Brake SUZUKI GRAND VITARA 2009 Workshop Manual

7-7INSPECTION AND MAINTENANCE
79K21-03E
Maintenance Recommended under Severe Driving ConditionsIf the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is recommended that appli-
cable maintenance operation be performed at the particular interval shown in the chart below.
Severe condition code
A – Repeated short trips
B – Driving on rough and/or muddy roads
C – Driving on dusty roads
D – Driving in extremely cold weather and/or on salted roads
E – Repeated short trips in extremely cold weather
H – Towing a trailer
Severe
Condition CodeMaintenanceMaintenance
OperationMaintenance Interval
A – C D E H Engine oil and oil filter REvery 5000 km (3000 miles)
or 3 months
A B – D – H Exhaust pipes and mountings IEvery 10000 km (6000 miles)
or 6 months
– – C – – – Air cleaner filter element *1IEvery 5000 km (3000 miles)
or 3 months
REvery 25000 km (15000 miles)
or 15 months
– – C – – – Canister air suction filter REvery 100000 km (60000 miles)
or 60 months
ABC– – HBrake discs and pads (front)
Brake drums and shoes (rear)IEvery 10000 km (6000 miles)
or 6 months
– B – D E H Propeller shafts/Drive shafts IEvery 10000 km (6000 miles)
or 6 months
– B – – E H Manual transmission oil REvery 25000 km (15000 miles)
or 15 months
Maintenance Recommended under Severe Driving Condi-
tions: 1, 2, 3, 4, 5, 6, 9, 10

7-19INSPECTION AND MAINTENANCE
79K21-03E
Front differential
79K133
Rear differential
79K134
(1) Oil filler and level plug
(2) Oil drain plug
Gear Oil Level CheckThe manual transmission, transfer gears,
extension case and differentials (front and
rear) are lubricated with gear oil. To check
the gear oil level in any of the above loca-
tions, use the following procedure:
1) Park the vehicle on a level surface. Set
parking brake and 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 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 filler plug hole (1) until the
oil level reaches the bottom of the filler
hole, then reinstall the plug.
Gear Oil ReplacementTo change the gear oil in the manual trans-
mission, transfer case, extension 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.
(1)
(2)
(1)
(2)
WARNING
After driving the vehicle, gear oil tem-
perature may be high enough to burn
you. Wait until the oil filler plug is
cool enough to touch with your bare
hands before inspecting or replacing
gear oil.
CAUTION
When tightening these plugs, apply
sealing compound “SUZUKI Bond
No. 1217G” or equivalent to the plug
threads to prevent oil leakage and
tighten them to the specified torque
shown below.
Spark Plugs: 1, 2
Brakes: 6

7-20
INSPECTION AND MAINTENANCE
79K21-03E
Tightening torque
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.
Automatic Transmission
FluidSpecified FluidUse an automatic transmission fluid
SUZUKI ATF 3317 or Mobil ATF 3309.Fluid Level CheckYou 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. Oil Filler
PlugOil Drain
Plug
Manual
transmission23 Nm
(17.0 lb-ft)
(2.3 kg-m) 23 Nm
(17.0 lb-ft)
(2.3 kg-m)
Tr a n s f e r23 Nm
(17.0 lb-ft)
(2.3 kg-m) 23 Nm
(17.0 lb-ft)
(2.3 kg-m)
Extension
case23 Nm
(17.0 lb-ft)
(2.3 kg-m) 23 Nm
(17.0 lb-ft)
(2.3 kg-m)
Front
differential23 Nm
(17.0 lb-ft)
(2.3 kg-m) 23 Nm
(17.0 lb-ft)
(2.3 kg-m)
Rear
differential23 Nm
(17.0 lb-ft)
(2.3 kg-m) 23 Nm
(17.0 lb-ft)
(2.3 kg-m)
CAUTION
Driving with too much or too little
fluid can damage the transmission.
CAUTION
Be sure to use the specified auto-
matic transmission fluid. Using auto-
matic transmission fluid other than
SUZUKI ATF 3317 or Mobil ATF 3309
may damage the automatic transmis-
sion of your vehicle.
Brakes: 6

7-21INSPECTION AND MAINTENANCE
79K21-03E
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 gear,
pausing for about three seconds in
each range. Then move it back to the
“P” (Park) position.
60A205
The handle of the A/T fluid dipstick is col-
ored red for easy identification.
65D109
6) Remove the dipstick, clean it and push
it back in until the cap seats. Pull out
the dipstick and read the fluid level. The fluid level should be between the
two marks in the “HOT” range on the
dipstick.
7) Add just enough specified fluid through
the dipstick hole to fill the transmission
to the proper level.
Changing OilSince 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.
WARNING
Be sure to depress the brake pedal
when moving the gearshift lever, or
the vehicle can move suddenly.
EXAMPLE
or
FULL HOT
LOW HOT
CAUTION
After checking or adding oil, be sure
to insert the dipstick securely.
Brakes: 6

7-22
INSPECTION AND MAINTENANCE
79K21-03E
BrakesBrake 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 DOT3 brake fluid.
65D477
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.
(Continued)
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.
Steering Wheel: 6
Clutch Pedal: 6

7-23INSPECTION AND MAINTENANCE
79K21-03E
NOTE:
With disc brakes, the fluid level can be
expected to gradually fall as the brake
pads wear.Brake Pedal
79K138
With the engine running and the parking
brake set, measure the distance between
the brake pedal and floor carpet 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 carpet distance asmeasured above is less than the minimum
distance 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.
60G104
Pedal to floor carpet minimum distance
“a”
80 mm (3.1 in.)
“a”
Floor carpet
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
 (Except ABS equipped vehicle)
Pedal pulsation (pedal pulsates
when pressed for braking.)
Tires: 6

7-24
INSPECTION AND MAINTENANCE
79K21-03E
Parking Brake Lever
60A226
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.
Steering Wheel
78K080
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 specification or
you find anything else to be wrong, an
inspection must be performed by your
SUZUKI dealer.
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. Ratchet tooth specification “b”
5th – 7th
200 N (44 lbs, 20 kg)
“b”
EXAMPLE
Steering wheel play “c”
0 – 30 mm (0.0 – 1.2 in.)
“c”
EXAMPLE
(1)
(2)
Tires: 6

7-32
INSPECTION AND MAINTENANCE
79K21-03E Snow Tires
Your vehicle is equipped with all-sea-
son tires which are designed for use in
summer and most winter conditions.
For improved traction in severe winter
conditions, SUZUKI recommends
mounting radial snow tires on all four
wheels. Snow tires must be the same
size as the standard tires. Also be sure
to use the tires of the same type and
brand on all four wheels of your vehi-
cle.
GLOSSARY OF TIRE TERMI-
NOLOGYAccessory Weight – the combined
weight (in excess of those standard
items which may be replaced) of auto-
matic transmission, power steering,
power brakes, power windows, power
seats, radio, and heater, to the extent
that these items are available as fac-
tory-installed equipment (whether
installed or not).
Cold Tire Inflation Pressure – the pres-
sure in a tire that has been driven less
than 1 mile or has been standing for
three hours or more.
Curb Weight – the weight of a motor
vehicle with standard equipment
including the maximum capacity of
fuel, oil, and coolant, and, if so
equipped, air conditioning and addi-
tional weight optional engine.
Intended Outboard Sidewall – (1) the
sidewall that contains a whitewall,
bears white lettering or bears manu-
facturer, brand, and/or model name
molding that is higher or deeper than
the same molding on the other side-
wall of the tire, or (2) the outward fac-
ing sidewall of an asymmetrical tire
that has a particular side that mustalways face outward when mounted
on a vehicle.
Maximum Inflation Pressure – the
maximum cold inflation pressure a tire
is designed to support in normal ser-
vice.
Maximum Loaded Vehicle Weight –
the sum of curb weight, accessory
weight, vehicle capacity weight (total
load capacity), and production options
weight.
Normal Occupant Weight – 68 kilo-
grams times the number of occupants
specified in the second column of
Table 1 (shown below).
Occupant distribution – distribution of
occupants in a vehicle as specified in
the third column of Table 1 (shown
below).
Production Options Weight – the com-
bined weight of those installed regular
production options weighing over 2.3
kilograms in excess of those standard
items which they replace, not previ-
ously considered in curb weight or
accessory weight, including heavy
duty brakes, ride levelers, roof rack,
heavy duty battery, and special trim.
WARNING
(Continued) 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.
 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 construc-
tion.
Battery: 9
Fuses: 7

8-2
EMERGENCY SERVICE
79K21-03E
Jacking Instructions
75F062
1) Place the vehicle on level, hard ground.
2) Set the parking brake firmly and shift
into “P” (Park) if your vehicle has an
automatic transmission, or shift into “R”
(Reverse) if your vehicle has a manual
transmission.
3) Turn on the hazard warning flasher if
your vehicle is near traffic.
4) Block the front and rear of the wheel
diagonally opposite of the wheel being
lifted.
5) Place the spare wheel near the wheel
being lifted as shown in the illustration
in case that the jack slips.
64J194
79K058
(1) Jacking point
6) Position the jack as shown in the illus-
tration and raise the jack by turning thejack-head groove fits around the jacking
point beneath the vehicle body.
79K059
(2) Jack handle
(3) Wheel brace
7) Continue to raise the jack slowly and
smoothly until the tire clears the
ground. Do not raise the vehicle more
than necessary.
(1)
(1)
(3)
(2)
Jacking Instructions: 5

8-7EMERGENCY SERVICE
79K21-03E
Jump Starting Instructions
When jump starting your vehicle, use
the following procedure:
60A269
1) Use only a 12-volt battery to jump start
your vehicle. Position the good 12-volt
battery close to your vehicle so that the
jumper cables will reach both batteries.
When using a battery installed on
another vehicle, DO NOT LET THE
VEHICLES TOUCH. Set the parking
brakes fully on both vehicles.2) Turn off all vehicle accessories, except
those necessary for safety reasons (for
example, headlights or hazard lights).
60A270
52D129
WARNING
 Never attempt to jump start your
vehicle if the battery appears to be
frozen. Batteries in this condition
may explode or rupture if jump
starting is attempted.
 When making jumper cable con-
nections, be certain that your
hands and the jumper cables
remain clear from pulleys, belts or
fans.
 Batteries produce flammable
hydrogen gas. Keep flames and
sparks away from the battery or an
explosion may occur. Never smoke
when working near the battery.
 If the booster battery you use for
jump starting is installed in another
vehicle, make sure the two vehicles
are not touching each other.
 If your battery discharges repeat-
edly, for no apparent reason, have
your vehicle inspected by an autho-
rized SUZUKI dealer.
 To avoid harm to yourself or dam-
age to your vehicle or battery, fol-
low the jump starting instructions
below precisely and in order. If you
are in doubt, call for qualified road
service.
CAUTION
Your vehicle should not be started by
pushing or towing. This starting
method could result in permanent
damage to the catalytic converter.
Use jumper cables to start a vehicle
with a weak or run-down battery.12V BATTERY
EXAMPLE
Engine Hook
Charged Battery
Discharged
Battery
EXAMPLE