1999 SUZUKI GRAND VITARA Exhaust

YH4
GRAND
VITARA
MAINTENANCE AND LUBRICATION 0B-11
1. Reservoir
2. FULL level mark
3. LOW level mark
4. Arrow mark
5. Reservoir cap
546) 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 cap, align arrow marks on reser-
voir and cap.
CAUTION:
When changing engine coolant, use mixture of 50% wa-
ter and 50% ANTIFREEZE / ANTICORROSION COOLANT
for the market where ambient temperature falls lower
than ±16C (3F) in winter, and mixture of 70% water and
30% ANTIFREEZE / ANTICORROSION COOLANT for the
market where ambient temperature doesn't fall lower
than ±16C (3F).
Even in a market where no freezing temperature is antici-
pated, mixture of 70% water and 30% ANTIFREEZE / AN-
TICORROSION COOLANT should be used for the pur-
pose of corrosion protection and lubrication.
ITEM 1-6
Exhaust System Inspection
WARING:
To avoid danger of being burned, do not touch exhaust sys-
tem when it is still hot. Any service on exhaust system
should be performed when it is cool.
When carrying out periodic maintenance, or the vehicle is raised for
other service, check exhaust system as follows:

Check rubber mountings for damage, deterioration, and out of
position.

Check exhaust system for leakage, loose connections, dents and
damages.
If bolts or nuts are loose, tighten them to specification.

Check nearby body areas for damaged, missing, or misposi-
tioned parts, open seams, holes, loose connections or other de-
fects which could permit exhaust fumes to seep into the vehicle.

Make sure that exhaust system components have enough clear-
ance from the underbody to avoid overheating and possible dam-
age to the floor carpet.

Any defects should be fixed at once.

YH4
GRAND
VITARA
0B-24 MAINTENANCE AND LUBRICATION
FINAL INSPECTION
Seats
Check that seat slides smoothly and locks securely at
any position. Also check that reclining mechanism of
front seat back allows it to be locked at any angle.
Seat Belt
Inspect belt system including webbing, buckles, latch
plates, retractors and anchors for damage or wear.
If ªREPLACE BELTº label on front seat belt is visible,
replace belt.
Check that seat belt is securely locked.
Battery Electrolyte Level Check
Check that the electrolyte level of all battery cells is
between the upper and lower level lines on the case.
If battery is equipped with built-in indicator, check bat-
tery condition by the indicator.
Accelerator Pedal Operation
Check that pedal operates smoothly without getting
caught or interfered by and other part.
Engine Start
Check engine start for readiness.
On automatic transmission vehicles, try to start the
engine in each select lever position. The starting mo-
tor should crank only in ªPº (Park) or ªNº (Neutral).
On manual transmission vehicles, place the shift le-
ver in ªNeutral,º depress clutch pedal fully and try to
start.
Exhaust System Check
Check for leakage, cracks or loose supports.
Clutch (For Manual transmission)
Check for the following:

Clutch is completely released when depressing
clutch pedal.

No slipping clutch occurs when releasing pedal and
accelerating.

Clutch itself is free from any abnormal condition.
Gearshift or Select Lever (Transmission)
Check gear shift or select lever for smooth shifting to
all positions and for good performance of transmis-
sion in any position.
With automatic transmission equipped vehicle, also
check that shift indicator indicates properly according
to which position select lever is shifted to.
With automatic transmission equipped vehicle, make
sure that vehicle is at complete stop when shifting se-
lect lever to ªPº range position and release all brakes.
Brake
[Foot brake]
Check the following:

that brake pedal has proper travel,

that brake works properly,

that it is free from noise,

that braking force is applied equally on all wheels,

and that brake do not drag.
[Parking brake]
Check that lever has proper travel.
WARNING:
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property damage.
Be prepared to apply regular brake quickly
even if vehicle should start to move.
Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and
brake lever is pulled all the way.
WARNING:
When carrying out road tests, select a safe
place where no man or no running vehicle is
seen so as to prevent any accident.
WARNING:
Before performing the following check, be
sure to have enough room around the vehicle.
Then, firmly apply both the parking brake and
the regular brakes. Do not use the accelerator
pedal. If the engine starts, be ready to turn off
the ignition promptly. Take these precautions
because the vehicle could move without warn-
ing and possibly cause personal injury or
property damage.

YH4
GRAND
VITARA
7A-6 MANUAL TRANSMISSION (TYPE 1)
3, (a)
1. Coupler
2. Clamp3. 4WD switch
4. Boot No. 2
1. Back up light switch
2. 4WD switch
1. Back up light switch coupler
2. Front propeller shaft
SWITCHES
TRANSFER 4WD SWITCH
1) Remove console box and lift transmission control lever boots
No. 2 and No. 3. (Refer to page 7A-4.)
2) Remove transfer control lever boot No. 2, unclamp wiring on
transfer case to free it and pull off coupler.
3) Replace switch and connect as it was.
Tightening Torque
(a): 20 N
.m (2.0 kg-m, 14.5 lb-ft)
4) Turn ON ignition switch, shift transfer shift control lever to 4WD
position and check that indicator lights. Turn OFF switch after
checking.
NOTE:

When removing and reinstalling switch, use care not to let
dust enter transfer box inside.

Make sure to reset clamp for wiring which is located
where invisible directly.

It is recommended to work on transfer shift control lever
boot No. 1 from underside of vehicle on lift.

Identify this switch by its leg part which is different for that
of back up light switch.
BACK UP LIGHT SWITCH
WARNING:
Refrain from work while exhaust center pipe is hot.
REMOVAL AND INSTALLATION
NOTE:
When replacing switch, use care not to let dust enter transmis-
sion through switch hole.
1) Lift up vehicle.
2) Remove coupler(s) for switch wiring.

YH4
GRAND
VITARA
1. Back up light switch
2. Exhaust center pipe
1. Ohmmeter
2. Back up light switch or 4WD switch1, (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
.m (4.5 kg-m, 32.5 lb-ft) (Type 2)
4) When back up light switch has been replaced, check switch for
proper function with ignition switch turned ON and gear shifted
to reverse position. Turn OFF switch after checking its function.
INSPECTION OF 4WD SWITCH AND BACK UP LIGHT
SWITCH
1) Undo clamp and disconnect coupler of back up light switch
and / or 4WD switch.
2) Function of back up light switch can be checked as shown in fig-
ure.
There should be conduction at these terminals only when shift
lever is shifted to reverse position.
3) Function of transfer 4WD switch can be checked in the same
manner as back up light switch.
There should be conduction at these terminals when shift lever
is shifted to 4H, and 4L positions.
Upon completion of check, connect coupler and clamp wiring har-
ness as they were.
NOTE:
When replacing switch(es), use care not to let dust enter trans-
mission through switch hole(s).

YH4
GRAND
VITARA
7A-14 MANUAL TRANSMISSION (TYPE 1)
09951-16060
Oil seal installer
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN.mkg-mlb-ft
Oil filler / level and drain plugs232.317.0
Control lever boot cover bolts60.64.0
4WD switch202.014.5
Back up light switch (Type 1)202.014.5
Back up light switch (Type 2)454.532.5
Control lever locating bolts171.712.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts and nut505.036.5
Exhaust center pipe to manifold nuts505.036.5
Muffler to exhaust center pipe bolts505.036.5
Universal joint flange bolts505.036.5
Select return spring bolts232.317.0
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)
Shift control lever.

Select return springs, bolts and guides.
Thread lock cementTHREAD LOCK CEMENT
SUPER 1333B (99000-32020)
Shift control lever locating bolts.
SealantSUZUKI BOND No. 1215
(99000-31110)
Oil Drain and filler / level plugs.
SPECIAL TOOL

YH4
GRAND
VITARA
MANUAL TRANSMISSION (TYPE 2) 7A1-5
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN´mkg-mlb-ft
Transfer oil filler / level and drain plugs232.317.0
Transmission oil filler / level and drain plugs383.827.5
Control lever boot cover bolts60.64.0
4WD switch202.014.5
Back-up light switch454.532.5
Control lever locating bolts171.712.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts505.036.5
Muffler to exhaust No. 2 pipe nuts505.036.5
Universal joint flange bolts505.036.5
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)
Shift control lever
Thread lock cement
THREAD LOCK CEMENT
SUPER 1333B
(99000-32020)

Shift control lever locating bolts
SealantSUZUKI BOND No. 1215
(99000-31110)
Oil drain and filler / level plugs

YH4
GRAND
VITARA
1. Monitor connector
AUTOMATIC TRANSMISSION (4 A / T) 7B1-17
AUTOMATIC TRANSMISSION DIAGNOSIS
This vehicle is equipped with an electronic transmission control system, which control the automatic shift up and
shift down timing, TCC operation, etc. suitably to vehicle driving conditions.
PCM (ECM) has an On-Board Diagnosis system which detects a malfunction in this system and abnormality of
those parts that influence the engine exhaust emission.
When diagnosing a trouble in transmission including this system, be sure to have full understanding of the outline
of ªOn-board Diagnostic Systemº and each item in ªPrecaution in Diagnosing Troubleº and execute diagnosis ac-
cording to ªAUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLEº given below to obtain correct result
smoothly.
NOTE:
There are two types of ON-BOARD DIAGNOSTIC SYSTEM de-
pending on vehicle specifications. The type of system for ve-
hicle being serviced can be identified by whether equipped
with monitor connector or not.

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 conditions.

Automatic fluid is at normal operating temperature (70 to 80C /
158 ± 176F).

Fluid is filled to proper level (between FULL HOT and LOW HOT
on dipstick).
1) Apply parking brake securely and place checks against wheels.
2) Attach oil pressure gauge to fluid pressure check hole in trans-
mission case.
Special Tool
(A): 09925-37810
CAUTION:
After attaching oil pressure gauge, check that not fluid
leakage exists.
3) Depress foot brake fully, run engine at idle and stall and then
check fluid pressure in ªDº or ªRº range.
CAUTION:
Do not continue running engine at stall speed longer than
5 seconds.
G16 Engine
Engine runningLine pressuregg
modeªDº rangeªRº range
At idle speed3.9 ± 4.4 kg / cm2
55 ± 63 psi
5.1 ± 5.7 kg / cm2
73 ± 81 psi
At stall speed11.7 ± 13.2 kg / cm2
166 ± 188 psi
14.2 ± 16.7 kg / cm2
202 ± 237 psi
J20 Engine
Engine runningLine pressuregg
modeªDº rangeªRº range
At idle speed3.8 ± 4.3 kg / cm2
54 ± 61 psi
5.3 ± 5.9 kg / cm2
75 ± 84 psi
At stall speed9.7 ± 11.2 kg / cm2
138 ± 159 psi
12.9 ± 15.5 kg / cm2
183 ± 220 psi
H25 Engine
Engine runningLine pressuregg
modeªDº rangeªRº range
At idle speed3.9 ± 4.4 kg / cm2
55 ± 63 psi
6.6 ± 7.2 kg / cm2
94 ± 102 psi
At stall speed11.3 ± 12.7 kg / cm2
161 ± 181 psi
14.7 ± 22.7 kg / cm2
209 ± 323 psi