1999 SUZUKI GRAND VITARA fun

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-77
ªAº, (d)
1. Drive plate
2. Torque converter
3. Case right stiffener (if equipped)
4. Automatic transmissionTightening torque
(a): 50 N´m
5.0 kg-m
36.5 lb-ft
(b): 65 N´m
6.5 kg-m
47.0 lb-ft
(c): 85 N´m
8.5 kg-m
61.5 lb-ft
(d): 78 N´m
7.8 kg-m
56.5 lb-ft
1. Automatic transmission
2. Transfer (4WD)
3. Engine rear mounting
4. Engine rear mounting member Tightening torque
(a): 50 N´m (5.0 kg-m, 36.5 lb-ft) ªAº: Sealant 99000-31110
REMOUNTING
WARNING:
When moving transmission assembly with torque convert-
er equipped in it, be sure to keep it horizontal. Tilting it with
its front facing down may allow converter to fall off. Where-
by an injury may result.
For remounting, reverse dismounting procedure. Use specified
torque as given below and left.
Tightening torque
N.mkg-mlb-ft
Exhaust No.1 pipe to manifold
bolts or nuts505.036.5
Muffler to exhaust No.2 pipe
nuts606.043.5
Universal joint flange bolts and
nuts505.036.5

Oil filler tube bolts

Select cable bracket bolts232.317.0

Clamp wiring harness and hoses securely.

Refer to ªSelect Cableº section for adjusting procedure of select
cable.

Refer to ªA / T Throttle Cableº section for tuning of A / T throttle
cable.

Follow fluid level check procedure for refilling automatic transmis-
sion fluid and its level adjusting.

Connect battery, and confirm that engine and transmission func-
tion acceptably.

When remounting drive plate, use specified bolts.

YH4
GRAND
VITARA
1. Bolt
2. Transfer assembly
1. Bolt
2. Engine rear mounting3. Transfer assembly
1. Bolt
2. Transfer assembly
3. Transmission jack
7D-6 TRANSFER
IN CABIN
Remove gear shift lever case and then remove transfer center case
bolt.
ON LIFT
1) Remove transfer mounting (engine rear mounting) by removing
bolts.
2) Apply transmission jack to transfer to support it.
3) Remove couplers for 4WD / 4WD-LOW switches lead.
4) Remove transfer front case bolts.
5) With transfer assembly supported with transmission jack, slide
it rearward and when it is apart from transmission, lower it.
REMOUNTING
For remounting, reverse dismounting procedure described above,
noting following.

Be sure to use specified torque for tightening.

Clamp wiring and breather hose securely.

Clamp shift lever boot securely.

Fill specified gear oil by specified amount.

Connect battery and check for function.

YH4
GRAND
VITARA
1. 4WD switch
2. Air pump assembly
3. Pump motor
4. Release valve
5. Pressure switch6. Transfer
7. Front differential
8. Air hose and pipe
9. 4WD indicator lamp
10. To ignition switch
11. ECM or PCM
Operation
(refer to ªComponents and Functionsº)
Power supply
(from ECM or PCM)
DIFFERENTIAL (FRONT) 7E-3
System Circuit and Operation

YH4
GRAND
VITARA
7E-4 DIFFERENTIAL (FRONT)
Components and Functions
ComponentFunction
4WD switch
When the transfer shift lever is shifted to 4L or 4H position, this switch turns ON
and causes the 4WD control system to turn ON, unless it is shifted to N or 2H
within 1 second.
ECM or PCM
When the 4WD switch turns ON [unless it turns OFF within 1 second], this com-
ponent actuates the pump assembly. If the pressure in the air pump assembly
fails to increase higher than the set level even after the pump motor has run more
than 10 seconds, this component stops the motor to protect it.
Air pump assembly

Pump motor

Release valve

Pressure switchThe air pump assembly consists of a pump motor, release valve and a pressure
switch.
Pump motor:
Produces positive pressure which actuates the actuator.
Release valve:
Closes when transfer shift lever is shifted to 4H or 4L so that the positive pressure
is applied to the actuator, and opens when N or 2H to release the pressure to the
atmosphere.
Pressure switch:
Turns ON and OFF depending on the pressure level in the pump assembly
(whether higher or lower than the set pressure level). ECM or PCM detects the
pressure level through this switch.
Differential case assembly

Free axle hub

Axle lock clutch

ActuatorThe free axle hub, axle lock clutch and actuator are installed in the differential
left case. The positive pressure produced in the air pump assembly is applied
to the actuator which then pushes the axle lock clutch to be engaged with the free
axle hub. In this state, the drive force is transmitted to the front axle, resulting in
the 4WD mode.
When the actuator is free from the positive pressure [when it is under the atmo-
spheric pressure], the axle lock clutch is pushed back by the return spring force
and cannot be engaged with the free axle hub, resulting in the 2WD mode.
ª4WDº indicator lampIt lights up when 4WD control system is in the 4WD mode.

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
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-5
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).
WINDSHIELD WIPER AND WASHER
FRONT WIPER AND WASHER
REAR WIPER AND WASHER (IF EQUIPPED)
TroublePossible causeCorrection
Wiper malfunctions
ªWIPER / WASHERº fuse blown (Hard Top
Model)
ªWIPº fuse blown (Canvas Top Model)

Wiper motor faulty

Wiper switch faulty

Wiring or grounding faultyReplace fuse to check for short
Replace motor
Replace switch
Repair
Washer malfunctions
Washer hose or nozzle clogged

ªWIPER / WASHERº fuse blown (Hard Top
Model)
ªWIPº fuse blown (Canvas Top Model)

Washer motor faulty

Washer switch faulty

Wiring faultyClean or repair clogged hose or
nozzle
Replace fuse to check for short
Replace motor
Replace switch
Repair
REAR WINDOW DEFOGGER (IF EQUIPPED)
TroublePossible causeCorrection
Defogger does not work
ªREAR DEFGº fuse blown

Defogger switch faulty

Defogger heat wire faulty

Wiring or grounding faultyReplace fuse to check for short
Replace switch
Repair heat wire
Repair
POWER WINDOW CONTROL SYSTEM
TroublePossible causeCorrection
All power windows do not
operate
ªPOWER WINDOWº fuse blown (Hard Top
Model)
ªP / Wº fuse blown (Canvas Top Model)

Ignition switch faulty

Wiring or grounding faultyReplace fuse to check for short
Replace switch
Repair
Only one power window
does not operate
Power window switch (main or sub) faulty

Power window motor faulty

Window lock switch faulty

Wiring or grounding faultyReplace switch
Replace motor
Replace switch
Repair

YH4
GRAND
VITARA
8G
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-1
GENERAL DESCRIPTION8G- 2 . . . . . . . . . . . . . .
Ignition Key 8G- 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Coil Antenna 8G- 3. . . . . . . . . . . . . . . . . . . . . . . . .
Immobilizer Control Module 8G- 4. . . . . . . . . . . .
ECM/PCM 8G- 4. . . . . . . . . . . . . . . . . . . . . . . . . . .
On-Board Diagnostic System
(Self-Diagnosis Function) 8G- 4. . . . . . . . . . . . .
DIAGNOSIS8G- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions in Diagnosing Troubles 8G- 6. . . . .
Diagnostic Flow Table with monitor coupler> 8G- 9. . . . . . . . . . . . . . . .
Diagnostic Flow Table equipped with monitor coupler> 8G-10. . . . . . .
Diagnostic Trouble Code Check
(Immobilizer Control Module) 8G-11. . . . . . . .
Diagnostic Trouble Code Check
(ECM / PCM) 8G-11. . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code Table 8G-13. . . . . . . . .
TABLE A DTC is not Output
from Diagnostic Output Terminal 8G-14. . . . . . .
TABLE B Immobilizer Indicator Lamp
Check (Immobilizer Indicator Lamp
does not Light at Ignition Switch ON) 8G-15. . .
TABLE C Immobilizer Indicator Lamp
Check (Immobilizer Indicator Lamp
Remains on after Engine Starts) 8G-16. . . . . . .
DTC11 Transponder Code Not Matched8G-17 . .
DTC31 Transponder Code Not
Registered 8G-17. . . . . . . . . . . . . . . . . . . . . . . . .
DTC12 Fault in Immobilizer
Control Module 8G-17. . . . . . . . . . . . . . . . . . . . . .
DTC13 No Transponder Code Transmitted
or Coil Antenna Opened/Shorted 8G-18. . . . . . DTC21 ECM/Immobilizer Control Module
Code Not Matched (Immobilizer Control
Module Side) 8G-20. . . . . . . . . . . . . . . . . . . . . . .
DTC81 (P1623) ECM/Immobilizer
Control Module Code Not Matched
(ECM/PCM Side) 8G-20. . . . . . . . . . . . . . . . . . . .
DTC84 (P1620) ECM/Immobilizer Control
Module Code Not Registered 8G-20. . . . . . . . .
DTC22 Ignition Switch Circuit Open/Short8G-21 . .
DTC23 No ECM/Immobilizer Control
Module Code Transmitted from ECM/
PCM or DLC Circuit Opened/Shorted8G-22 . . . .
DTC83 (P1621) No ECM/Immobilizer
Control Module Code Transmitted from
Immobilizer Control Module or DLC
Circuit Opened/Shorted 8G-22. . . . . . . . . . . . . .
DTC82 (P1622) Fault in ECM/PCM 8G-23. . . . .
Inspection of ECM/PCM, Immobilizer
Control Module and Its Circuit 8G-24. . . . . . . . .
Voltage Check 8G-24. . . . . . . . . . . . . . . . . . . . .
Resistance Check 8G-25. . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE8G-26 . . . . . . . . . . . . . . . .
Precautions in Handling Immobilizer
Control System 8G-26. . . . . . . . . . . . . . . . . . . . .
Immobilizer Control Module 8G-27. . . . . . . . . . . .
Coil Antenna 8G-27. . . . . . . . . . . . . . . . . . . . . . . . .
HOW TO REGISTER IGNITION KEY8G-28 . . . . .
PROCEDURE AFTER IMMOBILIZER
CONTROL MODULE REPLACEMENT8G-29 . .
PROCEDURE AFTER ECM/PCM
REPLACEMENT8G-30 . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS8G-30 . . . . . . . . . . . . . . . . . . . . . .
SECTION 8G
IMMOBILIZER CONTROL SYSTEM
(IF EQUIPPED)
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CONTENTS

YH4
GRAND
VITARA
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-3
1
A1 A2 A3 A4
A5 A6 A9 A10A7 A8
1. Coil antenna
2. Immobilizer Control Module
3. ECM/PCM
4. Immobilizer diagnostic coupler
4-1. Diagnostic output terminal
4-2. Ground terminal
5. Malfunction indicator lamp
6. Main relay
7. Ignition switch
8. Fuse
9. Main fuse
-10. To #9-pin in Data link connector
-11. To #7-pin in Data link connector
-12. To ABS control module
-13. Immobilizer indicator lamp
(Vehicle not equipped with monitor coupler)
-14. Monitor coupler (Vehicle not equipped
with immobilizer indicator lamp)) Terminal arrangement of Immobilizer
Control Module coupler (Viewed from
harness side)
B/R
BI
BI/B
B/W
V/Y
BI/B
B/W
B
V/W
V/W
BI
R
SbI
B
V/G
V
B
R/Y WIRE
SYMBOLWIRE
COLORabcdefghijklmn
1. Ignition key with built-in
transponder
1
1. Coil antenna
opqr
IGNITION KEY
The ignition key for the immobilizer control system has a built-in
transponder. Each transponder in the key has an each transmitting
code (Transponder code). The code will transmitted from the key
via the coil antenna to Immobilizer Control Module when the ignition
switch is turned ON.
COIL ANTENNA
The coil antenna is installed to the steering lock assembly. As it is
energized by Immobilizer Control Module, it transmits the trans-
ponder code of the ignition key to Immobilizer Control Module.