Suzuki Grand Vitara JB419. Service manual

Electronic Stability Program: 4F-53

Specifications

Tightening Torque Specifications

S5JB0B4607001

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

Special Tools and Equipment

Special Tool

S5JB0B4608001

Fastening part

Tightening torque

Note

⋅m

kgf-m

lb-ft

Yaw rate / G sensor assembly bolt

0.8

6.0

)

09956–02311

SUZUKI scan tool

Brake pressure gauge

—

)

This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12.) / ) / ) /
)

/ ) / ) / )

Table of Contents 5- i

Section 5

CONTENTS

Transmission / Transaxle

Precautions .................................................5-1

Precautions............................................................. 5-1

Precautions for Transmission / Transaxle............. 5-1

Manual Transmission/Transaxle ............ 5B-1

General Description .............................................5B-1

Manual Transmission Construction..................... 5B-1

Diagnostic Information and Procedures............5B-2

Manual Transmission Symptom Diagnosis ......... 5B-2

Repair Instructions ..............................................5B-3

Manual Transmission Assembly Components .... 5B-3
Gear Shift Lever Case Assembly

Components...................................................... 5B-5

Gear Shift Shaft and Fork Components.............. 5B-6
Input Shaft Assembly, Main Shaft Assembly

and Countershaft Assembly Components ........ 5B-7

Manual Transmission Oil Level Check................ 5B-8
Manual Transmission Oil Change ....................... 5B-8
Transmission Shift Control Lever Removal

and Installation.................................................. 5B-9

Transmission Shift Control Lever Inspection.....5B-11
Back Up Light Switch Removal and

Installation.......................................................5B-11

Back Up Light Switch Inspection....................... 5B-11
Gear Shift Lever Case Assembly Removal

and Installation................................................5B-12

Gear Shift Lever Case Assembly

Disassembly and Reassembly........................ 5B-13

Gear Shift Lever Case Assembly Inspection.....5B-13
Engine Rear Mounting Replacement ................5B-13
Manual Transmission Assembly Dismounting

and Remounting.............................................. 5B-14

Manual Transmission Unit Disassembly ........... 5B-16
Manual Transmission Unit Reassembly............5B-18
Locating Spring Inspection................................5B-22
Input Shaft Assembly Disassembly and

Reassembly .................................................... 5B-22

Input Shaft Inspection ....................................... 5B-23
Main Shaft Disassembly ...................................5B-23
Main Shaft Inspection ....................................... 5B-24
Main Shaft Reassembly .................................... 5B-26
Countershaft Assembly Disassembly and

Reassembly .................................................... 5B-29

Reverse Idle Gear Assembly Disassembly

and Reassembly .............................................5B-31

Countershaft and Reverse Idle Gear

Inspection........................................................5B-32

Manual Transmission Adapter Case

Disassembly and Assembly ............................5B-32

Specifications.....................................................5B-33

Tightening Torque Specifications......................5B-33

Special Tools and Equipment ...........................5B-33

Clutch ....................................................... 5C-1

General Description .............................................5C-1

Clutch (Hydraulic Type) Construction .................5C-1

Component Location ...........................................5C-2

Clutch Fluid Pipe and Hose Location ..................5C-2

Diagnostic Information and Procedures............ 5C-*

Clutch (Hydraulic Type) Symptom Diagnosis...... 5C-*

Repair Instructions ..............................................5C-2

Clutch Pedal Height Inspection ........................... 5C-*
Clutch Pedal Free Travel Check ......................... 5C-*
Clutch Fluid Inspection........................................ 5C-*

Air Bleeding of Clutch System.............................5C-2

Clutch Pedal Position (CPP) Switch Removal

and Installation .................................................. 5C-*

Clutch Pedal Position (CPP) Switch

Inspection and Adjustment................................ 5C-*

Clutch Fluid Pipe and Hose Removal and

Installation ......................................................... 5C-*

Clutch Fluid Pipe and Hose Inspection ............... 5C-*

Clutch Master Cylinder Removal and

Installation .........................................................5C-3

Clutch Master Cylinder Inspection ...................... 5C-*

Clutch Operating Cylinder Assembly

Removal and Installation...................................5C-4

Clutch Cover, Clutch Disc and Flywheel

Components......................................................5C-5

Clutch Cover, Clutch Disc and Flywheel

Removal and Installation...................................5C-5

Clutch Cover, Clutch Disc and Flywheel

Inspection.......................................................... 5C-*

Specifications.......................................................5C-7

Tightening Torque Specifications........................5C-7

Special Tools and Equipment .............................5C-7

NOTE
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual
mentioned in the “FOREWORD” of this manual.

Suzuki Grand Vitara JB419. Service manual - part 105