Section 8D SUZUKI GRAND VITARA 1999 2.G Service Workshop Manual

YH4
GRAND
VITARA
FRONT SUSPENSION 3D-9
1. Coil spring
8) Remove stabilizer bar, refer to steps 2) to 5) of item STABILIZ-
ER BAR / BUSHINGS REMOVAL in this section.
9) Disconnect tie rod end from knuckle by using puller.
10) Support lower arm, using jack as shown.
11) Remove strut bracket bolts.
12) Remove ball stud castle nut.
13) Using puller, disconnect knuckle from ball stud.
14) Remove knuckle and wheel hub comp, while lowering jack.
15) Remove coil spring.

YH4
GRAND
VITARA
3D-10 FRONT SUSPENSION
ªaº < ªbº
1. Circlip
2. Large diameter
1. Axle shaft drive flange
2. Bolt 1. Spring seat
Bottom
INSTALLATION
Reverse removal procedure to install coil spring.
NOTE:
Upper and lower diameters of coil spring are different.
Bring larger diameter end at bottom and set its open end in
place on spring seat.

Be sure to use specified torque for tightening each fastener.

Refer to torque specification chart at the end of this section.

As for ball stud nut, be sure to insert split pin and bend it after tight-
ening it.

Tighten tie-rod end nut with pushing ball stud to upper side so as
not ball stud to be rotated.

For 4WD vehicle
Apply lithium grease to front drive shaft washer and front wheel
spindle outer.
ªAº: Grease 99000-25010

For 4WD vehicle
When installing circlip to drive shaft, utilize screw hole in drive
shaft to pull it out and bring large diameter of circlip at right as
shown.

For 4WD vehicle
When installing axle shaft drive flange to wheel hub, apply sealant
to mating surface of axle shaft drive flange and tighten flange bolt
to specified torque.
ªAº: Sealant 99000-31090
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

YH4
GRAND
VITARA
FRONT SUSPENSION 3D-11
1. Front wheel speed sensor
2. Bolt
1. Spring rubber
seat
2. Bump stopper2, (b)
1

Check that no foreign material is attached to sensor and rotor.
Install wheel speed sensor and its harness clamp.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
CAUTION:

Do not pull wire harness or twist more than necessary
when installing front wheel speed sensor.

Fit harness grommet to inner fender securely.

Check that there is no clearance between sensor and knuckle.
BUMP STOPPER / SPRING RUBBER SEAT
REMOVAL
1) Remove coil spring. Refer to steps 1) to 15) of item ªCOIL
SPRING REMOVALº in this section.
2) Remove spring rubber seat.
3) Remove bump stopper, using special tool.
Special Tool
(A): 09941-66010
INSTALLATION
1) Tighten bump stopper to specified torque, using special tool.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
2) Install spring rubber seat.
3) Install coil spring. Refer to item ªCOIL SPRING INSTALLATIONº
in this section.

YH4
GRAND
VITARA
1. Axle shaft drive
flange
2. Bolt
3. Hub cap
4. Wheel hub
For 4WD vehicle
For 2WD vehicle
3D-16 FRONT SUSPENSION
11) Apply sealant and install axle shaft drive flange or hub cap.

For 4WD vehicle
Apply sealant mating surface of axle shaft drive flange, then
install axle shaft drive flange and tighten flange bolt to speci-
fied torque.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
ªAº: Sealant 99000-31090

For 2WD vehicle
Remove grease, old sealant and dusts from mating surfaces
of hub cap and hub to clean, apply water tight sealant ªAº to
cap mating surface evenly, and install cap to hub.
ªAº: Sealant 99000-31090
12) Install wheel.
Tightening Torque
(a): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
13) For vehicle equipped with ABS, perform driving test referring
to ªDRIVING TESTº of ªABS DIAGNOSTIC FLOW TABLEº in
Section 5E or 5E1.

YH4
GRAND
VITARA
1. Drive shaft
circlip
2. Spindle thrust
washer
3. Drive shaft
4. Wheel spindle
1. Tie-rod end
2. Knuckle
1. Strut
2. Knuckle
1. Dust cover
2. Wheel spindle
3. Knuckle
4. Inner oil seal /
knuckle cap
FRONT SUSPENSION 3D-17
KNUCKLE / WHEEL SPINDLE
REMOVAL
1) Remove wheel hub. Refer to ªWHEEL HUB (INCLUDED
WHEEL BEARING)º in this section.
2) Remove front drive shaft circlip and front spindle thrust washer
(for 4WD vehicle) or front hub cap (for 2WD vehicle).
3) Disconnect tie-rod end from knuckle.
4) Remove stabilizer bar. Refer to ªSTABILIZER BAR / BUSH-
INGSº in this section.
5) Remove ball stud nut.
6) Support lower arm with jack.
7) Remove strut bracket bolts from strut bracket.
8) By using puller, disconnect knuckle from ball stud.
9) While lowering jack, remove knuckle / wheel spindle comp.
10) Remove inner oil seal (for 4WD vehicle), knuckle cap (for 2WD
vehicle), dust cover and wheel spindle.

YH4
GRAND
VITARA
(a)
1. Axle shaft drive flange
2. Bolt1. Hub cap
2. Wheel hub
3D-20 FRONT SUSPENSION

Tighten control arm ball stud nut
When tightening ball stud nut, use new nut and tighten it to speci-
fied torque.
Tightening Torque
(a): 60 N
.m (6.0 kg-m, 43.5 lb-ft)

For 2WD vehicle
Apply water tight sealant to mating surface of wheel hub and
install hub cap to wheel hub.
ªAº: Sealant 99000-31090

For 4WD vehicle
When installing axle shaft drive flange to wheel hub, apply sealant
to mating surface of axle shaft drive flange.
ªAº: Sealant 99000-31090
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

For installation procedures of wheel hub component, refer to
ªWHEEL HUB (INCLUDED WHEEL BEARING)º in this section.

Connect tie-rod end to knuckle and tighten new tie-rod end nut.
Tightening Torque
(a): 43 N
.m (4.3 kg-m, 31.5 lb-ft)

For any tightening torque other than those specified in text, refer
to ªTIGHTENING TORQUE SPECIFICATIONº in this section.

YH4
GRAND
VITARA
FRONT SUSPENSION 3D-21
(1)
(2)
(A)
1. Hydraulic press
1. Hydraulic press Cut off flange
Bush outer diameter
SUSPENSION CONTROL ARM / BUSHINGS
REMOVAL
1) Remove coil spring. Refer to COIL SPRING in this section.
2) Remove control arm bolts and nuts. Then remove control arm.
3) Cut flange part of control arm bush (rubber and steel) with using
care not to damage control arm end surface.
Dimension ªAº: Approx. 6 mm (0.236 in.)
4) Place control arm and special tool on hydraulic press. Set con-
trol arm cutting flange to welded part (1) of the special tool and
control arm joint side to the stepped part (2) of special tool.
CAUTION:
Use special care in driving out control arm bush to press
it vertically.
Or it may cause personally injury.
Special tool
(A): 09951-46020
5) Remove front bushing by using hydraulic press and special
tools, pull out bushing.
Special Tool
(A): 09951-46020
(B): 09924-74510
(C): 09951-16060
6) Remove rear bushing by using hydraulic press and special
tools, pull out bushing.
Special Tool
(A): 09951-46020
(D): 09913-80112
(E): 09925-58210

YH4
GRAND
VITARA
3D-22 FRONT SUSPENSION
1. Hydraulic press
2. Front bushing
A: Bushing flange
contacts housing edge
1. Hydraulic press
2. Rear bushing
A: Bushing flange
contacts housing edge
INSTALLATION
1) Front bushing
Press-fit front bushing until its flange contacts housing edge of
control arm, use special tools as shown.
Special Tool
(C): 09951-16060
(F): 09913-85210
NOTE:
When press-fitting bushing, compounding oil or soap water
applied to inside of control arm housing will facilitate work.
2) Rear bushing
Press-fit rear bushing until its flange contacts housing edge of
control arm, use special tools as shown.
Special Tool
(E): 09925-58210
(F): 09913-85210
NOTE:
When press-fitting bushing, compounding oil or soap water
applied to inside of control arm housing will facilitate work.
3) Install control arm to chassis.
Tighten suspension arm nut to specified torque after lowering
hoist and vehicle in non-loaded condition.
Tightening Torque
(a): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
(b): 127 N.m (12.7 kg-m, 92.0 lb-ft)
4) As installation procedure hereafter is the same as that for coil
spring. Refer to ªCOIL SPRINGº in this section.
NOTE:
For any tightening torque other than those specified in text,
refer to ªTORQUE SPECIFICATION TABLEº at the end of
this section.

YH4
GRAND
VITARA
3E
REAR SUSPENSION 3E-1
GENERAL DESCRIPTION3E- 2 . . . . . . . . . . . . . .
DIAGNOSIS3E- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table 3E- 3. . . . . . . . . . . . . . . . . . . . . .
Shock Absorber Check 3E- 3. . . . . . . . . . . . . . . .
Lower / Upper / Lateral Rod Check 3E- 3. . . . . . . .
Axle Housing and Coil Spring Check 3E- 3. . . .
Bearing Retainer & Axle Shaft Inner Oil
Seal Check 3E- 4. . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Disc, Nut & Bearing Check 3E- 4. . . . . .
ON-VEHICLE SERVICE3E- 5 . . . . . . . . . . . . . . . .
Shock Absorber 3E- 5. . . . . . . . . . . . . . . . . . . . . . Coil Spring 3E- 6. . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Rod 3E- 8. . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Rod 3E- 9. . . . . . . . . . . . . . . . . . . . . . . . . .
Lateral Rod 3E-10. . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Shaft and Wheel Bearing 3E-10. . . . .
Rear Axle Shaft Inner Oil Seal 3E-15. . . . . . . . . .
Rear Axle Housing 3E-16. . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS3E-23 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS3E-23 . . . . . .
SPECIAL TOOLS3E-24 . . . . . . . . . . . . . . . . . . . . . .
SECTION 3E
REAR SUSPENSION
NOTE:

All suspension fasteners are an important attaching part in that it could affect the performance of vital
parts and systems, and / or could result in major repair expense. They must be replaced with one of the
same part number or with an equivalent part if replacement becomes necessary. Do not use a replace-
ment part of lesser quality or substitute design. Torque values must be used as specified during reas-
sembly to assure proper retention of this part.

Never attempt to heat, quench or straighten any suspension part. Replace it with a new part, or damage
to the part may result.
CONTENTS

YH4
GRAND
VITARA
ªAº: Drill hole with approximately
3 mm (0.12 in.) diameter.
REAR SUSPENSION 3E-3
DIAGNOSIS
DIAGNOSIS TABLE
Refer to SECTION 3.
SHOCK ABSORBER CHECK

Inspect for deformation or damage.

Inspect bushings for wear or damage.

Inspect for evidence of oil leakage.
Replace any defective part.
WARNING:
When handling rear shock absorber in which high-pressure
gas is sealed, make sure to observe the following precau-
tions.
1) Don't disassemble it.
2) Don't put it into the fire.
3) Don't store it where it gets hot.
4) Before disposing it, be sure to drill a hole in it where
shown by an arrow in the figure and let gas and oil out.
Lay it down sideways for this work.
5) The gas itself is harmless but it may issue out of the hole
together with chips generated by the drill. Therefore, be
sure to wear goggle.
LOWER ROD, UPPER ROD, LATERAL ROD
CHECK
Inspect for cracks, deformation or damage.
Replace any defective part.
Inspect each bush for wear and breakage. If found defective, re-
place.
AXLE HOUSING AND COIL SPRING CHECK
Inspect for cracks, deformation or damage.
Inspect for evidence of oil leakage at axle housing.
If any, replace defective part.