Unit repair SUZUKI GRAND VITARA 2002 2.G Service Owner's Guide
[x] Cancel search | Manufacturer: SUZUKI, Model Year: 2002, Model line: GRAND VITARA, Model: SUZUKI GRAND VITARA 2002 2.GPages: 801, PDF Size: 12.15 MB
Page 503 of 801
YH4
GRAND
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
Page 513 of 801
YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-11
1. Differential housing
2. Adjusting screw
3. To air compressor
Actuator
1) Disconnect air hose from pump assembly and install special tool
to air hose as shown in figure. Loosen adjusting screw of special
tool.
Special Tool
(A): 09918-18110
2) Connect compressor air hose to special tool.
Blow air and turn adjusting screw to obtain specified pressure.
Specified pressure: 30.0 kPa (0.3 kg / cm
2, 4.25 psi)
CAUTION:
Do not apply a pressure exceeding 200 kPa (2.0 kg / cm
2,
28.4 psi) which may cause damage to diaphragm.
3) With the vehicle lifted so that both of the front wheels are off the
ground, turn one of the front wheels by hand and check the other
wheel, which should act as described below.
When the pressure from compressor is applied to actuator:
The other front wheel should turn in the direction opposite to
the wheel being turned by hand.
When the pressure from compressor is not applied to actuator:
The other front wheel should remain stationary while the wheel
pushed by hand is turning.
If the result is not satisfactory, inspect differential assembly. Re-
fer to ªINSPECTIONº of SECTION 7E in UNIT REPAIR MANU-
AL.
Page 519 of 801
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
Page 520 of 801
YH4
GRAND
VITARA
7F
DIFFERENTIAL (REAR) 7F-1
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 7F
DIFFERENTIAL (REAR)
CONTENTS
GENERAL DESCRIPTION7F-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS7F-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7F-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Service7F-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismounting7F-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remounting7F-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7F-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS7F-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7F-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION
The differential assembly using a hypoid bevel pinion
and gear is installed to the rear axle. It is set in the con-
ventional type axle housing.
The reduction ratio and differential case vary depend-
ing on transmission or engine type.
Page 524 of 801
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.
Page 546 of 801
YH4
GRAND
VITARA
8C-4 INSTRUMENTATION / DRIVER INFORMATION
DIAGNOSIS
NOTE:
Fuse name (ª º) in the table below is shown on the fuse box cover (Hard Top Model) or the junction box
(Canvas Top Model).
SPEEDOMETER AND VSS
TroublePossible CauseCorrection
Speedometer shows no
operationªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)
VSS faulty
Printed plate in combination meter
faulty
Speedometer faulty
Wiring or grounding faultyReplace fuse to check for short
Replace VSS
Replace printed plate
Replace speedometer
Repair
FUEL METER / FUEL GAUGE UNIT
TroublePossible CauseCorrection
Fuel meter shows no
operationªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)
Fuel gauge unit faulty
Printed plate in combination meter
faulty
Fuel meter faulty
Wiring or grounding faultyReplace fuse to check for short
Replace fuel gauge unit
Replace printed plate
Replace fuel meter
Repair
ENGINE COOLANT TEMP. (ECT) METER AND SENSOR
TroublePossible CauseCorrection
Engine coolant temp.
meter shows no operationªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)
ECT meter faulty
Printed plate in combination meter
faulty
ECT sensor faulty
Wiring or grounding faultyReplace fuse to check for short
Replace ECT meter
Replace printed plate
Replace ECT sensor
Repair
OIL PRESSURE LIGHT
TroublePossible CauseCorrection
Oil pressure warning light
does not light upBulb in combination meter blown
ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)
Printed plate in combination meter
faulty
Oil pressure switch faulty
Wiring or grounding faultyReplace bulb
Replace fuse to check for short
Replace printed plate
Replace oil pressure switch
Repair
Page 551 of 801
YH4
GRAND
VITARA
INSTRUMENTATION / DRIVER INFORMATION 8C-9
1. Exhaust pipe
FUEL METER / FUEL GAUGE UNIT
FUEL METER
INSPECTION
1) Remove rear bumper facing.
2) Detach grommet (3) from vehicle.
3) Disconnect coupler (2) of fuel pump and gauge.
4) Turning switch ON, and check that fuel meter indicates E.
5) Turn ignition switch OFF.
6) Ground Bl / W lead through a 3.4 W test bulb (4) as illustrated.
7) Turn ignition switch ON and check that bulb light up and pointer
(5) moves to F side.
8) If fuel meter shows no operation, repair or replace defective
parts.
FUEL SENDER GAUGE
INSPECTION
1) Remove fuel pump assembly (1) referring to FUEL PUMP RE-
MOVAL in Section 6C.
2) Check resistance between terminals (A) and (B) under each
float position.
Float Position
FuelResistance ()56 model66 modelMeterResistance ()
ªaº88.3 mm
(3.48 in.)51.7 mm
(2.04 in.)F6 ± 8
ªbº157.2 mm
(6.20 in.)139.6 mm
(5.50 in.)1/229.5 ± 35.5
ªcº254.9 mm
(10.0 in.)254.9 mm
(10.0 in.)E94 ± 96
If measured valve is out of specification, replace fuel sender gauge.