Suzuki Grand Vitara JB419. Service manual — part 105

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

N

⋅m

kgf-m

lb-ft

Yaw rate / G sensor assembly bolt

8

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.) / ) / ) /
)

/ ) / ) / )

4F-54 Electronic Stability Program:

Table of Contents 5- i

5

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

Recommended Service Material . . . . . ...5B-33
Special Tool . . . . . . . . . . . . . ..5B-34

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

Recommended Service Material . . . . . . .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.

5-ii Table of Contents

Special Tool . . . . . . . . . . . . . . 5C-7