2004 SUZUKI GRAND VITARA Transmission

YH4
GRAND
VITARA
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
B ± Driving on rough and / or muddy roads cold weather
C ± Driving on dusty roads F ± Leaded fuel use
D ± Driving in extremely cold weather G ± ± ± ± ± ± ± ± ±
and / or salted roads H ± Trailer towing (if admitted)
Severe
Condition Code
MaintenanceMaintenance
OperationMaintenance Interval
BCDITEM 1-1IEvery 15,000 km
(9,000 miles) or 12 months
± B C D ± ± ± ±Drive belt (V-rib belt)REvery 45,000 km
(27,000 miles) or 36 months
A ± C D E F ± 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
CITEM 3-1IEvery 2,500 km
(1,500 miles)
± ± C ± ± ± ± ±Air cleaner filter*1REvery 30,000 km
(18,000 miles) or 24 months
ABC EF HITEM 2-1Nickel plugREvery 10,000 km
(6,000 miles) or 8 months
A B C ± E F ± HSpark plugsIridium plugREvery 30,000 km
(18,000 miles) or 24 months
± B ± D E ± ± HITEM 6-9
Propeller shafts and drive shaftsIEvery 15,000 km
(9,000 miles) or 12 months
± B ± ± E ± ± H
ITEM 6-10, 6-12, 6-13
Manual transmission,
transfer and differential oil
REvery 30,000 km
(18,000 miles) or 24 months
± B ± ± E ± ± HITEM 6-11
Automatic transmission fluidREvery 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
IEvery 15,000 km
(9,000 miles) or 12 months
± ± C D ± ± ± ±Air conditioning filter 2
(if equipped)REvery 45,000 km
(27,000 miles) or 36 months
NOTES:
ªIº : Inspect and correct, replace or lubricate if necessary
ªRº : Replace or change
ªTº : 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.

YH4
GRAND
VITARA
1. Drain plug (Apply sealant)
2. Reverse idle gear shaft bolt (DO NOT LOOSEN IT)
3. Filler / level plug (Apply sealant)
1. Drain plug
2. Filler / level plug
Type 1
Type 2
1. Level gauge
2. FULL HOT mark
3. LOW HOT mark
4. FULL COLD mark
5. LOW COLD mark
0B-20 MAINTENANCE AND LUBRICATION
ITEM 6-10
Manual Transmission Oil Inspection and Change
Inspection
1) Inspect transmission case for evidence of oil leakage.
Repair leaky point if any.
2) Make sure that vehicle is placed level for oil level check.
3) Remove level plug of transmission.
4) Check oil level.
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.
5) Tighten level plug to specified torque.
Refer to Section 7A or 7A1 for installation and tightening torque.
Change
Change transmission oil with new specified oil referring to Section
7A or 7A1.
ITEM 6-11
Automatic Transmission Fluid Inspection and Change
Inspection
1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Check fluid level.
For fluid level checking procedure, refer to On-vehicle service in
Section 7B1 and be sure to perform it under specified conditions.
If fluid level is low, replenish specified fluid.

YH4
GRAND
VITARA
1. Drain plug
Transfer
Front differential
Rear differential
1
21
2
MAINTENANCE AND LUBRICATION 0B-21
Change
1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Change fluid. For its procedure, refer to On-vehicle service in
Section 7B1.
Fluid cooler hose change
Replace inlet and outlet hoses of cooler hose and their clamps.
For replacement procedure, refer to On-vehicle service in Section
7B1.
ITEM 6-12 and 6-13
Transfer and Differential Oil Inspection and Change
Inspection
1) Check transfer case and differential for evidence of oil leakage.
Repair leaky point if any.
2) Make sure that vehicle is placed level for oil level check.
3) Remove level plug of transfer or differentials (front and rear) and
check oil level.
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
referring to Section 7D, 7B or 7F.
4) Tighten level plug to specified torque.
Refer to Section 7D, 7E or 7F for tightening torque.
Change
Change transfer oil or differentials oil with new specified oil referring
to Section 7D, 7E and 7F respectively.

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
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
3B1-12 POWER STEERING (P / S) SYSTEM
TIE-ROD END BOOT CHECK
Check boot for crack and damage and if any, replace it with a new
one.
AIR BLEEDING PROCEDURE
1) Hoist the front end of vehicle and apply safety stands.
2) Fill P / S fluid reservoir with fluid up to specified level.
NOTE:
Before starting engine, place transmission gear shift lever
in ªNeutralº (shift selector lever to ªPº range for A / T mod-
el), and set parking brake.
3) After running engine at idling speed for 3 to 5 seconds, stop it
and add fluid to satisfy specification.
4) With engine stopped, turn steering wheel to the right and left as
far as it stops, repeat it a few times and fill fluid to specified level.
5) With engine running at idling speed, repeat stop-to-stop turn of
steering wheel till all foams in P / S fluid reservoir are gone.
NOTE:
Make sure to bleed air completely. If air remains in fluid, P / S
pump may make humming noise or steering wheel may feel
heavy.
6) Finally check to make sure that fluid is filled to specified level.

YH4
GRAND
VITARA
1. Flexible hose
2. E-ring
3. Brake pipe
4. Cross member1. LSPV stay
1. Hose
2. Axle housing
1. Propeller shaft
2. Differential carrier
REAR SUSPENSION 3E-17
7) Using special tools (B) & (C) indicated below, draw out axle
shafts. For vehicle equipped with ABS, remove wheel speed
sensor from axle housing before drawing out axle shaft.
NOTE:
Use care not to pull brake back plate along with shaft.
Special Tool
(C): 09943-35512
(B): 09942-15510
8) For vehicle without ABS, remove LSPV stay from axle housing.
9) Remove brake back plate from rear axle housing.
10) Disconnect brake pipe from flexible hose and remove E-ring
(front side).
11) Remove brake pipe clamps and pipes from axle housing and
disconnect breather hose from axle housing.
12) Disconnect propeller shaft and remove propeller shaft from
transmission.

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-31
1. Diagnosis
connector
(6 pins connector)
2. Diag. switch
terminal
3. Ground
4. Service wire
Brake
pedal
Ignition
sw.
Motor
Solenoid
Rear3.0 sec.
3.0
ON-VEHICLE SERVICE
PRECAUTION
When connector are connected to ABS hydraulic unit / control mod-
ule assembly, do not disconnect connectors of sensors and turn
ignition switch ON. Then DTC will be set in ABS control module.
ABS HYDRAULIC UNIT OPERATION CHECK
1) Check that basic brake system other than ABS is in good condi-
tion.
2) Check that battery voltage is 11V or higher.
3) With ªABSº warning lamp, check that no abnormality is de-
tected in ABS. Refer to ªDIAGNOSTIC TROUBLE CODE
(DTC) CHECKº in this section.
4) Lift up vehicle.
5) Set transmission to neutral and release parking brake.
6) Turn each wheel gradually by hand to check if brake dragging
occurs. If it does, correct.
7) With diag. switch terminal of diagnosis connector connected to
ground by using service wire, turn ignition switch ON and check
if ªABSº warning lamp indicates DTC 12.
8) Turn ignition switch OFF.
9) Perform following checks with help of another person.
Brake pedal should be depressed and then ignition switch
turned ON by one person and wheel should be turned by
another person's hand. At this time, check that:

Operation sound of solenoid is heard and wheel turns only
about 0.5 sec. (Brake force is depressurized).

Operation sound of pump motor is heard and pulsation is felt
at brake pedal.
10) If all 4-wheels cannot be checked during one ignition cycle
(OFF
ON), repeat Steps 8) and 9) till all 4 wheels are
checked.
If a faulty condition is found in Steps 9) and 10), replace hydrau-
lic unit / control module assembly.
11) Turn ignition switch OFF and remove service wire from diagno-
sis connector.