2004 SUZUKI GRAND VITARA lamp

YH4
GRAND
VITARA
1. Pipe
2. Hose
3. Flare nut
1. Pipe
2. Hose
3. Flare nut
4. E-ring
1. Master cylinder
assembly
2. Clutch pipe
3. Attaching nut
4. Attaching bolt
5. Clevis pin
6. Clip
7. Flare nut
CLUTCH 7C1-5
INSPECTION
Check pipe and hose for dent, kink, crack, dirt and dust. Replace
if check result is not satisfactory.
INSTALLATION
Reverse removal sequence noting following points.
Tighten flare nuts to specified torque.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
NOTE:

For air bleeding of master cylinder alone, it must be removed
from vehicle.
(For procedures of removal and installation of master cylin-
der assembly and air bleeding, refer to CLUTCH MASTER
CYLINDER section.)

Do not allow fluid to get on painted surface.

Do not allow pipe and hose to contact hard against vehicle
or other parts.

Install each clamp securely.

Install E-ring securely as shown.

After installation, check clutch pedal free travel and bleed air
from system.

Check fluid leakage.

Add fluid close to MAX level of reservoir.
CLUTCH MASTER CYLINDER
REMOVAL
1) Clean around reservoir cap and take out fluid with syringe or
such.
2) Remove push rod clevis pin.
3) Disconnect fluid pipe from master cylinder.
NOTE:
Do not allow fluid to get on painted surfaces.
4) Remove master cylinder attaching nut and bolt.
5) Remove master cylinder assembly and gasket.

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. Transfer
3. Blank
4. Blank
5. ECM or PCM
6. Glove box7. Air pump assembly
8. Actuator
9. Axle lock clutch
10. Free axle hub
11. 4WD indicator lamp
7E-2 DIFFERENTIAL (FRONT)
4WD CONTROL SYSTEM
When the 4WD switch is turned ON by shifting the transfer shift lever, ECM (PCM) (G16 and J20 engine models)
or 4WD controller (H25 engine model) actuates (energizes) the air pump assembly. Then positive pressure is sent
from the air pump assembly to the actuator installed to the differential case and causes the axle lock clutch and
the free axle hub in the differential case to be engaged, resulting in the 4WD mode. Only when running in the 4WD
mode, front axles are joined to differential case, and they become free when 2WD mode is used (or when transfer
shift lever is shifted to N position), thereby reducing the power loss.

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
DIFFERENTIAL (FRONT) 7E-7
1
1. ECM (PCM); viewed from harness side
4WD CONTROL CIRCUIT INSPECTION
Voltage Check [G16 and J20 engine models]
Check for input or output voltage (voltage between each circuit and
body ground) of ECM (PCM) with ECM (PCM) connector con-
nected and ignition switch turned ON.
TER-
MINALCIRCUITWIRE
COLORNORMAL
VOLTAGECONDITION
E6110 ± 14 VTransfer shift lever: 2H or NE61-
194WD Indicator lampOr / B0 ± 1 V4 seconds after transfer shift lever shifted
to 4H or 4L
C51 2Air pump assembly0 ± 1 VTransfer shift lever: 2H or NC51-2
-7(Pump motor and release
valve)R10 ± 14 V1 seconds after transfer shift lever shifted
to 4H or 4L
C51-24WD switchB/Or10 ± 14 VTransfer shift lever: 2H or N
-184WD switchB/Or0 ± 1 VTransfer shift lever: 4H or 4L
C51-
3-17GroundB/Bl0 ± 1 V±
C51 2Airpumpassembly0 ± 1 VTransfer shift lever: 2H or NC51-2
-27
Air um assembly
(pressure switch)P10 ± 14 V4 seconds after transfer shift lever shifted
to 4H or 4L

YH4
GRAND
VITARA
7E-8 DIFFERENTIAL (FRONT)
1. ECM (PCM); viewed from harness side
Voltage Check [H25 engine model]
TER-
MINALCIRCUITWIRE
COLORNORMAL
VOLTAGECONDITION
C51 110 ± 14 VTransfer shift lever: 2H or NC51-1
-74WD Indicator lampOr / B0 ± 1 V4 seconds after transfer shift lever shifted
to 4H or 4L
C51 1Air pump assembly0 ± 1 VTransfer shift lever: 2H or NC51-1
-15(Pump motor and release
valve)R10 ± 14 V1 seconds after transfer shift lever shifted
to 4H or 4L
C51-14WD switchB/Or10 ± 14 VTransfer shift lever: 2H or N
-114WD switchB/Or0 ± 1 VTransfer shift lever: 4H or 4L
C51-3
-26GroundB/Bl0 ± 1 V±
C51-1Airpumpassembly0 ± 1 VTransfer shift lever: 2H or NC51-1
-18
Air um assembly
(pressure switch)P10 ± 14 V4 seconds after transfer shift lever shifted
to 4H or 4L