cv joint SUZUKI GRAND VITARA 2000 2.G Service Repair Manual

YH4
GRAND
VITARA
1. Drive shaft oil seal
1. Drive shaft flange bolt and nut
2. Front spindle thrust washer
3. Axle shaft drive flange
ªAº
1. Drive shaft joint
2. Oil seal
3. Pipe
4. Thrust washer4
4A2-8 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
INSTALLATION
Install drive shaft assembly by reversing removal procedure and
noting following points.

Clean front drive shaft oil seal and then apply lithium grease to oil
seal and DOJ shaft.
ªAº: Grease 99000-25010

Check oil seal for breakage or deterioration.
Replace it as necessary.

Drive in oil seal until its end contacts stepped surface of drive
shaft joint by using a pipe whose inner diameter is 76 mm (2.992
in.) or more and outer diameter is 80 mm (3.150 in.) or less.
Diameter ªaº: 76 mm (2.992 in.) or more
Diameter ªbº: 80 mm (3.150 in.) or less

Drive in drive shaft thrust washer (Vehicle with G16 or J20 en-
gine).

RH Side
Push differential side joint by hand until it is positioned by snap
ring fitted to its spline.
LH Side
Connect drive shaft flange bolts and nuts.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

Apply grease to front spindle thrust washer and front spindle part
of drive shaft.
ªAº: Grease 99000-25010

When installing axle shaft drive flange to wheel hub, apply sealant
to mating surface of axle shaft drive flange.
ªBº: Sealant 99000-31090
Tightening Torque
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
CAUTION:

To prevent breakage of boots (wheel side and differen-
tial side), be careful not to bring them into contact with
other parts when installing drive shaft assembly.

Do not pull housing of differential side joint.
If housing is pulled, it may be detached from drive shaft.

Fill specified differential gear oil into differential case to specified
level.

YH4
GRAND
VITARA
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-11
09913-75520
Bearing installer09924-74510
Installer attachment09930-30102
Sliding shaft09941-64510
Bearing remover
09951-16090
Oil seal installer
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Drive shaft flange nut (Dif. side)505.036.5
Oil level plug232.317.0
Drain plug232.317.0
Axle shaft drive flange bolt484.835.0
NOTE:
Refer to standard tightening torque specifications, if no description or specification is provided.
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Joint grease
(Molybdenum grease)SUZUKI SUPER GREASE H
(99000-25120)Drive axle joint
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)Drive shaft oil seal
Wheel spindle part of differential side
drive shaft (RH)
SealantSEALING COMPOUND 366E
(99000-31090)Axle shaft drive flange
SPECIAL TOOLS

YH4
GRAND
VITARA
4B
1. Front propeller shaft
(if equipped)
2. Rear propeller shaft
PROPELLER SHAFTS 4B-1
SECTION 4B
PROPELLER SHAFTS
NOTE:

All propeller shaft 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 propeller shaft part. Replace it with a new part, or dam-
age to the part may result.
CONTENTS
GENERAL DESCRIPTION4B- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS4B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table4B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Joint Check4B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE4B- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft4B- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATION4B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIAL4B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS4B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION
Most universal joints require no maintenance. They are lubricated for life and can not be lubricated on the vehicle.
If a universal joint becomes noisy or worn, it must be replaced.
The propeller shaft is a balanced unit. Handle it carefully so that balance can be maintained.

YH4
GRAND
VITARA
4B-2 PROPELLER SHAFTS
DIAGNOSIS
DIAGNOSIS TABLE
ConditionPossible CauseCorrection
Abnormal noise
Loose universal joint bolt.

Spider bearing worn out or stuck.

Wear spider.Tighten universal joint bolt.
Replace.
Replace propeller shaft.
Vibration
Deformed propeller shaft.Replace.
PROPELLER SHAFT JOINT CHECK
If universal joints are suspected of producing chattering or rattling
noise, inspect them for wear. Check to see if cross spider rattles in
yokes or if splines are worn down and replace defective propeller
shaft with new one.
Noise coming from universal joint can be easily distinguished from
other noises because rhythm of chattering or rattling is in step with
cruising speed. Noise is pronounced particularly on standing start
or in coasting condition (when braking effect of engine is showing
in the drive line).

YH4
GRAND
VITARA
1. Match mark
PROPELLER SHAFTS 4B-3
ON-VEHICLE SERVICE
PROPELLER SHAFT
REMOVAL
1) Hoist vehicle.
2) Drain transfer oil only when servicing front propeller shaft.
3) Before removing propeller shaft, give match marks on joint
flange and propeller shaft as shown.
4) Remove propeller shaft.
DISASSEMBLY
1) Using special tool(A), remove 2 circlips.
Special Tool
(A): 09900-06108
2) Using special tool(B), push spider bearing race out 3 ± 4 mm
(0.12 ± 0.16 in.) from shaft yoke race.
NOTE:
Before pushing it out, apply penetrate lubricant between
bearing race and yoke race.
Special Tool
(B): 09926-48010
Length ªaº: 3 ± 4 mm (0.12 ± 0.16 in.)
3) Tapping yoke with a hammer, completely remove bearing race.
4) Take out bearing race on the other side in the same way as in
2) and 3).

YH4
GRAND
VITARA
1. Copper hammer
2. Bearing race
3. Yoke
4. Spider
Center support equipped vehicle
PROPELLER SHAFTS 4B-5
1) Insert bearing race into yoke, tapping it with a hammer, until it is
flush with yoke face. When doing this, insert spider into bearing
race to prevent rollers in bearing race from coming out.
2) Insert the other bearing race on the opposite side into yoke, tap-
ping with a hammer until it is flush with yoke face.
3) Insert bearing races on the flange yoke side in the same way as
described in 1) and 2) above.
4) Place a metal plate on bearing races when tapping them in to
avoid damaging yoke.
5) Securely fit 4 circlips to shaft and flange yoke.
NOTE:

After assembly, check to ensure that both shaft yoke and
flange yoke move smoothly.

Make sure that each circlip is fitted in groove securely.
INSTALLATION
Reverse removal procedure to install propeller shaft.

Use following specification to torque universal joint flange bolts
(and center support bolts).
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

When installing propeller shaft, align the match marks.
Otherwise, vibration may occur during driving.
NOTE:
If transfer oil was drained for front propeller shaft removal,
pour specified gear oil into transfer case to specified level.

YH4
GRAND
VITARA
4B-6 PROPELLER SHAFTS
09900-06108
Snap ring pliers
(Closing type)09926-48010
Universal joint
disassembling tool set
TIGHTENING TORQUE SPECIFICATION
FastenerTightening torqueFastenerN.mkg-mlb-ft
Propeller shaft nut / Center support bolt505.036.5
REQUIRED SERVICE MATERIAL
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUPER GREASE C
(99000-25030)To apply to spider bearing race.
SPECIAL TOOLS

YH4
GRAND
VITARA
[FOR VEHICLE WITHOUT ABS]
[FOR VEHICLE WITH ABS]
1. Master cylinder
2-1. 4-way joint
2-2. 2-way joint
3. LSPV (Load Sensing Proportioning Valve)
4. Rear axle housing
5. ABS actuator (H.U.)
F.R.:Front side
5-2 BRAKES
GENERAL DESCRIPTION
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons
(two in front and four in rear).
The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make
two independent circuits. One connects front brakes (right and left) and the other connects rear brakes (right and
left).
The load sensing proportioning valve (LSPV) is included in these circuits between the master cylinder and the rear
brake for the vehicle without ABS.
In this brake system, the disc brake type is used for the front wheel brake and a drum brake type (leading / trailing
shoes) for the rear brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and me-
chanical linkage system. The same brake shoes are used for both parking and foot brakes.

YH4
GRAND
VITARA
1. 4-way joint / 2-way joint
2. Master cylinder
3. LSPV
4. Right brake caliper
5. Left brake caliper
6. Right wheel cylinder
7. Left wheel cylinder
8. ABS actuator

: Air bleeding point [A]: Without ABS
[B]: With ABS
1. Plug cap2. Vinyl tube (See-through tube)
3. Container
[A]
[B]
BRAKES 5-7
CHECK AND ADJUSTMENT
BLEEDING BRAKES
CAUTION:
Brake fluid is extremely damaging to paint. If fluid should
accidentally touch painted surface, immediately wipe
fluid from paint and clean painted surface.
NOTE:
For vehicle equipped with ABS, make sure that ignition switch
turns off.
Be sure to bleed air of brake system according to following proce-
dure when its oil hydraulic circuit has been disconnected.
Hydraulic lines of brake system consists of two separate lines, one
for front wheel brakes and the other for rear wheel brakes.
Air bleeding is necessary at right and left front wheel brakes, left
rear wheel brake and LSPV (if equipped without ABS), i.e. 4 places
(3 places for vehicle with ABS) in all.
1) Fill master cylinder reservoir with brake fluid and keep at least
one-half full of fluid during bleeding operation.
2) Remove bleeder plug cap.
Attach a vinyl tube to bleeder plug of wheel cylinder, and insert
the other end into container.
3) Depress brake pedal several times, and then while holding it de-
pressed, loosen bleeder plug about one-third to one half turn.

YH4
GRAND
VITARA
3. LSPV stay
1. Master cylinder
2. Disconnect brake pipe1. LSPV lever
2. LSPV spring
3, ªAº 2
1
2(a)
ªaº
ªbº
5-14 BRAKES
3) Depress brake pedal gradually till fluid pressure of front brake
becomes as specified below and check corresponding pressure
of rear brake then. It should be within specification given below.
Front brake
Rear brake
8,000 kPa
80 kg / cm2
3 Door
6,000 ± 7,300 kPa
60 ± 73 kg / cm2
853 ± 1,038 psi80 kg / cm2
1,138 psi5 Door
4,500 ± 7,300 kPa
45 ± 73 kg / cm2
640 ± 1,038 psi
As done above, apply 100 kg / cm2 pressure to front brake and
check that rear brake pressure then is within specification as giv-
en below.
Front brake
Rear brake
10,000 kPa
100 kg / cm2
3 Door
6,500 ± 8,000 kPa
65 ± 80 kg / cm2
924 ± 1,138 psi100 kg / cm2
1,422 psi5 Door
5,000 ± 8,000 kPa
50 ± 80 kg / cm2
711 ± 1,138 psi
4) If rear brake pressure is not within specification, adjust it by
changing stay ªAº position as follows.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

If rear brake pressure is higher than specification, move stay
ªAº to direction ªaº and if it is lower, to direction ªbº.

Repeat steps 3) and 4) until rear brake pressure is within spec-
ification.

After adjustment, be sure to torque bolt to specification.
5) Disconnect brake pipe (connecting between master cylinder
secondary side and 4-way joint) from master cylinder.
Tighten plug (special tool) to master cylinder.
Depress brake pedal. If rear brake pressure is 95 ± 100 kg / cm
2
when front brake pressure is 100 kg / cm2, it means that front fail-
safe system functions properly.
Front brake
Rear brake
10000 kPa
100 kg / cm2
1422 psi
9500 ± 10000 kPa
95 ± 100 kg / cm2
1350 ± 1422 psi
Special Tool
(A): 09956-02210