1987 SUZUKI GRAND VITARA air condition

ConditionPossible causeCorrection
Erratic idling
(Improper engine
idling)
Abnormal condition in fuel system
1. Clogged carburetor jets
2. Incorrect idle adjustment
3. Clogged air cleaner element
4. Leaky manifold, carburetor or cylinder
head gaskets
5. Improper float level
6. Malfunctioning choke system
7. Malfunctioning fuel cut solenoid valve
Clean
Adjust
Clean or replace
Replace
Adjust
Adjust or replace
Replace
Others
1. Loose connection or disconnection. of
vacuum hoses
Connect
2. Malfunctioning PCV valve
3. Low compression
4. Loose carburetor and intake manifold bolts
and nuts
Check and replace as
necessary
Previously outlined
Tighten bolts and nuts
5. Leaky carburetor and intake manifold
gaskets
Replace
Abnormal detonationAbnormal condition in ignition system
1. Spark plugs tending to overheatChange plug heat value
2. Improper ignition timingAdjust
3. Loose connection in high-tension or low-Retighten
tension circuit.
Abnormal condition in fuel system
1. Clogged fuel filter and fuel lines
2. Clogged carburetor jets
3. Improper adjustment of float level
4. Malfunctioning fuel pump
5. Air inhaling from intake manifold and
carburetor gaskets
Replace or clean
Clean
Adjust
Replace
Replace
Abnormal condition in engine
1. Excessive carbon deposit on piston crowns
or cylinder head
Clean
2. Blown cylinder head gasket, resulting in
low compression pressure
3. Improper valve clearance
4. Valves tending to seize
5. Weakened valve springs
Replace
Adjust
Replace
Replace
Others
Malfunctioning EGR valveReplace
2-6

9
Cond it ionPossible causeCorrection
OverheatingAbnormal condition in ignition system
1. Improper ignition timingAdjust
2. Wrong heat value of spark plugsChange heat value
Abnormal condition in fuel systems
1. Float level set too lowAdjust
2. Clogged jets in carburetorClean
3. Loose inlet manifoldRetighten
Abnormal condition in cooling system,,
1. Not enough coolantRefill
2. Loose or broken fan beltAdjust or replace
3. Erratically working thermostatReplace
4. Poor water pump performanceReplace
5. Leaky radiator coresRepair or replace
Abnormal condition in lubrication system
1. Clogged oil filterReplace
2. Clogged oil strainerClean
3. Deteriorated oil pump performanceReplace
4. Oil leakage from oil pan or pumpRepair
5. Improper engine oil gradeReplace with proper grade
oil
6. Not enough oil in oil panReplenish
Others
1. Dragging brakesRepair or replace
2. Slipping clutchAdjust or replace
3. Blown cylinder head gasketReplace
Engine noiseCrankshaft noise
Note: Before check- 1. Worn-down bearings, resulting in excessivelyReplace
ing the mechanicallarge running clearances
noise, make sure that:2. Worn connecting-rod bearingsReplace
0 Ignition timing is3. Distorted connecting rodsRepair or replace
properly adjusted.4. Worn crankshaft journalsRepair by grinding, or re-
l Specified spark plugplace crankshaft
is used.5. Worn crankpins.Repair by grinding, or re-
l Specified fuel is used.place crankshaft
Noise due to pistons, rings, pins or cylinders
1. Abnormally worn cylinder boresRebore to next oversize
or replace
2. Worn pistons, rings or pinsReplace
3. Pistons tending to seizeReplace
4. Broken piston ringsReplace
, Others
1’. Excessively large camshaft thrust playReplace
2. Excessively large crankshaft thrust clearanceAdjust as prescribed
3. Valve clearance too largeAdjust as prescribed
4. Not enough engine oilReplenish
2-7

ConditionPossible causeCorrection
High fuel consumptionAbnormal condition ignition system
1. Improper ignition timingAdjust
2. Leak or loose connection of high tension cordRepair or replace
3. Defective spark plug (improper gap, heavyClean, adjust or replace
deposits, and burned electrodes, etc..)
4. Cracked distributor cap or rotorReplace
5. Malfunctioning mechanical and vacuumCheck and repair or
advancers in distributorreplace
Abnormal condition in fuel system
1. Improper float levelAdjust
2. Fuel leakage from tank, pipe or carburetorRepair or replace
3. Malfunctioning carburetor choke systemRepair or replace
4. Dirty or clogged carburetor jetsClean
5. Clogged air cleaner elementClean or replace
6. Malfunctioning thermostatically controlledCheck and repair or
air cleanerreplace
Abnormal condition in engine
1. Low compressionPreviously outlined
2. Poor valve seatingRepair or replace
3. Improper valve clearanceAdjust
Emission control
1. Air leaks at exhaust manifoldTighten manifold bolts
and nuts.
Replace gasket.
2. Oxygen sensor out of orderReplace.
3. Water temperature switch out of orderReplace.
4. Malfunctioning throttle position switchReplace
5. Malfunctioning MCS (mixture controlReplace
solenoid) valve in carburetor
6. Malfunctioning EGR valveReplace
Others
1. Dragging brakesRepair or replace
2. Slipping clutchAdjust or replace
3. Improper tire pressureAdjust
Excessive engine oilOil leakage
consumption1. Loose oil drain plugTighten
2. Loose oil pan securing boltsTighten
3. Deteriorated or broken oil pan sealantReplace sealant
4. Leaky oil sealsReplace
5. Blown cylinder head gasketReplace
6. Improper tightening of oil filterTighten
7. Loose oil pressure switchTighten
2-8

Condition
Excessive engine oil
consumption
Possible cause
“Oil pumping” (Oil finding its way into
combustion chambers.)
1. Sticky piston ring
2. Worn piston ring groove and ring
3. Worn pistons or cylinders
Correction
Remove carbon and
replace rings
Replace piston and ring
Replace pistons and
rebore as necessary
Oil leakage along valve stems
1. Defective valve stem oil sealsReplace
2. Badly worn valve stemReplace
2-2. CARBURETOR
ConditionPossible causeICorrection
Fuel overflow from
carburetor
1, Float valve worn or dirty with foreign matterClean or replace
2. Float level set too highAdjust as prescribed
3. Float ruptured and containing some fuelReplace
4. Broken or otherwise defective gasketReplace
5. Loose float chamber securing screwsRetighten
2-3. EXHAUST AND MUFFLER
Condition
Poor muffling per-
formance
Possible cause
1. Loose exhaust pipe connection
2. Broken muffler gasket
3. Broken manifold, pipe or muffler
4. Exhaust manifold loose in place
5. Interference between body and muffler
Correction
Retighten
Replace
Repair or replace
Retighten
Repair, eliminating any
contact
2-4. CLUTCH
ConditionPossible causeICorrection
Slipping clutch Loss of clearance at the tip of release fork
2. Clutch facings dirty with oil
3. Clutch facings excessively worn
4. Weakened diaphragm spring
5. Distorted pressure plate or flywheel surface
6. Improper clutch pedal free travel
Adjust as prescribed
Replace
Replace
Replace
Replace
Adjust and, as necessary,
replace clutch facings
2-9
1.

Condition
Clutch vibration
Noisy clutch
Grabbing clutch
2-5. TRANSMISSION
Condition
Gears slipping out of
mesh
Gears refusing to dis-
engage
Possible cause
1. Improper clutch pedal free travel
2. Weakened diaphragm spring, or worn spring
tip
3. Damaged or worn splines of transmission
input shaft
4. Front input shaft bearing worn or broken
5. Excessively wobbly clutch disc
6. Clutch facings broken or dirty with oil
1. Glazed (glass-like) clutch facings
2. Clutch facings dirty with oil
3. Wobbly clutch disc, or poor facing contact
4. Weakened torsion springs (in clutchdisc)
5. Clutch disc rivets loose
6. Distorted pressure plate or flywheel surface
7. Weakened engine mounting or loosened
mounting bolt or nut
1. Worn or broken release bearing
2. Front input shaft bearing worn down
3. Excessive rattle of clutch disc hub
4. Cracked clutch disc
5. Pressure plate and diaphragm spring rattling
1. Clutch facings soaked with oil
2. Excessively worn clutch facings
3. Rivet heads showing out of the facing
4. Weakened torsion springs
Possible cause
1. Worn shift fork shaft
2. Worn locating steel balls
3. Weakened springs for locating steel balls
4. Worn shift fork
5. Excessive rattle in thrust direction of gears
6. Worn ring or hub in synchronizers
7. Worn bearings of input shaft, main shaft or
countershaft
1. Weakened or broken synchronizer springs
2. Worn inner groove of synchronizer ring
3. Synchronizer ring seized on. the cone
4.Distorted shift fork shaft or shift fork
Correction
Adjust free travel
Replace
Replace
Replace
Replace
Replace
Repair or replace
Replace
Replace
Replace
Replace the disc
Replace
Retighten or replace
Replace
Replace
Replace the disc
Replace
Replace
Replace
Replace
Replace
Replace
Correction
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace the ring
Replace.
Dragging clutch
2-10

2-7. PROPELLER SHAFTS
IConditionIPossible causeICorrection
Vibration and noise1. Broken or worn bearings of universal joint
spider
2. Distorted propeller shaft
3. Unbalanced propeller shaft
4. Loose propeller shaft
Replace
Replace
Replace
Retighten
Noise occurring at
standing start or
during coasting
1. Worn or damaged universal joint
2. Worn propeller shaft splines, due to lack
of lubrication
3. Loose propeller shaft
4. Loose flanged yoke of universal joint
Replace
Replace
Retighten
Retighten
2-8. BRAKES
Condition
Not enough braking
force
Possible causeCorrection
1. Brake oil leakage from brake linesLocate leak point and repair
2. Brake disc or pads stained with oilClean or replace
3. Overheated brakesDetermine cause and repair
4. Poor contact of shoes on brakeRepair for proper contact
drum
5. Brake shoes linings stained with
oil or wet with water
Replace
6. Badly worn brake shoe liningsReplace
7. Defective wheel cylindersRepair or replace
8. Malfunctioning caliper assemblyRepair or replace
Brake Pull (Brakes not1. Shoe linings wet with water orReplace
working in unison)stained with oil in some brakes
2. Drum-to-shoe clearance out ofCheck for inoperative auto adjusting
adjustment in some brakes (Mal-mechanism
functioning auto adjusting
mechanism)
3. Drum out of round in some
brakes
Replace
4. Wheel tires inflated unequally
5. Malfunctioning wheel cylinders
6. Disturbed front end aiignment
7. Unmatched tires on same axle
8. Restricted brake tubes or hoses
9. Malfunctioning caliper assembly
10. Loose suspension parts
11. Loose calipers
Inflate equally
Repair or replace
Adjust as prescribed
Use tires with approximately the same
amount of tread on the same axle
Check for soft hoses and damaged
lines. Replace with new hoses and net
double-walled steel brake tubing.
Check for stuck or sluggish pistons an
proper lubrication of caliper slide bus
Caliper should slide.
Check all suspension mountings
Check and torque bolts to specifica-
tions
2-12

Condition
Excessive pedal travel
(Pedal stroke too
large)
Possible cause
1. Partial brake system failure
2. Insufficient fluid in master
cylinder reservoirs
Correction
Check diagonal brake systems and
repair as necessary
Fill reservoirs with approved brake
fluid. Check for leaks and air in
brake systems. Check warning light.
Bleed system if necessary.
3. Air in system (Pedal soft/spongy)Bleed system
4. Rear brake system not adjustedAdjust rear brakes (Repair auto
(malfunctioning auto adjustingadjusting mechanism)
mechanism)
5. Bent brake shoesReplace brake shoes
6. Worn rear brake shoesReplace brake shoes.
Dragging brakes (A
very light drag is pre-
sent in all disc brakes
immediately after
pedal is released)
1. Master cylinder pistons not
returning correctly
2. Clogged return port in master
cylinder
3. Restricted brake tubes or hoses
4. Incorrect parking brake
adjustment
5. Weakened or broken return
springs in the brake
Repair master cylinder
Clean
Check for soft hoses or damaged tubes
and replace with new hoses and/or
new double-walled steel brake tubing
Check and adjust to correct specifica-
tions
Replace
6. Sluggish parking-brake cables or
linkage
Repair or replace
7. Wheel cylinder or caliper piston
sticking
Repair as necessary
Pedal pulsation1. Damaged or loose wheel bearingsReplace wheel bearings
(Pedal pulsates when2. Excessive disc lateral runout Check per instructions. If not within
depressed for braking)specifications, replace or machine the
disc.
3. Parallelism not within specifica-Check per instructions. If not within
tionsspecifications, replace or machine the
disc.
4. Rear drums out of roundCheck runout.
Braking noise1. Glazed shoe linings, or foreignRepair or replace shoe lining
matters stuck to linings
2. Worn or distorted shoe liningsReplace shoe lining (or pad)
3. Loose front wheel bearingsReplace wheel bearings
4. Distorted backing plates or looseReplace or retighten securing bolts
mounting bolts
2-13

2-9. SUSPENSION, STEERING SYSTEM AND TIRES
Condition
Hard steering
Possible causeCorrection
1. Wheel tires not adequately inflatedAdjust the pressure
2. Bind in tie rod end ball studReplace
3. Linkage connections tending to seizeRepair or replace
4. Steering gearbox out of adjustmentAdjust as prescribed
5. Unevenly worn steering shaft bushReplace
6. Disturbed front wheel alignmentAdjust as prescribed
Wobbly steering wheel1. Wheel tires inflated unequallyAdjust tire pressure
(Shimmy, shake or2. Wobbly wheelsRepair or replace
vibration)3. Large difference in tire diameter betweenReplace._
right and left wheels
4. Loose hub nutsRetighten
5. Damaged or worn wheel bearingsReplace
6. Worn or loose tie rod endsReplace or retighten
7. Steering gearbox out of adjustmentAdjust as prescribed
8. Steering gearbox mounted looseRetighten
9. Worn steering knuckle oil sealReplace
10. Tire or wheel out of balanceBalance wheel or replace tire
and/or wheel
11. Blister or bump on tireReplace tire
12. Disturbed front wheel alignmentCheck front wheel alignment
Steering wheel
pulling to one
side (car pulls)
1. Unevenly worn wheel tires
2. Brake dragging in one road wheel
3. Wheel tires unequally inflated
4. Worn or distorted link rods
5. Disturbed front wheel alignment
6. Loose, bent or broken front or rear
suspension parts
Replace
Repair
Adjust tire pressure
Replace
Adjust as prescribed
Tighten or replace suspension
parts
Shocks coming to1. Tire inflating pressure too highReduce to the specification
steering wheel2. Poor shock absorber performanceReplace
(or wheel tramp)3. Differences in tire diameter among fourAdjust
road wheels
4. Worn steering linkage connectionsReplace
5. Worn or broken front wheel bearingsReplace
6. Loose front wheelRetighten
7. Steering wheel loose in placeRetighten the nut
8. Blister or bump on tireReplace tire
Rapid wear or uneven1. Wheel tires imporperly inflatedAdjust tire pressure
wear of wheel tires2. Differences in diameter among four tiresAdjust or replace
(Abnormal or excessive3. Worn or loose road wheel bearingsReplace
tire wear)4. Wobbly wheel tiresRepair or replace
2-14