cv joint SUZUKI GRAND VITARA 2000 2.G Service Manual Online

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
DIFFERENTIAL (FRONT) 7E-15
A: Match marks
1. Mounting bracket bolt
2. Flange bolt and nut
1. Bolts
1. Mounting bracket bolt
2. Mounting bracket R
3. Differential housing
DISMOUNTING
1) Lift up vehicle and drain oil.
2) Disconnect air hose and breather hose from differential housing.
3) Before removing propeller shaft, give match marks on joint
flange and propeller shaft as shown.
4) Remove propeller shaft flange by removing its 4 bolts and sus-
pend it with cord or the like.
NOTE:
If pull out propeller shaft, transfer oil must be drained be-
fore pulling out.
5) Remove 3 bolts for left mounting bracket and 3 bolts for drive
shaft flange to set left side of differential free.
6) Remove 2 bolts from cross member to set differential rear
mounting free.
7) With differential housing assembly held with transmission jack,
remove mounting bolts on right end of housing.

YH4
GRAND
VITARA
7E-16 DIFFERENTIAL (FRONT)
(a)
(a)
(a)
1. Drive shaft joint R
2. Differential housing3. Transmission jack
4. Screw driver
8) Using 2 large screwdrivers as levers, pull out right side drive
shaft joint from differential and dismount housing assembly from
vehicle.
CAUTION:
During above work, use care not to cause damage to
drive shaft boot.
REMOUNTING
For remounting, reverse dismounting procedure and use following
tightening torque.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
After tightening all fasteners properly, fill hypoid gear oil as speci-
fied and check tightening of plugs with specification.

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
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.

YH4
GRAND
VITARA
1. Differential to rear axle nut
(a)
(a)
DIFFERENTIAL (REAR) 7F-5
REMOUNTING
1) Clean mating surfaces of rear axle and differential assembly and
apply sealant (Suzuki bond 1215) to axle side evenly.
ªAº: Sealant 99000-31110
2) Install differential assembly to axle and fix it with nuts tightened
to specified torque.
Tightening Torque
(a): 55 N
.m (5.5 kg-m, 40.0 lb-ft)
3) Install propeller shaft to joint flange aligning match marks and
torque flange bolts to specification.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
4) Install right and left rear axle shafts and drums.
(Refer to rear axle installation of SECTION 3E and rear brake
drum installation of SECTION 5.)
5) Install wheels.
6) Fill hypoid gear oil as specified and tighten plug to specification.
Lower lift.
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in Foreword of this manual.

YH4
GRAND
VITARA
8
BODY ELECTRICAL SYSTEM 8-1
SECTION 8
BODY ELECTRICAL SYSTEM
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 autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-vehicle Serviceº 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
ªLOCKº 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).
WIRING SYSTEM
(Harnesses, Connectors, Fuses, Relay, Switches, Grounds, System Circuit Diagram)Section 8A . . . . . . .
LIGHTING SYSTEMSection 8B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENTATION AND DRIVER INFORMATIONSection 8C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDOWS, MIRRORS, SECURITY AND LOCKSSection 8D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMMOBILIZER CONTROL SYSTEMSection 8F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS
GENERAL DESCRIPTION8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions in Servicing8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols and Marks8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Color Symbols8-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joint Connector8-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Box and Relay8-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Diagram8-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
Symbol
G : Green
G / Y : Green / Yellow G (Base Color)
G (Base Color)
Y (Stripe Color)G/Y
BODY ELECTRICAL SYSTEM 8-5
WIRE COLOR SYMBOLS
The wire color is abbreviated to the first (or first two) alphabet(s) of
each color.
There are two kinds of colored wire used in this vehicle. One is
single-colored wire and the other is dual-colored (striped) wire.
The single-colored wire uses only one color symbol (i.e. ªGº).
The dual-colored wire uses two color symbols (i.e. ªG / Yº). The first
symbol represents the base color of the wire (ªGº in the figure) and
the second symbol represents the color of the stripe (ªYº in the fig-
ure).
JOINT CONNECTOR (J / C)

Wiring of this vehicle employs joint connector (J / C) which divide
one wire into several different wires or combine several different
wires into one wire.

The joint connector is as shown in the figure.
FUSE BOX AND RELAY
Refer to Section 8A.

YH4
GRAND
VITARA
8B
LIGHTING SYSTEM 8B-1
SECTION 8B
LIGHTING SYSTEM
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 autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº 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
ªLOCKº 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).
CONTENTS
GENERAL DESCRIPTION8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions in Servicing8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols and Marks8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Color Symbols8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joint Connector8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Box and Relay8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Diagram8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights8B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight with Leveling System (If Equipped) 8B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS8B- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights8B- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights with Leveling System (If Equipped) 8B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal and Hazard Warning Lights 8B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance, Tail and License Plate Lights 8B- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back-up Lights8B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lights8B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Fog Light (If Equipped)8B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interior Lights8B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE8B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights8B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights with Leveling System (If Equipped) 8B- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal and Hazard Warning Lights 8B- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Fog Light (If Equipped)8B-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
6
5
1. Headlight assembly
2. Halogen bulb
3. Socket cover
4. Turn signal light bulb
5. Position light bulb
6. Turn signal light bulb socket
7. Position light bulb socket
8B-2 LIGHTING SYSTEM
GENERAL DESCRIPTION
CAUTIONS IN SERVICING
Refer to Section 8.
SYMBOLS AND MARKS
Refer to Section 8.
WIRING COLOR SYMBOLS
Refer to Section 8.
ABBREVIATIONS
Refer to Section 8.
JOINT CONNECTOR
Refer to Section 8.
FUSE BOX AND RELAY
Refer to Section 8.
POWER SUPPLY DIAGRAM
Refer to Section 8.
HEADLIGHTS