2005 SUZUKI GRAND VITARA height

YH4
GRAND
VITARA
5-16 BRAKES
Check Operation
1) With engine stopped, depress brake pedal several times with
the same load and make sure that pedal travel doesn't change.
2) Start engine while depressing brake pedal. If pedal travel in-
creases a little, operation is satisfactory. But no change in pedal
travel indicates malfunction.
Check Air Tightness Under Load
1) With engine running, depress brake pedal. Then stop engine
while holding brake pedal depressed.
2) Hold brake pedal depressed for 30 seconds. If pedal height does
not change, condition is good. But it isn't if pedal rises.

YH4
GRAND
VITARA
1. LSPV
2. LSPV lever
3. Spring
4. LSPV stay
5. Brake flare nut
[A]: Type A
[B]: Type B
1. Plunger
2. Lip seal
3. LSPV lever
4. Sensor spring
5. From master cylinder
primary chamber
(Rear wheel brake)
6. From master cylinder
secondary chamber
(Front wheel brake)
7. To rear wheel brake
8. Pin
9. Bolt hole
[A] [B]
44
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-3
LSPV (Load Sensing Proportioning Valve) ASSEMBLY (if equipped)
As shown in figure below, LSPV is included within the brake circuit which connects the master cylinder and the rear
wheel brake. It controls the hydraulic pressure applied to the rear wheel brake according to the loaded state of the
vehicle (or weight of the load), whereby preventing the rear wheels from getting locked prematurely.
Also, it releases the above described control over the hydraulic pressure applied to the rear wheel brake, should
any failure occur in the hydraulic circuit of the front wheel brake so that the hydraulic pressure produced in the mas-
ter cylinder is applied to the rear wheel brake directly to operate it.
CONSTITUTION
The LSPV components are grouped into three sections as follows.
ªAº: Sensor section
The main parts in this section are a lever and a spring which senses variation in the vehicle height as affected
by the loaded condition and converts it into the load.
ªBº: Hydraulic pressure control section
Included in this section are a stepped plunger and valve mechanism to execute proportional control.
ªCº: Fail-safe section
The main parts in this section are a chamber which draws in the hydraulic pressure from the front wheel brake
system and a fail-safe piston which releases the valve mechanism in the control section connected to the rear
wheel brake, should any failure occur in the front wheel brake system.

YH4
GRAND
VITARA
7C1
CLUTCH 7C1-1
GENERAL DESCRIPTION7C1 - 2 . . . . . . . . . . . . .
DIAGNOSIS7C1 - 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7C1 - 4 . . . . . . . . . . . . . . .
Clutch Pedal Height 7C1 - 4. . . . . . . . . . . . . . . . . .
Clutch Pedal Free Travel 7C1 - 4. . . . . . . . . . . . .
Clutch Fluid Pipe and Hose 7C1 - 4. . . . . . . . . . .
Clutch Master Cylinder 7C1 - 5. . . . . . . . . . . . . . .
Fluid Inspection 7C1 - 6. . . . . . . . . . . . . . . . . . . . .
Disassembly and Assembly
Clutch Master Cylinder 7C1 - 7. . . . . . . . . . . . . . Clutch Operating Cylinder 7C1 - 8. . . . . . . . . . . .
UNIT REPAIR7C1-10 . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Cover, Clutch Disc and
Flywheel 7C1 - 10. . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7C1-14 . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7C1-14 . . . . .
SPECIAL TOOLS7C1-14 . . . . . . . . . . . . . . . . . . . . .
SECTION 7C1
CLUTCH
CONTENTS

YH4
GRAND
VITARA
1. Clutch pedal
2. Clevis lock nut
3. Push rod
1. Clutch master cylinder
2. Clutch pipe
3. Clutch hose
4. Clutch operating cylinder
1. Pipe
2. Hose
3. Spanner
4. Flare nut wrench2, (a)
7C1-4 CLUTCH
ON-VEHICLE SERVICE
CLUTCH PEDAL HEIGHT
Adjust clutch pedal height by loosening clevis lock nut and turning
push rod as shown.
Clutch pedal height is normal if clutch pedal is about
20 mm (0.79 in.) higher than brake pedal.
After adjusting, tighten lock nut to specified torque.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
CLUTCH PEDAL FREE TRAVEL
Depress clutch pedal, stop the moment clutch resistance is felt and
measure distance (clutch pedal free travel). Free travel should be
within following specification.
Pedal free travel ªaº: 15 ± 25 mm (0.6 ± 1.1 in.)
CLUTCH FLUID PIPE AND HOSE
REMOVAL
NOTE:
Do not allow fluid to get on painted surface.
1) Remove dust and dirt from each joint of hose and pipe to be dis-
connected and clean around reservoir cap.
2) Take out fluid with syringe or such.
3) Disconnect fluid pipe from hose.
NOTE:
To disconnect pipe from hose, separate them by using flare
nut wrench and spanner so as not to kink them.

YH4
GRAND
VITARA
1. Molding
2. Fastener
1. Molding
2. Adhesive
3. Glass
ªAº: Primer for molding
1. Rubber sucker grip
9-10 BODY SERVICE
7) Using new brush, apply sufficient amount of primer for glass
along glass surface to be adhered to body.
NOTE:

Be sure to refer to maker's instruction for proper han-
dling and drying time.

Do not apply primer on outside of ceramic coated sur-
face.

Do not touch primer coated surface.
Width ªbº: 18 ± 19 mm (0.71 ± 0.75 in.)
ªcº: 16 ± 17 mm (0.63 ± 0.67 in.)
ªdº: 24 mm (0.94 in.)
ªeº: 27 mm (1.06 in.)
8) Apply primer for molding along molding surface all around as
shown in figure.
9) Apply adhesive referring to figure at the left.
NOTE:

Start from bottom side of glass.

Be careful not to damage primer.

Height of adhesive applied to lower side should be high-
er than that of other three sides.
Upper, right and left sides
Width ªeº : Approx. 11 mm (0.43 in.)
Height ªfº : Approx. 17 mm (0.67 in.)
ªgº : Approx. 25 mm (0.98 in.)
Distance ªhº : Approx. 16 mm (0.63 in.)

Press glass against body quickly after adhesive is ap-
plied.

Use of rubber sucker grip is helpful to hold and carry
glass after adhesive is applied.

Perform steps 9) to 10) within 10 min. to ensure sufficient
adhesion.

Be sure to refer to adhesive maker's instruction for prop-
er handling and drying time.
10) Holding rubber sucker grips, place glass onto body by aligning
mating marks marked in step 3) and press it.

YH4
GRAND
VITARA
BODY SERVICE 9-15
1. Fastener
2. Glass
3. Molding
4. Adhesive
5. Primer
QUARTER WINDOW
REMOVAL AND INSTALLATION
Refer to ªWINDSHIELDº section as removal and installation proce-
dures and cautions are basically the same. However, note the fol-
lowing.
NOTE:

Before applying primer to glass edge, install molding ac-
cording to installing position shown in figure.

Observe following precautions when applying adhesive
along glass edge.
±Adhesive should be applied evenly especially in height.
±Be careful not to damage primer.
±Press glass against body quickly after adhesive is applied.
Height ªbº : 12 mm (0.47 in.)
Width ªdº : 16 mm (0.63 in.)
ªcº : 8 mm (0.31 in.)
Clearance ªeº : 1 mm (0.04 in.)

YH4
GRAND
VITARA
9-16 BODY SERVICE
1. Molding
2. Glass
3. Fastener
1. Molding
2. Glass
3. Primer
4. Adhesive
5. Fastener
1. Door sealing cover
BACK DOOR GLASS
REMOVAL AND INSTALLATION
Refer to ªWINDSHIELDº section as removal and installation proce-
dures and cautions are basically the same. However, note the fol-
lowing.
NOTE:

Before applying primer to glass edge, install molding ac-
cording to installing position shown in figure.

Observe following precautions when applying adhesive
along glass edge.
±Adhesive should be applied evenly especially in height.
±Be careful not to damage primer.
±Press glass against body quickly after adhesive is applied.
Height ªbº : 15 mm (0.59 in.)
Width ªcº : 8 mm (0.31 in.)
Width ªdº : 16 mm (0.63 in.)
Clearance ªeº : 1 mm (0.04 in.)

When replacing back door, coat replacement door inside
with wax for proper anticorrosive treatment. Refer to ªUN-
DER COATING / ANTI-CORROSION COMPOUND APPLICA-
TION AREAº in this section.

Apply sealing compound to peripheral of door hem area and
reinstall door sealing cover.

When weatherstrip is hardened and water leaks have devel-
oped, replace it.

YH4
GRAND
VITARA
1. Side body
2. Fender
3. Pad
1. Side body
2. Pad
3. Knife
9-22 BODY SERVICE
1. Front fender
2. Front fender lining
3. Fender attaching bolts
4. Fender lining attaching screws
FRONT FENDER
REMOVAL
1) Remove front bumper.
2) Remove fender splush guard (H25 engine).
3) Remove front fender lining.
4) Remove front fender.
INSTALLATION
1) Remove pad from side body and (or) fender, using care not to
damage painted surface.
2) Attach new pad cutting appropriately size temporarily and adjust
height with a knife so that fender becomes flush with side body.
3) Reverse removal procedure for installation.
NOTE:
If paint on fender bolt is peeled off, be sure to apply paint
again.