SUZUKI GRand VITARA New JB Series Full 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 service 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 information 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 genuine 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

SUZUKI GRand VITARA New JB Series Full Service Repair Manual

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