2005 SUZUKI GRAND VITARA hazard

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
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)

YH4
GRAND
VITARA
Charge 440
50 g, 14.2
1.9 oz of
refrigerant in gas form
AIR CONDITIONING (OPTIONAL) 1B-23
REFRIGERANT RECOVERY, EVACUATION AND CHARGING
WARNING:

Your eyes should not be exposed to refrigerant (liquid).
Any liquid Refrigerant-134a escaping by accident shows a temperature as low as approx. ± 6C
(42.8F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause a seri-
ous injury. To protect your eyes against such accident, it is necessary to always wear goggles. Should
it occur that HFC-134a (R-134a) strikes your eye(s), consult a doctor immediately.
± DO NOT USE YOUR HAND TO RUB THE AFFECTED EYE(S). INSTEAD, use quantities of fresh cold
water to splash it over the affected area to gradually raise temperature of such area above freezing
point.
± Obtain proper treatment as soon as possible from a doctor or eye specialist.

Should the HFC-134a (R-134a) liquid come into contact with your skin, the affected area should be
treated in the same manner as when skin is frostbitten or frozen.

Refrigerant must not be handled near where welding or steam cleaning is performed.

Refrigerant should be kept at a cold and dark place. It should never be stored where a high tempera-
ture is anticipated, e.g. where exposed to direct sun light, close to fire or inside vehicle (including
trunk room).

Avoid breathing fumes produced when HFC-134a (R-134a) is burned. Such fumes may be hazardous
to health.
OPERATION PROCEDURE FOR CHARGING A / C WITH REFRIGERANT

YH4
GRAND
VITARA
3A
Alignment service data (without load)
Toe-in (Toe-in gauge measurement)
ªBº ± ªAº: 0
2 mm (0
0.08 in.)
Camber angle ªCº: 0'
1

Caster: 2
40'
1

*1. Forward
*2. Body center[A] : Top view
[B] : Front view
1. Center line of wheel
FRONT END ALIGNMENT 3A-1
SECTION 3A
FRONT END ALIGNMENT
CONTENTS
DIAGNOSIS3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION3A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toe-Setting3A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camber3A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Checks Prior to Adjusting Front Alignment 3A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toe Adjustment3A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camber and Caster Adjustment 3A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Angle3A-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION
Front alignment refers to the angular relationship between the front wheels, the front suspension attaching parts
and the ground. Generally, the only adjustment required for front alignment is toe setting.
Camber and caster can't be adjusted. Therefore, should camber or caster be out of specification due to the damage
caused by hazardous road conditions or collision, whether the damage is in body or in suspension should be deter-
mined. If the body is damaged, it should be repaired and if suspension is damaged, it should replaced.
TOE SETTING
Toe is the turning in or out of the front wheels. The purpose of a toe specification is to ensure parallel rolling of the
front wheels (Excessive toe-in or toe-out may increase tire wear).
Amount of toe can be obtained by subtracting ªAº front ªBº as shown in above figure and therefore is given in mm
(in.).

YH4
GRAND
VITARA
5-10 BRAKES
BRAKE PEDAL PLAY CHECK
Pedal play should be within specification. If out of specification,
check brake light switch for proper installation position and adjust
if necessary.
Also check pedal shaft bolt and master cylinder pin installation for
looseness and replace if defective.
Pedal play ªdº: 1 ± 8 mm (0.04 ± 0.32 in.)
BRAKE FLUID LEVEL CHECK
Be sure to use particular brake fluid either as indicated on reservoir
cap of that vehicle or recommended in owner's manual which
comes along with that vehicle.
Use of any other fluid is strictly prohibited.
Fluid level should be between MIN and MAX lines marked on reser-
voir.
When warning light lights sometimes during driving, replenish fluid
to MAX line.
When fluid decreases quickly, inspect brake system for leakage.
Correct leaky points and then refill to specified level.
CAUTION:
Do not use shock absorber fluid or any other fluid which
contains mineral oil. Do not use a container which has been
used for mineral oil or a container which is wet from water.
Mineral oil will cause swelling and distortion of rubber parts
in hydraulic brake system and water mixed into brake fluid
will lower fluid boiling point. Keep all fluid containers
capped to prevent contamination.
BRAKE HOSE AND PIPE CHECK
The brake hose assembly should be checked for road hazard dam-
age, for cracks and chafing of the outer cover, for leaks and blisters.
A light and mirror may be needed for an adequate inspection. If any
of the above conditions are observed on the brake hose, it is neces-
sary to replace it.
Inspect the pipe for damage, cracks, dents and corrosion. If any de-
fect is found, replace it.
MASTER CYLINDER CHECK
Check for a cracked master cylinder casting or brake fluid around
the master cylinder. Leaks are indicated only if there is at least a
drop of fluid. A damp condition is not abnormal.

YH4
GRAND
VITARA
8B
LIGHTING SYSTEM 8B-1
SECTION 8B
LIGHTING SYSTEM
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
GENERAL DESCRIPTION8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions in Servicing8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols and Marks8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Color Symbols8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joint Connector8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Box and Relay8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Diagram8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight with Leveling System (If Equipped) 8B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS8B- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights8B- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights with Leveling System (If Equipped) 8B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal and Hazard Warning Lights 8B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance, Tail and License Plate Lights 8B- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back-up Lights8B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lights8B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Fog Light (If Equipped)8B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interior Lights8B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE8B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights8B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights with Leveling System (If Equipped) 8B- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal and Hazard Warning Lights 8B- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Fog Light (If Equipped)8B-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
8B-4 LIGHTING SYSTEM
DIAGNOSIS
NOTE:
Fuse name (ª º) in the table below is shown on the fuse box cover (Hard Top Model) or the junction box
(Canvas Top Model).
HEADLIGHTS
TroublePossible causeCorrection
Only one light does not
light
Bulb blown

Headlight L or R fuse blown

Socket, wiring or grounding faultyReplace bulb
Replace fuse to check for short
Repair
Headlights do not light
Headlight L and R fuses blown

Lighting and dimmer switch faulty

Defective light relay

Wiring or grounding faultyReplace fuses to check for short
Replace switches
Replace light relay
Repair
Only one beam (ªHiº or
ªLoº) does not light
Bulb blown

Lighting or dimmer switch faultyReplace bulb
Replace switch
HEADLIGHTS WITH LEVELING SYSTEM (IF EQUIPPED)
TroublePossible causeCorrection
Both headlights do not
move
ªTURN / BACKº fuse blown (Hard Top Model)
ªTRNº fuse blown (Canvas Top Model)

Leveling switch faulty

Supply voltage too lowReplace fuse to check for short
Replace switch
Recharge or replace battery
One of headlights (either
Right or Left) does not
move
Socket, wiring or grounding faulty

Actuator faulty

Vehicle body around headlight deformed

Headlight ass'y itself deformedRepair
Replace actuator
Repair body
Replace headlight ass'y
TURN SIGNAL AND HAZARD WARNING LIGHTS
TroublePossible causeCorrection
Flash rate high or one side
only flashes
Incorrect bulb

One of light bulbs burnt out

Turn signal / hazard warning relay faulty

Open circuit or high resistance existing
Replace bulb
Replace
Replace relay
Repair
Oen circuit or high resistance existing
between turn signal / hazard warning
switch and lights on one side

Wiring or grounding faulty
Re air
Repair
No flashing
ªTURN / BACKº and / or ªHAZARDº fuse(s)
blown (Hard Top Model)
ªTRNº and / or ªHAZº fuse(s) blown
(Canvas Top Model)

Open circuit or high resistance existing
between battery and switch

Turn signal / hazard relay faulty

Combination switch or hazard switch faulty

Wiring or grounding faultyReplace fuse(s) to check for
short
Check bulb and check circuit
Replace relay
Replace switch
Repair
Flash rate low
Supply voltage too low

Turn signal / hazard relay faultyCheck charging system
Replace relay

YH4
GRAND
VITARA
1. Meter cluster
2. Hazard switch
Terminal
Wire ColorSwitch Position
LH steering vehicle shown
LIGHTING SYSTEM 8B-9
TURN SIGNAL AND HAZARD WARNING
LIGHTS
TURN SIGNAL SWITCH (IN COMBINATION SWITCH)
INSPECTION
1) Disconnect negative cable at battery.
2) Disconnect combination switch lead wire coupler.
3) Check for continuity between terminals at each switch position
shown below. If check result is not as specified, replace switch.
TLTBTR
G/RGG/Y
L
N
R
REMOVAL AND INSTALLATION
Refer to Section 3C COMBINATION SWITCH for vehicle without air
bag system and Section 3C1 CONTACT COIL AND COMBINA-
TION SWITCH ASSEMBLY for vehicle with air bag system.
HAZARD SWITCH
REMOVAL
1) Remove meter cluster.
2) Pull hazard switch out of instrument panel.
3) Disconnect coupler from hazard switch.
4) Remove hazard switch.
INSTALLATION
Reverse removal procedure.
INSPECTION
Check for continuity between terminals at each switch position
shown below. If check result is not as specified, replace siwtch.