SUZUKI GRAND VITARA 2008 3.G Inspection And Maintenance Manual

Downloaded from www.Manualslib.com manuals search engine Manual transmission/Transfer
Manual transmission
(1) Oil filler and level plug (2) Oil drain plug
65D260
Front/rear differential .
Front differential
[f~~ (1)
I~~~ tfJ _(2) __ -,
Rear differential
(1) Oil filler and level plug (2) Oil drain plug
64J187
INSPECTION AND MAINTENANCE
Tightening torque
Oil Filler Oil Drain Plug Plug
23Nm 23 Nm
Manual Gasoline 2.3
kg-m 2.3 kg-m (17.0Ib-ft) (17.0Ib-ft) trans-
mission 35 Nm 35Nm· Diesel 3.5 kg-m
3.5 kg-m
(25.3 Ib-ft) (25.3 Ib-ft)
23Nm 23 Nm
Transfer 2.3 klbm 2.3 kg-m
(17.0 I -ft) (17.0 Ib-ft)
23 Nm
23 Nm
Front differential 2.3 kg-m
2.3 kg-m
(17.0 Ib-ft) (17.0 Ib-ft)
23 Nm 23 Nm
Rear differential 2.3 kg-m
2.3 kg-m
(17.0 Ib-ft) (17.0 Ib-ft)
Gear Oil Level Check To check the gear oil level, use the follow­ing procedure:
1) Park the vehicle on a level surface with
the parking brake applied. Then, stop
the engine.
2) Remove the oil filler plug (1). 3) Check the inside of the hole with your
finger. If the oil level comes up to the
bottom (transfer case: within 10 mm from the bottom) of the plug hole, the oil level is correct. If so, reinstall the plug. 4) If the oil level is low, add gear oil through the oil filler plug hole (1) until
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the oil level reaches the bottom of the Clutch Pedal filler hole, then reinstall the plug.
.A WARNING
After driving the vehicle, the gear oil
temperature may be high enough to
burn you. Wait until the oil filler
plug is cool enough to touch with your W\\N bare hands before inspecting gear
oil.
CAUTION
When tightening the plug, apply seal­ing compound "SUZUKI Bond No. 1215" or equivalent to the plug threads to prevent oil leakage.
Gear Oil Change To change the gear oil in the manual trans­mission, transfer case or differential(s), use
the following procedure:
1) Remove the oil filler plug (1). 2) Remove the drain plug (2), drain the oil, and reinstall the drain plug. 3) Pour new gear oil of the specified 'type
through the filler hole until the oil level reaches the bottom of the filler hole. 4) Reinstall the filler plug.
7-21
64J154
Check the clutch pedal for smooth opera­tion 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 SAE J1703 or DOT-3 brake fluid.
Automatic Transmission (AT)
Fluid
Specified Fluid Use an automatic transmission fluid
SUZUKI ATF 3317 or Mobil ATF 3309.
Fluid Level Check
CAUTION
Driving with too much or too little
fluid can damage the transmission.
You must check the fluid level with the
automatic transmission fluid at normal operating temperature.
To check the fluid level: 1) To warm up the transmission fluid, drive
the vehicle or idle the engine until the
temperature gauge indicates normal operating temperature. 2) Then drive for ten more minutes.
CAUTION
Be sure to use the specified auto­matic transmission fluid. Using auto­matic transmission fluid other than SUZUKI ATF 3317 or Mobil ATF 3309 may damage the automatic transmis­sion of your vehicle.

Downloaded from www.Manualslib.com manuals search engine NOTE: Do not check the fluid level if you have just driven the vehicle for a long time at high
speed, if you have driven in city traffic in hot weather, or if the vehicle has been pull­
ing a trailer. Wait until the fluid cools down
(about
30 minutes), or the fluid level indica­
tion will not be correct.
3} Park your vehicle on level ground. 4} Apply the parking brake and then start
the engine in "P" (Park). Let it idle for two minutes and keep it running during
the fluid level check. . 5} With your foot on the brake pedal, move the gearshift lever through each range,
pausing for about three seconds in each range. Then move it back to the "P" (Park) position.
A. WARNING
Be sure to depress the brake pedal
when moving the gearshift lever, or the vehicle can move suddenly.
EXAMPLE or
60A205
6} The handle of the AfT fluid dipstick is colored red for easy identification.
Remove the dipstick, clean it and push it back in until the cap seats. Then pull out the dipstick. 7} Check both sides of the dipstick, and read the lowest level. The fluid level should be between the two marks in the "HOT' range on the dipstick.
INSPECTION AND MAINTENANCE
(3)
I?
~ (1)
(2) Co
(1) FULL HOT (2) LOW HOT (3) The lowest point = Fluid level
64J188
8} Add just enough specified fluid through the dipstick hole to fill the transmission to the proper level.
CAUTION
After checking or adding oil, be sure to insert the dipstick securely.
Changing Oil Since special procedures, materials, and tools are required to change the automatic
transmission oil, it is recommended that you trust this job to your authorized . SUZUKI dealer.
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Fuel Filter (Diesel engine)
F9Q diesel
78K077
The fuel filter works as a water sedimentor
as well.
Drain water when the fuel filter warning
light comes on. To drain water: 1) Place a pan or ample rag under the fuel filter drain nozzle. 2) Loosen the drain knob. The water will be drained. 3) Tighten the drain knob when the water
changes to the diesel fuel. 4) Tighten the drain knob.
7-23
Brakes
Brake Fluid
64J154
Check the brake fluid level by looking at
the reservoir in the engine compartment.
Check that the fluid level is between the "MAX" and "MIN" lines. If the brake fluid level is near the "MIN" line, fill it up to the "MAX" line with SAE J1703 or DOT3 brake
fluid.
A WARNING
Failure to follow the guidelines below can result in personal injury or seri­
ous damage to the brake system. . • If the brake fluid in the reservoir drops below a certain level, the
brake warning light on the instru­
ment panel will come on (the
engine must be running with the
parking brake fully disengaged).
Should the light come on, immedi­
ately ask your SUZUKI dealer to inspect the brake system. . • A rapid fluid loss indicates a leak In the brake system which should be
inspected by your SUZUKI dealer
immediately.
• Brake fluid can harm your eyes and
damage painted surfaces. Use cau­
tion when refilling the reservoir. • Do not use any fluid other than SAE
J1703 or 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 parti­cles and other liquids are kept out of the brake fluid reservoir.

Downloaded from www.Manualslib.com manuals search engine A WARNING
Brake fluid is harmful or fatal if swal­lowed, and harmful if it comes in con­tact 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 a~ention. ~ash thoroughly after
handling. Solution can be poisonous to animals. Keep out of the reach of
children and animals.
NOTE: With disc brakes, the fluid level can be
expected to gradually fall as the brake
pads wear.
Brake Pedal Check. if the ~rake pedal·stops at the regu­lar height without "spongy" feeling when you depress it. If not, have the brake sys­tem inspected by your SUZUKI dealer. If you doubt the brake pedal for the regular
height, check it as follows:
. .
54G108
Pedal to wall minimum distance "a": 70 mm (2.8 in.)
With the engine running, measure the dis­tance between the brake pedal and floor
wall when the pedal is depressed with
approximate~y. 300 ~ (30 kg, 66 Ibs) of force: .The ~Inlmum distance required is as spec!fled. SIn?e vour vehicle's brake sys­tem IS self-adJusting, there is no need for
pedal adjustment.
If the pedal to floor wall distance as mea­sured above is less than the minimum dis­~ance required, have your vehicle Inspected by your SUZUKI dealer.
NOTE: When measuring the distance between the i?rake pedal and floor wall, be sure not to mclude the floor mat or rubber on the floor
wall in your measurement.
INSPECTION AND MAINTENANCE
60G104S
A WARNING
If you experience any of the following
problems with your vehicle's brake
system, have the vehicle inspected
immediately
by your SUZUKI dealer. • Poor braking performance • Uneven braking (Brakes not work-
ing uniformly on all wheels.) • Excessive pedal travel • Brake dragging • Excessive noise • Pedal pulsation (Pedal pulsates
when depressed.) .
7-24

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Parking Brake
EXAMPLE
Ratchet tooth specification "b": 5th -7th Lever pull force (1): 200 N (20 kg, 44 Ibs)
54G109
Check the parking brake for proper adjust­
ment by counting the number of clicks made by the ratchet teeth as you slowly pull up on the parking brake lever to the
point of full engagement. The parking brake lever should stop between the speci­
fied ratchet teeth and the rear wheels
should be securely locked. If the parking brake is not properly adjusted or the
brakes drag after the lever has been fully released, have the parking brake inspected
and/or adjusted by your SUZUKI dealer.
7-25
Steering
EXAMPLE
Steering wheel play "c": 0-30 mm (0.0 -1.2 in.)
\! "c"
{)
7BKOBO
Check the play of the steering wheel by gently turning it from left to right and mea­
suring the distance that it moves before
you feel slight resistance. The play should be between the specified values.
Check that the steering wheel turns easily and smoothly without rattling by turning it all the way to the right and to the left while driving very slowly in an open area. If the
amount of free play is outside the specifi­
cation or you find anything else to be wrong, an inspection must be performed by your SUZUKI dealer.
Power Steering (if equipped)
(1) UPPER (2) LOWER
(1)
(2)
64J155
Check the steering box case, vane pump and hose connections for leaks or damage.
Power Steering Fluid Check the fluid level by looking at the res­ervoir 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 eauivalent to DEXRON®-II, DEXRON@-IIE or DEXRON®-III. Do not overfill.

Downloaded from www.Manualslib.com manuals search engine Tires
54G307
The front and rear tire pressure specifica­tions for your vehicle are listed on the Tire Information Label. 80th the front and rear
tires should have the specified tire pres­sure.
Note that the value does not apply to the
compact spare tire, if equipped.
Tire Inspection Inspect your vehicle's tires at least once a
month by performing the following checks:
1) Measure the air pressure with a tire
gauge. Adjust the pressure if neces­sary. Remember to check the spare
tire, too.
A. WARNING
• Air pressures should be checked
when the tires are cold or you may
get inaccurate readings.
• Check the inflation pressure from time to time while inflating the tire gradually, until the specified pres­sure is obtained. • Never underinflate or overinflate the tires.
Underinflation can cause unusual
handling characteristics or can cause the rim to slip on the tire
bead, resulting in an accident or
damage to the tire or rim. Overinflation can cause the tire to burst, resulting in personal injury. Overinflation can also cause unusual handling characteristics
which may result in an accident.
INSPECTION AND MAINTENANCE
EXAMPLE
(1)
(2)
(1) Tread wear indicator (2) Indicator location mark
54G136
2) Check that the depth of the tread
groove is more than 1.6 mm (0.06 in.). To help you check this, the tires have molded-in tread wear indicators in the
grooves. When the indicators appear
on the tread surface, the remaining
depth of the tread is 1.6 mm (0.06 in.)
or less and the tire should be replaced. 3) Check for abnormal wear, cracks and
damage. Any tires with cracks or other
damage
should be replaced. If any tires
show abnormal wear, have them
inspected by your SUZUKI dealer.
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A WARNING
Hitting curbs and running over rocks
can damage tires and affect wheel
alignment.
Be sure to have tires and
wheel alignment checked periodically by your SUZUKI dealer.
4) Check for loose wheel nuts. 5) Check that there are no nails, stones or
other objects sticking into the tires.
A WARNING
• Your SUZUKI is equipped with tires
which are all the same type and
size. This is important to ensure
proper steering and handling of the
vehicle. Never mix tires of different
size
or type on the four wheels of
your vehicle. The size and type of
tires used should
be only those
approved by SUZUKI as standard or optional equipment for your
vehicle.
• Replacing the wheels and tires
equipped on your vehicle with cer­tain combinations of aftermarket
wheels and tires can significantly
change the steering
and handling
characteristics of your vehicle. • Therefore, use only those wheel and tire combinations approved by SUZUKI as standard or optional
equipment for your vehicle.
7-27
CAUTION
Replacing the original tires with tires of a different size may result in false
speedometer or odometer readings.
Check with your
SUZUKI dealer
before purchasing replacement tires
that differ
in size from the original
tires.
Tire Rotation Vehicle equipped with 225nOR16 tires
have a spare wheel and tire that are the
same size as the wheels and tires on the
vehicle, and
can use a 5-tire rotation as
shown in the example below.
5-tire rotation
L: Left hand drive R: Right hand drive
65D445
A WARNING
Never perform a 5-tire rotation when
the type and size of the spare wheel and tire are not the same as the other
wheels and tires equipped on your
vehicle.
Vehicle equipped with 225/65R17 tires
have a spare wheel and tire that are a dif­ferent size than the wheels and tires on the vehicle, and must use a 4-tire rotation as
shown in the example below.
4-tire rotation
Front
65D459
To avoid uneven wear of your tires and to
prolong their life, rotate the tires as illus­trated. Tires should be rotated every 10000 km (6000 miles). After rotation, adjust front
and rear tire pressures to the specification

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Label.
A. WARNING
Vehicle equipped with 225/65R17 tires have a spare wheel and tire that
are a different size than the wheels and tires on the vehicle. The ·spare
wheel and tire on these vehicles are
intended for temporary emergency
use only. The wheel is painted yellow to remind you that the wheel and tire
are for temporary use only. Continu­ous use of this spare can result in tire
failure and loss of control. Always observe these precautions when using this spare: • Be aware that your vehicle will han­
dle differently with this temporary
spare.
• Do not exceed 80 km/h (50 mph)
speed.
• Replace the temporary spare with a
standard tire and wheel as soon as possible.
• Do not operate your vehicle in "4H
LOCK" or "4L LOCK" with this tem­porary spare. • Do not use tire chains on the spare
tire. If you must use tire chains,
rearrange the wheels so standard
tires and wheels are fitted to the rear axle. (Continued)
A. WARNING
(Continued) • Replace the spare tire with a new
one as soon as the tread wear indi­cator appears. • When replacing the spare tire, use
a replacement tire with the exact
same size and construction.
INSPECTION AND MAINTENANCE
Battery
A. WARNING
• Batteries produce flammable hydrogen gas. Keep flames and
sparks away from the battery or an explosion may occur. Never smoke when working in the vicinity of the battery. • When checking or servicing the
battery, disconnect the negative cable. Be careful not to cause a short circuit by allowing metal objects to contact the battery posts and the vehicle at the same time. • To avoid harm to yourself or dam­age to your vehicle or battery, fol­low the jump starting instructions in the "EMERGENCY SERVICE" section of this manual if it is neces­sary to jump start your vehicle.
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EXAMPLE (traditional type)
~"'-"""'-UPPER
LOWER
54G118
For maintenance-free battery (cap-less type), you need not add water. For tradi­
tional type battery, which has water filler caps, the level of the battery solution must
be kept between the "UPPER" and the "LOWER" level lines at all times. If the level is found to be below the "LOWER" level
line, add distilled water to the "UPPER"
level line. You should periodically check the
battery, battery terminals, and battery hold-down bracket for corrosion. Remove
corrosion using a stiff brush and ammonia
mixed with water, or baking soda mixed
with water. After removing corrosion, rinse
with
clean water.
If your vehicle is not going to be driven for
a month or longer, disconnect the cable from the negative terminal of the battery to help prevent discharge.
7-29
Replacement of the battery
EXAMPLE (3) (1)
(2)
To remove the battery: 1) Disconnect the negative cable (1). 2) Disconnect the positive cable (2). 3) Remove the retainer nuts (3) and
remove the retainer (4). 4) Remove the battery.
To install the battery: 1) Install the battery in the reverse order of removal. 2) Tighten the retainer nuts and battery cables securely.
NOTE:
When the battery is disconnected, some of the vehicle's function will be initialized and/ or deactivated.
These function are required to reset after the battery is reconnected.
A WARNING
Batteries contain toxic substances including sulfuric acid and lead. They could have potential negative conse­quences for the environment and
human health. Used battery must be disposed or recycled according to
the local law and must not be dis­carded with ordinary household waste. Make sure not to tip over the
battery when you remove it from the vehicle. Otherwise, sulfuric acid could run out and you might get
injury.