2004 SUZUKI GRAND VITARA maintenance

YH4
GRAND
VITARA
0B-8 MAINTENANCE AND LUBRICATION
ITEM 1-2
Camshaft Timing Belt Replacement (G16 engine only)
Replace timing belt referring to Section 6A1.
ITEM 1-3
Valve Lash Inspection (G16 engine only)
1) Remove cylinder head cover.
2) Inspect intake and exhaust valve lash and adjust as necessary.
Refer to Section 6A1 for valve lash inspection and adjustment
procedure.
Valve
lash
(ªº)
When cold
(Coolant tempera-
ture is 15 ± 25
C
or 59 ± 77
F)When hot
(Coolant tempera-
ture is 60 ± 68
C
or 140 ± 154
F)
(gap ªaº)
specifica-
tion
Intake0.13 ± 0.17 mm
(0.005 ± 0.007 in.)0.17 ± 0.21 mm
(0.007 ± 0.008 in.)
tion
Exhaust0.23 ± 0.27 mm
(0.009 ± 0.011 in.)0.28 ± 0.32 mm
(0.011 ± 0.013 in.)
3) Install cylinder head cover and tighten bolts to specification.
ITEM 1-4
Engine Oil and Filter Change
WARNING:
New and used engine oil can be hazardous.
Be sure to read ªWARNINGº in General Precaution in Sec-
tion 0A and observe what in written there.
Before draining engine oil, check engine for oil leakage. If any evi-
dence of leakage is found, make sure to correct defective part be-
fore proceeding to the following work.
1) Drain engine oil by removing drain plug.
2) After draining oil, wipe drain plug clean. Reinstall drain plug, and
tighten it securely as specified below.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)

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VITARA
2
1. Oil filter
2. Oil filter wrench
MAINTENANCE AND LUBRICATION 0B-9
3) Loosen oil filter by using oil filter wrench (special tool).
Special Tool
(A): 09915-47310 (H25 engine)
09915-47330 (G16 and J20 engines)
NOTE:
Before fitting new oil filter, be sure to oil its O-ring. Use engine
oil for this purpose.
4) Screw new filter on oil filter stand by hand until the filter O-ring
contacts the mounting surface.
CAUTION:
To tighten oil filter properly, it is important to accurately
identify the position at which at filter O-ring first contacts
the mounting surface.
5) Tighten the filter 3 / 4 turn from the point of contact with the
mounting surface using an oil filter wrench.
Tightening Torque (Reference)
(b): 14 N
.m (1.4 kg-m, 10.5 lb-ft)
6) Replenish oil until oil level is brought to FULL level mark on dip-
stick. (oil pan and oil filter capacity). The filler inlet is at the top
of the cylinder head cover.
It is recommended to use engine oil of SG, SH or SJ grade.
NOTE:
For temperature between ±20
C (±4
F) and 30
C (86
F), it
is highly recommended to use SAE 10W ± 30 oil.
G16 EngineJ20 EngineH25 Engine
Oil pan capacityAbout 4.0 liters
(10.6 / 8.8 US / Imp pt.)About 5.0 liters
(10.6 / 8.8 US / Imp pt.)

Oil filter capacityAbout 0.2 liters
(0.4 / 0.3 US / Imp pt.)
About 0.5 liters
(1.1 / 0.9 US / Imp pt.)
OthersAbout 0.3 liters
(0.6 / 0.5 US / Imp pt.)About 0.4 liters
(1.1 / 0.9 US / Imp pt.)About 0.7 liters
(1.5 / 1.2 US / Imp pt.)
TotalAbout 4.5 liters
(9.5 / 7.9 US / Imp pt.)About 5.6 liters
(11.8 / 9.8 US / Imp pt.)About 6.2 liters
(13.1 / 10.9 US / Imp pt.)

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VITARA
1. Full level mark (hole)
2. Low level mark (hole)
0B-10 MAINTENANCE AND LUBRICATION
NOTE:
Engine oil capacity is specified. However, note that the
amount of oil required when actually changing oil may
somewhat differ from the data in the table depending on
various conditions (temperature, viscosity, etc.).
7) Check oil filter and drain plug for oil leakage.
8) Start engine and run it for three minutes. Stop it and wait five min-
utes before checking oil level. Add oil, as necessary, to bring oil
level to FULL level mark on dipstick.
NOTE:
Step 1) ± 7) outlined above must be performed with ENGINE
NOT RUNNING. For step 8), be sure to have adequate ven-
tilation while engine is running.
ITEM 1-5
Engine Coolant Change
WARNING:
To help avoid danger of being burned, do not remove radia-
tor cap while engine and radiator are still hot. Scalding fluid
and steam can be blown out under pressure if cap is taken
off too soon.
1) Remove radiator cap when engine is cool.
2) Loosen radiator drain plug to drain coolant.
3) Remove reservoir, which is on the side of radiator, and drain.
4) Tighten plug securely. Also reinstall reservoir.
5) Fill radiator with specified amount of coolant, and run engine for
2 or 3 minutes at idle. This drives out any air which may still be
trapped within cooling system. STOP ENGINE. Add coolant as
necessary until coolant level reaches the filler throat of radiator.
Reinstall radiator cap.

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-12 MAINTENANCE AND LUBRICATION
IGNITION SYSTEM
ITEM 2-1
Spark Plugs Replacement
Replace spark plugs with new ones referring to Section 6F1 or 6F2.
FUEL SYSTEM
ITEM 3-1
Air Cleaner Filter
Inspection
1) Remove air cleaner case clamps.
2) Take cleaner filter out of air cleaner case.
3) Check air cleaner filter for dirt. Replace excessively dirty filter.
4) Blow off dust by compressed air from air outlet side of filter.
5) Install air cleaner filter into case.
6) Install air cleaner case cap and clamp it securely.
Replacement
Replace air cleaner filter with new one according to above steps 1),
2) and 5), 6).
ITEM 3-2
Fuel Lines and Connections Inspection
1) Visually inspect fuel lines and connections for evidence of fuel
leakage, hose cracking and damage. Make sure all clamps are
secure.
Repair leaky joints, if any.
Replace hoses that are suspected of being cracked.

YH4
GRAND
VITARA
MAINTENANCE AND LUBRICATION 0B-13
ITEM 3-3
Fuel Filter Replacement
WARNING:
This work must be performed in a well ventilated area and
away from any open flames (such as gas hot water heaters).
Fuel filter is located at the front part of fuel tank, inside the right-
hand side of chassis.
Replace fuel filter with new one periodically, referring to Section 6C
for proper procedure.
ITEM 3-4
Fuel Tank Inspection
Check fuel tank for damage, cracks, fuel leakage, corrosion and
tank bolts looseness.
If a problem is found, repair or replace.

YH4
GRAND
VITARA
[A]
[B]
[A]: Type 1
[B]: Type 2
0B-14 MAINTENANCE AND LUBRICATION
EMISSION CONTROL SYSTEM
ITEM 4-1
Crankcase Ventilation Hoses and Connections Inspection
(Vehicle not equipped with oxygen sensor)
Refer to the following item 4-2, PCV valve inspection.
ITEM 4-2
PCV (Positive Crankcase Ventilation) Valve Inspection
Check crankcase ventilation hose and PCV hose for leaks, cracks
or clog, and PCV valve for stick or clog. Refer to On-vehicle service
of Section 6E1 / 6E2 for PCV valve checking procedure.
ITEM 4-3
Evaporative Emission Control System Inspection
1) Visually inspect hoses for cracks, damage, or excessive bends.
Inspect all clamps for damage and proper position.
2) Check EVAP canister for operation and clog, referring to Section
6E1 / 6E2.
If a malfunction is found, repair or replace.

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.