SUZUKI GRAND VITARA 1999 2.G Owners Manual

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

DIFFERENTIAL (REAR) 7F-17
9) While tightening flange nut gradually with special tool and
power wrench (4 - 10 magnification) (1), set preload of pinion
to specification.
Pinion bearing preload
: 0.9 – 1.7 N·m (9.0 – 17.0 kg-cm, 7.8 – 14.7 lb-in.)
Spring measure reading with special tool
: 16 – 30 N (1.6 – 3.0 kg, 3.5 – 6.6 lb)
Special tool
(C) : 09922-76560
(J) : 09922-66021 NOTE:
Before taking measurement with spring balance (3) or
torque wrench (4), check for smooth rotation by hand.
On measuring preload, rotate the drive bevel pinion
about 1 rotation per 2 seconds.
Be sure to tighten gradually and carefully till specified
starting torque is obtained. Turning back overtightened
flange nuts should be avoided.
2. Socket wrench

7F-18 DIFFERENTIAL (REAR)
Assembling Unit
1) Place bearing outer races on their respective bearings.
Used left and right outer races are not interchangeable.
2) Install case assembly in carrier.
3) Install side bearing adjusters on their respective carrier,
making sure adjuster are threaded properly.
4) Align match marks (1) on cap and carrier. Screw in 2 side
bearing cap bolts 2 or 3 turns and press down bearing cap
by hand.
5) Tighten cap bolts (provisional torque).
Tightening torque
Bearing cap bolt (Provisional torque) (a) :
15 N·m (1.5 kg-m, 11.0 lb-ft)
6) Tighten both bearing adjusters (2) so as to obtain specified
gear backlash and at the same time, obtain preload of side
bearing.
Standard backlash
: 0.13 – 0.18 mm (0.005 – 0.007 in.)
Special tool
(A) : 09930-40120
(B) : 09930-40113
(C) : 09900-20701
NOTE:
If bearing cap does not fit tightly on carrier, side bearing
adjuster is not threaded properly. Reinstall adjuster.
NOTE:
Be sure to apply measuring tip of dial gauge at right
angles to convex side of tooth.
As a practical measure the following would be recom-
mended to obtain specified backlash and side bearing
preload at the same time.
–Obtain specified backlash by turning both adjusters
inward lightly.
–Tighten both adjusters further by one notch at a
time.
Measure at least 4 points on drive bevel gear periph-
ery.
1. Bearing cap bolt

DIFFERENTIAL (REAR) 7F-19
7) Measure preload of pinion bearing with spring balance (1) or
torque wrench (2) and check composite preload of pinion
bearing and side bearing.
Composite preload of pinion bearing and side bearing
: 1.1 – 2.0 N·m (11.0 – 20.0 kg-cm, 9.5 – 17.4 lb-in.)
Spring measure reading with special tool
: 19.5 – 35.5 N (1.95 – 3.55 kg, 4.30 – 7.83 lb)
Special tool
(D) : 09922-76560
8) Torque bearing cap bolts (2) to specification and install bear-
ing lock plates.
Tightening torque
Lock plate bolt (b) : 12 N·m (1.2 kg-m, 9.0 lb-ft)
Bearing cap bolt (c) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
9) As final step, check gear tooth contact as follows.
a) After cleaning 10 drive bevel gear teeth, paint them with
gear marking compound evenly by using brush or sponge
etc.
b) Turn gear to bring its painted part in mesh with drive bevel
pinion and turn it back and forth by hand to repeat their con-
tact.
c) Bring painted part up and check contact pattern, referring
to following chart. If contact pattern is not normal, readjust
or replace as necessary according to instruction in chart. NOTE:
Before taking measurement with spring balance (1) or
torque wrench (2), check for smooth rotation by hand.
On measuring preload, rotate the drive bevel pinion
about 1 rotation per 2 seconds.
3. Universal joint flange
4. Socket with adapter
1. Lock plate bolt
NOTE:
Be careful not to turn drive bevel gear more than one full
revolution, for it will hinder accurate check.
1. Brush
“A”: Paint gear marking compound evenly

7F-20 DIFFERENTIAL (REAR)
TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY
NORMAL
HIGH CONTACT
Pinion is positioned too far from the center of drive
bevel gear.
4) Increase thickness of pinion height adjusting
shim and position pinion closer to gear center.
5) Adjust drive bevel gear backlash to specifica-
tion.
LOW CONTACT
Pinion is positioned too close to the center of drive
bevel gear.
1) Decrease thickness of pinion height adjusting
shim and position pinion farther from gear cen-
ter.
2) Adjust drive bevel gear backlash to specification.
If adjustment is impossible, replace differential carrier.
1) Check seating of bevel gear or differential case.
(Check bevel gear for runout).
2) If adjustment is impossible, replace drive bevel gear & pinion
set or differential carrier.
Replace drive bevel gear & pinion set or differential case.

DIFFERENTIAL (REAR) 7F-21
10) Upon completion of gear tooth contact check in Step 9),
caulk flange nut (2) with caulking tool (1) and hammer.
Tightening Torque Specification
Required Service Material
Fastening partTightening torque
Nm kg-m lb-ft
Differential oil level/filler plug 50 5.0 36.5
Differential oil drain plug 28 2.8 20.5
Propeller shaft flange nuts 60 6.0 43.5
Differential carrier bolts 55 5.5 40.0
Bevel gear bolts 105 10.5 76.0
Bearing cap bolts 85 8.5 61.5
Lock plate bolts 12 1.2 9.0
Differential case screws 9 0.9 6.5
MaterialRecommended SUZUKI product
(Part Number)Use
Thread lock cement THREAD LOCK CEMENT
SUPER 1322
(99000-32110)Bevel gear bolts
Differential case bolts
Bevel gear mating surface
Propeller shaft flange bolt
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Oil seal lips
Sealant SUZUKI BOND NO. 1215
(99000-31110)Rear differential drain plug
Mating surface of differential housing
Mating surface of rear axle housing

7F-22 DIFFERENTIAL (REAR)
Special Tool
09900-20606 09900-20701 09913-61510 09913-65135
Dial gauge Magnetic stand Bearing puller Bearing puller
09922-76570 09913-75510 09913-85230 09922-66021
Attachment Bearing installer Bearing removing jig Flange holder
09922-75222 09922-76560 09924-74510 09925-18011
Preload checking tool Preload checking tool Installer attachment Bearing installer
09926-68310 09926-78311-002 09926-78320 09927-66010/J-23082-01
Bearing installer Pinion mounting dummy
(See NOTE.)Mounting dummy Oil pump aligner

DIFFERENTIAL (REAR) 7F-23
09928-06510 09930-40113 09930-40120 09944-66020
Differential torque
checking toolRotor holder Attachment Bearing installer
09951-16060 09951-18210 09951-46010
Lower arm bush remover Oil seal remover &
installer No. 2Drive shaft oil seal
installer
NOTE:
This tool is constituent of tools with 09926-78311.

7F-24 DIFFERENTIAL (REAR)

BODY ELECTRICAL SYSTEM 8-1
6F1
6F2
6G
6H
6K
7A
8
6K
7C1
7D
7E
7F
8A
8D
8E
9
10
10A
10B
SECTION 8
BODY ELECTRICAL SYSTEM
Wiring System
(Harnesses, Connectors, Fuses, Relay, Switches, Grounds, System Circuit Diagram) .......... Section 8A
Lighting System .............................................................................................................................. Section 8B
Instrumententation and Driver Information .................................................................................. Section 8C
Windows, Mirrors, Security and Locks ......................................................................................... Section 8D
Immobilizer Control System............................................................................................................Section 8F
CONTENTS
General Description .......................................... 8-3

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in FOREWORD of this manual.