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 Shafts...................................................... 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 ............................................ 00-12
Electrical Circuit Inspection Procedure ............. 00-12
Intermittent and Poor Connection Inspection .... 00-15
00-1 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
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Description
This workshop service repair manual covers all models and repairs from A-Z, including mechanical and electrical repairs. It contains detailed pictures and diagrams, and all pages are printable so you can easily print what you need. Whether you are a professional mechanic or a DIY enthusiast, this manual provides the knowledge to better understand your vehicle's parts and repair procedures, allowing you to perform your own servicing and repairs.
All models for the specified years and engine types are included in this specific manual. It encompasses a wide range of information, including routine maintenance, tune-up procedures, specifications, engine removal/installation, cylinder head/valve train, engine block, engine lubrication, intake manifold/exhaust system, cooling and heating, fuel and emissions, transaxle, clutch, manual transmission, automatic transmission, differential, driveshaft, steering, suspension, brakes (including ABS), body, heater and air conditioning, automatic climate control, electrical (including SRS), supplemental restraint system (SRS), engine repair, air conditioning, exhaust, emissions control, ignition, steering, wiring diagrams, valve timing procedures, chain & gear replacement, general removal & installation instructions, safety precautions, special tools, tensioner adjustments, tightening torques, timing marks, valve timing instructions, tensioner release & reset methods, chain routing & sprocket/gear valve timing marks, etc.
Delivery of this manual is instant upon payment, with no shipping involved. You will receive the manual right away, enabling you to start fixing the vehicle today. By utilizing the information and knowledge in this manual, you can save a significant amount of money that would otherwise be spent on mechanic services. The manual is user-friendly and compatible with any PC/MAC computer using Microsoft Windows, such as XP, NT, 2000, Vista, and Windows 7.
