SUZUKI GRAND VITARA 2002 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
3D-12 FRONT SUSPENSION
1. Lock washer
2. Screws 1. Axle shaft drive flange
WHEEL HUB (INCLUDED WHEEL BEARING)
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove axle shaft drive flange (4WD vehicle) or hub cap (2WD
vehicle).
3) If equipped with ABS, remove wheel speed sensor from knuckle
and harness clamp from strut.
4) Remove caliper bolt and suspend caliper.
CAUTION:
Hang removed caliper with a wire hook or the like so as to
prevent brake hose from bending and twisting excessively
or being pulled.
Don't operate brake pedal with pads removed.
5) Remove brake disc.
NOTE:
If brake disc can not be removed by hand, use 8 mm bolts as
shown.
6) Remove front wheel bearing lock washer by loosening 4 screws.
7) Remove front wheel bearing lock nut by using special tool.
Special Tool
(A): 09951-16050
8) Remove front wheel bearing washer.
9) Remove wheel hub component by hand.

YH4
GRAND
VITARA
1. Sensor rotor
2. Wheel hub
3. Vise
4. Flat end rod
1. Bearing lock washer
2. Screw
3. Bearing lock nut
4. Wheel bearing washer
5. Wheel hub component
6. Bolt
1. Oil hydraulic press
2. Hub bolt
FRONT SUSPENSION 3D-13
NOTE:
If wheel hub can not be removed by hand, use special tools
as shown.
Special Tool
(B): 09943-35512
(C): 09942-15510
CAUTION:
If wheel bearing inner race remains on wheel spindle
when removing wheel hub, which means break of wheel
bearing, replace wheel hub component (included wheel
bearing).
10) Remove sensor rotor from wheel hub as shown (if equipped
with ABS).
CAUTION:

Pull out sensor rotor from wheel hub gradually and
evenly.

Do not reuse sensor rotor once removed.
Be sure to new sensor rotor when installing.
11) Remove hub bolts from hub.
INSTALLATION
1) Insert new stud in hub hole. Rotate stud slowly to assure serra-
tions are aligned with those made by original bolt.

YH4
GRAND
VITARA
1. Wheel hub
2. Wheel spindle
3. Bearing inner race
1. Lock washer 1. Sensor rotor
2. Wheel hub
3. Hydraulic press
OK NG
3D-14 FRONT SUSPENSION
2) Install new sensor rotor by using special tool (if equipped with
ABS).
NOTE:
Use care not to insert wheel hub diagonally.
Special Tool
(A): 09952-86510
(B): 09924-74510
Wheel speed sensor rotor installing position
Reference Dimension ªaº : 4.9
0.1 mm (0.19
0.004 in.)
3) Install wheel hub component to spindle supporting wheel bear-
ing inner race by finger as shown.
CAUTION:
Don't tap wheel hub component by hammer or the like.
Otherwise, it will be broken.
NOTE:
When it is impossible to install wheel hub component by
hand, which means the inner race is out of alignment, re-
move wheel hub component once and reinstall it.
4) Install wheel bearing washer, and the install wheel bearing lock
nut.
5) Tighten wheel bearing lock nut to specified torque while turning
wheel hub by hand.
Special Tool
(A): 09951-16050
Tightening Torque
(a): 216 N
.m (21.6 kg-m, 157 lb-ft)
6) Using lock washer, lock bearing lock nut. If lock screw hole is not
aligned with screw hole in lock nut, turn lock nut in tightening
direction till they align.
Tightening Torque
(b): 1.5 N
.m (0.15 kg-m, 1.1 lb-ft)

YH4
GRAND
VITARA
2, (b)
1
1. Circlip
2. Large diameter
1. Front wheel speed sensor
2. Bolt
FRONT SUSPENSION 3D-15
7) For 4WD vehicle, apply lithium grease to front drive shaft wash-
er and front wheel spindle outer.
ªAº: Grease 99000-25010
8) 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.
9) For vehicle with ABS, 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.
10) Install brake disc and caliper assembly.
Tightening Torque
(e): 85 N
.m (8.5 kg-m, 61.5 lb-ft)

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
ªAº
ªBº
1. Wheel spindle
2. Drive shaft bearing
1. Wheel spindle
2. Drive shaft
bearing
3. Front drive shaft
thrust washer
4. Inner oil seal
5. Knuckle cap
6. Drive shaft oil sealType A Type B
1. Drive shaft bearing
2. Wheel spindle
3D-18 FRONT SUSPENSION
11) For 4WD vehicle
Remove drive shaft bearing by using special tool.
Special Tool
(A): 09923-74510
(B): 09930-30102
INSTALLATION
Reverse removal sequence to install knuckle, wheel spindle oil seal
and drive shaft bearing,noting following points.

For 4WD vehicle
Install drive shaft bearing by using special tool.
Special Tool
(A): 09913-76010 Type A drive shaft thrust washer. . . . . . . .
(A): 09913-80112 Type B drive shaft thrust washer. . . . . . . .
Dimension ªaº: 0 ± 1 mm (0 ± 0.04 in.)
Dimension ªaº: Type A drive shaft thrust washer . . . . . . . . .
Dimension ªaº: 1.75 ± 2.50 mm (0.069 ± 0.098 in.)
Dimension ªaº: Type B drive shaft thrust washer . . . . . . . . .

When installing wheel spindle to knuckle, coat their mating sur-
faces with sealant.
ªAº: Sealant 99000-31110

For 4WD vehicle
Also, fill recess in wheel spindle with about 10 g lithium grease.
ªBº: Grease 99000-25010