VitaraSMpart2.pdf

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.

WARNING

CAUTION

WARNING

Indicates a potential hazard that could result in death or injury.

CAUTION

Indicates a potential hazard that could result in vehicle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

WARNING

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.

The circle with a slash in this manual means “Don’t do this” or “Don’t let this happen”.

FOREWORD

This SUPPLEMENTARY SERVICE MANUAL is a supplement to GRAND VITARA (JB416/JB420) SERVICE

MANUAL.

It has been prepared exclusively for the following applicable model.

Applicable model:

GRAND VITARA (JB416/JB420) vehicles

This supplementary service manual describes only different service information of the above applicable model

as compared with GRAND VITARA (JB416/JB420) SERVICE MANUAL. Therefore, whenever servicing the

above applicable models, consult this supplement first. And for any section, item or description not found in this

supplement, refer to the related manual below.

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.

Related Manuals:

Manual Name

Manual No.

GRAND VITARA (JB416/JB420) SERVICE MANUAL

99500-64J00-01E

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.

TABLE OF CONTENTS

NOTE

For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same

sections of the service manual mentioned in the “FOREWORD” of this manual.

Precautions............................................................... 00-i

Precautions ............................................................ 00-1

General Information ................................................... 0-i

General Information ............................................... 0A-1

Maintenance and Lubrication ..................................0B-*

Engine ......................................................................... 1-i

Precautions ............................................................... 1-*

Engine General Information and Diagnosis ........... 1A-1

Aux. Emission Control Devices ...............................1B-*

Engine Electrical Devices....................................... 1C-*

Engine Mechanical................................................. 1D-*

Engine Lubrication System .....................................1E-*

Engine Cooling System...........................................1F-*

Fuel System ........................................................... 1G-*

Ignition System....................................................... 1H-*

Starting System........................................................ 1I-*

Charging System..................................................... 1J-*

Exhaust System ......................................................1K-*

Suspension ................................................................. 2-i

Precautions ............................................................... 2-*

Suspension General Diagnosis...............................2A-*

Front Suspension ................................................... 2B-1

Rear Suspension.................................................... 2C-*

Wheels and Tires ................................................... 2D-*

Driveline / Axle ........................................................... 3-i

Precautions ............................................................... 3-*

Drive Shaft / Axle ....................................................3A-*

Differential ...............................................................3B-*

Transfer..................................................................3C-1

Propeller Shafts...................................................... 3D-*

Brakes ......................................................................... 4-i

Precautions .............................................................. 4-1

Brake Control System and Diagnosis .................... 4A-1

Front Brakes........................................................... 4B-1

Rear Brakes ........................................................... 4C-*

Parking Brake......................................................... 4D-*

ABS ........................................................................ 4E-1

Electronic Stability Program ................................... 4F-1

Transmission / Transaxle .......................................... 5-i

Precautions ...............................................................5-*

Automatic Transmission/Transaxle ........................5A-1

Manual Transmission/Transaxle ............................ 5B-*

Clutch ..................................................................... 5C-*

Steering ....................................................................... 6-i

Precautions ...............................................................6-*

Steering General Diagnosis ................................... 6A-*

Steering Wheel and Column ..................................6B-1

Power Assisted Steering System ........................... 6C-*

HVAC ........................................................................... 7-i

Precautions ...............................................................7-*

Heater and Ventilation............................................7A-1

Air Conditioning System .........................................7B-1

Restraint......................................................................8-*

Precautions ...............................................................8-*

Seat Belts ............................................................... 8A-*

Air Bag System ...................................................... 8B-*

Body, Cab and Accessories ...................................... 9-i

Precautions .............................................................. 9-1

Wiring Systems ...................................................... 9A-*

Lighting Systems ....................................................9B-1

Instrumentation / Driver Info. / Horn .......................9C-1

Wipers / Washers ...................................................9D-1

Glass / Windows / Mirrors ...................................... 9E-*

Security and Locks ..................................................9F-*

Seats ...................................................................... 9G-*

Interior Trim ............................................................ 9H-*

Sun Roof / T-Top / Convertible Top .........................9I-*

Hood / Fenders / Doors ........................................... 9J-*

Body Structure ....................................................... 9K-*

Paint / Coatings .......................................................9L-*

Exterior Trim...........................................................9M-*

Control systems ....................................................... 10-i

Precautions .............................................................10-*

Cruise Control System .........................................10A-1

Body Electrical Control System ............................10B-1

Immobilizer Control System .................................10C-1

Keyless Start System ...........................................10E-1

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