2002 SUZUKI GRAND VITARA Service engine

YH4
GRAND
VITARA
1. Electric leak detector
AIR CONDITIONING (OPTIONAL) 1B-29
REMOVING MANIFOLD GAUGE SET
When A / C system has been charged with a specified amount of re-
frigerant, remove manifold gauge set as follows:
1) Close low pressure-side valve of manifold gauge set, (The high
pressure-side valve is closed continuously during the process
of charging.).
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service valves.
This operation must be performed rapidly.
WARNING:
High pressure-side is naturally under high pressure.
So, care must be used to protect your eyes and skin.
5) Put caps on service valves.
LEAK-TESTING REFRIGERANT SYSTEM
Whenever a refrigerant leak is suspected in the system or any ser-
vice operation has been performed which may result in disturbing
lines or connections, it is advisable to test for leaks.
Common sense should be used in performing any refrigerant leak
test, since the need and extent of any such test will, in general, de-
pend upon the nature of a complaint and the type of a service per-
formed on the system.
LIQUID LEAK DETECTORS
There are a number of fittings and places throughout the air condi-
tioning system where a liquid leak detector solution may be used
to pinpoint refrigerant leaks.
By merely applying the solution to the area in question with a swab,
bubbles will form within seconds if there is a leak.
For confined areas, such as sections of the evaporator and con-
denser, an electronic (gas) leak detector is more practical for deter-
mining leaks.
WARNING:

To prevent explosions or fires, make sure that there are no
flammables in the vicinity.

When exposed to fire, the refrigerant turns into a poison-
ous gas (phosgene). Do not inhale this gas.

YH4
GRAND
VITARA
For CAMI production vehicle
For IWATA production vehicle
2. High pressure side (Delivery side hose)
3. Lower pressure side (Suction side pipe)
AIR CONDITIONING (OPTIONAL) 1B-49
COMPRESSOR ASSEMBLY
CAUTION:
None of refrigerant, compressor oil and component parts is interchangeable between two types of A / C:
one using CFC-12 (R-12) and the other using HFC-134a (R-134a).
For identification between these two types, refer to page 1B-2.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A / C installed in the vehicle being serviced.
Use of incorrect refrigerant or compressor oil will result in leakage of refrigerant, damage in parts or
other faulty condition.
PRECAUTION
When servicing the compressor, keep dirt or foreign material away from getting on or into the compressor parts
and system. Clean tools and a clean work area are important for proper service.
The compressor connection and the outside of the compressor should be cleaned before any ªOn-vehicleº repair
or before removal of the compressor. The parts must be kept clean at all times and any parts to be reassembled
should be cleaned with Trichloroethane, naphtha, kerosene or equivalent solvent and dried with dry air. Use only
lint free cloths to wipe parts.
The operations described are based on bench overhaul with compressor removed from the vehicle, except as
noted. They have been prepared in order of accessibility of the components.
When compressor is removed from the vehicle for servicing, the oil remaining in the compressor should be dis-
carded and new refrigerant oil added to the compressor.
Minor repair procedures may be done on the vehicle without discharging the system. Major repair procedures re-
quire that the system be discharged of refrigerant.
INSPECTION
1) Install manifold gauge set (1) as shown in the figure.
2) Close Hi (4) and Lo (5) hand valves.
3) Run engine at fast idle.
4) Check compressor assembly for following items.
If any of the above checks indicated a defect, repair compressor
assembly.

High pressure gauge reading is not low and low pressure
gauge reading is not higher than normal.

Metallic sound.

Leakage from shaft seal.

YH4
GRAND
VITARA
1. P / S fluid reservoir
2. Attachment
3. Gasket4. Union bolt
5. High pressure side
6. Low pressure side
1. P / S fluid reservoir
2. Gauge valve (open)
3. P / S pump4. P / S gear box
5. High pressure side
6. Low pressure side
3B1-10 POWER STEERING (P / S) SYSTEM
HYDRAULIC PRESSURE IN P / S CIRCUIT
HYDRAULIC PRESSURE CHECK
1) After cleaning joint of high pressure hose and P / S pump thor-
oughly, disconnect hose from pump and install special tool (oil
pressure gauge, attachment and hose).
Tighten each flare nut to specified torque.
CAUTION:
Take care not to cause damage to A / C condenser during
service operation, if equipped.
Special Tool
(A): 09915-77410 (Oil pressure gauge)
(B): 09915-77420
2) Check each connection for fluid leakage and bleed air.
Refer to ªAIR BLEEDING PROCEDUREº in this section.
3) With engine idling, turn steering wheel and warm up engine till
temperature of fluid in P/S fluid reservoir rises to 50 ± 60
C (122
± 140
F).
4) Check back pressure by measuring hydraulic pressure with en-
gine idling and hands off steering wheel.
Back pressure: Lower than 1000 kPa (10 kg / cm
2, 142 psi)
When back pressure is higher than specified values, check con-
trol valve and piping for clogging.

YH4
GRAND
VITARA
3B1-26 POWER STEERING (P / S) SYSTEM
09915-77420
Oil pressure gauge
attachment and hose set09915-77410
Oil pressure gauge09943-55010
Boot clamp plier
TIGHTENING TORQUE SPECIFICATION
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Gear box mounting bolts555.540.0
Gear box cylinder pipe flare nuts292.921.0
Gear box low pressure pipe union bolt404.029.0
Gear box high pressure pipe union bolt353.525.5
Tie-rod end lock nut656.547.0
G16 Type engine555.540.0
Pump bracket boltJ20 Type engine252.518.5
H25 Type engine454.532.5
Pump union bolt606.043.5
Oil pump mount bolts252.518.5
Pipe clamp bolt / Reservoir bracket bolt111.18.0
Steering shaft joint bolt252.518.0
High pressure flare nuts404.029.0
Pump cover bolts232.317.0
Plug606.043.5
Pressure switch (Terminal)282.820
Suction connector bolt101.07.5
Tie-rod end nut484.835.0
Tie-rod (for canvas top LH model only)858.561.5
REQUIRED SERVICE MATERIAL
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUPER GREASE (A)
(99000-25010)
Oil seal lip of P / S pump pulley shaft
Power steering fluidAn equivalent of DEXRON
-III or
DEXRON
-II

To fill P / S fluid reservoir

Parts lubrication when installing
SPECIAL TOOL

YH4
GRAND
VITARA
[A]: With ABS
[B]: Without ABS
1. Piston stopper circlip
2. Piston stopper
3. Cylinder cup
4. Plate
5. Primary piston
6. Piston cup
7. Primary piston return spring
8. Primary spring retainer
9. Secondary piston pressure cup
10. Secondary piston
11. Return spring secondary seat
12. Secondary piston return spring
13. Secondary piston stopper bolt
14. Master cylinder body
ªAº: Primary piston
ªBº: Secondary piston
[B] [A]
5A-2 BRAKES PIPE / HOSE / MASTER CYLINDER
GENERAL DESCRIPTION
MASTER CYLINDER ASSEMBLY
The master cylinder has two pistons and three piston cups. Its hydraulic pressure is produced in the primary (ªaº
in the figure below) and secondary (ªbº) chambers. The hydraulic pressure produced in the primary chamber (ªaº)
acts on the front (for vehicle without ABS, rear) wheel brakes.
Also, the hydraulic pressure produced in the secondary chamber (ªbº) acts on the rear (for vehicle without ABS,
front) wheel brakes.
NOTE:
Replace all components included in repair kits to service this master cylinder. Lubricate rubber parts with
clean, fresh brake fluid to ease assembly. Do not use lubricated shop air on brake parts as damage to rub-
ber components may result. If any hydraulic component is removed or brake line disconnected, bleed the
brake system.
The torque values specified are for dry, unlubricated fasteners.
BOOSTER ASSEMBLY
The booster is located between the master cylinder and the brake pedal. It is so designed that the force created
when the brake pedal is depressed is mechanically increased combined with the engine vacuum.
The booster has two diaphragms of
ù7.5 in. (191 mm) effective diameter.
CAUTION:

Never disassemble brake booster assembly. If it is found faulty, replace it with new assembly.

The torque values specified are for dry, unlubricated fasteners. If any hydraulic component is re-
moved or brake line disconnected, bleed the brake system.

YH4
GRAND
VITARA
5E1-20 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
TABLE ± E EBD WARNING LAMP (BRAKE WARNING LAMP) CHECK-LAMP
COMES ªONº STEADY
CIRCUIT DESCRIPTION
EBD warning lamp (brake warning lamp) is controlled by parking brake switch, brake fluid level switch and ABS
control module / hydraulic unit assembly through lamp driver module in combination meter. Refer to ªTABLE-Aº for
circuit diagram.
STEP
ACTIONYESNO
11) Make sure that:

Parking brake is completely released.Go to step 2.Release parking
brake completely

Brake fluid level is upper than the minimum level.
Are the check results OK?and / or replenish
brake fluid.
2Does ªABSº warning lamp come on?Perform ªTABLE Bº
previously
outlined.Go to step 3.
31) Disconnect ABS hydraulic unit / control module
connector.
2) Check for proper connection to ABS hydraulic unit /
control module connector at terminals ªA26º.
3) If OK, apply chocks to wheels and select gear in neutral
position (P range for A / T).
4) Keep brake pedal depressed and start engine.
Release parking brake.
5) Connect terminal ªA26º of disconnected connector to
ground using service wire.
Does EBD warning lamp (brake warning lamp) turn off?Substitute a
known-good ABS
hydraulic unit /
control module
assembly and
recheck.ªBrº circuit open.
If wire and
connection are
OK, replace
combination
meter.

YH4
GRAND
VITARA
7A
MANUAL TRANSMISSION (TYPE 1) 7A-1
TYPE 1
GENERAL DESCRIPTION7A- 1 . . . . . . . . . . . . . .
DIAGNOSIS7A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7A- 3 . . . . . . . . . . . . . . . .
Gear Oil 7A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Control Levers 7A- 4. . . . . . . . . . . . . . . . . . .
Switches 7A- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Mounting 7A- 8. . . . . . . . . . . . . . . .
Dismounting of Trans. Unit 7A- 9. . . . . . . . . . . . .
Remounting of Trans. Unit 7A-12. . . . . . . . . . . . . Extension Case (2WD MODEL) 7A-13. . . . . . . .
Extension Case Oil Seal
(2WD MODEL) 7A-13. . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7A-14 . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7A-14 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7A-14 . . . . . .
SPECIAL TOOL7A-14 . . . . . . . . . . . . . . . . . . . . . . .
As the aluminum case is sealed with liquid type gas-
ket, it is necessary to use genuine sealant or its equiv-
alent on its mating surfaces when reassembling it.
Also, the case fastening bolts must be tightened to
specified torque by means of the torque wrench and
tightening over or below the specified torque should
be avoided.
The description under ON-VEHICLE SERVICE in this
section covers a part of the TYPE 2 manual transmis-
sion and the transfer. The transfer is next to the trans-
mission as well, but their gear boxes are independent
and each of them has its own drain and level / filler
plugs for the oil change or the level check.
For the repair procedure of the transfer unit, refer to
Section 7D.
SECTION 7A
MANUAL TRANSMISSION
(TYPE 1)
CONTENTS
GENERAL DESCRIPTION
The manual transmission consists of the input shaft,
main shaft, countershaft and reverse gear which are
installed in the aluminum case. Its gears are of for-
ward five speeds in synchro mesh and reverse one
speed in constant mesh system.
The main shaft gears are held by the needle bearings
and on them the synchronizer rings and synchronizer
sleeve & hubs are assembled.
The gear shift lever case is located at the upper be-
hind the transmission case and has a cam which pre-
vents direct gear shift from the 5th speed gear to the
reverse gear.

YH4
GRAND
VITARA
Viscosity chart
SAE
1. Reverse idle gear shaft bolt
(DO NOT LOOSEN IT)
MANUAL TRANSMISSION (TYPE 1) 7A-3
ON-VEHICLE SERVICE
GEAR OIL
INSPECTION AND CHANGE
1) Before changing or inspecting oil, be sure to stop engine and lift
vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage ex-
ists, correct or repair it.
3) Drain old oil and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
NOTE:

It is highly recommended to use SAE 75W-90 gear oil.

Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage and
status of breather hoses.

If water or rust is mixed in drained oil, be sure to check
breather hose and boot of transmission and transfer.
Gear Oil Specification
Oil grade: API GL-4
Viscosity: SAE 75W-85, 75W-90 or 80W-90
Oil Capacity:
Transmission 1.5 liters (3.2 / 2.6 US / Imp. pt)
Transfer 1.7 liters (3.6 / 3.0 US / Imp. pt)
4) Torque drain plug and level / filler plug as specified below after
applying sealant to its thread.
CAUTION:

Transmission oil must not be poured through gear shift
control lever part.

Do not loosen or remove reverse idle gear shaft bolt.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)