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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