2003 SUZUKI GRAND VITARA Rear brake

YH4
GRAND
vol.1
0A
0B
1A
1B
3
3A
3B1
3C
3C1
3D
3E
3F
4A2
4B
5
6
7A5A
5B
5C
5E1
6A1
6A2
6A4
6B
6C
6E1
6E2
6F1
6F2
6G
6G1
6H
6K
7A1
7B1
7C1
7D
7E
7F
8
8B
8C
8D
8G
9
10
10A
8A
10B
6-1ENGINE
General Information and
Diagnosis (G16 / J20)
General Information and
Diagnosis (H25)
Engine Mechanical (G16)
Engine Mechanical (H25)
Engine Mechanical (J20)
Engine Cooling
Engine Fuel
Engine and Emission Control
System (SFI for G16 / J20)
Engine and Emission Control
System (SFI for H25)
Ignition System (G16)
Ignition System (J20 / H25)
Cranking System
(Reduction Type)
Cranking System
(No-Reduction Type)
Charging System
Exhaust System
TRANSMISSION, CLUTCH
AND DIFFERENTIAL
Manual Transmission (Type 1)
Manual Transmission (Type 2)
Automatic Transmission
Clutch (Hydraulic Type)
Transfer
Differential (Front)
Differential (Rear)
BODY ELECTRICAL SYSTEM
Wiring Diagram
Lighting System
Instrumentation / Driver
Information
Windows, Mirrors, Security
and Lock
Immobilizer Control System
BODY SERVICE
RESTRAINT SYSTEM
Seat Belt
Air Bag System GENERAL INFORMATION
General Information
Maintenance and Lubrication
TABLE OF CONTENTS TABLE OF CONTENTS SECTIONSECTION
0B
HEATING AND AIR
CONDITIONING
Heater and Ventilation
Air Conditioning
STEERING, SUSPENSION,
WHEELS AND TIRES
Front End Alignment
Power Steering (P / S) System
Steering Wheel and Column
(Not Equipped with Air Bag)
Air Bag Steering Wheel
and Column
Front Suspension
Rear Suspension
Wheel and Tires
1A
3A 0A
1B
3B1
3C
3C1
3D
3E
3F36A16
6A2
6A4
6B
6C
6E1
6E2
6F1
DRIVE SHAFT / PROP. SHAFT
Front Drive Shaft / Shaft
Bearing, Oil Seal
Propeller Shaft
BRAKES
Brake Pipe / Hose / Master
Cylinder
Front Brakes
Parking and Rear Brakes
Antilock Brake System
4A2
4B
5
5A
5B
5C
5E1
6F2
6G
6G1
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8
8A
8B
8C
8D
8G
9
10
10A
10B
6-1
NOTE:
The screen toned Sections 6 ± 6K are included in Volume 2 and Section 8A is in Wiring
Diagram Manual.

YH4
GRAND
VITARA
When using frame contact hoist:
1. Front lifting point
2. Rear lifting point
3. Front
GENERAL INFORMATION 0A-19
VEHICLE LIFTING POINTS
WARNING

When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up the
vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by trying to
move vehicle body in both ways. Work can be started only after this confirmation.

Before applying hoist to underbody, always take vehicle balance throughout service into consider-
ation. Vehicle balance on hoist may change depending of what part to be removed.

Make absolutely sure to lock hoist after vehicle is hoisted up.

Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe,
fuel pipe, bracket or any other part.

YH4
GRAND
VITARA
1
1. Clutch pedal free travel
MAINTENANCE AND LUBRICATION 0B-15
CHASSIS AND BODY
ITEM 6-1
Clutch
Pedal inspection
Check clutch pedal for height and free travel referring to Section
7C1. Adjust or correct if necessary.
Fluid 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 fluid indicated on
clutch reservoir cap.
For the details, refer to On-vehicle service in Section 7C1.
CAUTION:
Since clutch system of this vehicle is factory-filled with
glycol-base brake fluid, do not use or mix different type
of fluid when refilling system; otherwise serious damage
will occur. Do not use old or used brake fluid, or one taken
from unsealed container.
ITEM 6-2
Brake Discs, Pads, Brake Drums and Shoes Inspection
[Brake discs and pads]
1) Remove wheel and caliper but don't disconnect brake hose from
caliper.
2) Check front disc brake pads and discs for excessive wear, dam-
age and deflection. Replace parts as necessary. For details, re-
fer to Section 5B.
Be sure to torque caliper pin bolts to specification.
[Brake drums and shoes]
1) Remove wheel and brake drum.
2) Check rear brake drums and brake linings for excessive wear
and damage, while wheels and drums are removed. At the same
time, check wheel cylinders for leaks. Replace these parts as
necessary.
For details, refer to Section 5C.

YH4
GRAND
VITARA
MAINTENANCE AND LUBRICATION 0B-25
Steering

Check to ensure that steering wheel is free from in-
stability, or abnormally heavy feeling.

Check that the vehicle does not wander or pull to
one side.
Engine

Check that engine responds readily at all speeds.

Check that engine is free from abnormal noise and
abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting sys-
tem are free from abnormal noise and abnormal
vibration or any other abnormal condition.
Meters and Gauge
Check that speedometer, odometer, fuel meter, tem-
perature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set fan switch lever to ªHIº position for this check.
RECOMMENDED FLUIDS AND LUBRICANTS
Engine oilSG, SH or SJ (Refer to engine oil viscosity chart in item 1-4)
Engine coolant (Ethylene glycol
base coolant)ªAntifreeze / Anticorrosion coolantº
Brake fluidDOT 3
Manual transmission oilRefer to Section 7A or 7A1Transfer oilRefer to Section 7A or 7A1.
Differential oil (front & rear)Refer to Section 7E or 7F.
Automatic transmission fluid and
Power steering fluidRefer to Section 3B1 or 7B1.
Door hingesEngine oil or water resistance chassis greaseHood latch assemblyEngine oil or water resistance chassis grease
Key lock cylinderSpray lubricant

YH4
GRAND
VITARA
3
STEERING, SUSPENSION, WHEELS AND TIRES 3-1
GENERAL DIAGNOSIS3-1 . . . . . . . . . . . . . . . . .
Diagnosis Table 3-1. . . . . . . . . . . . . . . . . . . . . .
TIRE DIAGNOSIS3-6 . . . . . . . . . . . . . . . . . . . . . .
Irregular and / or Premature Wear 3-6. . . . . . .
Wear Indicator 3-6. . . . . . . . . . . . . . . . . . . . . . . Radial Tire Waddle 3-6. . . . . . . . . . . . . . . . . . .
Radial Tire Lead 3-8. . . . . . . . . . . . . . . . . . . . . .
VIBRATION DIAGNOSIS3-8 . . . . . . . . . . . . . . .
SECTION 3
STEERING, SUSPENSION, WHEELS AND TIRES
DIAGNOSIS3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT END ALIGNMENT3A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER STEERING SYSTEM3B1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR BAG STEERING WHEEL AND COLUMN3C1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SUSPENSION3D-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SUSPENSION3E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEELS AND TIRES3F-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS
GENERAL DIAGNOSIS
Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered
when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first.
Proceed with the following preliminary inspections and correct any defects which are found.
1) Inspect tires for proper pressure and uneven wear.
2) Raise vehicle on a hoist and inspect front and rear suspension and steering system for loose or damaged parts.
3) Spin front wheel. Inspect for out-of-round tires, out-of-balance tires, bent rims, loose and / or rough wheel bear-
ings.
DIAGNOSIS TABLE
ConditionPossible CauseCorrection
Vehicle Pulls (Leads)
Mismatched or uneven tires.

Tires not adequately inflated.

Broken or sagging springs.

Radial tire lateral force.

Disturbed front end alignment.

Disturbed rear axle alignment.

Brake dragging in one road wheel.

Loose, bent or broken front or rear
suspension parts.Replace tire.
Adjust tire pressure.
Replace spring.
Replace tire.
Check front end alignment.
Check rear axle alignment.
Repair front brake.
Tighten or replace suspension part.

YH4
GRAND
VITARA
3-4 STEERING, SUSPENSION, WHEELS AND TIRES
ConditionPossible CauseCorrection
Wander or Poor
Steering Stability
Mismatched or uneven tires.

Loose ball joints and tie rod
ends.

Faulty shock absorbers / struts or
mounting.

Loose stabilizer bar.

Broken or sagging springs.

Rack and pinion not properly adjusted.
(if equipped with manual steering
gear case)

Disturbed front end alignment.Replace tire or inflate tires to
proper pressure.
Replace suspension control arm or
tie rod end.
Replace absorber / strut or repair
mounting.
Tighten or replace stabilizer bar or
bushes.
Replace spring.
Check or adjust rack and pinion
torque.
Check and adjust front end alignment.
Erratic Steering when
Braking
Worn wheel bearings.

Broken or sagging springs.

Leaking wheel cylinder or caliper.

Warped discs.

Badly worn brake linings.

Drum is out of round in some brakes.

Wheel tires are inflated unequally.

Defective wheel cylinders.

Disturbed front end alignment.Replace wheel bearing.
Replace spring.
Repair or replace wheel cylinder or
caliper.
Replace brake disc.
Replace brake shoe lining.
Replace brake drum.
Inflate tires to proper pressure.
Replace or repair wheel cylinder.
Check front end alignment.
Low or Uneven Trim
Height
Right-to-left trim height
(H) difference should be
within 15 mm (0.6 in.)
with curb weight.
*Same with rear side.
Broken or sagging springs.

Overloaded.

Incorrect springs.Replace spring.
Check loading.
Replace spring.
Ride Too Soft
Faulty shock absorber or struts.Replace shock absorber or strut.
Suspension Bottoms
Overloaded.

Faulty shocks or struts.

Incorrect broken or sagging springs.Check loading.
Replace shock absorber or strut.
Replace spring.

YH4
GRAND
VITARA
3-8 STEERING, SUSPENSION, WHEELS AND TIRES
RADIAL TIRE LEAD
ªLeadº is the deviation of the vehicle from a straight path on a level
road with no pressure on the steering wheel.
Lead is usually caused by:
1) Incorrect alignment.
2) Uneven brake adjustment.
3) Tire construction.
The way in which a tire is built can produce lead in a vehicle. An ex-
ample of this is placement of the belt. Off center belts on radial tires
can cause the tire to develop a side force while rolling straight down
the road. If one side of the tire is a little larger diameter than the oth-
er, the tire will tend to roll to one side. This will develop a side force
which can produce vehicle lead.
The procedure on previous page should be used to make sure that
front alignment is not mistaken for tire lead.
1) Part of the lead diagnosis procedure is different from the tire
rotation pattern currently in the owner's and service manuals. If
a medium to high mileage tire is moved to the other side of the
vehicle, be sure to check that ride roughness has not developed.
2) Rear tires will not cause lead.
VIBRATION DIAGNOSIS
Wheel unbalance causes most of the highway speed vibration
problems. If a vibration remains after dynamic balancing, it can be
caused by three things.
1) Tire runout.
2) Wheel runout.
3) Tire stiffness variation.
Measuring tire and / or wheel free runout will uncover only part of the
problem. All three causes, known as loaded radial runout, must be
checked by using a Tire Problem Detector (TPD). If a TPD is not
available, the more time consuming method of substituting known
good tire and wheel assemblies on the problem vehicle can be
used.

YH4
GRAND
VITARA
3B1-6 POWER STEERING (P / S) SYSTEM
ConditionPossible CauseCorrection
Vehicle pulls to
one side during
straight driving
Mismatched or uneven tire

Low or uneven tire inflation pressure

Brake dragging in one wheel

Front end alignment out of order

Rear end alignment out of order

Malfunction of control valve in gear boxReplace tire.
Inflate tires to proper pressure or
adjust right & left tires inflation
pressure.
Repair.
Check and adjust front end
alignment.
Check and adjust rear end
alignment.
Replace gear box.
Steering wheel
play is large and
vehicle wanders
Refer to ªDiagnosisº in Section 3.
Fluid leakage
Loose joints of (hydraulic pressure)
pipes and hoses

Deformed or damaged pipes or hosesRetighten.
Replace defective part.
Abnormal noise
Air drawn in due to insufficient amount of fluid

Air mixed into fluid from pipes or hoses

Slipping (loose) P / S belt

Worn P / S belt

Loose gear box fastening bolt

Loose linkage or joints

Pipes or hoses in contact with part of
vehicle body

Vanes of P / S pump defective

Malfunction of control valve in gear box

Bearing of P / S pump shaft defectiveAdd fluid and purge air.
Replace pipes or hoses.
Adjust belt tension.
Replace belt.
Retighten bolts.
Retighten.
Install pipes and hoses correctly.
Replace defective part.
Replace gear box.
Replace bearing.
No idle up
Power steering pressure switch defectiveReplace power steering
pressure switch.