For H27 Engine Model

WARNING: This page is about a different car, the 2003 Suzuki XL-7 and 2003 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

After applying differential oil to differential gear (4), pinions (5), pinion shafts (6) thrust washer (2) and spring washer (1), install them in differential right case (3).
For correct installing direction of thrust washer (2) and spring washer (1), refer to the figure.

Fig 1: Installing Differential Gear, Pinions, Pinion Shafts, Thrust Washer And Spring Washer In Differential Right Case
Courtesy of SUZUKI OF AMERICA CORP.
When installing pinion shaft No. 2 (2) (shorter) into differential case and pinion, insert its "a" side into pinion joint (1).
NOTE: "a" is longer than "b". ("a" > "b")

Fig 2: Installing Pinion Shaft No. 2
Courtesy of SUZUKI OF AMERICA CORP.
Check differential pinion gear (1) for smooth rotation.

Fig 3: Checking Differential Pinion Gear Rotation
Courtesy of SUZUKI OF AMERICA CORP.
In the same manner as described in Step 1, install thrust washer (2), spring washer (1) and differential gear (4).

Fig 4: Installing Thrust Washer, Spring Washer And Differential Gear
Courtesy of SUZUKI OF AMERICA CORP.
Install differential left case (1) and then tighten screws to specified torque.
"A": Thread lock cement 99000-32110

Tightening torque

Differential case screw (a): 9 N.m (0.9 kg-m, 6.5 lb-ft)

Fig 5: Installing Differential Left Case
Courtesy of SUZUKI OF AMERICA CORP.
Clean and degrease mating surface of drive bevel gear (hypoid gear) (1).
Apply thread lock cement to hatched part of drive bevel gear (1) as shown in the figure.
"A": Thread lock cement 99000-32110

Fig 6: Applying Thread Lock Cement To Drive Bevel Gear
Courtesy of SUZUKI OF AMERICA CORP.
Put drive bevel gear (3) on differential case (1) and fasten them with bolts (2) by tightening them to specified torque. Use thread lock cement for bolts (2).
CAUTION: Use of any other bolts than that specified is prohibited.

"A": Thread lock cement 99000-32110

Tightening torque

Bevel gear bolts (a): 105 N.m (10.5 kg-m, 76.0 lb-ft)

Fig 7: Installing Drive Bevel Gear On Differential Case
Courtesy of SUZUKI OF AMERICA CORP.
Install special tool to differential case assembly and check that preload is within specification. If preload exceeds specified value, check if foreign matter is caught or gear is damaged.
Special tool

(B): 09928-06510

Side gear preload

Max: 2.5 N.m (0.25 kg-m, 1.8 lb-ft)

Fig 8: Installing Special Tool To Differential Case Assembly

Courtesy of SUZUKI OF AMERICA CORP.