Suzuki Grand Vitara 1998 Service Manual

Page 2: Related Manual

Yh4 grand vol.1 related manual manual name manual no. Applicability sq416 / sq420 / sq625 unit repair manual 99501-65d01-xxx transmission, transfer and differentials (front and rear) of sq series. Sq416 / sq420 / sq625 wiring diagram manual 99512-65d10-015 applicable model mentioned in foreword of t...

Page 4: Section 0A

Yh4 grand vitara 0a general information 0a-1 section 0a general information contents how to use this manual 0a- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions 0a- 3 . . . . . . . . . . . . . . . . . . . . . ...

Page 6: Precautions

Yh4 grand vitara 1. Air bag wire harness 2. Passenger air bag (inflator) module 3. Sdm 4. Dlc 5. Contact coil 6. Driver air bag (inflator) module 7. Seat belt pretensioner (if equipped) general information 0a-3 precautions precaution for vehicles equipped with a supplemental restraint (air bag) syst...

Page 8

Yh4 grand vitara 1. Exhaust hole 1 1 ng general information 0a-5 warning: sdm during service procedures, be very careful when handling a sensing and diagnostic module (sdm). Never strike or jar the sdm. Never power up the air bag system when the sdm is not rigidly attached to the vehicle. All sdm an...

Page 10

Yh4 grand vitara general information 0a-7 general precautions the warning and caution below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be...

Page 12

Yh4 grand vitara general information 0a-9 when disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be re- installed correctly. After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leak...

Page 14

Yh4 grand vitara general information 0a-11 when checking connection of terminals, check its male half for bend and female half for excessive opening and both for locking (looseness), corrosion, dust, etc. Before measuring voltage at each terminal, check to make sure that battery voltage is 11v or hi...

Page 16

Yh4 grand vitara general information 0a-13 2v voltage drop continuity check 1) measure resistance between connector terminals at both ends of the circuit being checked (between a-1 and c-1 in the figure). If no continuity is indicated (infinity or over limit), that means that the circuit is open bet...

Page 18

Yh4 grand vitara 1. Check contact tension by inserting and removing just once. 2. Check each terminal for bend and proper alignment. General information 0a-15 intermittent and poor connection most intermittent are caused by faulty electrical connections or wir- ing, although a sticking relay or sole...

Page 20: Identification Information

Yh4 grand vitara g16 engine j20 engine h25 engine m / t (type1) 4-speed a / t m / t (type2) general information 0a-17 identification information body number the vehicle body number is on the left side of instrument panel and punched on the chassis inside the tire housing on the right front side. It ...

Page 22: Vehicle Lifting Points

Yh4 grand vitara when using frame contact hoist: 1. Front lifting point 2. Rear lifting point 3. Front general information 0a-19 vehicle lifting points warning when using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up the vehicle till 4 tires are a little of...

Page 24

Yh4 grand vitara general information 0a-21 a abs : anti-lock brake system atdc : after top dead center api : american petroleum institute atf : automatic transmission fluid alr : automatic locking retractor ac : alternating current a / t : automatic transmission a / c : air conditioning abdc : after...

Page 26: Metric Information

Yh4 grand vitara metric bolts–identification class numbers or marks correspond to bolt strength–increasing numbers represent increasing strength. Nut strength identification general information 0a-23 metric information metric fasteners most of the fasteners used for this vehicle are metric fasteners...

Page 28: Section 0B

Yh4 grand vitara 0b maintenance and lubrication 0b-1 section 0b maintenance and lubrication warning: for vehicles equipped with supplemental restraint (air bag) system: service on and around the air bag system components or wiring must be performed only by an autho- rized suzuki dealer. Refer to “ai...

Page 30

Yh4 grand vitara maintenance and lubrication 0b-3 interval: this interval should be judged by this table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at the same intervals respectively. This interval should be jud...

Page 32: Maintenance Service

Yh4 grand vitara 1. Crankshaft pulley 2. Water pump pulley 3. 100 n, 10 kg or 22 lb g16 h25 maintenance and lubrication 0b-5 maintenance service engine item 1-1 drive belt inspection and replacement warning: all inspection and replacement are to be performed with engine not running. Water pump and g...

Page 34

Yh4 grand vitara g16 with p / s g16 with p / s and a / c h25 with p / s h25 with p / s and a / c 1. Crankshaft pulley 2. P / s pump pulley 3. A / c compressor pulley (if equipped) 4. Tension pulley 5. Tension pulley bolts maintenance and lubrication 0b-7 power steering pump and / or a / c compressor...

Page 36

Yh4 grand vitara 2 1. Oil filter 2. Oil filter wrench maintenance and lubrication 0b-9 3) loosen oil filter by using oil filter wrench (special tool). Special tool (a): 09915-47310 (h25 engine) 09915-47330 (g16 and j20 engines) note: before fitting new oil filter, be sure to oil its o-ring. Use engi...

Page 38

Yh4 grand vitara maintenance and lubrication 0b-11 1. Reservoir 2. Full level mark 3. Low level mark 4. Arrow mark 5. Reservoir cap 5 4 6) add coolant to reservoir so that its level aligns with full mark. Then, reinstall cap aligning arrow marks on reservoir and cap. Note: when installing reservoir ...

Page 40

Yh4 grand vitara maintenance and lubrication 0b-13 item 3-3 fuel filter replacement warning: this work must be performed in a well ventilated area and away from any open flames (such as gas hot water heaters). Fuel filter is located at the front part of fuel tank, inside the right- hand side of chas...

Page 42

Yh4 grand vitara 1 1. Clutch pedal free travel maintenance and lubrication 0b-15 chassis and body item 6-1 clutch pedal inspection check clutch pedal for height and free travel referring to section 7c1. Adjust or correct if necessary. Fluid inspection 1) check around master cylinder and reservoir fo...

Page 44

Yh4 grand vitara 1. Wear indicator maintenance and lubrication 0b-17 item 6-6 tire inspection and rotation 1) check tires for uneven or excessive wear, or damage. If defective, replace. Refer to section 3 for details. 2) check inflating pressure of each tire and adjust pressure to specification as n...

Page 46

Yh4 grand vitara maintenance and lubrication 0b-19 11) check coil spring, upper rod, lower rod and lateral rod for de- formation and damage. 12) check upper rod, lower rod and lateral rod bushings and bump stopper for wear, damage and deterioration. 13) check other suspension parts for damage, loose...

Page 48

Yh4 grand vitara 1. Drain plug transfer front differential rear differential 1 2 1 2 maintenance and lubrication 0b-21 change 1) inspect transmission case for evidence of fluid leakage. Repair leaky point, if any. 2) make sure that vehicle is placed level for fluid level check. 3) change fluid. For ...

Page 50

Yh4 grand vitara 1. “upper” or “lower” mark maintenance and lubrication 0b-23 3) visually check pump drive belt for cracks and wear. 4) check belt for tension, referring to item 1-1. If necessary, have belt adjusted or replaced. Item 6-16 all hinges, latches and locks inspection doors check that eac...

Page 52

Yh4 grand vitara maintenance and lubrication 0b-25 steering check to ensure that steering wheel is free from in- stability, or abnormally heavy feeling. Check that the vehicle does not wander or pull to one side. Engine check that engine responds readily at all speeds. Check that engine is free from...

Page 54: General Description

Yh4 grand vitara 1. Side ventilator outlet 2. Side defroster outlet 3. Center ventilator outlet 4. Heater unit 5. Defroster duct 6. Ventilator duct 7. Heater control lever assembly 8. Heater mode control switch 9. Blower unit 10. Rear duct 1a-2 heater and ventilation general description the heater, ...

Page 56

Yh4 grand vitara 1a-4 heater and ventilation for lh vehicle for rh vehicle 1. From ignition switch 1 2. From ignition switch 2 3. From blower fuse 4. Head light relay 5. To a / c controller 6. Blower motor relay 7. Blower motor switch 8. Blower resistor 9. Blower motor 10. To ecm 11. To illumination...

Page 58

Yh4 grand vitara 1a-6 heater and ventilation 6) remove cooling unit (if equipped). Refer to item cooling unit (evaporator) removal in section 1b. 7) disconnect fresh air control cable from blower motor case. 8) remove blower motor unit (1) by removing its fastening nuts (2). 9) disconnect blower mot...

Page 60

Yh4 grand vitara 1a-8 heater and ventilation blower motor relay removal 1) disconnect negative (–) cable at battery. 2) disable air bag system, if equipped. Refer to disabling air bag system in section 10b. 3) open glove box, then remove screw. 4) remove glove box. 5) disconnect relay coupler. 6) re...

Page 62

Yh4 grand vitara 1a-10 heater and ventilation 2. Screws 1 2 heater mode control switch removal 1) disconnect negative (–) cable at battery. 2) if equipped with air bag system, disable air bag system. Refer to disabling air bag system in section 10b. 3) remove meter cluster hood (1) by removing its m...

Page 64

Yh4 grand vitara 1a-12 heater and ventilation 1. Temperature control lever 2. Fresh air control lever 1. Fresh air control cable 1. Heater unit 2. Control cable 1 2 installation 1) install in reverse order of removal procedure. 2) adjust cables as follows. (1) move control lever fully in arrow direc...

Page 66

Yh4 grand vitara 1. Blower motor switch connector 1 1a-14 heater and ventilation heater control lever assembly removal 1) disconnect negative (–) cable at battery. 2) if equipped with air bag system, disable air bag system. Refer to disabling air bag system in section 10b. 3) remove mode control swi...

Page 68

Yh4 grand vitara 1a-16 heater and ventilation 1. Heater unit 2. Heater core 3. Damper 4. Heater mode control actuator 5. Heater mode control switch 6. Heater control lever assembly heater unit.

Page 70

Yh4 grand vitara 1a-18 heater and ventilation 11) remove heater core pipe clamps (1) and grommet (2). 12) pull out heater core (1) from unit (2). Installation 1) install heater unit by reversing removal procedure, noting the following items. When installing each part, be careful not to catch any cab...

Page 72: Section 1B

Yh4 grand vitara 1b air conditioning (optional) 1b-1 general description 1b- 3 . . . . . . . . . . . . . . Identification of refrigerating system 1b- 3 . . . . Refrigerant flow of air conditioning system 1b- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Major components and location 1b- ...

Page 74: General Description

Yh4 grand vitara 1. Compressor label 2. Service valve seiko seiki denso air conditioning (optional) 1b-3 general description the air conditioning system of this model differs by the country of origin (the production plant.). One is japan (iwata) produced, other one is canada (cami) produced. For the...

Page 76

Yh4 grand vitara 1. Cooling unit 2. Compressor 3. Condenser assembly 4. Receiver / dryer 5. Discharge hose 6. Suction hose 7. Condenser outlet pipe 8. Liquid pipe 9. Expansion valve 10. Ventilation air 11. Foot air 12. Defroster air 13. Demister air 14. Fresh air 15. Recirculation air 16. Heater uni...

Page 78

Yh4 grand vitara air conditioning (optional) 1b-7 condition possible cause correction cool air does not come out or insufficient cooling (a / c system normal operative) compressor faulty air in a / c system air leaking from cooling unit or air duct heater and ventilation system faulty blower motor f...

Page 80

Yh4 grand vitara air conditioning (optional) 1b-9 abnormal noise from crankshaft pulley condition possible cause correction a large rattling noise is heard at idle or sudden acceleration. Loosen pulley mounting bolt. Worn or broken bearings. Retighten bolt. Replace bearings. Abnormal noise from tens...

Page 82

Yh4 grand vitara air conditioning (optional) 1b-11 compression system diagnosis compressor troubles are mainly following three types: gas leakage, noise and insufficient pressure. Compressor gas leakages in most cases develop from the shaft seal. When detecting gas leakage, always use a leak tester....

Page 84

Yh4 grand vitara air conditioning (optional) 1b-13 9) check for each pressure of low side and high side if it is within shaded range of graph. If each gauge reading is out of specified pressure, correct de- fective part referring to following test diagnosis table. Example: gauges should read as foll...

Page 86

Yh4 grand vitara air conditioning (optional) 1b-15 ambient temperature within 30 – 35 _ c (85 – 95 _ f) condition manifold gauge mpa (kg / cm 2 ) (psi) detail cause correction lo hi 0.23 – 0.35 (2.3 – 3.5) (33 – 50) 1.4 – 1.75 (14 – 17.5) (200 – 249) normal condition. —— —— negative pressure 0.5 – 0...

Page 88

Yh4 grand vitara air conditioning (optional) 1b-17 1. Blower motor main relay 2. Blower motor 3. Blower motor resistor 4. Blower motor switch 5. A / c controller 6. Ecm 7. Heater mode control switch 8. Evaporator temperature sensor 9. Refrigerant pressure switch for rh vehicle 10. Compressor relay 1...

Page 90

Yh4 grand vitara system circuit a. To heater fuse b. To rear defogger fuse c. To ignition / meter fuse d. To a / c fuse e. Only lh vehicle 1. Blower motor relay 2. Blower motor 3. Blower motor switch 4. A / c switch 5. Deflloster position switch 6. Deflloster / foot position switch 7. Dual pressure ...

Page 92

Yh4 grand vitara air conditioning (optional) 1b-21 terminal wire circuit measurement ground normal value condition ac2-1 l / y sensor ground ground to body (fig. A) – 0.4 – 0 volt engine running 1.5 volts (3150 ) evaporator thermistor temperature at approx. 15 _ c (59 _ f) with engine running ac2-2 ...

Page 94

Yh4 grand vitara charge 440 50 g, 14.2 1.9 oz of refrigerant in gas form air conditioning (optional) 1b-23 refrigerant recovery, evacuation and charging warning: d your eyes should not be exposed to refrigerant (liquid). Any liquid refrigerant-134a escaping by accident shows a temperature as low as ...

Page 96

Yh4 grand vitara for cami production vehicle for iwata production vehicle air conditioning (optional) 1b-25 evacuating evacuating procedure caution: do not evacuate before recovering refrigerant in system. Note: whenever opened (exposed to atmospheric air), air condition- ing system must be evacuate...

Page 98

Yh4 grand vitara 1. “hiss” air conditioning (optional) 1b-27 7) when refrigerant container (3) is emptied, use following proce- dure to replace it with a new refrigerant container (3). A. Close low pressure valve. B. Replace empty container (3) with a refrigerant container which has been charged wit...

Page 100

Yh4 grand vitara 1. Electric leak detector air conditioning (optional) 1b-29 removing manifold gauge set when a / c system has been charged with a specified amount of re- frigerant, remove manifold gauge set as follows: 1) close low pressure-side valve of manifold gauge set, (the high pressure-side ...

Page 102

Yh4 grand vitara air conditioning (optional) 1b-31 d tighten flared nuts to specified torque. Tightening torque (flared nut used for) 8 mm pipe: 13 n . M (1.3 kg-m, 9.5 lb-ft) 14.5 mm pipe: 23 n . M (2.3 kg-m, 16.6 lb-ft) 16 mm pipe: 33 n . M (3.3 kg-m, 23.8 lb-ft) d route drain hose so that drained...

Page 104

Yh4 grand vitara 2. Bolt for cami production vehicle for iwata production vehicle air conditioning (optional) 1b-33 a/c condenser assembly inspection check a) condenser fins for blockage b) condenser fittings for leakage c) condenser fins for damage clogged condenser fins should be washed with water...

Page 106

Yh4 grand vitara 1. Air flow air conditioning (optional) 1b-35 condenser cooling fan assembly inspection remove condenser assembly (refer to “a / c condenser as- sembly removal” in this section). Check continuity between terminal to terminal as shown. If check results are continuity, proceed to next...

Page 108

Yh4 grand vitara 1 for cami production vehicle for iwata production vehicle 1 air conditioning (optional) 1b-37 air filter element removal 1) disconnect negative (–) cable at battery. 2) for vehicle with air bag system, disable air bag system. Refer to “disabling air bag system” in section 10b. 3) p...

Page 110

Yh4 grand vitara air conditioning (optional) 1b-39 cooling unit (evaporator) removal 1) disconnect negative (–) cable at battery. 2) disable air bag system. Refer to “disabling air bag system” in section 10b. 3) recover refrigerant by using recovery and recycling equipment. Be sure to follow the ins...

Page 112

Yh4 grand vitara air conditioning (optional) 1b-41 inspection 1) check evaporator fins for blockage. If found clogged, use com- pressed air to clean the fins. Caution: do not use water for cleaning of evaporator. Be careful not to damage evaporator fins. If evaporator fin is bent, straighten it by u...

Page 114

Yh4 grand vitara 1. Evaporator thermistor temperature resistance ( ) air conditioning (optional) 1b-43 a/c evaporator thermistor (evaporator temperature sensor) a thermistor is a temperature sensor to sense the temperature of air discharged from evaporator. The electrical characteristic is shown in ...

Page 116

Yh4 grand vitara 1 1. Mode control switch coupler 2. A / c switch 3. Indicator lamp air conditioning (optional) 1b-45 a/c switch removal 1) disconnect negative (–) cable at battery. 2) if equipped with air bag system, disable air bag system. Refer to “disabling air bag system” in section 10b. 3) rem...

Page 118

Yh4 grand vitara pressure a b c d switch on (continuity) off (no continuity) air conditioning (optional) 1b-47 dual pressure switch inspection 1) check dual pressure switch (1) on liquid pipe for continuity at normal temperature (approx. 25 _ c (77 _ f)) when a / c system has a proper charge of refr...

Page 120

Yh4 grand vitara for cami production vehicle for iwata production vehicle 2. High pressure side (delivery side hose) 3. Lower pressure side (suction side pipe) air conditioning (optional) 1b-49 compressor assembly caution: none of refrigerant, compressor oil and component parts is interchangeable be...

Page 122

Yh4 grand vitara air conditioning (optional) 1b-51 g16 engine j20 engine h25 engine 3. Compressor pulley 4. Crankshaft pulley installation for iwata production vehicle 1) pour new compressor oil. The amount must be the same with the amount measured in removal. Note: compressor assembly supplied from...

Page 124

Yh4 grand vitara air conditioning (optional) 1b-53 1. Clutch plate bolt 2. Clutch plate 3. Circlip 4. Clutch pulley 5. Shim 6. Clutch coil 7. Compressor 5 6 7 magnet clutch assembly (for denso) inspection d inspect clutch plate and clutch pulley for signs of oil. D check clutch pulley for noise and ...

Page 126

Yh4 grand vitara air conditioning (optional) 1b-55 1. Armature plate 4) clutch pulley (1). (1) set clutch pulley squarely over clutch pulley installation boss. (2) place special tool (d) onto clutch pulley bearing. Ensure that edge rests only on inner race of bearing. (3) install snap ring. Special ...

Page 128

Yh4 grand vitara air conditioning (optional) 1b-57 3) using special tool (b), remove clutch plate (1). Special tool (b): 09991-06030 4) disconnect clutch coil lead wire from compressor thermal switch led wire. 5) remove felt ring (if equipped) and shims from shaft. 6) using special tool (c), remove ...

Page 130

Yh4 grand vitara air conditioning (optional) 1b-59 push 3. Cylinder 4. Case 5. O-ring 2. Bearing puller lip type seal (for seiko seiki) removal 1) remove magnet clutch assembly, referring to “magnet clutch assembly” in this section. 2) remove compressor front head (1) mounting bolt (10 pcs.). 3) rem...

Page 132: Required Service Material

Yh4 grand vitara air conditioning (optional) 1b-61 09900-06107 snap ring pliers (opening type) 09991-06010 magnet clutch pulley installer 09991-06020 armature plate spanner 09991-06030 armature plate remover 09991-06040 lip type seal protector 09991-06050 lip type seal installer required service mat...

Page 134

Yh4 grand vitara 3-2 steering, suspension, wheels and tires condition possible cause correction abnormal or excessive tire wear sagging or broken springs. Tire out of balance. Disturbed front end alignment. Faulty shock absorber. Hard driving. Overloaded vehicle. Tires not rotating. Worn or loose ro...

Page 136

Yh4 grand vitara 3-4 steering, suspension, wheels and tires condition possible cause correction wander or poor steering stability mismatched or uneven tires. Loose ball joints and tie rod ends. Faulty shock absorbers / struts or mounting. Loose stabilizer bar. Broken or sagging springs. Rack and pin...

Page 138: Tire Diagnosis

Yh4 grand vitara [a] [b] hard cornering under-inflation lack of rotation incorrect wheel alignment tire construction non-uniformity wheel heavy acceleration [a] [b] 3-6 steering, suspension, wheels and tires tire diagnosis irregular and/or premature wear irregular and premature wear has many possibl...

Page 140: Vibration Diagnosis

Yh4 grand vitara 3-8 steering, suspension, wheels and tires radial tire lead “lead” is the deviation of the vehicle from a straight path on a level road with no pressure on the steering wheel. Lead is usually caused by: 1) incorrect alignment. 2) uneven brake adjustment. 3) tire construction. The wa...

Page 142: Section 3A

Yh4 grand vitara 3a alignment service data (without load) toe-in (toe-in gauge measurement) “b” – “a”: 0 2 mm (0 0.08 in.) camber angle “c”: 0’ 1 caster: 2 40’ 1 *1. Forward *2. Body center [a] : top view [b] : front view 1. Center line of wheel front end alignment 3a-1 section 3a front end alignmen...

Page 144

Yh4 grand vitara 1. Turning radius gauge 1 front end alignment 3a-3 steering angle when tie rod end was replaced, check toe and then also steering angle with turning radius gauges. If steering angle is not correct, check if right and left tie-rods are equal in length (“a” in left figure). Steering a...

Page 146: General Description

Yh4 grand vitara 1. Power steering gear box 2. Power steering pump 3. P / s fluid reservoir 1. Power steering pump 2. Valve section 3. P / s fluid reservoir 4. Rack 5. Pinion 6. Cylinder 3b1-2 power steering (p / s) system general description power steering system the power steering (p / s) system i...

Page 148

Yh4 grand vitara 1. Suction connector 2. O-ring 3. Pressure switch 4. Flow control valve (relief valve) 5. Spring 6. Plug 7. Pump cover 8. Cam ring 9. Vane 10. Rotor 11. Snap ring 12. Side plate 13. Pulley (pump shaft) 14. Oil seal 15. Pump body 16. Flow control valve assembly 3b1-4 power steering (...

Page 150

Yh4 grand vitara 3b1-6 power steering (p / s) system condition possible cause correction vehicle pulls to one side during straight driving mismatched or uneven tire low or uneven tire inflation pressure brake dragging in one wheel front end alignment out of order rear end alignment out of order malf...

Page 152

Yh4 grand vitara [d] [c] [a] 1. P / s pump pulley 2. A / c compressor pulley (if equipped) 3. Crankshaft pulley 4. Tension pulley 5. Tension pulley bolts [a]: g16 type engine with a / c [b]: g16 type engine without a / c [c]: h25 type engine with a / c [d]: h25 type engine without a / c [b] 3b1-8 po...

Page 154

Yh4 grand vitara 1. P / s fluid reservoir 2. Attachment 3. Gasket 4. Union bolt 5. High pressure side 6. Low pressure side 1. P / s fluid reservoir 2. Gauge valve (open) 3. P / s pump 4. P / s gear box 5. High pressure side 6. Low pressure side 3b1-10 power steering (p / s) system hydraulic pressure...

Page 156

Yh4 grand vitara 3b1-12 power steering (p / s) system tie-rod end boot check check boot for crack and damage and if any, replace it with a new one. Air bleeding procedure 1) hoist the front end of vehicle and apply safety stands. 2) fill p / s fluid reservoir with fluid up to specified level. Note: ...

Page 158

Yh4 grand vitara 1. High pressure pipe 2. Union bolt 3. Low pressure hose 4. Steering lower shaft bolt 3b1-14 power steering (p / s) system 3) after installing wheels, lower vehicle and tighten wheel nuts to specified torque. Tightening torque (a): 100 n . M (10.0 kg-m, 72.5 lb-ft) 4) check that pro...

Page 160

Yh4 grand vitara 3b1-16 power steering (p / s) system 1. Clip 2. Wire make marking here rack boot and tie-rod (except canvas top lh model) removal caution: never disassemble tie-rod except for canvas top lh model. Performing this prohibited service will affect original per- formance. 1) remove steer...

Page 162

Yh4 grand vitara 3b1-18 power steering (p / s) system “a” 1 1 1. Mark 1. Tie-rod lock washer (a) installation 1) install new tie-rod lock washer and tie-rod to rack. 2) tighten tie-rod ball nut to specified torque. Tightening torque (a): 85 n . M (8.5 kg-m, 61.5 lb-ft) 3) bend lock washer 2 place at...

Page 164

Yh4 grand vitara 3b1-20 power steering (p / s) system 1. P/s fluid reservoir 2. Suction hose 1. P / s pulley 2. Mounting bolt 9. Vane 10. Rotor 11. Snap ring 12. Side plate 13. Pulley (pump shaft) 14. Oil seal 15. Pump body 16. Flow control valve assembly 1. Suction connector 2. O-ring 3. Pressure s...

Page 166

Yh4 grand vitara 3b1-22 power steering (p / s) system 1. Flow control spring 1. Oil seal 2. Shaft (pulley) 1. O-ring 1. Side plate 2. Bolt hole 1. Rotor 2. Snap ring 3. Dot check free length of relief valve spring. Free length: standard 22.0 mm (0.866 in.) limit 19.0 mm (0.748 in.) replace if any de...

Page 168

Yh4 grand vitara 3b1-24 power steering (p / s) system 1. Pump cover 1. Pressure switch 1. Suction connector 2. O-ring 1. Suction connector 15) gradually tighten new pump cover bolts to specified torque. Note: after installing pump cover, check to make sure that shaft can be turned by hand. Tightenin...

Page 170: Required Service Material

Yh4 grand vitara 3b1-26 power steering (p / s) system 09915-77420 oil pressure gauge attachment and hose set 09915-77410 oil pressure gauge 09943-55010 boot clamp plier tightening torque specification fastening parts tightening torque fastening arts n . M kg-m lb-ft gear box mounting bolts 55 5.5 40...

Page 172: Diagnosis

Yh4 grand vitara 1. Steering wheel pad 2. Steering wheel pad screw 3. Steering wheel nut 4. Steering wheel 5. Combination switch 6. Steering column upper cover 7. Steering column lower cover 8. Steering column assembly 9. Steering lock assembly 10. Steering column hole cover 11. Steering shaft joint...

Page 174

Yh4 grand vitara 1. Combination switch 1. Steering column hole cover : if equipped 2. Screw 1. Combination switch 2. Screw 1. Steering column cover screw 2. Steering column lower cover * 3. Steering column upper cover 3c-4 steering wheel and column combination switch removal 1) disconnect negative b...

Page 176

Yh4 grand vitara 1. Steering column assembly 2. Steering shaft joint 3. Marks 1. Steering column assembly 2. Steering shaft joint 3. Steering lower shaft assembly 4. Bolt (column side) 5. Bolt (lower shaft assembly side) 1. Steering column hole cover : if equipped * 3c-6 steering wheel and column 2)...

Page 178

Yh4 grand vitara 1. Steering column 2. Mounting bolt 3. Steering column lower seal 4. Dash panel 1. Steering column lower seal in engine room in cabin 3c-8 steering wheel and column 4) check steering column lower seal for breakage or deformation. If found defective, replace. 5) check steering shaft ...

Page 180

Yh4 grand vitara 1. Steering column 2. Steering lock 1. Center punch (with sharp point) 2. Steering lock mounting bolt 1. Steering column 2. Steering shaft 3c-10 steering wheel and column steering lock assembly (ignition switch) removal 1) remove steering column. Refer to “steering column” in this s...

Page 182

Yh4 grand vitara 1. Steering shaft joint 2. Bolt (steering column assembly side) 3. Bolt (lower steering shaft assembly side) 1. Steering column assembly 2. Steering shaft joint 3. Marks 1. Steering lower shaft assembly 2. Steering lower shaft assembly lower joint bolt 3. Steering shaft joint 1. Ste...

Page 184: Special Tool

Yh4 grand vitara 1. Lower position 2. Upper position 3c-14 steering wheel and column 09944-36011 steering wheel remover adjustable steering column release lever inspection check to make sure that the following: steering column moves smoothly when adjustable steering col- umn release lever is at lowe...

Page 186: General Description

Yh4 grand vitara 14 15 1. Driver air bag (inflator) module 2. Steering wheel 3. Steering wheel nut 4. Contact coil and combination switch assembly 5. Steering column upper cover 6. Steering column lower cover 7. Steering column assembly 8. Steering lock assembly 9. Steering column hole cover 10. Ste...

Page 188

Yh4 grand vitara 1 1 1 1. Mounting bolt 1. Driver air bag (inflator) module connector 2. Horn connector 3. Driver air bag (inflator) module 4. Steering wheel 3c1-4 air bag steering wheel and column drive air bag (inflator) module warning: when handling an air bag (inflator) module, be sure to read “...

Page 190

Yh4 grand vitara (a) 1 1. Make alignment marks 1. Steering wheel turn slowly till coil stops turn contact coil back about 2 and a half turns 1. Align marks 3c1-6 air bag steering wheel and column steering wheel caution: removal of the steering wheel allows the contact coil to turn freely but do not ...

Page 192

Yh4 grand vitara 1 1. Contact coil and combination switch assembly 2. Screw 1. Contact coil and combination switch assembly 1. Seal (if equipped, remove lock pin after installing contact coil and combination switch assembly.) 2. Lock pin (if equipped, remove lock pin after installing contact coil an...

Page 194

Yh4 grand vitara 1. Steering column assembly 2. Steering shaft joint 3. Marks 1. Steering column assembly 2. Steering shaft joint 3. Steering lower shaft assembly 4. Bolt (column side) 5. Bolt (lower shaft assembly side) 1. Steering column hole cover 1 3c1-10 air bag steering wheel and column remova...

Page 196

Yh4 grand vitara 1. Steering column 2. Mounting bolt 3. Steering column lower seal 4. Dash panel 1. Steering column lower seal in engine room in cabin 1. Shift (key) interlock cable 2. Screw 3c1-12 air bag steering wheel and column 4) check steering column lower seal for breakage or deformation. If ...

Page 198

Yh4 grand vitara 3c1-14 air bag steering wheel and column 1. Steering column 2. Steering lock 1 2 1. Center punch (with sharp point) 2. Steering lock mounting bolt 1. Steering column 2. Steering shaft steering lock assembly (ignition switch) removal 1) remove steering column. Refer to “steering colu...

Page 200

Yh4 grand vitara 2 1 1. Steering shaft joint 2. Bolt (steering column assembly side) 3. Bolt (steering lower shaft assembly side) 1. Steering shaft joint 2. Steering lower shaft assembly 1. Steering lower shaft assembly 2. Steering lower shaft assembly lower joint 3. Steering lower shaft assembly lo...

Page 202: Special Tool

Yh4 grand vitara 1. Lower position 2. Upper position 3c1-18 air bag steering wheel and column 09944-36011 steering wheel remover adjustable steering column release lever inspection check to make sure that the following: steering column moves smoothly when adjustable steering col- umn release lever i...

Page 204: General Description

Yh4 grand vitara 1. Body 2. Strut assembly 3. Steering knuckle 4. Suspension control arm (lower arm) 5. Ball stud 6. Wheel bearing 7. Axle shaft drive flange 8. Wheel 2wd 4wd 3d-2 front suspension general description the front suspension is the strut type independent suspension. The upper end of a s...

Page 206

Yh4 grand vitara 3d-4 front suspension suspension control arm joint check 1) check for smoothness of rotation. 2) inspect ball stud for damage. 3) inspect dust cover for damage. Replace any parts found defective in steps 1) – 3). Suspension control arm bushing check inspect for damage, wear or deter...

Page 208

Yh4 grand vitara 3d-6 front suspension 1. Strut tower bar 1. E-ring 1. Front wheel speed sensor harness clamp bolt 1. Strut bracket bolts 2. Lower arm 3. Jack 1. Strut support nuts strut damper removal 1) remove strut tower bar (if equipped). 2) hoist vehicle, allowing front suspension to hang free....

Page 210

Yh4 grand vitara 3d-8 front suspension 1. Circlip 2. Washer 1. Wire 1. Front wheel speed sensor 2. Harness clamp bolt coil spring removal 1) hoist vehicle, allowing front suspension to hang free. 2) remove wheels. 3) remove axle shaft drive flange (for 4wd vehicle). 4) remove front drive shaft circl...

Page 212

Yh4 grand vitara 3d-10 front suspension “a” 1. Circlip 2. Large diameter 1. Axle shaft drive flange 2. Bolt 1. Spring seat bottom installation reverse removal procedure to install coil spring. Note: upper and lower diameters of coil spring are different. Bring larger diameter end at bottom and set i...

Page 214

Yh4 grand vitara 3d-12 front suspension 1. Lock washer 2. Screws 1. Axle shaft drive flange wheel hub (included wheel bearing) removal 1) hoist vehicle and remove wheel. 2) remove axle shaft drive flange (4wd vehicle) or hub cap (2wd vehicle). 3) if equipped with abs, remove wheel speed sensor from ...

Page 216

Yh4 grand vitara 1. Wheel hub 2. Wheel spindle 3. Bearing inner race 1. Lock washer 1. Sensor rotor 2. Wheel hub 3. Hydraulic press ok ng 3d-14 front suspension 2) install new sensor rotor by using special tool (if equipped with abs). Note: use care not to insert wheel hub diagonally. Special tool (...

Page 218

Yh4 grand vitara 1. Axle shaft drive flange 2. Bolt 3. Hub cap 4. Wheel hub for 4wd vehicle for 2wd vehicle 3d-16 front suspension 11) apply sealant and install axle shaft drive flange or hub cap. For 4wd vehicle apply sealant mating surface of axle shaft drive flange, then install axle shaft drive ...

Page 220

Yh4 grand vitara “a” “b” 1. Wheel spindle 2. Drive shaft bearing 1. Wheel spindle 2. Drive shaft bearing 3. Front drive shaft thrust washer 4. Inner oil seal 5. Knuckle cap 6. Drive shaft oil seal type a type b 1. Drive shaft bearing 2. Wheel spindle 3d-18 front suspension 11) for 4wd vehicle remove...

Page 222

Yh4 grand vitara (a) 1. Axle shaft drive flange 2. Bolt 1. Hub cap 2. Wheel hub 3d-20 front suspension tighten control arm ball stud nut when tightening ball stud nut, use new nut and tighten it to speci- fied torque. Tightening torque (a): 60 n . M (6.0 kg-m, 43.5 lb-ft) for 2wd vehicle apply water...

Page 224

Yh4 grand vitara 3d-22 front suspension 1. Hydraulic press 2. Front bushing a: bushing flange contacts housing edge 1. Hydraulic press 2. Rear bushing a: bushing flange contacts housing edge installation 1) front bushing press-fit front bushing until its flange contacts housing edge of control arm, ...

Page 226: Required Service Materials

Yh4 grand vitara 3d-24 front suspension required service materials materials recommended suzuki product use no. Lithium grease suzuki super grease (a) (99000-25010) bearing inner oil seal / drive shaft oil seal recess of wheel spindles spindle outer washer spindle part of drive shaft spindle bush (i...

Page 228: Section 3E

Yh4 grand vitara 3e rear suspension 3e-1 general description 3e- 2 . . . . . . . . . . . . . . Diagnosis 3e- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosis table 3e- 3 . . . . . . . . . . . . . . . . . . . . . . Shock absorber check 3e- 3 . . . . . . . . . . . . . . . . Lower / up...

Page 230: Diagnosis

Yh4 grand vitara “a”: drill hole with approximately 3 mm (0.12 in.) diameter. Rear suspension 3e-3 diagnosis diagnosis table refer to section 3. Shock absorber check inspect for deformation or damage. Inspect bushings for wear or damage. Inspect for evidence of oil leakage. Replace any defective par...

Page 232: On-Vehicle Service

Yh4 grand vitara 1. Rear axle housing 2. Floor jack 1. Lock nut (if equipped) 2. Absorber nut 3. Upper support 4. Rubber bush 5. Lower support 6. Shock absorber 7. Bolt upper side lower side 1. Lock nut (if equipped) 2. Absorber nut 3. Body outside rear suspension 3e-5 on-vehicle service shock absor...

Page 234

Yh4 grand vitara 1. Rear axle housing 2. Spring seat 3. Coil spring 4. Stepped part 1. Body center 2. Body outside 1. Body center 2. Body outside 1. Parking brake cable hanger 2. Cross member 3. Clamp 4. Chassis frame rear suspension 3e-7 installation 1) install coil spring on spring seat of axle ho...

Page 236

Yh4 grand vitara 1. Clamp 2. Upper rod 1. Upper rod front bolt 2. Nut 3. Upper rod 4. Wheel speed sensor harness bracket (toward outside of body) 1. Upper rod 2. Bolt 5. Upper rod rear bolt 6. Washer 7. Body center 8. Front side rear suspension 3e-9 upper rod removal 1) hoist vehicle and remove rear...

Page 238

Yh4 grand vitara 1. Bearing retainer 2. Parking brake shoe lever 3. Clearance 1. Wheel speed sensor 1 l rear suspension 3e-11 4) remove wheel speed sensor from rear axle housing (if equipped with abs). Caution: do not pull wire harness or twist more than necessary when removing rear wheel speed sens...

Page 240

Yh4 grand vitara [b] 1 2 [a] 1. Bearing retainer 2. Oil seal 3. Wheel side 4. Differential side 1. Stud bolt 2. Nut 3. Washer 4. Flange of axle shaft 1. Axle shaft 2. Bearing retainer [a]: vehicle without abs [b]: vehicle with abs 1. Bearing 2. Retainer ring rear suspension 3e-13 installation instal...

Page 242

Yh4 grand vitara rear suspension 3e-15 1. Inner oil seal 2. Axle housing 1. Hammer 2. Screwdriver 3. Oil seal protector 4. Oil seal 5. Body center rear axle shaft inner oil seal removal 1) remove rear axle shaft. For details, refer to steps 1) to 7) of rear axle shaft removal in this section. 2) fix...

Page 244

Yh4 grand vitara 1. Flexible hose 2. E-ring 3. Brake pipe 4. Cross member 1. Lspv stay 1. Hose 2. Axle housing 1. Propeller shaft 2. Differential carrier rear suspension 3e-17 7) using special tools (b) & (c) indicated below, draw out axle shafts. For vehicle equipped with abs, remove wheel speed se...

Page 246

Yh4 grand vitara 1. Lower rod 2. Body center 1. Rear axle housing 2. Spring seat 3. Coil spring 4. Stepped part 1. Axle housing “a” 1. Body center 1 2 1 rear suspension 3e-19 installation install removed parts in reverse order of removal, noting the follow- ing. 1) place rear axle housing on floor j...

Page 248

Yh4 grand vitara 3. Container 1. Plug cap 2. Vinyl tube 1. Bearing retainer (e) (f) (g) rear suspension 3e-21 16) apply sealant to mating surface of bearing retainer with brake back plate. Note: make sure to remove old sealant before applying it anew. “b”: sealant 99000-31110 17) install rear axle s...

Page 250: Required Service Materials

Yh4 grand vitara rear suspension 3e-23 tightening torque specifications fastening parts tightening torque fastening arts n . M kg-m lb-ft shock absorber lock nut 29 2.9 21.0 shock absorber nut 29 2.9 21.0 shock absorber lower nut 85 8.5 61.5 lower rod bolt and nut upper rod bolt and nut 90 9.0 65.0 ...

Page 252: Section 3F

Yh4 grand vitara 3f wheels and tires 3f-1 general description 3f- 1 . . . . . . . . . . . . . . Tires 3f- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheels 3f- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement tires 3f- 1 . . . . . . . . . . . . . . . . ....

Page 254: Diagnosis

Yh4 grand vitara [a]: before correction [b]: corrective weights 1. Heavy spot wheel tramp 2. Balance weights addition point 3. C / l of spindle [c]: before correction [d]: corrective weights 1. Heavy spot wheel shimmy 2. Balance weights addition point 3. C / l of spindle wheels and tires 3f-3 diagno...

Page 256

Yh4 grand vitara 1. Front wheels and tires 3f-5 tire placard the tire placard is located on the driver’s side door lock pillar and should be referred to for tire information. The placard lists the maxi- mum load, tire size and cold tire pressure where applicable. Tire rotation to equalize wear, rota...

Page 258

Yh4 grand vitara wheels and tires 3f-7 tire mounting and demounting use tire changing machine to mount or demount tires. Follow equip- ment manufacturer’s instructions. Do not use hand tools or tire irons alone to change tires as they may damage tire beads or wheel rim. Rim bead seats should be clea...

Page 260: Section 4A2

Yh4 grand vitara 4a2 1. Drive shaft oil seal 2. Double off set joint (doj) 3. Joint circlip 4. Doj boot 5. Ball joint boot 6. Ball joint assembly (rh side) 7. Drive shaft assembly (lh side) 8. Left drive shaft 9. Drive shaft bearing circlip 10. Drive shaft bearing front drive shaft / shaft bearing, ...

Page 262: On-Vehicle Service

Yh4 grand vitara 1. Oil filler / level plug 2. Front drain plug 1. Circlip 2. Washer 1. Drive shaft flange bolts and nuts 1. Oil seal front drive shaft / shaft bearing, oil seal 4a2-3 on-vehicle service drive shaft removal (left side) 1) hoist vehicle and remove wheel. 2) remove axle shaft drive fla...

Page 264

Yh4 grand vitara 1. Boot 2. Snap ring 1. Circlip 2 snap ring plier 3. Cage front drive shaft / shaft bearing, oil seal 4a2-5 disassembly 1) remove boot band of differential side joint. 2) slide boot toward the center of shaft and remove snap ring from outer race, then take shaft out of outer race. 3...

Page 266

Yh4 grand vitara “a”: fill grease 90 – 95 g (3.2 – 3.4 oz) 1. Circlip [lh] [rh] differential side front drive shaft / shaft bearing, oil seal 4a2-7 7) apply grease to entire surface of cage. Use joint grease in tube included in spare part or joint grease (99000-25120). 8) insert cage into outer race...

Page 268

Yh4 grand vitara 1. Left drive shaft 2. Tire lever 1. Shaft bearing 1. Axle oil seal 2. Circlip 3. Axle bearing front drive shaft / shaft bearing, oil seal 4a2-9 shaft bearing/oil seal removal 1) remove drive shaft assembly. Refer to item drive shaft removal (left and right) in this section. For rig...

Page 270: Required Service Materials

Yh4 grand vitara front drive shaft / shaft bearing, oil seal 4a2-11 09913-75520 bearing installer 09924-74510 installer attachment 09930-30102 sliding shaft 09941-64510 bearing remover 09951-16090 oil seal installer tightening torque specifications fastening parts tightening torque fastening arts n ...

Page 272: Diagnosis

Yh4 grand vitara 4b-2 propeller shafts diagnosis diagnosis table condition possible cause correction abnormal noise loose universal joint bolt. Spider bearing worn out or stuck. Wear spider. Tighten universal joint bolt. Replace. Replace propeller shaft. Vibration deformed propeller shaft. Replace. ...

Page 274

Yh4 grand vitara 1. Vise 1. Spider 2. Bearing “a” 4b-4 propeller shafts 5) push out bearing race on flange yoke side as described in 1) and 2), and then, holding bearing race in a vise, tap flange yoke and take out race. (refer to the figure.) remove bearing race on the opposite side in the same way...

Page 276: Required Service Material

Yh4 grand vitara 4b-6 propeller shafts 09900-06108 snap ring pliers (closing type) 09926-48010 universal joint disassembling tool set tightening torque specification fastener tightening torque fastener n . M kg-m lb-ft propeller shaft nut / center support bolt 50 5.0 36.5 required service material m...

Page 278: General Description

Yh4 grand vitara [for vehicle without abs] [for vehicle with abs] 1. Master cylinder 2-1. 4-way joint 2-2. 2-way joint 3. Lspv (load sensing proportioning valve) 4. Rear axle housing 5. Abs actuator (h.U.) f.R.:front side 5-2 brakes general description when the foot brake pedal is depressed, hydraul...

Page 280

Yh4 grand vitara 5-4 brakes diagnosis table condition possible cause correction not enough brak- ing force brake oil leakage from brake lines. Brake disc or pads stained with oil. Overheated brakes. Poor contact of shoes on brake drum. Brake shoes linings stained with oil or wet with water. Badly wo...

Page 282

Yh4 grand vitara 5-6 brakes condition possible cause correction brake warning light turns on after engine start parking brake applied. Insufficient amount of brake fluid. Brake fluid leaking from brake line. Brake warning light circuit faulty. Malfunctioning ebd system, if equipped with abs. Release...

Page 284

Yh4 grand vitara 5-8 brakes 4) when fluid pressure in the cylinder is almost depleted, retigh- ten bleeder plug. 5) repeat this operation until there are no more air bubbles in hy- draulic line. 6) when bubbles stop, depress and hold brake pedal and tighten bleeder plug. For tightening torque specif...

Page 286

Yh4 grand vitara 5-10 brakes brake pedal play check pedal play should be within specification. If out of specification, check brake light switch for proper installation position and adjust if necessary. Also check pedal shaft bolt and master cylinder pin installation for looseness and replace if def...

Page 288

Yh4 grand vitara 1. Parking brake lever 2. Brake cable 3. Self locking nut 5-12 brakes parking brake check and adjustment check hold center of parking brake lever grip and pull it up with 20 kg (40 lbs) force. With parking brake lever pulled up as shown, count ratchet notches. There should be 5 to 7...

Page 290

Yh4 grand vitara 3. Lspv stay 1. Master cylinder 2. Disconnect brake pipe 1. Lspv lever 2. Lspv spring 3, “a” 2 1 2 (a) “a” “b” 5-14 brakes 3) depress brake pedal gradually till fluid pressure of front brake becomes as specified below and check corresponding pressure of rear brake then. It should be...

Page 292

Yh4 grand vitara 5-16 brakes check operation 1) with engine stopped, depress brake pedal several times with the same load and make sure that pedal travel doesn’t change. 2) start engine while depressing brake pedal. If pedal travel in- creases a little, operation is satisfactory. But no change in pe...

Page 294: Special Tools

Yh4 grand vitara 5-18 brakes 09950-78220 flare nut wrench (10 mm) 09900-20205 micrometer (0 – 25 mm) 09956-02310 fluid pressure gauge 09956-02210 brake circuit plug 09952-36310 / 09952-46510 pressure gauge attachment special tools.

Page 296: General Description

Yh4 grand vitara [a]: with abs [b]: without abs 1. Piston stopper circlip 2. Piston stopper 3. Cylinder cup 4. Plate 5. Primary piston 6. Piston cup 7. Primary piston return spring 8. Primary spring retainer 9. Secondary piston pressure cup 10. Secondary piston 11. Return spring secondary seat 12. S...

Page 298: Diagnosis

Yh4 grand vitara 5a-4 brakes pipe / hose / master cylinder diagnosis refer to section 5 (brakes) check and adjustment refer to section 5 (brakes) on-vehicle service front brake hose/pipe removal 1) raise and suitably support vehicle. Remove tire and wheel. This operation is not necessary when removi...

Page 300

Yh4 grand vitara 5a-6 brakes pipe / hose / master cylinder note: insert e-ring till its end surface is flush with or lower than bracket end surface. Tightening torque (a): 10 n . M (1.0 kg-m, 7.5 lb-ft) (b): 23 n . M (2.3 kg-m, 17.0 lb-ft) [c]: vehicle without abs for right hand steering vehicle [d]...

Page 302

Yh4 grand vitara 5a-8 brakes pipe / hose / master cylinder 1. Reservoir 2. Master cylinder 1. Reservoir 2. Connector pin 3. Grommets master cylinder reservoir removal 1) disconnect reservoir lead wire at coupler. 2) clean outside of reservoir. 3) take out fluid with syringe or such. 4) remove reserv...

Page 304

Yh4 grand vitara 4 3 1. Piston stopper circlip 2. Piston stopper 3. Cylinder cup and plate 4. Primary piston 5. Piston cup 6. Secondary piston pressure cup 7. Primary piston assy 8. Secondary piston 9. Secondary piston assy 10. Secondary piston stopper bolt 11. Master cylinder body 12. O-ring [a] [b...

Page 306

Yh4 grand vitara 5a-12 brakes pipe / hose / master cylinder vehicle not equipped with abs vehicle equipped with abs 1. Rod 2. Circlip 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 cups...

Page 308

Yh4 grand vitara 5 1 6 4 2 6 3 6 1. Brake master cylinder ass’y 2. Brake booster ass’y 3. Gasket 4. Push rod clevis 5. Nut 6. Clevis pin 7. Clip 8. Nut 9. Brake vacuum hose 1. Steering column 2. Push rod clevis 3. Brake pedal arm 4. Clevis pin 5. Clip 6. Nut 1. Abs hydraulic unit 2. Brake pipes 5a-1...

Page 310

Yh4 grand vitara 5a-16 brakes pipe / hose / master cylinder 1. Clevis 2. Nut 1. Steering column 4. Clevis pin 2. Push rod clevis 5. Clip 3. Brake pedal arm 6. Nut booster push rod clevis adjustment install push rod clevis so that measurement “a” is obtained and torque nut to specification. Tightenin...

Page 312

Yh4 grand vitara 5a-18 brakes pipe / hose / master cylinder 1. Lspv spring bolt 2. Lspv bolt 3. Brake pipe flare nut 4. Air bleeding plug 1. Lspv lever 2. Stopper bolt (if equipped) 3. Coil spring “a”: don’t turn (a) 2) torque each bolt and nut to specification as indicated respec- tively in figure....

Page 314: Section 5B

Yh4 grand vitara 5b front brake 5b-1 section 5b front brake note: all brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and / or could result in major repair expense. They must be replaced with one of same part number or with an equiv...

Page 316: Diagnosis

Yh4 grand vitara 1. Caliper 2. Caliper pin bolts 3. Disc 1. Caliper 2. Wire hook 3. Pad front brake 5b-3 diagnosis refer to section 5 (brakes). Check and adjustment refer to section 5 (brakes). On-vehicle service front disc brake pad removal 1) hoist vehicle and remove wheel. 2) remove caliper pin b...

Page 318

Yh4 grand vitara 1. Clips 2. Pads 3. Disc 4. Caliper carrier 5. Sensor 6. Shim 1. Caliper pin bolts electric brake caliper front brake 5b-5 installation note: see note at the beginning of this section. 1) install pad clips and pads. Note: install pad with sensor to body center side of caliper. 2) in...

Page 320

Yh4 grand vitara front brake 5b-7 2) remove piston seal using a thin blade like a thickness gauge, etc. Caution: be careful not to damage inside (bore side) of cylinder. Inspection cylinder boot check boots for breakage, crack and damage. If defective, replace. Piston seal excessive or uneven wear o...

Page 322

Yh4 grand vitara 1. Caliper pin bolts 1. Flexible hose bolt front brake 5b-9 caliper before installing caliper (cylinder body) to carrier, check to ensure that guide pin (pin bolt) inserted in each caliper carrier hole can be moved smoothly in thrust direction. Note: where temperature gets as low as...

Page 324: Required Service Material

Yh4 grand vitara front brake 5b-11 tightening torque specifications fastening parts tightening torque fastening arts n . M kg-m lb-ft brake caliper bleeder plug (for sumitomo electric brake caliper) 8.0 0.80 6.0 brake caliper bleeder plug (for tokico brake caliper) 8.5 0.85 6.5 caliper pin bolt (for...

Page 326: General Description

Yh4 grand vitara 1. Brake back plate 2. Brake shoe 3. Shoe return upper spring 4. Adjuster 5. Shoe return lower spring 6. Adjuster lever 7. Adjuster spring 8. Shoe hold down spring 9. Shoe hold down pin 10. Wheel cylinder 11. Link 12. Brake strut (a) tightening torque (a): 7.5 n . M (0.75 kg-m, 5.5 ...

Page 328

Yh4 grand vitara 1. Parking brake cable 2. Equalizer 3. Pin 4. Parking brake lever bolt 5. Parking brake lever assembly 5c-4 parking and rear brake installation 1) install in reverse order of removal procedure. Check equalizer inclined angle. Angle “a”: within 15 degrees tightening torque (a): 23 n ...

Page 330

Yh4 grand vitara 1. Brake back plate 2. Cable cap 3. Brake cable 1. Parking brake shoe lever 2. Spring 3. Nipple end 5c-6 parking and rear brake installation install parts in reverse order of removal procedure, noting the fol- lowing. 1) install brake cable cap to brake back plate securely as shown ...

Page 332

Yh4 grand vitara 1. Pawl lever 2. Adjuster 3. Brake shoes 5c-8 parking and rear brake cracked, scored, or grooved drum a cracked, drum is unsafe for further service and must be replaced. Do not attempt to weld a cracked drum. Smooth up any slight scores. Heavy or extensive scoring will cause excessi...

Page 334

Yh4 grand vitara 5c-10 parking and rear brake 1. Retainer 2. Parking brake shoe lever 3. Brake shoe 6) remove parking brake shoe lever from brake shoe. Inspection parking shoe lever inspect brake shoe lever for free movement against brake shoe web. If defective, correct or replace. Strut, adjuster c...

Page 336

Yh4 grand vitara 1. Wheel cylinder 1. Brake back plate 2. Brake pipe flare nut 3. Brake pipe 4. Wheel cylinder bolts 1. Bleeder plug cap 5c-12 parking and rear brake wheel cylinder removal 1) perform steps 1) to 5) of brake drum removal. 2) perform steps 2) to 4) of brake shoe removal. 3) loosen bra...

Page 338

Yh4 grand vitara 5c-14 parking and rear brake 1 2 3 1. Brake back plate 2. Cable cap 3. Brake cable 1. Wheel bearing retainer nut 1. Rear axle shaft 2. Wheel bearing 3. Brake back plate (a) brake back plate removal 1) perform steps 1) to 5) of brake drum removal. 2) perform steps 2) to 4) of brake s...

Page 340

Yh4 grand vitara 5c-16 parking and rear brake 1. Brake back plate 2. Cable cap 3. Parking brake cable 6) install wheel cylinder, and tighten wheel cylinder bolts and brake pipe flare nut (or nuts) to specified torque. (refer to steps 1) to 4) of wheel cylinder installation of this section.) 7) insta...

Page 342: Section 5E1

Yh4 grand vitara 5e1 antilock brake system (abs) (optional) 5e1-1 general description 5e1- 2 . . . . . . . . . . . . . . Brake hose / pipe routing 5e1- 3 . . . . . . . . . . . . . . System schematic 5e1- 4 . . . . . . . . . . . . . . . . . . . . Abs component parts location 5e1- 5 . . . . . . . . Ab...

Page 344

Yh4 grand vitara 1. Front disk brake 2. Rear drum brake 3. Abs hydraulic unit / control module assembly with abs pump motor relay and fail-safe relay 4. Brake master cylinder / reservoir lh steering vehicle rh steering vehicle antilock brake system (abs) (optional) 5e1-3 brake hose/pipe routing.

Page 346

Yh4 grand vitara 1. Wheel speed sensor (right-front) 2. Stop lamp switch 3. Data link connector 4. “abs” warning lamp 5. Wheel speed sensor (right-rear) 6. Wheel speed sensor (left-rear) 7. Ground 8. Diagnosis connector (black connector) 9. Wheel speed sensor (left-front) 10. Abs hydraulic unit/cont...

Page 348: Diagnosis

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-7 diagnosis to ensure that the trouble diagnosis is done accurately and smooth- ly, observe “precautions in diagnosing troubles” and follow “abs diagnostic flow table”. Precaution in diagnosing troubles if the vehicle was operated in any of...

Page 350

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-9 1-1. Customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown below will facilitate collecting information...

Page 352

Yh4 grand vitara example: when right-front wheel speed sensor circuit opens (dtc 21) 1. Diagnosis connector (6 pins connector) 2. Ground terminal 3. Diag. Switch terminal 4. Service wire voltmeter indicator (or “abs” warning lamp) high (on) low (off) time (sec.) 1. Ebd warning lamp (brake warning la...

Page 354

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-13 1. Data link connector (dlc) 1. Diagnosis connector (6 pins connector) 2. Ground terminal 3. Diag. Switch terminal 4. Service wire dtc check (using suzuki scan tool) 1) after setting cartridge for abs to suzuki scan tool, connect su- zuk...

Page 356

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-15 1. Battery 2. Main fuses 3. Ignition switch 4. Circuit fuses 5. Abs hydraulic unit / control module 5-1. Terminal arrangement for abs hydraulic unit / control module assembly 5-2. Abs fail-safe relay (solenoid valve relay) 5-3. Abs pump ...

Page 358

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-17 1. Abs hydraulic unit / control module connector table – b “abs” warning lamp circuit check – lamp comes “on” steady refer to table – a for system circuit diagram and circuit description. Inspection step action yes no 1 perform diagnosti...

Page 360

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-19 - 1. “abs” warning lamp - 2. Abs hydraulic unit / control module assembly - 3. Diagnosis connector 3-1. Diag. Switch terminal 3-2. Diag. Ground terminal - 4. Abs hydraulic unit/ control module connector of harness 1. Abs hydraulic unit /...

Page 362

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-21 1. Ignition switch 2. G sensor 3. Abs hydraulic unit control module assembly 4. Abs hydraulic unit/ control module connector of harness o / g dtc 15 (dtc c1015) – g sensor circuit (for 4wd model only) description while a vehicle is at st...

Page 364

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-23 1. Ignition switch 2. Abs hydraulic unit / control module assembly 3. Left-front wheel speed sensor 4. Right-front wheel speed sensor 5. Left-rear wheel speed sensor 6. Right-rear wheel speed sensor 7. Abs hydraulic unit / control connec...

Page 366

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-25 1. Abs hydraulic unit / control module connector fig. 1 fig. 2 fig. 3 fig. 4 fig. 5.

Page 368

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-27 1. Abs hydraulic unit/ control module assembly 2. Abs hydraulic unit/ control module connector 1. Abs hydraulic unit / control module connector dtc 57 (dtc c1057) – solenoid and pump motor power source circuit description the abs control...

Page 370

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-29 1. Ignition switch 2. Abs hydraulic unit/ control module assembly 3. Abs hydraulic unit/ control module connector of harness 2 1. Abs hydraulic unit / control module connector dtc 63 (dtc c1063) – abs fail-safe relay circuit description ...

Page 372: On-Vehicle Service

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-31 1. Diagnosis connector (6 pins connector) 2. Diag. Switch terminal 3. Ground 4. Service wire brake pedal ignition sw. Motor solenoid rear 3.0 sec. 3.0 on-vehicle service precaution when connector are connected to abs hydraulic unit / con...

Page 374

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-33 1. Abs hydraulic unit / control module assembly 2. Nut 1. To left-front 2. To right-front 3. To rear 4. From master cylinder 4) remove three nuts and take out abs hydraulic unit / control module assembly from bracket. Caution: do not giv...

Page 376

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-35 forward 1. Front wheel speed sensor connector 2. Headlight assembly 1. Front wheel speed sensor 2. Bolt removal 1) disconnect negative cable at battery. 2) hoist vehicle and remove wheel. 3) disconnect front wheel speed sensor connector....

Page 378

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-37 1. Rear wheel speed sensor 2. Sensor rotor 3. Rear axle housing 1. Rear wheel speed sensor harness 2. Connector 1. Sensor bolt 2. Clamps rear wheel speed sensor output voltage inspection check in the same procedure as that used of front ...

Page 380

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-39 1. Rear axle 2. Retainer ring 3. Sensor rotor 4. Vinyl envelope “a” grind with grinder “a” 1. Sensor rotor 4 3 1 2 2 1 3 rear sensor rotor removal 1) remove rear axle shaft. Refer to rear axle shaft re- moval in section 3e. 2) in order t...

Page 382

Yh4 grand vitara antilock brake system (abs) (optional) 5e1-41 (d) transfer 4wd switch for removal, inspection and installation of this switch, refer to switches in section 7a. Tightening torque specifications fastening parts tightening torque fastening arts n . M kg-m lb-ft brake pipe flare nut: (a...

Page 384: Section 7A

Yh4 grand vitara 7a manual transmission (type 1) 7a-1 type 1 general description 7a- 1 . . . . . . . . . . . . . . Diagnosis 7a- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . On-vehicle service 7a- 3 . . . . . . . . . . . . . . . . Gear oil 7a- 3 . . . . . . . . . . . . . . . . . . . . . ....

Page 386: On-Vehicle Service

Yh4 grand vitara viscosity chart sae 1. Reverse idle gear shaft bolt (do not loosen it) manual transmission (type 1) 7a-3 on-vehicle service gear oil inspection and change 1) before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally. 2) with vehicle lifted up, check oil...

Page 388

Yh4 grand vitara 1. Boot no. 1 2. Boot clamp 3. Boot cover 4. Boot no. 2 1. Transfer boot no. 1 2. Boot clamp 1. Console box bracket 2. Boot cover 3. Boot no. 3 manual transmission (type 1) 7a-5 5) install transmission boot no. 1 from inside of cabin and clamp it with a new clamp securely. 6) instal...

Page 390

Yh4 grand vitara 1. Back up light switch 2. Exhaust center pipe 1. Ohmmeter 2. Back up light switch or 4wd switch 1, (a) [type 1] [type 2] manual transmission (type 1) 7a-7 3) replace switch, connect and clamp as they were. Tightening torque (a): 20 n . M (2.0 kg-m, 14.5 lb-ft) (type 1) (a): 45 n . ...

Page 392

Yh4 grand vitara 1. Transmission 2. Breather clamp 3. Breather hose 4. Wiring harness clamp 5. Intake manifold manual transmission (type 1) 7a-9 dismounting of trans. Unit in cabin remove transmission shift control lever (refer to page 7a-4) and transfer shift control lever knob. In engine room 1) d...

Page 394

Yh4 grand vitara 1. Transmission assembly 2. Transfer assembly 3. Wiring harness 4. Breather hose 5. Gear shift lever case 6. Bolt 7. Bolt manual transmission (type 1) 7a-11 10) remove wiring harness and breather hose. 11) separate gear shift lever case and transfer assembly (or exten- sion case: 2w...

Page 396

Yh4 grand vitara manual transmission (type 1) 7a-13 1 1. Extension case 2. Select return spring bolt 3. Select return spring (short) 4. Select return spring (long) 5. Guide pin 6. Speed sensor assembly 6 2,“a”,(a) 3,“a” 5,“a” 5,“a” 4,“a” 2,“a”,(a) 1. Oil seal 2. Extension case “b” “a” 1 1 2 2 extens...

Page 398: Section 7A1

Yh4 grand vitara 7a1 manual transmission (type 2) 7a1-1 type 2 general description 7a1-1 . . . . . . . . . . . . . . Diagnosis 7a1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . On-vehicle service 7a1-3 . . . . . . . . . . . . . . . . Gear oil 7a1-3 . . . . . . . . . . . . . . . . . . . . ....

Page 400: On-Vehicle Service

Yh4 grand vitara viscosity chart sae temperature 1. Drain plug 2. Oil level / filler plug manual transmission (type 2) 7a1-3 on-vehicle service gear oil inspection and change 1) before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally. 2) with vehicle lifted up, check ...

Page 402: Required Service Materials

Yh4 grand vitara manual transmission (type 2) 7a1-5 tightening torque specifications fastening portion tightening torque fastening ortion n·m kg-m lb-ft transfer oil filler / level and drain plugs 23 2.3 17.0 transmission oil filler / level and drain plugs 38 3.8 27.5 control lever boot cover bolts ...

Page 404

Yh4 grand vitara 7b1-2 automatic transmission (4 a / t) dtc p0753 shift solenoid-a (#1) electrical 7b1-50 . . . . . . . . . . . . . . . . . . . . . . . . . Dtc p0758 shift solenoid-b (#2) electrical 7b1-50 . . . . . . . . . . . . . . . . . . . . . . . . . Dtc p1875 4wd low switch circuit malfunction...

Page 406

Yh4 grand vitara 7b1-4 automatic transmission (4 a / t) item specifications torque conver- ter type stall torque ratio 3-element, 1-step, 2-phase type (with tcc (lock-up) mechanism) 2.4 (g16 engine) 2.0 (j20 engine) 1.9 (h25 engine) oil pump type drive system trochoid type oil pump engine driven typ...

Page 408

Yh4 grand vitara 7b1-6 automatic transmission (4 a / t) element shift position table of component operation solenoid solenoid o / d forward direct clutch o / d second second reverse brake o/d one-way one-way valve no. 1–a valve no. 1–b o / d clutch forward clutch inner piston outer piston o / d brak...

Page 410

Yh4 grand vitara 7b1-8 automatic transmission (4 a / t) g16 / j20 engines 1. Pcm (ecm) 2. Vss 3. Cmp sensor 4. Tp sensor 5. Ect sensor 6. A / t input speed sensor 7. A / t output speed sensor 8. Transmission range switch 9. Shift solenoid-a 10. Shift solenoid-b 11. Tcc solenoid 12. Data link connect...

Page 412

Yh4 grand vitara 7b1-10 automatic transmission (4 a / t) shift the select lever with its button pushed in. Shift the select lever without pushing its button. Range gear solenoids fail safe function this function is provided by the safe mechanism that assures safe driveability even when the shift sol...

Page 414

Yh4 grand vitara gear shift diagram tcc lock-up diagram vehicle speed upshift downshift throttle valve opening vehicle speed throttle valve opening tcc on tcc off 4th gear 3rd gear (km / h) (km / h) 7b1-12 automatic transmission (4 a / t) normal mode for g16 engine unit: km / h (mile/h) shift thrott...

Page 416

Yh4 grand vitara gear shift diagram tcc lock-up diagram upshift downshift throttle valve opening vehicle speed throttle valve opening 3rd gear 4th gear tcc on tcc off vehicle speed (km / h) (km / h) 7b1-14 automatic transmission (4 a / t) normal mode for j20 engine unit: km / h (mile/h) shift thrott...

Page 418

Yh4 grand vitara 7b1-16 automatic transmission (4 a / t) gear shift diagram tcc lock-up diagram throttle valve opening vehicle speed throttle valve opening vehicle speed upshift downshift tcc on tcc off 3rd gear 4th gear (km / h) (km / h) normal mode for h25 engine unit: km / h (mile/h) shift thrott...

Page 420

Yh4 grand vitara 1. Malfunction indicator lamp (mil) 2. Scan tool 3. Dlc 7b1-18 automatic transmission (4 a / t) [for vehicle without monitor connector] on-board diagnostic system for automatic transmission control system, pcm (ecm) has follow- ing functions. Refer to section 6 / 6-1 for details. Wh...

Page 422

Yh4 grand vitara 7b1-20 automatic transmission (4 a / t) precaution in diagnosing trouble don’t disconnect couplers from pcm (ecm), battery cable from battery, pcm ground wire harness from engine or main fuse before checking the diagnosis information (dtc, freeze frame data, etc.) stored in pcm memo...

Page 424

Yh4 grand vitara 7b1-22 automatic transmission (4 a / t) 1. Customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a inspection form will facilitate collecting information to the point required fo...

Page 426

Yh4 grand vitara 7b1-24 automatic transmission (4 a / t) malfunction indicator lamp (mil) check refer to the same item in section 6 / 6-1 for checking procedure. “o/d off” lamp check 1) check that o / d cut switch button is at off position (pushed). 2) turn ignition switch on. 3) check that “o / d o...

Page 428

Yh4 grand vitara 7b1-26 automatic transmission (4 a / t) operation visual inspection visually check following parts and systems. Inspection item referring section a / t fluid – – – – – level, leakage, color a / t fluid hoses – – – – – disconnection, looseness, deterioration throttle (accelerator) ca...

Page 430

Yh4 grand vitara 7b1-28 automatic transmission (4 a / t) t ransmission fluid running condition running condition gear shift trouble diagnosis table 1 condition possible cause correction tcc does not operate brake pedal (stop lamp) switch or its circuit faulty (h25 engine only) 4wd low switch or its ...

Page 432

Yh4 grand vitara 7b1-30 automatic transmission (4 a / t) running condition gear shift abnormal noise condition possible cause correction poor 1st speed run- ning or excessive slippage in “d” or “2” fluid pressure leakage from forward clutch due to wear or breakage of o/d case seal ring replace. Over...

Page 434

Yh4 grand vitara 7b1-32 automatic transmission (4 a / t) transfer gear position “4l” or “n” “4h” or “2h” voltage 0 v battery voltage step action yes no 6 “4wd low” switch signal inspection: (1) with ignition switch on, check voltage between c51-1-26 (g16 / j20 engines) or c51-1-5 (h25 engine) termin...

Page 436

Yh4 grand vitara 7b1-34 automatic transmission (4 a / t) transfer gear position “4l” or “n” “4h” or “2h” voltage 0 v battery voltage step action yes no 5 4wd low switch signal inspection: (1) with ignition switch on, check voltage between c51-1-26 (g16 / j20 engines) or c51-1-5 (h25 engine) terminal...

Page 438

Yh4 grand vitara 7b1-36 automatic transmission (4 a / t) switch on position switch off position switch on position switch off position diagnostic flow table b-2 “o/d off” light circuit check (“o / d off” light comes on steadily) wiring diagram – refer to table b-1 in this section. Troubleshooting st...

Page 440

Yh4 grand vitara 7b1-38 automatic transmission (4 a / t) “5” “4” diagnostic flow table b-4 “power” light circuit check (“power” light comes on steadily) wiring diagram – refer to table b-3 in this section. Troubleshooting step action yes no 1 check power / normal change switch position. Is switch bu...

Page 442

Yh4 grand vitara 7b1-40 automatic transmission (4 a / t) dtc detecting condition and trouble area dtc detecting condition trouble area transmission range switch signal (p, r, n, d, 2 or l) is not inputted for 25 sec. At 60 km/h (38 mph) or higher vehicle speed. Or multiple signals are inputted simul...

Page 444

Yh4 grand vitara g16/j20 engines h25 engine g16/j20 engines h25 engine 1. Pcm 2. A / t input speed sensor 11 10 bl / y bl / g 16 8 bl / y bl / g 7b1-42 automatic transmission (4 a / t) dtc p0715 (dtc no.76) input/turbine speed sensor circuit malfunction wiring diagram dtc detecting condition and tro...

Page 446

Yh4 grand vitara g16/j20 engines h25 engine g16/j20 engines h25 engine 1. Pcm 2. A / t output speed sensor 23 22 w or 10 9 w or 7b1-44 automatic transmission (4 a / t) dtc p0720 (dtc no.75) output speed sensor circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detecting ...

Page 448

Yh4 grand vitara 7b1-46 automatic transmission (4 a / t) dtc p0741 tcc (lock-up) solenoid valve performance or stuck off dtc detecting condition and trouble area dtc detecting condition trouble area while running in 2nd or 4th gear, d range, tcc control of pcm does not agree with actual operation of...

Page 450

Yh4 grand vitara 7b1-48 automatic transmission (4 a / t) troubleshooting step action yes no 1 was “a / t diag. Flow table” performed? Go to step 2. Go to “a / t diag. Flow table”. 2 is the vehicle equipped with monitor connector? Go to step 3. Go to step 4. 3 is dtc no.65? G to step 4. Go to step 6....

Page 452

Yh4 grand vitara g16/j20 engines h25 engine h25 engine g16/j20 engines 1. Pcm 2. Shift solenoid-a 3. Shift solenoid-b 4. Tcc solenoid 7b1-50 automatic transmission (4 a / t) dtc p0753 (dtc no.61/62) shift solenoid-a (#1) electrical dtc p0758 (dtc no.63/64) shift solenoid-b (#2) electrical wiring dia...

Page 454

Yh4 grand vitara g16 / j20 engines h25 engine 1. Pcm 2. 4wd low switch 3. J / c 7b1-52 automatic transmission (4 a / t) dtc p1875 4wd low switch circuit malfunction (if equipped) wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area while driving at higher than...

Page 456

Yh4 grand vitara 1. Fluid pressure check hole 2. Oil pan 1. Oil pan 2. Exhaust pipe 7b1-54 automatic transmission (4 a / t) line pressure test purpose of this test is to check operating conditions of each part by measuring fluid pressure in fluid pressure line. Line pressure test requires following ...

Page 458

Yh4 grand vitara 7b1-56 automatic transmission (4 a / t) 8) stall speed should be within the following specification. Stall speed: 2,100 – 2,400 r / min. For g16 engine 2,300 – 2,600 r / min. For j20 engine 2,300 – 2,600 r / min. For h25 engine check result possible cause lower than standard level f...

Page 460

Yh4 grand vitara 7b1-58 automatic transmission (4 a / t) engine brake test warning: before test, make sure that there is no vehicle behind so as to prevent rear-end collision. 1) while driving vehicle in 3rd gear of “d” range, shift select lever down to “2” range and check if engine brake operates. ...

Page 462

Yh4 grand vitara 1. Dipstick (g16 / j20) 2. Dipstick (h25) 1. Drain plug 2. Propeller shaft 1. Dipstick (g16 / j20) 2. Dipstick (h25) 7b1-60 automatic transmission (4 a / t) level check at room temperature the fluid level check at room temperature performed after repair or fluid change before test d...

Page 464

Yh4 grand vitara 1. Manual selector assembly (select lever assembly) 2. Manual lever assembly 3. Select cable bracket 4. Select indicator 5. Slide cover 6. Select lever knob 7. Spring 8. Knob button 9. Shift lock solenoid rod 10. Shift lock solenoid 11. Cover 12. Illumination lamp 13. Interlock cam ...

Page 466

Yh4 grand vitara 7b1-64 automatic transmission (4 a / t) 1. A / t vehicle (output) speed sensor “n” reference line center line on manual valve shaft g16 / j20 1. Service wire 2. Pcm connectors disconnected switch position transmission range switch (sensor) inspection & adjustment 1) shift select lev...

Page 468

Yh4 grand vitara 7b1-66 automatic transmission (4 a / t) 1 4 2 3 installation reverse removal procedure to install solenoid valves and noting the following points. For details of solenoid valve installation, refer to “unit repair” section. Use new gasket and o-ring. Install oil tubes in such order a...

Page 470

Yh4 grand vitara 7b1-68 automatic transmission (4 a / t) 1. Select lever 2. Shift lock solenoid 3. Brake light switch 4. Brake pedal 5. Cable 6. Ignition switch 1. Select lever 2. Interlock cam 3. Shift lock solenoid rod 4. Shift lock solenoid type-1 brake interlock system shift lock solenoid contro...

Page 472

Yh4 grand vitara 7b1-70 automatic transmission (4 a / t) 1. Cover 2. Screw 3. Shift lock solenoid rod (or manual release plate) 4. Select lever 5. Button not turn between “acc” and “lock” positions. Type-1 type-2 with shift lock solenoid rod (or manual release plate) moved in arrow direction and ign...

Page 474

Yh4 grand vitara 1. Ignition switch assembly 2. Clamp screw 3. Outer end 1. Interlock cable 2. Steering column 3. Steering column holder type-1 1. Interlock cam 2. Lever plate 3. Interlock cable 4. Pin with 4 mm (0.15 in.) dia. 7b1-72 automatic transmission (4 a / t) installation 1) shift select lev...

Page 476

Yh4 grand vitara 7b1-74 automatic transmission (4 a / t) 1. Boot no.2 2. Boot cover 1. Boot clamp 2. Boot no.1 3. Gear shift control lever 1. Boot no.2 2. Transfer shift control lever 3. Transfer shift lever case 4. Transfer shift control case cover 5. Boot no.1 1. A / t throttle cable 2. Adjusting ...

Page 478

Yh4 grand vitara 7b1-76 automatic transmission (4 a / t) 12) remove engine to transmission nuts. 13) disconnect connectors from vss, output speed sensor, input speed sensor, tr switch, shift & tcc solenoid valves and oth- er electrical parts, and release their wire harness from clamps. 14) apply tra...

Page 480: Unit Repair

Yh4 grand vitara 7b1-78 automatic transmission (4 a / t) on-vehicle ser vice mounting external unit repair refer to the same section of unit repair manual mentioned in foreword of this manual. Tightening torque specifications fastening portion tightening torque fastening portion n·m kg-m lb-ft autom...

Page 482: Section 7C1

Yh4 grand vitara 7c1 clutch 7c1-1 general description 7c1 - 2 . . . . . . . . . . . . . Diagnosis 7c1 - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . On-vehicle service 7c1 - 4 . . . . . . . . . . . . . . . Clutch pedal height 7c1 - 4 . . . . . . . . . . . . . . . . . . Clutch pedal free tra...

Page 484: Diagnosis

Yh4 grand vitara clutch 7c1-3 diagnosis condition possible cause correction slipping improper clutch pedal free travel. Worn or oily clutch disc facing. Warped disc, pressure plate or flywheel surface. Weakened diaphragm spring. Master cylinder piston or seal cup not returning. Bleed air or replace ...

Page 486

Yh4 grand vitara 1. Pipe 2. Hose 3. Flare nut 1. Pipe 2. Hose 3. Flare nut 4. E-ring 1. Master cylinder assembly 2. Clutch pipe 3. Attaching nut 4. Attaching bolt 5. Clevis pin 6. Clip 7. Flare nut clutch 7c1-5 inspection check pipe and hose for dent, kink, crack, dirt and dust. Replace if check res...

Page 488

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...

Page 490

Yh4 grand vitara 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 492

Yh4 grand vitara clutch 7c1-11 inspection input shaft bearing and release bearing check bearing for smooth rotation and replace it if abnormality is found. Clutch disc measure depth of rivet head depression, i.E. Distance between rivet head and facing surface. If depression is found to have reached ...

Page 494

Yh4 grand vitara clutch 7c1-13 1. Release fork 2. Clip 3. Input shaft “b” “b” “a” 3 2 1 1 2 4) install clip to release fork and apply grease. “a”: grease 99000-25010 then install release fork and release bearing as shown in figure. 5) slightly apply grease to input shaft and install clutch disc. The...

Page 496: Section 7D

Yh4 grand vitara 7d transfer 7d-1 the aluminum transfer case directly connected to the back of the transmission contains the input gear, countershaft & gear, output rear shaft, output low gear and output front shaft (for front drive) connected by way of the hyvo-chain. The transfer has such a select...

Page 498: On-Vehicle Service

Yh4 grand vitara 1. Match mark 1. Transfer rear case 2. Oil seal “a” “b” transfer 7d-3 on-vehicle service gear oil refer to “on-vehicle service” of section 7a or 7a1. Transfer oil seals rear case oil seal 1) lift up vehicle horizontally. 2) give match marks on joint flange and propeller shaft as sho...

Page 500

Yh4 grand vitara 1. Wood block 2. Dash panel t: 45 mm / 1.8 in. H: 200 mm / 8 in. W: 100 – 150 mm / 4 – 6 in. 1. Transmission jack 2. Engine rear mounting member 3. Gear shift lever case 4. Bolt transfer 7d-5 transfer assembly dismounting and remounting of transfer and transmission together as a uni...

Page 502: Unit Repair

Yh4 grand vitara transfer 7d-7 09940-53111 bearing installer unit repair refer to the same section of unit repair manual mentioned in foreword of this manual. Tightening torque specifications fastening portion tightening torque fastening ortion n . M kg-m lb-ft oil filler / level and drain plugs 23 ...

Page 504

Yh4 grand vitara 1. 4wd switch 2. Transfer 3. Blank 4. Blank 5. Ecm or pcm 6. Glove box 7. Air pump assembly 8. Actuator 9. Axle lock clutch 10. Free axle hub 11. 4wd indicator lamp 7e-2 differential (front) 4wd control system when the 4wd switch is turned on by shifting the transfer shift lever, ec...

Page 506

Yh4 grand vitara 7e-4 differential (front) components and functions component function 4wd switch when the transfer shift lever is shifted to 4l or 4h position, this switch turns on and causes the 4wd control system to turn on, unless it is shifted to n or 2h within 1 second. Ecm or pcm when the 4wd...

Page 508

Yh4 grand vitara 7e-6 differential (front) step action yes no 1 turn on ignition switch (but engine at stop) and check malfunction indicator lamp. Does lamp light up? Go to step 2. A trouble has occurred at some place. Repair it referring to malfunction indicator lamp (“check engine” lamp) check in ...

Page 510

Yh4 grand vitara 7e-8 differential (front) 1. Ecm (pcm); viewed from harness side voltage check [h25 engine model] ter- minal circuit wire color normal voltage condition c51 1 10 – 14 v transfer shift lever: 2h or n c51-1 -7 4wd indicator lamp or / b 0 – 1 v 4 seconds after transfer shift lever shif...

Page 512

Yh4 grand vitara 7e-10 differential (front) 1. Plugged hose 2. Adjusting screw 3. Pipe (to air pump assembly) 4. Hose (to differential carrier) 5. Differential housing 4 5 inspection 4wd control system 1) install special tool to air hose connecting between air pump as- sembly and differential (actua...

Page 514

Yh4 grand vitara 7e-12 differential (front) 1. Pump assembly air pump assembly removal / installation 1) disconnect air hoses and coupler from air pump assembly. 2) remove pump assembly by removing bolts. 3) reverse removal procedure for installation. Tightening torque (a): 13 n . M (1.3 kg-m, 9.5 l...

Page 516

Yh4 grand vitara 7e-14 differential (front) 1. Mounting bracket r 2. Mounting bracket l 1. Bolt and nut 2. Differential carrier 3. Cross member 4. Bolt 5. Differential rear mounting assembly 7) position each bush to bracket as shown. Length “a”: 3.0 mm (0.12 in.) 8) use following torque for reinstal...

Page 518

Yh4 grand vitara 7e-16 differential (front) (a) (a) (a) 1. Drive shaft joint r 2. Differential housing 3. Transmission jack 4. Screw driver 8) using 2 large screwdrivers as levers, pull out right side drive shaft joint from differential and dismount housing assembly from vehicle. Caution: during abo...

Page 520: Section 7F

Yh4 grand vitara 7f differential (rear) 7f-1 the differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genu- ine parts and specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between bevel pinion and gear, it is ma...

Page 522: On-Vehicle Service

Yh4 grand vitara 1. Breather hose 2. Oil filler / level plug 3. Rear drain plug (apply sealant) viscosity chart sae differential (rear) 7f-3 on-vehicle service maintenance service note: when having driven through water, check immediately if wa- ter has entered (if so, oil is cloudy). Water mixed oil...

Page 524: Unit Repair

Yh4 grand vitara 1. Differential to rear axle nut (a) (a) differential (rear) 7f-5 remounting 1) clean mating surfaces of rear axle and differential assembly and apply sealant (suzuki bond 1215) to axle side evenly. “a”: sealant 99000-31110 2) install differential assembly to axle and fix it with nu...

Page 526: Section 8

Yh4 grand vitara 8 body electrical system 8-1 section 8 body electrical system warning: for vehicles equipped with supplemental restraint (air bag) system service on and around the air bag system components or wiring must be performed only by an autho- rized suzuki dealer. Refer to “air bag system c...

Page 528

Yh4 grand vitara body electrical system 8-3 when installing the wiring harness, fix it with clamps so that no slack is left. When installing vehicle parts, be careful so that the wiring har- ness is not interfered with or caught by any other part. To avoid damage to the harness, protect its part whi...

Page 530

Yh4 grand vitara symbol g : green g / y : green / yellow g (base color) g (base color) y (stripe color) g / y body electrical system 8-5 wire color symbols the wire color is abbreviated to the first (or first two) alphabet(s) of each color. There are two kinds of colored wire used in this vehicle. O...

Page 532: Section 8B

Yh4 grand vitara 8b lighting system 8b-1 section 8b lighting system warning: for vehicles equipped with supplemental restraint (air bag) system: service on and around the air bag system components or wiring must be performed only by an autho- rized suzuki dealer. Refer to “air bag system components ...

Page 534

Yh4 grand vitara 1. Headlight leveling switch 2. Headlight leveling unit (actuator) 3. Headlight 4. Headlight leveling unit shaft switch position headlight beam down angle 0 ——— 1 0.624 _ 2 1.243 _ 3 1.867 _ 4 2.479 _ lighting system 8b-3 headlight with leveling system (if equipped).

Page 536

Yh4 grand vitara lighting system 8b-5 clearance, tail and licence plate lights trouble possible cause correction all lights do not light “tail” fuse blown lighting switch faulty wiring or grounding faulty replace fuse to check for short replace switch repair some lights do not light up bulb(s) blown...

Page 538

Yh4 grand vitara lh steering vehicle shown x-x:horizontal center line of headlight bulbs a-a:vertical center line of left headlight bulb b-b:vertical center line of right headlight bulb 1. Screen 2. For right / left adjustment 3. For up / down adjustment (for vehicle without leveling system) 4. For ...

Page 540

Yh4 grand vitara 1. Meter cluster 2. Hazard switch terminal wire color switch position lh steering vehicle shown lighting system 8b-9 turn signal and hazard warning lights turn signal switch (in combination switch) inspection 1) disconnect negative cable at battery. 2) disconnect combination switch ...

Page 542

Yh4 grand vitara lighting system 8b-11 rear fog light (if equipped) rear fog light switch inspection check for continuity between terminals at each switch position shown below. Hold the switch button (on or off) pushed in during checking switch. Note: rear fog light lights up only when headlights (l...

Page 544: General Description

Yh4 grand vitara 1. Tachometer 2. Speedometer 3. Fuel level meter 4. Water temperature meter 5. Turn signal pilot light (lh) 6. 4wd indicator (if equipped) 7. Abs warning light (if equipped) 8. Immobilizer warning light (if equipped) 9. Check engine light 10. Turn signal pilot light (rh) 11. Air bag...

Page 546: Diagnosis

Yh4 grand vitara 8c-4 instrumentation / driver information diagnosis note: fuse name (“ ”) in the table below is shown on the fuse box cover (hard top model) or the junction box (canvas top model). Speedometer and vss trouble possible cause correction speedometer shows no operation “ig / meter” fuse...

Page 548: On-Vehicle Service

Yh4 grand vitara 8c-6 instrumentation / driver information key position terminal wire color hard top model canvas top model on-vehicle service ignition (main) switch inspection 1) disconnect negative cable at battery. 2) disable air bag system. Refer to disabling air bag system in section 10b of thi...

Page 550

Yh4 grand vitara 8c-8 instrumentation / driver information speedometer and vss vehicle speed sensor (vss) removal 1) hoist vehicle. 2) disconnect coupler from vss (1). 3) remove vss. Installation reverse removal procedure for installation. Tightening torque (a): 5.5 n . M (0.55 kg-m, 4.0 lb-ft).

Page 552

Yh4 grand vitara 8c-10 instrumentation / driver information g16 j20 h25 1. Ect sensor 1 engine coolant temp. (ect) meter and sensor engine coolant temperature (ect) meter inspection 1) disconnect y/w lead wire going to ect sensor. 2) turn ignition switch on, and check that ect meter indicates cool. ...

Page 554

Yh4 grand 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) conti...

Page 556: Section 8D

Yh4 grand vitara 8d windows, mirrors, security and locks 8d-1 general description 8d- 2 . . . . . . . . . . . . . . Cautions in servicing 8d- 2 . . . . . . . . . . . . . . . . . Symbols and marks 8d- 2 . . . . . . . . . . . . . . . . . . . Wiring color symbols 8d- 2 . . . . . . . . . . . . . . . . ....

Page 558

Yh4 grand vitara rear wiper switch rear wiper intermittent relay rear wiper assembly windows, mirrors, security and locks 8d-3 rear wiper and washer (if equipped).

Page 560: Diagnosis

Yh4 grand vitara windows, mirrors, security and locks 8d-5 diagnosis note: fuse name (“ ”) in the table below is shown on the fuse box cover (hard top model) or the junction box (canvas top model). Windshield wiper and washer front wiper and washer rear wiper and washer (if equipped) trouble possibl...

Page 562

Yh4 grand vitara windows, mirrors, security and locks 8d-7 power door lock and keyless entry system (if keyless entry is equipped) trouble possible cause correction all power doors are not locked / unlocked by both driver side door key switch and power door lock switch. But all power doors are locke...

Page 564: On-Vehicle Service

Yh4 grand vitara washer on int lo hi type a type b type c windows, mirrors, security and locks 8d-9 wiper sw terminal wiper sw terminal on-vehicle service windshield wiper and washer front wiper and washer inspection front wiper and washer switch (in combination switch) 1) disconnect negative cable ...

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Yh4 grand vitara windows, mirrors, security and locks 8d-11 slow fast 10 – 14 v 0 v 1.6 1 sec. 10 – 14 v 0 v 10.7 5 sec. Intermittent wiper relay circuit 1) disconnect negative cable at battery. 2) disconnect combination switch lead wire coupler. 3) turn the front wiper switch to int position. 4) tu...

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Yh4 grand vitara terminal switch terminal switch on int washer on br int windows, mirrors, security and locks 8d-13 rear wiper and washer (if equipped) inspection rear wiper and washer switch (in combination switch) 1) disconnect negative cable at battery. 2) disconnect combination switch lead wire ...

Page 570

Yh4 grand vitara windows, mirrors, security and locks 8d-15 2) disconnect positive terminal from terminal “7” checking voltage between terminal “6” and “5” of relay. If measured voltage changes from battery voltage to about 0 v 2.7 to 4.6 seconds after disconnecting positive terminal from ter- minal...

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Yh4 grand vitara 1. Masking tape 2. Wood spatula 3. Broken wire 4. Repair agent several volts 0 volt windows, mirrors, security and locks 8d-17 2) locating damage in wire a. Touch voltmeter positive (+) lead to heat wire positive termi- nal end. B. Touch voltmeter negative (–) lead with a foil strip...

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