2004 SUZUKI GRAND VITARA Front differential

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

YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-9
Viscosity chart SAE
Temperature
ON-VEHICLE SERVICE
MAINTENANCE SERVICE
NOTE:

When having driven through water, check immediately if wa-
ter 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.
Gear Oil Change
NOTE:

Hypoid gear oil must be used for differential.

It is highly recommended to use SAE 80W ± 90 viscosity.
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, cor-
rect its cause.
3) Drain old oil and pour proper amount of gear oil as specified be-
low (roughly up to level hole).
4) Apply sealant to thread of drain plug (b) and torque plugs to
specification.
Sealant 99000-31110
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
Specified gear oil: Hypoid gear oil API GL-5
SAE 75W ± 85, 90 or 80W ± 90
For oil viscosity, refer to left chart.
Oil capacity: 1.0 liters (2.1 / 1.8 US / lmp. pt)

YH4
GRAND
VITARA
7E-10 DIFFERENTIAL (FRONT)
1. Plugged hose
2. Adjusting screw
3. Pipe (to air pump assembly)
4. Hose (to differential carrier)
5. Differential housing
4 5
INSPECTION
4WD Control System
1) Install special tool to air hose connecting between air pump as-
sembly and differential (actuator) as shown in figure. Tighten ad-
justing screw of special tool as far as it stops. Close air check
side opening by using fuel hose as blind plug.
Special Tool
(A): 09918-18110
(B): 09367-04002
NOTE:
Use care not to bend any part of hose.
2) Turn ON ignition switch and shift transfer lever from 2H to 4H
range.
3) Check that motor starts running (a sound can be heard) within
1 second and it stops when gauge of special tool indicates speci-
fied pressure value.
Check also for air leakage.
Pressure specification:
30.0 ± 45.0 kPa (0.30 ± 0.45 kg / cm
2, 4.25 ± 6.40 psi)
4) Check that pressure value indicated on gauge of special tool
drops as soon as transfer lever is shifted to 2H position.
5) Start motor by shifting transfer lever to 4H position again. Loos-
en adjusting screw to lower pressure value on gauge. Motor
should start to run again and stop in about 4 seconds.
6) With the adjusting screw of special tool loosened, shift transfer
shift lever to N or 2H position and then 4L or 4H position.
Pump motor should stop about 10 seconds after motor starts to
run.

YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-11
1. Differential housing
2. Adjusting screw
3. To air compressor
Actuator
1) Disconnect air hose from pump assembly and install special tool
to air hose as shown in figure. Loosen adjusting screw of special
tool.
Special Tool
(A): 09918-18110
2) Connect compressor air hose to special tool.
Blow air and turn adjusting screw to obtain specified pressure.
Specified pressure: 30.0 kPa (0.3 kg / cm
2, 4.25 psi)
CAUTION:
Do not apply a pressure exceeding 200 kPa (2.0 kg / cm
2,
28.4 psi) which may cause damage to diaphragm.
3) With the vehicle lifted so that both of the front wheels are off the
ground, turn one of the front wheels by hand and check the other
wheel, which should act as described below.

When the pressure from compressor is applied to actuator:
The other front wheel should turn in the direction opposite to
the wheel being turned by hand.

When the pressure from compressor is not applied to actuator:
The other front wheel should remain stationary while the wheel
pushed by hand is turning.
If the result is not satisfactory, inspect differential assembly. Re-
fer to ªINSPECTIONº of SECTION 7E in UNIT REPAIR MANU-
AL.

YH4
GRAND
VITARA
7E-12 DIFFERENTIAL (FRONT)
1. Pump assembly
Air Pump Assembly
Removal / Installation
1) Disconnect air hoses and coupler from air pump assembly.
2) Remove pump assembly by removing bolts.
3) Reverse removal procedure for installation.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
Inspection
1) Install special tool, voltmeter and battery to pump assembly as
shown in figure.
2) Tighten adjusting screw of special tool as far as it stops and
close its air check side opening by using fuel hose as blind plug.
Special Tool
(A): 09918-18110
3) Check that motor starts to run (a sound can be heard) when bat-
tery is connected and it stops when specified pressure is ob-
tained.
Check also for air leakage.
Specified pressure: 30.0 ± 45.0 kPa
(0.30 ± 0.45 kg / cm
2, 4.25 ± 6.40 psi)
4) Check that value indicated on voltmeter is within specification
shown below.
When motor is running: 0 ± 1 V
When motor has stopped running: 10 ± 14 V
CAUTION:
Do not run motor more than 10 seconds continuously to
prevent motor breakage.

YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-13
1. Mounting bracket bolt
2. Mounting bracket R
3. Differential housing
4. Mounting front bolt
1. Differential housing
2. Mounting front bolt3. Mounting bracket L
4. Mounting bracket bolt
1. Mounting bracket
1. Mounting bracket L
2. Bush3. Mounting bracket R
A: Slit alignment 45
4
2
3
1
2
REMOVAL AND INSTALLATION
Differential Mountings
1) Lift up vehicle and turn steering wheel all way to the right.
2) Separate mounting bracket R from differential housing by re-
moving bolts from its lower part.
3) Remove mounting bracket R by removing mounting front bolt
from its upper part.
4) Remove mounting bracket L by removing upper and lower fas-
tening bolts.
5) Check conditions of each bush. If it is damaged or deteriorated,
drive it out with special tools and press for replacement.
Special Tool
(A): 09951-26010
(B): 09951-16080
6) Position slit in each bush as shown when press-fitting it.

YH4
GRAND
VITARA
7E-14 DIFFERENTIAL (FRONT)
1. Mounting bracket R
2. Mounting bracket L
1. Bolt and nut
2. Differential carrier
3. Cross member
4. Bolt
5. Differential rear mounting assembly
7) Position each bush to bracket as shown.
Length ªaº: 3.0 mm (0.12 in.)
8) Use following torque for reinstallation.
Tightening Torque
(a): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
REAR MOUNTING
(For front differential carrier)
1) Lift up vehicle and remove mounting assembly by removing 2
bolts and nuts from differential carrier side and 2 bolts from cross
member side.
2) Check mounting rubber for damage or deterioration and replace
as necessary.
3) Use following torque for reinstallation.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)