2001 SUZUKI GRAND VITARA ECU

AUTOMATIC TRANSMISSION (4 A/T) 7B1-45
A/T Throttle Cable
ADJUSTMENT
1) Pull inner cable (3) by force of 2 N (0.2 kg, 0.45 lb) or less to
be no slack of inner cable with A/T throttle cable (1) curved
as shown in the figure.
2) Fix stopper (2) to inner cable (3) with clearance “c”.
A/T throttle cable adjusting position (clearance “c”) :
0.8 – 1.5 mm (0.03 – 0.06 in.)
3) Warm up engine and transmission to normal operating tem-
perature.
4) Make sure that accelerator cable is adjusted as specified.
5) With throttle valve closed, check clearance “c”, which should
be within the following specification, of A/T throttle cable (1).
If it is out of specification, adjust it by turning cable adjusting
nut (2).
A/T throttle cable adjusting position (clearance “c”) :
0.8 – 1.5 mm (0.03 – 0.06 in.)
6) Tighten lock nut (3) securely.
Solenoid Valves (Shift Solenoid Valves and
TCC Solenoid Valve)
INSPECTION
With PCM couplers disconnected and using service wire as
shown in the figure, check each solenoid valve for clicking sound.
Shift solenoid valve - A (#1) C51-1-2
Shift solenoid valve - B (#2) C51-1-1
TCC (Lock-up) solenoid valve C51-1-8

7B1-46 AUTOMATIC TRANSMISSION (4 A/T)
MANUAL SELECTOR ASSEMBLY
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Remove console box.
3) Disconnect connector for illumination lamp, shift lock sole-
noid (if equipped) and overdrive OFF switch (if equipped).
4) Remove selector assembly mounting bolts.
5) Disconnect selector cable (1) from manual selector assem-
bly (2) expanding selector cable clip (3).
INSTALLATION
Reverse removal procedure to install manual selector assembly
noting the following instructions.
•Make sure that selector cable clip (3) hold selector cable (1)
on manual selector assembly (2) securely.
•Tighten manual selector assembly mounting bolts as speci-
fied torque.
Tightening Torque
Manual selector assembly mounting bolts :
18 N·m (1.8 kg-m, 13.5 lb-ft)
•Connect interlock cable end to cam referring to step 2) to 8)
of “Interlock cable installation” of the service manual men-
tioned in FOREWORD of this manual, if necessary.
•Confirm that brake (key) interlock system operates properly
(if equipped).
1. Manual lever assembly 4. Bulb filter 7. Shift lock solenoid (if equipped)
2. Select indicator assembly 5. Bulb 8. Manual selector assembly mounting bolt
3. Illumination assembly 6. knob assembly Tightening torque

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”.

7F-2 DIFFERENTIAL (REAR)
General Description
The differential assembly using a hypoid bevel pinion and gear is installed to the rear axle. It is set in the conven-
tional type axle housing.
The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine
parts and specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between
bevel pinion and gear, it is mandatory to lubricate them by hypoid gear oil.
Diagnosis
Diagnosis Table
Condition Possible Cause Correction
Gear noiseDeteriorated or water mixed lubricant Repair and replenish.
Inadequate or insufficient lubricant Repair and replenish.
Maladjusted backlash between drive bevel pin-
ion and gearAdjust as prescribed.
Improper tooth contact in the mesh between
drive bevel pinion and gearAdjust or replace.
Loose drive bevel gear securing bolts Replace or retighten.
Damaged differential gear(s) or differential pin-
ion(s)Replace.
Bearing noise(Constant noise) Deteriorated or water mixed
lubricantRepair and replenish.
(Constant noise) Inadequate or insufficient
lubricantRepair and replenish.
(Noise while coasting) Damaged bearing(s) of
drive bevel pinionReplace.
(Noise while turning) Damaged differential side
bearing(s) or axle bearing(s)Replace.
Oil leakageClogged breather plug Clean.
Worn or damaged oil seal Replace.
Excessive oil Adjust oil level.

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-6 DIFFERENTIAL (REAR)
3) Install propeller shaft to joint flange aligning match marks
and torque flange nuts to specification. Apply thread lock
cement to thread part of bolt if reused.
“A” : Cement 99000-32110
Tightening torque
Propeller shaft flange nuts (a) :
60 N·m (6.0 kg-m, 43.5 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 specifica-
tion.
7) Lower lift.
Unit Repair
Disassembling Unit
1) Hold differential assembly securely and put identification
marks on differential side bearing caps (6).
2) Take off differential side bearing lock plates (4) and differen-
tial side bearing caps (6) by removing their bolts and then
take out bearing adjusters (5), side bearing outer races and
drive bevel gear with differential case.
3) Remove drive bevel gear (hypoid gear), differential gears,
differential pinions and pinion shafts.
a) With aluminum plates (2) placed on vise first, grip differen-
tial case with it and remove drive bevel gear (hypoid gear)
(3) by removing its bolts (1).
1. Differential carrier
2. Drive bevel gear assembly
3. Differential case
A: Identification mark
1
3
2

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.

WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-1
8D
SECTION 8D
WINDOWS, MIRRORS, SECURITY AND LOCKS
CONTENTS
General Description ....................................... 8D-2
Rear Wiper and Washer (If Equipped) ......... 8D-2
On-Vehicle Service......................................... 8D-3
Windshield Wipers ....................................... 8D-3
Front wiper and washer ............................ 8D-3Rear Window Wiper and Washer
(For Vehicle with Cruise Control System) .... 8D-4
Rear Wiper and Washer Switch ............... 8D-4
Rear Window Wiper and Washer
(For Vehicle without Cruise Control
System) ........................................................ 8D-4
Rear Wiper Intermittent Relay...................... 8D-4

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.