1999 SUZUKI GRAND VITARA J20 engine

YH4
GRAND
VITARA
7C1-12 CLUTCH
(C)
1
ªAº, (a)1
2
1. Flywheel
2. Bolt
1. Clutch cover
INSTALLATION
NOTE:
Before assembling, make sure that flywheel surface and pres-
sure plate surface have been cleaned and dried thoroughly.
1) Install flywheel to crankshaft and tighten bolts to which sealant
is applied to specification.
Special Tool
(A): 09924-17810
ªAº: Sealant 99000-31110
Tightening Torque
(a): 78 N
.m (7.8 kg-m, 56.5 lb-ft) (G16 engine)
(a): 70 N
.m (7.0 kg-m, 50.5 lb-ft) (J20 and H25 engines)
2) Using special tool (B), install input shaft bearing to flywheel.
Special Tool
(B): 09925-98210
3) Aligning clutch disc to flywheel center by using special tool (C),
install clutch cover and bolts. Then tighten bolts to specification.
NOTE:

While tightening clutch cover bolts, compress clutch disc
with special tool (C) by hand so that disc centered.

Tighten cover bolts little by little evenly in diagonal order.
Special Tools
(A): 09924-17810
(C): 09923-36330 (G16 engine)
(C): 09923-36320 (J20 and H25 engines)
Tightening Torque
(b): 23 N
.m (2.3 kg-m, 16.5 lb-ft)

YH4
GRAND
VITARA
7C1-14 CLUTCH
09917-58010 (G16 engine)
09923-73210
(J20 and H25 engines)
Bearing remover09923-36330 (G16 engine)
09923-36320
(J20 and H25 engines)
Clutch center guide09924-17810
Flywheel holder09925-98210
Input shaft bearing installer
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN.mkg-mlb-ft
Flare nut161.611.5
Master cylinder nut131.39.5
Lock nut101.07.5
Flywheel boltsG16 engine787.856.5Flywheel boltsJ20 and H25 engines707.050.5
Clutch cover bolts232.316.5
Operating cylinder bolt505.036.5
Clutch hose union bolt232.316.5
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium grease
SUZUKI SUPER GREASE A
(99000-25010)
Clutch master cylinder clevis pin.

Release fork.

Push rod tip of operating cylinder.
SUZUKI SUPER GREASE I
(99000-25210)Input shaft spline front end.
Clutch fluid
(Brake fluid)DOT3 or SAE J1703

Clutch reservoir.

Clutch master cylinder.

Clutch operating cylinder.
SealantSUZUKI BOND No.1215
(99000-31110)Flywheel bolts
SPECIAL TOOLS

YH4
GRAND
VITARA
1. Wood block
2. Dash panel
t: 45 mm / 1.8 in.
H: 200 mm / 8 in.
W: 100 ± 150 mm / 4 ± 6 in.
1. Transmission jack
2. Engine rear mounting member
3. Gear shift lever case
4. Bolt
TRANSFER 7D-5
TRANSFER ASSEMBLY
Dismounting and remounting of transfer and transmission together
as a unit is described in Section 7A for Manual Transmission or 7B1
for Automatic Transmission, but it is also possible to dismount and
remount transfer assembly by itself as described below.
DISMOUNTING
IN ENGINE ROOM
1) Disconnect negative (±) cable from battery.
2) Remove distributor assembly (if equipped).
3) Place wood block between engine and dash panel so that it
serves as stopper when engine, transmission and transfer unit
hangs down as rear mounting member is removed.
CAUTION:
Make sure to use wood block to prevent contact which
may occur between dash panel and CMP sensor case
(G16), CMP sensor (J20) or intake manifold (H25), and fan
and shroud.
IN CABIN
1) Remove console box.
2) Remove shift lever of transmission and transfer.
ON LIFT
1) Drain transfer oil.
2) Remove rear propeller shaft.
3) Remove front propeller shaft.
4) Disconnect exhaust center pipe.
5) Disconnect speed sensor coupler.
6) Place transmission jack and remove mounting member.
7) Lower transmission jack gradually and check to ensure that
wood block serves as stopper between engine and dash panel.
8) Remove bolts for gear shift lever case.
9) Pull off breather hose.

YH4
GRAND
VITARA
1. 4WD switch
2. Transfer
3. Blank
4. Blank
5. ECM or PCM
6. Glove box7. Air pump assembly
8. Actuator
9. Axle lock clutch
10. Free axle hub
11. 4WD indicator lamp
7E-2 DIFFERENTIAL (FRONT)
4WD CONTROL SYSTEM
When the 4WD switch is turned ON by shifting the transfer shift lever, ECM (PCM) (G16 and J20 engine models)
or 4WD controller (H25 engine model) actuates (energizes) the air pump assembly. Then positive pressure is sent
from the air pump assembly to the actuator installed to the differential case and causes the axle lock clutch and
the free axle hub in the differential case to be engaged, resulting in the 4WD mode. Only when running in the 4WD
mode, front axles are joined to differential case, and they become free when 2WD mode is used (or when transfer
shift lever is shifted to N position), thereby reducing the power loss.

YH4
GRAND
VITARA
7E-6 DIFFERENTIAL (FRONT)
STEPACTIONYESNO
1Turn ON ignition switch (but engine at stop) and
check malfunction indicator lamp.
Does lamp light up?Go to step 2.A trouble has
occurred at some
place. Repair it
referring to
MALFUNCTION
INDICATOR LAMP
(ªCHECK ENGINEº
LAMP) CHECK in
DIAGNOSIS of
SECTION 6.
2Check 4WD switch circuit.
Turn ignition switch ON and check that voltage
between terminal C51-2-18 and terminal C51-3-17
(ground) for G16 / J20 (terminal C51-1-11 and terminal
C51-3-26 (ground) for H25) is as follows.

When transfer shift lever is in N or 2H: 10 ± 14 V

When transfer shift lever is in 4L or 4H: 0 ± 1 V
Is the check result satisfactory?Go to step 3.Check 4WD switch
(refer to SECTION
7A), ªB / Orº and ªBº
circuits of 4WD
switch.
If OK, substitute a
known-good ECM
(PCM) and recheck.
3Check power supply.
1) Turn ignition switch ON.
2) Check voltage between C51-2-7 and C51-3-17
(ground) for G16 / J20 (C51-1-15 and C51-3-26
(ground) for H25). The check results should be as
follows.

When transfer shift lever is in N or 2H: 0 ± 1 V

When transfer shift lever is in 4L or 4H: 10 ± 14 V
Is the check result satisfactory?Go to step 4.Check ªRº circuit. If
it is OK, substitute a
known-good ECM
(PCM) and recheck.
4Check air pump assembly circuit.
1) Check for proper connection to air pump
assembly at all terminals.
2) Turn ignition switch ON.
3) Check voltage between C51-2-27 and C51-3-17
(ground) for G16 / J20 (C51-1-18 and C51-3-26
(ground) for H25). The check result should be as
follows.

When transfer shift lever is in 2H or N: 0 ± 1 V

When transfer shift lever is in 4L or 4H
(more than 4 seconds after shifted to 4L or 4H):
10 ± 14 V
Is the check result satisfactory?Go to step 5.Check air pump
assembly referring
to ªON-VEHICLE
SERVICEº, and then
ªPº circuit.
If OK, substitute a
known-good ECM
(PCM) and recheck.
5Check 4WD indicator lamp circuit.
1) Turn ignition switch ON.
2) Check voltage between E61-19 and C51-3-17
(ground) for G16 / J20 (C51-1-7 and C51-3-26
(ground) for H25). The check result should be as
follows.

When transfer shift lever is in 2H or N: 10 ± 14 V

When transfer shift lever is in 4L or 4H: 0 ± 1 V
Is the check result satisfactory?4WD control system
is in good condition.Check ªOr / Bº circuit
(including indicator
lamp and
combination meter).
If OK, substitute a
known-good ECM
(PCM) and recheck.

YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-7
1
1. ECM (PCM); viewed from harness side
4WD CONTROL CIRCUIT INSPECTION
Voltage Check [G16 and J20 engine models]
Check for input or output voltage (voltage between each circuit and
body ground) of ECM (PCM) with ECM (PCM) connector con-
nected and ignition switch turned ON.
TER-
MINALCIRCUITWIRE
COLORNORMAL
VOLTAGECONDITION
E6110 ± 14 VTransfer shift lever: 2H or NE61-
194WD Indicator lampOr / B0 ± 1 V4 seconds after transfer shift lever shifted
to 4H or 4L
C51 2Air pump assembly0 ± 1 VTransfer shift lever: 2H or NC51-2
-7(Pump motor and release
valve)R10 ± 14 V1 seconds after transfer shift lever shifted
to 4H or 4L
C51-24WD switchB/Or10 ± 14 VTransfer shift lever: 2H or N
-184WD switchB/Or0 ± 1 VTransfer shift lever: 4H or 4L
C51-
3-17GroundB/Bl0 ± 1 V±
C51 2Airpumpassembly0 ± 1 VTransfer shift lever: 2H or NC51-2
-27
Air um assembly
(pressure switch)P10 ± 14 V4 seconds after transfer shift lever shifted
to 4H or 4L

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).