Lug nuts SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

YH4
GRAND
VITARA
0B-4 MAINTENANCE AND LUBRICATION
MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS
If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is
recommended that applicable maintenance operation be performed at the particular interval as given in the chart
below.
Severe condition code
A ± Repeated short trips E ± Repeated short trips in extremely
B ± Driving on rough and / or muddy roads cold weather
C ± Driving on dusty roads F ± Leaded fuel use
D ± Driving in extremely cold weather G ± ± ± ± ± ± ± ± ±
and / or salted roads H ± Trailer towing (if admitted)
Severe
Condition Code
MaintenanceMaintenance
OperationMaintenance Interval
BCDITEM 1-1IEvery 15,000 km
(9,000 miles) or 12 months
± B C D ± ± ± ±Drive belt (V-rib belt)REvery 45,000 km
(27,000 miles) or 36 months
A ± C D E F ± HITEM 1-4
Engine oil and oil filterREvery 5,000 km
(3,000 miles) or 4 months
± B ± ± ± ± ± ±ITEM 1-6
Exhaust pipe mountingsIEvery 15,000 km
(9,000 miles) or 12 months
CITEM 3-1IEvery 2,500 km
(1,500 miles)
± ± C ± ± ± ± ±Air cleaner filter*1REvery 30,000 km
(18,000 miles) or 24 months
ABC EF HITEM 2-1Nickel plugREvery 10,000 km
(6,000 miles) or 8 months
A B C ± E F ± HSpark plugsIridium plugREvery 30,000 km
(18,000 miles) or 24 months
± B ± D E ± ± HITEM 6-9
Propeller shafts and drive shaftsIEvery 15,000 km
(9,000 miles) or 12 months
± B ± ± E ± ± H
ITEM 6-10, 6-12, 6-13
Manual transmission,
transfer and differential oil
REvery 30,000 km
(18,000 miles) or 24 months
± B ± ± E ± ± HITEM 6-11
Automatic transmission fluidREvery 30,000 km
(18,000 miles) or 24 months
± B ± ± ± ± ± ±ITEM 6-8
Suspension bolts and nutsTEvery 15,000 km
(9,000 miles) or 12 months
± B C D ± ± ± HITEM 6-7
Wheel bearingIEvery 15,000 km
(9,000 miles) or 12 months
CD
ITEM 6-17
Air conditioning filter*2
IEvery 15,000 km
(9,000 miles) or 12 months
± ± C D ± ± ± ±Air conditioning filter 2
(if equipped)REvery 45,000 km
(27,000 miles) or 36 months
NOTES:
ªIº : Inspect and correct, replace or lubricate if necessary
ªRº : Replace or change
ªTº : Tighten to the specified torque
*1 : Inspect or replace more frequently if necessary.
*2 : Clean or replace more frequently if the air from the air conditioning decreases.

YH4
GRAND
VITARA
1. Suction hose
2. Discharge hose
3. Liquid pipe
4. Condenser outlet pipe
5. Expansion valve
6. Dual pressure switch
7. Suction pipe
: Apply compressor oil
(refrigerant oil) to O-ring.
1B-30 AIR CONDITIONING (OPTIONAL)
ON-VEHICLE SERVICE
WARNING:
Should refrigerant HFC-134a (R-134a) strike your eye(s), consult a doctor immediately.

DO NOT USE YOUR HAND TO RUB AFFECTED EYE(S).
Instead, use quantities of fresh cold water to splash it over affected area to thus gradually raise its
temperature above the freezing point.

Obtain proper treatment as soon as possible from a doctor or eye specialist.
Should liquid refrigerant HFC-134a (R-134a) get on your skin, such affected part should be treated
in the same manner as when skin is frostbitten or frozen.
CAUTION:
None of refrigerant, compressor oil and component parts is interchangeable between two types of A / C:
one using CFC-12 (R-12) and the other using HFC-134a (R-134a).
(For identification between these two types, refer to page 1B-2).
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A / C installed in the vehicle being serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.
PRECAUTION
When servicing air conditioning system, the following rules must be observed.
PIPING

When connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to seats of coupling nuts
and O-ring.

Never use heat for bending pipes. When bending a pipe, try to make its bending radius as slight as possible.

Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system,
install a blind plug or cap to the fitting immediately.

When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.

YH4
GRAND
VITARA
1. High pressure pipe
2. Union bolt3. Low pressure hose
4. Steering lower shaft bolt
3B1-14 POWER STEERING (P / S) SYSTEM
3) After installing wheels, lower vehicle and tighten wheel nuts to
specified torque.
Tightening Torque
(a): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
4) Check that proper amount of toe-in is obtained by referring to
ªFRONT WHEEL ALIGNMENTº.
5) After confirming proper amount of toe-in, tighten tie-rod end lock
nut to specified torque.
Tightening Torque
(a): 65 N
.m (6.5 kg-m, 47.0 lb-ft)
POWER STEERING GEAR BOX
ASSEMBLY
REMOVAL
1) Take out fluid in P / S fluid reservoir with syringe or such.
2) Disconnect high pressure pipe from steering gear box by remov-
ing union bolt.
NOTE:
As fluid flows out of disconnected joints, put a receptacle
under joints or a plug to pipe.
3) Disconnect low pressure hose from steering gear box.
NOTE:
As fluid flows out of disconnected joints, put a receptacle
under joints or a plug to hose.
4) Remove steering lower shaft bolt.
5) Hoist vehicle and remove both right and left wheels.
6) Disconnect both right and left tie rod ends from knuckle, refer to
steps 2) to 3) of ªTIE-ROD END REMOVALº in this section.

YH4
GRAND
VITARA
3B1-26 POWER STEERING (P / S) SYSTEM
09915-77420
Oil pressure gauge
attachment and hose set09915-77410
Oil pressure gauge09943-55010
Boot clamp plier
TIGHTENING TORQUE SPECIFICATION
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Gear box mounting bolts555.540.0
Gear box cylinder pipe flare nuts292.921.0
Gear box low pressure pipe union bolt404.029.0
Gear box high pressure pipe union bolt353.525.5
Tie-rod end lock nut656.547.0
G16 Type engine555.540.0
Pump bracket boltJ20 Type engine252.518.5
H25 Type engine454.532.5
Pump union bolt606.043.5
Oil pump mount bolts252.518.5
Pipe clamp bolt / Reservoir bracket bolt111.18.0
Steering shaft joint bolt252.518.0
High pressure flare nuts404.029.0
Pump cover bolts232.317.0
Plug606.043.5
Pressure switch (Terminal)282.820
Suction connector bolt101.07.5
Tie-rod end nut484.835.0
Tie-rod (for canvas top LH model only)858.561.5
REQUIRED SERVICE MATERIAL
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUPER GREASE (A)
(99000-25010)
Oil seal lip of P / S pump pulley shaft
Power steering fluidAn equivalent of DEXRON
-III or
DEXRON
-II

To fill P / S fluid reservoir

Parts lubrication when installing
SPECIAL TOOL

YH4
GRAND
VITARA
(a)
(a)
1. Bolt
2. Washer
3. Lateral rod
1. Nut
1
3E-10 REAR SUSPENSION
LATERAL ROD
REMOVAL
1) Hoist vehicle.
2) Remove lateral rod mounting bolts.
3) Remove lateral rod.
INSTALLATION
1) Install lateral rod to rear axle, and vehicle body.
2) Lower hoist.
3) Tighten lateral rod mounting bolts to specified torque.
Tightening Torque
(a): 90 N
.m (9.0 kg-m, 65.0 lb-ft)
REAR AXLE SHAFT AND WHEEL BEARING
REMOVAL
1) Remove rear brake drum. For details, refer to REAR BRAKE
DRUM REMOVAL in SECTION 5C.
2) Drain gear oil from rear axle housing by loosening drain plug.
3) Remove rear wheel bearing retainer nuts from axle housing.

YH4
GRAND
VITARA
3. Container 1. Plug cap
2. Vinyl tube
1. Bearing retainer
(e)
(f)
(g)
REAR SUSPENSION 3E-21
16) Apply sealant to mating surface of bearing retainer with brake
back plate.
NOTE:
Make sure to remove old sealant before applying it anew.
ªBº: Sealant 99000-31110
17) Install rear axle shaft to rear axle housing and tighten bearing
retainer nuts to specified torque.
NOTE:
When installing rear axle shaft, be careful not to cause
damage to oil seal lip in axle housing.
Tightening Torque
(e): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
18) For vehicle with ABS, tighten wheel speed sensor bolt to speci-
fied torque.
Tightening Torque
(f): 21 N
.m (2.1 kg-m, 15.5 lb-ft)
19) Connect brake pipes to wheel cylinders (right & left) and tighten
brake pipe flare nuts to specified torque.
Tightening Torque
(g): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
20) Install brake drum (right & left). For details, refer to SECTION
5C ªBRAKE DRUM INSTALLATIONº.
21) Refill differential gear housing with new specified gear oil. Re-
fer to ªON-VEHICLE SERVICEº in SECTION 7F for refill.
22) Fill reservoir with brake fluid and bleed brake system.(For
bleeding operation, see SECTION 5.)

YH4
GRAND
VITARA
3F
WHEELS AND TIRES 3F-1
GENERAL DESCRIPTION3F- 1 . . . . . . . . . . . . . .
Tires 3F- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheels 3F- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Tires 3F- 1. . . . . . . . . . . . . . . . . . .
Wheels Replacement 3F- 2. . . . . . . . . . . . . . . . .
Metric Lug Nuts and Wheel Studs 3F- 2. . . . . .
DIAGNOSIS3F- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table 3F- 3. . . . . . . . . . . . . . . . . . . . . .
Balancing Wheels 3F- 3. . . . . . . . . . . . . . . . . . . . MAINTENANCE AND MINOR
ADJUSTMENTS3F- 4 . . . . . . . . . . . . . . . . . . . . . .
Wheel and Tire 3F- 4. . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE3F- 6 . . . . . . . . . . . . . . . .
Wheel 3F- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tire 3F- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS3F- 8 . . . . . . . . . . . . . . . . . . . .
SECTION 3F
WHEELS AND TIRES
NOTE:
All wheel fasteners are important attaching parts in that they 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 replacement part
of lesser quality or substitute design. Torque values must be used as specified during reassembly to as-
sure proper retention of all parts.
There is to be no welding as it may result in extensive damage and weakening of the metal.
CONTENTS
GENERAL DESCRIPTION
TIRES
This vehicle is equipped with following tire. P215 / 65 R16, 215 / 65 R16 or 235 / 60 R16
The tires are of tubeless type. The tires are designed to operate satisfactorily with loads up to the full rated load
capacity when inflated to the recommended inflation pressure.
Correct tire pressures and driving habits have an important influence on tire life. Heavy cornering, excessively rapid
acceleration, and unnecessary sharp braking increase tire wear.
WHEELS
Standard equipment wheels are following steel wheel. 16
6 1 / 2 J or 16
7JJ
REPLACEMENT TIRES
When replacement is necessary, the original equipment type tire should be used. Refer to the Tire Placard. Re-
placement tires should be of the same size, load range and construction as those originally on the vehicle. Use
of any other size or type tire may affect ride, handling, speedometer / odometer calibration, vehicle ground clear-
ance and tire or snow chain clearance to the body and chassis.
NOTE:
Do not mix different types of tires on the same vehicle such as radial, bias and bias-belted tires except in
emergencies, because vehicle handling may be seriously affected and may result in loss of control.
It is recommended that new tires be installed in pairs on the same axle. If necessary to replace only one tire, it
should be paired with the tire having the most tread, to equalize braking traction.

YH4
GRAND
VITARA
3F-2 WHEELS AND TIRES
The metric term for tire inflation pressure is the kilopascal (kPa).
Tire pressures will usually be printed in both kPa and psi on the Tire
Placard. Metric tire gauges are available from tool suppliers. The
chart, left table, converts commonly used inflation pressures from
kPa to psi.kPakgf / cm2psi
160
180
200
220
240
260
280
300
320
3401.6
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.423
26
29
32
35
38
41
44
47
50
Conversion:1 psi = 6.895 kPa
1 kgf / cm
2 = 98.066 kPa
WHEELS REPLACEMENT
Wheels must be replaced if they are bent, dented, have excessive
lateral or radial runout, leak air through welds, have elongated bolt
holes, if lug nuts won't stay tight, or if they are heavily rusted.
Wheels with greater runout than shown in left figure may cause ob-
jectional vibrations.
Wheels for replacement must be equivalent to the originally
equipped wheels in load capacity, diameter, rim width, off-set and
mounting configuration. A wheel of improper size or type may affect
wheel and bearing life, brake cooling, speedometer / odometer cal-
ibration, ground clearance to the body and chassis.
To measure the wheel runout, it is necessary to use accurate dial
indicator. The tire may be on or off the wheel. The wheel should be
installed to the wheel balancer of the like for proper measurement.
Take measurements of both lateral runout and radial runout at both
inside and outside of the rim flange. With dial indicator set in place
securely, turn the wheel one full revolution slowly and record every
reading of the indicator.
When the measured runout exceeds the specification and correc-
tion by the balancer adjustment is impossible, replace the wheel.
If the reading is affected by welding, paint or scratch, it should be
ignored.
Lateral runout limit ªaº: 1.20 mm (0.047 in.)
Radial runout limit ªbº: 1.20 mm (0.047 in.)
METRIC LUG NUTS AND WHEEL STUDS
All models use metric lug nuts and wheel studs (size M12 x 1.25).

YH4
GRAND
VITARA
1. Oil filler / level plug
2. Front drain plug
1. Circlip
2. Washer
1. Drive shaft flange
bolts and nuts
1. Oil seal
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-3
ON-VEHICLE SERVICE
DRIVE SHAFT
REMOVAL (LEFT SIDE)
1) Hoist vehicle and remove wheel.
2) Remove axle shaft drive flange.
3) Remove drive shaft circlip and front spindle thrust washer.
4) Remove drive shaft flange bolts and nuts.
5) Remove drive shaft assembly to differential side as shown in left
figure.
CAUTION:
To prevent breakage of boots (wheel side and differential
side), be careful not to bring them into contact with other
parts when removing drive shaft assembly.
6) Remove drive shaft thrust washer (vehicle with G16 or J20 en-
gine) from drive shaft and remove drive shaft oil seal as shown
in figure.
CAUTION:
Be careful not to cause damage to drive shaft joint.

YH4
GRAND
VITARA
1. Wheel cylinder
1. Brake back plate
2. Brake pipe flare nut
3. Brake pipe
4. Wheel cylinder bolts1. Bleeder plug cap
5C-12 PARKING AND REAR BRAKE
WHEEL CYLINDER
REMOVAL
1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL.
2) Perform steps 2) to 4) of BRAKE SHOE REMOVAL.
3) Loosen brake pipe flare nut (or nuts) but only within the extent
that fluid does not leak.
4) Remove wheel cylinder mounting bolts. Disconnect brake pipe
(or pipes) from wheel cylinder and put wheel cylinder bleeder
plug cap onto pipe to prevent fluid from spilling.
INSPECTION
Inspect wheel cylinder disassembled parts for wear, cracks, corro-
sion or damage.
NOTE:
Clean wheel cylinder components with brake fluid.
INSTALLATION (For non sealed type)
1) Take off bleeder plug cap from brake pipe and connect pipe (or
pipes) to wheel cylinder just enough to prevent fluid from leak-
ing.
2) Tighten wheel cylinder to brake back plate to specified torque.
Tightening Torque
(a): 8.5 N
.m (0.85 kg-m, 6.5 lb-ft)
3) Torque flare nut (or nuts) of brake pipe which was connected in
step 1) to specification.
Tightening Torque
(b): 16 N
.m (1.6 kg-m, 12.0 lb-ft)