2001 SUZUKI GRAND VITARA service

DIFFERENTIAL (FRONT) 7E-3
Diagnosis
Differential Assembly Diagnosis Table
4WD Control System Diagnostic Flow Table
Before performing the trouble diagnosis, check that the transfer and front differential are in good condition and
there is no air leakage from air hoses and the actuator. Refer to “4WD CONTROL SYSTEM INSPECTION” in
this section for air leakage.
Notes on system circuit inspection
•Be sure to read “PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE” in Section 0A before circuit
inspection and observe what is written there.
•For system circuit, refer to the figure of “GENERAL DESCRIPTION” in this section.
•For terminal arrangement, refer to “4WD CONTROL CIRCUIT INSPECTION” in this section. Condition Possible Cause Correction
Gear noiseDeteriorated or water mixed lubricant Repair and replenish.
Inadequate or insufficient lubricant Repair and replenish.
Maladjusted backlash between bevel pinion and gear Adjust.
Improper tooth contact in the mesh between bevel pinion
and gearAdjust or replace.
Loose bevel gear securing bolts Replace or retighten.
Damaged side gear(s) or side pinion(s) Replace.
Bearing noise(Constant noise) Deteriorated or water mixed lubricant Repair and replenish.
(Constant noise) Inadequate or insufficientlubricant Repair and replenish.
(Noise while coasting) Damaged bearing(s) of bevel pinion Replace.
(Noise while turning) Damaged differential side bearing(s)
or axle bearing(s)Replace.
Oil leakageWorn or damaged oil seal Replace.
Excessive oil Adjust oil level.
Loose differential carrier bolts Replace or retighten.
2WD/4WD
switching errorDefective actuator Replace.
Abnormality in 4WD control system Inspect referring to “4WD
CONTROL SYSTEM DIAG-
NOSTIC FLOW TABLE”.

DIFFERENTIAL (FRONT) 7E-7
On-Vehicle Service
Differential Mountings
REMOVAL AND INSTALLATION
1) Lift up vehicle and turn steering wheel all way to the right.
2) Separate front mounting bracket R (2) from differential hous-
ing (3) by removing bolts (1) from its lower part.
3) Remove front mounting bracket R (2) by removing mounting
front bolt (4) from its upper part.
4) Remove front mounting bracket L (3) from differential hous-
ing (1) by removing upper and lower fastening bolts (2, 4).
5) Check conditions of each bush. If it is damaged or deterio-
rated, drive it out with special tools and press for replace-
ment.
Special tool
(A) : 09951-26010
(B) : 09951-16080

DIFFERENTIAL (REAR) 7F-1
7F
SECTION 7F
DIFFERENTIAL (REAR)
CONTENTS
General Description ........................................ 7F-2
Diagnosis ......................................................... 7F-2
Diagnosis Table ............................................ 7F-2
On-Vehicle Service.......................................... 7F-3
Precaution for Maintenance Service ............. 7F-4
Differential Gear Oil Change ......................... 7F-4
Rear Differential Assembly ............................ 7F-5
Dismounting .............................................. 7F-5
Remounting ............................................... 7F-5
Unit Repair ....................................................... 7F-6Disassembling Unit ....................................... 7F-6
Component Inspection .................................. 7F-9
Sub-Assembly Adjustment and Reassembly 7F-9
Differential carrier .................................... 7F-10
Differential case ...................................... 7F-10
Differential side bearing .......................... 7F-12
Drive bevel pinion.................................... 7F-13
Assembling Unit .......................................... 7F-17
Tightening Torque Specification ................. 7F-20
Required Service Material ............................ 7F-20
Special Tool ................................................... 7F-21

DIFFERENTIAL (REAR) 7F-3
On-Vehicle Service
1. Universal joint flange 9. Differential carrier assembly 17. Bearing adjuster 25. Bolt
2. Hypoid gear set 10. Differential pinion 18. Lock plate 26. Bolt
3. Bevel pinion spacer
Apply thread lock cement
99000-32110 referring to
“DIFFERENTIAL CASE” in
this section.11. Differential gear 19. Pinion shaft No.2 27. Differential case screw :
Apply thread lock
cement 99000-32110 to
thread part of bolt.
4. Shim 12. Pinion shaft No.1 20. Pinion joint Do not reuse.
5. Rear bearing 13. Differential left case 21. Spring washer Tightening torque
6. Front bearing 14. Differential right case 22. Washer Apply differential oil.
7. Oil seal :
Apply grease 99000-25010
to oil seal lip.15. Thrust washer 23. Bevel gear bolt :
Apply thread lock
cement 99000-32110
to thread part of bolt.
8. Flange nut :
After tightening nut so as
rotation torque of bevel pin-
ion shaft to be in specified
value, caulk nut securely.16. Differential side bearing 24. Bolt

7F-4 DIFFERENTIAL (REAR)
Precaution for Maintenance Service
•When having driven through water, check immediately if
water has entered (if so, oil is cloudy). Water mixed oil must
be changed at once.
•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.
Differential Gear Oil Change
1) Before oil change or inspection, be sure to stop engine and
lift up vehicle horizontally.
2) Check oil level and existence of leakage. If leakage is found,
correct its cause.
3) Drain old oil and pour proper amount of gear oil as specified
(roughly up to level hole).
4) Torque drain plug (3) and level/filler plugs (2) to specification.
“A” : Sealant 99000-31110
Tightening torque
Differential oil level/filler plug (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
Differential oil drain plug (b) :
28 N·m (2.8 kg-m, 20.5 lb-ft)
Hypoid gear oil :
API GL-5, SAE 75W-85, 80W-90 or 90
Oil capacity :
2.5 liters (5.3/4.4 US/Imp. pt.) NOTE:
Hypoid gear oil must be used for differential.
It is highly recommended to use SAE 80W-90 viscosity.
1. Breather hose

DIFFERENTIAL (REAR) 7F-21
10) Upon completion of gear tooth contact check in Step 9),
caulk flange nut (2) with caulking tool (1) and hammer.
Tightening Torque Specification
Required Service Material
Fastening partTightening torque
Nm kg-m lb-ft
Differential oil level/filler plug 50 5.0 36.5
Differential oil drain plug 28 2.8 20.5
Propeller shaft flange nuts 60 6.0 43.5
Differential carrier bolts 55 5.5 40.0
Bevel gear bolts 105 10.5 76.0
Bearing cap bolts 85 8.5 61.5
Lock plate bolts 12 1.2 9.0
Differential case screws 9 0.9 6.5
MaterialRecommended SUZUKI product
(Part Number)Use
Thread lock cement THREAD LOCK CEMENT
SUPER 1322
(99000-32110)Bevel gear bolts
Differential case bolts
Bevel gear mating surface
Propeller shaft flange bolt
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Oil seal lips
Sealant SUZUKI BOND NO. 1215
(99000-31110)Rear differential drain plug
Mating surface of differential housing
Mating surface of rear axle housing

BODY ELECTRICAL SYSTEM 8-1
6F1
6F2
6G
6H
6K
7A
8
6K
7C1
7D
7E
7F
8A
8D
8E
9
10
10A
10B
SECTION 8
BODY ELECTRICAL SYSTEM
Wiring System
(Harnesses, Connectors, Fuses, Relay, Switches, Grounds, System Circuit Diagram) .......... Section 8A
Lighting System .............................................................................................................................. Section 8B
Instrumententation and Driver Information .................................................................................. Section 8C
Windows, Mirrors, Security and Locks ......................................................................................... Section 8D
Immobilizer Control System............................................................................................................Section 8F
CONTENTS
General Description .......................................... 8-3

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
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” 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
“LOCK” 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).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in FOREWORD of this manual.

INSTRUMENTATION/DRIVER INFORMATION 8C-1
8C
SECTION 8C
INSTRUMENTATION/DRIVER INFORMATION
CONTENTS
General Description ........................................8C-2
Combination Meter ........................................8C-2
On-vehicle Service ..........................................8C-4
Fuel Meter/Fuel Gauge Unit ..........................8C-4
Fuel level sensor (sender gauge) ..............8C-4
Engine Coolant Temperature (ECT) Meter
and Sensor ....................................................8C-5Engine coolant temperature sensor .......... 8C-5
Oil Pressure Light ......................................... 8C-5
Oil pressure switch .................................... 8C-5
Brake Warning Light ..................................... 8C-5
Brake fluid level switch .............................. 8C-5

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
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” 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
“LOCK” 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).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in the FOREWORD of this manual.