transmission SUZUKI GRAND VITARA 2008 3.G Inspection And Maintenance Manual

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INSPECTION AND MAINTENANCE
Maintenance Schedule ....................................................... 7-2
Periodic Maintenance Schedule ........................................ 7-2
Maintenance Recommended under
Severe Driving
Conditions ........................................................................\
... 7-5
Drive Belt ........................................................................\
..... 7-7
Engine
Oil and Filter ........................................................... 7-8
Engine Coolant ..............................................................•..... \
7-13
Air Cleaner ., ........................................................................\
. 7-16
Spark Plugs ........................................................................\
. 7-17
Gear
Oil .................................................... ; ........................... 7-19
Clutch Pedal ........................................................................\

7-21 _
Automatic Transmission (AT) Fluid .................................. 7-21
Fuel Filter (Diesel engine) .................................................. 7-23
Brakes ........................................................................\
.......... 7-23
60G41 0 Steering ........................................................................\
........ 7-25
Power Steering
(if equipped) ............................................. 7-25
Tires ........................................................................\
.............. 7-26
Battery ........................................................................\
.......... 7-28
Fuses ...........................................
: ........................................ 7-30
Headlight Aiming ................................................................. 7-35
Head
Light Washer Fluid .................................................... 7-35
Bulb Replacement ............................................................... 7-35
Wiper Blades ....................................................................... \
7-42
Windshield Washer Fluid ................................................... 7-46
Air Conditioning System .................................................... 7-46

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60A187S
A. WARNING
You should take extreme care when working on your vehicle to prevent
accidental injury. Here are a few pre­
cautions that you should be espe­
cially careful to observe: (Continued)
7-1
A. WARNING
(Continued) • To prevent damage or unintended
activation of the air bag system or seat belt pretensioner system, be sure the battery is disconnected
and the ignition switch has been in
the "LOCK" position for at least 90 seconds before performing any
electrical service work on your SUZUKI. Do not touch air bag sys­tem components, seat belt preten­sioner system components or wires.
The wires are wrapped with yellow
tape or yellow tubing, and the cou­
plers are yellow for easy identifica­
tion.
• Do not leave the engine running in
garages or other confined areas. • When the engine is running, keep
hands, clothing, tools, and other objects away from the fan and drive belt. Even though the fan may not be moving, it can automatically turn on without warning. • 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). (Continued)
A. WARNING
(Continued) • Do not touch ignition wires or other ignition system parts when starting the engine or when the engine is
running, or you could receive an electric shock. • Be careful not. to touch a hot
engine, exhaust manifold and
pipes, muffler, radiator and water
hoses.
• Do not allow smOking, sparks, or flames around gasoline or the bat­
tery. Flammable fumes are present.
• Do not get under your vehicle if it is supported only with the portable jack provided in your vehicle. • Be careful not to cause accidental short circuits between the positive
and negative battery terminals.
• Keep used oil, coolant, and other fluids away from children and pets.
Dispose of used fluids properly;
never pour them on the ground, into sewers, etc ..

Downloaded from www.Manualslib.com manuals search engine EMISSION CONTROL SYSTEM *4-1 . Crankcase ventiiation -system .. *4'-2.-Fuel evaporatlve-em'issiOn control system -
BRAKE *5'-1. Brake discs and pads (front, rear) - . Brakedrunls and shoes -(if equippedf -*i)-2:Brake hoses arid pipes . --. -5:3. Brake-flu-iCl ---------------
i):4:-l3-rake lever and cable CHASSIS AND BODY '-S:1:Clutch ---~----
6-2. Tires *6:3. ",ii,rheels-*6-4. Drive shafts/Propeller shafts 'i3Tsuspensionsysiem -­-~6-if Steering-system ---.
*6-7. Manual transmission oil
*6-S. -Transfer- oil --. *6-9. Differentiai oil -6~ 6.~ Automatic transmission' -~
Check, -*Replacement
Check, -Adjustment -
(I:
1stJ"§.OQ9=k...m:~njYf
(R: 1st 15000 km-only)­
'Fluid-Ievel -------
*
Fluidc::hange' * Fll.Jid hOse . ,----
km (x1000) 15
miles (x1000)l 9
months I 12
-(Class 1] ---~--I--[Class 1] ..
INSPECTION AND MAINTENANCE
--I
30 18
24
. -_" . ----. -
I I
1-
I 45 60 75 I 90 I 27 36 I 45 I 54
36 48 I 60 I 72
~I---~ --l-':--I: '-~ --1--T . ,--~--------~ I - - -
I
------------.-----------'If------------1'1'----. -------,-R-'(1sffS066 km only) ------. -, 1--1--.---------._---
-------~..:----------~ ---T
.--, -Ft'or I
'-"T --1---
i
._-
.-. ---T
I -1-
I--T I - I
I
I
T I -----I -1---r
I '---R---
-----------_________ ~4_._
--, -Replace every 165000 km (99000 miles). -.. ----- . --.---------------. --'I' -,--.-. .. .. , .. -.. '--' "-1 -f 6-1 i. 'AII'hitches, hinges and locks . *6-f2~Power steerTng (if equipped) --_., _._._-"- ----,--------.---~---'--"----------.-----,--.--------.. --T ----.. -· .. -------1----'-"1
*6-13. Air conditioner filter element (if equipped) R I R
A WARNING
The shock absorbers are filled with high pressure gas. Never attempt to disassemble it or throw it into a fire. Avoid storing. it
near a heater or heating device'. When scrapping the absorber, the gas must be released from the absorber safely. Ask your dealer for assistance.
7-4

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Air
cleaner filter element --C -- -- -(Inspect or replace more frequently if necessary.)
- - - - --G -Fuel filter (Diesel engine)
(Change each time water is detected.)
-B - -E - -H Automatic transmission fluid change
-B - - - - - -Suspension bolts and ·nuts
-B C D - - -H Wheel bearings
-B -D E - -H Drive shafts and Propeller shafts
B E H Manual transmission oilfTransfer oil - - - - -Differential oil
Air conditioner filter element (if equipped) . - -C D -
-- -(Clean more frequently if the air flow from the air
conditioner decreases.)
NOTE: I - Inspect, clean, adjust, lubricate or replace as necessary
R - Replace or change
T - Tighten to the specified torque
INSPECTION AND MAINTENANCE
Maintenance
Operation Maintenance Interval
I
Every 2500 km (1500 miles)
R Every 30000 km (18000 miles)
. or 24 months
R Every 5000 km (3000 miles)
R Every 30000 km (18000 miles) or 24 months
T Every 15000 km (9000 miles) or 12 months
I Every 15000 km (9000 miles) or 12 months
I Every ~ 5000 km (9000 miles) or 12 months
Firsttime only:
15000 km (9000 miles) or 12 months .
R Second time and after:
Every 30000 km (18000 miles) or 24 months reckoning from 0 km (0 mile) or 0 month
I Every 15000 km (9000 miles) or 12 months .
R Every 45000 km (27000 miles) or 36 months
7-6

Downloaded from www.Manualslib.com manuals search engine Selection of Coolant CAUTION
SUZUKI LLC: Super (Blue) coolant;
SUZUKI LLC: Super (Blue) coolant is already diluted to the proper percent­
age. Do not dilute with distilled water additionally. Doing so may result in the possibility of freezing coolant and/or overheating.
To maintain optimum performance and durability of your engine, use SUZUKI Genuine Coolant or equivalent.
NOTE: If you replace the engine coolant other
than the SUZUKIl:.LC: Super (Blue), follow
.the schedule of SUZUKI LLC: Standard
(Green). To see the detail of the mainte­nance schedule, refer to "Periodic Mainte­nance Schedule" in this section.
This type of coolant is best for your cooling system as it: • Helps maintain proper engine tempera­ture. • Gives proper protection against freezing
and boiling.
• Gives proper protection against corro-
sion and rust. Failure to use the proper coolant can dam­age your cooling system. Your authorized SUZUKI dealer can help you select the
proper coolant.
CAUTION
To avoid damaging your cooling sys­tem: • Always use a high quality ethylene
glycol base non-silicate type cool­ant diluted with distilled water at the correct mixture concentration. • Make sure that the proper mix is 50/ 50 coolant to distilled water and in no case higher than 70/30. Concen­trations greater than 70/30 coolant to distilled water will cause over­heating conditions. • Do not use straight coolant nor plain water (except SUZUKI LLC: Super (Blue».
• Do not add extra inhibitors or addi­tives. They may not be compatible with your cooling system. • Do not mix different types of base coolants. Doing so may result in accelerated seal wear and/or the possibility of severe overheating and extensive engine/automatic
transmission damage.
INSPECTION AND MAINTENANCE
Coolant Level
Check Check the coolant level at the reservoir
tank, not at the radiator. With the engine cool, the coolant level should be between
the "FULL (MAXI)" and "LOW (MINI)" marks.
Adding Coolant
(For Gasoline Engine Model) If the coolant level is below the "LOW" mark, more coolant should be added. Remove the reservoir tank cap and add coolant until the reservoir tank level reaches the "FULt..:' mark. Never fill the res­ervoir tank above the "FULt..:' mark.
(For
Diesel Engine Model)
A. WARNING
It is hazardous to remove the degas­sing tank cap for Diesel engine when the water temperature is high,
because scalding fluid and steam may be blown out under pressure. Wait· until the coolant temperature has lowered before removing the cap.
If the coolant level is below the "MINI" mark, more coolant should be added. When the engine is cool, remove the degassing tank cap by turning it antic lock­wise slowly to release any pressure. And add coolant until the degassing tank level reaches the "MAXI" mark. Never fill the
degassing tank above the "MAXI" mark.
7-14

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Spark plug gap "a" IFR5J11/1FR6J11/SILFR6A11/41-990 1.0 -1.1 mm (0.039 -0.043 in.)
CAUTION
When replacing spark plugs, you should use the brand and type speci­fied for your vehicle. For the speci­fied plugs, refer to the "SPECIFICATIONS" section at the
end of this book. If you wish to use a
brand of spark plug other than the
specified plugs, consult your SUZUKI
dealer.
7-19
Gear Oil
Manual Transmission OillTransfer
Oil/Differential Oil
650259
When adding gear oil, use gear oil with the
appropriate viscosity and grade as shown
in the chart below. We highly recommend you use: API GL-4 SAE 75W-90 for manual trans­mission gear oil API GL-5 hypoid gear oil SAE 80W-90 for
front differential oil, rear differential oil and
transfer gear oil
Manual transmission oil (API GL-4)
< 75W-85,75W 90 > °C -30 -20 -10
0 10 20 30 40 I I I I . . I I of -22 -4
14 32 50 68 86 104
650571
Front differential oil,
rear differential oil and transfer oil (API GL-5 hypoid)
90 >
< 80W
90 > °C -30 -20 -10 0
10 20 30 40 I
I I I
I I I
I 'F -22 -4
14 32 50 68 86 104
650572

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
7-20

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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.
7-22

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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.