front diff SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

YH4
GRAND
vol.1
RELATED MANUAL
MANUAL NAMEMANUAL NO.APPLICABILITY
SQ416 / SQ420 / SQ625
Unit Repair Manual99501-65D01-xxxTransmission, Transfer and Differentials
(Front and Rear) of SQ series.
SQ416 / SQ420 / SQ625
Wiring Diagram Manual99512-65D10-015Applicable model mentioned in FOREWORD
of this manual.
SQ416 / SQ420 / SQ625
Service Manual99500-65D00-xxxVehicles before the vehicle identification number
mentioned in FOREWORD of this manual.
SQ416 / SQ420 / SQ625
Wiring Diagram Manual99512-65D01-015

YH4
GRAND
vol.1
0A
0B
1A
1B
3
3A
3B1
3C
3C1
3D
3E
3F
4A2
4B
5
6
7A5A
5B
5C
5E1
6A1
6A2
6A4
6B
6C
6E1
6E2
6F1
6F2
6G
6G1
6H
6K
7A1
7B1
7C1
7D
7E
7F
8
8B
8C
8D
8G
9
10
10A
8A
10B
6-1ENGINE
General Information and
Diagnosis (G16 / J20)
General Information and
Diagnosis (H25)
Engine Mechanical (G16)
Engine Mechanical (H25)
Engine Mechanical (J20)
Engine Cooling
Engine Fuel
Engine and Emission Control
System (SFI for G16 / J20)
Engine and Emission Control
System (SFI for H25)
Ignition System (G16)
Ignition System (J20 / H25)
Cranking System
(Reduction Type)
Cranking System
(No-Reduction Type)
Charging System
Exhaust System
TRANSMISSION, CLUTCH
AND DIFFERENTIAL
Manual Transmission (Type 1)
Manual Transmission (Type 2)
Automatic Transmission
Clutch (Hydraulic Type)
Transfer
Differential (Front)
Differential (Rear)
BODY ELECTRICAL SYSTEM
Wiring Diagram
Lighting System
Instrumentation / Driver
Information
Windows, Mirrors, Security
and Lock
Immobilizer Control System
BODY SERVICE
RESTRAINT SYSTEM
Seat Belt
Air Bag System GENERAL INFORMATION
General Information
Maintenance and Lubrication
TABLE OF CONTENTS TABLE OF CONTENTS SECTIONSECTION
0B
HEATING AND AIR
CONDITIONING
Heater and Ventilation
Air Conditioning
STEERING, SUSPENSION,
WHEELS AND TIRES
Front End Alignment
Power Steering (P / S) System
Steering Wheel and Column
(Not Equipped with Air Bag)
Air Bag Steering Wheel
and Column
Front Suspension
Rear Suspension
Wheel and Tires
1A
3A 0A
1B
3B1
3C
3C1
3D
3E
3F36A16
6A2
6A4
6B
6C
6E1
6E2
6F1
DRIVE SHAFT / PROP. SHAFT
Front Drive Shaft / Shaft
Bearing, Oil Seal
Propeller Shaft
BRAKES
Brake Pipe / Hose / Master
Cylinder
Front Brakes
Parking and Rear Brakes
Antilock Brake System
4A2
4B
5
5A
5B
5C
5E1
6F2
6G
6G1
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8
8A
8B
8C
8D
8G
9
10
10A
10B
6-1
NOTE:
The screen toned Sections 6 ± 6K are included in Volume 2 and Section 8A is in Wiring
Diagram Manual.

YH4
GRAND
VITARA
1. Front differential housing
2. Rear axle
housing
When using floor jack:
Front
Rear
1. Safety stands
0A-20 GENERAL INFORMATION
In raising front or rear vehicle end off the floor by jacking, be sure
to put the jack against the center portion of the front suspension
frame or rear axle housing.
WARNING:

Never apply jack against suspension parts (i.e., stabilizer,
etc.) or vehicle floor, or it may get deformed.

If the vehicle to be jacked up only at the front or rear end,
be sure to block the wheels on ground in order to ensure
safety.
After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on the
vehicle raised on jack alone.
To perform service with either front or rear vehicle end jacked up,
be sure to place safety stands under chassis frame so that body is
securely supported. And then check to ensure that chassis frame
does not slide on safety stands and the vehicle is held stable for
safety's sake.

YH4
GRAND
VITARA
1
1. Clutch pedal free travel
MAINTENANCE AND LUBRICATION 0B-15
CHASSIS AND BODY
ITEM 6-1
Clutch
Pedal inspection
Check clutch pedal for height and free travel referring to Section
7C1. Adjust or correct if necessary.
Fluid inspection
1) Check around master cylinder and reservoir for fluid leakage.
If found leaky, correct.
2) Check fluid level.
If fluid level is lower than the minimum level of reservoir, refilling
is necessary. Fill reservoir with specified brake fluid indicated on
clutch reservoir cap.
For the details, refer to On-vehicle service in Section 7C1.
CAUTION:
Since clutch system of this vehicle is factory-filled with
glycol-base brake fluid, do not use or mix different type
of fluid when refilling system; otherwise serious damage
will occur. Do not use old or used brake fluid, or one taken
from unsealed container.
ITEM 6-2
Brake Discs, Pads, Brake Drums and Shoes Inspection
[Brake discs and pads]
1) Remove wheel and caliper but don't disconnect brake hose from
caliper.
2) Check front disc brake pads and discs for excessive wear, dam-
age and deflection. Replace parts as necessary. For details, re-
fer to Section 5B.
Be sure to torque caliper pin bolts to specification.
[Brake drums and shoes]
1) Remove wheel and brake drum.
2) Check rear brake drums and brake linings for excessive wear
and damage, while wheels and drums are removed. At the same
time, check wheel cylinders for leaks. Replace these parts as
necessary.
For details, refer to Section 5C.

YH4
GRAND
VITARA
MAINTENANCE AND LUBRICATION 0B-19
11) Check coil spring, upper rod, lower rod and lateral rod for de-
formation and damage.
12) Check upper rod, lower rod and lateral rod bushings and bump
stopper for wear, damage and deterioration.
13) Check other suspension parts for damage, loose or missing
parts; also for parts showing signs of wear or lack of lubrication.
Replace any parts found defective in steps 1) to 13).
ITEM 6-9
Propeller Shafts and Drive Shafts Inspection
1) Check universal joint and spline of propeller shaft for rattle. If
rattle is found, replace defective part with a new one.
2) Check propeller shaft (front & rear) flange yoke bolts for tight-
ness, and retighten them as necessary.
Refer to Section 4B for tightening torque.
3) Check drive axle boots (wheel side and differential side) for
leaks, detachment, tear or other damage.
Replace boot as necessary.

YH4
GRAND
VITARA
1. Drain plug
Transfer
Front differential
Rear differential
1
21
2
MAINTENANCE AND LUBRICATION 0B-21
Change
1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Change fluid. For its procedure, refer to On-vehicle service in
Section 7B1.
Fluid cooler hose change
Replace inlet and outlet hoses of cooler hose and their clamps.
For replacement procedure, refer to On-vehicle service in Section
7B1.
ITEM 6-12 and 6-13
Transfer and Differential Oil Inspection and Change
Inspection
1) Check transfer case and differential for evidence of oil leakage.
Repair leaky point if any.
2) Make sure that vehicle is placed level for oil level check.
3) Remove level plug of transfer or differentials (front and rear) and
check oil level.
Oil level can be checked roughly by means of level plug hole.
That is, if oil flows out of level plug hole or if oil level is found up
to hole when level plug is removed, oil is properly filled.
If oil is found insufficient, pour specified amount of specified oil
referring to Section 7D, 7B or 7F.
4) Tighten level plug to specified torque.
Refer to Section 7D, 7E or 7F for tightening torque.
Change
Change transfer oil or differentials oil with new specified oil referring
to Section 7D, 7E and 7F respectively.

YH4
GRAND
VITARA
MAINTENANCE AND LUBRICATION 0B-25
Steering

Check to ensure that steering wheel is free from in-
stability, or abnormally heavy feeling.

Check that the vehicle does not wander or pull to
one side.
Engine

Check that engine responds readily at all speeds.

Check that engine is free from abnormal noise and
abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting sys-
tem are free from abnormal noise and abnormal
vibration or any other abnormal condition.
Meters and Gauge
Check that speedometer, odometer, fuel meter, tem-
perature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set fan switch lever to ªHIº position for this check.
RECOMMENDED FLUIDS AND LUBRICANTS
Engine oilSG, SH or SJ (Refer to engine oil viscosity chart in item 1-4)
Engine coolant (Ethylene glycol
base coolant)ªAntifreeze / Anticorrosion coolantº
Brake fluidDOT 3
Manual transmission oilRefer to Section 7A or 7A1Transfer oilRefer to Section 7A or 7A1.
Differential oil (front & rear)Refer to Section 7E or 7F.
Automatic transmission fluid and
Power steering fluidRefer to Section 3B1 or 7B1.
Door hingesEngine oil or water resistance chassis greaseHood latch assemblyEngine oil or water resistance chassis grease
Key lock cylinderSpray lubricant

YH4
GRAND
VITARA
3-4 STEERING, SUSPENSION, WHEELS AND TIRES
ConditionPossible CauseCorrection
Wander or Poor
Steering Stability
Mismatched or uneven tires.

Loose ball joints and tie rod
ends.

Faulty shock absorbers / struts or
mounting.

Loose stabilizer bar.

Broken or sagging springs.

Rack and pinion not properly adjusted.
(if equipped with manual steering
gear case)

Disturbed front end alignment.Replace tire or inflate tires to
proper pressure.
Replace suspension control arm or
tie rod end.
Replace absorber / strut or repair
mounting.
Tighten or replace stabilizer bar or
bushes.
Replace spring.
Check or adjust rack and pinion
torque.
Check and adjust front end alignment.
Erratic Steering when
Braking
Worn wheel bearings.

Broken or sagging springs.

Leaking wheel cylinder or caliper.

Warped discs.

Badly worn brake linings.

Drum is out of round in some brakes.

Wheel tires are inflated unequally.

Defective wheel cylinders.

Disturbed front end alignment.Replace wheel bearing.
Replace spring.
Repair or replace wheel cylinder or
caliper.
Replace brake disc.
Replace brake shoe lining.
Replace brake drum.
Inflate tires to proper pressure.
Replace or repair wheel cylinder.
Check front end alignment.
Low or Uneven Trim
Height
Right-to-left trim height
(H) difference should be
within 15 mm (0.6 in.)
with curb weight.
*Same with rear side.
Broken or sagging springs.

Overloaded.

Incorrect springs.Replace spring.
Check loading.
Replace spring.
Ride Too Soft
Faulty shock absorber or struts.Replace shock absorber or strut.
Suspension Bottoms
Overloaded.

Faulty shocks or struts.

Incorrect broken or sagging springs.Check loading.
Replace shock absorber or strut.
Replace spring.

YH4
GRAND
VITARA
[A]
[B]

Hard Cornering

Under-Inflation

Lack of Rotation
Incorrect Wheel Alignment

Tire Construction Non-Uniformity

Wheel Heavy Acceleration [A] [B]
3-6 STEERING, SUSPENSION, WHEELS AND TIRES
TIRE DIAGNOSIS
IRREGULAR AND / OR PREMATURE WEAR
Irregular and premature wear has many possible causes. Some of
them are: incorrect inflation pressures, lack of tire rotation, driving
habits, improper alignment.
If the following conditions are noted, rotation is in order:
1. Front tire wear is different from rear.
2. Uneven wear exists across the tread of any tire.
3. Left front and right front tire wear is unequal.
4. Left rear and right rear tire wear is unequal.
5. There is cupping, flat spotting, etc.
A wheel alignment check is in order if the following conditions are
noted:
1. Left front and right front tire wear is unequal.
2. Wear is uneven across the tread of any front tire.
3. Front tire treads have scuffed appearance with ªfeatherº edges
on one side of tread ribs or blocks.
WEAR INDICATOR
The original equipment tires have built-in tread wear indicators to
show when tires need replacement. These indicators will appear as
12 mm (0.47 in.) wide bands when the tire tread depth becomes 1.6
mm (0.063 in.). When the indicators appear in 3 or more grooves
at 6 locations, tire replacement is recommended.
RADIAL TIRE WADDLE
Waddle is side to side movement at the front and / or rear of the ve-
hicle. It is caused by the steel belt not being straight within the tire.
It is most noticeable at low speed, 8 to 48 km / h (5 to 30 mph). It is
possible to road test a vehicle and tell on which end of the vehicle
the faulty tire is located. If the waddle tire is on the rear, the rear end
of the vehicle will shake from side to side or ªwaddleº. From the driv-
er's seat it feels as though someone is pushing on the side of the
vehicle. If the faulty tire is on the front, the waddle is more visual.
The front sheet metal appears to be moving back and forth and the
driver feels as though he is at the pivot point in the vehicle.
Waddle can be quickly diagnosed by using a Tire Problem Detector
(TPD) and following the equipment manufacturer's recommenda-
tions.
If a TPD is not available, the more time consuming method of sub-
stituting known good tire / wheel assemblies on the problem vehicle
can be used as follows:

YH4
GRAND
VITARA
3-8 STEERING, SUSPENSION, WHEELS AND TIRES
RADIAL TIRE LEAD
ªLeadº is the deviation of the vehicle from a straight path on a level
road with no pressure on the steering wheel.
Lead is usually caused by:
1) Incorrect alignment.
2) Uneven brake adjustment.
3) Tire construction.
The way in which a tire is built can produce lead in a vehicle. An ex-
ample of this is placement of the belt. Off center belts on radial tires
can cause the tire to develop a side force while rolling straight down
the road. If one side of the tire is a little larger diameter than the oth-
er, the tire will tend to roll to one side. This will develop a side force
which can produce vehicle lead.
The procedure on previous page should be used to make sure that
front alignment is not mistaken for tire lead.
1) Part of the lead diagnosis procedure is different from the tire
rotation pattern currently in the owner's and service manuals. If
a medium to high mileage tire is moved to the other side of the
vehicle, be sure to check that ride roughness has not developed.
2) Rear tires will not cause lead.
VIBRATION DIAGNOSIS
Wheel unbalance causes most of the highway speed vibration
problems. If a vibration remains after dynamic balancing, it can be
caused by three things.
1) Tire runout.
2) Wheel runout.
3) Tire stiffness variation.
Measuring tire and / or wheel free runout will uncover only part of the
problem. All three causes, known as loaded radial runout, must be
checked by using a Tire Problem Detector (TPD). If a TPD is not
available, the more time consuming method of substituting known
good tire and wheel assemblies on the problem vehicle can be
used.