloaded from www.Manualslib.com manuals search engine INSPECTION AND MAINTENANCE
9
66J21-03E
60G410
INSPECTION AND MAINTENANCEMaintenance Schedule ....................................................... 9-2
Periodic Maintenance Schedule ........................................ 9-3
Drive Belt ............................................................................. 9-7
Engine Oil and Filter ........................................................... 9-7
Gear Oil ................................................................................ 9-11
Automatic Transmission Fluid ........................................... 9-13
Engine Coolant .................................................................... 9-15
Windshield Washer Fluid ................................................... 9-17
Air Cleaner ........................................................................... 9-18
Spark Plugs ......................................................................... 9-18
Brakes .................................................................................. 9-19
Steering Wheel .................................................................... 9-21
Clutch Pedal ........................................................................ 9-22
Tires ...................................................................................... 9-22
Battery .................................................................................. 9-33
Fuses .................................................................................... 9-33
Headlight Aiming ................................................................. 9-36
Bulb Replacement ............................................................... 9-37
Wiper Blades ....................................................................... 9-42
Air Conditioning System .................................................... 9-45

Downloaded from www.Manualslib.com manuals search engine 9-5 INSPECTION AND MAINTENANCE
66J21-03E
R: Replace or change
I : Inspect and correct, replace or lubricate if necessaryInterval: This interval should be judged by odometer
reading or months, whichever comes first.miles (x 1000) 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75
km (x 1000) 12.52537.55062.57587.5100112.5125
months 7.5 1522.53037.54552.56067.575CHASSIS AND BODY
1. Clutch (for manual transmission)
Pedal and fluid level
–
I
–
I
–
I
–
I
–
I
*2. Brake discs and pads (front) – I – I – I – I – I
Brake drums and shoes
(rear)
–
I
–
I
–
I
–
I
–
I
*3. Brake hoses and pipes – I – I – I – I – I
4.Brake fluid level check, *replacement
–
I
–
I
–
I
–
R
–
I
5. Brake pedal stroke check, *adjustment – I – I – I – I – I
6.Parking brake lever and *cableLever movement check, *adjustment –I–I–I–I–I7.Tires (including tire rotation)
I
I
I
I
I
I
I
I
I
I
*8.Wheel discs IIIIIIIIII
*9.
Wheel bearings
–
I
–
*I
–
I
–
*I
–
I
*10. Suspension system – I – I – I – I – I
*11.
Propeller shafts/Drive shafts
–
I
–
I
–
I
–
I
–
I
*12. Manual transmission oil I – – R – I – R – I
13.
Automatic transmission (A/T)
Fluid level
–
I
–
I
–
I
–
I
–
I
*Fluid change Replace every 175000 km (105000 miles)-----5-speed A/T
*Fluid hose
–
–
–
–
–
I
–
–
–
–
*14. Transfer oil I – – I – I – R – I
*15.
Differential & Extension (for 2WD) oil
R
–
–
I
–
I
–
I
–
I
16. Steering system
Steering wheel movement,
*linkage
I
I
I
I
I
I
I
I
I
I
*17. Power steering (if equipped) I I I I I I I I I I
18.
All Latches, Hinges and Locks
I
I
I
I
I
I
I
I
I
I
19. Air conditioner filter (if equipped) – I – R – I – R – I
Periodic Maintenance Schedule: 1, 2, 3, 4, 5, 6, 9, 10

Downloaded from www.Manualslib.com manuals search engine 9-6 INSPECTION AND MAINTENANCE
66J21-03E
R: Replace or change
I : Inspect and correct, replace or lubricate if necessary
NOTE:
This table shows the service schedule up to 250000 km (150000 miles).
Beyond 250000 km (150000 miles), perform the same services at the same intervals shown in the chart.
Beyond 250000 km (150000 miles), the maintenance services enclosed with a rectangle are required.
Item 9 *I - inspect for wear.Interval: This interval should be judged by odometer
reading or months, whichever comes first.miles (x 1000) 82.5 90 97.5 105112.5 120 127.5 135 142.5 150
km (x 1000) 137.5 150 162.5 175 187.5 200 212.5 225 237.5 250
months 82.5 90 97.5 105 112.5 120 127.5 135 142.5 150CHASSIS AND BODY
1. Clutch (for manual transmission)
Pedal and fluid level
–
I
–
I
–
I
–
I
–
I
*2. Brake discs and pads (front) – I – I – I – I – I
Brake drums and shoes
(rear)
–
I
–
I
–
I
–
I
–
I
*3. Brake hoses and pipes – I – I – I – I – I
4.Brake fluid level check, *replacement
–
I
–
I
–
R
–
I
–
I
5. Brake pedal stroke check, *adjustment – I – I – I – I – I
6.Parking brake lever and *cableLever movement check, *adjustment –I–I–I–I–I7.Tires (including tire rotation)
I
I
I
I
I
I
I
I
I
I
*8.Wheel discs IIIIIIIIII
*9.
Wheel bearings
–
*I
–
I
–
*I
–
I
–
I
*10. Suspension system – I – I – I – I – I
*11.
Propeller shafts/Drive shafts
–
I
–
I
–
I
–
I
–
I
*12. Manual transmission oil – R – I – R – I – R
13.
Automatic transmission (A/T)
Fluid level
–
I
–
I
–
I
–
I
–
I
*Fluid change Replace every 175000 km (105000 miles)-----5-speed A/T
*Fluid hose
–
I
–
–
–
–
–
I
–
–
*14. Transfer oil – I – I – R – I – I
*15.
Differential & Extension (for 2WD) oil
–
I
–
I
–
I
–
I
–
I
16. Steering system
Steering wheel movement,
*linkage
I
I
I
I
I
I
I
I
I
I
*17. Power steering (if equipped) I I I I I I I I I I
18.
All Latches, Hinges and Locks
I
I
I
I
I
I
I
I
I
I
19. Air conditioner filter (if equipped) – R – I – R – I – R
Periodic Maintenance Schedule: 1, 2, 3, 4, 5, 6, 9, 10

Downloaded from www.Manualslib.com manuals search engine 9-22 INSPECTION AND MAINTENANCE
66J21-03E
NOTE:
With disc brakes, the fluid level can be
expected to gradually fall as the brake
pads wear.Brake Pedal
65D345
With the engine running and the parking
brake set, measure the distance between
the brake pedal and floor wall when the
pedal is depressed with approximately 300
N (66 lbs, 30 kg) of force. The minimum
distance required is as specified. Since
your vehicle’s brake system is self-adjust-
ing, there is no need for pedal adjustment.
If the pedal to floor wall distance as mea-
sured above is less than the minimum dis-tance required, have your vehicle
inspected by your SUZUKI dealer.
NOTE:
When measuring the distance between the
brake pedal and floor wall, push in the floor
carpet as far as it goes and measure the
distance between the carpet surface and
the brake pedal.
WARNING
(Continued)
 Do not use any fluid other than
DOT3 brake fluid. Do not use
reclaimed fluid or fluid that has
been stored in old or open contain-
ers. It is essential that foreign parti-
cles and other liquids are kept out
of the brake fluid reservoir.
WARNING
Brake fluid is harmful or fatal if swal-
lowed, and harmful if it comes in con-
tact with skin or eyes. If swallowed,
do not induce vomiting. Immediately
contact a poison control center or a
physician. If brake fluid gets in eyes,
flush eyes with water and seek medi-
cal attention. Wash thoroughly after
handling. Solution can be poisonous
to animals. Keep out of the reach of
children and animals.
CAUTION
The brake fluid should be replaced
according to the maintenance sched-
ule. Have the brake fluid replaced by
your SUZUKI dealer.
Pedal to wall minimum distance “a”
70 mm (2.8 in.)
“a”
Floor carpet
Steering Wheel: 6
Clutch Pedal: 6

Downloaded from www.Manualslib.com manuals search engine 9-24 INSPECTION AND MAINTENANCE
66J21-03E
Power Steering (if equipped)
64J155
(1) UPPER
(2) LOWER
Check the steering box case, vane pump
and hose connections for leaks or damage.Power Steering FluidCheck the fluid level by looking at the res-
ervoir in the engine compartment when the
fluid is cold (about room temperature).
Check that the fluid level is between the (1)
and (2) lines. If the fluid level is near the (2)
line, fill it up to the (1) line with an auto-
matic transmission fluid equivalent to ATF
DEXRON
®-II (Esso JWS 2326) or
DEXRON®-III. Do not overfill.
Clutch Pedal
64J154
Check the clutch pedal for smooth opera-
tion and clutch fluid level from time to time.
If clutch dragging is felt with the pedal fully
depressed, have the clutch inspected by
your SUZUKI dealer. If the clutch fluid level
is near the “MIN” line, fill it up to the “MAX”
line with DOT3 brake fluid.
TiresFor safe operation of your vehicle, it is
important that the tires be the correct type
and size, in good condition, and properly
inflated. Be sure to follow the requirements
and recommendations in this section.Tire Sidewall LabelingUseful information about a tire is molded
into its sidewall. The example below shows
a typical passenger car tire.
Typical Passenger Car Tire Sidewall
67D027
A. Tire Manufacturer
The name of the tire manufacturer is
shown here.
B. Tire Name/Model
The tire name or model is shown
here.
(1)
(2)
AH B
G
E
FD
J I
C
EXAMPLE
Tires: 6

Downloaded from www.Manualslib.com manuals search engine 15-1 INDEX
15
66J21-03E
INDEXSymbols“AIR BAG” Light
..................................................................4-8
“CRUISE” Indicator Light
...................................................4-9
“ESP OFF” Indicator Light .......................................... 4-6
, 6-20
“ESP OFF” Switch
...............................................................4-16
“ESP” (Electronic Stability Program) Warning Light
.......4-6
“ESP” Warning Light
...........................................................6-20
“PASS AIR BAG OFF” Indicator
.........................................4-14
“SET” Indicator Light
..........................................................4-9
Numerics5-Speed Automatic Transmission
......................................6-5
AA/T Selector Position Indicator
..........................................4-11
Accelerator Pedal
................................................................5-2
Accessory Socket ................................................................5-16
Adding Engine Coolant
.......................................................9-17
Adjusting Seat Position ......................................................2-18
Adjusting Seatbacks
...........................................................2-18
Air Cleaner
...........................................................................9-20
Air Conditioning System
.....................................................9-47
Anti-Lock Brake System (ABS)
..........................................6-16
Anti-Lock Brake System (ABS) Warning Light
.................4-5
Anti-Lock Braking System (ABS)
.......................................6-19
Armrest
.................................................................................5-7
Assist Grips
.........................................................................5-10
Audio Systems .....................................................................4-29
Automatic Heating and Air Conditioning System
(Climate Control) .................................................................4-25Automatic Locking Retractor (ALR)
.................................. 2-22
Automatic Transmission Fluid
.......................................... 9-15
Auto-On Headlight System
................................................ 3-6
BBasic Operations
................................................................ 4-32
Battery
.................................................................................. 9-35
Brake Assist System
.......................................................... 6-16
Brake Fluid
.......................................................................... 9-21
Brake Pedal ..................................................................5-2
, 9-22
Brake System Warning Light
............................................. 4-5
Brakes
.................................................................................. 9-21
Braking ................................................................................. 6-15
Break-In ................................................................................ 6-25
Brightness Control
............................................................. 4-11
Bulb Replacement ............................................................... 9-39
CCatalytic Converter
............................................................. 6-25
Changing Engine Oil and Filter
......................................... 9-11
Changing Wheels
................................................................ 9-29
Charging Light
.................................................................... 4-7
Child Lock System
.............................................................. 2-13
Child Restraint Systems
..................................................... 2-27
Cigarette Lighter and Ashtray
........................................... 5-17
Clock
.................................................................................... 4-17
Clutch Pedal
.................................................................5-2
, 9-24
Coat Hooks
.......................................................................... 5-11
Corrosion Prevention
......................................................... 11-1
Cruise Control
..................................................................... 3-10