change SUZUKI GRAND VITARA 2004 2.G Service Repair Manual

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-9
Viscosity chart SAE
Temperature
ON-VEHICLE SERVICE
MAINTENANCE SERVICE
NOTE:

When having driven through water, check immediately if wa-
ter has entered (if so, oil is cloudy). Water mixed oil must be
changed at once.

Whenever vehicle is hoisted for any other service work than
oil change, also be sure to check for oil leakage and status
of breather hoses.
Gear Oil Change
NOTE:

Hypoid gear oil must be used for differential.

It is highly recommended to use SAE 80W ± 90 viscosity.
1) Before oil change or inspection, be sure to stop engine and lift
up vehicle horizontally.
2) Check oil level and existence of leakage. If leakage is found, cor-
rect its cause.
3) Drain old oil and pour proper amount of gear oil as specified be-
low (roughly up to level hole).
4) Apply sealant to thread of drain plug (b) and torque plugs to
specification.
Sealant 99000-31110
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
Specified gear oil: Hypoid gear oil API GL-5
SAE 75W ± 85, 90 or 80W ± 90
For oil viscosity, refer to left chart.
Oil capacity: 1.0 liters (2.1 / 1.8 US / lmp. pt)

YH4
GRAND
VITARA
1. Breather hose
2. Oil filler / level plug
3. Rear drain plug
(Apply sealant)
Viscosity chart SAE
DIFFERENTIAL (REAR) 7F-3
ON-VEHICLE SERVICE
MAINTENANCE SERVICE
NOTE:

When having driven through water, check immediately if wa-
ter has entered (if so, oil is cloudy). Water mixed oil must be
changed at once.

Whenever vehicle is hoisted for any other service work than
oil change, also be sure to check for oil leakage and status
of breather hoses.
CHANGING OIL
NOTE:

Hypoid gear oil must be used for differential.

It is highly recommended to use SAE 80W-90 viscosity.
1) Before oil change or inspection, be sure to stop engine and lift
up vehicle horizontally.
2) Check oil level and existence of leakage. If leakage is found, cor-
rect its cause.
3) Drain old oil and pour proper amount of gear oil as specified
(roughly up to level hole).
4) Torque drain and level / filler plugs to specification.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
(b): 28 N
.m (2.8 kg-m, 20.5 lb-ft)
Specified gear oil: Hypoid gear oil API GL-5
SAE 75W-85, 80W-90 or 90
For oil viscosity, refer to the chart
at the left.
Oil capacity : 2.2 liters (4.6 / 3.9 US / Imp. pt.)

YH4
GRAND
VITARA
WASHER
ONON
OFF
10 ± 14V
0VApprox. 2.5 sec.
Approx. 0.5 sec.
8D-12 WINDOWS, MIRRORS, SECURITY AND LOCKS
Washer Linked Operation
1) Disconnect negative cable at battery.
2) Disconnect combination switch lead wire coupler.
3) Make sure that front wiper switch is at OFF position.
4) Connect battery positive terminal to terminal ªB3º and battery
negative terminal to terminal ªEº.
5) Connect voltmeter positive lead to terminal ª+1º and negative
lead to terminal ªEº.
6) Pull washer switch and check that voltage changes as shown in
the table.
Washer switch
Voltmeter

YH4
GRAND
VITARA
8D-14 WINDOWS, MIRRORS, SECURITY AND LOCKS
2) TESTING AUTOMATIC STOP ACTION
a) First, connect battery (+) terminal to terminal ªDº and battery
(±) terminal to black lead wire (2) and let the motor (1) turn.
b) Then disconnect terminal ªDº from battery and let the motor
stop.
c) Next connect terminal ªDº and terminal ªAº with a jumper wire
(3) and connect terminal ªBº to battery (+) terminal. Observe the
wiper motor turns once again, then stops at a given position.
d) Repeat these steps several times, and inspect if the motor
stops at the given position every time.
Rear Wiper Intermittent Relay
[ON circuit]
1) Connect positive terminal of battery to terminals ª1º and ª4º of
relay, negative terminal to terminal ª5º of relay and check voltage
between terminals ª6º and ª5º of relay.
If measured voltage is battery voltage, relay is in good condition.
If not, replace relay.
2) Connect positive terminal of battery to terminal ª2º of relay, then
disconnect positive terminal from terminal ª4º of relay and check
voltage between terminals ª6º and ª5º of relay.
If measured voltage is battery voltage, relay is in good condition.
If not, replace relay.
3) Disconnect positive terminal from terminal ª2º of relay and check
voltage between terminals ª6º and ª5º of relay.
If measured voltage is about 0 V, relay is in good condition.
If not, replace relay.
[WASH circuit]
1) Connect positive terminal of battery to terminal ª1º of relay and
negative terminal to terminal ª5º of relay. Then connect positive
terminal to terminal ª7º checking voltage between terminals ª6º
and ª5º of relay.
If measured voltage changes from about 0 V to battery voltage
0.6 to 1.5 seconds after connecting positive terminal to terminal
ª7º, relay is in good condition. If not, replace relay.

YH4
GRAND
VITARA
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-15
2) Disconnect positive terminal from terminal ª7º checking voltage
between terminal ª6º and ª5º of relay.
If measured voltage changes from battery voltage to about 0 V
2.7 to 4.6 seconds after disconnecting positive terminal from ter-
minal ª7º, relay is in good condition.
If not, replace relay.
[INT circuit]
1) Connect positive terminal of battery to terminals ª1º of relay and
negative terminal to terminal ª5º of relay. Then positive terminal
to terminal ª3º of relay checking voltage between terminals ª6º
and ª5º of relay.
If measured voltage changes from about 0 V to battery voltage
when connecting positive terminal to terminal ª3º, relay is in
good condition.
If not, replace relay.
2) Connect positive terminal of battery to terminal ª2º of relay, then
disconnect positive terminal from terminal ª2º of relay checking
voltage between terminals ª6º and ª5º of relay.
If measured voltage changes from battery voltage to about 0 V
when disconnecting positive terminal from terminal ª2º and
about 0 V to battery voltage 8
2 seconds after disconnecting
positive terminal from terminal ª2º, relay is in good condition.
If not, replace relay.

YH4
GRAND
VITARA
0.5TIME (sec.) Ignition switch ON
High Immobilizer
control system
is normal
Immobilizer
control system
is abnormalLow
0.5 0.5 0.5 0.5
High
Low
0.5TIME (sec.) Ignition switch ON
High Immobilizer
control system
is normal
Immobilizer
control system
is abnormalLow
0.5 0.5 0.5 0.5
High
Low
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-5
<Vehicle equipped with monitor coupler>
With the diagnosis switch terminal of monitor coupler for
ECM / PCM not grounded, the ignition switch turned ON (but the en-
gine at stop) and regardless of the condition of the electronic fuel
injection system, ECM / PCM indicates whether a trouble has oc-
curred in the immobilizer control system or not by causing the mal-
function indicator lamp to flash or turn ON.
Malfunction indicator lamp is ON:
No trouble exists in the immobilizer control system.
Malfunction indicator lamp is flashing:
ECM / PCM or Immobilizer Control Module has detected some
trouble in the immobilizer control system.
NOTE:
As soon as the ignition switch is turned ON, ECM / PCM and Im-
mobilizer Control Module diagnose if a trouble has occurred
in the immobilizer control system. While the diagnosis is being
made, the malfunction indicator lamp stays ON and if the diag-
nosis result is ªabnormalº, it immediately changes to flashing
but if the result is ªnormalº, it remains ON. Diagnosis takes
about 3 seconds at maximum.
<Vehicle not equipped with monitor coupler>
With the ignition switch turned ON (but the engine at stop) regard-
less of the condition of the electronic fuel injection system,
ECM / PCM indicates whether a trouble has occurred in the immobi-
lizer control system or not by causing the immobilizer indicator lamp
to flash or turn ON.
Immobilizer indicator lamp is ON:
No trouble exists in the immobilizer control system.
Immobilizer indicator lamp is flashing:
ECM / PCM or Immobilizer Control Module has detected some
trouble in the immobilizer control system.
NOTE:
As soon as the ignition switch is turned ON, ECM / PCM and Im-
mobilizer Control Module diagnose if a trouble has occurred
in the immobilizer control system. While the diagnosis is being
made, the Immobilizer indicator lamp stays ON and if the diag-
nosis result is ªabnormalº, it immediately changes to flashing
but if the result is ªnormalº, it remains ON. Diagnosis takes
about 3 seconds at maximum.
When ECM / PCM and Immobilizer Control Module detects a
trouble which has occurred in the above areas, it stores DTC corre-
sponding to the exact trouble area in ECM / PCM and Immobilizer
Control Module memory.
DTCs stored in memory of each controller (Immobilizer Control
Module and ECM / PCM) can be read by using the procedure de-
scribed in ªDIAGNOSTIC TROUBLE CODE CHECK (IMMOBILIZ-
ER CONTROL MODULE)º and ªDIAGNOSTIC TROUBLE CODE
CHECK (ECM / PCM)º in this section.

YH4
GRAND
VITARA
(A)
10B-8 AIR BAG SYSTEM
INTERMITTENT AND POOR CONNECTIONS
Most intermittent are caused by faulty electrical connections or wir-
ing. When a check for proper connection is requested in a diagnos-
tic flow table, perform careful check of suspect circuits for:

Poor mating of connector halves, or terminals not fully seated in
the connector body (backed out).

Dirt or corrosion on the terminals. The terminals must be clean
and free of any foreign material which could impede proper termi-
nal contact.
However, cleaning the terminal with a sand paper or the like is
prohibited.

Damaged connector body, exposing the terminals to moisture
and dirt, as well as not maintaining proper terminal orientation
with the component or mating connector.

Improperly formed or damaged terminals.
If any abnormality is found, repair or replace as a wire harness as-
sembly.
Check each connector terminal in problem circuits carefully to en-
sure good contact tension by using the corresponding mating termi-
nal included in the connector test adapter kit (special tool).
If contact tension is not enough, reform it to increase contact ten-
sion or replace.
Special Tool (Connector Test Adapter Kit)
(A): 09932-76010

Poor terminal-to-wire connection.
Check each wire harness in problem circuits for poor connection
by shaking it by hand lightly.
If any abnormal condition is found, change the wire harness as-
sembly or component parts with new ones.