Suzuki Grand Vitara JB416 / JB420. Manual — part 2

00-5 Precautions:

CAUTION

!

• Before starting any service work, cover

fenders, seats and any other parts that are
likely to get scratched or stained during
servicing. Also, be aware that what you
wear (e.g. buttons) may cause damage to
the vehicle’s finish.

• When performing service to electrical parts

that does not require use of battery power,
disconnect the negative cable of the
battery.

• When disconnecting the negative cable

from the battery, be careful to the
following.
– Check and record DTCs in ECM, PS

control module and/or immobilizer
control module if necessary before
disconnecting.

– Record displayed contents of the clock

and/or audio system, etc. before
disconnecting and reset it as before
after connecting.

– For vehicle equipped with electric

throttle body system, perform electric
throttle body system calibration
referring to “Electric Throttle Body
System Calibration in Section 1C” after
reconnecting the negative cable to the
battery.

– For vehicle equipped with power sliding

roof (sunroof), initialize sliding roof
position data in motor unit by
performing “How to reactivate the
system to prevent being pinched by the
sunroof” in Sunroof section of Owner’s
manual.

• When removing the battery, be sure to

disconnect the negative cable first and
then the positive cable. When
reconnecting the battery, connect the
positive cable first and then the negative
cable, and replace the terminal cover.

• When removing parts that are to be reused,

be sure to keep them arranged in an
orderly manner so that they may be
reinstalled in the proper order and
position.

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Precautions: 00-6

• Whenever you use oil seals, gaskets,

packing, O-rings, locking washers, split
pins, self-locking nuts, and certain other
parts as specified, be sure to use new
ones. Also, before installing new gaskets,
packing, etc., be sure to remove any
residual material from the mating surfaces.

• Make sure that all parts used in

reassembly are perfectly clean.

• When use of a certain type of lubricant,

bond or sealant is specified, be sure to
remove the old one thoroughly and use the
specified type.

“A”: Sealant 99000–31150 (SUZUKI Bond
No.1207C)

• Be sure to use special tools when

instructed.

Special tool
(A): 09917–98221
(B): 09916–58210

• When disconnecting vacuum hoses, attach

a tag describing the correct installation
positions so that the hoses can be
reinstalled correctly.

• After servicing fuel, oil, coolant, vacuum,

exhaust or brake systems, check all lines
related to the system for leaks.

• For vehicles equipped with fuel injection

systems, never disconnect the fuel line
between the fuel pump and injector
without first releasing the fuel pressure, or
fuel can be sprayed out under pressure.

• When performing a work that produces a

heat exceeding 80

°C in the vicinity of the

electrical parts, remove the heat sensitive
electrical part(s) beforehand.

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00-7 Precautions:

• Use care not to expose connectors and

electrical parts to water which will be a
cause of a trouble.

• Always be careful not to handle electrical

parts (computer, relay, etc.) in a rough
manner or drop them.

Precaution in Servicing Full-Time 4WD Vehicle

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WARNING

!

This full-time 4WD vehicle can not be
converted to 2WD manually.
Observe the following caution in servicing.
Otherwise, front wheels drive rear wheels or
vise-versa and vehicle accidents, drivetrain
damage and personal injury may result.
• Never perform any of the following types

of service work.
[A]:
Testing with 2-wheel chassis dynamometer
or speedometer tester (which tester roller
is driven by vehicle wheels).
[B]:
Driving front or rear wheels, which are
jacked up.
[C]:
Towing under the condition where either
front or rear wheels can not rotate.

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[A]

[B]

[C]

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Precautions: 00-8

• When testing with 2-wheel brake tester, be

sure to observe the following instructions.
Otherwise, drive train damage and
personal injury may result.
– Shift transmission to N (Neutral)

position.

– Shift transfer to N (Neutral) position if

transfer position is selectable.

– Run engine at specified idle speed.
– Rotate wheels (tires) by brake tester at

vehicle speed below 5 km/h (3 mile/h).

– Do not rotate wheels (tires) for 1 min. or

more.

• When testing with 2-wheel speedometer

tester (which wheels are driven by tester),
be sure to observe the following
instructions. Otherwise, drivetrain damage
and personal injury may result.
– Set rear wheels on tester roller and front

wheels on free roller.

– Shift transmission to N (Neutral)

position.

– Shift transfer to N (Neutral) position if

transfer position is selectable.

– Rotate wheels (tires) by tester at vehicle

speed below 60 km/h (37 mile/h).

– Do not rotate wheels (tires) for 1 min. or

more.

– Ensure that vehicle does not move using

wire ropes or chains.

• When testing with 2-wheel chassis

dynamometer, speedometer tester or brake
tester, be sure to make the vehicle as rear
wheel drive by removing front propeller
shaft or as front wheel drive by removing
rear propeller shaft, referring to “Transfer
Warning: Motor-Shift Type (Transfer with
Shift Actuator) in Section 3C” or “Transfer
Warning: Non-Shift Type (Transfer without
Shift Actuator) in Section 3C”.
Note that speedometer of vehicle does not
display vehicle speed because rear wheel
speed sensor signal is not output if rear
propeller shaft is removed.

• When testing with 4-wheel free chassis

dynamometer or speedometer tester
(which tester roller is driven by vehicle
wheels), be sure to shift transfer to 4H-
Lock position according to the step 4) in
“Transfer Warning: Motor-Shift Type
(Transfer with Shift Actuator) in Section
3C”.

• When using On-vehicle type wheel

balancing equipment (1), be sure to jack up
all for wheels, off the ground completely
and support vehicle with safety stands (2).
Be careful of the other wheels, which will
rotate at the same time.

CAUTION

!

• This vehicle should be towed under one of

the following condition:
– With all wheels on a flatbed truck.
– With front or rear wheels lifted and a

dolly under the other wheels.

Precautions for Catalytic Converter

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For vehicles equipped with a catalytic converter, use
only unleaded gasoline and be careful not to let a large
amount of unburned gasoline enter the converter or it
can be damaged.
• Conduct a spark jump test only when necessary,

make it as short as possible, and do not open the
throttle.

• Conduct engine compression checks within the

shortest possible time.

• Avoid situations which can result in engine misfire

(e.g. starting the engine when the fuel tank is nearly
empty.)

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