engine removal SUZUKI GRAND VITARA 2002 2.G Service User Guide

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-65
1. Drain plug
2. Propeller shaft
1. Oiler (with transmission fluid)
2. Solenoid valve
3. BatteryA: Hole (Should be dry)
B: Exhausting fluid Terminal Arrangement of PCM Coupler
(Viewed from harness side)
WITH BATTERY VOLTAGE WITHOUT BATTERY VOLTAGE
H25 Engine
Shift solenoid valve ± A (#1)C51-1-6
Shift solenoid valve ± B (#2)C51-1-1
TCC (Lock-up) solenoid valveC51-1-2
REMOVAL
1) Pull out dipstick and lift up vehicle.
2) With engine cooled, remove drain plug from oil pan and drain
A / T fluid.
3) Install drain plug with gasket.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
4) Remove exhaust pipe bracket and disconnect front propeller
shaft from front differential (if equipped).
5) Remove oil pan bolts.
6) Remove oil pan.
7) Remove oil tubes.
8) Remove solenoid valve No.1 (shift solenoid valve A and B) or so-
lenoid valve No.2 (TCC solenoid valve).
OPERATION CHECK
Whenever shift solenoid valves and TCC (lock-up) solenoid valve
are removed from transmission, verify their valve function physical-
ly before they are reinstalled.
1) Apply oiler to solenoid valve and give compression by hands
and then check to be sure that transmission fluid from oiler does
not come out of holes in solenoid valve when battery voltage is
not conducted.
2) Under the same conditions as above, conduct battery voltage
and then make sure that fluid comes out with vigor.
NOTE:

If fluid does not come out with vigor in above step 2 in-
spection, do not re-use that solenoid valve.

Figure at the left shows shift solenoid valve check.
Check TCC solenoid valve also in the same way.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-67
1. Oil cooler pipes
2. Union gaskets
3. Pipe bolt
OIL COOLER PIPES
REMOVAL
1) Lift up vehicle.
2) Make sure to wash dirt off from around pipe joints.
3) With engine is cool, loosen oil cooler pipe union bolts with oil out-
let union locked and remove oil cooler pipes from oil outlet
unions and hoses.
NOTE:
To avoid fluid leakage, plug open ends of oil outlet unions
and hoses right after they are disconnected.
INSTALLATION
1) Use new union gaskets and connect oil cooler pipes to oil outlet
unions.
2) Connect hoses to pipes and clamp them securely.
3) Tighten union bolts to specified torque with oil outlet union
locked.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)
4) Tighten pipe bolt securely.
5) Check A / T fluid level according to procedure described in ªFluid
Levelº section.
Add if necessary.
6) Check for fluid leakage after warming up A / T.

YH4
GRAND
VITARA
7C1-10 CLUTCH
(B)1
12
(A)
1. Input shaft bearing
2. Flywheel
3. Clutch disc
4. Clutch cover
5. Bolt
6. Release bearing
7. Clutch release fork
8. Boot
9. Clip
10. Clutch release fork support
1. Bolt
2. Clutch cover
1. Input shaft bearing
UNIT REPAIR
CLUTCH COVER, CLUTCH DISC AND FLYWHEEL
DISMOUNTING / REMOUNTING
Refer to SECTION 7A ªDismounting / Remounting of Trans Unitº.
REMOVAL
1) Hold flywheel stationary with special tool (A) and remove clutch
cover bolts, clutch cover and clutch disc.
Special Tool
(A): 09924-17810
2) Pull out input shaft bearing by using special tool (B) and wrench.
Special Tool
(B): 09917-58010 (G16 engine)
(B): 09923-73210 (J20 and H25 engines)
3) Remove release bearing and release fork.

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.

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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
8C-10 INSTRUMENTATION / DRIVER INFORMATION
G16
J20
H25
1. ECT sensor
1
ENGINE COOLANT TEMP. (ECT) METER AND
SENSOR
ENGINE COOLANT TEMPERATURE (ECT) METER
INSPECTION
1) Disconnect Y/W lead wire going to ECT sensor.
2) Turn ignition switch ON, and check that ECT meter indicates
COOL.
3) Turn ignition switch OFF.
4) Ground Y/W lead wire through a 3.4 W test bulb (1) as illustrated.
5) Turn ignition switch ON, and check that bulb light up and pointer
(2) moves to hot side.
6) If ECT meter shows no operation, repair or replace defective
parts.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
REMOVAL AND INSTALLATION
Refer to ECT SENSOR in ON-VEHICLE SERVICE in Section 6E1
(for G16 and J20) or Section 6E2 (for H25) of this manual for details.

YH4
GRAND
VITARA
G16
J20
H25
1. Oil pressure switch
INSTRUMENTATION / DRIVER INFORMATION 8C-11
INSPECTION
1) Warm up ECT sensor (1) observing resistance between sensor
terminal (2) and sensor unit (1). Resistance should be de-
creased with increase of its temperature.
2) Check resistance between sensor terminal (2) and sensor unit
(1) shown below. If check result is not as specified, replace sen-
sor.
Temperature
Resistance
50
C (122
F)136 ± 216

OIL PRESSURE LIGHT
OIL PRESSURE SWITCH
REMOVAL AND INSTALLATION
Refer to OIL PRESSURE CHECK in Section 6A1 (for G16), Section
6A2 (for H25), and Section 6A4 (for J20) of this manual for details.
INSPECTION
1) Disconnect oil pressure switch (1) lead wire.
2) Check for continuity between oil pressure switch terminal (2)
and cylinder block (3) as shown.
During Engine Running
No continuity
At Engine StopContinuity
If check result is not as specified, replace oil pressure switch (1).

YH4
GRAND
VITARA
1. Side body
2. Fender
3. Pad
1. Side body
2. Pad
3. Knife
9-22 BODY SERVICE
1. Front fender
2. Front fender lining
3. Fender attaching bolts
4. Fender lining attaching screws
FRONT FENDER
REMOVAL
1) Remove front bumper.
2) Remove fender splush guard (H25 engine).
3) Remove front fender lining.
4) Remove front fender.
INSTALLATION
1) Remove pad from side body and (or) fender, using care not to
damage painted surface.
2) Attach new pad cutting appropriately size temporarily and adjust
height with a knife so that fender becomes flush with side body.
3) Reverse removal procedure for installation.
NOTE:
If paint on fender bolt is peeled off, be sure to apply paint
again.

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.