1998 SUZUKI GRAND VITARA Differential lock

YH4
GRAND
vol.1
0A
0B
1A
1B
3
3A
3B1
3C
3C1
3D
3E
3F
4A2
4B
5
6
7A5A
5B
5C
5E1
6A1
6A2
6A4
6B
6C
6E1
6E2
6F1
6F2
6G
6G1
6H
6K
7A1
7B1
7C1
7D
7E
7F
8
8B
8C
8D
8G
9
10
10A
8A
10B
6-1ENGINE
General Information and
Diagnosis (G16 / J20)
General Information and
Diagnosis (H25)
Engine Mechanical (G16)
Engine Mechanical (H25)
Engine Mechanical (J20)
Engine Cooling
Engine Fuel
Engine and Emission Control
System (SFI for G16 / J20)
Engine and Emission Control
System (SFI for H25)
Ignition System (G16)
Ignition System (J20 / H25)
Cranking System
(Reduction Type)
Cranking System
(No-Reduction Type)
Charging System
Exhaust System
TRANSMISSION, CLUTCH
AND DIFFERENTIAL
Manual Transmission (Type 1)
Manual Transmission (Type 2)
Automatic Transmission
Clutch (Hydraulic Type)
Transfer
Differential (Front)
Differential (Rear)
BODY ELECTRICAL SYSTEM
Wiring Diagram
Lighting System
Instrumentation / Driver
Information
Windows, Mirrors, Security
and Lock
Immobilizer Control System
BODY SERVICE
RESTRAINT SYSTEM
Seat Belt
Air Bag System GENERAL INFORMATION
General Information
Maintenance and Lubrication
TABLE OF CONTENTS TABLE OF CONTENTS SECTIONSECTION
0B
HEATING AND AIR
CONDITIONING
Heater and Ventilation
Air Conditioning
STEERING, SUSPENSION,
WHEELS AND TIRES
Front End Alignment
Power Steering (P / S) System
Steering Wheel and Column
(Not Equipped with Air Bag)
Air Bag Steering Wheel
and Column
Front Suspension
Rear Suspension
Wheel and Tires
1A
3A 0A
1B
3B1
3C
3C1
3D
3E
3F36A16
6A2
6A4
6B
6C
6E1
6E2
6F1
DRIVE SHAFT / PROP. SHAFT
Front Drive Shaft / Shaft
Bearing, Oil Seal
Propeller Shaft
BRAKES
Brake Pipe / Hose / Master
Cylinder
Front Brakes
Parking and Rear Brakes
Antilock Brake System
4A2
4B
5
5A
5B
5C
5E1
6F2
6G
6G1
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8
8A
8B
8C
8D
8G
9
10
10A
10B
6-1
NOTE:
The screen toned Sections 6 ± 6K are included in Volume 2 and Section 8A is in Wiring
Diagram Manual.

YH4
GRAND
VITARA
1. Front differential housing
2. Rear axle
housing
When using floor jack:
Front
Rear
1. Safety stands
0A-20 GENERAL INFORMATION
In raising front or rear vehicle end off the floor by jacking, be sure
to put the jack against the center portion of the front suspension
frame or rear axle housing.
WARNING:

Never apply jack against suspension parts (i.e., stabilizer,
etc.) or vehicle floor, or it may get deformed.

If the vehicle to be jacked up only at the front or rear end,
be sure to block the wheels on ground in order to ensure
safety.
After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on the
vehicle raised on jack alone.
To perform service with either front or rear vehicle end jacked up,
be sure to place safety stands under chassis frame so that body is
securely supported. And then check to ensure that chassis frame
does not slide on safety stands and the vehicle is held stable for
safety's sake.

YH4
GRAND
VITARA
MAINTENANCE AND LUBRICATION 0B-3
Interval:
This interval should be
judged by
This table includes services as scheduled up to 90,000 km
(54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry
out the same services at the same intervals respectively.
This interval should be judged by
odometer reading or months,Km (x 1,000)153045607590g
whichever comes first.Miles (x 1,000)91827364554
Months122436486072
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 transmissionFluid level±I±I±I
Fluid changeReplace 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
NOTES:
ªRº : Replace or change
ªIº : Inspect and correct, replace or lubricate if necessary

YH4
GRAND
VITARA
MAINTENANCE AND LUBRICATION 0B-25
Steering

Check to ensure that steering wheel is free from in-
stability, or abnormally heavy feeling.

Check that the vehicle does not wander or pull to
one side.
Engine

Check that engine responds readily at all speeds.

Check that engine is free from abnormal noise and
abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting sys-
tem are free from abnormal noise and abnormal
vibration or any other abnormal condition.
Meters and Gauge
Check that speedometer, odometer, fuel meter, tem-
perature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set fan switch lever to ªHIº position for this check.
RECOMMENDED FLUIDS AND LUBRICANTS
Engine oilSG, SH or SJ (Refer to engine oil viscosity chart in item 1-4)
Engine coolant (Ethylene glycol
base coolant)ªAntifreeze / Anticorrosion coolantº
Brake fluidDOT 3
Manual transmission oilRefer to Section 7A or 7A1Transfer oilRefer to Section 7A or 7A1.
Differential oil (front & rear)Refer to Section 7E or 7F.
Automatic transmission fluid and
Power steering fluidRefer to Section 3B1 or 7B1.
Door hingesEngine oil or water resistance chassis greaseHood latch assemblyEngine oil or water resistance chassis grease
Key lock cylinderSpray lubricant

YH4
GRAND
VITARA
1. Brake pipe flare nut
2. Brake pipe
3. Brake back plate
1. Bearing retainer
2. Parking brake shoe
lever
3. Clearance1. Nut 1. Wheel speed sensor
2. Wheel speed sensor coupler
3. Wheel speed sensor harness clamp
4. Wheel speed sensor harness
3E-16 REAR SUSPENSION
REAR AXLE HOUSING
REMOVAL
1) Drain differential gear oil.
Carry out steps 2) to 7) and 15) to 18) on both right and left
wheels.
Note that left wheel and its related parts are used in illustrations
in this section.
2) Remove rear brake drum. (Refer to steps 1) to 5) of BRAKE
DRUM REMOVAL.)
3) Disconnect brake pipe from wheel cylinder. With right side wheel
cylinder, disconnect 2 brake pipes.
4) For vehicle with ABS, disconnect wheel speed sensor coupler
and remove wheel speed sensor with its harness.
5) Remove rear wheel bearing retainer nuts from rear axle hous-
ing.
6) Check to ensure that there is clearance between rear wheel
bearing retainer and parking brake shoe lever. If no clearance
is found, loosen cable locking nut further to obtain clearance.

YH4
GRAND
VITARA
REAR SUSPENSION 3E-23
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mKg-mlb-ft
Shock absorber lock nut292.921.0
Shock absorber nut292.921.0
Shock absorber lower nut858.561.5
Lower rod bolt and nut
Upper rod bolt and nut909.065.0
Lateral rod bolt
Differential carrier nut555.540.0
Propeller shaft nut505.036.5
Brake pipe flare nut161.611.5
Bearing retainer nut232.317.0
Differentiation gear oilFiller plug505.036.5g
filler & drain plugDrain plug272.716.0
Wheel nut10010.072.5
REQUIRED SERVICE MATERIALS
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)Oil seal lip
Brake fluidDOT 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 oilFor gear oil information, refer to
SECTION 7F of this manualDifferential gear
(Refer axle housing.)

YH4
GRAND
VITARA
7B1-4 AUTOMATIC TRANSMISSION (4 A / T)
ItemSpecifications
Torque
conver-
terType
Stall torque ratio3-element, 1-step, 2-phase type (with TCC (lock-up)
mechanism)
2.4 (G16 engine) 2.0 (J20 engine) 1.9 (H25 engine)
Oil
pumpType
Drive systemTrochoid type oil pump
Engine driven
TypeForward 4-step, reverse 1-step planetary gear type
Shift position
ªPº range Gear in neutral, output shaft fixed,engine start
ªRº range Reverse
ªNº range Gear in neutral, engine start
ªDº range Forward 1st
2nd
3rd
4th (O / D)
(O / D ON) automatic gear change
ªDº range Forward 1st
2nd
3rd
(O / D OFF) automatic gear change
ª2º range (Normal mode) Forward 1st
2nd  3rd automatic gear
change
(Power mode) Forward 2nd  3rd automatic gear
change and fixed at 2nd gear
ªLº range Forward 1st  2nd  3rd reduction, and fixed at 1st gear
GearEngine typeG16 engineJ20 / H25 engines
change
device1st (low gear)2.8262.826device2nd (second gear)1.4931.493
Gear3rd (top gear)1.0001.000Gear
ratio4th (overdrive
4th gear)0.7300.689
Reverse (reverse
Reverse gear)2.7032.703
Control elements
Wet type multi-disc clutch 3 sets. . . . . . . . . .
Wet type multi-disc brake 4 sets. . . . . . . . . .
One-way clutch 3 sets. . . . . . . . . . . . . . . . . . .
TransferHi: 1.000 Lo: 1.816 (4WD model only)
Final gear reduction
ratio (Differential)5.125 (G16 engine) 4.875 (J20 / H25 engines)
Lubrica-
tionLubrication systemForce feed system by oil pump
CoolingCooling systemRadiator assisted cooling (water-cooled)
Fluid usedAn equivalent of DEXRON
III

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.