2001 SUZUKI GRAND VITARA 4 wheel drive

Important
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
WARNING, CAUTION
and NOTE
have special meanings. Pay special attention to the messages highlighted by
these signal words.
WARNING:
Indicates a potential hazard that could result in death or injury.
CAUTION:
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
WARNING:
This service manual is intended for authorized Suzuki dealers and qualified service mechanics only.
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the driver
and passengers.
WARNING:
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
 If the air bag system and another vehicle system both need repair, Suzuki recommends that the air
bag system be repaired first, to help avoid unintended air bag system activation.
 Do not modify the steering wheel, instrument panel or any other air bag system component (on or
around air bag system components or wiring). Modifications can adversely affect air bag system
performance and lead to injury.
 If the vehicle will be exposed to temperatures over 93°C (200°F) (for example, during a paint baking
process), remove the air bag system components (air bag (inflator) modules, forward sensor(s),
SDM and/or seat belt pretensioners) beforehand to avoid component damage or unintended activa-
tion.

Table of Contents
GENERAL INFORMATION TRANSMISSION, CLUTCH AND
DIFFERENTIAL0A7A1
General Information0A
0B7B1
Maintenance and Lubrication0B
Manual Transmission7A1
7C1
HEATING AND AIR CONDITIONING
Automatic Transmission7B1
1A7D
Heater and Ventilation1A
Clutch7C1
1B7E
Air Conditioning1B
Transfer7D7F
STEERING, SUSPENSION, WHEELS
AND TIRESDifferential (Front)7E
3
Differential (Rear)7F
3A8
Steering, Suspension, Wheels and Tires3 ELECTRICAL SYSTEM3B18A
Front End Alignment3A
Electrical System8
3C18B
Power Steering (P/S) System3B1
Wiring Diagram8A3D8C
Air Bag Steering Wheel and Column3C1
Lightening System8B3E8D
Front Suspension3D
Instrumentation / Driver Information8C
3F8E
Rear Suspension3E
Windows, Mirrors, Security and Lock8D
8G
Wheels and Tires3F
Cruise Control System8E
4A2
DRIVE SHAFT AND PROPELLER SHAFT
Immobilizer control system (if equipped)8G4B9
Front Drive Shaft / Shaft Bearing,
Oil Seal4A2BODY SERVICE
Body Service9
510
Propeller Shaft4B RESTRAINT SYSTEM
5A10A
BRAKE SYSTEM
Restraint System10
5B10B
Brakes5
Seat Belt10A
5C
Brake Pipe / Hose / Master Cylinder5A
Air Bag System10B
5E2
Front Brake5B
Parking and Rear Brake5C
6-1
Antilock Brake System (ABS)5E2
6A2
ENGINE
6B
General Information and
Diagnosis (H27 Engine)6-1
6C
6E2
Engine Mechanical (H27 Engine)6A2
6F2
Engine Cooling6B
6G
Engine Fuel6C
6H
Engine and Emission Control System
(SFI For H27 Engine)6E2
6K
Ignition System (H27 Engines)6F2
Cranking System6G
Charging System6H
Exhaust System6K
NOTE:
For the screen toned Sections in the above table, refer to the same section of the Related Manuals
mentioned in FOREWORD of this manual.

0A-2 GENERAL INFORMATION
Precautions
Precaution for Vehicles Equipped with A Sup-
plemental Restraint
(Air Bag) System
Diagnosis
 When troubleshooting air bag system, be sure to follow
“DIAGNOSIS” in SECTION 10B. Bypassing these proce-
dures may result in extended diagnostic time, incorrect
diagnosis, and incorrect parts replacement.
 Never use electrical test equipment other than that
specified in this manual. WARNING:
 The configuration of air bag system parts are as shown
in the figure. When it is necessary to service (remove,
reinstall and inspect) these parts, be sure to follow
procedures described in SECTION 10B. Failure to fol-
low proper procedures could result in possible air bag
system activation, personal injury, damage to parts or
air bag system being unable to activate when neces-
sary.
 If the air bag system and another vehicle system both
need repair, SUZUKI recommends that the air bag sys-
tem be repaired first, to help avoid unintended air bag
system activation.
 Do not modify the steering wheel, dashboard, or any
other air bag system components. Modifications can
adversely affect air bag system performance and lead
to injury.
 If the vehicle will be exposed to temperatures over
93°C (200°F) (for example, during a paint baking pro-
cess), remove the air bag system components before-
hand to avoid component damage or unintended air
bag system activation.
1. Air bag wire harness 5. Contact coil
2. Passenger air bag (inflator) module 6. Driver air bag (inflator) module
3. SDM 7. Forward sensors
4. Seat belt pretensioners
15
2 6
7
5
3
44 7
1
WARNING:
Never attempt to measure the resistance of the air bag
(inflator) modules (driver and passenger) and seat belt
pretensioners (driver and passenger). It is very danger-
ous as the electric current from the tester may deploy the
air bag or activate the pretensioners.

MAINTENANCE AND LUBRICATION 0B-3
IntervalKm (× 1,000) 153045607590
Miles (× 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
CHASSIS AND BODY
6-1. Clutch (pedal and fluid level)–I–I–I
6-2.Brake discs and pads (thickness, wear, damage) IIIIII
Brake drums and shoes (wear, damage)–I–I–I
6-3. Brake hoses and pipes (leakage, damage, clamp)–I–I–I
6-4. Brake fluid–R–R–R
6-5. Brake lever and cable (damage, stroke, operation) Inspect at first 15,000 km (9,000 miles)
only
6-6.Tires (wear, damage, rotation) IIIIII
6-7.Wheel discs (damage) IIIIII
6-8. Suspension system (tighteness, damage, rattle, breakage)–I–I–I
6-9. Propeller shafts and drive shafts––I––I
6-10. Manual transmission oil (leakage, level) (I: 1st 15,000 km only) I–R––R
6-11. Automatic transmission Fluid level –I–I–I
Fluid change Replace every 165,000 km (99,000
miles)
Fluid hose–––R––
6-12. Transfer oil (leakage, level) I–I–I–
6-13. Differential oil (leakage, level) (R: 1st 15,000 km only) R or I–I–I–
6-14. Steering system (tighteness, damage, breakage, rattle)–I–I–I
6-15.Power steering (if equipped) IIIIII
6-16. All latches, hinges and locks–I–I–I
6-17. Air conditioning filter (if equipped)–IR–IR
NOTE:
 “R”: Replace or change
 “I”: Inspect and correct, replace or lubricate if necessary

0B-4 MAINTENANCE AND LUBRICATION
Maintenance Recommended under Severe Driving Conditions
If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is
recommended that applicable maintenance operation be performed at the particular interval as given in the
chart below.
Severe condition code :
A: Repeated short trips E: Repeated short trips in extremely cold weather
B: Driving on rough and/or muddy roads F: Leaded fuel use
C: Driving on dusty roads G: – – – – – –
– –
D: Driving in extremely cold weather
and/or salted roadsH: Trailer towing (if admitted)
Severe
Condition CodeMaintenanceMaintenance
OperationMaintenance Interval
– B CD – – –ITEM 1-1
Drive belt (V-rib belt)IEvery 15,000 km
(9,000 miles) or 12 months
REvery 45,000 km
(27,000 miles) or 36 months
A – CDEF – HITEM 1-4
Engine oil and oil filterREvery 5,000 km
(3,000 miles) or 4 months
– B– – – – – –ITEM 1-6
Exhaust pipe mountingsIEvery 15,000 km
(9,000 miles) or 12 months
– – C – – – – – ITEM 3-1
Air cleaner filter *1IEvery 2,500 km
(1,5000 miles)
REvery 30,000 km
(18,000 miles) or 24 months
ABC–EF–HITEM 2-1
Spark plugsNickel plug REvery 10,000 km
(6,000 miles) or 8 months
Iridium plug REvery 30,000 km
(18,000 miles) or 24 months
– B – D E – – HITEM 6-9
Propeller shafts and drive shafts IEvery 15,000 km
(9,000 miles) or 12 months
– B – – E – – HITEM 6-10, 6-12, 6-13
Manual transmission,
transfer and differential oilREvery 30,000 km
(18,000 miles) or 24 months
– B – – E – – HITEM 6-11
Automatic transmission fluid REvery 30,000 km
(18,000 miles) or 24 months
– B – – – – – – ITEM 6-8
Suspension bolts and nutsTEvery 15,000 km
(9,000 miles) or 12 months
– B C D – – – HITEM 6-7
Wheel bearingIEvery 15,000 km
(9,000 miles) or 12 months
– – CD – – – –ITEM 6-17
Air conditioning filter *2
(if equipped)IEvery 15,000 km
(9,000 miles) or 12 months
REvery 45,000 km
(27,000 miles) or 36 months
NOTE:
“I”: Inspect and correct, replace or lubricate if necessary
”R”: Replace or change
”T”: Tighten to the specified torque
*1: Inspect or replace more frequently if necessary.
*2: Clean or replace more frequently if the air from the air conditioning decreases.

3C1-2 AIR BAG STEERING WHEEL AND COLUMN
General Description
This double tube type steering column has the following three important features in addition to the steering func-
tion:
The column is energy absorbing, designed to compress in a front-end collision.
The ignition switch and lock are mounted conveniently on this column.
With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehi-
cle.
To insure the energy absorbing action, it is important that only the specified screws, bolts, and nuts be used as
designated and that they are tightened to the specified torque. When the column assembly is removed from the
vehicle, special care must be taken in handling it. Use of a steering wheel puller other than the one recom-
mended in this manual or a sharp blow on the end of the steering shaft, leaning on the assembly, or dropping
the assembly could shear the plastic shear pins which maintain column length and position.
The driver air bag (inflator) module is one of the supplemental restraint (air bag) system components and is
mounted to the center of the steering wheel. During certain frontal crashes, the air bag system supplements the
restraint of the driver’s and passenger’s seat belts by deploying the air bags. The air bag (inflator) module
should be handled with care to prevent accidental deployment. When servicing, be sure to observe all WARN-
INGS in this section. Refer to “SERVICE PRECAUTIONS” in Section 10B.
1. Driver air bag (inflator) module 5. Steering column upper cover 9. Steering column hole cover 13. Steering column lower seal
2. Steering wheel 6. Steering column lower cover 10. Steering shaft joint 14. Cap (if equipped)
3. Steering wheel nut 7. Steering column assembly 11. Steering lower shaft assembly 15. Steering upper shaft assembly
4. Contact coil and combination
switch assembly8. Steering lock assembly 12. Adjustable steering column
release lever

3C1-12 AIR BAG STEERING WHEEL AND COLUMN
Take measurement “b” as shown in the figure. If it is shorter
than specified length, replace steering upper shaft assembly
with new one.
Steering upper shaft assembly length “b” :
419.0 ± 1.0 mm (16.50 ± 0.04 in.)
Tightening Torque Specification
“b”
Fastening partTightening torque
Nm kg-m lb-ft
Driver air bag (inflator) module bolt 9 0.9 6.5
Steering shaft nut 33 3.3 23.5
Steering column mounting bolt and nut 25 2.5 18.0
Steering shaft joint bolt 25 2.5 18.0
Steering lower shaft assembly lower joint bolt 25 2.5 18.0
Shift (key) interlock cable screw 2.2 0.22 1.6
Steering upper shaft mounting bolt 23 2.3 17.0
Steering upper shaft upper joint nut 23 2.3 17.0

4A2-2 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL
On-Vehicle Service
Drive Shaft
ASSEMBLY
1) Fully apply joint grease to wheel side joint.
Use joint grease in the tube included in spare part.
“A” : Joint Grease (about 85- 95 g (3.0 - 3.4 oz) (Yellow))
2) Fit wheel side boot (1) on shaft.
Fill up inside of boot (1) with joint grease.
Before fixing boot band (2), insert screwdriver into boot (1)
on joint side and allow air to enter boot so that air pressure in
boot (1) becomes the same as atmospheric pressure.
3) Fixing boot band (2).
4) Install boot (1) onto drive shaft till its small diameter side fits
to shaft groove and fix there with boot band (2).
5) Install cage (1) to shaft.CAUTION:
To prevent any problem caused by washing solution,
do not wash joint boots. Degreasing of those parts
with cloth is allowed.
Bend each boot band against forward rotation.
Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its
durability.
[A] : Wheel side
CAUTION:
Install cage (1) directing smaller outside diameter side to
shaft end.