Front diff SUZUKI GRAND VITARA 2001 2.G Owner's Manual

DIFFERENTIAL (REAR) 7F-3
On-Vehicle Service
1. Universal joint flange 9. Differential carrier assembly 17. Bearing adjuster 25. Bolt
2. Hypoid gear set 10. Differential pinion 18. Lock plate 26. Bolt
3. Bevel pinion spacer
Apply thread lock cement
99000-32110 referring to
“DIFFERENTIAL CASE” in
this section.11. Differential gear 19. Pinion shaft No.2 27. Differential case screw :
Apply thread lock
cement 99000-32110 to
thread part of bolt.
4. Shim 12. Pinion shaft No.1 20. Pinion joint Do not reuse.
5. Rear bearing 13. Differential left case 21. Spring washer Tightening torque
6. Front bearing 14. Differential right case 22. Washer Apply differential oil.
7. Oil seal :
Apply grease 99000-25010
to oil seal lip.15. Thrust washer 23. Bevel gear bolt :
Apply thread lock
cement 99000-32110
to thread part of bolt.
8. Flange nut :
After tightening nut so as
rotation torque of bevel pin-
ion shaft to be in specified
value, caulk nut securely.16. Differential side bearing 24. Bolt

DIFFERENTIAL (REAR) 7F-9
6) Using a hammer and brass bar (1), drive out front bearing
outer race with bearing (2) and oil seal (3).
7) Drive out rear bearing outer race in the same way as in the
step 6).
Component Inspection
•Check companion flange for wear or damage.
•Check bearings for wear or discoloration.
•Check differential carrier for cracks.
•Check drive bevel pinion and drive bevel gear for wear or cracks.
•Check differential gears, pinions and pinion shafts for wear or damage.
•Check differential gear spline for wear or damage.
Sub-Assembly Adjustment and Reassembly
Judging from faulty conditions noted before disassembly and
what is found through visual check of bearing and gear tooth etc.
after disassembly, prepare replacing parts and proceed to reas-
sembly according to procedures as described below.
CAUTION:
Drive bevel gear and pinion must be replaced as a set
when either replacement becomes necessary.
When replacing taper roller bearing, replace as inner
race & outer race assembly.

DIFFERENTIAL (REAR) 7F-13
Drive bevel pinion
To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier
properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel
pinion, differential carrier and mounting dummy.
Special tool
(A) : 09900-20606
(B) : 09926-78320
(C) : 09922-75222
(D) : 09922-76570
(E) : 09951-46010
(F) : 09926-78311-002
1. Universal Joint flange (P/No. 27110-60A00)“a”: Pinion dummy height + Attachment height
2. Nut“b”: Axle dummy radius
3. Front bearing“a” + “b”Mounting dummy size 110.00 mm/4.3307 in.
4. Differential carrier“c”: Measured dimension
5. Rear bearing“d”: Drive bevel pinion mounting distance 110.00 mm/4.3307 in.
6. Spacer“e”: Shim size for mounting distance adjustment (= “c”)
7. Drive bevel pinion
8. Drive bevel gear

7F-16 DIFFERENTIAL (REAR)
6) Select adjusting shim(s) (2) closest to calculated value from
among following available sizes and put it in place and then
press-fit rear bearing (1).
Calculated valve
“f” : Closest value to “e” (refer to Step 5).)
Special tool
(G) : 09925-18011
(H) : 09927-66010
Available shim thickness
: 1.12, 1.15, 1.18, 1.21,1.24, 1.27, 1.30 and 0.3 mm
(0.044, 0.045, 0.046, 0.047 0.048, 0.049, 0.050 and 0.012 in.)
7) With new pinion spacer (3) inserted as shown in the figure,
install front bearing (5) to differential carrier (4).
8) Using special tool and plastic hammer, drive oil seal (2) into
differential carrier (1) till it becomes flush with carrier end.
Then apply grease “A” to oil seal lip.
“A” : Grease 99000-25010
Special tool
(I) : 09951-18210
3. Drive bevel pinion
NOTE:
Make sure to use new spacer for reinstallation.
Apply differential oil to bearings.
1. Drive bevel pinion
2. Rear bearing

SEAT BELT 10A-5
Seat belt switch
Check driver side seat belt strap switch for continuity by using
ohmmeter.
Seat belt strap switch specification
Without inserted buckle tongue to buckle catch:
Terminal “A” and “B” : Continuity
With inserted buckle tongue to buckle catch:
Terminal “A” and “B” : No continuity (∞Ω
∞Ω∞Ω ∞Ω)
INSTALLATION
Install in reverse order of removal, noting the followings.
•Seat belt anchor bolts should have an unified fine thread (7/16-20 UNF). Under no circumstances should
any different sized or metric screw threads be used.
•Connect Yellow connector for seat belt pretensioner securely and fit seat belt pretensioner connector onto
front pillar lower panel, if necessary.
a) Connect connector
b) Lock connector with lock lever
•Enable air bag system referring to “ENABLING AIR BAG SYSTEM” under “SERVICE PRECAUTIONS” in
Section 10B, if necessary.
1. Buckle tongue
2. Buckle catch

10A-6 SEAT BELT
Second Rear Seat Belt
REMOVAL
Refer to the figure above to remove rear seat belts.
INSPECTION
Check second rear seat belt in the same way as when inspecting front seat belt except pretesioner inspection.
(Refer to “FRONT SEAT BELT” in this section.)
INSTALLATION
Install in reverse order of removal, noting the followings.
•Seat belt anchor bolts should have an unified fine thread (7/16-20 UNF). Under no circumstances should
any different sized or metric screw threads be used. WARNING:
Be sure to read “SERVICE PRECAUTIONS” in this section before starting to work and observe every
precaution during work.
1. Upper anchor 4. Buckle
2. Lower anchor Tightening Torque
3. Retractor assembly
2
35 N·m (3.5 kg-m, 25.5 lb-ft)
35 N·m (3.5 kg-m, 25.5 lb-ft)
35 N·m (3.5 kg-m, 25.5 lb-ft)
35 N·m (3.5 kg-m,
25.5 lb-ft)
4
4
4

10B-2 AIR BAG SYSTEM
DTC B1031 – Power Source Voltage
High........................................................... 10B-33
DTC B1032 – Power Source Voltage
Low ........................................................... 10B-33
DTC B1035 – RH Forward Sensor Circuit
Open or Short to Ground .......................... 10B-36
DTC B1036 – RH Forward Sensor Circuit
Short Between Two Wires or Short to
Power Circuit............................................. 10B-36
DTC B1037 – LH Forward Sensor Circuit
Open or Short to Ground .......................... 10B-36
DTC B1038 – LH Forward Sensor Circuit
Short Between Two Wires or Short to
Power Circuit............................................. 10B-36
DTC B1041 – Driver Pretensioner Initiator
Circuit Resistance High............................. 10B-40
DTC B1042 – Driver Pretensioner Initiator
Circuit Resistance Low ............................. 10B-40
DTC B1043 – Driver Pretensioner Initiator
Circuit Short to Ground ............................. 10B-40
DTC B1044 – Driver Pretensioner Initiator
Circuit Short to Power Circuit .................... 10B-40
DTC B1045 – Passenger Pretensioner
Initiator Circuit Resistance High ................ 10B-40
DTC B1046 – Passenger Pretensioner
Initiator Circuit Resistance Low................. 10B-40
DTC B1047 – Passenger Pretensioner
Initiator Circuit Short to Ground ................ 10B-40
DTC B1048 – Passenger Pretensioner
Initiator Circuit Short to Power Circuit ....... 10B-40
DTC B1051 – Frontal Crash Detected
(System Activation Command Outputted). 10B-46DTC B1061 – “AIR BAG” Warning Lamp
Circuit Failure............................................ 10B-47
DTC B1071 – Internal SDM Fault ............. 10B-48
DTC B1013 – System Specifications
Different from SDM Specifications ............ 10B-48
On-Vehicle Service ..................................... 10B-49
Service Precautions .................................. 10B-49
Service and diagnosis ........................... 10B-49
Disabling air bag system ....................... 10B-50
Enabling air bag system........................ 10B-50
Handling and storage ............................ 10B-51
Repairs and Inspections Required after
an Accident ............................................... 10B-56
Accident with deployment/activation -
component replacement ....................... 10B-56
Accident with or without deployment/
activation - component inspections....... 10B-57
SDM .......................................................... 10B-60
Forward Sensor ........................................ 10B-62
Seat Belt Pretensioner .............................. 10B-64
Air Bag (Inflator) Module and Seat Belt
Pretensioner Disposal................................ 10B-65
Deployment/Activation Outside Vehicle .... 10B-66
Deployment/Activation Inside Vehicle....... 10B-72
Deployed Air Bag (Inflator) Module and
Activated Seat Belt Pretensioner
Disposal .................................................... 10B-76
Tightening Torque Specification............... 10B-77
Special Tool ................................................ 10B-77

AIR BAG SYSTEM 10B-15
DTC“AIR BAG” warning lamp
flashing pattern
Diagnosis
NO. MODE
B1041 41
Driver preten-
sioner circuitResistance high
Diagnose trou-
ble according to
diagnostic flow
table corre-
sponding to
each code No. B1042 42 Resistance low
B1043 43 Short to ground
B1044 44 Short to power circuit
B1045 45
Passenger
pretensioner
circuitResistance high
B1046 46 Resistance low
B1047 47 Short to ground
B1048 48 Short to power circuit
B1051 51
SDMFrontal crash detected
B1061 61“AIR BAG” warning lamp cir-
cuit failure
B1071 71 Internal fault
B1013 13Specifications different
between air bag system and
SDM
NOTE:
When 2 or more codes are indicated, the lowest numbered code will appear first.
Current DTC and history DTC can be identified by lighting and flashing of “AIR BAG” warning lamp
as follows. However, if a multiple number of DTC’s are set or even one of them is a current DTC,
“AIR BAG” warning lamp remains on after ignition switch is turned ON. Therefore, it is not possible
to identify any of them as to whether it is a current one or a history one. (But use of SUZUKI scan
tool will make identification possible.)
Current DTC is set.
(Abnormality exists at present.)History DTC is set only.
(Faulty condition occurred once
in the past but normal condition
is restored at present.)
“AIR BAG” warning lamp after
ignition switch ONFlashing 6 times and turns on. Flashing 6 times and turns off.
“AIR BAG” warning lamp when
grounding diagnosis switchCurrent DTC is displayed. History DTC is displayed.