Suzuki Grand Vitara JB419. Service manual - part 2

 

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Suzuki Grand Vitara JB419. Service manual - part 2

 

 

Table of Contents 0- i

0

Section 0

CONTENTS

General Information

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

General Description .............................................0A-1

Abbreviations ...................................................... 0A-1

Symbols ...............................................................0A-*
Wire Color Symbols .............................................0A-*

Fastener Information........................................... 0A-2

Vehicle Lifting Points............................................0A-*
Engine Supporting Points ....................................0A-*
Vehicle Identification Number ..............................0A-*

Engine Identification Number.............................. 0A-4
Transmission Identification Number.................... 0A-4

Component Location ...........................................0A-5

Warning, Caution and Information Label 

Location ............................................................ 0A-5

Maintenance and Lubrication................. 0B-1

Precautions........................................................... 0B-*

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

Scheduled Maintenance ......................................0B-1

Maintenance Schedule under Normal Driving 

Conditions ......................................................... 0B-1

Maintenance Recommended under Severe 

Driving Conditions............................................. 0B-2

Repair Instructions ..............................................0B-3

Engine Accessory Drive Belt, Tensioner and 

Idler Replacement............................................. 0B-3

Camshaft Timing Belt and Tensioner 

Replacement..................................................... 0B-3

Engine Oil and Filter Change.............................. 0B-3
Engine Coolant Change...................................... 0B-4
Exhaust system Inspection ................................. 0B-4
Air Cleaner Filter Inspection................................ 0B-4

Air Cleaner Filter Replacement ...........................0B-4
Fuel Lines and Connections Inspection ..............0B-5
Fuel Filter Replacement ......................................0B-5

Fuel Tank Inspection........................................... 0B-*
Brake Discs and Pads Inspection ....................... 0B-*
Brake Drums and Shoes Inspection.................... 0B-*
Brake Hoses and Pipes Inspection ..................... 0B-*
Brake Fluid Change ............................................ 0B-*
Parking Brake Lever and Cable Inspection......... 0B-*
Clutch Fluid Inspection........................................ 0B-*
Tire / Wheel Inspection and Rotation .................. 0B-*
Wheel Discs Inspection....................................... 0B-*
Wheel Bearing Inspection ................................... 0B-*
Suspension System Inspection ........................... 0B-*

Steering System Inspection ................................0B-5

Propeller Shafts and Drive Shafts Inspection...... 0B-*

Manual Transmission Oil Inspection ...................0B-6
Manual Transmission Oil Change .......................0B-6
Transfer Oil Inspection (If Equipped) ..................0B-6

Differential Oil Inspection .................................... 0B-*

Transfer (If Equipped) and Differential Oil 

Change..............................................................0B-6

Power Steering (P/S) System Inspection ............0B-6

All Hinges, Latches and Locks Inspection........... 0B-*
HVAC Air Filter Inspection (If Equipped)............. 0B-*
HVAC Air Filter Replacement (If Equipped) ........ 0B-*
Final Inspection for Maintenance Service ........... 0B-*

Specifications.......................................................0B-7

Tightening Torque Specifications........................0B-7

Special Tools and Equipment .............................0B-7

Recommended Fluids and Lubricants.................0B-7
Special Tool ........................................................0B-7

NOTE
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual 
mentioned in the “FOREWORD” of this manual.

0A-1 General Information: 

General Information

General Information

General Description

Abbreviations

S5JB0B0101001

A:  
ABDC:  
After Bottom Dead Center
ABS:  Anti-lock Brake System
AC:  Alternating Current
A/C:  Air Conditioning
A-ELR:  Automatic-Emergency Locking Retractor
A/F:  Air Fuel Mixture Ratio
ALR:  Automatic Locking Retractor
API:  American Petroleum Institute
ATDC:  After Top Dead Center
ATF:  Automatic Transmission Fluid
A/T:  Automatic Transmission
AWD:  All Wheel Drive
B:  
BBDC:  
Before Bottom Dead Center
BCM:  Body Electrical Control Module
BDC:  Bottom Dead Center
BTDC:  Before Top Dead Center
B+:  Battery Positive Voltage
C:  
CAN:  
Controller Area Network
CKP Sensor:  Crankshaft Position Sensor
CKT:  Circuit
CMP Sensor:  Camshaft Position Sensor
CO:  Carbon Monoxide
CPP Switch:  Clutch Pedal Position Switch (Clutch 

Switch, Clutch Start Switch)

CPU:  Central Processing Unit
CRS:  Child Restraint System
D:  
DC:  
Direct Current
DLC:  Data Link Connector (Assembly Line Diag. Link, 

ALDL, Serial Data Link, SDL)

DOHC:  Double Over Head Camshaft
DOJ:  Double Offset Joint
DRL:  Daytime Running Light
DTC:  Diagnostic Trouble Code (Diagnostic Code)
E:  
EBCM:  
Electronic Brake Control Module, ABS Control 

Module

EBD:  Electronic Brake Force Distribution
ECM:  Engine Control Module
ECT Sensor:  Engine Coolant Temperature Sensor 

(Water Temp. Sensor, WTS)

EFE Heater:  Early Fuel Evaporation Heater (Positive 

Temperature Coefficient, PTC Heater)

EGR:  Exhaust Gas Recirculation
EGRT Sensor:  EGR Temperature Sensor (Recirculated 

Exhaust Gas Temp. Sensor, REGTS)

ELR:  Emergency Locking Retractor
EPS:  Electronic Power Steering
EVAP:  Evaporative Emission
EVAP Canister:  Evaporative Emission Canister 

(Charcoal Canister)

F:  
FWD:  
Front Wheel Drive
4WD:  4 Wheel Drive
G:  
GEN:  
Generator
GND:  Ground
H:  
HC:  
Hydrocarbons
HO2S:  Heated Oxygen Sensor
HVAC:  Heating, Ventilating and Air Conditioning
I:  
IAC Valve:  
Idle Air Control Valve (Idle Speed Control 

Solenoid Valve, ISC Solenoid Valve)

IAT Sensor:  Intake Air Temperature Sensor (Air 

temperature Sensor, ATS)

ICM:  Immobilizer Control Module
IG:  Ignition
IMT:  Intake Manifold Tuning
ISC Actuator:  Idle Speed Control Actuator (Motor)
L:  
LH:  
Left Hand
LSPV:  Load Sensing Proportioning Valve
M:  
MAF Sensor:  
Mass Air Flow Sensor (Air Flow Sensor, 

AFS, Air Flow Meter, AFM)

MAP Sensor:  Manifold Absolute Pressure Sensor 

(Pressure Sensor, PS)

Max:  Maximum
MFI:  Multiport Fuel Injection (Multipoint Fuel Injection)
MIL:  Malfunction Indicator Lamp (“SERVICE ENGINE 

SOON” Light)

Min:  Minimum
M/T:  Manual Transmission
N:  
NOx:  
Nitrogen Oxides
O:  
OBD:  
On-Board Diagnostic System (Self-Diagnosis 

Function)

OCM:  Occupant Classification module
O/D:  Overdrive
OHC:  Over Head Camshaft
O2S:  Oxygen Sensor
P:  
PCM:  
Powertrain Control Module
PCV:  Positive Crankcase Ventilation
PNP:  Park / Neutral Position
PSP Switch:  Power Steering Pressure Switch (P/S 

Pressure Switch)

P/S:  Power Steering
R:  
RH:  
Right Hand

General Information:  0A-2

S:  
SAE:  
Society of Automotive Engineers
SDM:  Sensing and Diagnostic Module (Air Bag 

Controller, Air bag Control Module)

SFI:  Sequential Multiport Fuel Injection
SOHC:  Single Over Head Camshaft
T:  
TBI:  
Throttle Body Fuel Injection (Single-Point Fuel 

Injection, SPI)

TCC:  Torque Converter Clutch
TCM:  Transmission Control Module (A/T Controller, A/T 

Control Module)

TDC:  Top Dead Center
TPMS:  Tire Pressure Monitoring System
TP Sensor:  Throttle Position Sensor
TVV:  Thermal Vacuum Valve (Thermal Vacuum 

Switching Valve, TVSV, Bimetal Vacuum Switching 
Valve, BVSV)

TWC:  Three Way Catalytic Converter (Three Way 

Catalyst)

2WD:  2 Wheel Drive
V:  
VIN:  
Vehicle Identification Number
VSS:  Vehicle Speed Sensor
VVT:  Variable Valve Timing (Camshaft Position Control)
W:  
WU-OC:  
Warm Up Oxidation Catalytic Converter
WU-TWC:  Warm Up Three Way Catalytic Converter

Fastener Information

S5JB0B0101005

Metric Fasteners
Most of the fasteners used for this vehicle are JIS-
defined and ISO-defined metric fasteners. When 
replacing any fasteners, it is most important that 
replacement fasteners be the correct diameter, thread 
pitch and strength.

CAUTION

!

 

Even when the nominal diameter (1) of thread 
is the same, the thread pitch (2) or the width 
across flats (3) may vary between ISO and 
JIS. Refer to JIS-TO-ISO Main Fasteners 
Comparison Table below for the difference.
Installing a mismatched bolt or nut will cause 
damage to the thread.
Before installing, check the thread pitch for 
correct matching and then tighten it by hand 
temporarily. if it is tight, recheck the thread 
pitch.

 

JIS-TO-ISO Main Fasteners Comparison Table

Fastener Strength Identification
Most commonly used metric fastener strength property 
classes are 4T, 6.8, 7T, 8.8 and radial line with the class 
identification embossed on the head of each bolt. Some 
metric nuts will be marked with punch, 6 or 8 mark 
strength identification on the nut face. Figure shows the 
different strength markings.
When replacing metric fasteners, be careful to use bolts 
and nuts of the same strength or greater than the original 
fasteners (the same number marking or higher). It is 
likewise important to select replacement fasteners of the 
correct diameter and thread pitch. Correct replacement 
bolts and nuts are available through the parts division.
Metric bolts: Identification class numbers or marks 
correspond to bolt strength (increasing numbers 
represent increasing strength).

Nominal diameter

M6

M8

M10 M12 M14

JIS

Thread pitch

1.0

1.25 1.25 1.25

1.5

Width across flats

10

12

14

17

19

ISO

Thread pitch

1.0

1.25

1.5

1.5

1.5

Width across flats

10

13

16

18

21

1. Nut strength identification

I4RH0A010005-01

I5RH01010001-01

0A-3 General Information: 

Standard Tightening Torque
Each fastener should be tightened to the torque specified in each section of this manual. If no description or 
specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When 
a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener.

NOTE

• For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening 

torque given in the following chart.

• The following chart is applicable only where the fastened parts are made of steel light alloy.

 

Tightening torque chart

Strength

Unit

Thread Diameter (Nominal Diameter) (mm)

4

5

6

8

10

12

14

16

18

A equivalent of 4T strength fastener N

m

kgf-m
lb-ft

1.5
0.15
1.0

3.0
0.30
2.5

5.5
0.55
4.0

13
1.3
9.5

29
2.9
21.0

45
4.5
32.5

65
6.5
47.0

105
10.5
76.0

160
16.0
116.0

A equivalent of 6.8 strength 
fastener without flange

N

m

kgf-m
lb-ft

2.4
0.24
2.0

4.7
0.47
3.5

8.4
0.84
6.0

20
2.0
14.5

42
4.2
30.5

80
8.0
58.0

125
12.5
90.5

193
19.3
139.5

280
28.0
202.5

A equivalent of 6.8 strength 
fastener with flange
*: Self-lock nut (6 strength)

N

m

kgf-m
lb-ft

2.4
0.24
2.0

4.9
0.49
3.5

8.8
0.88
6.5

21
2.1
15.5

44
4.4
32.0

84
8.4
61.0

133
13.3
96.5

203
20.3
147.0

298
29.8
215.5

A equivalent of 7T strength fastener N

m

kgf-m
lb-ft

2.3
0.23
2.0

4.5
0.45
3.5

10
1.0
7.5

23
2.3
17.0

50
5.0
36.5

85
8.5
61.5

135
13.5
98.0

210
21
152.0

240
24
174.0

A equivalent of 8.8 strength bolt (8 
strength nut) without flange

N

m

kgf-m
lb-ft

3.1
0.31
2.5

6.3
0.63
4.5

11
1.1
8.0

27
2.7
19.5

56
5.6
40.5

105
10.5
76.0

168
16.8
121.5

258
25.8
187.0

373
37.3
270.0

A equivalent of 8.8 strength bolt (8 
strength nut) with flange

N

m

kgf-m
lb-ft

3.2
0.32
2.5

6.5
0.65
5.0

12
1.2
9.0

29
2.9
21.0

59
5.9
43.0

113
11.3
82.0

175
17.5
126.5

270
27
195.5

395
39.5
286.0

I1SQ01010004-01

I1SQ01010005-01

I1SQ01010006-01

I1SQ01010007-01

I1SQ01010008-01

I1SQ01010009-01

 

 

 

 

 

 

 

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