Section 6B SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

YH4
GRAND
VITARA
1. Speed sensor assembly
2. Transfer
7D-4 TRANSFER
SPEEDOMETER DRIVEN GEAR
REMOVAL
1) Lift up vehicle horizontally or rear up.
2) Disconnect speed sensor coupler at transfer case.
3) Remove bolt and take off speed sensor from transfer.
INSTALLATION
1) Make sure that O-ring and speed sensor have not been dam-
aged.
2) Inspect speedometer driven gear for abnormal wear of gear
teeth or bend of shaft portion and replace it if necessary.
3) Make sure its smooth rotation.
4) Install speed sensor assembly to transfer and connect coupler
as it was.
Tightening Torque
(a): 6 N
.m (0.6 kg-m, 4.5 lb-ft)
ENGINE REAR MOUNTING
Refer to ªON-VEHICLE SERVICEº of Section 7A.

YH4
GRAND
VITARA
1. Wood block
2. Dash panel
t: 45 mm / 1.8 in.
H: 200 mm / 8 in.
W: 100 ± 150 mm / 4 ± 6 in.
1. Transmission jack
2. Engine rear mounting member
3. Gear shift lever case
4. Bolt
TRANSFER 7D-5
TRANSFER ASSEMBLY
Dismounting and remounting of transfer and transmission together
as a unit is described in Section 7A for Manual Transmission or 7B1
for Automatic Transmission, but it is also possible to dismount and
remount transfer assembly by itself as described below.
DISMOUNTING
IN ENGINE ROOM
1) Disconnect negative (±) cable from battery.
2) Remove distributor assembly (if equipped).
3) Place wood block between engine and dash panel so that it
serves as stopper when engine, transmission and transfer unit
hangs down as rear mounting member is removed.
CAUTION:
Make sure to use wood block to prevent contact which
may occur between dash panel and CMP sensor case
(G16), CMP sensor (J20) or intake manifold (H25), and fan
and shroud.
IN CABIN
1) Remove console box.
2) Remove shift lever of transmission and transfer.
ON LIFT
1) Drain transfer oil.
2) Remove rear propeller shaft.
3) Remove front propeller shaft.
4) Disconnect exhaust center pipe.
5) Disconnect speed sensor coupler.
6) Place transmission jack and remove mounting member.
7) Lower transmission jack gradually and check to ensure that
wood block serves as stopper between engine and dash panel.
8) Remove bolts for gear shift lever case.
9) Pull off breather hose.

YH4
GRAND
VITARA
TRANSFER 7D-7
09940-53111
Bearing installer
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN.mkg-mlb-ft
Oil filler / level and drain plugs232.317.0
Engine rear mounting bolts505.036.5
Universal joint flange bolts505.036.5
Speed sensor bolt60.64.5
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)

Oil seal lips and O-rings.

Splines of propeller shaft.

Select return system.

Shift control lever.
SPECIAL TOOL

YH4
GRAND
VITARA
7E
DIFFERENTIAL (FRONT) 7E-1
The differential assembly using a hypoid bevel pinion
and gear is installed to the front axle.
4WD control system controls drive force to be trans-
mitted to front axles or not. The reduction ratio varies
depending on transmission or engine type.The differential assembly is decisive in that the drive
power is concentrated there. Therefore, use of genu-
ine parts and specified torque is compulsory. Further,
because of sliding tooth meshing with high pressure
between bevel pinion and gear, it is mandatory to lu-
bricate them by hypoid gear oil.
SECTION 7E
DIFFERENTIAL (FRONT)
CONTENTS
GENERAL DESCRIPTION7E- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WD CONTROL SYSTEM7E- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS7E- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS TABLE7E- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly7E- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WD Control System Diagnostic Flow Table 7E- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WD CONTROL CIRCUIT INSPECTION 7E- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7E- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SERVICE7E- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Oil Change7E- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION7E-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WD Control System7E-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuator7E-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Pump Assembly7E-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION 7E-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Mountings7E-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISMOUNTING7E-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOUNTING7E-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS7E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIAL7E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS7E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION

YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-5
DIAGNOSIS
DIAGNOSIS TABLE
Differential Assembly
ConditionPossible CauseCorrection
Gear noise
Deteriorated or water mixed lubricant

Inadequate or insufficient lubricant

Maladjusted backlash between bevel
pinion and gear

Improper tooth contact in the mesh between
bevel pinion and gear

Loose bevel gear securing bolts

Damaged side gear(s) or side pinion(s)Repair and replenish
Repair and replenish
Adjust
Adjust or replace
Replace or retighten
Replace
Bearing noise
(Constant noise) Deteriorated or water
mixed lubricant

(Constant noise) Inadequate or insufficient
lubricant

(Noise while coasting) Damaged bearing(s)
of bevel pinion

(Noise while turning) Damaged diff. side
bearing(s) or axle bearing(s)Repair and replenish
Repair and replenish
Replace
Replace
Oil leakage
Worn or damaged oil seal

Excessive oil

Loose differential carrier boltsReplace
Adjust oil level
Replace or retighten
2WD / 4WD
switching error
Defective actuator

Abnormality in 4WD control systemReplace
Inspect referring to ª4WD
CONTROL SYSTEM DIAG-
NOSTIC FLOW TABLEº.
4WD Control System Diagnostic Flow Table
Before performing the trouble diagnosis, check that the transfer and front differential are in good condition and
there is no air leakage from air hoses and the actuator. Refer to ªON-VEHICLE SERVICEº in this section for air
leakage.
[NOTES ON SYSTEM CIRCUIT INSPECTION]

Be sure to read ªPrecautions for Electrical Circuit Serviceº in Section 0A before circuit inspection and observe
what is written there.

For system circuit, refer to the figure of ªGENERAL DESCRIPTIONº in this section.

For terminal arrangement, refer to ª4WD Control Circuit Inspectionº in this section.

YH4
GRAND
VITARA
7E-6 DIFFERENTIAL (FRONT)
STEPACTIONYESNO
1Turn ON ignition switch (but engine at stop) and
check malfunction indicator lamp.
Does lamp light up?Go to step 2.A trouble has
occurred at some
place. Repair it
referring to
MALFUNCTION
INDICATOR LAMP
(ªCHECK ENGINEº
LAMP) CHECK in
DIAGNOSIS of
SECTION 6.
2Check 4WD switch circuit.
Turn ignition switch ON and check that voltage
between terminal C51-2-18 and terminal C51-3-17
(ground) for G16 / J20 (terminal C51-1-11 and terminal
C51-3-26 (ground) for H25) is as follows.

When transfer shift lever is in N or 2H: 10 ± 14 V

When transfer shift lever is in 4L or 4H: 0 ± 1 V
Is the check result satisfactory?Go to step 3.Check 4WD switch
(refer to SECTION
7A), ªB / Orº and ªBº
circuits of 4WD
switch.
If OK, substitute a
known-good ECM
(PCM) and recheck.
3Check power supply.
1) Turn ignition switch ON.
2) Check voltage between C51-2-7 and C51-3-17
(ground) for G16 / J20 (C51-1-15 and C51-3-26
(ground) for H25). The check results should be as
follows.

When transfer shift lever is in N or 2H: 0 ± 1 V

When transfer shift lever is in 4L or 4H: 10 ± 14 V
Is the check result satisfactory?Go to step 4.Check ªRº circuit. If
it is OK, substitute a
known-good ECM
(PCM) and recheck.
4Check air pump assembly circuit.
1) Check for proper connection to air pump
assembly at all terminals.
2) Turn ignition switch ON.
3) Check voltage between C51-2-27 and C51-3-17
(ground) for G16 / J20 (C51-1-18 and C51-3-26
(ground) for H25). The check result should be as
follows.

When transfer shift lever is in 2H or N: 0 ± 1 V

When transfer shift lever is in 4L or 4H
(more than 4 seconds after shifted to 4L or 4H):
10 ± 14 V
Is the check result satisfactory?Go to step 5.Check air pump
assembly referring
to ªON-VEHICLE
SERVICEº, and then
ªPº circuit.
If OK, substitute a
known-good ECM
(PCM) and recheck.
5Check 4WD indicator lamp circuit.
1) Turn ignition switch ON.
2) Check voltage between E61-19 and C51-3-17
(ground) for G16 / J20 (C51-1-7 and C51-3-26
(ground) for H25). The check result should be as
follows.

When transfer shift lever is in 2H or N: 10 ± 14 V

When transfer shift lever is in 4L or 4H: 0 ± 1 V
Is the check result satisfactory?4WD control system
is in good condition.Check ªOr / Bº circuit
(including indicator
lamp and
combination meter).
If OK, substitute a
known-good ECM
(PCM) and recheck.

YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-11
1. Differential housing
2. Adjusting screw
3. To air compressor
Actuator
1) Disconnect air hose from pump assembly and install special tool
to air hose as shown in figure. Loosen adjusting screw of special
tool.
Special Tool
(A): 09918-18110
2) Connect compressor air hose to special tool.
Blow air and turn adjusting screw to obtain specified pressure.
Specified pressure: 30.0 kPa (0.3 kg / cm
2, 4.25 psi)
CAUTION:
Do not apply a pressure exceeding 200 kPa (2.0 kg / cm
2,
28.4 psi) which may cause damage to diaphragm.
3) With the vehicle lifted so that both of the front wheels are off the
ground, turn one of the front wheels by hand and check the other
wheel, which should act as described below.

When the pressure from compressor is applied to actuator:
The other front wheel should turn in the direction opposite to
the wheel being turned by hand.

When the pressure from compressor is not applied to actuator:
The other front wheel should remain stationary while the wheel
pushed by hand is turning.
If the result is not satisfactory, inspect differential assembly. Re-
fer to ªINSPECTIONº of SECTION 7E in UNIT REPAIR MANU-
AL.

YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-17
09951-16080
Bearing installer09951-26010
Bush remover plate09918-18110
Air pressure regulator
09367-04002
3-way joint
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN.mKg-mlb-ft
Differential oil filler / level plug232.317.0
Differential oil drain plug232.317.0
Differential mounting front bolts858.561.5
Differential mounting bracket bolts505.036.5
Front drive shaft flange bolts505.036.5
Propeller shaft flange bolts505.036.5
Pump assembly bolts131.39.5
REQUIRED SERVICE MATERIAL
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
SealantSUZUKI BOND NO. 1215
(99000-31110)Front differential drain plug
SPECIAL TOOLS

YH4
GRAND
VITARA
7F
DIFFERENTIAL (REAR) 7F-1
The differential assembly is decisive in that the drive
power is concentrated there. Therefore, use of genu-
ine parts and specified torque is compulsory. Further,
because of sliding tooth meshing with high pressure
between bevel pinion and gear, it is mandatory to lu-
bricate them by hypoid gear oil.
SECTION 7F
DIFFERENTIAL (REAR)
CONTENTS
GENERAL DESCRIPTION7F-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS7F-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7F-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Service7F-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismounting7F-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remounting7F-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7F-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS7F-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7F-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION
The differential assembly using a hypoid bevel pinion
and gear is installed to the rear axle. It is set in the con-
ventional type axle housing.
The reduction ratio and differential case vary depend-
ing on transmission or engine type.

YH4
GRAND
VITARA
1. Match mark
1. Differential to rear axle nut
7F-4 DIFFERENTIAL (REAR)
DISMOUNTING
1) Lift up vehicle and drain oil from rear differential housing.
2) Remove rear brake drums and pull out right and left rear axle
shafts. (Refer to rear axle shaft removal of SECTION 3E.)
3) Before removing propeller shaft, give match marks on joint
flange and propeller shaft as shown.
4) Remove propeller shaft by removing its 4 flange bolts and nuts.
5) Remove differential assembly by removing its 8 fastening nuts.