Repair manual
Suzuki Grand Vitara II Repair Manual
Step-by-step repair and maintenance instructions for the Suzuki Grand Vitara II (2005–2008): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
73sections
590articles
ENManual language
- General information
- SDM
- Live (Undeployed) Air Bag (Inflator) Modules
- Live (Inactivated) Seat Belt Pretensioner
- Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner
- Air Bag Wire Harness and Connector
- Precautions on Disposal of Air Bag and Seat Belt Pretensioner
- Connector "G46" (SDM connector)
- Connector "L32" (SDM connector)
- Connector "L33" (SDM connector)
- Air Bag Diagnostic System Check
- Air Bag Diagnostic System Check Flow
- Flow test description
- SDM DTC
- Data list of SDM
- Scan Tool Data Definition
- Troubleshooting
- Wiring Diagram
- DTC Will be Set when
- DTC Troubleshooting — Part 1
- DTC Troubleshooting — Part 2
- Inspection of Intermittent and Poor Connections
- Repair and Inspection Required after Accident
- Accident with Deployment/Activation - Component Replacement
- Accident with or without Deployment/Activation - Component Inspections
- SDM Removal and Installation
- Installation
- SDM Inspection
- OCM with Sensor Mat Removal and Installation
- OCM with Sensor Mat Inspection
- Driver Air Bag (Inflator) Module Removal and Installation
- Driver Air Bag (Inflator) Module Inspection
- Passenger Air Bag (Inflator) Module Removal and Installation
- Passenger Air Bag (Inflator) Module Inspection
- Side-Air Bag (Inflator) Module Removal and Installation
- Side-Air Bag (Inflator) Inspection
- Side Curtain-Air Bag (Inflator) Module Removal and Installation
- Side Curtain-Air Bag (Inflator) Module Inspection
- Forward-Sensor Removal and Installation
- Forward-Sensor Inspection
- Side-Sensor Removal and Installation
- Side-Sensor Inspection
- Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal
- Deployment/Activation Outside of Vehicle
- Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal
- Tightening Torque Specifications
- Use of Special Tools
- Recommended Service Material
- Special Tool
- Using Monitor Connector (If Equipped) — Part 1
- Using Monitor Connector (If Equipped) — Part 2
- Deployment/Activation Inside of Vehicle
- PRECAUTIONS IN DIAGNOSING TROUBLE
- GENERAL SERVICE PROCEDURE INFORMATION
- PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY
- Part Inspection and Correction Table
- TABLE OF A/T COMPONENT OPERATION
- CAN COMMUNICATION SYSTEM DESCRIPTION
- Operation of Shift Solenoids and TCC Solenoid
- Shift Lock Solenoid Control
- A/T DIAGNOSIS GENERAL DESCRIPTION
- ON-BOARD DIAGNOSTIC SYSTEM DESCRIPTION
- 2 Driving Cycle Detection Logic
- Pending DTC
- Freeze Frame Data
- DTC Description/Detecting Condition/Confirmation Procedure
- Monitoring procedure
- Operation
- Enable conditions
- Typical malfunction thresholds
- AUTOMATIC GEAR SHIFT TABLE
- A/T SYSTEM CHECK
- Step 1. Customer Complaint Analysis
- Step 2. DTC/Freeze Frame Data Check, Record and Clearance
- Step 3 and Step 4. Visual Inspection
- Step 5. Trouble Symptom Confirmation
- Step 6 and Step 7. Recheck and Record of DTC/Freeze Frame Data
- Step 8. A/T Basic Check and A/T Trouble Diagnosis
- Step 9. Troubleshooting for DTC
- Step 10. Check for Intermittent Problem
- Step 11. Final Confirmation Test
- MALFUNCTION INDICATOR LAMP (MIL) CHECK
- DTC TABLE
- DTC CHECK
- DTC CLEARANCE
- FAIL SAFE TABLE
- SCAN TOOL DATA
- Scan Tool Data Definitions
- VISUAL INSPECTION
- A/T BASIC CHECK
- ROAD TEST
- Troubleshooting
- MANUAL ROAD TEST
- STALL TEST
- TIME LAG TEST
- LINE PRESSURE TEST
- ENGINE BRAKE TEST
- "P" RANGE TEST
- Electrical repair
- On-vehicle repair
- Off-vehicle repair
- System Description
- DTC Detecting Condition and Trouble Area
- DTC Confirmation Procedure
- DTC Troubleshooting
- Wiring Diagram
- Table for detecting condition
- INSPECTION OF TCM AND ITS CIRCUITS
- Reference Waveform No. 1
- Reference Waveform No. 2
- Reference Waveform No. 3
- Reference Waveform No. 4
- Reference Waveform No. 5
- Reference Waveform No. 6
- Reference Waveform No. 7
- At Room Temperature
- OIL COOLER HOSES REPLACEMENT
- MANUAL SELECTOR ASSEMBLY REMOVAL AND INSTALLATION
- Installation
- SELECT LEVER KNOB INSTALLATION
- MANUAL SELECTOR ASSEMBLY INSPECTION
- KEY INTERLOCK CABLE REMOVAL AND INSTALLATION
- Solenoid Valves (Shift Solenoid-A, Shift Solenoid-B and Shift Solenoid-E) Resistance check
- Resistance check
- Operation check
- TRANSMISSION FLUID TEMPERATURE SENSOR A AND B INSPECTION
- TRANSMISSION CONTROL MODULE (TCM) REMOVAL AND INSTALLATION
- Removal
- Dismounting
- OIL PUMP DISASSEMBLY AND ASSEMBLY
- OIL PUMP INSPECTION
- CLUTCH DRUM & INPUT SHAFT ASSEMBLY DISASSEMBLY
- CLUTCH DRUM & INPUT SHAFT ASSEMBLY REASSEMBLY
- CLUTCH DRUM & INPUT SHAFT ASSEMBLY INSPECTION
- TIGHTENING TORQUE SPECIFICATIONS
- RECOMMENDED SERVICE MATERIAL
- SPECIAL TOOL
- General information
- EVAPORATIVE EMISSION SYSTEM LEAK INSPECTION
- Assembly
- Output pressure calibration
- Pressurization Test
- EVAPORATIVE EMISSION SYSTEM SMOKE TEST
- EVAP CANISTER PURGE VALVE AND ITS CIRCUIT
- EVAP CANISTER PURGE VALVE INSPECTION
- Installation
- EVAP LEAK CHECK MODULE AND ITS CIRCUIT INSPECTION
- EVAP Leak Check Pressure Sensor Circuit Check
- EVAP LEAK CHECK MODULE INSPECTION
- EVAP Canister Vent Valve Check
- EVAP Leak Detection Pump Check
- EVAP Leak Check Pressure Sensor (combine with BARO sensor) check
- EVAP Leak Check Module Visual Check
- EVAP CANISTER INSPECTION
- EVAP CANISTER AIR SUCTION FILTER INSPECTION
- VACUUM PASSAGE INSPECTION
- PCV HOSE INSPECTION
- Removal
- PCV VALVE INSPECTION
- EGR VALVE ASSEMBLY INSPECTION
- TIGHTENING TORQUE SPECIFICATIONS
- RECOMMENDED SERVICE MATERIAL
- SPECIAL TOOL
- ENGINE CONTROL MODULE (ECM) REMOVAL AND INSTALLATION
- Installation
- MAF Sensor Signal Inspection
- Intake Air Temperature (IAT) Sensor Inspection
- MASS AIR FLOW (MAF) AND INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL AND INSTALLATION
- ELECTRIC THROTTLE BODY ASSEMBLY ON-VEHICLE INSPECTION
- Throttle Valve Visual Check
- ELECTRIC THROTTLE BODY SYSTEM CALIBRATION
- ACCELERATOR PEDAL POSITION (APP) SENSOR ASSEMBLY REMOVAL AND INSTALLATION
- Removal
- ACCELERATOR PEDAL POSITION (APP) SENSOR ASSEMBLY INSPECTION
- ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
- MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR INSPECTION
- AIR FUEL RATIO (A/F) SENSOR ON-VEHICLE INSPECTION
- HEATED OXYGEN SENSOR (HO2S-2) HEATER ON-VEHICLE INSPECTION
- IMT VACUUM TANK ASSEMBLY INSPECTION
- TIGHTENING TORQUE SPECIFICATIONS
- SPECIAL TOOL
- ENGINE GENERAL INFORMATION
- AIR CLEANER FILTER INTRODUCTION
- Description
- COMPRESSION CHECK
- ENGINE VACUUM CHECK
- Installation
- AIR CLEANER FILTER INSPECTION AND CLEANING
- Inspection
- Cleaning
- ELECTRIC THROTTLE BODY ASSEMBLY ON-VEHICLE INSPECTION
- ELECTRIC THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION
- IMT (INTAKE MANIFOLD TUNING) VALVE REMOVAL AND INSTALLATION
- INTAKE COLLECTOR AND INTAKE MANIFOLD REMOVAL AND INSTALLATION
- ENGINE BLOCK HEATER (IF EQUIPPED) INSPECTION
- TIMING CHAIN COVER REMOVAL AND INSTALLATION
- TIMING CHAIN COVER INSPECTION
- LH (NO. 1) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER REMOVAL AND INSTALLATION
- LH (NO. 1) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER INSPECTION
- Timing Chain Guide No. 4 and No. 5
- Camshaft Sprocket
- Timing Chain
- 1ST TIMING CHAIN AND CHAIN TENSIONER REMOVAL AND INSTALLATION
- 1ST TIMING CHAIN AND CHAIN TENSIONER INSPECTION
- Timing Chain Guides No. 1 and No. 2
- Timing Chain Tensioner
- 1st Timing Chain Crankshaft Sprocket
- RH (No. 2) Bank 1st Timing Chain Intake Camshaft Sprocket
- Idler Sprocket No. 1
- Idler Sprocket No. 2
- 1st Timing Chain
- Timing Chain Tensioner Adjuster No. 1
- RH (NO. 2) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER REMOVAL AND INSTALLATION
- RH (NO. 2) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER INSPECTION
- Timing Chain Guide No. 3
- RH (No. 2) Bank 2nd Timing Chain Sprockets
- RH (No. 2) Bank 2nd Timing Chain
- CAMSHAFTS, TAPPETS AND SHIMS REMOVAL AND INSTALLATION
- CAMSHAFTS AND CAMSHAFT HOUSINGS INSPECTION
- Cam Wear
- Camshaft Runout
- Camshaft Journal Wear
- TAPPETS AND SHIMS INSPECTION
- VALVES AND CYLINDER HEADS REMOVAL AND INSTALLATION
- VALVES AND CYLINDER HEADS DISASSEMBLY AND REASSEMBLY
- Reassembly
- VALVES AND VALVE GUIDES INSPECTION
- Valve Guides
- CYLINDER HEAD INSPECTION
- VALVE SPRINGS INSPECTION
- PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS REMOVAL AND INSTALLATION
- Removal
- PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS DISASSEMBLY AND REASSEMBLY
- CYLINDERS, PISTONS AND PISTON RINGS INSPECTION
- Piston Rings
- PISTON PINS AND CONNECTING RODS INSPECTION
- CRANK PINS AND CONNECTING ROD BEARINGS INSPECTION
- MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION
- CRANKSHAFT INSPECTION
- Crankshaft Runout
- Crankshaft Thrust Play
- Out-of-Round and Taper (Uneven Wear) of Journals
- MAIN BEARINGS INSPECTION
- Main Bearing General Information
- REAR OIL SEAL AND FLYWHEEL INSPECTION
- Rear Oil Seal
- Flywheel
- CYLINDER BLOCK INSPECTION
- Distortion of Gasketed Surface
- SPECIFICATIONS
- TIGHTENING TORQUE SPECIFICATIONS
- Metric Fasteners
- Fastener Strength Identification
- Standard Tightening Torque
- RECOMMENDED SERVICE MATERIAL
- SPECIAL TOOL
- General information
- FRONT WHEEL ALIGNMENT CONSTRUCTION
- Preliminary Checks Prior to Adjustment Front Wheel Alignment
- Toe Inspection and Adjustment
- Inspection
- Steering Angle Check and Adjustment
- Reference Information
- FRONT STRUT ASSEMBLY REMOVAL AND INSTALLATION
- Removal
- Installation
- FRONT STRUT ASSEMBLY DISASSEMBLY AND ASSEMBLY
- Assembly
- FRONT STRUT ASSEMBLY CHECK
- FRONT WHEEL HUB ASSEMBLY AND STEERING KNUCKLE COMPONENTS
- FRONT WHEEL HUB ASSEMBLY REMOVAL AND INSTALLATION
- STEERING KNUCKLE REMOVAL AND INSTALLATION
- SUSPENSION CONTROL ARM / BUSHING DISASSEMBLY AND ASSEMBLY
- SUSPENSION CONTROL ARM / STEERING KNUCKLE CHECK
- SUSPENSION CONTROL ARM BUSHING CHECK
- SUSPENSION CONTROL ARM JOINT CHECK
- Stabilizer Bar
- Stabilizer Bushing
- TIGHTENING TORQUE SPECIFICATIONS
- RECOMMENDED SERVICE MATERIAL
- SPECIAL TOOL
- General information
- FUEL DELIVERY SYSTEM DESCRIPTION
- FUEL PUMP DESCRIPTION
- FUEL PRESSURE INSPECTION
- FUEL CUT OPERATION INSPECTION
- FUEL HOSE DISCONNECTING AND RECONNECTING
- Fuel tank system
- Reconnecting
- FUEL PRESSURE RELIEF PROCEDURE
- FUEL LEAKAGE CHECK PROCEDURE
- FUEL LINES ON-VEHICLE INSPECTION
- FUEL PIPE REMOVAL AND INSTALLATION
- Installation
- FUEL INJECTOR REMOVAL AND INSTALLATION
- FUEL INJECTOR INSPECTION
- FUEL PRESSURE REGULATOR REMOVAL AND INSTALLATION
- FUEL PRESSURE REGULATOR INSPECTION
- FUEL FILLER CAP INSPECTION
- FUEL TANK INLET VALVE REMOVAL AND INSTALLATION
- FUEL TANK INLET VALVE INSPECTION
- FUEL TANK REMOVAL AND INSTALLATION
- FUEL TANK INSPECTION
- FUEL TANK PURGING PROCEDURE
- FUEL PUMP ON-VEHICLE INSPECTION
- FUEL PUMP ASSEMBLY REMOVAL AND INSTALLATION
- MAIN FUEL LEVEL GAUGE REMOVAL AND INSTALLATION
- FUEL PUMP INSPECTION
- SUB FUEL LEVEL GAUGE REMOVAL AND INSTALLATION
- SUB FUEL LEVEL GAUGE INSPECTION
- TIGHTENING TORQUE SPECIFICATIONS
- RECOMMENDED SERVICE MATERIAL
- SPECIAL TOOL
- Rear End Door Window Defogger System Description
- Windshield Construction
- Rear Quarter Window Construction
- Rear End Door Window Defogger Symptom Diagnosis
- Power Window Control System Symptom Diagnosis
- Power Door Mirror Control System Symptom Diagnosis (If Equipped)
- Door Mirror Heater Symptom Diagnosis (If Equipped)
- Windshield Removal and Installation
- Rear Quarter Window Removal and Installation
- Front Door Glass Removal and Installation
- Installation
- Front Door Window Regulator Removal and Installation
- Front Door Window Regulator Inspection
- Rear Door Glass Removal and Installation
- Rear Door Window Regulator Removal and Installation
- Rear Door Window Regulator Inspection
- Rear End Door Glass Removal and Installation
- Rear End Door Window Defogger Wire Inspection
- Door Mirror Removal and Installation
- Door Mirror Heater Inspection (If Equipped)
- Recommended Service Material
- General information
- Installation
- TRANSMISSION SHIFT CONTROL LEVER INSPECTION
- BACK UP LIGHT SWITCH REMOVAL AND INSTALLATION
- Removal
- BACK UP LIGHT SWITCH INSPECTION
- GEAR SHIFT CONTROL LEVER REAR CASE ASSEMBLY DISASSEMBLY AND REASSEMBLY
- GEAR SHIFT CONTROL LEVER REAR CASE ASSEMBLY INSPECTION
- GEAR SHIFT LEVER FRONT CASE ASSEMBLY DISASSEMBLY AND REASSEMBLY
- GEAR SHIFT LEVER FRONT CASE ASSEMBLY INSPECTION
- ENGINE REAR MOUNTING REPLACEMENT
- Remounting
- LOCATING SPRING INSPECTION
- INPUT SHAFT DISASSEMBLY
- INPUT SHAFT INSPECTION
- INPUT SHAFT REASSEMBLY
- COUNTERSHAFT DISASSEMBLY AND ASSEMBLY
- Assembly
- COUNTERSHAFT AND REVERSE IDLE GEAR INSPECTION
- OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY
- OUTPUT SHAFT INSPECTION
- Disassembly
- EXTENSION CASE DISASSEMBLY AND REASSEMBLY
- EXTENSION CASE ASSEMBLY INSPECTION
- TIGHTENING TORQUE SPECIFICATIONS
- RECOMMENDED SERVICE MATERIAL
- SPECIAL TOOL
- P/S SYSTEM NOTE
- P/S SYSTEM CONSTRUCTION
- STEERING GEAR CASE CONSTRUCTION
- P/S PUMP CONSTRUCTION
- Flow Control Valve (Relief Valve)
- P/S SYSTEM SYMPTOM DIAGNOSIS
- STEERING WHEEL RECOVERY CHECK
- IDLE UP SYSTEM CHECK
- P/S FLUID CHANGE
- P/S FLUID LEVEL CHECK
- P/S FLUID LEAKAGE CHECK
- P/S SYSTEM AIR BLEEDING PROCEDURE
- Installation
- TIE-ROD END BOOT CHECK
- TIE-ROD END BALL JOINT INSPECTION
- P/S GEAR CASE ASSEMBLY REMOVAL AND INSTALLATION
- STEERING GEAR CASE MOUNT BUSHING INSPECTION
- P/S PUMP REMOVAL AND INSTALLATION
- Removal
- P/S PUMP INSPECTION
- Pump Body, Cover, Side Plate and Shaft
- Cam Ring
- TIGHTENING TORQUE SPECIFICATIONS
- RECOMMENDED SERVICE MATERIAL
- SPECIAL TOOL
- General information
- REAR WHEEL ALIGNMENT CONSTRUCTION
- REAR WHEEL ALIGNMENT INSPECTION AND ADJUSTMENT
- Toe and Camber Inspection and Adjustment
- Toe Inspection
- Camber Inspection
- Side slip limit
- REAR SHOCK ABSORBER REMOVAL AND INSTALLATION
- Installation
- SHOCK ABSORBER CHECK
- CONTROL ROD REMOVAL AND INSTALLATION
- CONTROL ROD/BUSHING DISASSEMBLY AND ASSEMBLY
- CONTROL ROD CHECK
- TRAILING ROD/BUSHING DISASSEMBLY AND ASSEMBLY
- TRAILING ROD CHECK
- Disassembly
- LOWER ARM CHECK
- UPPER ARM/BUSHING DISASSEMBLY AND ASSEMBLY
- Assembly
- UPPER ARM CHECK
- TIGHTENING TORQUE SPECIFICATIONS
- RECOMMENDED SERVICE MATERIAL
- SPECIAL TOOL
- General information
- Precautions in Diagnosing Trouble
- Retry Control
- Indicator And Buzzer Operation
- Function of 4WD Control System Component
- 4WD Control System Operation
- 4H (4WD High) Position
- 4H-lock (4WD High Center Differential Lock) Position
- N (Neutral) Position
- 4L-lock (4WD Low Center Differential Lock) Position
- Input/Output Signal Table of 4WD Control Module
- On-Board Diagnostic System Description
- DLC (Data Link Connector)
- CAN Communication System Description
- 4WD Control System Check
- Step 1: Customer complaint analysis
- Step 2. DTC/freeze frame data check, record and clearance
- Step 3 and 4. Visual inspection
- Step 5. Trouble symptom confirmation
- Step 6 and 7. Rechecking and record of DTC and freeze frame data
- Step 8. 4WD control symptom diagnosis
- Step 9. Troubleshooting for DTC
- Step 10. Check for intermittent problem
- Step 11. Final confirmation test
- 4WD Control System Operation Inspection
- Visual Inspection
- DTC Table
- Fail-Safe Table
- Scan Tool Data
- Scan Tool Data Definitions
- 4WD Control Symptom Diagnosis
- Circuit Description
- Troubleshooting
- DTC Detecting Condition and Trouble Area
- DTC Confirmation Procedure
- Wiring Diagram
- Inspection of 4WD Control Module and Its Circuits
- Removal
- Installation
- Remounting
- Disassembly
- Input Gear Assembly Disassembly and Reassembly
- Counter Gear Assembly Disassembly and Reassembly
- Front Output Shaft Assembly Disassembly and Reassembly
- Rear Output Shaft Assembly Disassembly and Reassembly
- Tightening Torque Specifications
- Recommended Service Material
- Special Tool
- CAUTIONS IN BODY ELECTRICAL SYSTEM SERVICING
- PRECAUTIONS FOR WIRING SYSTEM
- ABBREVIATIONS
- WIRE / CONNECTOR COLOR SYMBOLS
- HOW TO READ CONNECTOR LAYOUT DIAGRAM
- HOW TO READ GROUND POINT
- HOW TO READ POWER SUPPLY DIAGRAM
- HOW TO READ SYSTEM CIRCUIT DIAGRAM
- CONNECTOR LAYOUT DIAGRAM
- C: Engine harness
- D: Injector harness
- E: Main harness
- E: Controller wire
- B: A/C wire
- F: Console wire
- G: Instrument panel harness
- Q: A/B wire
- J: Front door wire (Drive side)
- J: Front door wire (Passenger side)
- J: Rear door wire
- K: Roof wire
- L: Floor harness
- L: Canister wire
- L: Seat sensor (L) wire
- L: Seat sensor (R) wire
- R: Fuel pump wire
- O: Rear end door harness
- GROUND (EARTH) POINT
- FUSES AND THE PROTECTED PARTS
- LIST OF CONNECTORS