2005 SUZUKI GRAND VITARA Rear

YH4
GRAND
vol.1
RELATED MANUAL
MANUAL NAMEMANUAL NO.APPLICABILITY
SQ416 / SQ420 / SQ625
Unit Repair Manual99501-65D01-xxxTransmission, Transfer and Differentials
(Front and Rear) of SQ series.
SQ416 / SQ420 / SQ625
Wiring Diagram Manual99512-65D10-015Applicable model mentioned in FOREWORD
of this manual.
SQ416 / SQ420 / SQ625
Service Manual99500-65D00-xxxVehicles before the vehicle identification number
mentioned in FOREWORD of this manual.
SQ416 / SQ420 / SQ625
Wiring Diagram Manual99512-65D01-015

YH4
GRAND
vol.1
0A
0B
1A
1B
3
3A
3B1
3C
3C1
3D
3E
3F
4A2
4B
5
6
7A5A
5B
5C
5E1
6A1
6A2
6A4
6B
6C
6E1
6E2
6F1
6F2
6G
6G1
6H
6K
7A1
7B1
7C1
7D
7E
7F
8
8B
8C
8D
8G
9
10
10A
8A
10B
6-1ENGINE
General Information and
Diagnosis (G16 / J20)
General Information and
Diagnosis (H25)
Engine Mechanical (G16)
Engine Mechanical (H25)
Engine Mechanical (J20)
Engine Cooling
Engine Fuel
Engine and Emission Control
System (SFI for G16 / J20)
Engine and Emission Control
System (SFI for H25)
Ignition System (G16)
Ignition System (J20 / H25)
Cranking System
(Reduction Type)
Cranking System
(No-Reduction Type)
Charging System
Exhaust System
TRANSMISSION, CLUTCH
AND DIFFERENTIAL
Manual Transmission (Type 1)
Manual Transmission (Type 2)
Automatic Transmission
Clutch (Hydraulic Type)
Transfer
Differential (Front)
Differential (Rear)
BODY ELECTRICAL SYSTEM
Wiring Diagram
Lighting System
Instrumentation / Driver
Information
Windows, Mirrors, Security
and Lock
Immobilizer Control System
BODY SERVICE
RESTRAINT SYSTEM
Seat Belt
Air Bag System GENERAL INFORMATION
General Information
Maintenance and Lubrication
TABLE OF CONTENTS TABLE OF CONTENTS SECTIONSECTION
0B
HEATING AND AIR
CONDITIONING
Heater and Ventilation
Air Conditioning
STEERING, SUSPENSION,
WHEELS AND TIRES
Front End Alignment
Power Steering (P / S) System
Steering Wheel and Column
(Not Equipped with Air Bag)
Air Bag Steering Wheel
and Column
Front Suspension
Rear Suspension
Wheel and Tires
1A
3A 0A
1B
3B1
3C
3C1
3D
3E
3F36A16
6A2
6A4
6B
6C
6E1
6E2
6F1
DRIVE SHAFT / PROP. SHAFT
Front Drive Shaft / Shaft
Bearing, Oil Seal
Propeller Shaft
BRAKES
Brake Pipe / Hose / Master
Cylinder
Front Brakes
Parking and Rear Brakes
Antilock Brake System
4A2
4B
5
5A
5B
5C
5E1
6F2
6G
6G1
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8
8A
8B
8C
8D
8G
9
10
10A
10B
6-1
NOTE:
The screen toned Sections 6 ± 6K are included in Volume 2 and Section 8A is in Wiring
Diagram Manual.

YH4
GRAND
VITARA
When using frame contact hoist:
1. Front lifting point
2. Rear lifting point
3. Front
GENERAL INFORMATION 0A-19
VEHICLE LIFTING POINTS
WARNING

When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up the
vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by trying to
move vehicle body in both ways. Work can be started only after this confirmation.

Before applying hoist to underbody, always take vehicle balance throughout service into consider-
ation. Vehicle balance on hoist may change depending of what part to be removed.

Make absolutely sure to lock hoist after vehicle is hoisted up.

Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe,
fuel pipe, bracket or any other part.

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
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.

YH4
GRAND
VITARA
1. Wear indicator
MAINTENANCE AND LUBRICATION 0B-17
ITEM 6-6
Tire Inspection and Rotation
1) Check tires for uneven or excessive wear, or damage.
If defective, replace.
Refer to Section 3 for details.
2) Check inflating pressure of each tire and adjust pressure to
specification as necessary.
Refer to Section 3F for details.
NOTE:

Tire inflation pressure should be checked when tires are
cool.

Specified tire inflation pressure should be found on tire
placard or in owner's manual which came with the vehicle.
3) Rotate tires.
For details, refer to Section 3F.
ITEM 6-7
Wheel Discs Inspection
Inspect each wheel disc for dents, distortion and cracks. A disc in
badly damaged condition must be replaced.
Wheel Bearing Inspection
1) Check front wheel bearing for wear, damage, abnormal noise or
rattles. For details, refer to Section 3D.
2) Check rear wheel bearing for wear, damage, abnormal noise or
rattles. For details, refer to Section 3E.

YH4
GRAND
VITARA
0B-18 MAINTENANCE AND LUBRICATION
ITEM 6-8
Suspension System Inspection
Check suspension bolts and nuts for tightness and retighten them
as necessary.
Repair or replace defective parts, if any.
NOTE:
For details of check points, refer to tables of Tightening Torque
Specification in Section 3D and 3E.
Front
1) Check stabilizer bar for damage or deformation.
2) Check bushing for damage, wear or deterioration.
3) Inspect strut for damage, deformation, oil leakage and opera-
tion. If strut is found faulty, replace it as an assembly unit, be-
cause it can not be disassembled.
Refer to strut check Section 3D for operation check.
4) Inspect strut boot for damage or crack.
5) Inspect for cracks or deformation in spring seat.
6) Inspect for deterioration of bump stopper.
7) Inspect strut mount for wear, cracks or deformation.
8) Check ball joint stud dust seal (boot) for leaks, detachment,
tear or other damage. Check suspension arm bushing for dam-
age, wear or deterioration.
Rear
9) Check shock absorber for damage, deformation, oil leakage
and operation.
10) Check bushings for wear and damage.

YH4
GRAND
VITARA
MAINTENANCE AND LUBRICATION 0B-19
11) Check coil spring, upper rod, lower rod and lateral rod for de-
formation and damage.
12) Check upper rod, lower rod and lateral rod bushings and bump
stopper for wear, damage and deterioration.
13) Check other suspension parts for damage, loose or missing
parts; also for parts showing signs of wear or lack of lubrication.
Replace any parts found defective in steps 1) to 13).
ITEM 6-9
Propeller Shafts and Drive Shafts Inspection
1) Check universal joint and spline of propeller shaft for rattle. If
rattle is found, replace defective part with a new one.
2) Check propeller shaft (front & rear) flange yoke bolts for tight-
ness, and retighten them as necessary.
Refer to Section 4B for tightening torque.
3) Check drive axle boots (wheel side and differential side) for
leaks, detachment, tear or other damage.
Replace boot as necessary.