1987 SUZUKI GRAND VITARA engine

FINAL INSPECTION
Carry out road test in safe place.
WARNING:
When carrying out the following road
tests, select a safe place where no man or
no running car is seen so as to prevent any
accident.
1) Engine start
Check engine start for readiness.
2) Clutch
Check the following:
l that clutch is completely released when
depressing clutch pedal,
l that no slipping clutch occurs when releas-
ing pedal and accelerating,
l and that clutch itself is free from any
abnormal condition.
3) Gearshift Lever (Transmission and Transfer)
Check gearshift lever for smooth shifting
to all positions and for good performance of
transmission and transfer in any position.
4) Brake
[Foot brake]
Check the following when depressing brake
pedal while driving;
l that brake works properly,
l that it is free from noise,
l and that braking force applies equally on
all wheels.
[Parking brake]
Check to ensure that parking brake is fully
effective when the car is stopped on the slop
and brake lever is pulled all the way.
5) Steering
Check to ensure that steering wheel is free
from instability, or abnormally heavy feeling
while driving.
1-22

2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-6.
2-9.
SECTION 2
TROUBLE SHOOTING
CONTENTS
ENGINE...................................................2-2
CARBURETOR...........................................
EXHAUST AND MUFFLER.................................
CLUTCH.................................................2-9
TRANSMISSION..........................................
DIFFERENTIALS.........................................2-11
PROPELLER SHAFTS.....................................2-12
BRAKES.............................................. 2-12
SUSPENSION, STEERING SYSTEM AND TIRES................
STARTING MOTOR.....................................
2-11. ALTERNATOR...........................................

FUEL METER............................................ 2-19
2-14. SPEEDOMETER..........................................2-19
2-15. WATER TEMPERATURE METER.............................2-19
2-9
2-9
2-10
2-14
2-16
2-17
2-18WIPER MOTOR.......................................
2-10.
2-12.
2-13.
2-1
2

2-1. ENGINE
Cond it ion
Poor starting
(Hard starting)
Possible cause
Starter will not run
1. Main fuse blown off
2. Contact not closing in main switch, or this
switch open-circuited
3. Run-down battery
4. Defective magnetic switch of starter
5. Loose battery terminal connection
6. Defective brushes in starter
7. Loose battery cord connection
8. Open in field or armature circuit of starter.
Correction
Replace
Repair or replace
Recharge
Replace
Clean and retighten
Replace
Retighten
Repair or replace
No sparking
1. Defective spark plugAdjust gap, or replace
2. High tension cord short-circuited (grounded)Repair or replace
3. Cracked rotor or cap in distributorReplace
4. Defective signal generator or ignitorReplace
5. Maladjusted signal rotor air gap.Adjust
6. Contact not closing positively in main switch,Replace
or this switch open-circuited
7. Loose or blown fuseSet right or replace
8. Improper ignition timingAdjust
9. Defective ignition coil.Replace
Faulty intake and exhaust systems
1. Carburetor out of adjustment
2. Fuel pump not discharging adequately
3. Clogged fuel filter
4. Defective choke mechanism
5. Loose intake manifold
6. Dirty and clogged carburetor
7. Float level out of adjustment
8. Clogged fuel hose or pipe
9. Not enough fuel in the tank
10. Malfunctioning fuel cut solenoid valve
Adjust
Replace
Clean, or replace
Repair or replace
Retighten
Disassemble and clean
Adjust
Clean or replace
Refill
Check solenoid valve for
proper operation and
replace if necessary
Abnormal engine internal condition
1. Ruptured cylinder head gasket
2. Improper valve clearance
3. Weakened or broken valve spring
4. Loose manifold, permitting air to be
drawn in
5. Worn pistons, rings or cylinders
Replace
Adjust
Replace
Retighten and, as neces-
sary, replace gasket
Replace worn rings and
pistons and rebore as
necessary
2-2

Condition
Poor starting
(Hard starting)
Possible cause
6. Broken valve timing belt
7. Poor valve seating
8. Wrong kind of engine oil
9. Burnt valves
10. Sticky valve stem
Correction
Replace
Repair or replace
Replace
Replace
Correct or replace valve
and guide
Emission control
1. Malfunctioning PCV valve
2. Loose connection or disconnection of
vacuum hoses
Replace.
Connect securely.
3. ECM is poorly grounded.Ground ECM securely
Not enough powerInadequate compression
1. Improper valve clearance
2. Valves not seating tight
3. Valve stems tending to seize
4. Broken or weakened valve spring
5. Piston rings seized in grooves, or broken
6. Worn pistons, rings or cylinders
Adjust
Repair
Replace
Replace
Replace
Replace worn parts and
rebore as necessary
7. Leaky cylinder head gasketReplace
Improperly timed ignition
1. Improper ignition timing
2. Defective spark plug
3. Worn distributor terminals
4. Leaks, loose connection or disconnection of
high tension cord
5. Malfunctioning ignition timing advancers
Adjust
Adjust gap or replace
Dress or replace
Connect or replace as
necessary
Replace
Fuel system out of order
1. Clogged carburetor jets
2. Defective fuel pump
3. Clogged fuel filter
4. Malfunctioning choke system
5. Float level out of adjustment
6. Clogged fuel pipe
7. Clogged fuel tank outlet
8. Loose joint in fuel system
Disassemble and clean
Repair or replace
Replace
Adjust or replace
Adjust
Clean or replace
Clean
Retighten
Abnormal condition in air intake system
1. Air cleaner dirty and clogged
2. Poor returning motion of choke valve
Clean or replace
Repair, adjust or replace
Overheating tendency of engine
1. (Refer to the section entitled “over-
heating.“)
2-3

ConditionPossible causeCorrection
Not enough powerEmission control
1. Malfunctioning EGR valve
Check and replace as
necessary.
Check and replace as
2. Malfunctioning bowl vent solenoid valve.necessary.
Check and replace as
3. Malfunctioning high altitude switch.necessary
Check nad replace as
4. Malfunctioning throttle position switch
(wide open switch)
necessary
Others
1. Dragging brakes
2. Slipping clutch
.Repair or replace
Adjust or replace
Engine hesitatesAbnormal condition in electrical systems
(Momentary lack of1. Defective spark plug or plug gap out ofReplace or adjust gap
response as the acceler-
ator
adjustment
is depressed. Can2. Cracked rotor or cap in distributor,Replace
occur at all car speeds.resulting in leakage
Usually most severe3. Deteriorated ignition coil, or crackReplace
when first trying toresulting in leakage
make the car move, as4. Leaky high-tension cordsReplace
from a stop sign.)5. Ignition timing out of adjustmentAdjust as prescribed
Abnormal condition in fuel system
1. Improper adjustment of float level
2. Clogged carburetor jets
3. Malfunctioning accelerator pump
Adjust
Clean
Check and replace as
necessary
4. Inadequately discharging fuel pumpReplace
Abnormal condition in engine
1. Loss of compression pressure due to leaky
cylinder head gasket
Replace
2. Compression pressure too low because ofReplace and rebore as
worn pistons, rings, cylinders or burnt valvesnecessary
Emission control
1. Malfunctioning bowl vent solenoid valveCheck and replace as
necessary
2. Malfunctioning throttle position switch
(wide open switch)
3. Malfunctionnig high altitude switch
4. Malfunctioning EGR valve
Check and replace as
necessary
Check and replace as
necessary
Check and replace as
necessary
5. Malfunctioning thermostatically controlled
air cleaner
Check and replace as
necessary
2-4

ConditionPossible causeCorrection
SurgesFuel system out of order
(Engine power varia- 1. Clogged fuel filterReplace
tion under steady2. Kinky, leaky or damaged fuel hoses and linesCheck and replace as
throttle or cruise.necessary
Feels like the car3. Malfunctioning fuel pumpCheck and replace as
speeds up and downnecessary
with no change in the4. Leaky manifold and carburetor gasketsReplace
accelerator pedal.)5. Improper float levelAdjust
Ignition system out of order
1. Improper ignition timing
2. Malfunctioning ignition timing advancers
(mechanical and vacuum)
Adjust
Check or replace
3. Leaky or loosely connected high tension cordCheck and repair or
replace
4. Defective spark plug (excess carbon deposits,Check and clean, adjust
improper gap, burned electrodes, etc..)or replace
5. Cracked rotor or cap in distributorReplace
Emission control
1. Malfunctioning bowl vent solenoid valve
2. Malfunctioning throttle position switch
(wide open switch)
3. Malfunctioning high altitude switch
4. Malfunctioning EGR valve
5. Malfunctioning thermostatically controlled
air cleaner
Check and replace as
necessary
Check and replace as
necessary
Check and replace as
necessary
Check and replace as
necessary
Check and replace as
necessary.
Dieseling
(Engine continues to
run after ignition
switch is turned off.
it runs unevenly and
may make knocking
noise. )
Malfunctioning fuel cut solenoid valve in
carburetor
Check solenoid valve for
proper operation and
replace as necessary
Erratic idling
(Improper engine
idling)
Abnormal condition in ignition system
1. Defective spark plug
2. Leaky or disconnected high tension cord
3. Worn distributor terminals
4. Improper ignition timing
5. Cracked cap in distributor, leakage inside
Adjust or replace
Connect or replace
Replace
Adjust
Replace
2-5

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