Engine bolt torque SUZUKI GRAND VITARA 1999 2.G Service Owner's Manual

YH4
GRAND
VITARA
7B1-76 AUTOMATIC TRANSMISSION (4 A / T)
12) Remove engine to transmission nuts.
13) Disconnect connectors from VSS, output speed sensor, input
speed sensor, TR switch, shift & TCC solenoid valves and oth-
er electrical parts, and release their wire harness from clamps.
14) Apply transmission jack and take off rear mounting member by
removing its bolts.
15) With transmission (and transfer if equipped) assembly held up
on jack, move them to the rear and lower them including torque
converter.
WARNING:
Transmission (and transfer if equipped) assembly may
tilt rearward on jack. It is recommended to use an auxil-
iary arm of jack for the purpose of safety.
AFTER DISMOUNTING
WARNING:
Be sure to keep transmission (and transfer if equipped) as-
sembly horizontal throughout the work. Should they be
tilted, torque converter may fall off and cause personal inju-
ry and A / T fluid may flow out.
1) Remove breather hoses.
2) Remove transfer by removing its bolts, if equipped.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-77
ªAº, (d)
1. Drive plate
2. Torque converter
3. Case right stiffener (if equipped)
4. Automatic transmissionTightening torque
(a): 50 N´m
5.0 kg-m
36.5 lb-ft
(b): 65 N´m
6.5 kg-m
47.0 lb-ft
(c): 85 N´m
8.5 kg-m
61.5 lb-ft
(d): 78 N´m
7.8 kg-m
56.5 lb-ft
1. Automatic transmission
2. Transfer (4WD)
3. Engine rear mounting
4. Engine rear mounting member Tightening torque
(a): 50 N´m (5.0 kg-m, 36.5 lb-ft) ªAº: Sealant 99000-31110
REMOUNTING
WARNING:
When moving transmission assembly with torque convert-
er equipped in it, be sure to keep it horizontal. Tilting it with
its front facing down may allow converter to fall off. Where-
by an injury may result.
For remounting, reverse dismounting procedure. Use specified
torque as given below and left.
Tightening torque
N.mkg-mlb-ft
Exhaust No.1 pipe to manifold
bolts or nuts505.036.5
Muffler to exhaust No.2 pipe
nuts606.043.5
Universal joint flange bolts and
nuts505.036.5

Oil filler tube bolts

Select cable bracket bolts232.317.0

Clamp wiring harness and hoses securely.

Refer to ªSelect Cableº section for adjusting procedure of select
cable.

Refer to ªA / T Throttle Cableº section for tuning of A / T throttle
cable.

Follow fluid level check procedure for refilling automatic transmis-
sion fluid and its level adjusting.

Connect battery, and confirm that engine and transmission func-
tion acceptably.

When remounting drive plate, use specified bolts.

YH4
GRAND
VITARA
7B1-78 AUTOMATIC TRANSMISSION (4 A / T)
ON-VEHICLE
SERVICE MOUNTING
EXTERNAL
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.
TIGHTENING TORQUE SPECIFICATIONS
Fastening portion
Tightening torque
Fastening portion
N´mkg-mlb-ft
Automatic transmission fluid drain plug232.317.0
Transfer oil filler / level and drain plugs232.317.0
Transmission case plug171.712.5
Manual select lever nut131.39.5
Manual select cable nut70.75.5
Manual selector assembly bolts181.813.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts
Engine rear mounting member bolts
Transmission case right stiffener bolts
505.036.5
Universal joint flange bolts and nuts505.036.5
Torque converter mounting bolts656.547.0
Adapter case or extension case bolts
(G16 engine)353.525.5
Adapter case or extension case bolts
(J20 / H25 engines)424.230.0
Transmission range switch lock bolt5.50.554.0
Oil pipe union bolts353.522.5
Drive plate bolts787.856.5
Interlock cable clamp screw2.20.221.5
Interlock cable outer mounting nut131.39.5

YH4
GRAND
VITARA
7C1-12 CLUTCH
(C)
1
ªAº, (a)1
2
1. Flywheel
2. Bolt
1. Clutch cover
INSTALLATION
NOTE:
Before assembling, make sure that flywheel surface and pres-
sure plate surface have been cleaned and dried thoroughly.
1) Install flywheel to crankshaft and tighten bolts to which sealant
is applied to specification.
Special Tool
(A): 09924-17810
ªAº: Sealant 99000-31110
Tightening Torque
(a): 78 N
.m (7.8 kg-m, 56.5 lb-ft) (G16 engine)
(a): 70 N
.m (7.0 kg-m, 50.5 lb-ft) (J20 and H25 engines)
2) Using special tool (B), install input shaft bearing to flywheel.
Special Tool
(B): 09925-98210
3) Aligning clutch disc to flywheel center by using special tool (C),
install clutch cover and bolts. Then tighten bolts to specification.
NOTE:

While tightening clutch cover bolts, compress clutch disc
with special tool (C) by hand so that disc centered.

Tighten cover bolts little by little evenly in diagonal order.
Special Tools
(A): 09924-17810
(C): 09923-36330 (G16 engine)
(C): 09923-36320 (J20 and H25 engines)
Tightening Torque
(b): 23 N
.m (2.3 kg-m, 16.5 lb-ft)

YH4
GRAND
VITARA
7C1-14 CLUTCH
09917-58010 (G16 engine)
09923-73210
(J20 and H25 engines)
Bearing remover09923-36330 (G16 engine)
09923-36320
(J20 and H25 engines)
Clutch center guide09924-17810
Flywheel holder09925-98210
Input shaft bearing installer
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN.mkg-mlb-ft
Flare nut161.611.5
Master cylinder nut131.39.5
Lock nut101.07.5
Flywheel boltsG16 engine787.856.5Flywheel boltsJ20 and H25 engines707.050.5
Clutch cover bolts232.316.5
Operating cylinder bolt505.036.5
Clutch hose union bolt232.316.5
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium grease
SUZUKI SUPER GREASE A
(99000-25010)
Clutch master cylinder clevis pin.

Release fork.

Push rod tip of operating cylinder.
SUZUKI SUPER GREASE I
(99000-25210)Input shaft spline front end.
Clutch fluid
(Brake fluid)DOT3 or SAE J1703

Clutch reservoir.

Clutch master cylinder.

Clutch operating cylinder.
SealantSUZUKI BOND No.1215
(99000-31110)Flywheel bolts
SPECIAL TOOLS

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. Bolt
2. Transfer assembly
1. Bolt
2. Engine rear mounting3. Transfer assembly
1. Bolt
2. Transfer assembly
3. Transmission jack
7D-6 TRANSFER
IN CABIN
Remove gear shift lever case and then remove transfer center case
bolt.
ON LIFT
1) Remove transfer mounting (engine rear mounting) by removing
bolts.
2) Apply transmission jack to transfer to support it.
3) Remove couplers for 4WD / 4WD-LOW switches lead.
4) Remove transfer front case bolts.
5) With transfer assembly supported with transmission jack, slide
it rearward and when it is apart from transmission, lower it.
REMOUNTING
For remounting, reverse dismounting procedure described above,
noting following.

Be sure to use specified torque for tightening.

Clamp wiring and breather hose securely.

Clamp shift lever boot securely.

Fill specified gear oil by specified amount.

Connect battery and check for function.

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
1. (a)
1. (a)
1
11
Tightening Torque
(a): 23 N.m (2.3 kg-m, 17.0 lb-ft)
1. Bolt
BODY SERVICE 9-33
INSTRUMENTATION AND DRIVER INFORMATION
INSTRUMENT PANEL
WARNING:
See WARNING at the beginning of this section.
REMOVAL
1) Disconnect negative cable at battery.
2) Disable air bag system. Refer to ªDisabling Air Bag Systemº in
Section 10B.
3) Remove console box.
4) Remove glove box and column hole cover.
5) Disconnect wires and cables from heater unit and blower motor
assembly.
6) Remove steering column assembly. Refer to Section 3C1.
7) Disconnect speedometer connector and remove speedometer
assembly. If equipped with air bag, disconnect wire coupler at
SDM and air bag ground terminal for air bag.
8) Remove engine hood opener.
9) Disconnect couplers which need to be disconnected for removal
for instrument panel.
10) Remove instrument panel mounting screws.
11) Remove instrument panel mounting bolt.
12) Remove instrument panel.
CAUTION:
For vehicle with Air Bag, instrument panel could not be re-
moved with SDM coupler connected and ground terminal
installed.
Use care not to damage Air Bag harness.
INSTALLATION
1) Install instrument panel by reversing removal procedure, noting
the following items.

When installing each part, be careful not to catch any cable or
wiring harness.

When installing steering column assembly, refer to ªAIR BAG
STEERING COLUMN INSTALLATIONº in Section 3C1.
2) Adjust control cables. (Refer to Section 1A ªHEATER CON-
TROL CABLESº.)
3) Enable air bag system. Refer to ªEnabling Air Bag Systemº in
Section 10B.