1987 SUZUKI GRAND VITARA Service Repair Manual

1-3. CHASSIS AND BODY
30. CLUTCH PEDAL INSPECTION
1) Check clutch pedal height. It should be the
same as brake pedal height.
2) Check clutch pedal free travel.
Clutch pedal free travel20 - 30 mm
(0.8 - 1.1 in.)
For the details of the above steps 1) and 2),
refer to MAINTENANCE SERVICE (p. 11-8) of
SECTION 11.
31. BRAKE DISCS, PADS, BRAKE DRUMS
AND SHOES INSPECTION
Brake Discs and Pads
I) Remove wheel and caliper but don’t discon-
nect brake hose from caliper.
2) Check front disc brake pads and discs for
excessivewear,damageand deflection.
Replace parts as necessary. For the details,
refer to p. 19-I 6 and 19-I 7 of SECT ION 19.
Be sure to torque caliper guide pins to specifi-
cation for reinstallation.
Brake Drums and Shoes
I) Remove wheel and brake drum.
2) Check rear brake drums and brake linings for
excessive wear and damage, while wheels and
drums are removed. Also check wheel cylin-
ders for leaks, at the same time. Replace
these parts as necessary.
For the details, refer to p. 19-21 and p. 19-
22 of SECTION 19.
32. BRAKE HOSES AND PIPES INSPECTION
Check brake hoses and pipes for proper hook-
up, leaks, cracks, chafing and other damage.
Replace any of these parts as necessary.
CAUTION:
After replacing any brake pipe or hose, be
sure to carry out air purge operation.
33. BRAKE FLUID INSPECTION AND
CHANGE
[INSPECTION]
1) Check around master cylinder and reservoir
for fluid leakage.
If found leaky, correct.
2) Check fluid level
If fluid level is lower than the minimum level
of reservoir, refilling is necessary. Fill reservoir
with specified brake fluids.
Brake fluid Speifi;t3ons
For the details, refer to MAINTENANCE
SERVICE (p. 19-42) of SECTION 19.
CAUTION:
Since the brake system of this car is factory-
filled with glycol-base brake fluid, do not
use or mix different type of fluid when
refilling the system; otherwise serious
damage will occur. Do not use old or used
brake fluid, or one taken from unsealed
container.
[CHANGE]
1) Change brake fluid. As fluid change procedure,
drain existing fluid from brake system com-
pletely, fill the system with above recom-
mended fluid and carry out air purge opera-
tion.
For description of air purge, refer to p. 19-46
and 19-47 of SECTION 19.
34. BRAKE PEDAL INSPECTION
Check brake pedal travel.
For -checking procedure, refer to PEDAL TRA-
VEL CHECK (p. 19-43) of SECTION 19.
35. BRAKE LEVER AND CABLE
INSPECTION
Parking Brake Lever
I) Check tooth tip of each notch for damage or
wear. If any damage or wear is found, replace
parking lever.
2) Check parking brake lever for proper opera-
tion and stroke, and adjust it if necessary.
For checking and adjusting procedures,
refer to PARKING BRAKE INSPECTION
AND ADJUSTMENT (p. 19-44) of SECTION
19.
1-17

Parking Brake Cable
Inspect brake cable for damage and smooth
movement. Replace cable if it is in deteriorat-
ed condition.
36. TIRE INSPECTION AND ROTATION
1) Check tires for uneven or excessive wear, or
damage. If defective, replace.
2) Check inflating pressure of each tire and
adjust pressure to specification as necessary.
NOTE:
l Tire inflation pressure should be checked
when tires are cool.
l Specified tire inflation pressure should be
found on tire placard or in owners’ manual
which came with the car.
3) Rotate tires.
For the details of above steps 1) to 3), refer
to MAINTENANCE SERVICE (p. 18-19 and
18-20) of SECTION 18.
37. WHEEL DISCS AND FREE WHEELING
HUBS (if equipped) INSPECTION
Wheel Discs
Inspect each wheel disc for dents, distortion and
cracks. A disc in badly damaged condition must
be replaced.
Free Wheeling Hub
This is applicable to the car equipped with
free wheeling hubs.
Check free wheeling hub for proper operation
by moving free wheeling hub knob to LOCK
and FREE positions. (The same check on both
right and left wheels)
For checking procedure, refer to MAINTE-
NANCE SERVICE (p. 17-29) of SECTION 17.
38. STEERING KNUCKLE OIL SEAL
REPLACEMENT
For replacement procedure, refer to MAIN-
TENANCE SERVICE (p. 17-23) of SECTION
17.
39. WHEEL BEARING INSPECTION
[Inspection of wheel bearing]
1) Check front wheel bearing for wear, damage,
abnormal noise or rattles. For the details,
refer to MAINTENANCE (p. 17-20 and
17-21) of SECTION 17.
2) Check rear wheel bearing for wear, damage
abnormal noise or rattles. For the details,
refer to MAINTENANCE SERVICE (p. 17-24)
of SECTION 17.
[Inspection of front wheel bearing grease]
1) Remove wheel hub and spindle referring to
FRONT WHEEL HUB REMOVAL of SEC-
TION 17.
2) Check grease around front wheel bearing
rollars and between front axle shaft surface
and wheel spindle bush for deterioration and
capacity.
If grease is deteriorated, remove grease tho-
roughly and apply enough amount of new
SUZUKI SUPER GREASE A or wheel bearing
grease. If grease is found insufficient, add some
more.
1-18

3) Install spindle, bearings, wheel hub, bearing
nut and brake disc referring to INSTALLA-
TION (p. 17-12) of SECTION 17.
4) Adjust bearing preload and then tighten
bearing lock nut to specification. Refer to
MAINTENANCE (p. 17-21) of SECTION 17.
5) Install drive flange or free wheeling hub (if
equipped), brake caliper with mounting and
wheel referring to INSTALLATION (p. 17-
12) of SECTION 17.
For tightening torque of each bolt and nut,
refer to torque table (p. 17-26) of SECTION
17.
40. SHOCK ABSORBERS INSPECTION
1) Inspect absorbers for evidence of oil leakage,
dents or any other damage on sleeves; and
inspect anchor ends for deterioration.
2) Depending on the results of the above inspec-
tion, replace absorbers.
2
1. Shock absorber
2. Leaf spring
WARNING:
When handling rear shock absorber in
which high-pressure gas is sealed, make
sure to observe the following precautions.
1. Don’t disassemble it.
2. Don’t put it into fire.
3. Don’t store it where it gets hot
4. Before disposing it, be sure to drill a
hole in it where shown in the illustration
below and let gas and oil out. Lay it
down sideways for this work.
Drill hole with approx-imately 3 mm (0.12 in.)diameter.
Cover with a vinyl envelope asshown so that drill dust willnot scatter around.
41. PROPELLER SHAFTS INSPECTION AND
LUBRICATION
1) Lubricate propeller shaft,
The nipple for lubrication is located on each
sliding yoke. Be sure to use chassis grease.
2) Check universal joint and spline of propeller
shaft for rattle. If rattle is found, replace
defective part with a new one.
1-19

3) Check propeller shaft (No. 1, No. 2, No. 3)
flange yoke bolts for tightness, and retighten
them as necessary:
N.mkg-mlb-ftTighteningtorque23-302.3-3.017.0-21.5
42. TRANSMISSION, TRANSFER,
DIFFERENTIAL OIL INSPECTION
AND CHANGE
[I nspectionl
1) Inspect transmission case, transfer case and
differential housing for evidence of oil leakage.
Repair leaky point if any.
2) Make sure that the car is placed level for oil
level check.
3) Remove each level plug of transmission,
transfer and differential (front and rear).
In any of these cases, oil level can be checked
roughly by means of level plug hole. That is,
,if oil flows out of level plug hole or if oil
level is found up to hole when level plug is
removed, oil is properly filled.
If oil is found insufficient, pour specified
amount of specified oil as given in the below
table.
[Change]
Oil change procedure is as follows.
Place the car level and drain oil by removing
drain plug. Pour specified amount of specified
oil as in the below table and tighten drain plug
and filler plug to specified torque.
It is highly recommended to use SAE 75W-90
gear oil.
Viscosity chart
SAE
75w-ao,75w-90
"C -30 --20 -10 0 10 20 30 40"F -22 -4lb 32 50 68 86104
Temperature
Transmission oil change
Oil capacity
Type of oil
1.3 liters
(2.7/2.3 US/Imp pt.)
Gear oil, SAE
8OW-90,75W-80 or
75w-90
l-20
18-28N.m
I ”’
1. Oil filler plug
2. Oil drain plug
3. Oil level plug
Transfer oil change
Oil capacity0.8 liters
(1.7/l .4 US/Imp. pt.)
Type of oilGear oil SAE 8OW-90,
75W-80 or 75W-90
18 - 28 N.m(1.8 - 2.8 kg-m)(13.5 - 20.0 lb-ft)-R-Oil drair18 - 28 N&(1.8 - 2.8 kg-m)(13.5 - 20.0 lb-ft)
Differential oil change (Front and rear)
1.5 liters
(3.2/2.6 US/Imp pt.)
2.0 liters
(4.2/3.5 US/Imp pt.)
FrontRear
Oil
capacity
Type of
oil
Hypoid gear oil, SAE 80W-90,
75W-80 or 75W-90

Oil filler andlevel plug
Oil drain plug
18 - 25 N.m(1.8 - 2.5 kg-m)(13.5 - 18.0 lb-ft)
43. LEAF SPRING lNSPECTlON
Check leaf spring for wear, crack and damage.
(Where each end of the shorter leaf contacts.)
If excessive wear of cracking is noted, replace
the spring with a new one.
44. BOLTS AND NUTS TIGHTENING
Check suspension bolts and nuts for tightness
and retighten them as necessary.
Repair or replace defective parts, if any.
NOTE:
For the details of check points, refer to the
table of MAINTENANCE SERVICE (p. 17-24)
of SECTION 17.
45. STEERING SYSTEM INSPECTION
1) Check steering wheel for play and rattle,
holding car in straight forward condition on
the ground.
Steering wheel play10 - 30 mm
(0.4 - 1.2 in.)
3) Check bolts and nuts for tightness and retigh-
ten them as necessary. Repair or replace
defective parts, if any.
Refer to MAINTENANCE SERVICE on p.
18-18 for particular check points.
4) Inspect steering gear box for evidence of oil
leakage. If leakage is found, check oil level
in gear box.
NOTE:
For the details of the above steps 1) to 41, refer
to MAINTENANCE SERVICE (p. 18-18) of
SECTION 18.
.5) Check boots of tie rod ends for damage. If
damage is found, replace it with a new one.
6) Check wheel alignment.
Alignment service data
Side slipOUTO-IN3m/km
Toe-in2-6mm
(0.079 - 0.236 in.)
Camber1 degree (1”) *45’
Kingpin inclination 9 degrees (9”) f 2’
Caster3 degrees 30 minutes
(3” 30’) f I0
NOTE:
For the details of wheel alignment, refer to
WHEEL ALIGNMENT (p. 18-16) of SECTION
18.
46. DOOR HINGES LUBRICATION
Lubricate door hinges for smooth operation.
2) Check universal joint and rubber joint of
steering shaft for rattle and damage. If rattle
or damage is found, replace defective part
with a new one.
1-21

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