1999 SUZUKI GRAND VITARA tightening torque specification

YH4
GRAND
VITARA
Diagnostic Trouble Code (DTC) Table 5E1-14. . .
System Circuit 5E1-15. . . . . . . . . . . . . . . . . . . . . . .
Table ± A ªABSº Warning Lamp Circuit
Check ± Lamp does not come ªONº
at ignition switch on 5E1-16. . . . . . . . . . . . . . . . . .
Table ± B ªABSº Warning Lamp Circuit
Check ± Lamp comes ªONº steady 5E1-17. . . .
Table ± C ªABSº Warning Lamp Circuit
Check ± The lamp flashes continuously
while ignition switch is on5E1-18 . . . . . . . . . . . . . .
Table ± D Code (DTC) is not Outputted
even with Diag. Switch Terminal
Connected to Ground 5E1-19. . . . . . . . . . . . . . . .
Table ± E EBD Warning Lamp (Brake
Warning Lamp) Check-lamp Comes
ªONº Steady 5E1-20. . . . . . . . . . . . . . . . . . . . . . . .
DTC 15 ± G Sensor Circuit 5E1-21. . . . . . . . . . . .
DTC 21, 22, 25, 26, 31, 32, 35 or 36
± Wheel Speed Sensor Circuit 5E1-23. . . . . . . .
DTC 41, 45 or 56 ± Solenoid Circuit 5E1-26. . . . .
DTC 57 ± Solenoid and Pump Motor
Power Source Circuit 5E1-27. . . . . . . . . . . . . . . .
DTC 61 ± ABS Pump Motor Circuit 5E1-28. . . . . .
DTC 63 ± ABS Fail-Safe Relay Circuit 5E1-29. . .
DTC 71 ± ABS Control Module 5E1-30. . . . . . . . .
ON-VEHICLE SERVICE5E1-31 . . . . . . . . . . . . . . . .
Precaution 5E1-31. . . . . . . . . . . . . . . . . . . . . . . . . . .
ABS Hydraulic Unit Operation Check 5E1-31. . . .
ABS Hydraulic Unit / Control Module
Assembly 5E1-32. . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic unit inspection 5E1-32. . . . . . . . . . . . . Removal 5E1-32. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5E1-33. . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Speed Sensor 5E1-34. . . . . . . . . . . .
Output voltage inspection 5E1-34. . . . . . . . . . . .
Removal 5E1-35. . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor inspection 5E1-35. . . . . . . . . . . . . . . . . .
Sensor rotor inspection 5E1-35. . . . . . . . . . . . . .
Installation 5E1-36. . . . . . . . . . . . . . . . . . . . . . . . .
Front Sensor Rotor 5E1-36. . . . . . . . . . . . . . . . . . .
Removal 5E1-36. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5E1-36. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wheel Speed Sensor 5E1-37. . . . . . . . . . . .
Output voltage inspection 5E1-37. . . . . . . . . . . .
Removal 5E1-37. . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor inspection 5E1-38. . . . . . . . . . . . . . . . . .
Sensor rotor inspection 5E1-38. . . . . . . . . . . . . .
Installation 5E1-38. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Sensor Rotor 5E1-39. . . . . . . . . . . . . . . . . . . .
Removal 5E1-39. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5E1-39. . . . . . . . . . . . . . . . . . . . . . . . .
G Sensor 5E1-40. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5E1-40. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 5E1-40. . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5E1-40. . . . . . . . . . . . . . . . . . . . . . . . .
Transfer 4WD Switch 5E1-41. . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS5E1-41 . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS5E1-42 . . . . . . . . . . . . . . . . . . . . . .
5E1-2 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
GENERAL DESCRIPTION
The ABS (Antilock Brake System) controls the fluid pressure applied to the wheel cylinder of each brake from the
master cylinder so that each wheel is not locked even when hard braking is applied. This ABS is a 4-wheel type
which controls the fluid pressure applied to the wheel cylinder of each of the four brakes to prevent each wheel
from getting locked.
The component parts of this ABS includes following parts in addition to those of the conventional brake system.

Wheel speed sensor which senses revolution speed of each wheel and outputs its signal.

In this ABS, ABS hydraulic unit (actuator assembly), ABS control module, pump motor relay and fail-safe relay
are combined as one component.

ABS control module which sends operation signal to ABS hydraulic unit to control fluid pressure applied to each
wheel cylinder based on signal from each wheel speed sensor so as to prevent wheel from locking.

ABS hydraulic unit which operates according to signal from ABS control module to control fluid pressure applied
to wheel cylinder of each of 4 wheels.

Fail-safe (solenoid valve) relay which supplies power to solenoid valve in ABS hydraulic unit and pump motor
relay.

Pump motor relay which supplies power to pump motor in ABS hydraulic unit.

ªABSº warning lamp which lights to inform abnormality when system fails to operate properly.

G sensor which detects body deceleration speed. (For 4WD model only)
This ABS is equipped with Electronic Brake force Distribution (EBD) system that controls a fluid pressure of rear
wheels to best condition, which is the same function as that of proportioning valve, by the signal from wheel sensor
independently of change of load due to load capacity and so on. And if the EBD system fails to operate properly,
the brake warning lamp lights to inform abnormality.

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VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-41
(d)
TRANSFER 4WD SWITCH
For removal, inspection and installation of this switch, refer to
SWITCHES in Section 7A.
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Brake pipe flare nut: (a)161.611.5
ABS hydraulic unit nut: (b)212.115.5
ABS hydraulic unit bracket bolt: (c)101.07.5
Wheel speed sensor bolt(Front): (d)232.317.0Wheel s eed sensor bolt(Rear): (e)212.115.5
Parking lever assy mounting bolt: (f)232.317.0

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GRAND
VITARA
7A
MANUAL TRANSMISSION (TYPE 1) 7A-1
TYPE 1
GENERAL DESCRIPTION7A- 1 . . . . . . . . . . . . . .
DIAGNOSIS7A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7A- 3 . . . . . . . . . . . . . . . .
Gear Oil 7A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Control Levers 7A- 4. . . . . . . . . . . . . . . . . . .
Switches 7A- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Mounting 7A- 8. . . . . . . . . . . . . . . .
Dismounting of Trans. Unit 7A- 9. . . . . . . . . . . . .
Remounting of Trans. Unit 7A-12. . . . . . . . . . . . . Extension Case (2WD MODEL) 7A-13. . . . . . . .
Extension Case Oil Seal
(2WD MODEL) 7A-13. . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7A-14 . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7A-14 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7A-14 . . . . . .
SPECIAL TOOL7A-14 . . . . . . . . . . . . . . . . . . . . . . .
As the aluminum case is sealed with liquid type gas-
ket, it is necessary to use genuine sealant or its equiv-
alent on its mating surfaces when reassembling it.
Also, the case fastening bolts must be tightened to
specified torque by means of the torque wrench and
tightening over or below the specified torque should
be avoided.
The description under ON-VEHICLE SERVICE in this
section covers a part of the TYPE 2 manual transmis-
sion and the transfer. The transfer is next to the trans-
mission as well, but their gear boxes are independent
and each of them has its own drain and level / filler
plugs for the oil change or the level check.
For the repair procedure of the transfer unit, refer to
Section 7D.
SECTION 7A
MANUAL TRANSMISSION
(TYPE 1)
CONTENTS
GENERAL DESCRIPTION
The manual transmission consists of the input shaft,
main shaft, countershaft and reverse gear which are
installed in the aluminum case. Its gears are of for-
ward five speeds in synchro mesh and reverse one
speed in constant mesh system.
The main shaft gears are held by the needle bearings
and on them the synchronizer rings and synchronizer
sleeve & hubs are assembled.
The gear shift lever case is located at the upper be-
hind the transmission case and has a cam which pre-
vents direct gear shift from the 5th speed gear to the
reverse gear.

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GRAND
VITARA
Viscosity chart
SAE
1. Reverse idle gear shaft bolt
(DO NOT LOOSEN IT)
MANUAL TRANSMISSION (TYPE 1) 7A-3
ON-VEHICLE SERVICE
GEAR OIL
INSPECTION AND CHANGE
1) Before changing or inspecting oil, be sure to stop engine and lift
vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage ex-
ists, correct or repair it.
3) Drain old oil and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
NOTE:

It is highly recommended to use SAE 75W-90 gear oil.

Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage and
status of breather hoses.

If water or rust is mixed in drained oil, be sure to check
breather hose and boot of transmission and transfer.
Gear Oil Specification
Oil grade: API GL-4
Viscosity: SAE 75W-85, 75W-90 or 80W-90
Oil Capacity:
Transmission 1.5 liters (3.2 / 2.6 US / Imp. pt)
Transfer 1.7 liters (3.6 / 3.0 US / Imp. pt)
4) Torque drain plug and level / filler plug as specified below after
applying sealant to its thread.
CAUTION:

Transmission oil must not be poured through gear shift
control lever part.

Do not loosen or remove reverse idle gear shaft bolt.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

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GRAND
VITARA
MANUAL TRANSMISSION (TYPE 1) 7A-13
1
1. Extension case
2. Select return spring bolt
3. Select return spring (short)
4. Select return spring (long)
5. Guide pin
6. Speed sensor assembly 62,ªAº,(a)
3,ªAº
5,ªAº
5,ªAº
4,ªAº
2,ªAº,(a)
1. Oil seal
2. Extension case
ªBºªAº
1
1
22
EXTENSION CASE (2WD MODEL)
DISASSEMBLY
1) Remove oil seal.
2) Remove select return spring bolts and then springs and guide
pins.
3) Remove speed sensor assembly.
REASSEMBLY
1) Install oil seal.
2) After applying grease, install select guide pins, select return
springs and spring bolts and torque them to specification.
ªAº: Grease 99000-25010
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
After installing, check to make sure that each pin moves smooth-
ly.
3) Install speedometer driven gear case assembly to extension
case.
EXTENSION CASE OIL SEAL (2WD MODEL)
REMOVAL AND INSTALLATION
1) Remove propeller shaft referring to SECTION 4B.
2) Using screwdriver, remove oil seal.
3) Using special tool (A) and plastic hammer, press fit new oil seal
into extension case till oil seal contacts stepped part of extension
case as shown. Be sure to apply grease to oil seal lip.
ªAº: Grease 99000-25010
Special Tool
(A): 09951-16060
4) Clean and inspect sliding portion of propeller shaft front end
(where oil seal contacts) before installation and if even small
dent or scratch exists, correct and clean it again.
Then apply grease inside splines of propeller shaft.
ªBº: Grease 99000-25010
5) Install propeller shaft referring to SECTION 4B.

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GRAND
VITARA
7A-14 MANUAL TRANSMISSION (TYPE 1)
09951-16060
Oil seal installer
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
Oil filler / level and drain plugs232.317.0
Control lever boot cover bolts60.64.0
4WD switch202.014.5
Back up light switch (Type 1)202.014.5
Back up light switch (Type 2)454.532.5
Control lever locating bolts171.712.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts and nut505.036.5
Exhaust center pipe to manifold nuts505.036.5
Muffler to exhaust center pipe bolts505.036.5
Universal joint flange bolts505.036.5
Select return spring bolts232.317.0
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)
Shift control lever.

Select return springs, bolts and guides.
Thread lock cementTHREAD LOCK CEMENT
SUPER 1333B (99000-32020)
Shift control lever locating bolts.
SealantSUZUKI BOND No. 1215
(99000-31110)
Oil Drain and filler / level plugs.
SPECIAL TOOL

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GRAND
VITARA
7A1
MANUAL TRANSMISSION (TYPE 2) 7A1-1
TYPE 2
GENERAL DESCRIPTION7A1-1 . . . . . . . . . . . . . .
DIAGNOSIS7A1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7A1-3 . . . . . . . . . . . . . . . .
Gear Oil 7A1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Control Levers 7A1-4. . . . . . . . . . . . . . . . . . .
Switches 7A1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Mounting 7A1-4. . . . . . . . . . . . . . . . Dismounting / Remounting of
Trans. Unit 7A1-4. . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7A1-4 . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7A1-5 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7A1-5 . . . . . .
The manual transmission consists of the input shaft,
main shaft, counter shaft and reverse gear which are
installed in the aluminum and castings cases. Its
gears are of forward five speeds in synchro mesh and
reverse one speed in sliding idler gear arrangement
system.
The main shaft gears are held by the needle bear-
ings and on them the synchronizer rings and syn-
chronizer sleeve & hubs are assembled.
The gear shift lever case is located at the upper be-
hind the transmission case and has a cam which pre-
vents direct gear shift from the 5th speed gear to the
reverse gear.As the aluminum and castings cases are sealed with
liquid type gasket, it is necessary to use genuine seal-
ant or its equivalent on its mating surfaces when reas-
sembling them. Also, the case fastening bolts must be
tightened to specified torque by means of the torque
wrench and tightening over or below the specified
torque should be avoided.
The description under ON-VEHICLE SERVICE in this
section covers the transfer partially which is next to
the transmission as well, but their gear boxes are in-
dependent and each of them has its own drain and
level / filler plugs for the oil change or the level check.
For the repair procedure of the transfer unit, refer to
Section 7D.
SECTION 7A1
MANUAL TRANSMISSION
(TYPE 2)
CONTENTS
GENERAL DESCRIPTION

YH4
GRAND
VITARA
Viscosity chart
SAE
Temperature
1. Drain plug
2. Oil level / filler plug
MANUAL TRANSMISSION (TYPE 2) 7A1-3
ON-VEHICLE SERVICE
GEAR OIL
INSPECTION AND CHANGE
1) Before changing or inspecting oil, be sure to stop engine and lift
vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage ex-
ists, correct or repair it.
3) Drain old oil and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
NOTE:

It is highly recommended to use SAE 75W-90 gear oil.

Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage and
status of breather hoses.

If water or rust is mixed in drained oil, be sure to check
breather hose and boot of transmission and transfer.
Gear Oil Specification
Oil grade: API GL-4
Viscosity: SAE 75W-85, 75W-90 or 80W-90
Oil Capacity:
Transmission 2.6 liters (5.5 / 4.6 US / Imp. pt)
Transfer 1.7 liters (3.6 / 3.0 US / Imp. pt)
4) Torque drain plug and level / filler plug as specified below after
applying sealant to thread of plug (c).
CAUTION:
Transmission oil must not be poured through gear shift
control lever part.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 38 N´m (3.8 kg-m, 27.5 lb-ft)
(b): 23 N´m (2.3 kg-m, 17.0 lb-ft)