2002 SUZUKI GRAND VITARA Lug nuts

YH4
GRAND
VITARA
1. Oil filler / level plug
2. Front drain plug
1. Circlip
2. Washer
1. Drive shaft flange
bolts and nuts
1. Oil seal
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-3
ON-VEHICLE SERVICE
DRIVE SHAFT
REMOVAL (LEFT SIDE)
1) Hoist vehicle and remove wheel.
2) Remove axle shaft drive flange.
3) Remove drive shaft circlip and front spindle thrust washer.
4) Remove drive shaft flange bolts and nuts.
5) Remove drive shaft assembly to differential side as shown in left
figure.
CAUTION:
To prevent breakage of boots (wheel side and differential
side), be careful not to bring them into contact with other
parts when removing drive shaft assembly.
6) Remove drive shaft thrust washer (vehicle with G16 or J20 en-
gine) from drive shaft and remove drive shaft oil seal as shown
in figure.
CAUTION:
Be careful not to cause damage to drive shaft joint.

YH4
GRAND
VITARA
1. Wheel cylinder
1. Brake back plate
2. Brake pipe flare nut
3. Brake pipe
4. Wheel cylinder bolts1. Bleeder plug cap
5C-12 PARKING AND REAR BRAKE
WHEEL CYLINDER
REMOVAL
1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL.
2) Perform steps 2) to 4) of BRAKE SHOE REMOVAL.
3) Loosen brake pipe flare nut (or nuts) but only within the extent
that fluid does not leak.
4) Remove wheel cylinder mounting bolts. Disconnect brake pipe
(or pipes) from wheel cylinder and put wheel cylinder bleeder
plug cap onto pipe to prevent fluid from spilling.
INSPECTION
Inspect wheel cylinder disassembled parts for wear, cracks, corro-
sion or damage.
NOTE:
Clean wheel cylinder components with brake fluid.
INSTALLATION (For non sealed type)
1) Take off bleeder plug cap from brake pipe and connect pipe (or
pipes) to wheel cylinder just enough to prevent fluid from leak-
ing.
2) Tighten wheel cylinder to brake back plate to specified torque.
Tightening Torque
(a): 8.5 N
.m (0.85 kg-m, 6.5 lb-ft)
3) Torque flare nut (or nuts) of brake pipe which was connected in
step 1) to specification.
Tightening Torque
(b): 16 N
.m (1.6 kg-m, 12.0 lb-ft)

YH4
GRAND
VITARA
2
1. Wheel cylinder
2. Gasket
1. Brake back plate
2. Brake pipe flare nut
3. Brake pipe
4. Wheel cylinder bolts
PARKING AND REAR BRAKE 5C-13
4) Install bleeder plug cap taken off from pipe back to bleeder plug.
5) For procedure hereafter, refer to steps 1) to 5) of BRAKE SHOE
INSTALLATION.
NOTE:
Be sure to bleed brake system. (for bleeding operation, re-
fer to BLEEDING BRAKES in Section 5.)
INSTALLATION (For gasket sealed type)
1) Install gasket to joint seam of wheel cylinder and brake back
plate. Then take off bleeder plug cap from brake pipe and con-
nect pipe (or pipes) to wheel cylinder just enough to prevent fluid
from leaking.
NOTE:
Be sure to check gasket for deterioration or any damage be-
fore installation and replace if found defective.
2) Tighten wheel cylinder to brake back plate to specified torque.
3) Torque flare nut (or nuts) of brake pipe which was connected in
step 1) to specification.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
(b): 16 N
.m (1.6 kg-m, 12.0 lb-ft)
4) Install bleeder plug cap taken off from pipe back to bleeder plug.
5) For procedure hereafter, refer to BRAKE SHOE INSTALLA-
TION.
NOTE:
Be sure to bleed brake system. Refer to ªCHECK AND AD-
JUSTMENTº in BRAKES section.

YH4
GRAND
VITARA
5E1-32 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
1. ABS hydraulic
unit /control
module
assembly
2. Brake pipe
1. ABS hydraulic
unit / control
module connector 1. Brake pipe
2. ABS hydraulic unit /
control module assembly
3. Bracket
ABS HYDRAULIC UNIT / CONTROL MODULE
ASSEMBLY
CAUTION:
Never disassemble ABS hydraulic unit / control module as-
sembly, loosen blind plug or remove motor. Performing any
of these prohibited services will affect original performance
of ABS hydraulic unit / control module assembly.
HYDRAULIC UNIT INSPECTION

Check hydraulic unit for fluid leakage.
If any, repair or replace.
REMOVAL
1) Disconnect negative cable at battery.
2) Using special tool, disconnect brake pipes from ABS hydraulic
unit / control module assembly and loosen flare nuts as shown
figure.
Special Tool
(A): 09950-78220
NOTE:
Put bleeder plug cap onto pipe to prevent fluid from spilling.
Do not allow brake fluid to get on painted surfaces.
3) Disconnect ABS hydraulic unit / control module assembly con-
nector.

YH4
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

YH4
GRAND
VITARA
MANUAL TRANSMISSION (TYPE 2) 7A1-5
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN´mkg-mlb-ft
Transfer oil filler / level and drain plugs232.317.0
Transmission oil filler / level and drain plugs383.827.5
Control lever boot cover bolts60.64.0
4WD switch202.014.5
Back-up light switch454.532.5
Control lever locating bolts171.712.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts505.036.5
Muffler to exhaust No. 2 pipe nuts505.036.5
Universal joint flange bolts505.036.5
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)
Shift control lever
Thread lock cement
THREAD LOCK CEMENT
SUPER 1333B
(99000-32020)

Shift control lever locating bolts
SealantSUZUKI BOND No. 1215
(99000-31110)
Oil drain and filler / level plugs

YH4
GRAND
VITARA
7B1-78 AUTOMATIC TRANSMISSION (4 A / T)
ON-VEHICLE
SERVICE MOUNTING
EXTERNAL
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.
TIGHTENING TORQUE SPECIFICATIONS
Fastening portion
Tightening torque
Fastening portion
N´mkg-mlb-ft
Automatic transmission fluid drain plug232.317.0
Transfer oil filler / level and drain plugs232.317.0
Transmission case plug171.712.5
Manual select lever nut131.39.5
Manual select cable nut70.75.5
Manual selector assembly bolts181.813.5
Transmission to engine bolts and nuts858.561.5
Engine rear mounting bolts
Engine rear mounting member bolts
Transmission case right stiffener bolts
505.036.5
Universal joint flange bolts and nuts505.036.5
Torque converter mounting bolts656.547.0
Adapter case or extension case bolts
(G16 engine)353.525.5
Adapter case or extension case bolts
(J20 / H25 engines)424.230.0
Transmission range switch lock bolt5.50.554.0
Oil pipe union bolts353.522.5
Drive plate bolts787.856.5
Interlock cable clamp screw2.20.221.5
Interlock cable outer mounting nut131.39.5

YH4
GRAND
VITARA
1. Master cylinder
1. Attaching bolt
2. Attaching nut
3. Clevis pin
ªAº
7C1-6 CLUTCH
INSTALLATION
1) To bleed air from master cylinder itself, tilt it as shown in figure
and add fluid into it.
NOTE:
After bleeding air from master cylinder, plug pipe hole in it
to prevent fluid from spilling out of it till pipe is connected.
2) Install master cylinder assembly and new gasket to body, attach-
ing bolt, nuts and push rod clevis pin.
NOTE:
Do not reuse gasket.
3) Torque attaching bolt and nut to specification.
4) Connect fluid pipe and torque flare nut to specification.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
(b): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
5) Apply grease to clevis pin and install it.
ªAº: Grease 99000-25010
6) Fill reservoir with specified brake fluid and check fluid leakage.
7) After installation, bleed air from system and check clutch pedal
free travel. Refer to BRAKE section for air bleeding procedure.
FLUID INSPECTION
Fluid level should be always between MIN and MAX lines on reser-
voir. If fluid decreases quickly, check for leakage, repair leaky point,
if any, and add fluid up to MAX level.
NOTE:

Brake fluid damages painted surface badly. Should it get on
painted surface, remove it immediately and clean surface
thoroughly.

Do not use shock absorber fluid or any other fluid which con-
tains mineral oil. Do not use container which has been used
for mineral oil or which is wet from water. Mineral oil will
cause swelling and distortion of rubber parts in hydraulic
clutch system and water will mix with brake fluid, lowering
fluid boiling point. Keep all fluid containers capped to pre-
vent contamination.

Make sure not to use fluid whose container cap was first
opened more than a year ago.