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Vitara 95 1.6L cutting out when in 4wd
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Author:  TasAlex [ Sun Sep 17, 2017 7:26 pm ]
Post subject:  Vitara 95 1.6L cutting out when in 4wd
Hi all, I thought this would be the best place to talk as I consider myself a n00b!

I recently bought a Vitara. A 95 model, 1.6L 4Cyl Automatic.

It drives great in 2 wheel drive. But as soon as I come to a stop. Flick it in Neutral and place it into 4L or 4H, then flick back to drive. It starts to lose power and stalls when no acceleration is applied. Just before it cuts out, the engine starts vibrating weirdly. I had to stop start, stop start a few times. I even lost breaks at one point which was a bit nerve wracking. In the end I gave up and went back into 2wd, and it acted fine.

Any ideas on what it could be? :)
Author:  Gwagensteve [ Sun Sep 17, 2017 8:41 pm ]
Post subject:  Re: Vitara 95 1.6L cutting out when in 4wd
Very strange.
Disconnect the 4wd light switches (one for 4wd, one for high/low range, they're on the top of the gearbox between the transfer and and the gearbox) and see if it still does it.
Author:  TasAlex [ Mon Sep 18, 2017 10:56 am ]
Post subject:  Re: Vitara 95 1.6L cutting out when in 4wd
Thanks Steve, I will try and attempt that. Sounds like a tricky process for someone like me but I shall give it a go.

I spoke with Brad the Suzuki wrecker in Tassie. He suggested checking underneath to see if the diff is moving freely.
Author:  watermouse [ Tue Sep 19, 2017 11:51 am ]
Post subject:  Re: Vitara 95 1.6L cutting out when in 4wd
Possibly different diff ratios front and rear or cactus front diff.
As in stalling due to driveline binding.
Author:  Gwagensteve [ Tue Sep 19, 2017 12:25 pm ]
Post subject:  Re: Vitara 95 1.6L cutting out when in 4wd
That's possible watermouse, good call, I guess it isn't clear from the OP's post whether the stalling occurs immediately the transmission goes back into drive or on initial acceleration.

Another check- unlock the hubs and put the transfer in 4wd and see if it still does it. (Pretty sure a 95 estate still has manual free wheeling hubs?)
Author:  TasAlex [ Sun Oct 15, 2017 10:06 am ]
Post subject:  Re: Vitara 95 1.6L cutting out when in 4wd
Hi Steve, you are right I was a bit vague. I haven't taken it off road in the last few weeks so didn't notice it again until yesterday.

It's an automatic fuel injected zook. The issue seems to happen in both 4H and 4L. I can crawl in 4wd without acceleration and it seems fine. I then accelerate, and as long as I am applying pressure to the gas, it will drive fine. But as soon as I take my foot off the pedal, it will idle really weird, the engine will vibrate and finally stall. I am then able to start it fine first go and do not seem to have the issue when in 2wd.

I am going to bring it into a mechanic to go over, anything you can suggest I do in the meantime? A friend suggested changing the oil in the transmission.
Author:  Gwagensteve [ Mon Oct 16, 2017 6:41 am ]
Post subject:  Re: Vitara 95 1.6L cutting out when in 4wd
Do the test I suggested. Put the car in 4h or 4L with the free wheeling hubs unlocked. This will not cause damage to anything. Drive the car the same way you were when it was behaving strangely.

Report back.
Author:  TasAlex [ Mon Oct 16, 2017 11:18 am ]
Post subject:  Re: Vitara 95 1.6L cutting out when in 4wd
Thanks for the suggestion Steve. This is an Auto with Automatic Hubs, so doesn't appear to be anyway to unlock them manually.

Also I noticed underneath that the Cross member under the gearbox is bent to buggery, could this be related?
Author:  Gwagensteve [ Tue Oct 17, 2017 6:21 am ]
Post subject:  Re: Vitara 95 1.6L cutting out when in 4wd
Hmm. Ok. Regardless, you need to confirm front and rear gear ratios match. This can be done by jacking each axle up and turning the driveshafts while counting turns at the wheels.

A bent gearbox crossmember shouldn't be related to this issue.

Another test would be to jack up the whole car and confirm the driveshafts turn freely with the gearbox in neutral and the transfer in 4H or 4L.
Author:  TasAlex [ Mon Oct 15, 2018 11:27 am ]
Post subject:  Re: Vitara 95 1.6L cutting out when in 4wd
I know this reply is pretty late. Just wanted to reference that the fault was fixed by replacing the EGR Valve. The old one was pretty well worn. No longer having this issues when in 4wd and accelerating. :)
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