2004 SUZUKI GRAND VITARA sec 8

YH4
GRAND
VITARA
GENERAL INFORMATION 0A-7
GENERAL PRECAUTIONS
The WARNING and CAUTION below describe some general precautions that you should observe when servicing
a vehicle. These general precautions apply to many of the service procedures described in this manual, and they
will not necessarily be repeated with each procedure to which they apply.
WARNING:

Whenever raising a vehicle for service, be sure to follow the instructions under ªVEHICLE LIFTING
POINTSº on SECTION 0A.

When it is necessary to do service work with the engine running, make sure that the parking brake
is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for automatic
transmission vehicles). Keep hands, hair, clothing, tools, etc. away from the fan and belts when the
engine is running.

When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.

Do not perform service work in areas where combustible materials can come in contact with a hot
exhaust system. When working with toxic or flammable materials (such as gasoline and refrigerant),
make sure that the area you work in is well-ventilated.

To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail-
pipe, muffler, etc.

New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or
used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory animals.
Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a
long-sleeve shirt and moisture-proof gloves (such as dishwashing gloves) when changing engine oil.
If engine oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags
if wet with oil, recycle or properly dispose of used oil and filters.

Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly
during driving, obstructing your view and resulting in an accident.
CAUTION:

Before starting any service work, cover fenders, seats and
any other parts that are likely to get scratched or stained dur-
ing servicing. Also, be aware that what you wear (e.g, but-
tons) may cause damage to the vehicle's finish.

When performing service to electrical parts that does not re-
quire use of battery power, disconnect the negative cable of
the battery.

YH4
GRAND
VITARA
1. Front differential housing
2. Rear axle
housing
When using floor jack:
Front
Rear
1. Safety stands
0A-20 GENERAL INFORMATION
In raising front or rear vehicle end off the floor by jacking, be sure
to put the jack against the center portion of the front suspension
frame or rear axle housing.
WARNING:

Never apply jack against suspension parts (i.e., stabilizer,
etc.) or vehicle floor, or it may get deformed.

If the vehicle to be jacked up only at the front or rear end,
be sure to block the wheels on ground in order to ensure
safety.
After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on the
vehicle raised on jack alone.
To perform service with either front or rear vehicle end jacked up,
be sure to place safety stands under chassis frame so that body is
securely supported. And then check to ensure that chassis frame
does not slide on safety stands and the vehicle is held stable for
safety's sake.

YH4
GRAND
VITARA
0A-24 GENERAL INFORMATION
Self-lock
nut
STANDARD TIGHTENING TORQUE
Each fastener should be tightened to the torque specified in each section of this manual. If no description or specifi-
cation is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When
a fastener of greater strength than the original one is used, however, use the torque specified for the original fasten-
er.
NOTE:

For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening torque
given in the chart below.

The chart below is applicable only where the fastened parts are made of steel or light alloy.
Tightening torque chart
Thread Diameter (Nominal Diameter)
(mm)
45681012141618
Strength
45681012141618
A equivalent of 4T strength
fastenerN.m1.53.05.513294565105160
kg-m0.150.300.551.32.94.56.510.516
lb-ft1.02.54.09.521.032.547.076.0116.0
A equivalent of 6.8 strength
fastener without flan
geN.m2.44.78.4204280125193280g
kg-m0.240.470.842.04.28.012.519.328
lb-ft2.03.56.014.530.558.090.5139.5202.5
A equivalent of 6.8 strength
fastener with flan
geN.m2.44.98.8214484133203298g
kg-m0.240.490.882.14.48.413.320.329.8
lb-ft2.03.56.515.532.061.096.5147.0215.5
A equivalent of 7T strength
fastenerN.m2.34.510235085135210240
kg-m0.230.451.02.35.08.513.52124
lb-ft2.03.57.517.036.561.598.0152.0174.0
A equivalent of 8.8 strength
fastener without flan
geN.m3.16.3112756105168258373g
kg-m0.310.631.12.75.610.516.825.837.3
lb-ft2.54.58.019.540.576.0121.5187.0270.0
A equivalent of 8.8 strength
fastener with flan
geN.m3.26.512295911 3175270395g
kg-m0.320.651.22.95.911.317.52739.5
lb-ft2.55.09.021.043.082.0126.5195.5286.0

YH4
GRAND
VITARA
0B
MAINTENANCE AND LUBRICATION 0B-1
SECTION 0B
MAINTENANCE AND LUBRICATION
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº 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.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CONTENTS
MAINTENANCE SCHEDULE0B - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Schedule Under Normal Driving Conditions 0B - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Recommended Under Severe Driving Conditions 0B - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SERVICE0B - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine0B - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System0B - 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System0B - 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emission Control System0B - 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis and Body0B - 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Inspection0B - 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECOMMENDED FLUIDS AND LUBRICANTS0B - 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
1. Crankshaft pulley
2. Water pump pulley
3. 100 N, 10 kg or 22 lb
G16
H25
MAINTENANCE AND LUBRICATION 0B-5
MAINTENANCE SERVICE
ENGINE
ITEM 1-1
Drive Belt Inspection and Replacement
WARNING:
All inspection and replacement are to be performed with
ENGINE NOT RUNNING.
Water pump and generator drive belt (G16 and H25 engines)
Inspection
1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
If any defect exists, replace.
Check belt for tension.
Water pump and generator belt tension
ªaº: 6 ± 8 mm (0.24 ± 0.32 in.) deflection for G16, 9 ± 11 mm
(0.35 ± 0.43 in.) deflection for H25 under 100 N, 10 kg or
22 lb pressure
NOTE:
When replacing belt with a new one, adjust belt tension to
5 ± 6 mm (0.20 ± 0.24 in.) for G16, 7 ± 9 mm (0.28 ± 0.35 in.)
for H25.
3) If belt is too tight or too loose, adjust it to specification by adjust-
ing alternator position.
4) Tighten alternator adjusting bolt and pivot bolts.
5) Connect negative cable to battery.
Replacement
Replace belt. Refer to Section 6B for replacement procedure of
pump belt.

YH4
GRAND
VITARA
J20
J20
1. 100 N, 10 kg or 22 lb
2. Fan pulley3. Crankshaft pulley
4. Adjusting and pivot bolt
0B-6 MAINTENANCE AND LUBRICATION
Water pump, generator, power steering and / or A / C
compressor (if equipped) drive belt (J20 engine)
Inspection
1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
If any of above conditions are found, replace.
Also, check belt for tension.
Tension indicator ªBº should be the right of indicator ªAº as
shown in figure. If indicator ªBº is found to the left of indicator ªAº,
replace generator belt.
Replacement
Replace belt referring to Section 6H for replacement procedure of
generator drive belt.
Engine cooling fan drive belt (J20 engine)
Inspection
1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
If any defect exists, replace. Check belt for tension.
Cooling fan belt tension
ªaº: 5 ± 7 mm (0.20 ± 0.27 in.) deflection under 100 N, 10 kg
or 22 lb pressure.
NOTE:
When replacing belt with a new one, adjust belt deflection
to 4 ± 5 mm (0.16 ± 0.19 in.).
3) If the belt is too tight or too loose, adjust it to specification by ad-
justing cooling fan pulley position.
4) Tighten adjusting bolt and pivot bolt.
5) Connect negative cable at battery.
Replacement
Replace belt referring to Section 6B for replacement procedure of
cooling fan drive belt.

YH4
GRAND
VITARA
G16 with P / S
G16 with P / S and A / C
H25 with P / S
H25 with P / S and A / C
1. Crankshaft pulley
2. P / S pump pulley
3. A / C compressor pulley
(if equipped)4. Tension pulley
5. Tension pulley bolts
MAINTENANCE AND LUBRICATION 0B-7
Power steering pump and / or A / C compressor drive belts (if
equipped) for G16 and H25 engines.
Inspection
1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
If any defect exists, replace.
Check belt for tension.
Power steering pump and / or A / C compressor drive belt
tension.
ªaº: 6 ± 9 mm (0.24 ± 0.35 in.) deflection under 100 N, 10 kg
or 22 lb pressure.
ªbº: 4 ± 7 mm (0.16 ± 0.28 in.) deflection under 100 N, 10 kg
or 22 lb pressure.
If belt tension is out of above specification, adjust it referring to
Section 1B or 3B1.
3) Connect negative cable to battery.
Replacement
Replace belt referring to Section 1B or 3B1 for replacement proce-
dure of belt.

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)