2001 SUZUKI GRAND VITARA Owners Manual

7F-20 DIFFERENTIAL (REAR)
TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY
NORMAL
HIGH CONTACT
Pinion is positioned too far from the center of drive
bevel gear.
4) Increase thickness of pinion height adjusting
shim and position pinion closer to gear center.
5) Adjust drive bevel gear backlash to specifica-
tion.
LOW CONTACT
Pinion is positioned too close to the center of drive
bevel gear.
1) Decrease thickness of pinion height adjusting
shim and position pinion farther from gear cen-
ter.
2) Adjust drive bevel gear backlash to specification.
If adjustment is impossible, replace differential carrier.
1) Check seating of bevel gear or differential case.
(Check bevel gear for runout).
2) If adjustment is impossible, replace drive bevel gear & pinion
set or differential carrier.
Replace drive bevel gear & pinion set or differential case.

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

7F-22 DIFFERENTIAL (REAR)
Special Tool
09900-20606 09900-20701 09913-61510 09913-65135
Dial gauge Magnetic stand Bearing puller Bearing puller
09922-76570 09913-75510 09913-85230 09922-66021
Attachment Bearing installer Bearing removing jig Flange holder
09922-75222 09922-76560 09924-74510 09925-18011
Preload checking tool Preload checking tool Installer attachment Bearing installer
09926-68310 09926-78311-002 09926-78320 09927-66010/J-23082-01
Bearing installer Pinion mounting dummy
(See NOTE.)Mounting dummy Oil pump aligner

DIFFERENTIAL (REAR) 7F-23
09928-06510 09930-40113 09930-40120 09944-66020
Differential torque
checking toolRotor holder Attachment Bearing installer
09951-16060 09951-18210 09951-46010
Lower arm bush remover Oil seal remover &
installer No. 2Drive shaft oil seal
installer
NOTE:
This tool is constituent of tools with 09926-78311.

7F-24 DIFFERENTIAL (REAR)

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.

8-2 BODY ELECTRICAL SYSTEM
General Description
WIRE COLOR SYMBOLS
There are two kinds of colored wire used in this vehicle. One is
single-colored wire and the other is dual-colored (striped) wire.
The single-colored wire uses only one color symbol (i.e. “GRN”).
The dual-colored wire uses two color symbols (i.e. “GRN/YEL”).
The first symbol represents the base color of the wire (“GRN” in
the figure) and the second symbol represents the color of the
stripe (“YEL” in the figure). Symbol Wire Color Symbol Wire Color
B BLK Black O, Or ORN Orange
Bl BLU Blue R RED Red
Br BRN Brown W WHT White
GGRN Green Y YEL Yellow
Gr GRY Gray P PNK Pink
Lbl LT BLU Light blue V PPL Violet
Lg LT GRN Light green

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.