2004 SUZUKI GRAND VITARA capacity

YH4
GRAND
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.)

YH4
GRAND
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
3. Bubbles
1B-10 AIR CONDITIONING (OPTIONAL)
QUICKLY CHECKING OF REFRIGERANT
CHARGE (IF EQUIPPED WITH SIGHT GLASS)
CHARGE OF REFRIGERANT
The following procedure can be used for quickly checking whether
the A / C system has a proper charge of refrigerant or not.
Run engine at fast idle, and operate A / C at its max. cooling capacity
for a few minutes. Then, look at the sight glass (1) on receiver / dryer
(2) and compare what is observed with the symptoms listed in
ªCHECKING REFRIGERANT CHARGEº table given below.
CHECKING REFRIGERANT CHARGE
CONDITIONPOSSIBLE CAUSESCORRECTION
Bubbles observed in sight glassInsufficient charge of refrigerant in
systemCheck system for leaks with a leak
tester.
No bubbles observed in sight glassNo charge or proper or too much
charge of refrigerant in systemRefer to the following item.
No temperature difference
between compressor inlet and
outletEmpty or nearly empty systemRecovery, evacuate and charge
system and then check it for leaks
with a leak tester.
Noticeable temperature difference
between compressor inlet and
outletProper or too much charge of
refrigerant in systemRefer to the following item.
When A / C is turned OFF,
refrigerant in sight glass clears
immediately and remains clearToo much charge of refrigerant in
systemDischarge excess charge of
refrigerant to adjust it to a specified
charge.
When A / C is turned OFF,
refrigerant in sight glass once
produces bubbles and then clearsProper charge of refrigerant in
systemNo correction needed because
charge of refrigerant is normal.

YH4
GRAND
VITARA
1. Suction connector
2. O-ring
3. Pressure switch
4. Flow control valve
(Relief valve)
5. Spring
6. Plug
7. Pump cover
8. Cam ring
9. Vane
10. Rotor
11. Snap ring
12. Side plate
13. Pulley (pump shaft)
14. Oil seal
15. Pump body
16. Flow control valve Assembly
3B1-4 POWER STEERING (P / S) SYSTEM
POWER STEERING (P / S) PUMP
The power steering pump is a vane type and is driven by the V-ribbed belt from the crankshaft.
ModelVane type
Hydraulic
pressure
controlRelieved
pressure
6500 kPa (65 kg / cm2, 924 psi)
G16 Type engine . . . . . . . . . . . . . . . . . . . . . .
7000 kPa (70 kg / cm
2, 995 psi)
J20 Type engine . . . . . . . . . . . . . . . . . . . . . . .
7350 kPa (73.5 kg / cm
2, 1045 psi)
H25 Type engine . . . . . . . . . . . . . . . . . . . . . .
ControlFlow control valve
deviceRelief valve
Power steering
pressure switch
Switch turns on (closes) when the
pressure is higher than 2500 ± 3500 kPa
(25 ± 35 kg / cm
2, 356 ± 498 psi).
ECM uses this signal for idle speed control.
Capacity0.70 ± 0.75

(1.48 / 1.23 ± 1.58 / 1.32 US / Imp. pt)
Specified fluidDEXRON
II, DEXRON
III A / T fluid
or equivalent
FLOW CONTROL VALVE
As the discharge rate of the P/S pump increases in proportion to the
pump revolution speed, a flow control valve is added to control it so
that the optimum amount of fluid for steering operation is supplied
according to the engine speed (driving condition).
Described below is its operation at different engine speed.

YH4
GRAND
VITARA
3F
WHEELS AND TIRES 3F-1
GENERAL DESCRIPTION3F- 1 . . . . . . . . . . . . . .
Tires 3F- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheels 3F- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Tires 3F- 1. . . . . . . . . . . . . . . . . . .
Wheels Replacement 3F- 2. . . . . . . . . . . . . . . . .
Metric Lug Nuts and Wheel Studs 3F- 2. . . . . .
DIAGNOSIS3F- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table 3F- 3. . . . . . . . . . . . . . . . . . . . . .
Balancing Wheels 3F- 3. . . . . . . . . . . . . . . . . . . . MAINTENANCE AND MINOR
ADJUSTMENTS3F- 4 . . . . . . . . . . . . . . . . . . . . . .
Wheel and Tire 3F- 4. . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE3F- 6 . . . . . . . . . . . . . . . .
Wheel 3F- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tire 3F- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS3F- 8 . . . . . . . . . . . . . . . . . . . .
SECTION 3F
WHEELS AND TIRES
NOTE:
All wheel fasteners are important attaching parts in that they could affect the performance of vital parts
and systems, and / or could result in major repair expense. They must be replaced with one of the same
part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used as specified during reassembly to as-
sure proper retention of all parts.
There is to be no welding as it may result in extensive damage and weakening of the metal.
CONTENTS
GENERAL DESCRIPTION
TIRES
This vehicle is equipped with following tire. P215 / 65 R16, 215 / 65 R16 or 235 / 60 R16
The tires are of tubeless type. The tires are designed to operate satisfactorily with loads up to the full rated load
capacity when inflated to the recommended inflation pressure.
Correct tire pressures and driving habits have an important influence on tire life. Heavy cornering, excessively rapid
acceleration, and unnecessary sharp braking increase tire wear.
WHEELS
Standard equipment wheels are following steel wheel. 16
6 1 / 2 J or 16
7JJ
REPLACEMENT TIRES
When replacement is necessary, the original equipment type tire should be used. Refer to the Tire Placard. Re-
placement tires should be of the same size, load range and construction as those originally on the vehicle. Use
of any other size or type tire may affect ride, handling, speedometer / odometer calibration, vehicle ground clear-
ance and tire or snow chain clearance to the body and chassis.
NOTE:
Do not mix different types of tires on the same vehicle such as radial, bias and bias-belted tires except in
emergencies, because vehicle handling may be seriously affected and may result in loss of control.
It is recommended that new tires be installed in pairs on the same axle. If necessary to replace only one tire, it
should be paired with the tire having the most tread, to equalize braking traction.

YH4
GRAND
VITARA
3F-2 WHEELS AND TIRES
The metric term for tire inflation pressure is the kilopascal (kPa).
Tire pressures will usually be printed in both kPa and psi on the Tire
Placard. Metric tire gauges are available from tool suppliers. The
chart, left table, converts commonly used inflation pressures from
kPa to psi.kPakgf / cm2psi
160
180
200
220
240
260
280
300
320
3401.6
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.423
26
29
32
35
38
41
44
47
50
Conversion:1 psi = 6.895 kPa
1 kgf / cm
2 = 98.066 kPa
WHEELS REPLACEMENT
Wheels must be replaced if they are bent, dented, have excessive
lateral or radial runout, leak air through welds, have elongated bolt
holes, if lug nuts won't stay tight, or if they are heavily rusted.
Wheels with greater runout than shown in left figure may cause ob-
jectional vibrations.
Wheels for replacement must be equivalent to the originally
equipped wheels in load capacity, diameter, rim width, off-set and
mounting configuration. A wheel of improper size or type may affect
wheel and bearing life, brake cooling, speedometer / odometer cal-
ibration, ground clearance to the body and chassis.
To measure the wheel runout, it is necessary to use accurate dial
indicator. The tire may be on or off the wheel. The wheel should be
installed to the wheel balancer of the like for proper measurement.
Take measurements of both lateral runout and radial runout at both
inside and outside of the rim flange. With dial indicator set in place
securely, turn the wheel one full revolution slowly and record every
reading of the indicator.
When the measured runout exceeds the specification and correc-
tion by the balancer adjustment is impossible, replace the wheel.
If the reading is affected by welding, paint or scratch, it should be
ignored.
Lateral runout limit ªaº: 1.20 mm (0.047 in.)
Radial runout limit ªbº: 1.20 mm (0.047 in.)
METRIC LUG NUTS AND WHEEL STUDS
All models use metric lug nuts and wheel studs (size M12 x 1.25).

YH4
GRAND
VITARA
Diagnostic Trouble Code (DTC) Table 5E1-14. . .
System Circuit 5E1-15. . . . . . . . . . . . . . . . . . . . . . .
Table ± A ªABSº Warning Lamp Circuit
Check ± Lamp does not come ªONº
at ignition switch on 5E1-16. . . . . . . . . . . . . . . . . .
Table ± B ªABSº Warning Lamp Circuit
Check ± Lamp comes ªONº steady 5E1-17. . . .
Table ± C ªABSº Warning Lamp Circuit
Check ± The lamp flashes continuously
while ignition switch is on5E1-18 . . . . . . . . . . . . . .
Table ± D Code (DTC) is not Outputted
even with Diag. Switch Terminal
Connected to Ground 5E1-19. . . . . . . . . . . . . . . .
Table ± E EBD Warning Lamp (Brake
Warning Lamp) Check-lamp Comes
ªONº Steady 5E1-20. . . . . . . . . . . . . . . . . . . . . . . .
DTC 15 ± G Sensor Circuit 5E1-21. . . . . . . . . . . .
DTC 21, 22, 25, 26, 31, 32, 35 or 36
± Wheel Speed Sensor Circuit 5E1-23. . . . . . . .
DTC 41, 45 or 56 ± Solenoid Circuit 5E1-26. . . . .
DTC 57 ± Solenoid and Pump Motor
Power Source Circuit 5E1-27. . . . . . . . . . . . . . . .
DTC 61 ± ABS Pump Motor Circuit 5E1-28. . . . . .
DTC 63 ± ABS Fail-Safe Relay Circuit 5E1-29. . .
DTC 71 ± ABS Control Module 5E1-30. . . . . . . . .
ON-VEHICLE SERVICE5E1-31 . . . . . . . . . . . . . . . .
Precaution 5E1-31. . . . . . . . . . . . . . . . . . . . . . . . . . .
ABS Hydraulic Unit Operation Check 5E1-31. . . .
ABS Hydraulic Unit / Control Module
Assembly 5E1-32. . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic unit inspection 5E1-32. . . . . . . . . . . . . Removal 5E1-32. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5E1-33. . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Speed Sensor 5E1-34. . . . . . . . . . . .
Output voltage inspection 5E1-34. . . . . . . . . . . .
Removal 5E1-35. . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor inspection 5E1-35. . . . . . . . . . . . . . . . . .
Sensor rotor inspection 5E1-35. . . . . . . . . . . . . .
Installation 5E1-36. . . . . . . . . . . . . . . . . . . . . . . . .
Front Sensor Rotor 5E1-36. . . . . . . . . . . . . . . . . . .
Removal 5E1-36. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5E1-36. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wheel Speed Sensor 5E1-37. . . . . . . . . . . .
Output voltage inspection 5E1-37. . . . . . . . . . . .
Removal 5E1-37. . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor inspection 5E1-38. . . . . . . . . . . . . . . . . .
Sensor rotor inspection 5E1-38. . . . . . . . . . . . . .
Installation 5E1-38. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Sensor Rotor 5E1-39. . . . . . . . . . . . . . . . . . . .
Removal 5E1-39. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5E1-39. . . . . . . . . . . . . . . . . . . . . . . . .
G Sensor 5E1-40. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5E1-40. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 5E1-40. . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5E1-40. . . . . . . . . . . . . . . . . . . . . . . . .
Transfer 4WD Switch 5E1-41. . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS5E1-41 . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS5E1-42 . . . . . . . . . . . . . . . . . . . . . .
5E1-2 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
GENERAL DESCRIPTION
The ABS (Antilock Brake System) controls the fluid pressure applied to the wheel cylinder of each brake from the
master cylinder so that each wheel is not locked even when hard braking is applied. This ABS is a 4-wheel type
which controls the fluid pressure applied to the wheel cylinder of each of the four brakes to prevent each wheel
from getting locked.
The component parts of this ABS includes following parts in addition to those of the conventional brake system.

Wheel speed sensor which senses revolution speed of each wheel and outputs its signal.

In this ABS, ABS hydraulic unit (actuator assembly), ABS control module, pump motor relay and fail-safe relay
are combined as one component.

ABS control module which sends operation signal to ABS hydraulic unit to control fluid pressure applied to each
wheel cylinder based on signal from each wheel speed sensor so as to prevent wheel from locking.

ABS hydraulic unit which operates according to signal from ABS control module to control fluid pressure applied
to wheel cylinder of each of 4 wheels.

Fail-safe (solenoid valve) relay which supplies power to solenoid valve in ABS hydraulic unit and pump motor
relay.

Pump motor relay which supplies power to pump motor in ABS hydraulic unit.

ªABSº warning lamp which lights to inform abnormality when system fails to operate properly.

G sensor which detects body deceleration speed. (For 4WD model only)
This ABS is equipped with Electronic Brake force Distribution (EBD) system that controls a fluid pressure of rear
wheels to best condition, which is the same function as that of proportioning valve, by the signal from wheel sensor
independently of change of load due to load capacity and so on. And if the EBD system fails to operate properly,
the brake warning lamp lights to inform abnormality.

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)