1999 SUZUKI GRAND VITARA Stall

YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-13
1. Mounting bracket bolt
2. Mounting bracket R
3. Differential housing
4. Mounting front bolt
1. Differential housing
2. Mounting front bolt3. Mounting bracket L
4. Mounting bracket bolt
1. Mounting bracket
1. Mounting bracket L
2. Bush3. Mounting bracket R
A: Slit alignment 45
4
2
3
1
2
REMOVAL AND INSTALLATION
Differential Mountings
1) Lift up vehicle and turn steering wheel all way to the right.
2) Separate mounting bracket R from differential housing by re-
moving bolts from its lower part.
3) Remove mounting bracket R by removing mounting front bolt
from its upper part.
4) Remove mounting bracket L by removing upper and lower fas-
tening bolts.
5) Check conditions of each bush. If it is damaged or deteriorated,
drive it out with special tools and press for replacement.
Special Tool
(A): 09951-26010
(B): 09951-16080
6) Position slit in each bush as shown when press-fitting it.

YH4
GRAND
VITARA
7E-14 DIFFERENTIAL (FRONT)
1. Mounting bracket R
2. Mounting bracket L
1. Bolt and nut
2. Differential carrier
3. Cross member
4. Bolt
5. Differential rear mounting assembly
7) Position each bush to bracket as shown.
Length ªaº: 3.0 mm (0.12 in.)
8) Use following torque for reinstallation.
Tightening Torque
(a): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
REAR MOUNTING
(For front differential carrier)
1) Lift up vehicle and remove mounting assembly by removing 2
bolts and nuts from differential carrier side and 2 bolts from cross
member side.
2) Check mounting rubber for damage or deterioration and replace
as necessary.
3) Use following torque for reinstallation.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

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
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.

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
BODY ELECTRICAL SYSTEM 8-3

When installing the wiring harness, fix it with clamps so that no
slack is left.

When installing vehicle parts, be careful so that the wiring har-
ness is not interfered with or caught by any other part.

To avoid damage to the harness, protect its part which may con-
tact against a part forming a sharp angle by winding tape or the
like around it.

When replacing a fuse, make sure to use a fuse of the specified
capacity. Use of a fuse with a larger capacity will cause a damage
to the electrical parts and a fire.

Always be careful not to handle electrical parts (computer, relay,
etc.) in a rough manner or drop them.

YH4
GRAND
VITARA
Terminal
Wire ColorSwitch Position
Terminal
Switch Position
Wire Color
HEAD
OFFHI
PASS SMALL
8B-6 LIGHTING SYSTEM
ON-VEHICLE SERVICE
HEADLIGHTS
HEADLIGHT SWITCH (IN COMBINATION SWITCH)
INSPECTION
1) Disconnect negative cable at battery.
2) Disconnect combination switch lead wire coupler.
3) Check for continuity between terminals at each switch position
shown below. If check result is not as specified, replace switch.
Lighting Switch
ELTH
WGR
OFF
SMALL
HEAD
Dimmer & Passing Switch
EDHLHUHF
W/BR/WRR/B
Passing (PASS)
Low Beam
High Beam (HI)
REMOVAL AND INSTALLATION
For vehicle without air bag system, refer to Section 3C COMBINA-
TION SWITCH, and for vehicle with air bag system, refer to Section
3C1 CONTACT COIL AND COMBINATION SWITCH ASSEMBLY.
REMOVAL
1) Disconnect negative cable at battery.
2) Remove front grille.
3) Disconnect harness and couplers from headlight assembly.
4) Remove three bolts and pull headlight assembly off vehicle.
INSTALLATION
Reverse removal procedure for installation.
Make sure to follow HEADLIGHT AIMING WITH SCREEN and aim
headlight after installation.

YH4
GRAND
VITARA
LH steering vehicle shown
X-X:Horizontal center line of headlight bulbs
A-A:Vertical center line of left headlight bulb
B-B:Vertical center line of right headlight bulb1. Screen
2. For right / left adjustment
3. For up / down adjustment
(for vehicle without leveling system)
4. For up / down adjustment
(for vehicle with leveling system)
5. Headlight leveling actuatorHOT
SPOT LH. HEADLIGHT RH. HEADLIGHT
LIGHTING SYSTEM 8B-7
BULB REPLACEMENT
WARNING:
Don't touch when the bulb is hot.
1) Disconnect negative cable at battery.
2) Disconnect harness from bulb.
3) Remove socket cover and bulb.
4) Replace bulb and install in reverse removal procedure.
HEADLIGHT AIMING WITH SCREEN
NOTE:

Unless otherwise obligated by local regulations, adjust
headlight aiming according to following procedure.

After replacing headlight, be sure to perform its aiming.

When inspecting and adjusting headlight with leveling sys-
tem, make sure to set the leveling switch to ª0º position with
IG switch ON.
Before adjustment, make sure the following.
a) Place vehicle on a flat surface in front of blank wall as below
ahead of headlight surface.
Clearance ªaº: 10 m (32.8 ft)
b) Adjust air pressure of all tires to a specified value respectively.
c) Bounce vehicle body up and down by hand to stabilize suspen-
sion.
d) Carry out one driver aboard.
Driver's weight: 75 kg (165 lb)
Adjustment
1) Check to see if hot spot (high intensity zone) of each main (low)
beam axis falls as illustrated.
Clearance ªHº: Approx. 130 mm (5.15 in.)
2) If headlight aiming is not set properly, align it to specification by
adjusting aiming screw and aiming gear.