2005-2010 Suzuki Grand Vitara Service & Repair Manual

IMPORTANT WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the words , and NOTE have special meanings. Pay special attention to the messages high- lighted by these signal words. The circle with a slash in this manual means “Don’t do this” or “Don’t let this happen”. WARNING ! CAUTION ! Indicates a potential hazard that could result in death or injury. WARNING ! Indicates a potential hazard that could result in vehicle damage. CAUTION ! NOTE: Indicates special information to make maintenance easier or instructions clearer. This service manual is intended for authorized Suzuki dealers and qualified service technicians only. Inexperienced technicians or technicians without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the technician and may render the vehicle unsafe for the driver and passengers. WARNING ! For vehicles equipped with a Supplemental Restraint (Air Bag) System: • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser- vice Precautions” under “On-Vehicle Service” 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. • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation. • Do not modify the steering wheel, instrument panel or any other air bag system component on or around air bag system components or wiring. Modifications can adversely affect air bag system performance and lead to injury. • If the vehicle will be exposed to temperatures over 93 °C (200 °F), for example, during a paint baking process, remove the air bag system components, that is air bag (inflator) modules, SDM and/or seat belt with pretensioner, beforehand to avoid component damage or unintended activation. WARNING !

FOREWORD This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and assembly of major components (Unit Repair-Overhaul). VOLUME 1 contains General information, Engine, Suspension, Drive/Axle and Brakes sections (Sections 0 – 4). VOLUME 2 contains Transmission/Transaxle, Steering, HVAC, Restraint, Body/Cab/Accessories and Control Systems sections (Sections 5 – 10). Applicable model: GRAND VITARA (JB416/JB420) vehicles The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on following page. And on the first page of each individual section is an index of that section. This manual should be kept in a handy place for ready reference of the service work. Strict observance of the so specified items will enable one to obtain the full performance of the vehicle. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description. All information, illustrations and specifications contained in this literature are based on the latest product infor- mation available at the time of publication approval. And used as the main subject of description is the vehicle of standard specifications among others. Therefore, note that illustrations may differ from the vehicle being actually serviced. The right is reserved to make changes at any time without notice. © COPYRIGHT SUZUKI MOTOR CORPORATION 2005

RECOMMENDATON OF GENUINE SUZUKI PARTS AND ACCESSORIES USE SUZUKI strongly recommends the use of genuine SUZUKI parts* and accessories. Genuine SUZUKI parts and accessories are built to the highest standards of quality and performance, and are designed to fit the vehicle's exact specifications. A wide variety of non-genuine replacement parts and accessories for SUZUKI vehicles are currently available in the market. Using these parts and accessories can affect the vehicle performance and shorten its useful life. Therefore, installation of non-genuine SUZUKI parts and accessories is not covered under warranty. Non-Genuine SUZUKI Parts and Accessories Some parts and accessories may be approved by certain authorities in your country. Some parts and accessories are sold as SUZUKI authorized replacement parts and accessories. Some genu- ine SUZUKI parts and accessories are sold as re-use parts and accessories. These parts and accessories are non-genuine Suzuki parts and accessories and use of these parts are not covered under warranty. Re-use of Genuine SUZUKI Parts and Accessories The resale or re-use of the following items which could give rise to safety hazards for users is expressly forbid- den: 1) Air bag components and all other pyrotechnic items, including their components (e.g. cushion, control devices and sensors) 2) Seatbelt system, including their components (e.g. webbing, buckles, and retractors) The air bag and seat belt pretensioner components contain explosive chemicals. These components should be removed and disposed of properly by SUZUKI authorized service shop or scrap yard to avoid unintended explo- sion before scrapping. *The parts remanufactured under SUZUKI's approval can be used as genuine SUZUKI parts in Europe.

00 0 1 2 3 4 5 6 7 8 9 10 11 Volume 1 Precautions............................................................... 00-i Precautions ............................................................ 00-1 General Information ................................................... 0-i General Information ............................................... 0A-1 Maintenance and Lubrication ................................. 0B-1 Engine ......................................................................... 1-i Precautions .............................................................. 1-1 Engine General Information and Diagnosis ........... 1A-1 Aux. Emission Control Devices .............................. 1B-1 Engine Electrical Devices....................................... 1C-1 Engine Mechanical ................................................. 1D-1 Engine Lubrication System .................................... 1E-1 Engine Cooling System.......................................... 1F-1 Fuel System ...........................................................1G-1 Ignition System....................................................... 1H-1 Starting System....................................................... 1I-1 Charging System.....................................................1J-1 Exhaust System ..................................................... 1K-1 Suspension ................................................................. 2-i Precautions .............................................................. 2-1 Suspension General Diagnosis .............................. 2A-1 Front Suspension ................................................... 2B-1 Rear Suspension.................................................... 2C-1 Wheels and Tires ................................................... 2D-1 Driveline / Axle ........................................................... 3-i Precautions .............................................................. 3-1 Drive Shaft / Axle ................................................... 3A-1 Differential .............................................................. 3B-1 Transfer .................................................................. 3C-1 Propeller Shaft ....................................................... 3D-1 Brakes ......................................................................... 4-i Precautions .............................................................. 4-1 Brake Control System and Diagnosis .................... 4A-1 Front Brakes........................................................... 4B-1 Rear Brakes ........................................................... 4C-1 Parking Brake......................................................... 4D-1 ABS ........................................................................ 4E-1 Volume 2 Precautions ............................................................... 00-i Precautions ............................................................ 00-1 Transmission / Transaxle .......................................... 5-i Precautions .............................................................. 5-1 Automatic Transmission/Transaxle ........................ 5A-1 Manual Transmission/Transaxle ............................ 5B-1 Clutch ..................................................................... 5C-1 Steering ....................................................................... 6-i Precautions .............................................................. 6-1 Steering General Diagnosis ................................... 6A-1 Steering Wheel and Column .................................. 6B-1 Power Assisted Steering System ........................... 6C-1 HVAC ........................................................................... 7-i Precautions .............................................................. 7-1 Heater and Ventilation............................................ 7A-1 Air Conditioning System ......................................... 7B-1 Restraint ...................................................................... 8-i Precautions .............................................................. 8-1 Seat Belts ............................................................... 8A-1 Air Bag System ...................................................... 8B-1 Body, Cab and Accessories ...................................... 9-i Precautions .............................................................. 9-1 Wiring Systems ...................................................... 9A-1 Lighting Systems .................................................... 9B-1 Instrumentation / Driver Info. / Horn ....................... 9C-1 Wipers / Washers ................................................... 9D-1 Glass / Windows / Mirrors ...................................... 9E-1 Security and Locks ................................................. 9F-1 Seats ..................................................................... 9G-1 Interior Trim ............................................................ 9H-1 Sun Roof / T-Top / Convertible Top ........................ 9I-1 Hood / Fenders / Doors .......................................... 9J-1 Body Structure ....................................................... 9K-1 Paint / Coatings ...................................................... 9L-1 Exterior Trim.......................................................... 9M-1 Control Systems ....................................................... 10-i Precautions ............................................................ 10-1 Cruise Control System ......................................... 10A-1 Body Electrical Control System ............................ 10B-1 Immobilizer Control System ................................. 10C-1 Keyless Start System ........................................... 10E-1 TABLE OF CONTENTS

Table of Contents 00- i 00 Section 00 CONTENTS Precautions Precautions ............................................... 00-1 Precautions........................................................... 00-1 Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System ........ 00-1 General Precautions ........................................... 00-4 Precaution in Servicing Full-Time 4WD Vehicle .............................................................. 00-7 Precautions for Catalytic Converter .................... 00-8 Precaution for CAN Communication System ...... 00-9 Precautions for Electrical Circuit Service ............ 00-9 Precautions for Installing Mobile Communication Equipment ............................. 00-11 Air Bag Warning ................................................ 00-11 Discharge Headlight Warning ........................... 00-11 A/C System Caution .......................................... 00-11 Fastener Caution............................................... 00-11 Suspension Caution .......................................... 00-12 Wheels and Tires Caution ................................. 00-12 Brakes Caution and Note .................................. 00-12 Differential Gear Oil Note .................................. 00-12 Repair Instructions ............................................ 00-13 Electrical Circuit Inspection Procedure ............. 00-13 Intermittent and Poor Connection Inspection .... 00-15

00-1 Precautions: Precautions Precautions Precautions Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System S5JB0A0000001 WARNING ! • The configuration of air bag system parts are as shown in the figure. When it is necessary to service (remove, reinstall and inspect) these parts, be sure to follow procedures described in “Precautions on Service and Diagnosis of Air Bag System in Section 8B”. Failure to follow proper procedures could result in possible air bag system activation, personal injury, damage to parts or air bag system being unable to activate when necessary. • If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air bag system be repaired first, to help avoid unintended air bag system activation. • Do not modify the steering wheel, dashboard, or any other air bag system components. Modifications can adversely affect air bag system performance and lead to injury. • If the vehicle will be exposed to temperatures over 93 °C (200 °F) (for example, during a paint baking process), remove the air bag system components beforehand to avoid component damage or unintended air bag system activation. 1. Passenger air bag (inflator) module 9. Ground for air bag system 2. Driver air bag (inflator) module 10. SDM 3. Contact coil assembly 11. Side-sensor (if equipped) 4. Air bag harness in main harness 12. Seat belt pretensioner 5. Forward-sensor 13. Side curtain-air bag (inflator) module (if equipped) 6. “A/B” fuse in junction block assembly 14. Air bag harness in instrument panel harness 7. Air bag harness in floor harness 15. “AIR BAG” monitor coupler (if equipped) 8. Side-air bag (inflator) module (if equipped) 16. Passenger air bag harness 5 4 6 5 15 3 2 14 16 1 8 9 10 11 8 13 7 11 12 12 7 13 I5JB0A000003-02

Precautions: 00-2 Diagnosis • When troubleshooting air bag system, be sure to follow “Air Bag Diagnostic System Check in Section 8B”. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect parts replacement. • Never use electrical test equipment other than that specified. WARNING ! Never attempt to measure the resistance of the air bag (inflator) modules (driver, passenger, side and curtain) and seat belt pretensioners (driver and passenger). It is very dangerous as the electric current from the tester may deploy the air bag or activate the pretensioners. Servicing and Handling WARNING ! Many of service procedures require disconnection of “A/B” fuse and all air bag (inflator) module(s) from system circuit to avoid an accidental deployment. Driver, Passenger, Side and Curtain Air Bag (Inflator) Modules • For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65 °C (150 °F), without high humidity and away from electric noise. • When carrying a live air bag (inflator) module, make sure the bag opening is pointed away from you. In case of an accidental deployment, the bag will then deploy with minimal chance of injury. Never carry the air bag (inflator) module by the wires or connector on the underside of the module. When placing a live air bag (inflator) module on a bench or other surface, always face the bag up, away from the surface. This is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental deployment. Otherwise, personal injury may result. I5JB0A000001-02 [A]: Always carry air bag (inflator) module with trim cover (air bag opening) away from body. [B]: Always place air bag (inflator) module on workbench with trim cover (air bag opening) up, away from loose objects. [A] [B] I5JB0A000002-02

00-3 Precautions: • Never dispose of live (undeployed) air bag (inflator) modules (driver, passenger, side and curtain). If disposal is necessary, be sure to deploy them according to deployment procedures described in “Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal in Section 8B”. • The air bag (inflator) module immediately after deployment is very hot. Wait for at least half an hour to cool it off before proceeding the work. • After an air bag (inflator) module has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by- products of the chemical reaction. As with many service procedures, gloves and safety glasses should be worn. WARNING ! SDM • During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). • Never strike or jar the SDM. • Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system. The SDM could be activated when powered while not rigidly attached to the vehicle which could cause deployment and result in personal injury. WARNING ! Driver and Passenger Seat Belt Pretensioners • For handling and storage of a live seat belt pretensioner, select a place where the ambient temperature below 65 °C (150 °F), without high humidity and away from electric noise. • Never carry seat belt pretensioner by wire or connector of pretensioner. When placing a live seat belt pretensioner on the workbench or some place like that, be sure not to lay it with its exhaust hole (1) provided side facing down. It is also prohibited to put something on its face with an exhaust hole or to put a seat belt pretensioner on top of another. Otherwise, personal injury may result. • Never dispose of live (inactivated) seat belt pretensioners (drive and passenger). If disposal is necessary, be sure to activate them according to activation procedures described in “Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal in Section 8B” before disposal. • The seat belt pretensioner immediately after activation is very hot. Wait for at least half an hour to cool it off before proceeding the work. • With many service procedures, gloves and safety glasses should be worn to prevent any possible irritation of the skin or eyes. 1 I4JA01822118-01