differential SUZUKI GRAND VITARA 2001 2.G Owners Manual

Foreword
This manual contains only different service information of the following applicable model as compared with
SQ416/SQ420/SQ625 SERVICE MANUAL.
Applicable model: GRAND VITARA XL-7
Therefore, whenever servicing the above applicable model, consult this manual first. And for any section, item
or description not found in this manual, refer to the related manual below.
When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials (lubricant, sealants, etc.) as specified in each description.
All information, illustrations and specifications contained in this literature are based on the latest product infor-
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
RELATED MANUAL:
© COPYRIGHT SUZUKI MOTOR CORPORATION 2001Manual Name Manual No.
SQ416/SQ420/SQ625 Service Manual 99500-65D10-01E
SQ416/SQ420/SQ625 Unit Repair Manual for Manual Transmis-
sion, Automatic Transmission, Transfer and Differential99501-65D01-01E
GRAND VITARA XL-7 Wiring Diagram Manual 99512-52D00-015

Table of Contents
GENERAL INFORMATION TRANSMISSION, CLUTCH AND
DIFFERENTIAL0A7A1
General Information0A
0B7B1
Maintenance and Lubrication0B
Manual Transmission7A1
7C1
HEATING AND AIR CONDITIONING
Automatic Transmission7B1
1A7D
Heater and Ventilation1A
Clutch7C1
1B7E
Air Conditioning1B
Transfer7D7F
STEERING, SUSPENSION, WHEELS
AND TIRESDifferential (Front)7E
3
Differential (Rear)7F
3A8
Steering, Suspension, Wheels and Tires3 ELECTRICAL SYSTEM3B18A
Front End Alignment3A
Electrical System8
3C18B
Power Steering (P/S) System3B1
Wiring Diagram8A3D8C
Air Bag Steering Wheel and Column3C1
Lightening System8B3E8D
Front Suspension3D
Instrumentation / Driver Information8C
3F8E
Rear Suspension3E
Windows, Mirrors, Security and Lock8D
8G
Wheels and Tires3F
Cruise Control System8E
4A2
DRIVE SHAFT AND PROPELLER SHAFT
Immobilizer control system (if equipped)8G4B9
Front Drive Shaft / Shaft Bearing,
Oil Seal4A2BODY SERVICE
Body Service9
510
Propeller Shaft4B RESTRAINT SYSTEM
5A10A
BRAKE SYSTEM
Restraint System10
5B10B
Brakes5
Seat Belt10A
5C
Brake Pipe / Hose / Master Cylinder5A
Air Bag System10B
5E2
Front Brake5B
Parking and Rear Brake5C
6-1
Antilock Brake System (ABS)5E2
6A2
ENGINE
6B
General Information and
Diagnosis (H27 Engine)6-1
6C
6E2
Engine Mechanical (H27 Engine)6A2
6F2
Engine Cooling6B
6G
Engine Fuel6C
6H
Engine and Emission Control System
(SFI For H27 Engine)6E2
6K
Ignition System (H27 Engines)6F2
Cranking System6G
Charging System6H
Exhaust System6K
NOTE:
For the screen toned Sections in the above table, refer to the same section of the Related Manuals
mentioned in FOREWORD of this manual.

MAINTENANCE AND LUBRICATION 0B-3
IntervalKm (× 1,000) 153045607590
Miles (× 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
CHASSIS AND BODY
6-1. Clutch (pedal and fluid level)–I–I–I
6-2.Brake discs and pads (thickness, wear, damage) IIIIII
Brake drums and shoes (wear, damage)–I–I–I
6-3. Brake hoses and pipes (leakage, damage, clamp)–I–I–I
6-4. Brake fluid–R–R–R
6-5. Brake lever and cable (damage, stroke, operation) Inspect at first 15,000 km (9,000 miles)
only
6-6.Tires (wear, damage, rotation) IIIIII
6-7.Wheel discs (damage) IIIIII
6-8. Suspension system (tighteness, damage, rattle, breakage)–I–I–I
6-9. Propeller shafts and drive shafts––I––I
6-10. Manual transmission oil (leakage, level) (I: 1st 15,000 km only) I–R––R
6-11. Automatic transmission Fluid level –I–I–I
Fluid change Replace every 165,000 km (99,000
miles)
Fluid hose–––R––
6-12. Transfer oil (leakage, level) I–I–I–
6-13. Differential oil (leakage, level) (R: 1st 15,000 km only) R or I–I–I–
6-14. Steering system (tighteness, damage, breakage, rattle)–I–I–I
6-15.Power steering (if equipped) IIIIII
6-16. All latches, hinges and locks–I–I–I
6-17. Air conditioning filter (if equipped)–IR–IR
NOTE:
 “R”: Replace or change
 “I”: Inspect and correct, replace or lubricate if necessary

0B-4 MAINTENANCE AND LUBRICATION
Maintenance Recommended under Severe Driving Conditions
If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is
recommended that applicable maintenance operation be performed at the particular interval as given in the
chart below.
Severe condition code :
A: Repeated short trips E: Repeated short trips in extremely cold weather
B: Driving on rough and/or muddy roads F: Leaded fuel use
C: Driving on dusty roads G: – – – – – –
– –
D: Driving in extremely cold weather
and/or salted roadsH: Trailer towing (if admitted)
Severe
Condition CodeMaintenanceMaintenance
OperationMaintenance Interval
– B CD – – –ITEM 1-1
Drive belt (V-rib belt)IEvery 15,000 km
(9,000 miles) or 12 months
REvery 45,000 km
(27,000 miles) or 36 months
A – CDEF – HITEM 1-4
Engine oil and oil filterREvery 5,000 km
(3,000 miles) or 4 months
– B– – – – – –ITEM 1-6
Exhaust pipe mountingsIEvery 15,000 km
(9,000 miles) or 12 months
– – C – – – – – ITEM 3-1
Air cleaner filter *1IEvery 2,500 km
(1,5000 miles)
REvery 30,000 km
(18,000 miles) or 24 months
ABC–EF–HITEM 2-1
Spark plugsNickel plug REvery 10,000 km
(6,000 miles) or 8 months
Iridium plug REvery 30,000 km
(18,000 miles) or 24 months
– B – D E – – HITEM 6-9
Propeller shafts and drive shafts IEvery 15,000 km
(9,000 miles) or 12 months
– B – – E – – HITEM 6-10, 6-12, 6-13
Manual transmission,
transfer and differential oilREvery 30,000 km
(18,000 miles) or 24 months
– B – – E – – HITEM 6-11
Automatic transmission fluid REvery 30,000 km
(18,000 miles) or 24 months
– B – – – – – – ITEM 6-8
Suspension bolts and nutsTEvery 15,000 km
(9,000 miles) or 12 months
– B C D – – – HITEM 6-7
Wheel bearingIEvery 15,000 km
(9,000 miles) or 12 months
– – CD – – – –ITEM 6-17
Air conditioning filter *2
(if equipped)IEvery 15,000 km
(9,000 miles) or 12 months
REvery 45,000 km
(27,000 miles) or 36 months
NOTE:
“I”: Inspect and correct, replace or lubricate if necessary
”R”: Replace or change
”T”: Tighten to the specified torque
*1: Inspect or replace more frequently if necessary.
*2: Clean or replace more frequently if the air from the air conditioning decreases.

REAR SUSPENSION 3E-5
Rear Axle Shaft Inner Oil Seal
INSTALLATION
1) Using special tool drive in oil seal until it contacts oil seal pro-
tector in axle housing.
Special tool
(A) : 09924-74510
(B) : 09944-88210
“A” : Grease 99000-25010
“B” : Sealant 99000-31110
2) For procedure hereafter, refer to steps 6) to 11) of “INSTAL-
LATION” under “REAR AXLE SHAFT” in the service manual
mentioned in the FOREWORD of this manual.
Rear Axle Housing
INSTALLATION
For Step 1) to 4), 7) and 9) to 30), refer to the same section in the
Service Manual mentioned in the FOREWORD of this manual.
3) Clean mating surfaces of axle housing (1) and differential
carrier and apply sealant “A” to housing side.
“A” : Sealant 99000-31110
4) Install differential carrier assembly to axle housing and
tighten carrier bolts to specified torque.
Tightening torque
Differential carrier bolt (a) :
55 N·m (5.5 kg-m, 40.0 lb-ft) NOTE:
Make sure that oil seal is free from inclination as it is
installed.
Refer to the figure so that oil seal is installed in proper
direction.
1. Hammer 4. Oil seal
2. Rod 5. Body center
3. Oil seal protector

3E-6 REAR SUSPENSION
5) Apply thread lock cement to thread of propeller shaft flange
bolt if reused. Install propeller shaft to joint flange aligning
match marks and torque flange nuts to specification.
“A” : Cement 99000-32110
Tightening torque
Propeller shaft nut (a) :
60 N·m (6.0 kg-m, 43.5 lb-ft)
Tightening Torque Specification
Required Service Material
Fastening partTightening torque
Nm kg-m lb-ft
Shock absorber nut 29 2.9 21.0
Shock absorber lower nut 85 8.5 61.5
Lower rod bolt and nut 100 10.0 72.5
Upper rod bolt and nut 100 10.0 72.5
Lateral rod bolt 100 10.0 72.5
Differential carrier bolt 55 5.5 40.0
Propeller shaft nut 60 6.0 43.5
Brake pipe flare nut 16 1.6 11.5
Bearing retainer nut 50 5.0 36.5
Differentiation gear oil filler & drain plug (filler plug) 50 5.0 36.5
Differentiation gear oil filler & drain plug (drain plug) 27 2.7 16.0
Wheel nut 100 10.0 72.5
Wheel speed sensor bolt 21 2.1 15.5
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Oil seal lip
Brake fluid DOT 3Brake reservoir tank
Sealant SUZUKI BOND NO. 1215
(99000-31110)Joint seam of axle and brake back plate
Joint seam of bearing retainer and brake
back plate
Joint seam of differential carrier and axle
housing
Drain plug
Mating surface of oil seal and axle housing
Gear oil For gear oil information, refer to Section 7FDifferential gear (Rear axle housing)
Thread lock
cementTHREAD LOCK CEMENT SUPER 1322
(99000-32110)Rear propeller shaft flange bolts

FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL 4A2-3
6) Install circlip (1) by using snap ring plier.
7) Apply grease to entire surface of cage.
Use joint grease in tube included in spare part.
8) Insert cage into outer race and fit circlip (1) into groove of
outer race.
9) Apply grease in tube included in spare part to inside of outer
race, and fit boot to outer race.
Fill up inside of boot with joint grease.
“A” : Joint Grease
(about 90 - 100 g (3.2 - 3.5 oz) (Black))
10) Fitting boot to outer race, adjust so that measurements “b”
and “c” become as shown in the figure.
Differential side (RH) boot installation position
(Length “b”) : 196.8 - 206.8 mm (7.75 - 8.14 in.)
Differential side (LH) boot installation position
(Length “c”) : 127.5 - 137.5 mm (5.02 - 5.41 in.)
11) Before fixing boot band, insert screwdriver into boot on joint
side and allow air to enter boot so that air pressure in boot
becomes the same as atmospheric pressure.
12) Clamp boot band. Check boots for distortion or dent.
CAUTION:
Position opening of circlip “a” so that it will not be lined
up with a ball.
[A] : Differential side (RH)
[B] : Differential side (LH)

4A2-4 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL
Required Service Material
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Drive shaft oil seal
Wheel spindle part of differential
side drive shaft (RH)
Sealant SEALING COMPOUND 366E
(99000-31090)Axle shaft drive flange

5C-6 PARKING AND REAR BRAKE
4) Tighten brake back plate nuts to specified torque.
Tightening torque
Brake back plate nut (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
5) Install wheel cylinder, and tighten wheel cylinder bolts and
brake pipe flare nut (or nuts) to specified torque.
Tightening torque
Wheel cylinder bolt :
13.5 N·m (1.35 kg-m, 10.0 lb-ft)
Brake pipe flare nut : 16 N·m (1.6 kg-m, 12.0 lb-ft)
6) Install parking brake cable (3) to brake back plate (1) and
tighten parking brake cable nut (2) to specified torque.
Tightening torque
Parking brake cable nut (a) : 10 N·m (10 kg-m, 7.5 lb-ft)
7) Install brake shoes, referring to steps 1) to 4) of “INSTALLA-
TION” under “BRAKE SHOE” in this section.
8) Install brake drum. Refer to steps 1) to 2) of “INSTALLA-
TION” under “BRAKE DRUM” in this section.
9) Refill differential housing with new specified gear oil. Refer to
“ON-VEHICLE SERVICE” in Section 7F for refill.
10) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation, refer to “BLEEDING BRAKE” in Section
5).
11) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nut (b) : 100 N·m (10.0 kg-m, 72.5 lb-ft)
12) Upon completion of all jobs, depress brake pedal with about
30 kg (66 lbs) load 3 to 10 times so as to obtain proper drum-
to shoe clearance.
Adjust parking brake cable. (For adjustment, refer to “PARK-
ING BRAKE CHECK AND ADJUSTMENT” in Section 5).
13) Tighten parking brake lever cover screws.
14) Check to ensure that brake drum is free from dragging and
proper braking is obtained. Then remove vehicle from hoist
and perform brake test (foot brake and parking brake).
15) Check each installed part for oil leakage.
(a)

6A2-20 ENGINE MECHANICAL (H27 ENGINE)
12) Install oil pan and oil pump strainer.
Refer to “OIL PAN AND OIL PUMP STRAINER” in this sec-
tion.
13) Install cylinder head cover.
Refer to “CYLINDER HEAD COVER” in this section.
14) Install exhaust manifold.
Refer to “EXHAUST MANIFOLD” in this section.
15) Install radiator outlet pipe, radiator, cooling fan and water
hose.
Refer to “COOLING WATER PIPES OR HOSES”, “RADIA-
TOR” and “COOLING FAN AND FAN CLUTCH” in Section
6B.
16) Install throttle body and intake manifold.
Refer to “THROTTLE BODY AND INTAKE MANIFOLD” in
this section.
17) Adjust water pump drive belt tension.
Refer to “COOLING FAN BELT TENSION CHECK AND
ADJUSTMENT” in Section 6B.
18) Adjust power steering pump drive belt tension.
Refer to “POWER STEERING PUMP DRIVE BELT” in Sec-
tion 3B1.
19) Adjust accelerator cable play and A/T throttle cable play.
Refer to “ACCELERATOR CABLE ADJUSTMENT” and “A/T
THROTTLE CABLE ADJUSTMENT (A/T VEHICLE)” in Sec-
tion 6E2.
20) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
21) Refill engine with engine oil, referring to “ENGINE OIL
CHANGE” in Section 0B.
22) Refill cooling system referring to “COOLING SYSTEM
FLUSH AND REFILL” in Section 6B.
23) Refill front differential housing with gear oil if drained, refer-
ring to “MAINTENANCE SERVICE” in Section 7E.
24) Connect negative cable at battery.
25) Check ignition timing and adjust as necessary, referring to
“IGNITION TIMING CHECK AND ADJUSTMENT” in Section
6F2.
26) Verify that there is no fuel leakage, water leakage, oil leak-
age and exhaust gas leakage at each connection.
27) Check wheel alignment, referring to “STEERING ANGLE” in
Section 3A.