Thread: Suzuki Vitara / Escudo / Geo Tracker / Mazda Levante 1988-1998 - repairs, maintenance, operation of the vehicle.

Suzuki Vitara / Escudo / Geo Tracker / Mazda Levante 1988-1998 - manual repair, maintenance and operation of the vehicle.
Guidelines for repair and maintenance of car Suzuki Vitara / Escudo / Geo Tracker / Mazda Levante 1988-1998, the production, equipped with 8 - and 16-valve petrol engine G16A working volume of 1.6 liters, Inline 4-cylinder gasoline engine J20A workers volume of 2.0 liters, V-shaped 6-cylinder gasoline engine H20A working volume of 2.0 liters
The publication contains detailed information on repair and adjustment of the elements of the engine management system (CFI and MFI) and the carb, how to use the Automatic self-diagnostic system and ABS, the brake system (including ABS), steering and suspension.
The possible faults and remedies, matched the size of the main parts and the limits of their allowable wear, recommended lubricants and hydraulic fluids.
In some sections of the book includes advice on maintenance and the electrical circuit (wiring) Suzuki Vitara / Escudo / Geo Tracker / Mazda Levante.
The manual is intended for car owners of Suzuki Vitara / Escudo / Geo Tracker / Mazda Levante, SRT workers and service stations.

Spoiler: Contents:

Identification of three
Number on the frame and identification plate 3
Engine Number 3
Identification of the gearbox 3
Specifications engines fitted to the model of Suzuki Escudo / Vitara 3
Abbreviations 3
Manual Suzuki Vitara 4
Lock the doors 4
Odometer and odometer 4
Tachometer 4
A pointer to fuel 5
Coolant temperature gauge 5
Indicators and warning lights dash 5
Windows 6
Latch side glass (three-door models) 7
Warning light on car 7
Falshfeyer 7
The hood and tailgate 7
Hatch filler 8
Windshield wiper and washer switch 8
Managing mirror 8
Adjusting the seats 9
Increased trunk 9
Safety belts 10
LUKE 11
Control heater and air conditioning 11
Anti-lock braking system (ABS) 1912
Driving a car with automatic transmission 12
Driving a car with manual transmission 13
Features of transmission and general advice on the choice of modes of motion 14
Tips for driving in different conditions 15
Towing 15
Starting the engine 15
Engine trouble while driving 16
Ram 1917
Car jacking in 1917
Replacement wheels 17
Checking tire pressure and condition of 18
Replacement tires 1918
Operation features aluminum wheels 18
Replacing the drive wheels 19
Indicators for wear on brake pads 19
Catalytic converter and exhaust system 19
Checking and replacing fuses and fuse 19
Lamp Replacement 20
Maintenance Suzuki Vitara 1921
Service intervals 21
Precautions when working with oils in 1921
Engine G16A 21
Specifications (G16A) 21
Choice of motor oil (G16A) 22
Check engine oil level (G16A) 22
Change engine oil and filter (G16A) 22
Checking and replacing the coolant (G16A) 22
Checking and cleaning the air filter (G16A) 23
Check drive belts mounted units (G16A) 23
Component testing timing belt (G16A) 23
Check and adjust ignition timing (G16A) 23
Check the pressure end of the compression stroke (G16A) 24
Checking the vacuum in the intake manifold (G16A) 24
J20A Engine 24
Specifications J20A 24
Choice of motor oil (J20A) 25
Change engine oil and filter (J20A) 25
Check oil pressure (J20A) 25
Check the pressure end of the compression stroke (J20A) 25
Checking the vacuum in the intake manifold (J20A) 25
Checking and replacing the coolant (J20A) 25
Check drive belts mounted units (J20A) 26
Engine N20A 1926
Choice of motor oil (N20A) 26
Change engine oil and filter (N20A) 26
Check oil pressure (N20A) 27
Check the pressure end of the compression stroke (N20A) 27
Checking the vacuum in the intake manifold (H20A) 27
Checking and replacing the coolant (N20A) 27
Check drive belts mounted units (N20A) 28
Check the battery status 28
Check high-voltage cables 28
Check spark plugs 1928
Checking the fluid clutch and brake system 29
Checking and replacing oil in manual transmission 1929
Checking automatic transmission fluid in 1929
Replacement of fluid in the automatic transmission 29
Replacement Filter Auto 1929
Checking the oil in the transfer case 30
Change oil in transfer case 30
Checking and replacing oil in the gearbox rear-axle 30
Checking and replacing oil in the gear front axle 30
Checking the fluid level Power steering control 30
Installation point jack 30
Engine G16A. Mechanical Part 31
Check and adjust valve clearance in the drive (G16A 8V) 31
Check and adjust valve clearance in the drive (G16A 16V) 31
Removing and installing the distributor 31
Exhaust manifold (G16ACBRn G16ACFI) 31
Exhaust manifold (G16A MF1) 32
Cylinder head cover (G16A CBR) 32
Throttle body and intake manifold (G16A CFI) 33
Throttle body and intake manifold (G16A MFI) 1934
Timing belt (G16A CBR, CFI) 34
Timing belt (G16A MFI) 1936
Axis rocker assembly (G16A CFI) 37
Axis rocker assembly (G16A MFI 16V) 38
Cylinder Head (G16A8V CBR, CFI) 40
Cylinder Head (G16A 16V MFI) 1943
Piston group 45
Check the status of the piston and connecting rod 46
Removing and installing engine 48
Crank shaft 50
Rear seal 52
Flywheel 52
The cylinder block 52
Engine J20A. Mechanical part 54
Timing chain 56
Removing 56
Installation 56
Engine N20A. Mechanical part 57
Intake Manifold 57
Exhaust manifold 1957
Exhaust tract 58
Timing chain 59
Oil pump 64
Camshaft 65
Cylinder head 1966
Piston group 69
Crankshaft and cylinder block 71
Flywheel 73
The cylinder block 73
Cooling System Sudzuki VITARA 1974
Cooling System (G16A) 74
Thermostat 74
Cooling fan, coolant pump pulley 74
Radiator 74
Coolant pump 74
Cooling System (J20A) 75
Cooling System (N20A) 75
Check radiator cap 75
Thermostat 76
Check oil pressure (G16A CBR) 77
Lubrication System Suzuki VITARO 77
Oil pan (G16A) 77
Oil Pump (G16A) 78
Exhaust System (G16A) 80
Fuel Injection System EPI (G16A CFI) 81
Fuel delivery system 81
Air supply system 82
Electronic control system 84
The system of diagnosing 84
The voltage on the output of electronic control unit 85
The accelerator cable 85
Automatic transmission shift control 86
Speed \u200b\u200bcontrol of idling 86
Mechanism priotkryvaniya throttle 86
Check fuel pressure 86
To test the fuel pump 86
Throttle Body 1986
Nozzle 88
Fuel pressure regulator 88
The valve control system speed idle (ISCV) 89
The electronic control unit 90
Absolute pressure sensor 90
Throttle position sensor 90
Sensor intake air temperature 91
Coolant temperature sensor 91
Control relay 91
Mechanism priotkryvaniya throttle 91
Epv of 91
Air heater inlet (Auto) 92
Crankcase ventilation system in 1992
Fuel vapor recovery system 92
Fuel System 92
The fuel tank 92
Fuel Filter 93
Fuel line 93
Fuel Injection System EPI (G16A MFI) 1994
The voltage on the output of electronic control unit 100
System diagnostics 103
The accelerator cable 104
Speed \u200b\u200bcontrol of idling 104
Check and adjust ignition timing 104
Adjusting the composition of the fuel / air mixture 105
Check fuel pressure 105
To test the fuel pump 105
Fuel pressure regulator 105
Fuel pressure pulsation damper 106
Checking nozzles (from 08.1990) 106
Nozzle (with a 10.1993) 106
Check valve control system speed idle (ISCV) 107
Coolant temperature sensor 107
Air temperature sensor at the inlet 107
Air flow sensor 107
Throttle position sensor 107
Throttle body (from 10.1993) 108
The valve control system speed idle (ISCV) (from 10.1993) 108
The electronic control unit (with a 10.1993) 108
The main relay and fuel pump relay (from 10.1993) 108
Air flow sensor (with 10.1993) 109
Throttle position sensor (from 10.1993) 109
Oxygen sensor (with 10.1993) 109
Pomehopodavitelny filter (10.1993) 109
Switch (from 10.1993) 109
Exhaust gas recirculation (EGR) (from 10.1993) 110
Fuel vapor recovery system (from 10.1993) 110
Fuel Injection System EPI (J20A) 111
Check with an oscilloscope 115
System diagnostics 116
The accelerator cable 116
Check and adjust ignition timing 117
Checking the speed of idling 118
Check fuel pressure 118
Throttle Body 118
The valve control system speed idling 118
To test the fuel pump 118
Fuel Pump Relay 118
Fuel Filter 119
Fuel pressure regulator 119
The fuel tank 119
Injector 119
Exhaust gas recirculation (EGR) 120
Fuel vapor recovery system 120
Valve ventilation crankcase 120
Throttle position sensor 120
Oxygen sensor 121
Coolant temperature sensor 121
Air temperature sensor at the inlet 121
Crankshaft Position Sensor 121
Fuel Injection System EPI (H20A) 122
The voltage on the output of electronic control unit 125
Check with an oscilloscope 126
System diagnostics 126
The accelerator cable 127
Check and adjust ignition timing 127
Checking the speed of idling 128
Check fuel pressure 128
Throttle Body 129
The valve control system speed idling 129
To test the fuel pump 129
Fuel pump relay and main relay 129
Fuel Filter 129
Fuel pressure regulator 129
Injector 129
Exhaust gas recirculation (EGR) 130
Fuel vapor recovery system 130
Valve ventilation crankcase 130
Throttle position sensor 131
Air flow sensor 131
Coolant temperature sensor 131
Air temperature sensor at the inlet 131
Crankshaft Position Sensor 131
Fuel system Syzuki VITARA (G16A CBR) 132
General description 132
Checking on the car 133
Fuel pump 133
Fuel hoses 133
Fuel filler cap 133
The fuel tank 133
Fuel Filter 134
Carburetor Suzyki VITARA (G16A CBR) 135
General description 135
Description of individual systems and devices carb 138
Removing and replacing the carburetor 147
Repair parts and assemblies carb 148
Checking and adjusting on the car 150
Check and adjust backlash accelerator cable 150
Check and adjust the float (the level of fuel in the float chamber) 150
Check and adjust the speed and composition of the mixture on the natural mode of idling 151
Checking and adjusting the system to improve the speed of idling when you turn on electrical loads 151
Check and adjust starter carburetor (choke) 152
Check and adjust starter carburetor (choke) 153
Checking and adjusting the system to improve speed idle cold start 154
Check the vacuum actuator control inclusion of the secondary chamber of the carburettor 154
Checking the "discharge of 155
Checking off the fuel supply system 155
Check and adjust the accelerator pump 155
System to reduce toxicity (G16ACBR) Suzuky VITARA 156
Crankcase ventilation system 157
Throttle damper 157
Switching system air intake 158
Fuel vapor recovery system 158
System off the fuel supply 159
Exhaust gas recirculation (EGR) 160
Ignition system Cuzuki VITARA 162
Ignition System (G16A CBR, CFI) 162
Check the ignition coil 162
Check valve 162
Housing is the distributor 163
Ignition System (G16A MFI) 164
Check the ignition coil (s 08.1990) 164
Check valve (to 10.1993) 164
Check the switch (from 05.1995) 165
Check the ignition coil (P 05.1995) 165
Ignition System (J20A) 165
Check the ignition coil 165
Spark Plugs 165
Ignition coil (with a power transistor) 165
Ignition System (N20A) 165
Check the ignition coil 165
Spark Plugs 165
Switch 165
Pomehopodavitelny filter 165
System startup Suzuki VYTARA 166
Starter (with planetary gear) 166
Diagram of the system startup 166
Removing and replacing the starter 166
Traction Relay 166
Starter brush 166
Anchor and stator winding 167
Overrunning clutch 167
Checking the starter 168
Check the operation of the starter 169
Starter (without gear) 170
Removing and replacing the starter 170
Disassembly 170
Checking the starter 170
Check the operation of the starter 172
Charging system Sutsuki Vitara 173
Engine G16A (CBR) 173
Checking the oscillator circuit (battery is not charged) 173
Checking the oscillator circuit (the battery is charged) 173
Removing and installing the generator 173
Disassembly of the generator 173
Check the generator 174
Assembling generator 175
Engine 175 N20A
Checking the oscillator circuit (battery is not charged) 175
Checking the oscillator circuit (the battery is charged) 175
Removing and installing the generator 175
Disassembly and reassembly of the generator 176
Check the generator 176
Clutch 177
Bleeding the Clutch (model 1994) 177
Checking and adjustment of the clutch pedal 177
Switch on the clutch pedal (models before 1994) 177
Clutch cable (models before 1994) 178
Master cylinder drive clutch (model 1994) 178
Cylinder clutch drive (model 1994) 178
Strength (models before 1994) 179
Clutch (model 1994) 180
Manual gearbox 182
Gearshift 182
Electric elements gearbox 182
Replacing the speedometer driven gear 183
Removing and replacing the gear box assembly 183
Assembly and disassembly of the gearbox 184
Automatic Transmission 186
General information 186
Preliminary checks 187
Check and adjust valve control cable forced downshifts (kick - down) 187
Check and adjust the switch ban starting 187
Check and adjust the cable-throttle valve control 187
Removal and installation of cable transmission control 188
Diagnosis CAT 188
Self-diagnostic system (model 1990) 188
General information 188
Check indicator deactivate overdrive transmission 188
Reading the fault codes (models up to November 1996) 188
Reading the fault codes (models with November 1996) 189
Checking the gear 190
The system selector lock and the ignition key 190
The mechanical systems of CPR 191
Test on a fully braked vehicle (stall test) 191
Check-in time enable the transfer of 191
Hydraulic Test 191
Road Test 192
Replacement Filter 193
Verification of components of the electric control system (model 1990) 193
Check the torque converter 194
Removing and replacing the gear box assembly 194
Transfer Case 196
Replacement seals rear and front drive shaft 196
Removing and installing 196
Sensor on AWD 197
Driveshaft 198
Removal of 198
Checking 198
Replacing the bearings cross 198
Installation 199
Driveshafts 200
Removal of 200
Checking 200
Disassembly 201
Replacement of anther 201
Assembly 201
Replacement of the bearing and seal the front axle 202
Installation 202
Front axle gearbox 203
Removing and installing 203
Replacing the bearings gearbox 205
System including all-wheel drive (4WD) (model in October 1996) 205
Gearbox rear axle 207
Removing and installing 207
Suspension 209
Preliminary checks 209
Inspection and alignment of the front wheels 209
Front Suspension 210
Sway Bar 210
Rack front suspension 210
Spring front suspension 211
Hub front axle 212
Steering knuckle 213
Lower arm front suspension 214
Freewheel (with mechanical lock) 215
Freewheel (with automatic) type 1216
Freewheel (with automatic) type 2217
Rear Suspension 218
Shock absorber rear suspension 218
Spring rear suspension 219
Lower arm rear suspension 219
Upper arm rear suspension 220
Semiaxis 221
Rear axle 223
Steering 226
Check wheel play 226
Check the efforts of the steering wheel 226
Check and adjust drive belt steering pump 226
Checking the fluid level 227
Checking the system to increase the speed of idling 227
Check leakage of working fluid 227
Bleeding the power steering system 227
Checking the working fluid pressure power steering 228
The steering column 228
Steering mechanism (models without power steering) 230
Swingarm 231
Tie rods 232
Steering mechanism (models with power steering) 232
Power assisted steering pump 234
Brake system 236
Check and adjust the brake pedal 236
Check the vacuum brake booster 236
Bleeding the brake system 236
Check and adjust parking brake 237
Check lining thickness of brake pads 237
Brake master cylinder 238
Vacuum brake booster 239
Front brake 239
Rear drum brakes 242
Parking brake 244
The pressure regulator (Escudo to August 1990 and August 1995) 246
Valve redistribution of braking forces depending on the load on the rear axle (Vitara, Escudo from August 1990) 246
Antilock braking system (ABS) (model August 1995) 247
Pressure Modulator 248
Speed \u200b\u200bsensor front wheel 248
Speed \u200b\u200bsensor rear wheel 249
ABS electronic control unit 249
Deceleration sensor 249
Diagnosis of ABS 250
Check the electrical elements 251
Body 253
The front bumper 253
Rear bumper 254
Adjusting the hood 254
Front fender 254
The front door 255
Rear side door (five-door model) 258
The back door (body TA01W) 259
Removable plastic top (body TA01R) 260
The windshield 260
Rear side window cabin (three-door model) 261
Rear side window interior (five-door model) 262
Soffits 263
The instrument panel 264
Arc security 265
Decorative side plates 265
Body sizes 266
Underbody 266
Rear door aperture (model 05.1988 of release, the body TA01W) 271
Rear door aperture (model 1995 issue) 271
The back of the body (three-door model with 05.1988 of release, the body TA01R) 271
Engine compartment and side door openings (three-door model with 05.1988 of release) 271
Engine compartment and side door openings (five-door model with 09.1990 of release) 272
Engine compartment (model 1995 issue) 272
Openings of the side doors (model 1995 issue) 272
Opening windshield (model 1995 issue) 272
Air conditioning, heating and ventilation 273
Safety measures when working with refrigerant 273
Using the power gauges 273
Installation of gauges and discharge system 273
Evacuation of 273
Charging system 274
Checking the tightness of the system 274
Refueling refrigerant 274
Removing the pressure gauge 274
Replacement of the pipeline 274
Checking the amount of refrigerant 275
Evaporator 275
Check the expansion valve 275
Heater 275
Check the electrical elements of air-conditioning system (Escudo) 278
Check the air conditioner switch 278
Checking the coolant temperature sensor in the radiator and the heater 278
Check the air temperature sensor for the evaporator 278
Relay test the air conditioner compressor 279
Check servo operation mode heater (models with February 1996) 279
Check the front panel heater (models with February 1996) 279
Verifying electronic control unit air conditioner (model with February 1996) 279
Check air-conditioning amplifier (model in October 1993) 280
Check servo operation mode heater (models with February 1996) 280
Check switch operation mode heater (models with February 1996) 281
Airbag system (SRS) 282
Precautions for maintenance and repair work 282
System Components 282
System diagnostics 283
Removing and installing 283
Body Electrical 285
Precautions 285
Fuses 285
Switches 286
Ignition lock 286
Combined switch 286
The instrument cluster 286
Connectors 286
Checking the fuel gauge 287
Check the fuel level sensor 287
Check the coolant temperature gauge 287
Checking the coolant temperature sensor 288
Checking the oil pressure sensor 288
Check sensor low level of oil (1994) 288
Check warning system for low brake fluid level 288
Check warning system seat belt 288
Reset indicator replacing the timing belt 288
Check rheostat light dash 288
Lights and lighting 288
Wiper and washer 289
Rear Glass 291
Windows and door locks 291
Remote locking 292
Power Mirrors 293
Power moonroof 293
Electrical circuit (wiring) 294
Launch system (2,0 V6) (Scheme A1). Power Distribution (2,0 V6) 294
Cleaner and windshield washers (Figure B2). Charging system (2,0 V6) (scheme A2) 295
The engine management system (2,0 V6) (scheme A3) 296
Automatic Control System (2,0 V6) (Scheme B1) 298
Heating the glass back door (Scheme B4). Cleaner and washer glass rear door (Scheme OT) 299
Electric window (figure B5) 300
Central locking (Figure B6) 301
Sound signal (Figure B8). Power Mirrors (Figure B7) 302
Headlight cleaner (Figure B10). Seat belts (Figure B9) 303
Lights (Scheme D1). Power moonroof (Figure B11) 304
Combination of devices (2,0 V6) (scheme S1) 305
Combination of devices (2,0 V6) (Scheme S1) (continued). Interior lighting (2 door model) (Figure D3) 306
Size and number plate lights (Scheme D2) 307
Indicators and alarms (Figure D4). Interior lights (4 door models) (Scheme D3) 309
Rear lights (Figure D6). Stoplights (Scheme D5) 310
Ventilation and air conditioning (Figure E1) 311
Buzzer warning system (scheme F2). Cassette / Radio (scheme F1) 312
Cigarette lighter, clock, ashtray light (Figure F3) 313
Connectors 313
Models with the October 1996 distribution of food (2,0 L4) 317
Charging system (2,0 L4) (scheme A2). Launch system (2,0 L4) (Scheme A1) 318
Cleaner and windshield washers (Scheme B1). Ignition system (2,0 L4) (scheme A3) 319
The engine management system (2.01 _4sMKPP) (shemaA4) 320
The engine management system (2,0 L4 with automatic transmission) (Scheme A5) 322
Heating the glass back door (Scheme EOI). Cleaner and washer glass rear door (Figure B2) 325
Electric window (Figure B4) 326
Central locking (Figure B5) 327
Sound signal (Figure B8). Power Mirrors (Scheme B6) 328
Headlight cleaner (5 door models) (Scheme B10). Seat belts (Figure B9) 329
Combination of devices (2,0 L4, V6) (Scheme C2). Combination of devices (2,0 L4, V6) (scheme S1) 330
Combination of devices (2,0 L4) (Scheme NW) 331
Interior lighting (3 door model) (Scheme D5). Lights (Scheme D1) 332
Indicators and alarms (Figure D6). Interior lighting (5 door models) (Scheme D5) 333
Size and number plate lights (Scheme D2) 334
Illumination (Figure D4) 335
Rear lights (2,0 L4) (Scheme D8). Stoplights (2,0 L4) (Scheme D7) 336
Ventilation and air conditioning (Figure E1) 337
Ventilation and air conditioning (Figure E1) (continued). Cassette / Radio (scheme F1) 338
Buzzer warning system (Scheme F3). Cigarette lighter, Clock (Figure F2) 339
Airbags (Figure G4). Management system all-wheel drive (4WD) (Scheme G2) 340
Antilock braking system (Scheme G5) 341
Connectors 342
Contents 346

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Hi:
please I don´t found the download link, I´m new here
I have a vitara '93 and want to leanr about it and the maintenance
Can you help me please?

Thanks

Excelente aporte .. buscaba algo asi para conocer mejor mi Vitara.
Gracias por compartir

Se ve excelente este manual... voy a descargarlo , si ustedes me lo permiten tenia bastante tiempo buscando algo asi para reparaciones menores de mi vitara.
Muchisimas gracias por el aporte

nice manual, thanks for sharing

marbrilo, billydump - PM

[lang=es]Justo estaba buscando el manual de la vitara en espa

apophis - .... PM

As dori si eu acest manual, un link daca se poate. Multumesc pentru ajutor. - -PM

answered a personal message